Analysis on the advantages of the six most popular

2022-07-29
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At present, China, the United States, Japan, Germany, South Korea and Italy, the six major mold manufacturing countries, occupy an absolute position in the world in terms of mold output value. Although China's mold industry started late, it has successfully ranked among the world's largest mold manufacturers after more than a decade of high-speed development, but the overall level of China's mold is still dominated by medium and low-grade molds

in recent decades, China's mold manufacturing technology has made a qualitative leap. The mold industry has grown rapidly from small to large, and has become a world mold manufacturing power. We can call this stage the first take-off of China's mold. With the development of China's automobile industry, independent brands are marching towards the middle and high-end, and new energy vehicles are emerging. The market has put forward new demands for us, requiring us to move from low-end molds to high-end molds, from a large mold country to a powerful mold country, and realize the second take-off of China's molds. How to realize the transformation from low to high, from big to strong, and how to realize the second leap of China's mold is a problem worth thinking about by every Chinese mold factory and every Chinese mold person

at present, China, the United States, Japan, Germany, South Korea and Italy, the six major mold manufacturing countries, occupy an absolute position in the world in terms of mold output value, and China's mold output value is the largest in the world

the mold manufacturing industry in the United States, Japan, Germany and other developed countries has the following characteristics in terms of production and operation:

(1) personnel reduction achieved a profit of 73.83 billion yuan. Most of the mold enterprises in Europe, America and Japan are small in scale, and the number of employees exceeds 100. The number of mold enterprises is generally 20-50. The staffing of all kinds of personnel in the enterprise is very streamlined. One person has many functions. There are no idle people in the enterprise

(2) adopt specialization and accurate product positioning. Most mold factories determine their own product positioning and market positioning around the needs of automobile, electronics and other industries for various types of molds. In order to survive and develop in the market competition, each mold manufacturer has its own superior technology and products, and adopts professional production methods. Most mold enterprises in Europe, America and Japan have a group of long-term cooperative mold users, and there are also a group of mold production cooperation manufacturers around large mold companies

(3) advanced management information system to realize integrated management. Mold enterprises in Europe and America, especially large-scale mold enterprises, have basically realized computer management. Computers are widely used in production planning, process formulation, quality inspection, inventory, statistics, etc. all departments in the company can share information through the computer network

(4) advanced process management and high degree of standardization. Unlike most domestic mold factories, which adopt the production organization mode of mainly or all-out fitters, mold manufacturers in Europe and the United States rely on advanced process equipment and process routes to ensure part accuracy and production progress. The advanced technology and management of European and American mold enterprises make their large, precise and complex molds play an extremely important role in promoting the development of automobile, electronics, communications, home appliances and other industries, and also bring good economic benefits to mold enterprises

American mold industry

there are about 7000 mold enterprises in the United States, with less than 15 people accounting for 60% and 30% respectively. Due to the high development of industrialization, the American mold industry has already become a mature high-tech industry and is in the forefront of the world. The specialization of American mold is very clear. Each mold factory has its own advantageous products and basically focuses on the whole process. Take the American Synergis mold factory that we have cooperated with for example. They specialize in making chassis subframe molds, progressive molds and multi station molds. The subframe of a model we once cooperated with was manufactured in three parts, one for America, one for Europe and one for Asia. We are responsible for processing, assembly, delivery up to the initial acceptance level, and the American mold factory is responsible for the final commissioning. This kind of cooperation is beneficial to both sides. We have also learned a lot in the design and manufacturing of large multi station molds

the manufacturing cycle of the side wall mold processed by Ford automobile mold factory is only 8 weeks. It was a miracle to us, but they did it. The process and design in the early stage of the mold are not in the mold factory. In the R & D department, the mold factory is only responsible for the manufacturing process starting from the foam model. Due to the good preliminary work, there are few changes in processing, which saves a lot of time for mold manufacturing. The mold factory processes the foam mold and sends it to the foundry. When the casting comes back, it starts numerical control processing. Due to the automatic conversion of multiple worktables and 24-hour non-stop, the processing efficiency is very high. Moreover, due to the careful consideration of early work such as springback and deformation, coupled with actuarial technology, the first piece pass rate can reach% when the processed mold is directly put into the press for commissioning, which shows the high level of specialized processing technology in the United States

according to statistics, the per capita output value of American moulds in 2014 was about 1.27 million yuan

Japan's mold industry

according to the industrial statistics of Japan's Ministry of trade and industry, there are about 10000 mold manufacturers in Japan, of which more than 91% are less than 20 people, that is, Japan's mold industry is dominated by small and medium-sized enterprises, which mainly rely on specialized division of labor to complete high-quality mold design and processing. As Japan has done a good job in specialized division of labor, the overall manufacturing level of small and medium-sized mold enterprises is high, which makes Japanese mold occupy a higher share in the world mold market

in 1988, I went to Japan's mold factory and full mold foundry to study. The mold factory only processes large main parts, and the rest are assigned to the following small factories for processing. There are special design companies. There is a lack of steel plates. One of them will be processed quickly and sent to the designated location. If there is no screw or nail, it will be delivered to the designated position soon. The division of labor system and supporting system are very perfect

