/PRZWT/GUANGZHOU, December 10, 2024 - Looking back over the past two or three decades, China's home appliance industry has undergone a transformation from scratch, from following to leading. As a part of China's home appliance industry, GMCC Meizhi and its partners continue to write the history of China's home appliance development with perseverance and innovation.
From 1996, the first air conditioner compressor went offline, to 2002, the output exceeded 10 million units, from 2010 production and sales exceeded 100 million units, and then to 2024, the 1 billion unit went offline, Meizhi continued to break through the "ceiling" of the industry, and also realized the comprehensive layout from a single product to consumer electrical parts, becoming a system-level solution provider for core components of consumer electrical appliances.
In 2024, GMCC Meizhi ushered in the 1 billion air conditioner compressor and won the title of Guinness World Records ™
GMCC's air-conditioning compressors can achieve the "first brand" and "invisible champion" in the industry. In addition to the support of many air-conditioning customers, it is also inseparable from the courage to actively embrace the diverse market demand, and the "confidence" of delivering more than 100 million air-conditioning compressors every year. Behind the high-quality manufacturing and large-scale delivery and supply, it is inseparable from the continuous cultivation and practice of Meizhi in digital transformation.
GMCC focuses on the three main axes of quality excellence, agile delivery, and green security to comprehensively consolidate the manufacturing foundation, build sustainable, zero-breakpoint all-scenario digital intelligence driving capabilities, and work towards building a smart factory. In the production process, GMCC applies a variety of ICT technologies to the original production factors, resulting in business innovation and restructuring. In the transformation process, it continuously accumulates and forms digital assets and digital practices, builds data advantages and experience, and keeps the competitiveness ahead.
GMCC Meizhi Technology Industrial Park: The digitalization of the whole process, reshaping the new pattern of production and operation
Located in Shunde District, Foshan, Guangdong Province, GMCC Meizhi Science and Technology Industrial Park (Meizhi Xingtan Factory) was officially put into operation in 2023. It is one of the largest and most advanced factories in the world of GMCC Meizhi. At the beginning of construction, Meizhi Xingtan Factory aimed to build a "μ-level precision intelligent manufacturing" benchmark factory in the field of consumer electronics, from intelligent scheduling, intelligent quality, intelligent logistics, digital process, Facility Management, green energy, smart park, smart laboratory and data operation. Various digital technologies and applications help it achieve this goal successfully.
With digitalization as the base, digitalization has started to play a role in the Meizhi Xingtan factory and is ubiquitous since the beginning of sales orders. Orders are automatically synchronized to the planning system, and the scheduling system acts like a precise commander, breaking down material requirements and production plans according to customer needs. Purchase orders are then issued to suppliers, enabling seamless connection between production and distribution of materials. The production systems of the factory receive detailed production orders, and production tasks are immediately executed.
At the same time, under the command of the digital platform MLS system, various materials used in production have also begun to be distributed by intelligent logistics equipment such as AGVs, RGVs, and unmanned forklifts, realizing intelligent scheduling and real-time monitoring of logistics. This intelligent scheduling and logistics system, like the neural networks of the factory, ensures the smooth and efficient production process, and realizes the intelligent management of the whole chain from order receipt to product delivery.
In terms of process and quality improvement, thanks to the constantly updated digital technology, Meizhi uses simulation tools to verify production and other issues in advance to ensure that improvement measures are effective. Core process parameters are monitored by digital systems to ensure optimal processing conditions; the combination of AI vision and automatic detection technology is like the "eye of wisdom" of the factory, guarding product details and ensuring excellent quality. Barcode technology gives each product an "ID card" to achieve transparent management of the whole process.
Similarly, as an important engine for the smart transformation and upgrading of the factory, the Meizhi Xingtan factory has also integrated digitalization into all aspects of smart operation, covering on-site management, machining equipment, plant energy use, laboratories, and other scenarios to build a green smart operation system.
For example, the health of core processing equipment is monitored in real time through sensors and system digital models, and AR remote maintenance technology is used to reduce equipment failure rates, improve maintenance efficiency, and ensure the efficient and steady operation of "industrial mother machines" on the entire production line. In terms of on-site management, Meizhi uses DMS system to build an efficient digital bridge, and relies on the five-level conference mechanism to capture and deeply analyze on-site problems to ensure timely resolution of problems.
In the digital green energy consumption, Meizhi uses smart meters to collect energy consumption data in real time, and realizes energy consumption optimization through algorithm models to reduce energy consumption costs. In the smart laboratory, Meizhi realizes real-time monitoring and accurate analysis of experimental data through digitalization, and the experimental results are automatically analyzed, providing a solid guarantee for product quality.
