The first domestic industry to explore the Compton Industrial 4.0 wisdom park

The construction principles of Compton Huangdao Industrial Park are all based on customers, and everything is to meet the needs of customers. In the design, the design concept of Industry 4.0 is used to automatically optimize the layout, equipment selection and manufacturing process. The layout of the entire plant area consists of west-to-east buildings including general office buildings, R&D laboratories, storage tanks, integrated production plants, and intelligent three-dimensional warehouses. The manufacturing related departments are effectively integrated to meet maximum efficiency. The need for production and sales.

Compton Industrial Park is located in Huangdao District, Qingdao City. This visit is the company's first phase project, covering an area of ​​115 acres. The designed annual production capacity of lubricants (single shift) is 80,000 tons, and the annual production capacity of antifreeze is 20,000 tons. Annual production capacity of 1,000 tons. There are three outdoor tank farms with a total tank capacity of 103 and a total tank capacity of 29,370 cubic meters. From the production capacity to tank storage capacity, they are among the leading domestic companies. Here's just to explore with us where the wisdom of the Compton factory is.

Compton Technology Co., Ltd. is the first listed company in the lubricants industry. Since its establishment in 1989, Compton Technology Co., Ltd. has always adhered to the quality concept of “Doing What You Do Not Do, Doing Yourself,” and promoting the craftsmanship. Just after entering the park, you will see banner banners promoting this spirit.

The first impression of walking into the gate is that there are not many staff working in a large factory area. This is because Compton Huangdao Industrial Park has fully adopted the smart object-connected and intelligent manufacturing system and passed the anti-counterfeit and anti-counterfeiting system of IOT. The entire manufacturing process is effectively managed and tracked, and information management can be performed throughout the manufacturing and delivery system of the product, thus saving manpower.

Entering the park at a glance, you will see oil tanks that are used to store base oils and additives in the plant area. The raw material storage and reception links are measured using the domestic first-class hardware static pressure method, and advanced, mature “Tank Star” integration is adopted. The system achieves accurate canister stock material management and measurement management. The quality measurement error is ≤±0.2% (or the measurement accuracy is 0.2%), and it reaches the advanced level in the industry.

In particular, the additive storage has accomplished the special tank special line, and fundamentally eliminates the influence of the mixture on the quality of oil products during the unloading, storage and feeding process. The built-in local heaters are installed at the bottom of each tank to not only sequentially heat the materials during the unloading process, but also avoid the performance impact caused by repeated heating of the additives. In addition, each process pipeline has an electric heat tracing system to maintain the pipeline temperature at a set value, which not only reduces the heat loss during the material transportation, but also maximizes the harmonic efficiency.

After the tank area came to the center of the entire industrial park production - the Central Automatic Control Center. This is the core of the entire park's intelligent production. With the construction of this part, Compton has introduced and adopted the world-class “Emerson Corporation” to provide an automatic reconciliation system that uses a series of new technologies and equipment to achieve precise product reconciliation. , Including accurate SMB raw material synchronous metering, BBV fast reconciliation, DDU barreled metering extraction, ball clearing, manifold management and other highly automated reconciliation and measurement integration systems.

Its core role is two:

1. The Central Automatic Control Center can conduct real-time monitoring of the interior of the tank area and the production areas of the plant area.

2. Emerson's automatic reconciliation system controls the reconciliation of the entire campus production line in this office.

From the large screen of the monitoring center, it can also be seen that he can monitor the entire production process of the entire plant.

For the lubricant manufacturers, the laboratory is absolutely representative of the technical hard power. The Compton New Industrial Park's laboratories are divided into eight analysis and testing areas. There are 3 experimental equipment rooms on the east side, which are mainly responsible for the detection of viscosity, moisture, density, and chromaticity of lubricants and car care products. The value of the instrument used to detect the kinematic viscosity and low temperature apparent viscosity is up to 2 million yuan. Top imported automatic equipment.

In the west, there are five experimental equipment rooms where new products are started and developed, modulated samples, and finally introduced to the market. The remaining four laboratories mainly analyze and inspect Antifreeze products, greases, and brake fluids produced by Compton, as well as the oil antiwear properties and the detection and analysis of oil elements.

For product quality, Compton places great emphasis on strict control of details and is responsible for the quality of each product delivered to the customer. Strictly follow the requirements of TS16949, ISO9001 quality system. Taking the quality system as the foundation, proceeding with basic management, implementing each link and solid quality management norms.

