Zhejiang news client reporter Xu Xianfei Xue Wenchun sharing alliance Lanxi station Lang Qingyu Wang Yinfeng
After the intelligent transformation, the number of workers in the textile production line has been greatly reduced. Shared Alliance Lanxi Station Photo by Wang Ping
The productivity of the Lanxi textile industry is being activated by "numbers". After the digital transformation of textile enterprises, energy consumption, error rate and labor can be reduced, and the efficiency has increased by an average of 12.3%.
On July 7, at the 2021 China Textile Industry Intelligent Manufacturing Site Conference, the digital transformation mode of Lanxi textile industry was praised by three academicians of the Chinese Academy of Engineering. Chen Wenxing, academician of the Chinese Academy of Engineering and president of Zhejiang Sci-Tech University, said that the intelligent manufacturing of Lanxi textile industry has realized data interconnection, which can be copied and promoted.
Such an evaluation is meaningful. Like the traditional industries in other places, after entering a new stage of development, the Lanxi textile industry is difficult to recruit workers, the labor is expensive, the contradictions such as large production capacity and thin profits are becoming increasingly prominent, and the development encounters difficulties. Enterprises have searched for ways in many ways, and have not found a good solution. Two years ago, Lanxi City seized the opportunity of the "No. 1 Project" of the province's digital economy, began to explore the path of digital transformation of traditional industries, and led the high-quality development of traditional industries with industrial digitalization, which is worth studying.
Xinlan Textile introduced a robotic arm to create an automated production line. Shared Alliance Lanxi Station Photo by Wang Ping
From rejection to like, the enterprise has a "number" in mind
After years of industry infiltration, Lanxi textile people are very confident and distressed.
Confidently, since 1965, the state invested in the construction of Lanxi Cotton Textile Factory, which has become an important production base in China's textile industry, and its main products white blank cloth and denim production have ranked first in the country.
The distress is that although Lanxi has made great efforts to "machine substitution" and introduce 25,000 global advanced looms, there is still a shortage of workers and profits are getting thinner and thinner.
Such a contradiction makes the experts of the Zhejiang Intelligent Manufacturing Expert Committee (referred to as the Zhejiang Intelligent Manufacturing Committee) eat less "closed door soup".
Zhang Youyi, chairman of Zhejiang Weichen Textile Co., Ltd., still remembers that in the summer of 2019, when Xu Jiping, deputy director of the Zhejiang Wisdom Commission, first went to their enterprises to investigate, he still loved to ignore them. "At that time, I also found a lot of ways, can intelligent manufacturing help me solve the problem, I don't believe it." Zhang Youyi said that in fact, in the past few years, their company has also tried intelligent manufacturing and spent money unjustly, "it is very high, most of them cannot understand it, and the investment is very large and has no effect." ”
But not long after, Xu Jiping brought experts and professors to visit, and this time Zhang Youyi understood. "As soon as the experts arrived, they said that the investment should not be too large, and intelligent manufacturing is not just about introducing high-end equipment, but about making data a productive force." Zhang Youyi said that although we use the most advanced looms, they can only be used for weaving. The machines are not connected, the data is not used, and our production management decisions are not refined and too extensive. These experts and professors are straightforward and easy to understand, making Zhang Youyi feel for the first time that intelligent manufacturing is not so high and unattainable. He decided to give it a try.
Later, Zhejiang Chimelong Textile Co., Ltd., a subsidiary of Zhejiang Weichen Textile Co., Ltd., became one of the 9 pilot enterprises for the digital transformation of the textile industry in Lanxi City. Today's Zhang Friendship is "a machine in hand, the whole factory can know." In his mobile phone application, all the data of the factory's production, procurement and sales are clear at a glance, "very easy to use."
From rejection to "true incense", it is inseparable from the promotion of the Lanxi Municipal Party Committee and Municipal Government.
