Sayyas Window Industry: How to manage production in the world's largest passive factory?

Source: Black Lake Technology

The wave of the new era is surging, the traditional factory management method has fallen behind, and the digital transformation has become a problem that the manufacturing factory must face.

However, in this process, many factories have encountered difficulties, and as the leader of China's wood window industry, Harbin Sayyas Window Industry Co., LTD. (hereinafter referred to as "Sayyas"), as early as many years ago, has been walking in the forefront of digitalization and information technology, and has quickly become the industry leader.

The mystery is not only its strong product strength, the exploration of digital transformation, but also the booster of Sayyas's continuous progress.

With the world's largest passive factory, Mori Eagle Window Industry was founded in 1998, taking the lead in introducing German wood window systems to China and proposing the concept of "aluminum-clad wood window". For more than 20 years, adhering to the corporate mission of "limit consumption reduction · extremely beautiful life", driving green zero-carbon new life with innovative technology, we are committed to the research and development, design, manufacturing and sales of high-quality energy-saving aluminum-clad wood window products.

Mori Yinying Window industry won the Guinness World Records "largest passive factory" title, in accordance with the "German standard" construction, and equipped with photovoltaic power generation, rainwater collection, water treatment, waste biochemistry, waste heat exchange, sunlight utilization and other functions, a total annual savings of 1.8 million heating and cooling costs, a total annual carbon dioxide emission reduction of 420,000 kilograms.

As a passive window, Sayyas is the "first to eat crabs" in China. In its custom wood window digital manufacturing workshop, you can see a variety of international leading processing equipment. Using these equipment, Sayyas gives full play to the advantages of independent research and development integration, through the four core modules of wood processing center, aluminum processing and production system, glass processing and production system and vertical assembly line, processing and production of top-quality high-end aluminum-clad wood doors and Windows.

However, the demand for personalized customization of doors and Windows is becoming more and more intense, and the old production management model is gradually unable to achieve the market's requirements for large-scale and flexible production of factories. Sayyas's choice is: improve production efficiency through digital systems, maximize production capacity while fine control costs, while providing more personalized choices, taking into account quality, efficiency and delivery cycle, to create an industry-leading digital factory.

"Standard window" pain

Sayyas has always had high quality requirements for products, from all over the world to purchase aluminum-clad wood doors and Windows need high-quality wood, and the use of aluminum seamless welding technology for production, with high-quality products and services to stabilize the domestic aluminum-clad wood doors and Windows industry leading position.

However, as the high-end door and window market continues to expand, the capacity of Sayyas window industry also needs to expand. The need to reduce costs and increase efficiency is becoming more and more intense.

For a long time, the factory has been hoping to optimize the accounting method of production costs, but the production of various window types, order requirements are also ever-changing, personnel allocation, planning and scheduling are based on the "standard window type" as a reference. The actual orders vary greatly, which will lead to uneven busy and leisure between posts, and it is difficult to further improve human efficiency.

In addition, the original system could not knead optimized wood across orders, requiring manual calculation and transcription, using thousands of processing drawings every day, and relying on drawings to convey various processes and changes. Even experienced workers are not immune to omissions.

In order to assist the factory to better optimize, Black Lake Intelligent manufacturing has given three solutions:

1. Design customized system pages and numbering rules for different production links through in-depth use of bill of materials and window diagram, so that different products of the same window type can leave records in each link of the production process, and workers can display product details only by scanning two-dimensional code. When accounting, the system can quickly distinguish differences between products by numbering rules based on product style and size.

2. The way of kneading optimized wood is changed from manual to MES system cross-order kneading. The material consumption is closely related to the order, and the real loss is directed to the order, making the data in the production process more precise and accurate. The wood optimization rate is improved by about 1.5%, and the annual cost reduction is about 1 million yuan.

3. In-depth use of original factory data, eliminate hand-copy plans, reduce the use of drawings, and reduce the dependence on manual labor. The "valuable experience" of the craftsmen is transformed into the operating rules of the system, and the standard process route is precipitated. The time for hand-copying plans is reduced by about 16H per day, the time for selecting materials is reduced by about 4H, and the paper drawings and plans are reduced by about 600,000 pieces per year.

The amount of paper documents is greatly reduced

How do high-end factories manage production?

As the world's largest passive factory, covering an area of 15,570.40 square meters, and with high-quality process equipment imported from Germany and Austria, how to manage such a large and high-end factory in order to efficiently and easily produce?

In the production links of many large factories, the time-consuming and confusing communication process production instructions often become a pain point that seriously restricts efficiency. The lack of an effective material management program will also lead to the situation of "finding materials by luck and relying on people to ask for progress", which often leads to some unnecessary waste.

But Mori Eagle will not be troubled by this, but has its own solution, that is, through the digital platform to solve the management problem.

Through the management of the materials in the workshop, the status and location of the materials can be displayed in real time, strengthen the efficiency of business collaboration, make the production process transparent, refine the production report, achieve the material alignment of the assembly process, prevent the situation of the workshop plan and task fragmentation, and reduce the use of paper documents.

By reading third-party system data, Black Lake Intelligence can automatically complete data cleaning, conversion, and unstructured data processing in the background, and provide workers with optimized task lists after calculation.

According to the time order of the completion of the current process task, push to the subsequent process, so that the data flow smoothly in the system, and the workers of each link can receive the process production instructions in real time. For example, in the grinding workshop, task allocation is automatically carried out by the system, which not only eliminates the subjective factors of manual allocation, but also pursues the highest efficiency as the main goal, which helps to improve the overall collaborative production efficiency. In addition, when workers report working hours by mobile phone after completing the current process, the system will automatically bring out the information of reported workers, link the actual production and personnel to form performance pay, and provide effective performance data for the accounting of the overall salary of employees.

In addition, the factory has also made a large number of BI Kanban boards based on the massive first-line production data in the system, which can not only serve the future production management and the data cornerstone that firmly supports the development of the group, but also become the highlight of the visit and further build a model factory.

Optimize the quality control management process to ensure product quality

Sayyas window industry, with an annual capacity of about 600,000 square meters, also has very high requirements for product quality. When each window begins to be installed, it has gone through 38 manual inspections, but if the quality of each production process can not be grasped in real time, it may not be able to locate defective products in time, or affect the next process. Such a labor-intensive quality inspection process has not reduced Sayyas's high standards for quality control.

But is there a way to optimize this management process in a way that saves manpower and avoids manual inspection lapses? The answer is: Yes.


In the quality management optimization scheme of Black Lake Intelligent Manufacturing, different stations will set different quality inspection tasks, and the system will combine inspection and work report, effectively regulate workers' self-inspection, and reduce quality loss during processing. These data will also be collected by the system in real time, timely share the quality inspection status of the product, support the first inspection, process inspection, inspection, and finished product inspection, improve the data structure of product quality, and form data assets.

In addition, the defective records in the production process need to go through the approval process, and the quality inspector will automatically receive the relevant quality inspection tasks pushed by the system and complete the closed loop of the defective product treatment process in time.

Today, Sayyas is still moving forward on the digital road, the digital workshop is the starting point, to create the industry digital factory, world-class lighthouse factory, with their own practice to inspire and drive the transformation of the old industrial base in the northeast, is constantly approaching the goal. Black Lake Technology will also continue to assist Sayyas in this process to explore the future of factory digitization.