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For consumers, it is natural that the products they want to buy are both economical and reliable; but if you change your identity into a manufacturing business owner, you want the sales and profits of the products to be as good as possible.
Different companies and different brands of products have different settings for this balance point, but it is undoubted that the essence of the enterprise is a social and economic organization that uses the various production factors to provide goods or services to the market. Therefore, in the product design and manufacturing process, it is necessary to make a trade-off between reliability and economy.
If the reliability is too high, it will greatly increase the design and manufacturing cost, and it will not meet the economic requirements. The increased cost will also reduce the user's purchasing desire. If the reliability is too bad, the user's maintenance cost and downtime will be greatly increased. In line with economic requirements, it will also dispel the user's desire to purchase.
Reliability economy
The reporter recently read a piece of information. Zhang Genbao, professor of Chongqing University and director of the Institute of Mechanical Design and Manufacturing, mentioned the related research on reliability economic analysis of CNC machine tools. In the literature, he said that the main purpose of reliability economic analysis is to find a reliability. And economical at the same time to achieve the best solution.
He believes that it can be simply divided into two aspects: reliability guarantee cost and loss due to poor reliability. As the reliability of the product increases, the guaranteed cost increases and the loss decreases. The intersection of the two data can achieve the best total cost of reliability.
Zhang Genbao said that the current domestic machine tool users are willing to pay high cost to import high-end CNC machine tools from abroad. In addition to the accuracy requirements, more is due to the consideration of the total cost of optimal reliability. At the same time, a large amount of data has also confirmed that there is still a considerable gap between the reliability level of domestic machine tools and the best reliability, and many companies are still engaged in low-cost competition. Therefore, domestic machine tool enterprises urgently need reasonable and effective optimization methods to improve reliability.
It is reported that reliability economic analysis and control mainly includes four parts: the collection of reliability economic analysis data, the modeling of reliability economic characteristics, the analysis of reliability economic characteristics, and the control of reliability economic characteristics.
Zhang Genbao emphasized that the production of enterprises will change constantly according to the needs of market competition. Therefore, the analysis and control process of reliability is a dynamic closed-loop feedback process. Through the data collection of reliability economic analysis, enterprises can understand the actual situation of production, comprehensively consider the decision-making basis by using the economic characteristics model, form the decision of reliability improvement after the analysis of economic characteristics, and finally feedback to the production process through the control of economic characteristics. Each of these links needs to be quantitatively analyzed according to the actual situation of the enterprise, so as to achieve the best economic benefits.
Reliability Economic Analysis Numerical control mainly includes two aspects of product reliability data and economic data, including reliability test data, user usage data, after-sales maintenance data and product inspection data.
“Although there is a certain cost to improve the reliability of the product, there is no contradiction between it and the economics of the product.†In Zhang Genbao’s view, in economics, utility refers to consumers making their own needs through consumption. A metric is met, so reliability also has a corresponding utility. The utility of product reliability has a utility curve with the improvement of product reliability. The higher the reliability, the higher the reliability utility, but the marginal utility is decreasing.
For example, if the machine tool with an average fault-free working time of three months is upgraded to an average trouble-free operation for one year, the user will feel that the reliability of the machine tool changes greatly and the utility increases significantly. However, by increasing the average trouble-free working time to three years, users may not be able to feel the obvious difference between the two.
Indeed, from three months to one year, every one month of average failure-free time, users can intuitively feel the change of machine reliability. This change is marginal utility, and direct economic benefits, subjective use and other factors. related. From two to three years, this marginal utility will be weakened a lot.
Therefore, the improvement of the former's reliability can be considered as an increase in the added value of the product, and consumers are willing to pay for it, and the latter is redundant in Zhang Genbao's view.
Intelligent requirements require high reliability
However, current smart manufacturing has become a new trend in the international manufacturing field. In 2011, Germany proposed the “fourth industrial revolution†(Industry 4.0) at the Hannover Fair, which is now in the implementation stage.
Liu Bingye, director of the Beijing Machine Tool Research Institute, said that the goal of the "fourth industrial revolution" is the intelligence of the factory. In 2013, the United States began the re-industrialization of the intelligent era with the theme of manufacturing resurgence. On the basis of flexible manufacturing, Japan has formed a relatively mature intelligent manufacturing technology. China's current manufacturing labor costs are rising, and the “labor shortage†in some areas has also forced manufacturing companies to transform into intelligence.
The general trend of intelligent manufacturing technology requires that the machine tool must adapt to its application requirements. The most typical application feature is the high reliability of various configurations. As the most basic component of intelligent manufacturing, the reliability of machine tool equipment becomes the most important assessment. index.
For the user enterprise, the direct effect of the utility is the availability of the equipment. Under the influence of the market cycle, the annual production always has a certain idle period. Therefore, the ability of equipment to work continuously during production is the key to affecting utility and marginal utility.
Here, the availability specifically refers to the extent to which the product is available or operable when it is needed and started to perform at any time. If the probability of availability is measured as availability, it is calculated as the ratio of the average time between failures of the product to the sum of the average time between failures and the average time to repair, or the reaction time of the product and the working time of the product, which cannot work. The ratio of the sum of time. In this state, the external conditions of equipment such as regular maintenance measures and human resource allocation can be fully utilized.
Although the higher the reliability of the product and the higher the reliability guarantee cost, the two are nonlinear, and there is also a marginal cost.
For example, a machine with an average of 100 hours of trouble-free operation can be upgraded to 200 hours, which may be achieved only by using high-quality components, and the cost does not change much.
However, if a machine with an average trouble-free working time of 2,000 hours is increased to 2,100 hours and the original component reliability level is already high, only a higher-priced alternative or a thorough improvement of the product can be used. The design and manufacturing process, such reliability and cost increase will inevitably increase significantly. .
Combined with marginal utility, product reliability improvement decisions are particularly important. When the reliability is low, the marginal utility is high and the marginal cost is low, and the reliability can be achieved with half the effort, and vice versa.
However, the average reliability level of domestic machine tool products is generally low, and the reliability of the product has a great influence on the user's equipment procurement decision, which directly determines the sales volume of the machine tool. Under the pressure of market competition, enterprises must constantly improve the reliability of products to ensure their survival and development.
Especially in the current process of industrial transformation and upgrading, domestic machine tool manufacturers have put the focus of competition on the competition of the high-end CNC machine tool market, and compared with foreign competitors, the stability and accuracy of the maintenance has been the domestic machine tool. The weakness of the enterprise, the user's expectations for product reliability and economic benefits continue to increase, and the reliability of the machine tool must also increase. On the other hand, in the case of low average reliability level, the marginal utility of the product is high, and the machine tool enterprises that can make the product reliability well can stand out in the industry, gain wide recognition from users, and occupy a dominant position in the competition.
Machine tool companies must go the way: looking for the best reliability and economy
Abstract Reliability and economy are a happy family. For consumers, it is natural that the products they want to buy are both economical and reliable; but if you change your identity into a manufacturing business owner, you want the sales and profits of the products to be as good as possible. Different companies, different products...
Reliability and economy are a happy family.