At the end of 2018, the Lanxi Municipal Party Committee and Municipal Government specially invited the expert group of the Zhejiang Wisdom Commission to settle in and guide the digital transformation of the textile industry throughout the process. As an institution established by the provincial government with reference to the State Council's establishment of the Strategic Advisory Committee for the Construction of a Manufacturing Power, the Zhejiang Intellectual Affairs Commission provides intellectual advice and technical guidance for the transformation and upgrading of traditional industries. In July 2019, Lanxi City listened to the suggestions of the Zhejiang Wisdom Commission and issued the "Decision on The Creation of an Intelligent Manufacturing Demonstration City in the Textile Industry in Lanxi City" with the high-standard documents of the Municipal Party Committee. It is planned to use 3 years to gradually realize the equipment networking, data interconnection, paperless documents, transparent process, workshop reduction, management visualization, and service platform of textile enterprises.
"In my opinion, this is also a backwater battle for the textile industry." Tong Yongsheng, director of the Lanxi Economic and Information Bureau, said that over the years, the Lanxi textile industry has searched for ways in many ways, and the effect is not obvious. "The world's most advanced equipment has been used, but some companies can't even inventory clearly, only to digital transformation, to the data to be productive." Tong Yongsheng said that such a new transformation, highly professional, beyond the cognition of many business owners, needs the help of the government's "competent hand".
An accurate digital "make-up lesson" was opened in the Lanxi textile industry. As Zhang Youyi said, this class aims to make machines "dialogue" and data interconnected, and generally does not involve equipment updates. As long as the enterprise is equipped with sensors, scanning guns, display screens, etc., to solve the problem of "deaf, dumb, blind" equipment and materials, to achieve data collection; and then through the MES (manufacturing enterprise production information management system) and ERP (enterprise resource planning management system) two software systems, to achieve production, procurement, sales data interconnection; and then through several applications, from the operation layer, management to the decision-making level to install different permissions of the intelligent terminal (Kanban) system, you can realize the digital management of enterprises.
Wanzhou textile automatic winding production line. Shared Alliance Lanxi Station Photo by Wang Ping
From collection to application, enterprises have a good "number"
This interconnection of data activates productivity.
The data shows that after 98% of the production equipment data of the nine pilot enterprises in Lanxi were connected, the average consumption of water, electricity and steam per 10,000 meters of cloth decreased by 9.8%, 1.6% and 5.6% respectively, the error rate dropped from the original 2.4% to 1%, and the average efficiency increased by 12.3%.
Standing in front of the company's large data screen covered with several walls, looking at the operation of each loom flashing on it, Qiu Haibin, chairman of Zhejiang Xinhai Textile Co., Ltd., was full of emotions. "When is the machine, how efficient it is, now it is clear at a glance." But two years ago, in order to understand these data, we specially assigned 6 meter readers. The clerical error is right or wrong, I will not know how the machine is working until 24 hours later. Qiu Haibin said.
The reporter learned that in the traditional textile workshop, the production status relies on manual copying of reports, blackboard records, manpower, material resources consumption, data records are neither complete nor accurate, it is more difficult to achieve real-time synchronization. Digital transformation networks each process equipment and realizes the collection and transmission of data protocols for the whole process equipment. Enterprise managers and workers can monitor status data in real time and push and receive production tasks through equipment such as shop floor boards, mobile phones and bracelets. In this way, the production status can be managed in real time, the data can be automatically recorded, and the report can be automatically sorted, which will reduce the workload of statisticians by 60% and increase the scheduling efficiency by 30%.
The collection of data is for the better application of data. After the machines are interconnected, the change comes -
Electricity was saved. "Xinhai"'s large electricity user, the air compressor, is no longer "stupid" to supply gas. It "reads" the demand for looms and supplies them on demand. On this one, Xinhai Textile can save nearly 5 million yuan in electricity bills a year, the company's production efficiency increased by 10%, and energy consumption decreased by 10%.
