[China Building Waterproofing Association Quality Wanli Line] Hongyuan Waterproofing: Using Big Data to Help Enterprises Improve Quality

At the conference at the beginning of this year, Zheng Xianguo, president of Weifang Hongyuan Waterproof Material Co., Ltd. (hereinafter referred to as "Hongyuan Waterproof"), put forward the annual goal of "informatization and quality improvement", requiring all Hongyuan people to work hard around this goal.

With the development of information technology, the quality field is also filled with massive data. A large number of data analysis is used to optimize the various operational aspects of the enterprise, especially in quality management. Through data-based optimization and docking, cost savings can be achieved while improving product quality.

"After the (product) quality improvement has reached a certain stage, it is impossible to solve the feeding accuracy during batching and the control of coil tension and thickness during production only based on personal experience and sense of responsibility." In November, when the media interview group of "Quality Improvement Miles" in the building waterproofing industry walked into Weifang, Shandong Province, and visited the modified asphalt waterproofing membrane production line of Adi Group in the United States, which Hongyuan Waterproofing just put into production in October, Hu Xibao, general manager of Hongyuan Waterproofing Engineering Company, said, "At this time, modern equipment is needed to realize our precision in quality control. Especially those production equipment with a high degree of automation and informatization can store a lot of data. Through the scientific analysis of big data, we can carry out comprehensive quality management."

The so-called worker wants to do a good job, must first sharper its tools, this sentence is reflected incisively and vividly in Hongyuan waterproof body.

"The key equipment of our two waterproof coiled material production lines are purchased from Adi of the United States, including full-automatic deflection adjustment device, online automatic thickness measurement device, intelligent temperature control feeding and batching system," said Chen Junhua, deputy director of Hongyuan Waterproof North China Production Base. "It has the characteristics of controllable continuous cooling, double mixture dipping and multi-coating technology, and can quickly switch varieties. The product thickness deviation does not exceed 0.05mm to improve and stabilize product quality; at the same time, the fastest line speed can reach 80 meters per minute, and the annual production capacity of a single production line will reach 20 million square meters."

The annual production capacity of a single production line is 20 million square meters! The reporter was surprised. It should be known that the "Access Conditions for Modified Asphalt Waterproofing Membrane Production Line in Building Waterproofing Industry" issued by the Ministry of Industry and Information Technology in 2013 is a single-line production capacity of 10 million square meters, and the annual production capacity of Hongyuan Waterproofing's new production line is fully doubled compared with the access conditions.

Industry experts said that according to incomplete statistics, there are more than 1000 modified asphalt waterproofing membrane manufacturers in China. However, less than 10% of the enterprises have an annual production capacity of 10 million square meters, that is, these 10% of the enterprises are also faced with problems such as low degree of mechanization and refinement, excessive energy consumption per unit product, unstable product quality and so on.

Experts said that Hongyuan Waterproofing, following the commissioning of two Adi waterproofing membrane production lines in the South China production base in June last year, quickly promoted the commissioning of two Adi waterproofing membrane production lines in the North China production base in October this year, which is a typical representative of the transformation and upgrading of the industry. The production of high quality production line not only expands the scale effect of Hongyuan waterproof, improves the production efficiency, reduces the energy consumption, but also stabilizes the product quality.

As a fresh model of "quality improvement", Hongyuan Waterproof has never been satisfied with the improvement brought about by advanced equipment and technology. The annual production skills competition of the five major production bases and the monthly product quality day have aroused the strong interest of the accompanying press group. Chen Junhua introduced to everyone, "The five major production bases now have a competition every year for the assessment of production skills, safety and environmental protection. This year's competition will be held in November and will be completed by the end of November. The competition includes theoretical examination, coil thickness/length control, testing competition and safety and environmental inspection.

"Apart from the self-inspection, random inspection and inspection that we usually do every day, the 15th of each month is designated as the product quality day. On this day of each month, the entire production research and development and quality inspection system of our five major production bases will conduct a major product quality comparison, including cost control, energy saving control, environmental protection index, product performance, etc." Dr. Chen Yang Fei, assistant director of Hongyuan waterproof product research and development, said.

"Only when there is a comparison can we see the gap. In addition to internal benchmarking, we will also carry out industry benchmarking to align with the best products in our industry. At the same time, we will benchmark the waterproof products of the most advanced countries in the world and look at the excellent products of the world to learn and continuously improve." Speaking of these, Dr. Chen is full of passion.

"What is the basis for your technical transformation and the final determination of the optimal modification temperature?"

Chen Junhua said: "Big data is the premise for us to make all decisions. Starting from the ingredients, the parameters of the entire production process are automatically collected and stored. Our intelligent temperature-controlled feeding and batching system adopts advanced automatic control system to complete automatic operation. It collects, tracks and analyzes process parameters such as time, temperature, weight, motor frequency and current changes in the batching process, establishes a database of process parameters and product performance indicators, and provides a strong guarantee for optimizing the production process through data accumulation and curve analysis."

Hu Xibao said that the collection, tracking and analysis of process parameters such as temperature curve, weight curve, motor frequency and current curve in the batching process, and the establishment of a database of process parameters and product performance indicators can ensure the traceability and stability of product quality. Finished product thickness, width, weight to achieve online measurement and storage, through data accumulation, will provide a clear direction for the enterprise's lean production.

Big data brings great opportunities for Hongyuan waterproof. Through big data solutions, they can reduce costs, increase productivity, and ultimately improve product quality by quickly solving problems and improving products based on how users actually use them.(Author's DepartmentChina Building Materials News reporter)