精良制造
人与历史
精良制造
IH八大系统
IH八大系统
IH八大系统
IH八大系统
IH八大系统
IH八大系统
IH八大系统
IH八大系统
IH八大系统
IH八大系统
Advanced way of organization suitable for modern manufacturing
To lead industrial frontier technology and promote cooperation among international communities
Sophisticated manufacturing, with its core concept of “just in time supply”, greatly improves enterprises’ production efficiency, and is widely recognized as a way of organization suitable for modern manufacturing industry. Competition among modern enterprises is oriented toward meeting the customers’ demands and striving for breakthroughs in rational changes of production paces, human resources utilization and effective resource allocation. Bearing this exact concept of sophisticated manufacturing in mind, Zongshen Motorcycle actively fulfills its mission of “To manufacture products beyond customers’ expectation and to create value in multiple aspects” and actively marches on the path of pursuing “sophisticated manufacturing, international cooperation and leading technologies”.
01
Product manufacturing and R&D system
Industrial leading R&D capability to response to and guide market demand
9KS product management pattern fully ensures competitiveness and sustainable reliability of products
Technological R&D is indispensable to the sound development of an enterprise. Being deeply aware of the fact that R&D is the inherent need and inevitable choice for an enterprise to survive and develop, Zongshen established its technological R&D center in 1999. After years of development, the center has become a product R&D center engaged in multiple fields, with its total number of authorized patents ranking among the top in China’s motorcycle industry (by 2010, the total number of patents is 2,551, including 106 items of invention, 1,772 practical new-type patents, which makes it rank top in China’s motorcycle industry. It has also become a post-doctorate research work station specially set by the national human resources department. The center established IPD development pattern to carry out horizontal and vertical management and develop products through cross-team cooperation. It uniquely created the 9KS product management pattern to manage all links of product development, including design and R&D, continued improvement, value project, cultural articles, after-sale service, sales process, cost control, production consistency and life cycle, involving the Company’s various departments. The 9KS pattern specified the expected capability of the Company’s various departments and the measures they are supposed to take from new product development to commercial mass production, ensuring consistency in mass production and sophisticated and fine manufacturing quality.
After years of exploration and accumulation, Zongshen has established a whole set of product development process that is suitable to its own conditions, that is the Product Development Book (PDB). This process divides product R&D into seven phases, including product planning, proposal design, style design, detailed design, mold motorcycle, small-batch pilot and mass production. Through the multiple-procedure checks of the first six phases, the quality, reliability and durability of the newly developed products can be fully guaranteed.

9KS product management pattern fully ensures competitiveness and sustainable reliability of products
02
Product supply chain system
To build high-standard supply chain through sophisticated manufacturing, and implement quality management across the whole process
To strengthen control over the manufacturing process to realize sophisticated manufacturing
Sophisticated manufacturing effectively applies modern advanced manufacturing technologies and management techniques, and adopts the point of view of overall optimization to effectively allocate and rationally utilize the company’s resources. As early as in 2000, Zongshen Motorcycle started its effort to establish a closely interlinked supply chain in the entire industry, to enable coordinated business operation of many enterprises under the same ERP management. Under the unified ERP planning for the supply chain, upstream and downstream enterprises can minimize their inventories, and the products of all upstream enterprises can be accurately and timely delivered to downstream enterprises. This has not only helped to accelerate the logistics speed on the supply chain but also reduced the inventories and capital occupation of enterprises. Through the optimization effect of this whole supply chain ERP management, value addition is realized for the entire value chain.
For enterprises pursuing sophisticated manufacturing, suppliers are precious wealth for long-term business operation. In this regard, Zongshen Motorcycle has on the one hand carefully selected quality suppliers who are dedicated to supplying parts and components with high cost-performance ratio, through seven steps of defining potential suppliers, designing evaluation methods, determining candidate suppliers, determining suppliers, evaluating the suppliers’ response rate, negotiating on the contract with suppliers, and signing contract, and on the other hand manufactured some key parts and components by itself to ensure the quality of products. At present, in terms of self-manufacturing, there are 5 frame production lines, 3 bottom fork production lines, 1 muffler production line, 1 main support production line, 1 painting and coating line, 2 plastic and rubber coating line, and 1 oil tank coating line under preparing. In addition, the Company also manufactures and sells engineering plastic products such as automotive plastic intake manifold, motorcycle plastic intake pipe, motorcycle plastic cover, motorcycle air cleaner and machine function parts. The self-manufactured parts and components have not only met internal need, but have also been sold out in the market.

