Importance of assembly

Take the importance of sewing machine assembly as an example:

-& gt； Any machine is assembled from countless parts. As a traditional mechanical equipment, sewing machine is also assembled from many parts. The production and processing of sewing machine mainly includes casing processing and parts assembly, in which the assembly level of sewing machine directly determines the technical performance of the machine.

From some angles, the stability, advancement and reliability of sewing machines depend largely on the assembly level of assemblers. Therefore, it can be said that the assembly level of sewing machine manufacturers also directly affects the product quality, reputation and market competitiveness of enterprises.

Sewing machine assembly

The devil is in the details

Sewing machine is a kind of mechanical product with complex design structure. According to different requirements, the assembly methods of sewing machines can be divided into general assembly, grouping assembly, dual assembly, component assembly, machine assembly and debugging (including "adjustment" and "trial operation"). According to the assembly requirements of different models, the assembly of sewing machines can also be divided into: synchronous, comprehensive, differential and other models of the whole machine assembly.

It should be noted here that the assembly of sewing machine not only refers to the assembly in the production process, but also includes the installation and debugging in the repair.

In the production process, sewing machine assembly mainly includes six links: 1, main structure and working principle; 2. Read the parts catalogue, parts samples and shaft sleeve positioning diagram; 3. Part drawing number search, part application, quality analysis and defect identification; 4. Assembly and testing of the whole machine; 5. Quality analysis of the whole machine; 6. Judgment and maintenance of the whole machine fault.

In the process of sewing machine maintenance, the assembly links mainly include: 1. Types and discrimination of common faults in product use; 2. Troubleshooting of common faults during product use; 3. Installation and debugging of the whole machine in the user environment.

Any sewing machine enterprise wants to produce sewing machines with qualified quality and specifications, so the assembly process of sewing machines in our factory must meet the following two basic technical requirements:

The first is the finishing of parts. All sewing machine parts with surface treatment such as baking paint and electroplating have adhesive layers on their assembly joints (including holes, grooves, planes and screw holes). Therefore, before entering the assembly process, these parts must be finished according to the technical requirements.

Secondly, it is the cleaning and cleaning of parts. When talking about the assembly details of sewing machines, Master Fu Yanghui Qing, an assembler in Shanghai Sewing Machine Factory No.3, said, "For our assemblers, the cleaning and cleaning of parts, especially the cleaning and cleaning of shaft sleeves, bearings and other parts, is very important. For example, in the assembly process, if all kinds of shaft parts are not cleaned in strict accordance with the process requirements, the temperature of the shaft sleeve will be very high, the transmission torque will be too heavy, sand, chips and other debris will be involved, the wear of the shaft sleeve will be accelerated, and even serious failures such as "seizure" will occur. Therefore, we must do a good job in cleaning and cleaning the product parts. "

It is also worth noting that the cleaning and cleaning of sewing machine parts are different concepts. The cleaning of parts refers to the removal of residual debris, abrasives, paint, rust, etc. Parts before assembly; Cleaning of parts means cleaning accessories with common cleaning solutions such as kerosene, light diesel oil and chemical cleaning solution. If sewing machine manufacturers do not pay enough attention to the assembly process of sewing machines, and workers are careless and do not assemble sewing machines according to the specifications, it will definitely affect the normal operation of sewing machine products in the future.

Sewing machine assembler

All-round applied talents

The development of modern sewing machinery industry puts forward higher assembly production requirements for sewing machine manufacturers, that is, emphasizing "multi-variety, small batch and strong personalization". In order to adapt to this objective trend and improve the level of skilled workers in assembly workshops, it is necessary to strengthen the post training of technicians. Master Wang Jianlin, an assembler in Shanghai Gong Hui Sewing Machine Factory No.3, said that to be a qualified sewing machine assembler, it takes three months of prenatal training and then one-on-one teaching by the master. After two years of practical study, I can become a qualified assembler.

Qualified assembly workers are the mainstay of sewing machine manufacturing enterprises and an important guarantee for the normal operation of the machine. If the assembly operation does not meet the specified technical requirements and the mutual position between the parts and the mechanism is incorrect, then the sewing machine will not work normally, which will affect the working performance of the sewing machine or become a scrapped machine. If there is a little burr on the thread passing part, the sewing machine will not work.

Sewing machines with poor assembly quality have low precision, poor performance, large noise, large torque and short service life; On the contrary, for some sewing machines with low accuracy, products with better performance can still be assembled if they are carefully selected and assembled and accurately adjusted.