In the Wyson textile inspection workshop, high-speed cameras collect cloth information in real time, automatically look for errors, and one worker can operate multiple machines at the same time. Shared Alliance Lanxi Station Photo by Wang Ping
The cloth inspection is fast. After Zhejiang Wanzhou Holding Group completed data automation collection, software interconnection, digital display and intelligent manufacturing training for employees, they created a visual cloth inspection system. The original cloth inspection machine, after installing 10 cameras and an operation display, the original inspection machine required two workers, and now the two machines are only responsible for one person, and the cloth inspection per minute is increased from the original 33 meters to 55 meters. "After all the data and machines are opened, the output and pass rate calculated by the visual cloth inspection system can also guide the production of the loom." We set a threshold value, once the cloth defect point exceeds the threshold, we can actively warn the relevant loom for overhaul, thereby reducing the production of substandard products. Xu Jianzhong, secretary of the party committee and executive vice president of Zhejiang Wanzhou Holding Group, introduced that through intelligent transformation, the company's management level and economic benefits have been greatly improved, the comprehensive efficiency of looms has increased by 2%, operating costs have dropped by 10%, energy consumption has dropped by 5%, labor has dropped by 16.6%, and order delivery has been shortened by more than 5 days.
The warehouse is "big". Traditional textile warehouses use manual management, low space utilization rate, low material access efficiency. Zhejiang Qixing Textile Co., Ltd. on the basis of digital transformation, to achieve digital warehousing transformation, through two-dimensional code, PAD and other mature technologies, virtual cargo space management, the formation of a digital map of the warehouse, cloth found efficiency increased by 80%. Xinlan Textile realized the automatic entry and exit of cloth in and out of the warehouse, and the utilization rate of the warehouse was increased by 50% and the efficiency was increased by 70%.
Wanzhou textile automatic packaging production line. Shared Alliance Lanxi Station Photo by Wang Ping
From pilot to promotion, the industrial expansion "number" is listed
Lanxi textile industry has typical subdivision industry characteristics, mainly small and medium-sized enterprises, equipped with similar equipment, using similar processes, and producing similar products. This means that the purpose of "trying a batch and driving a piece" can be achieved.
But two years ago, many business owners in Lanxi were like Zhang Youyi, and they talked about "counting" discoloration. "Smart manufacturing on the tall is piled up with money. We small and medium-sized enterprises have a thin foundation and thin profits, how to do it? In the interview, a business owner talked about the doubts he had once had.
Such doubts gradually disappeared as the pilot enterprises had "numbers" and used "numbers". Xinhai, Wanzhou and other pilot enterprises invested more than 2 million yuan, energy saving and consumption reduction and other income of millions, input and output is very cost-effective.
In order to accelerate the cognitive speed of business owners and realize the rapid promotion of the industry, experts from the Zhejiang Wisdom Commission and relevant departments of Lanxi City have worked together to extract the "4 + X" textile digital transformation model. To put it bluntly, it is to use "small transformation" plus "large subsidies" to guide. "4" is based on the prescribed actions, which refers to the four links of opening up data, application data, presenting data and implementing training; "X" is a self-selected upgrade action, including intelligent logistics warehouse, energy management system, visual intelligent cloth inspection and so on based on the in-depth application of data. Municipal finance is supplemented with different subsidy ratios, as a "small transformation" of the "4" subsidy up to 50%, "X" production equipment can also be subsidized 10%.
At the same time, in view of the high cost, difficult maintenance, lack of talents and other problems of the traditional information management system, Lanxi City has selected through competition to let the third-party enterprise Zhejiang Buwei Information Technology Co., Ltd. undertake cloud platform services. Textile enterprises can choose the platform system services for different stages of the enterprise according to the three files of entry, basic and improvement, so as to achieve lightweight application. At present, there are 31 enterprises settled in the platform, more than 10,000 cloud equipment, and more than 30 special industrial APP for the textile industry, which has initially formed a platform effect.
"Our purpose is to lead enterprises to gradually move towards the track of intelligent manufacturing, so that enterprises can easily take the first step of intelligent manufacturing - digital transformation, with less investment, to achieve greater benefits." Chen Fengqi, secretary of the Lanxi Municipal Party Committee, said that there are now more than 500 textile enterprises in the city, and more than 40 have been exposed to digital transformation in various ways. Business owners have changed from talking about "numbers" to talking about "numbers" for fun.
