Chapter 752

This audit is of great significance to the future of the company. However, it is only half a month from the audit date, and the workload is huge. There are a lot of translation materials. The Japanese translator just recruited works late every day, which makes me feel that he is a sincere person. The things to be audited are all details, such as the management of measuring tools, which is the most troublesome. It needs to first point out all measuring tools in the company, and then log them into the account. If there is no checking, check them immediately. If the files are not perfect, make files immediately. If the files are made, check and implement them one by one. These details need a lot of manpower and material resources, more than 100 details Section, the workload can be imagined. On the one hand, Licheng has pulled more than ten sets of molds to produce, and on the other hand, it has to keep improving. I feel that my life is not my own during this period. Together with two managers and a group of supervisors and engineers, Licheng has been improving, checking and reviewing day and night. Sometimes I can hear employees muttering behind their backs: Zihan and I are just like a bunch of madmen these days.

On the 19th, the result of the audit was 58.5 points, which was very strict and meticulous. Zhang lichai, the quality manager, participated in the certification of TS16949 in the company before, but he didn't feel so strict.

Their audit includes the company's strategy, how to achieve the goal effectively, the skills and quality of the management personnel, and the training of the staff, which is more detailed than the content of their e-mails. The audit includes not only the system file audit, but also the on-site audit. Zhenhe is required to pull volt's mold to the trial production, and conduct on-site audit at the same time of trial production. They agree with the quality system documents of Zhenhe and think that most of them are covered, but they haven't fully implemented them. However, they are confident when they learn that most of the management and technical personnel are new people and that the management system has just been completely overthrown and has been re established for less than a month.

The audit is very strict. For example, the company has formulated the quality objectives and broken them down to all departments, but the methods and means to achieve them and how to review and improve them regularly are not clear, so we have to revise the files again. It is found that the company has done customer investigation, but the analysis of customer complaints is not in place, so we need to re analyze them, and we have to ask five whys in the analysis. It is also feasible to change the operation staff Know the customer, the staff training assessment is lower than 85 points, absolutely can't work, in the field randomly ask the staff, once the staff answer is not clear, all retraining.

However, they had two audits. The second one had to reach 85 points. Otherwise, they couldn't pass. Last time, Licheng failed to pass the first one and passed the second one. In addition, they sent people to come in and force them in. However, the time given to Zhenhe this time is too short, only half a month. However, before the audit of Licheng company, volt gave them three months. No way, there is no reason on the battlefield, there is no excuse, I understand the meaning of this sentence, the customer will not listen to your explanation.

In the second audit, we should translate all the improvement plans and the basis of improvement files and send them an email. Later, after the verification, the quality manager measured the translated materials with a ruler, which was nearly half a foot thick. After several overnight shifts, the translators got sick and finally invited the professional translation company to complete the translation.

For more than a month, two department managers and I, together with a group of supervisors and engineers, revised the documents, prepared the process operation instructions, process inspection instructions and QC engineering drawings of volt lion products, and translated them into Japanese for training, implementation and inspection.

The second audit was more stringent. Two engineers from the quality department and the purchasing department went through the audit for three days, including system audit and on-site audit. I have been accompanying the audit for the past three days. I admire Mr. Murata's professionalism of volt quality department. He is not very proficient in the process and technology of aluminum alloy casting, but he has to personally operate every process in the production process. If he has any questions about every detail of every process, he will never let go. Sometimes a process takes two hours. The work of the day must be completed on the same day, and a summary meeting must be held after the audit every day. If not, he will never leave work. Every night, he will work until 1 o'clock to have dinner, and the hotel that sent him back to stay on that night is more than 2 o'clock. He will get up at 6 o'clock the next morning, and the company car will pick him up at 7 o'clock, and arrive at the company on time at 8 o'clock.

After the audit on the last day, Mr. Murata agreed with the company very much. He thought that the improvement effect of the company this time was very good, which was obviously better than that of the last time. I don't know how many points they will give, but I understand that they will definitely pass this time. From Mr. Murata's words, he feels that the Japanese attach great importance to the improvement actions of the suppliers. If the suppliers make great efforts to improve, even if the scores are a little lower, they will agree. If the suppliers only act in form, they will not cooperate.

In this audit, in addition to one problem caused by the deviation in the communication between the two sides in the early stage, which led to the wrong installation of an equipment temperature controller, there are two or three very minor problems, which can be solved immediately. I gave a score of 92 according to the scoring standard provided by the customer. I've been busy for more than a month, but I've got something.

