肇慶動力金屬股份分會報告

2015年11月

1、公司簡介CompanyProfile?企業(yè)概況Generalintroduction?發(fā)展歷程Developmenthistory?行業(yè)地位Positioninindustry?戰(zhàn)略價值Strategicvalue?競爭優(yōu)勢Competitiveadvantage?重要客戶Maincustomers?主要產(chǎn)品Mainproducts?生產(chǎn)裝備

Facility

2、PD報告

?研發(fā)能力R&Dability?技術(shù)交流

Technologyexchange?品質(zhì)保證Qualityassurance?反應(yīng)能力Reactionability?售后服務(wù)After-salesservice?案例分享Caseshare?奮斗目標(biāo)Goal?鄭重承諾Solemncommitment目錄CatalogPART1：公司簡介公司名稱廣東肇慶動力金屬股份有限公司Companyname:GuangdongZhaoqingPowerFoundry(Holding)Co.,Ltd法人代表董事長何韶先生Legalrepresentative:Mr.HeShao(Directoroftheboard)公司成立于1951年10月Foundeddate:InOct.1951公司地址廣省肇慶市三榕港工業(yè)加工區(qū)璣東路Address:JidongRd.,SanrongIndustrialZone,Zhaoqing,Guangdong占地面積現(xiàn)廠房占地面積6.5萬平方米,建筑面積5.4萬平方Floorarea65,000m2(withbuildingarea48,000m2)銷售收入約5.3億元人民幣(2015年計劃)SalesrevenueAbout530millionRMB(2015forecast)公司人員約1500人（2015年10月末)HumanResourceAbout1500staffs(UptoendofOct2015)主要產(chǎn)品Mainproduct

?汽缸套半成品、加工完成品Cylinderliners(Semi-finishedandfinished)?汽車各種鋁合金重力/低壓鑄造缸蓋Aluminumalloyparts/CylinderHead(Gravitycasting/Lowpressurecasting)?汽車新能源殼體、鋁合金支架、歧管、底盤支架等加工完成品Newenergyshellforautomobile,aluminumbracket,manifold,chassis(finished).

?通信設(shè)備的鋁合金支撐件的毛坯、涂裝完成品industries(Semi-finishedandfinished)

?不銹鋼柴油汽車排氣系統(tǒng)零件Stainlesssteelpartforexhaustsystemondieselcar公司概要CompanyGeneralIntroduction1951肇慶動力配件廠成立（國營）1995出資成立合資企業(yè)：肇慶本田金屬有限公司1998通過ISO90012002出資成立：肇慶本田模具有限公司2003公司改制成為民營企業(yè)2006新工場建設(shè)2007廠區(qū)搬遷，通過TS16949認證2010更名為“廣東肇慶動力技研有限公司”2011通過ISO14001認證2013啟動福特Q1認證程序，不銹鋼精鑄項目上馬2014肇慶動力湖北咸寧工場簽約2015更名為“廣東肇慶動力金屬股份有限公司”公司名稱：肇慶本田金屬有限公司ZhaoqingHondaFoundryCo.,Ltd成立：1995年1月注冊資金：500萬美元銷售額：5億元產(chǎn)品：缸蓋、活塞下機體、歧管等公司名稱：本田金屬模具（肇慶）有限公司ZhaoqingHondaFoundryMoldCo.,Ltd成立：2002年7月注冊資金：400萬元銷售額：5000萬元產(chǎn)品：模具、夾具等發(fā)展歷程Developmenthistory肇慶動力持股40%ZPshareholding40%本田金屬持股60%ZHFshareholding60%持股比例：Shareholdingratio行業(yè)地位:Positioninindustry※

國家級高新技術(shù)企業(yè)；Nationalhighandnewtechnologyenterprise※

國家汽車零部件出口基地；Nationalautopartsexportbase※

國家安全生產(chǎn)標(biāo)準(zhǔn)化二級企業(yè)。Thenationalproductionsafetystandardizationsecondlevelenterprise※

