Horizontal comparison of the six most popular mold

2022-08-13
  • Detail

Horizontal comparison of the six major mold manufacturing countries, and the per capita output value ranks first in Germany

Abstract: from the current mold manufacturing mode of large and comprehensive, small and comprehensive, it has gradually changed to large and strong, specialized and precise, and formed a professional and intensive production mode of large with small, point with area

in recent decades, China's mold manufacturing technology has made a qualitative leap. The mold industry has grown rapidly from small to large, and has become a world mold manufacturing power. We can call this stage the first take-off of China's mold. With the development of China's automobile industry, independent brands are marching towards the middle and high-end, and new energy vehicles are emerging. The market has put forward new demands for us, requiring us to move from low-end molds to high-end molds, from a large mold country to a powerful mold country, and realize the second take-off of China's molds. How to realize the transformation from low to high, from big to strong, and how to realize the second leap of Chinese mold is a problem worth thinking about by every Chinese mold factory and every Chinese mold person

at present, China, the United States, Japan, Germany, South Korea and Italy, the six major mold manufacturing countries, account for the absolute position of mold output value in the world, and China's mold output value is the largest in the world

the mold manufacturing industry in the United States, Japan, Germany and other developed countries has the following characteristics in terms of production and operation:

the number of personnel is streamlined. Most mold enterprises in Europe, America and Japan are small, and the number of employees is less than 100. The number of mold enterprises is generally 20-50. The allocation of all kinds of personnel in the enterprise is very streamlined. One person has many functions, and there are no idle people in the enterprise

adopt specialization and accurate product positioning. Most mold factories determine their product positioning and market positioning around the needs of various molds in the automotive, electronic and other industries. In order to survive and develop in the market competition, each mold manufacturer has its own advantageous technology and products, and adopts professional production methods. Most mold enterprises in Europe, America and Japan have a group of mold users who have long-term cooperation, and there are also a group of mold production cooperation manufacturers around large mold companies

advanced management information system to realize integrated management. Mold enterprises in Europe and the United States, especially large-scale mold enterprises, have basically realized computer management. Computers are widely used in production planning, process formulation, quality inspection, inventory, statistics, etc. all departments in the company can share information through the computer network

advanced process management and high degree of standardization. Unlike domestic mold factories, which mostly adopt the production organization mode of mainly or all-out fitters, mold manufacturers in Europe and the United States rely on advanced process equipment and routes to ensure the accuracy of parts and production progress. The advanced technology and management of European and American mold enterprises have made their large, precise and complex molds play an extremely important role in promoting the development of automobile, electronics, communications, home appliances and other industries, and also brought good economic benefits to mold enterprises

American mold industry

there are about 7000 mold enterprises in the United States, with less than 15 people accounting for 60% and 30% respectively. Due to the high development of industrialization, the American mold industry has long become a mature high-tech industry, ranking in the forefront of the world. The specialized division of labor of American mold is very clear. Each mold factory has its own advantageous products, and basically focuses on the whole way. Take the American Synergis mold factory we once cooperated with as an example, they are specialized in making chassis subframe molds, progressive molds and multi station molds. The subframe of a car model we used to cooperate with was manufactured in three parts, one in America, one in Europe and one in Asia. We are responsible for processing, assembly, delivery to the level of initial acceptance, and the American mold factory is responsible for the final commissioning. This kind of cooperation is beneficial to both sides, and we have also learned a lot in the design and manufacturing of large-scale multi station molds

the manufacturing cycle of the side wall mold processed by Ford automobile mold factory in the United States is only 8 weeks. It was a miracle to us, but they did it. The early process and design of the mold are not in the mold factory, but in the R & D department, the mold factory is only responsible for the manufacturing process starting from the foam model. Due to the good preliminary work, there are few changes in processing, which saves a lot of time for mold manufacturing. The mold factory processes the foam mold and sends it to casting, and the castings come back to start NC processing. Because of the automatic conversion of multiple worktables and 24-hour non-stop, the processing efficiency is very high. Moreover, due to the careful consideration of preliminary work such as springback and deformation, coupled with actuarial technology, the processed mold can be directly put on the press for debugging, and the first piece pass rate can reach%, which shows the high level of professional processing technology in the United States

according to statistics, the per capita output value of American molds in 2014 was about 1.27 million yuan

Japanese mold industry

according to the industrial statistics of Japan's Ministry of trade and industry, there are about 10000 mold manufacturing plants in Japan, of which more than 91% are less than 20 people, that is, Japan's mold industry is dominated by small and medium-sized enterprises, which mainly rely on professional division of labor to complete high-quality mold design and processing. Due to the good specialization in Japan, the overall manufacturing level of small and medium-sized mold enterprises is high, which makes Japanese mold occupy a higher share in the world mold market

in 1988, I went to Japan's mold factory and full mold foundry to study. The mold factory only has one seat in the future market competition to process large main parts, and the rest are assigned to the following small factories to process. There are special design companies, and there is a lack of steel plates. One of them is processed quickly and sent to the designated location. Lack of screws or nails is also a problem that can be quickly sent to the designated position. The division of labor system and supporting system are very perfect

however, due to the rise of molds in China and South Korea, Japan has been greatly impacted by its price advantage, and has become the main competitor of Japanese small and medium-sized mold enterprises in the mold market with medium and low-end technology. Because of this, Japanese mold enterprises have to devote themselves to the production and technological upgrading of high-end molds to avoid price competition. That is, taking the accumulation of small but refined and specialized technology as the source of competitiveness to promote the continuous innovation of small and medium-sized mold enterprises and create a sustainable development environment. Many mold manufacturers in Japan are actively expanding equipment investment. In processing, a large number of unattended processing units are used, or online control through computers. The technological development of molds mainly develops to high precision, high speed, long life, complexity, large scale, integration and high performance

according to statistics, the per capita output value of Japanese molds in 2014 was about 1.2 million yuan

