Yuchai Craftsman: Two Generations of Tradesmen Pursue the Precision of 0.01mm

The handsome face, iconic black-rimmed glasses, 30-year-old Liu Ningzhao looks younger than the actual age. If it is not organic oiled hands, it is difficult to recognize that this is a deal with the engine for more than a decade. people.

In the assembly and testing workshop of Yumeng Shipbuilding Co., Ltd. (hereinafter referred to as “Yuchai Ship”), the W7X35 low-speed marine diesel engine is undergoing final assembly. Liu Ningzhao carefully installed the cylinder liner in the workshop.

Although it seems to be a simple repetition, he has practiced more than a thousand times, and it has become possible to "see" the machine with his hands.

After the workers completed all processes, the 62-year-old workshop director, Hung Xiping, took the precision lead wire of the measuring equipment and walked up again to install the test tower. Once again, all processes were checked again to ensure that there were no problems before leaving. Although he knows that checking it again may also be "useless merit," he still insists on this "just in case" reluctance.

The ship is a sea, and the engine is the source of power. Yuchai Ship, which mainly produces ship engines, has already produced the world's first dual-fuel ship engine and is at the forefront of the industry. The two generations of craftsmen, represented by Liu Ningzhao and Hong Xiping, used their own actions to pass on the pursuit of technology and escort the "heart" of the giant ship.

Liu Ningzhao is checking Yuchai's dual-fuel low-speed marine engine

Hand "see" the status of the machine

"In the middle, slow down, down, slow down, down..."

At the 3rd floor of the test tower of the Yuchai Ship's mobile loading test shop, 6 workers in light blue work clothes are installing the piston liner of the W7X35 low-speed machine. At this point, even masters with more than a decade of experience began to be cautious. At this time, Liu Ningzhao, the section chief of the bench work section, was controlling eight jacks back and forth, constantly adjusting the horizontal position of the cylinder liner, and for a time becoming the focus on the tower.

This is a timid process. In general, engine assembly includes component pre-assembly and overall assembly. Workers need to install pistons, gears, and other components, and then put them into the machine base for assembly. The installation of the piston cylinder liners that Liu Ningzhao and his coworkers are working on was also called by the workers one of the "three major difficulties" of engine pre-installation. "The piston is a moving part and the piston rod cannot contact the inner wall of the cylinder liner, otherwise the cylinder liner will wear and thin, causing the piston to break."

Because the diameter of the piston rod is very close to the inner diameter of the cylinder liner, the pre-assembly operation requires very high precision for workers. In order to ensure that the cylinder liner and the crankshaft end face of the diesel engine remain coaxial, Liu Ningzhao needs one person to complete the fine tuning of the eight jacks. "To ensure that there is no contact between the two, there is no standard. Only one person can confirm the position by virtue of his experience and feel." For workers like Liu Ningzhao who can skillfully complete this operation, there are no more than ten workshops.

In 2006, Liu Ningzhao, who just graduated from the university, entered a shipyard engaged in engine maintenance work and began a four-year front-line study. In 2011, Yuchai’s Zhuhai workshop was put into operation. The 25-year-old Liu Ningzhao became the first batch of skilled workers recruited by the company and entered the assembly plant to carry out engine assembly. In 5 years, he grew from a fitter to a section chief who controlled the quality of the production line.

From the basic fitter to the “master” in the workshop, in the view of Liu Ningzhao, the most direct consideration is the “three major difficulties”. "The installation of piston liners, the adjustment of intermediate gears and the installation of hydraulic dynamometers are the most challenging steps in the assembly process. Each link is 'big things, small kung fu, and high precision'."

When Liu Ningzhao introduced the engine assembly process, the most commonly used word was "hands on." In the eyes of workers, "hands" are the unique skills of Liu Ningzhao. In order to achieve high-precision assembly, Liu Ning Zhao had performed a “hand” practice at the test tower for no less than a thousand times during the first two years of entering the company. Frequent contact with the machine, Liu Ningzhao's hands are stained with black oil that cannot be washed for years. "Every process, spare parts and machines have corresponding strengths. Only with repeated hands to feel, can the hands look like the eyes and 'see' the state of the machine. This is also the place where the engine assembly is different from the general mechanical work. ”

"0.01 mm" precision pursuit

At 12:30 in the afternoon, it was time for workshop workers to take lunch. An old man wearing dark blue work clothes walked alone to carry out a test stand, and tested the assembled parts and pipes one by one. This old man is none other than Liu Xizhao’s “head boss”—Hong Xiping, the director of the loading and testing workshop. With the supervision of Liu Ningzhao and others, most of the time, Hong Xiping walked onto the test tower to do “do nothing”, but in Hong Xiping’s view, this is the habit of over 40 years of assembly work.

The 62-year-old Hong Xiping, with more than 40 years of rich experience, was recruited by Yuchai Ships after retirement and returned to the workshop to manage and dispatch diesel engine test jobs. From the front-line workers to the managers of a production workshop, Hung Xiping’s attention was increased from one screw to each engine. In his own words, this was “dedicated to the engine for most of his life”.

