CNC machine tool operator boosts 'Made in China'
On a field trip to Southwest China's Sichuan province 14 years ago, Liu Ping, a tool operator of a computer numerically controlled (CNC) machine, got a chance to see the local military products.
"It is better for these kinds of products to be made on our machines," he said.
His words interested the director of the military product enterprise. After sharing technical issues with each other, Liu earned his company a trial-produce order from this enterprise.
Liu completed the order in just three days, much shorter than the client's expectation. It laid the basis for Liu and his company, Chongqing Chuanyi Control Valve Co Ltd (CCV), to get involved in manufacturing the components of Long March-2F carrier rockets in the following years.
"However, it was not easy at all to make that batch of products," Liu admitted. "Although we had already accumulated some experience in machining thin-wall parts at that time, this order contained all the difficulties."
"They ordered a tail nozzle of the rocket flame thrower, which was designed to be 180 mm in length and 1.3 to 1.5 mm in its single side wall thickness. Having many slant and curved surfaces, it is one of those most difficult-to-machine products."
Liu spent a whole day on adjusting the machining process and grinded cutting tools by himself to reduce deformation of parts in machine process.
In Liu's 30-year career, he has received a variety of difficult and complex parts orders like this, which have given him a wealth of experience in processing pieces that have slender shaft, thin-wall or abnormal structure.
Between 1987 to 2000, when he was just an ordinary machine operator in CCV's machine shop, Liu could complete more than 200 percent of the quota production task and process more than 300 pieces of difficult and complex parts of various specifications and kinds annually in average.
In addition, with ingenuity and bold study, Liu made his quality index reach 99.9 percent.
Breaking through the manufacturing bottleneck
In 2001, Liu asked his leader to transfer him from the ordinary machine shop to the company's newly established CNC workshop.
There was a lack of CNC machine tool operators at that time and Liu wanted to enter the new field.
"I bought a computer in the late 1990s. I could feel this computer numerical control will be the trend and the future," he recalled.
Already well aware of the importance of keeping up with the rapid pace of innovation, Liu made every effort to study the new CNC machine tool.
After diligent studying and strenuous training, Liu mastered how to give full play to the functions of the CNC lathe. Not only he could efficiently complete the processing task, he could also explore process and tool solutions for high-tech products.
Since 2011, Liu has been involved in the research and development of HVH Black Water Control Valves, Butterfly Valves, High Pressure Ball Valves and many other special purpose valves, some of which could only be imported from overseas companies in the past.
"We gradually broke up the technical monopoly of international companies. Our products not only replaced the imported one, they are also exported to foreign markets such as Kazakhstan," Liu said.
Liu's brilliant craftsmanship has brought him many honors. He has a national-level skilled master studio named after him and was elected as one of the 10 craftsmen representing Chongqing's craftsman spirit last year.
"There is no perfect product. What I can do is try my best to improve the accuracy of our products. It requires the repeating of tests and the courage to make innovation," he said.
In addition, he would sometimes go to college to exchange knowledge and experience with teachers there, to get a quicker and deeper understanding of the new technologies and skills in the field.
Passing craftsmanship
In charge of his studio, Liu no longer spends too much time in the frontline but plays a significant role in offering technical guidance to workers and coordinating processing issue with CNC machine tool manufacturers.
On Tuesday, he went round in the CNC workshop to check work. Young operators would like to talk to him to get some comments or guidance.
He often works overtime, especially when there are some urgent orders.
"I usually leave home at 7:50 am and come back home from work at 11:00 pm," Liu said.
However, he does not want the hardship of his work to be mentioned too much.
"Fewer and fewer young people would like to do my job, even if it is better paid than many blue-collar works. They think my job is dirty, drab as well as hard, they prefer to become truck drivers," Liu said with pity.
He values patience and the spirit of bearing hardships very much.
"I asked every freshman I taught to learn from standing. They have to develop more patience."
In order to pass his skills and experience to the next generation and spread technical achievements, Liu has compiled several training materials and has published a paper.
"I love the job of machining, and that is why I can persist on and would like to work hard at it," Liu said.