The deep integration of digitalization and business has enabled the Meizhi Xingtan factory to achieve remarkable achievements: a single-line compressor is offline in 6 seconds, far exceeding the industry level, and the delivery cycle is greatly shortened.
GMCC Meizhi Wuhu Factory: Create a "Zero Bad Outflow" Benchmark Production Line with Digitalization
In the field of consumer electronics, in the context of large-scale delivery, it is quite difficult to improve product quality and greatly improve delivery quality. Especially in the case of mass delivery, how to maintain product consistency is a difficult and pain point for the whole industry.
As an absolute leader in the field of air-conditioning compressors, Meizhi has gone through many years of digital practice and has given the answer in the Wuhu factory: with the help of intelligent technologies such as machine learning and big data analytics, the Joint Group Intelligence Research Institute has jointly created "intelligent acquisition, intelligent analysis, intelligent early warning, intelligent control, intelligent prediction, intelligent decision" Six Wisdom "Zero Bad Outflow" quality benchmarking line, including the industry's first QR code for upper bearing engraving, AI detection for riveting anomalies, AI detection for three-spot welding, AI detection for stator and rotor clearance, predictive maintenance of equipment, and adaptive adjustment of test parameter thresholds through AI intelligent algorithms.
Combined with SCADA and MES systems, the cloud storage and distribution of test parameters are realized, and the intelligent performance line of test results is judged using the principle of image product difference. In response to industry problems, Meizhi has not only formed a "methodology" combining quality management and lean production through practice, but also created an industry performance of "zero bad outflow" for millions of units delivered.
Control product quality from the source, intelligent management creates a new brand model, Meizhi Air Pressure Wuhu Factory is committed to becoming a leader in the era of industrial 4.0 intelligent manufacturing. Focusing on the μ-level processing capacity and digital intelligence intelligent quality control benchmarking line, Meizhi Air Pressure Wuhu Factory realizes the μ-level processing level and assembly effect of products through the introduction of μ-level equipment, μ-level process technology, and μ-level detection ability.
In order to continuously improve product quality and strengthen market competitiveness, Meizhi listens to the voice of customers (VOC) and drives production improvement (VOP) with it. For example, in response to high customer feedback "equipment does not cool or have poor effect, external machine noise is large, and does not start" and other problems, quickly identify the root cause and give rectification measures by digital means. Including compressor one-yard traceability, intelligent riveting station, pump body torque detection, intelligent magnetization detection, three-spot welding inspection, stator and rotor clearance inspection, shell welding online monitoring, etc.
With the formal help of these digital means, Meizhi Wuhu Factory has implemented a comprehensive digital innovation of the compressor production line, marking the factory's success in crossing the gap from manual operation to intelligent control, from fuzzy management to precise management.
Take compressor traceability as an example. At the Meizhi Wuhu factory, each compressor is given a unique logo - a QR code containing production information. The QR code is like the compressor's ID card, recording its production process, quality inspection data and other key information.
Including the lack of anti-stupidity measures in key positions and quality problems caused by low-level errors, the lack of consistency and accuracy caused by manual visual inspection of riveting/welding stations, and the lack of production data basis for troubleshooting of defective products, etc., can be queried through QR code to find relevant visual/vibration and other performance inspection data, production information of each compressor, and data correlation analysis of the whole process.
Through one-yard traceability of compressors, Meizhi Wuhu Factory has reduced and eliminated the occurrence of low-level errors, improved the quality consistency of the production line, and finally achieved "zero bad outflow" in the final assembly line.
The SCADA connection rate of the equipment is 100%, which realizes real-time transparency of intelligent number taking and production. The first paperless intelligent point inspection of the equipment realizes true remote control of the equipment. The integrated intelligent detection equipment greatly improves the detection efficiency while greatly improving the detection effectiveness. With the help of digital production line reshaping, the six-smart benchmarking line of the Meizhi Wuhu factory has also come naturally, helping the factory achieve transparency, visualization and traceability of the whole production process.
Workers can not only control the running status and production progress of the production line in real time, ensure product quality and safety, but also help to quickly locate and solve quality problems, ultimately helping Meizhi Wuhu factory maintain industry competitiveness in agile delivery, efficiency improvement, quality and technology leadership.
Digital transformation means far-reaching impact and change in many aspects for enterprises. Through the deep integration of cutting-edge digital technology and the creation of an intelligent manufacturing system, GMCC has not only accurately captured and met the diverse needs of the market, but also achieved a qualitative leap in energy conservation and emission reduction, management efficiency improvement and innovation ability stimulation, providing a beneficial paradigm for the digital transformation of the entire industry.
Looking to the future, GMCC will promote the depth and breadth of digital transformation, promote the sustainable development of China's consumer appliance manufacturing with continuous digital investment and practice, and work with customers to present higher quality, higher efficiency and greener products and services to global consumers.
