The road to transformation and upgrading of Zhejiang enterprises: intelligent manufacturing promotes both quality and efficiency

With the release of the "Guiding Opinions of the Central Committee of the Communist Party of China on the Implementation of Quality Improvement Actions", the quality improvement has been mentioned to an unprecedented height. As a pioneer in quality innovation and quality improvement, Zhejiang Province has in-depth implementation of the quality improvement strategy, creating “Made in Zhejiang” and promoting “three strong and one manufacturing”. Recently, the author went deep into Zhejiang Province and visited the Zhejiang manufacturing industry on the spot. He deeply felt the huge “dividends” brought by smart manufacturing to the industry and enterprises.

"Machine Substitution" realizes the butterfly change from "manufacturing" to "intelligence"

According to the "Made in China 2025" issued by the State Council, it is necessary to accelerate the integration of the new generation of information technology and manufacturing industry as the main line, and to promote the direction of intelligent manufacturing as the main direction, so as to realize the historical leap of manufacturing from large to strong.

The in-depth advancement of intelligent manufacturing has opened a new chapter in Zhejiang's manufacturing industry, and the glasses companies in Bohai District are deeply touched. Glasses is the city card of Ouhai District. It has a history of more than 30 years of development in the optical industry and is one of the top five glasses production bases in China. As of the first half of 2017, there were 45 companies in the Bohai District, with an output value of 1.426 billion yuan, a year-on-year increase of 21.21%.

"Machine substitution" as the name suggests is to replace labor with machines. The glasses industry is a labor-intensive industry, relying on labor to complete a series of production and processing links, but workers will inevitably make mistakes in the production process. The unique stability of machine production will, to a certain extent, avoid errors that may occur in manual production.

"Replacement of labor with machines will not only reduce labor costs and energy consumption, but also increase efficiency, output value, and the improvement of process quality and product quality." Zhou Aisong, chairman of Bohai Optical Co., Ltd., said: “The laser spot welding machine replaces the original manual welding, the material loss is greatly reduced, and the production efficiency is increased several times. The automatic plate machine can replace the production capacity of nearly 10 people. Incomplete statistics, the use of the machine saves the enterprise. Hundreds of workers' labor."

In recent years, the Wenzhou City and the Bohai District Government have issued a series of policies to vigorously support "machine substitution." At the same time, it has also established a "machine substitution" industrial development alliance, joint government, industry associations, scientific research units, equipment manufacturing enterprises and nationally renowned institutions of higher learning to jointly provide advice and services for enterprises in need.

It is understood that in 2017, Bohai District should realize the full coverage of “machine substitution” in the optical industry. By 2018, the optical industry in the region plans to complete a technological transformation investment of 300 million yuan, with an average annual growth rate of more than 20%, and implement 20 key points every year. The Machine Substitution Project promotes the transformation of the Bohai Optical Industry and promotes intelligent development.

To this end, on October 19 this year, Bohai District announced the “Administrative Measures for the Use of Special Funds for Machine Substitution” in the Optical Industry of Ouhai District (hereinafter referred to as the “Measures”). The "Measures" emphasizes that enterprises are encouraged to purchase advanced technologies and equipment such as industrial robots, intelligent manufacturing systems, factory Internet of Things and 3D printing in technological transformation to achieve technological progress and industrial upgrading. For technological transformation projects such as equipment purchase, technology transfer, and software purchase, the government grants financial subsidies according to different proportions. The maximum amount of subsidies for individual projects is up to 3 million yuan.

Intelligentization greatly reduces production cycle

There are still many Zhejiang enterprises that have tasted the sweetness from intelligent production. One of the top 100 enterprises in China's garment industry is the news.

“Currently, the company has more than 1,500 physical sales outlets and an online marketing network covering mainstream sales platforms, and three production bases in Wenzhou, Shanghai and Hefei. The annual retail revenue is more than 5 billion yuan, ranking among the top 100 enterprises in China's apparel industry.” When Wu Zhize, chairman of the newsbird company, said this, the excitement was overwhelming.

Intelligent production is a "trump card" for the Annunciation. Into the newsletter show hall, the two large screens on the left and right sides of the wall have become the focus of attention, this is the omni-channel war room and the cloud wing intelligent manufacturing war room. Bar charts, hot maps, pie charts, tables, etc. are all on the screen, which can be described as a model for data visualization. The information on the screen shows the distribution of the newsletter national members, customer feature keywords, customer volume parameter information, real-time order progress and pipeline dynamics.

“After the customer places the order remotely, the local branch dispatches the body to carry out on-site service and measures more than 20 body data. The body data will be transmitted to the headquarters production center, the information will start to be diverted, and the CAD intelligent group will be introduced to the plate making. The process generates a digitally operable version; the other side is introduced into the raw material warehouse, and the warehouse will sort out the fabrics, surface accessories, button lines, zippers, etc. that the customer needs.” Wu Zhize, Chairman of the Baoxi Bird Group, introduced the author in detail. The process of garment production.

In the intelligent workshop of the Baoxin Bird, the author witnessed the manufacturing process of the garment: In the custom production line of the Baoxin Bird, a piece of clothing will be divided into five parts: the front body, the back body, the sleeves, the collar and the noodle, which are then divided into several parts. The pieces of each part will be hung to the intelligent "hanger" and enter the smart hanging system for sewing. Clothes parts of the same color and the same craft are transported to the same station after being intelligently matched. After each part is finished, it will enter the screening area uniformly, and the intelligent hanging system will automatically match the parts of the clothes.

“Creating the operating system of Yunyi Internet's intelligent manufacturing architecture, accelerating the transformation of the newsbird from traditional manufacturing to intelligent manufacturing, and striving to explore a transformation path of “customized, large-scale production and branded marketing” for traditional clothing enterprises.” Wu Zhize expressed his pride in his expression. He told the author that customizing a suit requires nearly 400 processes, and the intelligent assembly line meets individualized demands at the speed of the assembly line, increasing production efficiency by 50%, reducing the production cycle from an average of 15 days to 7 days, and the quality pass rate. Increased from 95% to 99.6%. ”

Editor in charge: Xu Yuehua