Zhang Xinping: Revitalizing Old Equipment with Innovation
Introduction: Every bit of innovation contributes to shaping the Hicorp future. At the third-quarter innovation review conference held on October 24th, a large number of innovative achievements from the production frontline emerged, with everyone using innovation to solve practical problems and inject new momentum into the company's digital and intelligent development. To this end, the Group Office and the Internal Control Center have jointly launched the "Strengthening Through Innovation, Thriving with Fresh Ideas" special report on innovation, sharing stories of innovation, transmitting the spirit of innovation, feeling the pulse of innovation, and conveying the power of innovation.
"These are our 1992 and 1996 gantry planers. After the transformation, they are not inferior to new equipment at all. We also have equipment from the 1960s and 1970s over there,"Zhang Xinping pointed to several old gantry planers standing in the corner of the workshop and said with a smile. At the quarterly innovation review conference, theCraftsmanship Maintenance Innovation Workshop led by Zhang Xinping won the second prize in the quarterly technological transformation and innovation category for upgrading these gantry planers, not only bringing old equipment back to life but also achieving increased production and efficiency in the processing workshop.
From left to right: Shao Xingsen, Zhang Xinping, Zheng Jiwei, Wang Lizhi
Following the Trend and Moving Forward with Innovation
At the beginning of 2024, Hicorp proposed the goal at the Amiba meeting that the processing division should achieve a "doubling of output value without increasing personnel." Upon hearing this target, the processing division was taken aback. To increase production without adding personnel, new equipment could be added, but the equipment investment cost would reduce the output value. To increase production with existing equipment, it was necessary to maximize equipment utilization, but this would still be insufficient for "doubling output value," and increasing personnel contradicted the requirement of "no increase in personnel."
"Neither solution was financially controllable. We carefully evaluated both plans. We had considered utilizing old equipment before, but their low efficiency meant employees didn't want to use them, and the input and output were too mismatched. No one wanted to use the 'old machines' for work. So we also considered renovation. Firstly, old equipment occupies space and sells for little. Secondly, purchasing new equipment is costly, has a long production cycle, and requires a significant investment, with a long payback period," analyzed Zheng Jiwei, the Safety Director and Equipment Section Chief of Hicorp. "At that time, including Master Zhang Xinping, our team discussed and explored many schemes together, racking their brains to find a perfect solution."
Their efforts paid off. When progress was slow and collective wisdom hit a bottleneck, a customer's request to renovate their existing coarse spinning frame headstock sparked Zhang Xinping's idea. "Since customers can modify their equipment, why can't we try it too? If done well, it can make our workshop's 'antiques' valuable again." This flash of thought pointed out a new direction for Zhang Xinping's team, and the Craftsmanship Maintenance Innovation Workshop came into being.
Turning Stone into Gold: Improving Efficiency with Innovation
"The renovation was not as smooth as it sounds now. We faced many challenges. The initial plan almost involved replacing the entire structure of the old equipment, and the high cost forced us to reconsider the purpose of the renovation. Zhang also suggested not being too radical," Zheng Jiwei said.
Based on this, Zhang Xinping decided to aim for practicality and cost savings, starting with experimenting on one machine, making full use of existing parts, and striving to improve efficiency with minimal modifications. Zhang Xinping first identified the main purpose of the renovated old equipment from the perspective of "first principles," and after learning that the first machine was mainly to test whether the efficiency of the gantry planer could be improved and make it usable for operators, Zhang Xinping began with a "small test." After multiple discussions, he first tried to modify the two milling heads, and the Gantry Planer 1.0 was officially unveiled. The results were surprising: its operating efficiency was significantly improved, eliminating the need for much manual operation. This gantry planer, which no one wanted to use before, had become one of the main power equipment in the processing division.
Comparison before (left) and after (right) the 1.0 version of the innovative renovation
The positive feedback from the Gantry Planer 1.0 boosted the confidence of Zhang Xinping's innovation team, and they turned their attention to the other old gantry planers quietly standing in the corner of the workshop. "With the experience from the 1.0 renovation, we were bolder in the subsequent renovations. Just then, the HCP2030 new coarse spinning frame was announced and was ready for mass production. Its large components required confidential processing and needed to be completed within the company. With limited existing machining centers, this led us to research how to meet the processing needs of large components for new products," Zhang Xinping said with a smile.
For this renovation of the gantry planer, Zhang Xinping's innovation team began to take bold steps. After promptly assessing the equipment layout, they directly dismantled and eliminated the AC/DC conversion structure and changed the workbench to a variable-frequency motor drive, enabling fast and slow speed control. Secondly, they removed the main mechanical parts, including the cross-beam planer blade and side blade, selected ball screw transmission, and servo-controlled milling heads to ensure feed accuracy, converting the gantry planer into a commonly used gantry milling machine. They also modified the horizontal feed ordinary motor to a servo motor, extensively rebuilt the internal structure of the gearbox, changed intermittent feed to continuous feed, enabling horizontal processing of the milling head. Finally, with an additional servo drive system, the workbench reciprocated, the milling head moved horizontally and vertically, and the side box moved backward and forward for multi-axis integration, allowing programmable operation. This significantly improved efficiency and ultimately achieved "one person operating multiple machines." After this breakthrough and renovation, the old equipment was revitalized.
Equipment Renovation 2.0 Version
An Old Horse, Still Willing to Learn: Continuous Innovation
"Looking back at our entire renovation process, it was like crossing a river while feeling the stones," Zhang Xinping admitted. "Replacing the frequency converter was a difficult hurdle for us at that time. We didn't think much. We weren't afraid of failure, and we didn't worry about what would happen if we failed. Since we had a direction, we were willing to try. Being willing to make mistakes is also a tradition at Hicorp."
Zheng Jiwei also praised the renovation of old equipment: "The effects of the old equipment renovation were immediate. Our old machine tools were initially rejected by even novice operators. Now, after the renovation, everyone wants to use them, and the increase in output value meets our internal self-sufficiency requirements. In terms of economic value, it reduces the expensive cost of purchasing new equipment in the short term, and in the long term, the increase in per capita output value is a natural result. Just changing the drive workbench to a variable-frequency motor drive saves 21,000 kWh of electricity annually, which is tangible cost reduction and efficiency enhancement."
The 2.0 version has been successfully put into use in the processing division of Hicorp. After the automation renovation, it can achieve one person operating two machines, with overall efficiency doubled compared to before. However, Zhang Xinping's innovation team has not stopped there. "Our processing division still has multiple gantry milling machines older than 20 years. Based on the experience from this renovation, we will further upgrade them by combining different processes and product structure layouts."
Currently, the 3.0 project for old equipment renovation is poised to launch, and Zhang Xinping leads his innovation team with high aspirations. The stories of innovation on Hicorp's century-long journey are being told in different sectors and scenarios, and the journey of innovation continues to unfold.
