At night in Changsha, it is a flowing colored light. In those lights, there are electric vehicle lights that deliver milk tea to and from, high-rise neon that dots the banks of the XiangJiang River, moonlight in the sky, and star cities on earth.
At this time, more than 200 people hurriedly finished their dinner and walked into the night illuminated by the lighthouse factory.
This is the last link of "walking into the benchmark factory - big country heavy equipment • Sany Heavy Industry", the review class. In the class, they reviewed what they saw and learned from sany heavy industry no. 18 factory and heavy truck factory that rely on the tree root interconnection industrial Internet operating system to achieve digital transformation that morning, and the sharing meeting full of dry goods such as He Dongdong, co-founder and CEO of tree root interconnection, Liu Yan, president of Sany Heavy Industry Intelligent Manufacturing Research Institute, and wu Xiaobo teacher.
"What is the most profound thing that touched you during this study tour?"
The most frequently mentioned points by the students were:
01.
Degree of depersonalization
The main plant of the 200,000-square-meter heavy-duty truck factory can be rolled off the production line every 10 minutes, while there are only 132 workers and managers in total.
There are nearly 2,000 cameras in the factory to help managers understand the scene, the current object, and the reality of each place - Sany calls it "three modernizationism". A person who operates improperly, or even a piece of clothing that is put on a place where it should not appear, will be recognized and reminded by the system. In fact, you can see the real-time situation of Sany's factories across the country from the big screen, and the camera will automatically capture all the non-compliant behavior, such as the material is not stacked neatly, even if it is only a stack of steel plates at the top of the plate with a slight tilt.
In addition, there are hundreds of industrial robots one after another, hundreds of AGVs transporting accessories, industrial workers do not need to learn to screw, but to learn programming.
"There are fewer people than our factory." The head of a company that supplies parts to Sany lamented.
02.
Intensive capital investment
"A lot of money, a lot of money." One practitioner repeated this sentence.
After all, everything that happens in the huge factory building of the steel structure is too shocking, and behind the intelligent manufacturing is the boldness of the Billion level of investment. The mentor also responded at the review meeting that the future of China's manufacturing industry will inevitably be an industry with intensive capital investment.
03.
Garden factory
Reflecting the production line robot arm is the dusty ground - it is really dusty, and Sany has an obsession with this, thinking that if it is not even neat, then precision cannot be talked about.
There are also huge green plants and swimming fish in the factory building, so that the staff can relax their bodies and minds.
Some students also mentioned that the slogans of Sany Heavy Industry are particularly large, and slogans such as "grateful" and "strive to achieve the Chinese dream" are particularly eye-catching and inspiring.
This is China's benchmark factory, this is the Chinese factory that cannot be moved to Southeast Asia.
04.
Excavator index
Since 2014, Sany Heavy Industry has summarized the operation of nearly 800,000 excavators from its own factory, and now reports to the relevant ministries and commissions of the State Council every half a month, which is the "excavator index" that best reflects the operation of infrastructure and real estate across the country. The first in the national market share for ten consecutive years and the first place in the global market share in the past two years are the confidence they represent the entire industry.
In front of the excavator index display screen, which could not be made public, the trainees stayed for a long time, and everyone wanted to see the data of their hometown, "as if satisfying a kind of voyeurism."
05.
Either roll over or overturn the ship
"Digital transformation, either turn over or overturn the ship." This is a sentence of Liang Wengen, chairman of Sany, which was repeatedly mentioned in the venue and touched everyone.
We must be stable and far-reaching, and if we can't change the big times, we must do ourselves well.
In addition, the turnover rate of accounts receivable of 257 times, the parade-like rows of heavy trucks, and the staff canteen of "True Fragrance" have become the memory points of the trainees' visit.
Of course, you can't skip the speeches of several teachers and experts, and the minibus has sorted out the essence of it and shared it with everyone.
He Dongdong
Co-founder and CEO of Treeroot Interconnection
We make a vision of the future of manufacturing.
