Variant-rich small batch production with LPP
Zhengzhou Hengda Intelligent Control Technology Co., Ltd. was founded in 1999 and is a leading supplier to the mining machinery industry.
As a subsidiary of Zhengzhou Coal Mining Machinery (Group) Co., Ltd. the company specializes in the development, production and sales of key components for intelligent control systems in coal mining. Zhengzhou Hengda is one of the first companies in China to apply such intelligent technologies in the mining industry. Its portfolio includes hydraulic support control systems, electrohydraulic control systems and centralized intelligent control systems for the mine face. To produce the often-large components in such a way that they meet the high safety requirements in mining, Zhengzhou Hengda uses innovative machine tool technology from DMG MORI. There will be 14 NH 5000 DCG horizontal machining centers installed by the end of 2023 including pallet handling, which will play a decisive role in production.
Automated production of batch sizes 1 – 10
Like most industries, mining is undergoing a major transformation. Processes are becoming more intelligent and the automation of mining machines is advancing. The trend is toward customization and made-to-measure production, so more and more orders involve small batch sizes and multiple variants. For example, Zhengzhou Hengda produced only a few dozen product models in 2012. By 2022, the number of models had increased to more than 1,390 and by 2023, the number is expected to reach nearly 2,000. Lot sizes range from one to no more than ten parts in most cases. This clearly shows that the mining industry needs efficient and flexible production lines. Zhengzhou Hengda has proactively grasped this trend and achieved significant growth through its forward-looking strategy. The company has always focused on the ongoing development of its products. This goes hand in hand with the optimization of manufacturing processes, i. e. the search for ever more advanced machining solutions. “In 2010, we were impressed with the NH 5000 DCG horizontal machining center from DMG MORI,” recalls Wang Haipeng, head of machining at Zhengzhou Hengda. “The machine’s box-inbox design ensures high rigidity and reliability.” A perfect solution, Wang Haipeng thinks: “We bought two NH 5000 DCGs and significantly advanced our manufacturing.”
Automated manufacturing: Convinced by facts
Due to the outstanding performance of both NH 5000 DCGs, Zhengzhou Hengda repeatedly chose DMG MORI when expanding its production capacity. Soon, the topic of automation through linear pallet pools (LPP) came to the fore. At that time, Zhengzhou Hengda was not convinced about automation. The fear was that with a higher degree of automation of the machines, the need for maintenance would also increase. To ensure continuous operation of the new machine tools, Wang Haipeng – who was still a maintenance engineer at the time – was assigned to this task as an operations engineer. “DMG MORI provided factual information that completely changed our understanding of automation,” Wang Haipeng recounts. “After the initial changeover, both plants were running very reliably and efficiently.”
Intelligent production layout with linear pallet pools
By the end of 2023, 14 NH horizontal series machines will be installed and automated with linear pallet pools (LPP). Initially, DMG MORI automated six models in 2018 using an LPP with 48 pallet positions and three setup stations. The existing two machines were integrated as well. This was followed in 2020 by another LPP with 48 pallet positions and two setup stations. Here, four automated NH 5000 DCGs were put into operation. The satisfaction with these solutions is reflected in the latest investment. “In 2022, we purchased another four NH 5000 DCGs with LPP, which will be installed at the end of 2023,” says the management of Zhengzhou Hengda. The intensive cooperation with DMG MORI has sustainably strengthened trust. Wang Haipeng adds. “When it comes to orders for major projects, especially in the area of research & development, we can rely 100 percent on machines supplied by DMG MORI.”
Customer-oriented cooperation
Zhengzhou Hengda is satisfied with what DMG MORI has accomplished in recent years. The management has been impressed by the customer-oriented consulting and on-time implementation of the projects. Even more important, they said, was the handling of individual requirements: “In particular, the integration of existing machines into a new LPP and the associated change in the production layout were a major challenge that DMG MORI mastered perfectly.” DMG MORI worked out a detailed plan for the modernization of the production line. “During the adaptation and commissioning, which took almost 20 days, almost all machines remained in normal operation, so production capacity was not affected.” Zhengzhou Hengda has had an equally good experience in the area of maintenance.
With DMG MORI into the future
Zhengzhou Hengda intends to maintain the good cooperation with DMG MORI into the future. This is because the investments in R&D activities as well as the expansion of the product range will continue in order to further advance future-oriented projects in mining. Intelligent mines and digital twins are just two examples of this progress. DMG MORI will remain an important player in this development as a reliable partner in the field of machine tool technology.
Zhengzhou Hengda
Intelligent Control Technology Co., Ltd.
No. 167, 9th Street
Econ-Tech Development Zone
Zhengzhou, China
www.zmj.com