While building its supply chain system, Zongshen Motorcycle has established a comprehensive quality management system covering the supplier, workshop manufacturing process and market users, and integrated the ISO9001, TS 16949, ISO14001 and OHSAS18001 systems to build an integrated quality management platform. It is the first among its peers to introduce the ISO9001 quality management system, and has introduced ISO14001 environmental management system and OHSAS18001 occupational health and safety management system in 2006. In November 2010, the two-wheel motorcycle manufacturing enterprise under Zongshen Group was awarded the honorary title of “China’s Quality-Reliable Enterprise” by China Entry & Exit Inspection and Quarantine Association.


China’s Quality-credible Enterprise
03
Introduction of flexible production line
To design and build the first flexible production line for assembly and testing of motorcycle in China
A milestone in the transformation of motorcycle production method in China
Zongshen Motorcycle has carried out a series of deep reform and bold innovation practices on the path of pursuing sophisticated manufacturing. In 2005, when the growth of motorcycle production and sales were about to come to an end, Mr. Zuo Zongshen acutely sensed the subtle change of the market and made a resolute decision to abandon the forced tempo plate chain production line (off-line qualification rate was 70~80%, featuring high labor intensity) which was at that time widely used by the rivals and to design and build the first flexible production line for assembly and testing of motorcycle in China (patent No. 200610095358). This assembly line integrates assembly and testing as a whole and blends ergonomics principles into its design. While ensuring 100% off-line qualification rate, it also manages to reduce labor intensity to the great extent, improve product quality steadily and enhance individual working efficiency by 25% on average, laying a solid foundation for the enterprise to transform its extensive manufacturing to sophisticated manufacturing. By 2008, with an investment of over 21 million yuan, totally 7 assembly lines of this kind have been built and put into operation, leading the enterprise to set on the path of sophisticated manufacturing.