First, the future of manufacturing, will certainly be from the front-line physical world to the digital world, it can be like the consumer Internet, through the network to operate, make decisions, issue implementation instructions. Even similar to playing computer games, your role in the background online can make these machines offline accurately execute instructions.
Second, our corporate form will change a lot, just like the changes that occur when we see the sales pattern. Now this kind of factory, which is maintained by power management, will change a lot. Platform-based organization, networked manufacturing and services, and industrial knowledge accumulation will all come out.
Third, the widespread use of blockchain will automate our transactions. The transaction cost of manufacturing is very high, but if the technology of blockchain can be combined with the IoT, transactions can be automated.
Fourth, the production capacity is integrated. All of us here may often receive phone calls asking if you want a loan, because your consumption digital model and credit model have been established, and financial institutions can give you a loan. But it is very difficult for a well-to-do manufacturing industry to get a loan. Why can't the value of venture capital in manufacturing be loaned at any time? The difference is that its entire production cooperation has not established a digital model, and a real-time credit model.
But after adding IoT statistics, after all your production behavior can be profiled, our manufacturing enterprises are likely to lend very accurately anytime and anywhere, which can also solve a very big problem in our manufacturing industry, that is, the difficulty of financing.
To sum up a little, the system of intelligent manufacturing is a networked real-time dynamic system. At that time, the boundaries of the factory will be broken, I want to devote myself to manufacturing entrepreneurship, may not have to buy my own factory, buy machinery, I can find the right machine online, the right factory to help me produce.
Based on this vision of the future, the digital transformation of industry will definitely bring several needs.
First, external interconnection. I have to connect all the machinery, equipment, materials and materials.
Second, two data sources– a lot of IoT data and Internet data to be processed, are no longer the structured data in traditional manufacturing information systems. So there are two sources of big data.
Third, the introduction of new technologies. Just talked about the digitization of our manufacturing industry, which is essentially to introduce Internet technology into the manufacturing industry. But with so many new technologies on the Internet, which manufacturing company can keep up? Definitely can't keep up. So, we need to have a platform to turn these new technologies into simple and easy-to-use applications.
The fourth, the most important application direction of Industrial App 4.0, is the data-driven application, which is a massive number of applications. Every part that I produce with each device can be made into an operator, an algorithmic model to express its process. It's just a separate app, and the app is constantly learning. Think about it, how many such apps will there be? In the field of marketing, where to produce this massive app, how to tackle the problem? This is a very new requirement.
Fifth, the platform-based industrial chain. The platform of the industrial Internet wants to optimize and split the orders of a large number of factories, which is a change in the business model.
Sixth, the industrial Internet platform. From the perspective of demand, all these new connection objects, new data sources, new applications, ERP, the most important industrial software in the 3.0 era, which one can meet so many needs? We couldn't meet it, so we needed a new architecture, the Industrial Internet platform.
Just like the mobile phones of each of us now, they are all interconnected, but it is not that the mobile phones are directly interconnected one-on-one, but connected to the operator's platform, and then the operator does the most efficient connection.
Seventh, data specification. We need to have some data specifications, data models, to be able to converge the diversification of manufacturing, so that our information technology can deal with, rather than everyone to build their own data twins, there will be some norms that everyone recognizes.
Liu Yan
Senior Deputy General Manager of Sany Heavy Industry
Deputy Director of Intelligent Manufacturing Headquarters, President of Intelligent Manufacturing Research Institute
Sany's digital industrial brain is at the leading level of the global heavy industry industry as a whole.
First, automatic scheduling. By automatically scheduling production in the system to the station, the accuracy rate of the on-line plan can reach more than 95%;
Second, the computer automatically issues production tasks, basically realizing the unmanned mobilization of production tasks;
Third, the use of central control automatic reporting, the automatic reporting rate of more than 50%, which includes non-lighthouse projects, if you remove only the lighthouse factory, this data will be higher.