Many new technicians did not underestimate the embarrassment of the master when they first entered the company. “The requirements of the master to clean the workshop, especially the test tower, must be clean. This is where many newcomers do not understand at first.” Liu Ningzhao said that sometimes production tasks are heavy, and workers put tools on the test tower, and After you see it, you will be criticized.

"If there is a bit of gray in the engine and there is a little drawing, it will pull into a groove and damage the engine," said Hong Xiping. And in the impression of Liu Ningzhao, Hong Xiping often hangs his lips: The engine is different from other machines, and the host will not stop in the sea for a month or two. Once stopped, it will be easy to destroy the ship. So any There is room for optimization in one area.

Compared with the meticulousness of his disciples, Hong Xiping’s rigorousness is also reflected in the quality control of each link, and his heart has corresponding figures to judge. "Intermediate gear adjustment, the degree of engagement of two gears should exceed 80%, the parallelism of each tooth should be controlled within 1 wire, the best of the half wire, the centering of the piston, and the total distance between the piston rod and cylinder liner should be controlled at 60 wires. Inside."

The “silk” that Hong Xiping said is the unit of measure used by the mechanical workers to measure precision every day. "A silk is only 0.01 millimeters, which is one-tenth of a hair filament." Marine engine tens of thousands of parts, assembly precision requirements to achieve "silk" level, in order to ensure that the engine is not only accurate operation, but also can reduce The life caused by friction between machines is reduced.

“The younger generation of mechanics has strong execution ability and good foundation, but in the face of the temptation of the surrounding environment, it is very difficult to calm down and persist in doing technology.” Hong Xiping said that with the popularity of machining, more and more young technicians ignore Kung fu. "The older generation of mechanics must be divided into eight levels. Only technicians above the four levels can actually operate on the machine. Today, there are few such divisions in the industry."

In spite of this, Hong Xiping continued to “punch” his disciples on the level of “level”. "You can use your hand to try it out with your hands. This will make the machine feel the most direct touch." Strict training allowed Liu Ningzhao and other young people to gradually take hold of his heart, and he began to return to the manual "most stupid" method. "Skills, speed up talent.

Different interpretations of two generations of craftsmen

The persistence and inheritance of the new and old two generations of craftsmen promoted the transformation of Yuchai Ships from start to growth.

In November 2011, the world's first W6X35 low-speed machine was successfully tested at Yuchai Shipbuilding. The 12-month construction period also set the fastest construction and production speed in the low-speed machine industry; only one year later, the first W7X35 machine successfully passed the ship. East and BV Classification Society inspection; on June 2, 2015, the world's first commercial-operated 5RT-flex50DF marine dual-fuel low-speed machine was successfully tested in Yuchai.

Yu Tianliang, Chairman of Yuchai Shipbuilding Trade Union and Secretary of the Board of Directors, stated that during the “Thirteenth Five-Year Plan” period, Yuchai’s ships will carry forward the “artisan spirit” to help companies exert their efforts in lean production and lean manufacturing and promote Chinese marine equipment manufacturing industry. In the downside environment, we will embark on a road of innovation to provide our customers with the best quality products and best services.

According to Liu Ningzhao, "excellent products" require "excellent employees" before they can be produced. The spirit of craftsmen should be the pursuit of skilled workers. “Artisans emphasize skills, which need to be polished repeatedly in practice. The so-called refining of steel, craftsmen should also be worn out.”

Contrary to disciple's viewpoints, Hong Xiping is more willing to use the word “qualities” to make demands on craftsmen while affirming the ability of the younger generation. “This includes people’s social morality, responsibility, and job reputation. Young workers grow fast, but Often overlooked the training of professional qualities, lack of this, but also can not be called craftsman."

Hong Xiping hopes that more people will pursue the craftsmanship. "Each ship's engine does not rely on one person's power to complete the assembly. The spirit of artisans should not be advocated by only a few people, but must be passed on to a team or even a generation of skilled workers."

Dialogue: To nurture "artisan spirit" we must first respect the blue collar

Mentioning that skilled workers have an important supporting role in the transformation and upgrading of the industry is also an important part of the craftsman. You think that the cultivation of “artisan spirit” requires such a social atmosphere. Liu Ningzhao said that the craftsmanship requires skilled workers to pursue technology and products with excellence. On the one hand, from the point of view of the workers themselves, it is necessary to pursue such pursuits and improve the overall level of the industry through benign competition and catching up with others. On the other hand, society and enterprises should provide a platform and environment for the advancement and development of craftsmen.

Hong Xiping said that "the craftsmanship spirit" is not a new word. In the past, our country’s society was more or less contemptuous for technical talents, including craftsmen, and considered that “dry technicians are better off sitting in the office”. In fact, technical workers, engineers, and scientists are different in the division of talent, not in the level of talent.

Therefore, in order to nurture the spirit of artisans, we must first grasp the orientation of respecting artisans, respect blue-collar technical workers, and make great efforts to cultivate technical talents. On the one hand, the craftsmen should be guaranteed income and more people should be willing to engage in technical work. In addition, we must truly create a social atmosphere that respects labor, respects technology, and respects creativity, and improve the sense of achievement of blue-collar workers.  

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