全國鑄造行業(yè)綜合百強企業(yè)；Thetop100enterpriseofChinafoundryindustry※

中國鑄造協(xié)會副理事長單位；DeputydirectoroftheunitofChinafoundryassociation

※

廣東省鑄造行業(yè)協(xié)會會長單位。Guangdongprovincefoundryindustryassociationunit※

廣東省清潔生產(chǎn)企業(yè)；GuangdongprovinceCleanProductionenterprises※

廣東省級企業(yè)技術(shù)中心；TechnologycenterofGuangdongprovincialenterprise.※

廣東省技術(shù)創(chuàng)新優(yōu)勢企業(yè)；

TechnologyinnovationadvantageenterprisesinGuangdongprovince※

廣東省裝備制造業(yè)100重點培育企業(yè)；Maintop100cultivateenterpriseoffacilitymanufacturingindustryinGuangdongprovince

※

廣東省民營企業(yè)創(chuàng)新產(chǎn)業(yè)化示范基地。PrivateenterpriseinnovationindustrializationdemonstrationbaseinGuangdongprovince立足中國，建設(shè)面向全球汽車發(fā)動機汽缸蓋、新能源汽車驅(qū)動電機殼體、通訊裝備配套的優(yōu)秀精密鑄造零部件企業(yè)。StrivingtomakeourselvestobethestrongestmanufacturingbaseinChinaforautomotivecylinderhead,newenergyautomotivedrivingmotorshellandindustries.創(chuàng)新引領(lǐng)創(chuàng)造價值卓越品質(zhì)永續(xù)發(fā)展LeadandinnovationValuecreationExcellentquality

Sustainabledevelopment發(fā)展戰(zhàn)略DevelopingStrategic核心價值CoreValue競爭優(yōu)勢Competitiveadvantage國內(nèi)外業(yè)界知名度較高的“肇慶動力”品牌；Well-knownbrandof“ZP”.消化、吸收本田先進管理經(jīng)驗后創(chuàng)新形成的ZP獨特管理模式；DigestandabsorbadvancedmanagementexperiencefromHonda,innovatetheuniquemanagementmodeinZP.覆蓋全球三大汽車配套體系：歐美系、日系汽車、中國自主品牌；Covertheworld'sthreebigcarsseries:EuropeanandtheUSseries,Japaneseseries,Chineseindependentbrandsseries.結(jié)構(gòu)合理的三大產(chǎn)品系列：缸套、鋁合金、不銹鋼鑄件；Reasonableproductstructurewith3kindsofproducts:Cylinderliner,aluminumalloyparts,stainlesssteelparts擁有凸刺狀缸套、鋁合金低壓/重力鑄造、不銹鋼精鑄的核心技術(shù)；Ownthecoretechnologyofconvexcylinderliner,gravity/lowpressurecastingforaluminumalloyparts,precisioncastingforstainlesssteelparts.穩(wěn)定的戰(zhàn)略素養(yǎng)強的經(jīng)營會議班子；Havethestabletopmanagementwithstrongstrategyconcept素質(zhì)較高的員工隊伍；Highqualitystaffs穩(wěn)健的財務(wù)狀況和長期良好的現(xiàn)金流管理。Steadyfinancialandlong-termgoodcashflowmanagement1989配套玉柴缸套1989YuCaiCylinderliner2000配套美國哈雷摩托缸套2000Harleymotorcyclecylinderliner2002配套廣汽本田飛度、鋒范進氣歧管2002IntakemanifoldforGACHonda(Fit&City)2005通過伊藤忠商事配套小松康明斯彎管長安鈴木、長安汽車缸套2005ElbowforKomatsucummins,CylinderlinerforChanganSuzuki&Chang’anAutomobile2006配套東風(fēng)本田CRV發(fā)動機支架與歧管2006

