Process of building an engine

The building of an engine includes 3 processes: machining, assembly, test.

In machining shop, there’re operations of cylinder body, cylinder head, crankshaft. Numerical controlled work centers are used to cut metal pieces into target components.

The key functions of MES in machining shop:

1)       Traceability of raw parts serial number and lot number.

2)       Monitoring of machine status.

3)       Monitoring of key process parameters.

4)       Data collection of key test result such as of leak test.

5)       Scrap management.

System is not required to manage orders.

Monitoring device status can act quickly to abnormal situations.

The traceability of raw parts and key process parameters, is very helpful while it’s required to call back products by batch.

 

Key processes of assembly shop:

1)       Cylinder head sub-assembly.

2)       Piston sub-assembly.

3)       Interior assembly.

4)       Exterior assembly.

5)       Cold test – test without starting up engine.

 

Assembly shop is managed by scheduled orders. If production line supports multiple models, then it also requires just-in-time material handling. And the most important stations are assembly stations and torque stations.

The key functions of MES:

1)       Release orders to lift-on stations.

2)       Material error proofing.

3)       Key parts traceability.

4)       Torque error proofing.

5)       Travel record and broadcast, and interface for material handling.

6)       Device monitoring.

7)       Quality call.

8)       Quality defect management.

9)       Data collection of gap detection and cold test.

 

Hot test means to start up engine, and simulate real working situation and worst conditions, and record the running data.

Hot test usually uses custom test stations and software, and MES collects test data via interface.

 

Diagram 1.3-1 shows key process of engine plant:

Diagram 1.3-1: key process of engine plant