FAW Xichai over 200 million layout heavy duty diesel engine Huishan base

Wuxi, which is in a critical period of transformation and upgrading, urgently needs to introduce new industries and projects. In 2012, Wuxi will start with “three years” such as “project promotion year, style construction year, and grassroots organizational year”, including “projects. "Advancing" as an entry point will play a crucial role in promoting the sound and rapid development of Wuxi's economy.

If we compare the five years of the “Twelfth Five-Year Plan” to five steps, the first step of 2011 has already passed. In 2012, the second step is to start. This is where the second step is going. In the spring of 2012, it was the responsibility of the “propulsion project” for Wuxi’s pillar enterprises, such as Xichai, Hongdou and others.

In early February, the cold and cold outside the factory building is already raging, and the factory building has long been in full swing. Located in the factory building of the FAW Xichai heavy-duty diesel engine base in Huishan District, everything is in order, indicating that this industry is also striding into the "spring." After the 493-acre, heavy-duty diesel engine base with an initial investment of 1.67 billion yuan was completed and put into production, Xichai will plan and realize a total of 800,000 sets of heavy, medium, and light diesel engines, which will increase the supply of Jiefang brand heavy-duty trucks. The core powertrain. Relying on the new base of Huishan, this national brand is going through the independent R&D and large-scale development, taking the government to vigorously develop the advanced manufacturing of Shunfeng Express, and tapping the industry “gold mine”.

Industry status The company with the widest power coverage in the domestic engine industry

The continuous development of innovative capabilities allows FAW Wuxi to always maintain its leading position in the industry's first camp. In terms of emissions, Xichai has already achieved full national and national IV emissions and has the potential for national V. In terms of power coverage, there are seven major series of W, X, K, F, L, M, and N, and a full range of light, medium and heavy product development platforms. This company has become the largest domestic engine industry with the largest displacement span and the widest power coverage, and is known as the "power supermarket."

In 2012, the profit of raw materials may have decreased

Cai Zhenfa, party secretary of FAW Xichai, said that last year, the company completed sales of 10.3 billion yuan, sold 370,000 diesel engines, and realized a profit of 250 million yuan. This year's goal is to sell 400,000 diesel engines, with a sales income of 11.8 billion yuan. However, he set a profit of 100 million yuan this year, which is a reduction from last year. Why does the profit fall as the sales increase? Cai Zhenfa revealed that under the influence of factors such as price increases of raw and auxiliary materials and bank repayments this year, the cost expenditure will be 200 million yuan more than last year, so profit planning will be adjusted accordingly.

“The auto industry is related to GDP, investment intensity and so on. The overall trend this year is estimated to be the trend of low and high before. In January, 22,000 units were sold. In February, the volume of the market has exceeded 40,000 units, showing upward climbing. The situation is estimated to continue to go upwards in March and April." Cai Zhenfa said that when he saw this trend, his heart was also practical.

Facing Challenges There is still a gap between the equipment industry chain and foreign countries

As soon as he started work in the spring, technicians of FAW Xichai dismantled the latest Volvo engine to see if the "heart" of the people was growing. “Opening up and discovering that some of our processes are not inferior to foreign countries in terms of the degree of sophistication, and even exceed foreign countries. As far as cylinders are concerned, we are already a drum with a more complex process, and foreign countries are still flat.” Cai Zhenfa Say.

In his view, independent intellectual property rights will determine the survival and death of the Chinese auto industry. The biggest gap between Xican and the international community is autonomy, and the most promising is autonomy. Cai Zhenfa said that most of the domestic diesel engines are currently joint ventures, but Xichai believes that the automotive industry is the backbone of the national industry. Therefore, it must adhere to independent development and maintain the right to speak in market competition. In order to keep pace with the changing market and ensure that there are always marketable products, Xichai will use independent innovation as the main line of development, integrate global resources, continuously increase research investment, accelerate the pace of new product development, and form high-end advantages in technology.

The reporter learned that at present, the price of the 11-liter engine developed by Xichai is around 60,000 yuan, while similar foreign products are basically over 100,000 yuan. Although it has a higher price/performance ratio, the company has not ignored the gap between technology and foreign competitors. "First of all, in the brand, our competitor Cummins has been accumulating for more than 100 years, and we were founded in 1943. Secondly, equipment manufacturing is a systematic project. At present, our oil supply system is a product of Bosch, and some of its components are also Must be equipped with imported products, so there is a certain gap between the equipment manufacturing industry chain and foreign countries, affecting the level of the whole machine.Thirdly, after-sales service, Bosch and other brands will be directly replaced if there is a problem, and our after-sales are more. Or emphasize the repair package." Cai Zhenfa said.

New Opportunity The "Spring" of Advanced Manufacturing Comes

The policy support from the country to the local governments has clearly defined the direction of development for the city’s traditional advantageous industries and has become a new opportunity for these advanced manufacturing companies, including Xichai.

At present, China’s auto industry is welcoming unprecedented development opportunities. At the same time, many factors such as the energy crisis and environmental pollution are also testing the Chinese auto industry. Therefore, energy saving, emission reduction, and consumption reduction have become the main background of the automobile industry. Under the support of national policies, auto parts remanufacturing has gone from behind the scenes to the front desk and the development of remanufacturing industries has far-reaching strategic significance for China. In 2008, the state promulgated the “Administrative Measures on the Remanufacturing of Auto Parts and Pilots”. FAW Group, as the eldest son of the automotive industry, was identified as one of the first pilot units for auto parts remanufacturing. Xichai remanufacturing base came into being and took the lead in ushering in new opportunities for development.