EnginesupportandmanifoldforDongfengHondaCivic2008成為一級供應(yīng)商配套克萊斯勒鏈箱蓋同年配套久保田農(nóng)用機歧管、配套比亞迪汽車缸套2008ChaincasecoverforChryslerasTier1supplier,AndmanifoldforKubotaandcylindersforBYD2009成為福特二級供應(yīng)商配套變速器油泵蓋配套海馬汽車騎士缸蓋、廣汽傳祺缸蓋2009TransmissionoilpumpcoverforFordtier2supplier,andcylinderheadforHaimaAutomobileandGACTRUMPCHI2010上馬江鈴汽車3.0L柴油E802缸蓋項目20103.0LdieselE802cylinderheadprojectforJMC2012配套上汽GM五菱B15缸蓋配套、廣汽豐田漢蘭達制動器卡鉗、長安鈴木、卡斯馬麥格納支架開發(fā)成功2012B15cylinderheadforSGMW,brakecalipersforGACToyotaHighlander,

developedbracketforChanganSuzukiandMAGNACOSMA2013成為福特一級供應(yīng)商,上馬美國新REMY能源殼體2013OilpumpcoverforFordmotorasTier1supplierandstartingQ1approval,NewenergyMotorShellforRemyUSA2014配套歐洲柴油機排氣顆粒收集器項目(大眾、寶馬、奔馳柴油發(fā)動機)

配套廣汽菲亞特JEEP虎鯊缸蓋2014ExhasutgrannulecollectorfororiginalEuroDieselengine(FAWVolkswagen,BMW,Benz,dieselengine).Tiger-SharkCylinderheadfoJeepofFiatGAC2015克萊斯勒V86.2L缸蓋開發(fā)，湖北恒隆轉(zhuǎn)向節(jié)殼體（間接供貨克萊斯勒），美國水上飛人水管項目，上海電驅(qū)動電機殼體20156.2LHellcatcylinderheadprojectforFCA.ChryslerknuckleforHubeiHenglong.WaterpipeforFlyDiveUS.

公司重要客戶配套歷程Customerdevelopment進氣歧管座Intakemanifoldseat發(fā)動機支架Bracket缸套CylinderLiner●發(fā)動機零部件Engineparts●●進氣歧管與水管類零部件Intakemanifoldseatandwaterpipe發(fā)動機支架、底盤安全件、制動器卡鉗Bracket、Safetypartsforchassis、BrakeCaliper制動器卡鉗Brakecalliper●●水管Waterpipe電機零部件Motorparts電機殼體Electromotor

shell傳動裝置零件Transmissionparts鏈箱蓋Chaincover油泵蓋Oilpumpcover排氣系統(tǒng)零件Exhaustparts底盤盤安全件Chassisparts下機體Lowerblock機體Block主要產(chǎn)品MainProduct缸蓋（1.5T&1.8T）CylinderHead(1.5T&1.8T）缸蓋（V8）CylinderHead(LV8)NGD3.0LHM2.0LYC1.5LP31.8LMS2.0LP71.3TG5011.5&1.8TE8023.0LPUMA2.4L&2.2LPUMA2.0L6.4L(V8)6.2L(V8)Tigershark2.4LTigershark2.0L缸蓋重要客戶配套噴砂Blasting機加工車間Machiningworkshop宏創(chuàng)珩磨機Hchoningmachine德國格林珩磨機GreenhoningmachineFromgermany缸套生產(chǎn)裝備5噸美國彼勒電爐LntermediatefrequencyelectricFurnace德國杜克長管離心3工位鑄造機GermanthreestationlongtubeCentrifugalcastingmachinr(1unit)全自動機加工生產(chǎn)線Automaticprocessingline熱芯盒制芯機HotCoreBoxMakingMachine砂芯生產(chǎn)線SandCoreMakingLine油泵蓋無塵房Dust-FreeRoomForOilPumpCover切斷機械手Cuttingdevice熱處理爐HeatTreatmentFurnaceFATA重力自動鑄造生產(chǎn)線FATAAutomaticGravityCastingProductionLine低壓鑄造機群Low-PressureCastingMachine翻轉(zhuǎn)式重力鑄造機OverTurningGravityCastingMachine冷芯盒制芯機ColdCoreBoxMakingMachine加工中心MachiningCentre油泵蓋機加工線MachiningLineForOilPumpCover鋁合金生產(chǎn)裝備金型制作Moldmaking射蠟成形Waxinjection蠟樹組裝Treesclustering蠟?zāi)１砻嫱垦bMoldsurfacecoating沾沙Sandmoistening脫蠟Dewaxing鑄模加熱Castingmoldheating鑄造Casting水口切斷Risercutting噴沙

