5
2025.8
author
155
Reading volume
The following is an in-depth analysis and technical solution for the three types of machining enterprises, combined with industry practice and productivity factors to explain in detail:
1. Mass Production
▶ Core features
|
dimension |
Technical details: |
Data support |
|
Device configuration |
Dedicated production lines (e.g. crankshaft machines) Automated loading and unloading manipulator Online inspection station integration |
Equipment investment accounts for total assets60%+ |
|
Production beats |
The cycle time is fixed (eg30second/cases) → Synchronous control via cam mechanism |
Production line balance rate≥95% |
|
Production change logic |
Monthly scheduled production schedule → Tooling fixtures need to be adjusted for production change (time-consuming4-8hours) |
The number of annual production changes <12times |
▶ Technical solutions
Typical Cases:Automobile crankshaft production line (annual output of 500,000 pieces)
Key equipment: Comau high-speed special machine (12-station turntable)
Tool management: PCD forming knife (lifespan 500,000 pieces)
Cost control: material utilization rate 92% (near-net forming of forgings)
Pain point solved:
Modular quick-change units (e.g. Hainbuch modular chucks) reduce changeover times to 1.5 hours
2. Flexible manufacturing type (FMS)
▶ Core features
|
dimension |
Technical details: |
Data support |
|
System architecture |
Unitized layout (machining center+Logistics system) AGV+RGVMaterial flow The central control tower (MESscheduling) |
Equipment utilization85%+ |
|
Flexibility |
Automatic switching300+seedNCprocedure → based onRFIDPallet recognition is automatically called |
Mixed-flow ratio (product type/Day) ≥15 |
|
Responsiveness |
Changeover time≤15minute → Zero point positioning fixture (e.g3R/EROWA） |
OEE(Comprehensive efficiency) ≥75% |
▶ Technical solutions
Typical Cases:Mazak iSMART Factory (Aerospace Parts Manufacturing)
Core equipment: INTEGREX e-800V (turning-milling + 5-axis)
Intelligent Scheduling: AI Dynamic Scheduling (Responding to Emergency Orders)
Tool system: HSK tool magazine + laser tool setter (tool change time 1.3 seconds)
Innovative technology:
Digital twin rehearsal: validation of new workpiece machining procedures in a virtual environment (40% reduction in trial cut costs)
3. Job Shop
▶ Core features
|
dimension |
Technical details: |
Data support |
|
Equipment features: |
Universal machine tool (Vertical Increase/Lathe) → No automatic tool change system (manual dependence) |
The average service age of the equipment is >10year |
|
Personnel dependence |
Led by high-skilled masters → Empirically adjust parameters (e.g. cutting vibration listening position) |
Labor cost proportion35%+ |
|
Order characteristics |
Single batch≤50item → Daily switching3-5Different workpieces |
The types of parts processed are > per year1000 |
▶ Technical solutions
Typical Cases:German precision mold workshop (medical implant processing)
Core equipment: DMU 50 5-axis machining center (no automation configuration)
Know-how: Micron-scale hand polishing (Ra≤0.05μm)
Survival logic: ultra-high value-added parts (unit price>€2000/piece)
Upgrade path:
Zero positioning pallets (e.g. Schunk VERO-S) → changeover time from 2h → 25 minutes
4. Comparison of productivity of three types of enterprises
|
index |
Mass production type |
Flexible manufacturing type |
Workshop production type |
|
Batch size |
＞500item |
5-300item |
1-50item |
|
Cost per piece |
Excellent (scale effect) |
Good (flexible balance) |
Poor (no scale effect) |
|
Product complexity cap |
Low (standardized) |
Extremely high (5-axis multi-sided machining) |
High (Technician Dependent) |
|
Suitable for workpiece type |
Automotive standard parts |
Aviation precision structural parts |
medical/Cultural and creative customized parts |
|
The difficulty of digital transformation |
★★ ☆☆☆ (cured) |
★★★★★ (refactoring required) |
★★★ ☆☆ (Partial Modification) |
5. Practical suggestions for transformation
▶ Workshop-style → flexible manufacturing upgrade steps
1. Step 1: Standardization and foundation
Implement tool preset (improve tool loading consistency)
Establish a process parameter library (curing master experience)
2. Step 2: Unitized transformation
Introduction of Robot Island (1 robot serving 3 machines)
Deploy a lightweight MES (electronic dispatch order)
3. Step 3: Smart Transition
Installation of machine tool IoT box (data acquisition)
Access to the cloud process platform (obtain AI programming support)
Cost estimation (medium-sized workshop):
Initial investment of ¥1.8 million → payback within 2 years (40% efficiency improvement + 15% order premium)
6. The rules of survival of various types of enterprises
Mass production type: Cost sticking → Extend the life of the special machine through TPM full maintenance, and the equipment depreciation is reduced to ¥0.5/piece
Flexible manufacturing: technical barriers → Master 20 core processes such as titanium alloy thin-wall machining, with a gross profit margin of > 35%
Workshop-style production: scarce value → Focus on unpopular fields such as cultural relics restoration knives to avoid price wars
Decisive points for the next ten years:
Batch type supply chain resilience|flexible spelling algorithm iteration|workshop type spelling skill inheritance
