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Abstract: This article discusses the effect of coating process design on coating equipment investment and coating production costs.
1 Introduction
With the vigorous development of China's auto industry, competition is becoming increasingly fierce, price war is inevitable, and the high-profit era of the auto industry will never return. Reducing costs and improving efficiency are inevitable choices for the automotive industry. Reducing costs involves various factors such as investment planning, product design, supporting procurement, production processes, product sales, and process management. This article only from the automotive coating process design point of view, talk about how to reduce the cost of experience.
Automotive coating is one of the four major processes for automobile manufacturing. Large-scale automotive coating lines not only have complex processes, have long construction periods, but also have huge project investment. The coating process design is the “leading†of the construction of the coating line. It not only directly affects the investment cost, but also relates to coating quality and production cost. Therefore, the cost is considered from the source of the coating process design. It is very important to reduce costs.
2 Determination of production plan
The production program is an important design basis for process design and directly relates to investment costs. The determination of the new production line's production program is mainly based on the company's development plan and market forecast. Because there are many uncertainties, the production program is difficult to grasp accurately, too small may not complete production tasks, resulting in market losses, too The increase in costs may result in not only wasting construction investment costs but also increasing the production cost of a single product. The relationship between the cost and output of automotive products is very close. It is particularly noticeable in automobile painting that if a certain batch volume is not reached, starting a large-scale coating line will likely result in a loss of production. Some companies have seen large-scale paint lines already built. However, due to lack of production batches, they were unable to start the production line. As a result, a large number of assets were idle and capital was wasted. In determining the production plan, we must be very cautious and avoid inadvertent investment resulting in major losses. The author believes that if the expected output is not very clear. Or it is expected that the product market will require a longer period of growth. It may be relatively conservative in designing the production plan or adopt a rolling development strategy.
The design and production program is too small, causing oversaturation of production capacity. Some countermeasures can be taken, mainly to increase the year-to-date base rate of the equipment and the equipment start-up rate. Most of the domestic production lines have a considerable margin in calculating the year-on-year base rate and equipment operating rate. The year base calculation deducts all weekends and holidays, etc. The calculation of equipment operating rate is also lower than that of foreign countries. Therefore, the annual base of the equipment is increased. There is a lot of room for equipment to operate. Raising the year-to-date base of the equipment and increasing the load factor of the equipment can not only increase the output, but also reduce the production cost of a single product.
There are also two basic modes for the rolling development of coating capabilities; one is to reconstruct a production line when the production capacity of one production line is difficult to meet production needs; the other is to supplement and reform the existing production line to increase its production. ability. Despite the rolling development. However, a design plan is very important, especially for the second mode. In the first phase of design, it is necessary to design the second phase of the supplement and reconstruction program. It will help reduce the cost of renovation and construction period. To build capacity in a rolling development model. If only the investment amount per unit of production capacity is considered, it may be greater than one-time investment. However, considering investment risk, comprehensive cost and other factors, rolling development is a practical capacity-building model. There are many such successful precedents in the domestic automotive industry.
For commercial vehicle painting. The program of paint and varnish is also an important factor affecting investment costs. In the coating of passenger cars, there must be a middle coating, and the coating methods for top coat (including metal base paint) and cover varnish in the top coat are in the majority, while in the current commercial vehicle painting, middle coat and The varnish usually only occupies a very small proportion, and in order to save costs, the varnish generally shares the varnish line. However, as users continue to increase the coating requirements for commercial vehicles, the topcoats for commercial vehicles that have been painted and shaded have a tendency to expand. Therefore, new commercial vehicle painting lines should be prepared in this area. Reserve positions such as paintings and coverings are to be implemented in phases.
3 The determination of the craft level
The level of technology of the coating production line directly determines the investment cost and the subsequent production cost. Determining the level of craftsmanship is a complex task. A comprehensive analysis of product market positioning, coating quality requirements, the management level of the company, and the economic status of the company should be carried out, and a suitable level should be selected from low to high. The author believes that the determination of the level of technology should be as far as possible, do not have to pursue "icing on the cake." Many paint designers are often accustomed to adopting insurance policies that are not low when determining the level of technology, which often leads to unnecessary cost increases. The primary principle for determining the technological level is that the process is suitable for the quality requirements of the product coating, combined with the comprehensive consideration of the management level of the enterprise, the economic status of the enterprise, and the economic benefits.