German mold industry

Germany is one of the first countries in Europe to engage in mold production. Its mold manufacturing technology and mold quality are affirmed by global users. It is well-known in the world and is one of the most important high-end mold suppliers in the world. After years of practice and exploration, German mold manufacturers have formed a consensus: the whole industry must coordinate, work together, make technological innovation, learn from each other, make common progress, and give full play to the overall advantages in order to achieve the success of the industry. In addition, in order to meet the needs of today's rapid development of new products, not only large companies have established new development centers in Germany, but also many small and medium-sized enterprises have done so, taking the initiative to do research and development for customers. Germany has always been very active in research, which has become an important basis for it to remain invincible in the international market. In the fierce competition, the German mold industry has maintained a strong position in the international market for many years, and the export rate has been stable at about 33%. According to the data of the German machinery factory manufacturing association, there are about 5000 mold manufacturers, but the mold industrial structure of the country is still dominated by small and medium-sized enterprises: less than 20 people account for 80%, 19%, and more than 100 people account for 1%

according to statistics, the per capita output value of German molds in 2014 was about 2million yuan

mold industry in Taiwan

the mold industry in Taiwan is basically small and medium-sized enterprises, with fine professional division of labor, close production coordination, and relatively stable customers. Each enterprise only produces a certain type of mold, and each has its own fist products, which is conducive to technological excellence, so that it can survive and develop in the fierce competition. The mold standard parts required by the mold factory are purchased, and some parts processing industries are produced by other cooperative factories

the belt production of mold enterprises is relatively common. Taiwan's mold industry pays attention to the integration of mold and products. Mold and products complement each other and promote each other. It is conducive to the development of mold enterprises

closely follow the needs of main products, develop molds, and pay attention to exploring overseas markets. Taiwan's mold industry has developed rapidly. Among them, closely following the main product demand to develop and manufacture molds is also an important factor. In recent years, the rapid development of electronic industry and automobile industry has driven the development of Taiwan's mold industry. At present, 76% of Taiwan's mold output value comes from electronic products and automobiles

I once visited Taiwan's CNC machine tool factory, and the main engine factory is only responsible for assembly and some finishing. The bed is welded by steel plates, and a special factory is responsible for blanking, and then sent to the welding factory, then sent to the annealing factory after welding, then sent to the processing factory after annealing, and then sent to the main engine factory for assembly after processing. In addition to the larger scale of the main engine plant, other plants are very small, and each plant is responsible for only one process, which shows the fine division of labor and close coordination of Taiwan's manufacturing industry

China's mold industry

China's mold industry started relatively late. Since the mid-1980s, great changes have taken place in China's mold industry, especially in the past ten years. The changes can be said to be earth shaking, and now it has become a major mold production country in the world. In most fields, Chinese molds have occupied a considerable share. However, in high-end molds, we still need to import a large amount from abroad. As a whole, the overall level of China's mold industry is still dominated by medium and low-grade molds

from the development history of China's mold factories, after the founding of the people's Republic of China, there were no professional mold factories in China. With the establishment of automobile factories in the 1950s and 1960s, tool factories attached to the main engine factory were gradually established, basically large and comprehensive tool factories established with reference to the Soviet model. With the development of the automobile industry, these tool factories gradually turned into mold factories

take BAIC, which I used to work for example. In the 1960s, it was called BAIC tool factory, and in the 1980s, Beijing jeep was established, called tool workshop. It mainly produces measuring tools, cutting tools, stamping dies, forging dies, casting core boxes, die-casting dies, injection molds, rubber molds and all kinds of fixtures, and gradually turned into a stamping die factory in the late 1990s

since the 1990s, the rise of private mold factories, the introduction of a large number of numerical control machine tools, the gradual implementation of CAD, CAE and cam, and the vigorous development of the mold industry have made China a big mold manufacturing country. However, most of these factories' production methods are large and complete or small and complete. The basis of manufacturing is low-end molds, and there are few medium and high-end molds. Basically, everyone competes maliciously in the low-end market

what hinders us from becoming strong, specialized and refined? One of the biggest obstacles is our large and all-round or small and all-round production mode. Our mold production has no or insufficient professional division of labor

at present, there are about 30000 mold manufacturing plants in China, of which state-owned enterprises account for about 5%, joint ventures account for about 10%, private enterprises account for about 85%, about 1million employees, and about 5000 enterprises with an annual output value of more than 20million yuan. In 2015, the total output value of molds was about 170billion yuan, and the enterprise has

Copyright © 2011 JIN SHI