Blasting檢查

Inspection不銹鋼精鑄裝備PART2：PD

報告我們的設(shè)計能力OurDesignAbility：CAE能力：UG、CATIA、CAD、

MAGMA的熟練使用。CAEability:MastersMAGMA,UG,CATIA,Pro-E,JSCASTetc※

UG產(chǎn)品輪廓及肉厚分析，模具開發(fā)；UseUGtoanalyzeproductprofileandwallthickness,moulddevelopment.※Magma鑄造模擬分析，充型、凝固等分析；UseMagmasoftwaretosimulatethecasting,filling,solidification.※PFMEA數(shù)據(jù)庫PFEMAdatabase專設(shè)的MAGMA軟件分析室MagmaroomPUMA2.2L缸蓋凝固過程模流分析SolidificationsimulationforPUMA2.2LcylinderheadE8023.0L缸蓋殘余應(yīng)力分析ResidualstressanalysisforE8023.0LcylinderheadPUMA2.4L缸蓋模具及砂芯組合設(shè)計PUMA2.4LCylinderheadtoolingandsandcoreassemblydesign澆口Pouringgate頂模Uppermold水冷鑄銷Waterchilledpin排氣側(cè)模Exhaustsidemold進氣側(cè)模Intakesidemold前模Frontmold后模Backmold底模Bottommold升液管LiftTube鑄件Castings升液箱Liquidliftingbox進氣道芯Intakecore排氣道芯Exhaustportcore水道芯W(wǎng)aterjacketcore油池芯Oilcavitycore模具結(jié)構(gòu)Mouldstructure澆口設(shè)計Pouringgatedesign砂芯組合Sandcoreassembly案例1-1Case1-1下型面Bottommoldface上型面Uppermoldface為改善燃燒室面的枝晶間距（DAS），模具設(shè)計時采用獨特的水冷、氣冷的方式，最終實現(xiàn)了低壓鑄造的方式也可以保證Puma缸蓋DAS控制在35um以內(nèi)的目標(biāo),滿足了技術(shù)要求。ToimprovetheDASofcombustionchamber,themoulddesignwiththemethodoftheuniquewater-cooled,air-cooled,finallyrealizesthewaylowpressurecastingcanalsoensurethePumacylinderheadwithin35umDAScontrolgoal,meetsthetechnicalrequirements.※冷卻配置

Coolingconfiguration

1.下型面采用獨立的燃燒室鑲塊→目的是確保燃燒室的DAS

Bottommoldface:useindependentinsertforcombustionchamber,toensuretheDASforcombustionchamber.