The paint shop floor is an important aspect of the support level. It is very important for the car body painting with high decorative requirements and the cleanliness of the painting environment. therefore. It requires the use of a closed air-conditioned plant, which requires that the floor and wall (paint) be smooth and that dust is not easily accumulated. This plant has high cost and operating costs, but it is very necessary for the quality of the coating appearance. Can significantly reduce the rate of topcoat repair, from the perspective of saving repair costs is also worthy of consideration. However, paintings with less decorative requirements, such as chassis parts and truck compartments, can use ordinary open workshops to save costs.
The degree of automation in the paint shop is a major manifestation of the level of craftsmanship. It is also a key factor affecting investment and production costs. The automation of the coating shop mainly includes automation of logistics transportation, automation of spraying (spraying, painting), automatic control of process parameters, automatic identification and control of workpieces, and digital management. Determine its level is mainly based on product grade, production program, funding status, management level, economic efficiency and other aspects. In general, when the product is of low grade and the output is not large (the annual output is less than 2,000 cars), the technical means are mainly man-made: the product is of higher grade, and the annual output (5000-20000) of the vehicle body can be transported by mechanical automatic , Artificial transition between lines, using manual spraying; product quality is higher, the annual production (30000 - 60,000) body, you can use the coating process all automated transport, the key process parameters are automatically controlled, spraying the main artificial, Automatic transfer of paint, manual color change: high product quality, large production (annual output is greater than 100,000 body). All the contents of the paint shop automation can be realized. In the design of the coating process, choosing the appropriate level of automation in line with local conditions is very important for cost control.
In the coating process design, following the progress of the coating and coating technology, the use of new technologies can reduce coating costs. For example, in the traditional middle coating, base paint, and varnish applications, the “three-coat-two-bake†process was applied. In recent years, automotive paint companies have developed “three-coat-and-bake†materials for middle coat, base coat, and varnish. And crafts. Can be used for commercial vehicles and low-end passenger cars, the promotion and application of this technology, you can save investment in coating equipment and floor space. reduce manufacturing cost. However, prior to the use of new technologies, sufficient investigations and studies should be conducted to pay attention to the application conditions of new technologies and ensure the reliability of applications. For example: Using far-infrared drying technology can save energy. It is suitable for the drying of powders and other primers. However, if the infrared drying is used for the top coat drying, the appearance quality of the top coat may be affected. Coatings and coating technologies are constantly evolving and rely on advances in technology. Reducing coating costs is one of the directions for the development of coating technology.
4 process layout
Process layout is an important part of process design. It is a comprehensive embodiment of all data calculations. It is also a complex task. The layout plan should be optimized and then optimized to select the best results. If the layout is not reasonable, it may cause long-term production inconvenience, quality problems are difficult to solve, resulting in invalid labor and increased production costs. For the layout of a large coating line, in addition to the completion of the entire process, it should also pay attention to logistics, zoning, emptying, repair and plant structure, and other aspects of content: logistics should avoid excessive cross, excessive unnecessary round-trip The connection should be good; in order to better ensure the painting environment, the workshop layout should be divided into clean areas, dust production areas, high temperature areas, auxiliary areas and other areas as much as possible; in order to ensure the coating quality, the coating line is stopped. Before, the workpieces in the pre-processing, electrophoresis, and drying must be run empty; the paintings require high decoration. In particular, car painting, design should leave enough room for repair: the use of large-scale body coating line, the use of multi-layer structure is more advanced and reasonable, easy space utilization and workshop zoning, and reduce the underground structure, but the multi-layer structure of the factory Single-storey factory cost is high.