Through 151 quality management documents: including 38 quality management documents, 86 product implementation process guides and 27 laboratory-related management documents, comprehensively covering quality management processes, and actively promoting a customer-centric closed-loop quality management system. Internally, through training, we constantly emphasize the concept of “zero defects” in our products, and continuously improve our product quality standards. The implementation rate of quality control is 100%.

Approaching the manifold area, you will see numerous pipelines on the factory floor. Before the oil is filled, the oil is transported from the different storage tanks and then transported through the pipeline for final reconstitution. As you can see from the picture, how complex the control area of ​​the manifold system is.

The manifold system is used for the connection and removal of multiple pipelines. The pipeline is designed for 8 input and 6 output. One of the pipelines corresponds to each other. The other pipelines can be connected in multiple orientations such as vertical and horizontal lines. Up to 43 pipelines can be connected. To ensure timely switching of oil during production. During the oil switching process, the inside of the pipeline is cleaned by means of a ball-sweeping line. The residual oil in the pipe wall after the sweep is <1g/m. This is the most advanced manifold system in the world and ensures that the oil is not affected by oil. Pollution, ensure product quality.

After passing through the manifold area, it came to the filling line. The working efficiency of the filling line determines the production capacity per unit of time. Compton has invested 19 fully automatic lines in the production line arrangement, and it is used for mass production filling. Two fully-automatic high-speed filling lines manufactured by “OCME Italy” realize the high-volume, high-speed precision filling operation of Compton and OEM products, and the filling accuracy error is controlled at 5‰.

The entire OCME line is mainly U-shaped, which not only saves space but also increases production efficiency. The entire line is an intelligent automated production. Only 5 people can complete all the operations from the bucket to the storage, showing how powerful the intelligent operation of the filling line is. This is the so-called development direction of Industry 4.0. The impression that the entire production line is overcrowded is no longer present.

Lubricants are stored in the tank area, controlled in the automatic control room, transported through the manifold area, and reconciled and packaged on the ornamental production line. They are finally sorted and put into storage before leaving the factory. In fact, when you enter the factory gate, you will see a tall house. This is Compton automated storage warehouse.

A 25-meter high-storage warehouse built within a length of 102.9 meters wide and 38.4 meters in length has achieved a storage of 10,560 locations on a floor area of ​​less than 4,000 square meters. Full inventory can store about 600,000 Compton products of various types, valued at more than 200 million. Not only greatly reduced the floor space warehouse, but also improve the space utilization. All outbound storage is automated, and all varieties of products automatically follow the principle of first-in, first-out. Each outlet has an electronic screen to guide the loading of logistics vehicles, greatly improving the logistics efficiency. The entire automatic storage center has realized automatic warehouse management from product down-line, storage to delivery, which greatly saved manpower and material resources.

Compton is the first company in the domestic lubricants industry in terms of logistics and warehousing. It is the first company to adopt the most advanced elevated cargo spaces and fully-automated three-dimensional libraries to achieve highly efficient and flexible cargo collection and storage and data analysis of finished products, as well as space closure through three-dimensional libraries. The characteristics of cleaning can effectively reduce the appearance of dust on the appearance of the product. At the same time, the opening of the three-dimensional library will provide a qualitative change in the guaranteed supply of peak seasons under the adjustment of storage capacity. Compton will complete the distribution of goods by regional dealers nationwide with faster efficiency and shorten the delivery cycle.

In the packaging of products, 55 physical indicators need to be strictly tested before mass production. In the process and delivery process, strict control and inspection are carried out according to the requirements of the quality system and the internal 61 quality control points that are higher than the national standard. . In this way, it can be ensured that each product has passed 153 quality control points before it can be formally delivered, to ensure that each offline product is a qualified product, and the final inspection pass rate reaches 100%; through the implementation of the integrated tracking system for the entire manufacturing process, All-round quality supervision to meet the high quality requirements of customers, to ensure that dealers, customers get satisfaction, rest assured products.

To be honest, before I visited Compton's new factory, my imaginary lubricant production process was in a dark, pungent factory with workers in greasy uniforms, artificially blending lubricants and filling them. It was only through the visit that the original production of lubricants can be of such a high end. The completion and use of the Huangdao Industrial Park marked the completion of the modern upgrade of Compton to a new level.