As a sewing machine manufacturer, it is necessary to expand the existing assembly technology backbone team, promote the transformation of assembly line, and lay a solid foundation for the development of high-quality sewing machine production. The training of assembly talents will also be the top priority of employee training in enterprises. A qualified assembly worker not only needs to master all kinds of skills in the trial-production stage of the new model, master the assembly process rules of the new model, draw a simple process flow chart and organize assembly line production, but also should have the ability to analyze and eliminate all kinds of common faults and have certain after-sales service.

Sewing machine manufacturing enterprises should train assembly workers in all directions, and cultivate an excellent assembly worker from all angles of theory and practice.

The author thinks that the training of assemblers mainly includes the following aspects: 1. Mechanical drawing: master the basic knowledge of mechanical drawing and national standards, be able to understand the assembly drawing with medium complexity and draw the assembly process drawing of parts with medium complexity, and mark the dimensions and technical requirements symbols reasonably; 2. Structure and principle of industrial sewing machine: master the general knowledge of sewing machine and the structure, principle and use of commonly used sewing machine, have a certain foundation of industrial sewing machine assembly process, and can correctly understand the professional process requirements; 3. Quality inspection, adjustment and repair of sewing machine products: master the quality inspection specifications and test methods of sewing machine heads, correctly debug sewing machines according to quality standards, and judge and eliminate sewing machine failures in time; 4. Sewing machine head assembly technology: master the knowledge of sewing machine tolerance fit and technical measurement, as well as the names and functions of various components, components and parts of sewing machine head, correctly implement the assembly process regulations, correctly master the assembly sequence, assembly means and detection technology of sewing machine head, and reasonably analyze the causes and solutions of common faults in production; 5. Sewing machine head assembly operation skills: be able to skillfully assemble a complete sewing machine, eliminate common faults and complete the indicators according to the quantity, correctly analyze the assembly quality problems and the quality interaction between various processes, and propose solutions; At the same time, it can reasonably select tools according to the process requirements and assembly specifications, correctly detect the assembly quality and debug qualified sewing machines; 6. Quality management and quality assurance: master the knowledge of quality management system and quality assurance, correctly use the commonly used analytical methods and mathematical statistics tools in team quality management, and analyze, count and apply them in team quality management.

Vocational training for assemblers

It is urgent to compile teaching materials.

In the process of vocational training for sewing machine assemblers, many sewing machine enterprises gradually feel that the training contents and assessment standards cannot be mastered, and the problem of lack of professional training materials for assemblers appears.

Many large sewing machine enterprises attach great importance to the training of assemblers, and all of them have special training institutions, which constantly provide vocational training for assemblers in various ways, such as theoretical study, teacher guidance, independent practice and professional title examination. However, in this process, with the variety of products produced by enterprises changing from single to diversified, and the technical difficulty changing from ordinary machines to special machines, trainers in many enterprises feel that the training work is getting more and more difficult and lack a targeted vocational training textbook.

Due to the lack of funds and technical strength, many small and medium-sized sewing machine enterprises lack their own training strength. Therefore, the training of assemblers is often superficial and formal, relying entirely on the traditional way of master taking apprentices for practical training, so it is urgent to write a targeted vocational training textbook for the development of the industry. If there are unified vocational training textbooks compiled by authoritative departments, the training work of enterprises will be easier to carry out, which is not only beneficial to the development of enterprises and product markets, but also beneficial to the development of sewing machinery industry in China, and it is also an objective need for sewing machinery industry in China to change from "big" to "strong".

Fortunately, the vocational training materials for sewing machine assemblers organized by China Sewing Machinery Association will be published soon.

In May, 2006, China Sewing Machinery Association held a meeting in Wuxi, Jiangsu Province to compile vocational training materials for sewing machine assemblers. The meeting invited many experts who are familiar with sewing machine assembly technology and have certain educational experience to have a heated discussion on the compilation of vocational training materials for sewing machine assemblers. The meeting proposed that the compilation of training materials should be completed in accordance with the requirements of implementing national vocational standards and the principles and requirements of national vocational qualification training courses.

As the production center and big country of sewing equipment in the world, the development of sewing machinery industry in China is obvious to all. However, with the deepening of world economic integration, we must re-examine the development strategy of sewing machinery industry in China. The great shift of sewing machinery industry in the world has brought new opportunities to the development of sewing machinery industry in China at this stage. How to make good use of this opportunity and do a good job in product assembly and other details is also the key to improve product quality and technical content, upgrade product grade, change extensive development mode and realize the development and transformation of sewing machinery industry in China from "following" to "leaping".