Wuxi’s emphasis on advanced manufacturing has also created a better environment for the company’s “four ventures”. For Wuxi, manufacturing is an indispensable key figure in the economic structure. In order to support the rapid development of advanced manufacturing, the city introduced in August last year, “Opinions on the Implementation of Manufacturing Competitiveness Improvement Project,” clearly clarified that it is necessary to upgrade the pillar industries and put the development of advanced manufacturing in a more important position, and increase the advanced level. Investment in manufacturing has accelerated the upgrading of manufacturing technology and equipment, fostered the development of specialty industries. By 2015, the total output value of the five pillar industries will increase by 12% annually.

"Twelfth Five Year Plan" Independent Strategy Helps "6518" Target

In the reform and development, FAW Xichai has witnessed independent innovation achievements. In the “Twelfth Five-Year Plan”, it further emphasized the independent strategy and proposed a transition from a learning enterprise to an innovative enterprise, and from a technology follower to a technology leader. The overall vision of the transition from product marketing to brand marketing and from content management to lean management. Taking the “national brand, high-end power” as the goal, according to Cai Zhenfa, during the “12th Five-Year Plan”, FAW Xichai proposed the “6518” target, which means that Xichai Diesel’s annual sales volume will ensure 650,000 units and strive to reach 700,000 units; sales revenue Ensure 18 billion yuan and strive to achieve 20 billion yuan; realize a profit of 800 million yuan. Standing on a new starting point, it can be predicted that a generous expansion of the layout will accumulate more momentum for the continued development of this “power supermarket”.

Project promotion Over 2 billion yuan to build a strong independent brand base

Last year, Xichai invested 1.67 billion yuan and invested a total of more than 2 billion yuan to build a heavy-duty diesel engine manufacturing base in Huishan District. By the end of last year, the project had already been mass-produced. In March this year, it will complete the first phase of the construction of a CA6DM (11 liters) 50,000 engine production line. The second phase of the project has also been started. The newly-added investment is more than 520 million yuan, which is mainly used for the expansion of the 6DM cylinder head cylinder machining to 75,000 units, and it will be put into production by the end of 2012.

It is reported that the construction of the new base is the first major project of FAW Group in the “Twelfth Five-Year Plan” period. On the existing basis, it will also start three phases of construction and it is planned to be completed by the end of 2014. The new base is mainly engaged in the production of heavy-duty engines, focusing on products above 6DL. By then, Xichai will have the capacity to produce 250,000 heavy engines per year. The expansion of over RMB 2 billion has increased the continuous power for the future development of the company.

After the completion of the heavy-duty diesel engine manufacturing base project of Huishan, in addition to the huge economic benefits to Xichai itself, it will also drive the output value of 58 suppliers in Wuxi area to nearly 2 billion yuan, and the tax revenue will be nearly 300 million yuan. At the same time, Xichai also set up a remanufacturing base in the new district, and the total investment of the project is 50 million yuan, with an annual production capacity of 5,000 units. This is a strong attempt by the plant to respond to the country's call to promote the development of a recycling economy. After the completion of the four major bases for Xichai, the established targets for the major production bases for engines with independent brands in China, major manufacturing bases for heavy-duty engines, and major export bases for self-owned engines will become closer and closer.

Visit hotel workshops, robots to help

As early as before the interview, we heard that the new Huishan project successfully used the green factory design concepts of domestic and foreign advanced manufacturing companies and low-carbon manufacturing production experience. The on-site visit did indeed feel the details of the modern factory's practice of low-carbon concepts in architectural design and ancillary engineering, manufacturing technology and process equipment.

Entering the workshop, we found that the biggest difference between the entire workshop and the ordinary workshop in the layout of the production line is that, with the joint workshop as the center, the parts warehouse and the whole warehouse are scientifically integrated according to the production process, and the machine is added with the cylinder and the cylinder head. The line is at the upper line of the assembly area and the delivery distance is very short. According to the staff, after straightening out the process flow, the logistics distance can be shortened as much as possible, and it can also effectively reduce the consumption of long-distance transportation and scratch damage, and can ensure continuous, rapid and convenient production.

Two 90-degree flips and two 180-degree flips. The cylinder parts are sent to the shuttle station and sent to the outer assembly line by the truss handler. On the assembly line, an installation robot drew the attention of the reporter. Looking around the workshop, there were a total of five robots with different assignments. They were assigned to various processes in the workshop. They were glued, assembled, transported, and changed in attitude. According to the staff, with the help of these robots, the overall line automation rate has been greatly improved. On the one hand, robot work can reduce the labor intensity. It is said that the efficiency of a robot can reach 4 workers.

“Enjoy our hotel-style workshop? The energy for central air-conditioning is provided by our ground-source heat pump, which is the first in Wuxi's industrial enterprises.” The staff who accompanied the reporters visited said proudly. Originally, the principle of the ground-source heat pump compound system was to extract cold heat from shallow layers of the Earth’s surface through the use of 1821 heat exchange wells buried deep in the depth of 120 meters underground and circulating water in a 211,000-meter U-shaped heat exchanger. For use in air conditioning systems. “The system itself has no combustion and emission process, neither destroys groundwater resources nor requires a lot of water recharge like a cooling tower. It is a clean and environmentally friendly renewable energy source. When the system is heating in winter, it can store cold at the same time. In order to prepare for summer use, in the summer air conditioning, it can also store heat in the ground for winter use, and its operating efficiency is much higher than that of traditional air-conditioning systems, saving more than 70% of energy when compared with oil-fired boilers when heating; Air conditioning is 35%-40%,” said the staff. It is understood that although one-time investment costs more than 10 million yuan more than traditional air-conditioning, it can save operating costs of more than 2.8 million yuan each year, and it can be recovered in 5 years after normal use.