In addition, he believes operators with real rare skills will never be replaced by automatic machines and will be treasured in the future.
"The repeating work can be replaced but the experience never."
His words interested the director of the military product enterprise. After sharing technical issues with each other, Liu earned his company a trial-produce order from this enterprise.
Liu completed the order in just three days, much shorter than the client's expectation. It laid the basis for Liu and his company, Chongqing Chuanyi Control Valve Co Ltd (CCV), to get involved in manufacturing the components of Long March-2F carrier rockets in the following years.
"However, it was not easy at all to make that batch of products," Liu admitted. "Although we had already accumulated some experience in machining thin-wall parts at that time, this order contained all the difficulties."
"They ordered a tail nozzle of the rocket flame thrower, which was designed to be 180 mm in length and 1.3 to 1.5 mm in its single side wall thickness. Having many slant and curved surfaces, it is one of those most difficult-to-machine products."
Liu spent a whole day on adjusting the machining process and grinded cutting tools by himself to reduce deformation of parts in machine process.
In Liu's 30-year career, he has received a variety of difficult and complex parts orders like this, which have given him a wealth of experience in processing pieces that have slender shaft, thin-wall or abnormal structure.
Between 1987 to 2000, when he was just an ordinary machine operator in CCV's machine shop, Liu could complete more than 200 percent of the quota production task and process more than 300 pieces of difficult and complex parts of various specifications and kinds annually in average.
In addition, with ingenuity and bold study, Liu made his quality index reach 99.9 percent.
Breaking through the manufacturing bottleneck
In 2001, Liu asked his leader to transfer him from the ordinary machine shop to the company's newly established CNC workshop.
There was a lack of CNC machine tool operators at that time and Liu wanted to enter the new field.
"I bought a computer in the late 1990s. I could feel this computer numerical control will be the trend and the future," he recalled.
Already well aware of the importance of keeping up with the rapid pace of innovation, Liu made every effort to study the new CNC machine tool.
After diligent studying and strenuous training, Liu mastered how to give full play to the functions of the CNC lathe. Not only he could efficiently complete the processing task, he could also explore process and tool solutions for high-tech products.
Since 2011, Liu has been involved in the research and development of HVH Black Water Control Valves, Butterfly Valves, High Pressure Ball Valves and many other special purpose valves, some of which could only be imported from overseas companies in the past.
"We gradually broke up the technical monopoly of international companies. Our products not only replaced the imported one, they are also exported to foreign markets such as Kazakhstan," Liu said.
Liu's brilliant craftsmanship has brought him many honors. He has a national-level skilled master studio named after him and was elected as one of the 10 craftsmen representing Chongqing's craftsman spirit last year.
"There is no perfect product. What I can do is try my best to improve the accuracy of our products. It requires the repeating of tests and the courage to make innovation," he said.
In addition, he would sometimes go to college to exchange knowledge and experience with teachers there, to get a quicker and deeper understanding of the new technologies and skills in the field.
Passing craftsmanship
In charge of his studio, Liu no longer spends too much time in the frontline but plays a significant role in offering technical guidance to workers and coordinating processing issue with CNC machine tool manufacturers.
On Tuesday, he went round in the CNC workshop to check work. Young operators would like to talk to him to get some comments or guidance.
He often works overtime, especially when there are some urgent orders.
"I usually leave home at 7:50 am and come back home from work at 11:00 pm," Liu said.
However, he does not want the hardship of his work to be mentioned too much.
"Fewer and fewer young people would like to do my job, even if it is better paid than many blue-collar works. They think my job is dirty, drab as well as hard, they prefer to become truck drivers," Liu said with pity.
He values patience and the spirit of bearing hardships very much.
"I asked every freshman I taught to learn from standing. They have to develop more patience."
In order to pass his skills and experience to the next generation and spread technical achievements, Liu has compiled several training materials and has published a paper.
"I love the job of machining, and that is why I can persist on and would like to work hard at it," Liu said.
In addition, he believes operators with real rare skills will never be replaced by automatic machines and will be treasured in the future.
"The repeating work can be replaced but the experience never."