2.上型面在噴油孔鑄銷上配置水冷銷→目的是能保證順序凝固

Uppermoldface:setawaterchillingpinonoiljetholepin,toensurethesequencesolidification.PUMA2.4L缸蓋模具水冷方式設(shè)計WatercoolingsystemdesignforPUMA2.4Lcylinderheadmold案例1-2Case1-2E8023.0L缸蓋模具及砂芯組合設(shè)計MolddesignandsandcoreassemblyforJMCE8023.0LCylinderhead湯道Runner澆注湯道Pouringrunner水冷管watercoolingpipe后模Backmold左模Leftmold底模Bottommold頂出桿Ejectorpin右模Rightmold前模Frontmold湯道、冒口設(shè)計Runnerandriserdesign補縮冒口FeedingriserEGRcoreO/JSandcoreW/JSandcoreSandcoreofintakeSandcoreofexhaust案例2-1Case2-1G501缸蓋模具及砂芯組合設(shè)計MolddesignandsandcoreassemblyforG501Cylinderhead案例3-1Case3-1冒口芯、油池芯采用冷芯Coldbox進、排氣道芯采用熱芯Hotboxforintakeandexhaustsandcore上水套芯采用熱芯HotboxforupperW/Jsandcore下水套芯采用熱芯HotboxG面、IN面、EX面、T/B面、M面采用金屬型MetalG501缸蓋制作方案設(shè)計ManufactureplanforG501案例3-1Case3-1我們的技術(shù)隊伍:OurTechnologyability：※

日本鑄造專家長駐技術(shù)支持；

InvitecastingexpertsfromJapanaslong-termtechnologycounselor.※

日本本田金屬20年合作經(jīng)驗；

20yearscooperationexperiencewithZhaoqingHondaFoundryCo.,Ltd※

十年以上工作經(jīng)驗的技術(shù)骨干團隊；

Technicalbackboneteamwithmorethan10yearsofworkingexperience放砂芯轉(zhuǎn)盤Turntableforsandcoreplacing取砂芯機器手Robotforsandcorepicking澆鋁液機器手Robotforaluminumliquidfilling取制品機器手RobotforpartstakingoffE802缸蓋項目成功開發(fā)制造SuccessfuldevelopmentofE802cylinderheadprojectAssemblingintakeandexhaustAssemblingsandcoreofriserandsandcoreofO/JAssemblingFinishPouringManipulatortaketheworkpieceManipulatortakethealuminiumliquid

E802缸蓋項目成功開發(fā)制造SuccessfuldevelopmentofE802cylinderheadproject廣泛的國際技術(shù)交流InternationalTechnologyExchange最終數(shù)模確定3Dconfirmed模具Molds模具設(shè)計Molddesign生產(chǎn)線設(shè)備FacilitiesFATA三工位自動澆注重力生產(chǎn)線FATA3stationcastingline送樣計劃OTSPlan10pcs100pcs模具調(diào)試Toolingdebugging2013/32013/4模具制作Moldmaking模具納入Receivedmolds項目啟動Projectkickoff2013/62013/7小批生產(chǎn)smallbatchrun2013/82013/5我們的開發(fā)速度:OurDevelopmentrate：※3個工作日內(nèi)完成開發(fā)的可行性評審，7天內(nèi)完成最終的產(chǎn)品報價

（接收客戶產(chǎn)品2D圖紙、技術(shù)文件報價信息后）。Finishthefeasibilitywithin3workingdays.Finishthequotationwithin7workingdays.(Afterget2Ddrawingandtechnologyinformationfromcustomer.※

4.5個月提供合格OTS樣件

ProvidethegoodOTSsampleswithin4.5months.G501缸蓋開發(fā)速度實績（4.5個月）G501CYLINDERHEADACTUALDEVELOPMENTSCHEDULE(4.5MONTHS)樣件提交SubmitOTS我們的反應(yīng)能力Reactionability：

※2個工作日內(nèi)完成缸蓋可能失效檢測。

Finishtheheadspotentialfailuredetectionwithin2workingdays

※2周內(nèi)提交完整的失效分析報告。

Submitthewholefailureanalysiswithin2weeks.X光探傷機X-raydetector圖像分析儀

Imageanalyzer直讀光譜分析儀Directreadingspectrometer材料試驗機Materialtestingmachine洛/布硬度計Roughnesstestingmachine華南理工大學(xué)產(chǎn)學(xué)研究合作的強大支持SupportfromSouthChinaUniversityofTechnologySEM微觀形貌&能譜EDS檢測SEMmicrostructure&energyspectrumdetection斷口微觀形貌檢測FracturemicrostructuredetectionZP與華南理工大學(xué)等高校建立產(chǎn)學(xué)研的戰(zhàn)略合作關(guān)系，迅速定義失效及給出改善措施。ZPestablishstrategiccooperativerelationshipwithSouthChinaUniversityofTechnology,to