Digitalization has increased the benefits of businesses and benefited workers. Ma Zongxia, a female cloth inspector of Zhejiang Wanzhou Holding Group, was originally worried that she could not keep up with digitalization, but she did not expect that digitalization would reduce her burden. "The original cloth inspection, all day long eyes have to stare at the cloth, very sour, very tired, now the cloth is flawed, the machine will stop, the camera will show the location, the cloth inspection speed is fast, the operation is simple." Ma Zongxia said that after the efficiency increase, her monthly salary also increased by four or five hundred yuan.
Textile industry experts in-depth Lanxi enterprise guidance. Photo courtesy of the Propaganda Department of lanxi municipal party committee
【Expert and scholar evaluation】
Yu Jianyong, Academician of chinese Academy of Engineering and President of Donghua University:
At present, the goal of China's textile power has been basically achieved, and the level of fiber raw materials, spinning and weaving, garment home spinning process manufacturing and equipment has been at the international advanced level. Under the influence of multiple factors such as the epidemic, cost, employment, and international situation, the textile industry has gradually entered the era of digital dividends, network dividends, and intelligent dividends, and intelligent manufacturing has become one of the five key development projects of the textile industry during the "14th Five-Year Plan" period. However, there are still some key technologies in China's intelligent manufacturing that have not been mastered. Core equipment and core industrial software must be fully mastered, and textile intelligent manufacturing talent training and public research and development platform need to be further strengthened to get rid of dependence on foreign technology.
Chen Wenxing, Academician of the Chinese Academy of Engineering and President of Zhejiang Sci-Tech University:
Large enterprises have strong capital, perfect enterprise structure, solid production foundation, complete team, and the implementation of digital transformation has inherent advantages. Due to the relatively high cost of digital transformation, the lack of information management talents, and the low degree of equipment automation, the road to digital transformation of small and medium-sized enterprises is relatively difficult. Zhejiang Province, as the most active private economy and the most developed area of the block economy in China, is increasing investment in the field of intelligent manufacturing, setting up different intelligent manufacturing pilots in Zhuji, Yiwu, Lanxi, Xinchang, Changxing and other places, promoting small and medium-sized enterprises to complete intelligent transformation and enhance regional industrial competitiveness and economic vitality. In Lanxi, intelligent manufacturing has realized data interconnection.
Gao Yong, Secretary of the Party Committee and Secretary General of China Textile Industry Federation:
In recent years, under the full promotion of Zhejiang Intelligent Manufacturing Expert Committee and Lanxi City, Lanxi Textile Industry takes digitalization, informatization and network improvement as the starting point, based on the introduction of intelligent manufacturing willingness for small and medium-sized enterprises, focuses on cloud platform services, provides lightweight transformation, general-purpose, sustainable, replicable and easy to promote the "Lanxi Experience", and provides a good path and practical experience for the intelligent transformation and upgrading of the textile industry based on small and medium-sized enterprises, which is worth learning and promoting. During the "14th Five-Year Plan" period, we must build a high-quality textile intelligent manufacturing system, promote the advancement of the industrial base, enhance the modernization of the industrial chain, promote the high-end of manufacturing capacity, and apply the "Lanxi Experience" to implement digitalization, informatization, and network transformation and upgrading, so that intelligent manufacturing can enter the homes of ordinary people and blossom in the whole industry.
Mao Guanglie, Director of Zhejiang Intelligent Manufacturing Expert Committee:
Promoting the intelligent manufacturing of the cotton weaving industry is a very complex system engineering, there are many problems that need to be considered and solved, we adhere to transparent operations, gradually open up the data of each link, use data to reflect the value of production, increase efficiency for enterprises, reduce personnel and increase efficiency, improve quality and efficiency, reduce costs and increase efficiency, so that enterprises can obtain a greater sense of gain.