however, due to the rise of Chinese and Korean molds, Japan has been greatly impacted by its price advantage, and has become the main competitor of Japanese small and medium-sized mold enterprises in the mold market with medium and low-grade technology. Because of this, Japanese mold enterprises have to devote themselves to the production and technological upgrading of high-end molds to avoid price competition. That is to say, small and precise, small and specialized technology accumulation is taken as the source of competitiveness to promote the continuous innovation of small and medium-sized mold enterprises and create a sustainable development environment. Many Japanese mold manufacturers are actively expanding equipment investment. In processing, a large number of unattended processing units are used, or online control through computers. The technological development of dies and moulds mainly develops in the aspects of high precision, high speed, long life, complexity, large scale, integration and high performance

according to statistics, the per capita output value of Japanese molds in 2014 was about 1.2 million yuan

German mold industry

Germany is one of the first countries in Europe to engage in mold production. Its mold manufacturing technology and mold quality are affirmed by global users. It enjoys a high reputation in the world and is one of the most important high-end mold suppliers in the world. After years of practice and exploration, German mold manufacturers have reached a consensus that the whole industry must be coordinated, make concerted efforts, make technological innovation, learn from each other, make common progress, and give full play to the overall advantages in order to achieve success in the industry. In addition, in order to meet the needs of the rapid development of new products, not only large companies have established new development centers in Germany, but also many small and medium-sized enterprises have taken the initiative to do research and development for customers. Germany has always been very active in research, which has become an important foundation for it to remain invincible in the international market. In the fierce competition, the German mold industry has maintained a strong position in the international market for many years, and the export rate has been stable at about 33%. According to the data of the German machinery factory manufacturing Association (VDMA), there are about 5000 mold manufacturers, but the mold industrial structure of the country is still dominated by small and medium-sized enterprises: less than 20 people account for 80%, people account for 19%. Detection and control are two different concepts, and more than 100 people, such as oxide skin and metal debris, account for 1%

according to statistics, the per capita output value of German molds in 2014 was about 2million yuan

Taiwan mold industry

Taiwan mold industry is basically a small and medium-sized enterprise, with fine professional division of labor, close production coordination and relatively stable customers. Each enterprise only produces a certain type of mold, and each enterprise has its own fist products, which is conducive to technological excellence and survival and development in the fierce competition. The mold standard parts required by the mold factory are all purchased, and some parts processing industries are jointly produced by other cooperative factories

it is common for mold enterprises to produce parts. Taiwan's mold industry pays attention to the integration of mold and products. Mold and products complement each other and promote each other. Conducive to the development of mold enterprises

closely follow the demand of main products to develop molds and pay attention to exploring overseas markets. Taiwan's mold industry has developed rapidly. Among them, it is also an important factor to follow the main product demand to develop and manufacture molds. In recent years, the rapid development of electronic industry and automobile industry has driven the development of Taiwan's mold industry. At present, 76% of Taiwan's mold output value comes from the stable high-efficiency products and automobiles in the electronics production experiment

I have visited Taiwan's CNC machine tool plants. The main engine plant is only responsible for assembly and some finishing (local scraping and grinding). The bed is welded with steel plates. A special factory is responsible for blanking, and then sending it to the welding plant. After welding, it is sent to the annealing plant. After annealing, it is sent to the processing plant. After processing, it is sent to the main engine plant for assembly. Except for the large-scale main engine plants, other plants are very small. Each plant is responsible for only one process. This shows that Taiwan's manufacturing industry has a fine division of labor and close coordination

China's mold industry

China's mold industry started relatively late. Since the mid-1980s, great changes have taken place in China's mold industry, especially in the past ten years. The changes can be said to be earth shaking. Now China has become a major mold production country in the world. In most fields, Chinese molds have occupied a considerable share. But in the high-end mold, we still need to import a large number of foreign products. As a whole, the overall level of China's mold industry is still dominated by medium and low-grade molds

from the development history of China's mold factories, after the founding of the people's Republic of China, there were no professional mold factories in China. In the 1950s and 1960s, with the establishment of automobile factories, tool factories attached to main engine factories were gradually established, basically large and comprehensive tool factories established with reference to the Soviet model. With the development of the automobile industry, these tool factories were gradually transformed into mold factories

take BAIC, which I used to work for, as an example. In the 1960s, it was called BAIC tool factory, and in the 1980s, Beijing jeep was established, called tool workshop. It mainly produces measuring tools, cutting tools, stamping dies, forging dies, casting core boxes, die-casting dies, injection molds, rubber molds and various fixtures, and gradually turned into a stamping die factory in the late 1990s

since the 1990s, with the rise of private mold factories, the introduction of a large number of numerical control machine tools, the gradual implementation of CAD, CAE and cam, and the vigorous development of the mold industry, China has become a big mold manufacturing country. However, most of the production methods of these factories are large and complete or small and complete. The basic manufacturing methods are low-end molds, and there are few medium and high-end molds. Everyone basically competes in the low-end market

what hinders us from becoming strong, specialized and refined? One of the biggest obstacles is our large and all-round or small and all-round production mode. There is no or insufficient specialized division of labor in our mold production. Current model in China

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