quicklydefinefailureandworkouttheimprovement.我們的研發(fā)體制:OurDevelopmentSystem：※針對JMC的每一個產(chǎn)品，都由開發(fā)部副部長統(tǒng)一協(xié)調(diào)，并實行項目經(jīng)理負責(zé)制，由技術(shù)、品質(zhì)、現(xiàn)場組成核心團隊，相關(guān)職能部門通力配合的全面保障體制，確保按時、按質(zhì)、按量配合JMC的整個開發(fā)過程。Eachproduct/projecttoJMCiscoordinatedbytheviceministerofTechnologydepartment,andimplementprojectmanagerresponsibilitysystem,createtheprojectteamwithTechnology,QualityandWorkshop3departments,toensure

therelatedfunctionaldepartmentstocooperatefully,toensurethequantity,quality,ontimewiththeentiredevelopmentprocessofJMC.我們的資金保障Financialsupport：※產(chǎn)品從立項開始，設(shè)立專項資金，用于設(shè)備的購買、模具、夾具、檢具配置；Fromtheprojectkickedoff,wesetaspecialfundforthefacilities,molds,fixtures,gaugespurchasing.設(shè)變前Beforedesignchanged設(shè)變后AfterdesignchangedFrom8.6mmto12mmFrom3mmto11mm我們的開發(fā)成本收取OurDevelopmentcost：※

開發(fā)全周期內(nèi)設(shè)計“0”費用;0designcostintheprojectdevelopmentstage.※

樣件生產(chǎn)全程調(diào)試“0”費用；0costforproductiondebuggingandsamples.材料試驗機MaterialTestingMachine金相檢測儀MicrostructureInstrument英國粗糙度檢測儀RoughnessTestingMachine三坐標(biāo)檢測儀CMMX光探傷機X-RayTestingMachine日本島津光普儀Spectrometer二維精密投影機Twodimensionalprecisionvideoprojector英國粗糙度檢測儀RoughnessTestingMachine主要檢測設(shè)備INSPECTIONEQUIPMENT我們的品質(zhì)保證:OurQualityAssurance：過程質(zhì)量管理

InprocessqualitymanagementItem質(zhì)量門

Quallitygate管理項目

Controlitems品保方法

Method檢查頻次

Frequence過程Process原材料檢查Rawmaterialinspection材料成分Composition光譜分析spectralanalysis1pcs/批次batch熔解Melting1.含氫量Hydrogencontent密度比重Densityweightingmethod1pcs/4Hr2.含渣量DregginessK模斷口檢查Kmoldfracturecheck1pcs/4Hr3.鋁液成分Aluminumliquidelement光譜分析spectralanalysis1pcs/4Hr鑄造Casting1.內(nèi)部品質(zhì)Innerquality著色檢查Dyepenetration1pcs/班shift2.毛坯尺寸DimensionalCMM3pcs/批次batch3.粗糙度Roughness粗糙度儀Roughmeter3pcs/批次batch4.金相組織Microstructure顯微鏡Microscope1pcs/批次batch熱處理Heattreatment1.硬度Hardness硬度計Hardnessmeter1pcs/爐次furnace2.機械性能Mechnicalproperty拉伸試驗Tensilestrengthtesting1pcs/送樣sampling1pcs/半年halfyear機加工Machining加工尺寸DimensionalCMM1pcs/班shift入庫Stock外觀Appearance目視Byvisual100%系統(tǒng)System項目Item方法Method1.過程監(jiān)測ProcessmonitoringCPK、SPC、MSA2.過程故障、客戶投訴Processfailure,customercomplaintPDCA、8D