Zongshen Motorcycle builds the corporate culture of lean production and digs up deeply the Company’s potential in various aspects, including human resources, machinery, materials, laws and regulations and environment protection
In the recent years when the performance of the manufacturing industry has been sliding, Zongshen Motorcycle sought advices from Japanese experts in lean production and domestic well-known professional consultancy firm (such as IBM and China-Co) to build the corporate culture of lean production and involve every one of its staff in this process, digging up deeply the Company’s potential in various aspects, including human resources, machinery, materials, laws and regulations and environment protection. During the 2009 global economic crisis, the motorcycle industry’s integration was intensifying, the economic performance of the whole industry was far from well-off, and main efficiency indexes saw remarkable decline. Against this context, Zongshen Motorcycle still ranked among the top 10 of the industry in terms of production and sales. As the competition intensifies, corporate managers have been keenly aware that the “internal strength” of an enterprise should be its foundation stone. In 2011, according to Zongshen Group’s development strategies, Zongshen Motorcycle put forward its five-year planning strategy of “making overall arrangement in 2012, making hard efforts to improve our performance in 2013, making continuous efforts to further improve our performance in 2014, displaying our strength in 2015 and rising among our peers in 2016”. Currently Zongshen is moving forward step by step on this exact path. When looking back, we cannot help but admire the far insight and unique vision of Mr. Zuo Zongshen as an outstanding entrepreneur.
04
Training of versatile workers
The spirit of manufacturing lies in workers
Highly efficient “versatile workers” training plan promotes the practice of sophisticated manufacturing
In order to further stress that employees are assets which are more important than machinery and to bring their creativity into full play in cultivating corporate culture, and furthermore, to promote the company’s development toward sophisticated manufacturing, meet the demand of the factories’ production pattern featuring multiple status and small batches of orders, and improve the quality and efficiency of production, Zongshen Motorcycle has implemented a system for training middle-level and senior-level technicians specializing in one field yet with versatile skills. Through theoretical training on Basic Knowledge of Safe Production, Lean Production, Assembly Process, Quality Awareness, Must Knows and Must Learns for Assembly Operations, a three-month special coaching for rotating-post operations is provided for employees applying for a certain production post, which enables them to shift to different working posts within specified time to get working experience in all these posts. This is an important way of training versatile workers. There are also other ways such as process optimization and flexible use of human resources. All these ways help build a team with the capability for flexible manufacturing, and have to a great extent solved such problems as single skill of production line workers, change of work place and waste of time in face of product change, and instability in assembly quality. Versatile workers not only master multiple skills and are competent in many posts and familiar with situations on the production site, but they may also make flexible arrangement for production and operation activities. In case of absence of other workers, the versatile workers who possess the skills for the same post may take their place In case of sudden increase in orders and shortfall of labor in some procedures, the versatile workers may help ease the situation of labor shortfall. In this way, we have been able to improve the assembly quality, ensure product consistency, constantly promote the improvement of production efficiency and quality, and greatly push the Company forward toward its goal of sophisticated manufacturing.


Highly efficient “versatile workers” of which Zongshen feels pround
Evolution of versatile workers
05
Ecological friendly plant
To implement the standard of lean production across the production line, production workshop and industrial park
To create a broad environment for complete lean production covering plants and the industrial park


Zongshen ecological friendly plant themed as “Ecological friendly plant, homeland of the heart”
While seeking its own development, Zongshen has also invested a great deal in creating a better ecological environment for the plants. If the Zongshen enterprises which pursue sophisticated production fail to effectively manage themselves and only find chaos in the workplace and littering of tools everywhere, the result could only be low production efficiency and less enthusiasm of the workers. In this regard, Zongshen Industrial Group proposed 6S on-site management to effectively address such kind of issues. Based on this concept, Zongshen Industrial Group invested 14.7 million yuan to launch the campaign themed as “ecological friendly plant, homeland of the heart”, and actively made efforts to apply for the building of “forest plant area” and “municipal-level garden plant”. The greenery around the plant area features combination of arbor, shrub and grass, forming a forest landscape featuring a mixture of multiple layers of plants of different ages. Besides, potted landscape, rockery, spring, fishing pool, swan lake and peacock garden dot the garden with unique beauty. Inhaling the fresh air, listening to the birds chirping and insects vibrating, smelling the aroma of flowers, watching the fish playing with water, you will see the harmonious co-existence between man and nature. In 2009, the plant area was rated as Chongqing’s “forest plant area” and “garden plant area”. However, Zongshen, with its constant innovative spirit, was not satisfied in face of these honorary titles. From 2009, the Company has been actively carried out the campaign to build a “national eco-friendly enterprise”.

Zongshen has placed more emphasis on the ecological effect of the product manufacturing process. It has invested a large sum of funds to implement technical transformation on spray coating and casting processes and establish industrial waste water treatment station to treat the industrial water to meet national standards for water discharge, thus has made contributions to protecting the water environment of the Yangtze River Three Gorges reservoir area. In the meantime, the company emphasizes on the comprehensive utilization rate of resources. Specific consumption indexes have been made for various raw materials / parts and components / energy, and lean production is practiced throughout the entire production process to constantly reduce energy consumption. As to product consumption and circulation, through continuous updating and upgrading, Zongshen has been able to enhance emission standards and guide consumers to choose cleaner, more environmental-friendly and energy-saving products.
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