5 equipment selection
The selection of key equipment reflects the level of technology and directly affects the investment costs, product quality and production costs. For example, the pre-body treatment, electrophoresis equipment used in stepping, or continuous investment has a great influence on equipment investment. Step-by-step pre-processing, electrophoresis equipment covers an area of ​​small, equipment investment is small, but the production program can not be too large, in general, the annual program of 30,000 or less. Step-by-step pre-processing, electrophoresis equipment, annual program
More than 30,000 vehicles. Use continuous type. Now there are manufacturers who suggest that in order to save equipment investment, the annual program is less than 60,000, and the pre-processing and electrophoresis equipment can still adopt a step-by-step method. The measures taken are to use a spreader to hold two workpieces, or a longer process time. The phosphating process uses two stations.
The selection of spraying equipment in the body coating line employs the simplest air spray gun for manual spraying, which has the lowest investment cost, but the spraying efficiency is very low, the paint utilization rate is generally around 30% to 40%; and the most advanced modern spraying equipment is High-speed static electrostatic cup sprayer or robot. Spraying efficiency can reach more than 85%, which can save a lot of paint materials and waste paint processing costs, and coating quality is obviously better than other spraying methods, but this kind of automatic spraying system is very expensive. Which type of spraying equipment is used has a lower overall cost, which is mainly determined by factors such as production volume. It is more cost-effective to use a high-efficiency automatic spraying machine for high-volume high-grade production lines, and a production line with an annual output of less than 30,000. The use of expensive automatic sprayers may not be worthwhile. The robot can spray the inside and outside surfaces of the car body. With the development of the robot technology, the price will be lowered, and the spraying robot will gradually expand its application.
There are many types of equipment selection, ranging from one system to one equipment. According to the actual situation, comparing the comprehensive cost should be an important part of equipment selection.
6 Selection of Process Materials
Process materials are closely related to production costs. Under the premise of guaranteeing the quality of the coating, the cost of the process material is not only to compare the price of the material, but also to compare the consumption of the material, the production cost (energy consumption, etc.), and even the environmental protection cost. Trying to use low-energy, environmentally friendly materials is an effective way to reduce costs. For example: choose low-temperature phosphating materials, choose low baking temperature electrophoretic paint, can reduce energy consumption.
Generally, the price of a material is related to its performance index. The higher the performance index, the higher the price. According to the type and grade of the product, determining the material's performance index properly is also an important aspect affecting the cost. For example, electrophoretic coating of a vehicle body is required to have a high throwing power due to its complex shape and a chamber structure. However, the electrophoretic paint has a low requirement for the throwing power of automotive parts having a simple shape. The price is also lower.
7 energy strategy
The paint shop is a large energy consumer, and the energy policy chosen in the process design directly affects the operating costs of the shop. Painting process design should be based on the actual situation, choose to supply adequate and more economical energy. The more economical heating energy used for pre-processing equipment and air conditioning equipment is steam or hot water. The more economical energy source for drying and exhaust gas treatment is natural gas or gas.
Old paint shop. Because of the shortage of natural gas or gas supply, electric energy is often used as a drying heat source, which is not economical from the perspective of energy costs. many places. There is not necessarily sufficient supply of natural gas or gas, but now the supply of oil is abundant everywhere. Compared with electricity, using petroleum for drying energy may also be much more economical. It can be calculated simply. The calorific value of one litre of light diesel oil is equivalent to about eleven degrees of electricity. Based on the local oil and electricity prices, the energy cost of fuel savings can be roughly calculated. Compared with electricity, the use of combustion equipment has another advantage. It can be combined with exhaust gas treatment to directly treat the exhaust gas. Not only comprehensive use of drying furnace exhaust gas. It also saves waste gas treatment and operating costs. With regard to the one-off investment of both, if the cost of the exhaust gas treatment device is calculated, it is basically the same. Therefore, using petroleum as the energy source for drying can also reduce the coating cost.
8 Conclusion
Costs are related to the life of a company. There are many aspects involved in reducing costs. Design is the source. Calculating the cost account from the source will definitely bring about a positive cost reduction effect. Auto painting is one of the most important processes in automobile manufacturing. With careful design and careful planning around the painting process, it will definitely make important contributions to reducing the cost of the entire vehicle.