Fourth, the wages of front-line workers are paid daily, although in practice, they may not be paid daily, but the daily wages are closed, so that we can know the working hours and working status of each worker, which corresponds to his wages on the same day;
Fifth, industrial software and hardware are perfectly coordinated, and the distribution rate of AGV on the lighthouse factory line is 100%;
Sixth, promote the in-depth application of "scene, current objects, reality", equipment interconnection, energy "water, electricity, oil, gas" four tables, 5G and data, to achieve energy management, efficiency management, cost savings, failure prediction, etc.
We use data to support management decisions, including manufacturing dashboards, manufacturing system portraits, etc. Through the dashboard, we can clearly know our more than 100 work centers, dozens of warehousing centers, what is the state of its operation, which efficiency is relatively high, which efficiency may need to be improved, which costs may exceed the standard, and which equipment needs maintenance.
Just now an entrepreneur said that when he visited the Sany factory, all he saw was money (investment). I think it is also true that investment is necessary, but on the other hand, from traditional manufacturing to intelligent manufacturing, it is more important to choose strategically, where to invest money and resources? How do we respond to changes in the labor structure, respond to the upward pressure of raw materials, and achieve higher production efficiency, shorter lead times, and greater returns. Therefore, intelligent manufacturing, which must be accompanied by a change in the future business model. For example, when we visited a heavy-duty truck factory, some people asked why we invested so much to build such a large production capacity? Because only with such a large production capacity can it establish an agile model to cope with the Internet sales model of heavy trucks and realize C2M (direct user manufacturing).
Therefore, the essence of the digital transformation of traditional enterprises is the transformation of business models, and the transformation of business models must require a strong manufacturing capacity and a digital system to support it in order to support its manufacturing flexibility, support its supply chain stability, and support its overall online marketing.
The future is the era of software-defined everything, all fortune-500 companies will be software companies, and the card neck problem of China's manufacturing industry will also change from precision mechanical parts to chips and industrial software. Sany has initially realized the intelligent manufacturing system, and our follow-up planning in the field of intelligent manufacturing focuses on the autonomy of industrial software and the deep mining of data applications and data intelligence.
In addition, Sany has collected all the data at present, but the use of data needs to be improved. But I think it's just a matter of time, and doing real data recording and collection is the first step to achieving intelligence. Also share an experience with you by the way, don't go to collect it because you don't know how to use a lot of data now, because many data cross-application scenarios are not something you can think of when you collect it, and when you think of this scene one day, you may find that there is none, then it is difficult for you to go back and collect these data. When the data accumulates to a certain extent, and then goes back to do process optimization, quality analysis, consumer insight, and product improvement, you will find that the more dimensions of the data, the more meticulous and real the data records, the greater the value that the data can play.
Wu Xiaobo
Financial writer
How to distinguish between Japanese factories and European and American factories? There is a very simple method, the production team of the Japanese factory has a blackboard with everyone's name written on it. Once I saw a few circles drawn on the ground in front of the blackboard, and no classmates on the scene knew what it was used for? They told me that every day before work, colleagues in this production group would come here for a small meeting, and everyone would give advice, and whoever gave more advice would select an excellent employee of the day. This excellent employee stood in the circle, and the other employees stood next to him and applauded.
This is a good amoeba learning organization. When we look at the factory, we must also learn to learn.
Over the years, I have often said that we must have the ability to learn, and our enterprises must become learning organizations. I have found that there is a big difference between the learning ability of entrepreneurs and the learning ability of students in other industries. We entrepreneurs don't necessarily have the best academic qualifications, right, but many of our entrepreneurs are able to stay well because we usually have a particularly important ability – one example.
Our learning may not necessarily be from books, nor from teachers, but from practice. Our visit to the factory is a kind of practice, so after we visit, we ask questions, review, discuss together, but also practice and learn.
In today's Chinese factories, in fact, we rarely see an all-round champion, generally in some aspects, in some fields, have their own more prominent characteristics and practical experience. We must prepare in advance, be good at observation, be able to draw the key points, and ask questions, so that our visit will be more effective.