But also can't relax, although the system and engineering audit passed, but also use Licheng original mold proofing, only after the sample qualified, can mass production. Licheng company's mold design technology and manufacturing technology is very poor. Mr. Wang and manager Ma of the technology department have inspected their molds. In a word, they comment that they are "garbage molds". Licheng has changed the molds many times, proofing many times before they are qualified, and the product size is near the limit value. It is very difficult to guarantee the quality of production with this kind of mold. Moreover, Zhenhe organizes technical personnel to be honest After checking the original process, it was found that many of them had problems with the original process. They produced 50000 sets of goods, only less than 20000 sets of goods were sent out, and the defective rate was more than 60%. Originally, Zhenhe wanted to design his own mold for proofing, including changing the process of Licheng company, but volt disagreed because they spent hundreds of millions of yuan on the design of a fully automatic production line. If Zhenhe changed the process, he was worried that there would be deviation. He had to wait until Zhenhe designed a new mold himself before applying for changing the process.Licheng will pull the mold to Zhenhe to start proofing. Volt is also very strict with the inspection and experiment of samples. Half of the samples are sent to the factory and half to the laboratory. Both sides are OK. It usually takes half a month from the sample preparation to the sample confirmation in Japan. There are too many problems with Licheng's mould. The new mould is also welded, and many dimensions are in the limit value. Often this dimension is OK, and that dimension deviates again. It took one and a half months to repeatedly test, and finally the proofing was successful at the end of February. In February, it was reported that the 20000 sets of products originally sent out by Licheng were all scrapped if they were not up to standard, and the products assembled by volt lion were all scrapped, resulting in a loss of millions of yuan.

After passing the system audit, the whole company was very happy. Mr. Zhen invited the management to the restaurant to have a meal to celebrate.

After that, the company began to design and manufacture new molds. Licheng's molds were produced one by one, and Zhenhe's molds were produced two by one and four by one. The company checked the original quotation of Licheng company, and actually quoted it at 13500 yuan / ton. At this time, the price of aluminum material rose to more than 20000 yuan. Licheng's mold came out one by one. With such a low quotation and such a high defect rate, it would definitely lose two. Zhenhe Zhongxin negotiated a reasonable price with customers.

Zhenhe used the old mold provided by Licheng to arrange the mass production of the first batch of goods. The first mass production was 6000 pieces, and the defect rate was nearly 16%. I believe that if the new mold designed by our company, the defect rate will definitely drop sharply. After the new mold is tested, the formal mass production can be started one month, and the production capacity will reach 50000 sets. When we use the new mold, the defect rate will be controlled at more than 5% In this case, the profit margin is considerable.

After the first batch of 6000 sets of goods were delivered to Japan for assembly, they were completely qualified. After the first batch of mass production goods were delivered to Japan for qualification, Japanese volt sent senior executives of material department and Engineering Department to visit Zhenhe, confirmed that Zhenhe was a qualified supplier of Zhenhe, and placed an order to Zhenhe for one year:

50000 sets of orders per month, the amount of which is nearly 1.5 million; if Zhenhe has sufficient production capacity, every year Another 30000 sets of orders will be added each month, totaling 80000 sets, with the amount exceeding 2 million; if the quality and delivery date meet the requirements of volt, 200000 sets of orders will be added each month, with the amount exceeding 5 million.

In this way, Zhenhe can get at least 20 million orders based on 50000 sets of orders per month, and 35 million orders if the quality and delivery date meet the standard and increase the orders. In the whole year, we can get 50-60 million orders. If we develop such a customer every year, the enterprise will develop very rapidly. I plan to focus half of my energy on internal management construction and half on market development in 2006, striving to develop some heavyweight customers and eliminate those small customers.

A famous European motorcycle manufacturer also went to Zhenhe for audit. After the audit of volt, the management of the company improved a step. After two days of strict audit, the company successfully passed the audit with a high score at one time. Zhenhe became the qualified supplier of that European motorcycle manufacturer. They decided to put some products into Zhenhe for production.

After that, DDK company conducted an annual audit on Zhenhe, and their quality director thought that Lifeng had greatly improved in the past year, with obvious progress in management system and personnel quality. In particular, the foundry shop was much better than other similar suppliers, with complete process operation guidance, process inspection guidance, equipment maintenance and other records, and all kinds of parameters were very clear. The only thing I think is that the progress of CNC workshop is not big, and there is still a gap with other similar companies.

With the increase of my understanding of the aluminum alloy casting industry, I have the following strategic thinking:

foundry enterprises are the basic manufacturing industry, and the core of the basic manufacturing industry is mold technology. We should learn from Foxconn's mold management. At that time, under the risk of the collective resignation of all mold masters, Gou decided to open mold technology for technical precipitation, Only by carrying out the standardization of mold production process can hongzhun mold develop to today's scale of 10000 or 20000 people, and design and manufacture a set of large precision mold in seven days. Many small mold workshops are made by several primary and junior high school graduates. The master takes a few apprentices with him. All the apprentices want to be the boss. Therefore, the master guards against the apprentices. A few years later, the apprentices open a smaller mold workshop by themselves, which lacks standardized operation, long-term vision, vicious low-level and low-level competition, low-cost and high-quality manufacturing of precision mold The ability to possess is never long.

At present, Zhenhe's core competitiveness is to produce more than one piece of mold design technology. However, the company's mold manufacturing level is not high. Most of the employees in the mold workshop are related households, and the mold quality is not high. I intended to spend one to two years to introduce some graduates of technical secondary school who have theoretical basis in mold specialty, and standardize the operation, so as to combine Zhenhe's mold manufacturing technology Make it a reality. The mold quality of foundry industry determines 70% - 80% of the product quality.

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