Materials completeness rate
Processes performed per day
CRRC Zhuzhou Locomotive Co., Ltd. (CRRC ZELC) is a key subsidiary of CRRC Corporation Limited, and a leading player in Hunan’s RMB 100 billion worth rail transportation industry cluster, an important electric locomotive R&D base in China. Hailed as “China’s Electric Locomotive Hub”, CRRC ZELC is engaged in new-tech public transit vehicles, including electric locomotives, urban rail vehicles, EMUs/DMUs, maglev trains, energy storage trams, important parts and components, derivative products of know-how, and maintenance services.
At present, CRRC ZELC has total assets of RMB 26.6 billion and 21 subsidiaries at home and abroad. As a pioneer in globalization of made-in-China equipment, the company exported the first electric locomotive in 1997. It has so far received orders from 20-plus countries and exported products including locomotives, metro vehicles, light rails, EMUs/DMUs, and metro maintenance vehicles. Meanwhile, subsidiaries have been formed in Malaysia, South Africa, Turkey, India and Austria to expand international business.
When Premier Li Keqiang visited CRRC ZELC, he praised CRRC ZELC products as an icon of made-in-China equipment “Going Global”.
The rail transit industry will witness a shift in competition in the next decade. CRRC ZELC will be faced with a combination of challenges in economy, market, policies and technologies. Meanwhile, urbanization in China, advancement of the Bet and Road Initiative and change of the rail transit industry will also create historical opportunities for CRRC ZELC.
Given the opportunities and challenges, the shift to digitalization and intelligence is the only way by which CRRC ZELC may “go global”, survive, create a new CRRC ZELC and make breakthroughs in all aspects in the coming years. All business lines and product lines have a pressing need to move from traditional business and traditional products to digital business and digital products. Product R&D, Purchase, Production and Services have all recognized the importance of data. There is a general consensus among all members about the need to drive innovation with data, and build a digitalization-driven operation system on real-time data sharing, real-time analysis and real-time decision-making.
CRRC ZELC features a typical project management model, in which all production activities are project-driven. It teamed up with Kingdee to kick start an intelligent manufacturing project in 2016 and over two years, sorted out the manufacturing process, integrated core activities such as design, process, planning, logistics, quality and exceptions, connected planning, logistics and production execution around projects and realized integration of business flows and data flows.
Design and Manufacturing Integration
Conversion of design process into production process is realized. A planning system and MRP operation are built in EAS. Production order plans are generated and issued to APS and MES. APS combines multiple constraints and conditions. Auto scheduling produces workpiece –workstation (process)-equipment task plans, which are sent to the central control system or workstation of the production line for execution. NC programs required by production machines are sent to the central control system and written into the machines. Meanwhile, process drawings are issued and on-site interactive query is run to realize paperless manufacturing. Real-time feedback on plan dynamics and the integrated classified exception reporting and handling process assure effective control over plan execution.
Planning and Logistics Integration
Purchase Logistics: Operation in the EAS planning system generates stocking plan and delivery plan, which are sent to suppliers via the supplier collaboration platform on real-time basis, to make sure all materials required when a production task plan is issued will be purchased and received timely.
Production Logistics: A 7-day stocking plan and 3-day bound plan are made and issued in MES. The former is used by Logistics to prepare materials and set up pallets, while the latter is used to generate AGV/forklift materials delivery plan. As per dynamics of plan execution, AGV runs auto-delivery. Mobile app helps realize materials delivery and handover at production site.
Production quality is integrated to create a complete quality traceability system
Test requirements are preset in specific processes. Quality test tasks are generated as per the rules automatically depending on production dynamics. Via EAS and MES integration, a complete inferior quality handling process is put in place (rework, release, scrap and replenishment). All production and quality data are combined with unique workpiece ID (Serial No.), and plus the QR code system, traceability via one code is realized. The traceable content includes: process information, production process data, quality test records, rework records, logistics delivery information, and assembly records. Electronic product profile is also realized.
Supplier collaboration speeds up exchange of internal and external information
CRRC ZELC has established a full-fledged industrial cluster and exchanges massive information with its suppliers every day, for example, PO, stocking plan, delivery plan, quality information, notice of technical change, drawings, and financial reconciliation information. The supplier collaboration platform of CRRC ZELC is equipped with a cross-organization win-win business collaboration mechanism and realizes business collaboration between Purchase, Production, QC, Warehouse and Finance, and suppliers via real-time data sharing. As a result, exchange of internal and external information is accelerated and timely response to market demand is made possible.
Smart production scheduling assures on-time execution of production plans
At CRRC ZELC, production schedules are presented in the form of on-site touch screen, mobile app, and lean electronic dashboard. MES enables assignment of tasks to group members and processes, fault management, report on commencement/completion of work, and QC. Meanwhile, with interface to the design process system, electronic design process files are displayed on terminals at production site to realize paperless site management. Real-time on-site information acquisition and analysis and quick response to project manufacturing progress, process and exceptions assure on-time execution of production plans.
Kingdee and CRRC ZELC have teamed up to combine its proven software system with advanced management mode in an organic manner. A project-oriented intelligent manufacturing management platform has been successfully built for CRRC ZELC to realize lifecycle management, covering project progress, project purchase, project costs and project quality. The project management-based operation and governance mode of CRRC ZELC is well developed and being rolled out and tried by its branches and subsidiaries at home and abroad.
In addition, Kingdee and CRRC ZELC are furthering their partnership into the industrial internet field and aim to create an industrial internet platform and to promote the CRRC ZELC Model in the rail transit industry. The Construction Plan for State Advanced Rail Transit Equipment Innovation Center jointly funded by Kingdee and CRRC ZELC was approved in January 2019.
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