Lead
Today, when the mainland's economy and society have entered high-quality development, the extensive development of the traditional printing and dyeing industry with high energy consumption and heavy pollution has become unsustainable. To this end, the company tries to introduce the advanced technology of the machinery industry into the textile industry, innovate the production and operation model, and establish an intelligent sharing factory to solve the urgent needs of the mainland textile industry. After more than ten years of industry-university-research cooperation and exploration, Kangpina has achieved major technological breakthroughs and commercialization, and has become a typical example of the transformation of the mainland textile printing and dyeing industry to digital and intelligent manufacturing.
Text / Wang Hongsheng, Li Yingxia, Lv Meixuan, Chen Qi
On December 9, 2018, the "Package Yarn Intelligent Dyeing Industry Demonstration Project" independently developed by Shandong Kangpina Company won the highest award in the industrial field of the mainland - China Industry Award, marking that the company has embarked on a road of new product development of dyeing and finishing equipment in line with the process characteristics of the printing and dyeing industry in the mainland. This is also another national honor won by Compina after winning the first prize of the National Science and Technology Progress Award. After more than ten years of industry-university-research cooperation and exploration, Kangpina has achieved a major breakthrough in printing and dyeing technology and the successful commercialization of the company, becoming a typical example of the transformation of the mainland textile printing and dyeing industry to digital and intelligent manufacturing.
In the face of the extensive development of the traditional printing and dyeing industry for a long time with high energy consumption and heavy pollution, Kangpina Company resolutely entered the textile industry earlier, trying to introduce the advanced technology of the machinery industry into the textile industry, innovate the production and operation model, establish an intelligent sharing factory, and completely solve the stubborn disease of the mainland textile industry. At the same time, after the market reshuffle to survive the textile printing and dyeing enterprises have good strength, if the company wants to occupy a place in the textile industry, it must go out of a suitable for its own characteristics of the development of the road. What is this characteristic path? Can Compina continue to innovate and become a leader in the textile industry?
The textile industry is a traditional pillar industry of the national economy in the mainland, an important livelihood industry and an industry that creates new advantages in internationalization, and plays an important role in stimulating the growth of domestic demand, beautifying people's lives, promoting social harmony, enhancing cultural self-confidence, and building ecological civilization. Today, when the mainland economy and society have entered high-quality development, the high-quality development of the textile industry is also facing some outstanding problems, such as the traditional manufacturing mode of many small and medium-sized enterprises needs to be changed, the use of new printing and dyeing machines to reduce environmental pollution is imminent, and the brand effect needs to be formed urgently.
According to the 2014 Annual Report on Environmental Statistics, in 2014, 1.96 billion tons of textile wastewater was discharged from 20.53 billion tons of industrial wastewater in the country, ranking third among 41 industries, of which 80% of the textile wastewater was discharged from printing and dyeing. The discharge of a large number of printing and dyeing pollutants has brought serious harm to the ecological environment and agricultural development. After the 18th National Congress of the Communist Party of China, ecological civilization has become a national strategy for the overall layout of the "five-in-one", how to adopt digital, intelligent, platform-based, and green advanced manufacturing methods for printing and dyeing enterprises to solve the problems of low equipment level, poor dyeing quality, high energy consumption, and large wastewater discharge, which has become the top priority of China's textile industry transformation and upgrading and high-quality development.
In Shandong Province in mainland China, textile is one of the "five" trillion-level key pillar industries, and is an important supporting force for the stable development of the province's industrial economy. In 2017, the province's textile industry achieved a main business income of 1.18 trillion yuan, of which spinning, printing and dyeing, weaving, chemical fiber, textile machinery and other industries accounted for 50.5%, 2.7%, 13.3%, 2.6% and 1.6% respectively; Apparel, home textiles and industrial end products accounted for 29.4%. As a leader in the textile and garment industry in Shandong Province, in recent years, Kangpina Group has moved from the textile industry to the manufacturing industry, from Shandong to the whole country, and from the whole country to the world. It integrates wool textile and intelligent dyeing and finishing equipment manufacturing, and is the industry leader in domestic automated dyeing and finishing technology and equipment.
The company was founded in 1998 and initially engaged in wool spinning. In 1999, Kangpina leased Tai'an Woolen Textile Factory, revitalized state-owned assets, and resettled more than 1,300 laid-off workers, and in 2003, Kangpina registered a new company to build Kangpina Woolen Industrial Park. In 2004, Kangpina settled in Taishan Industrial Park, through the configuration of advanced international dyeing and finishing equipment, the introduction of Italian Columbus design and production technology, built the highest level of woolen hardware and software platform in China, and successfully created a high-end woolen fabric brand. Since 2008, Compina has been among the top 10 woolen enterprises in China, and in 2016 and 2017, it represented China to participate in the world's top textile fabric exhibition in the French PV Exhibition, and the wool spinning business has entered a period of healthy and stable development.
In recent years, Compina has recognized the seriousness of the problems in the textile industry, such as the front end of the industrial chain due to the "yarn dominance" of the homogeneous surplus, the middle of the industrial chain due to the "printing and dyeing shortcomings" of the development lag, and the end of the industrial chain due to the "clothing, home textiles, industrial scale is weak" effective supply shortage. In the face of a series of problems such as the lack of self-supporting ability and printing and dyeing capacity of the textile industry in Shandong Province, Kangpina decided to break through the shortcomings of printing and dyeing at a high starting point, achieve transcendence in the corner, be the leader of the textile industry in Shandong Province, and take the lead in textile innovation.
Exploration – Campina's path to innovation
Smart factory, opening up a new era of textile industry
The traditional textile printing and dyeing industry is highly polluting, energy-intensive and labor-intensive, but in Compinna, we do not see busy workers, crowded workshops and cross-flowing sewage. In the control room of its workshop, workers only need to press a few buttons to control the entire production line, and the robotic hand under the control of the computer is endless, and batches of packages are neatly printed and dyed, and are neatly placed on the shelves by the manipulator; Outside the control room, in the workshop of Nuoda, I saw two or three workers patrolling back and forth.
In 2009, the Compina Group set up a fully automatic package yarn dyeing production demonstration line, which is the first in China, and has been continuously improved and upgraded in the following five years, and won the first prize of the National Science and Technology Progress Award in 2014 (Figure 1), which is the first National Science and Technology Progress Award in the history of mainland textile machinery. On this basis, Compina has established a smart factory for yarn dyeing, which has realized the unmanned production site and greatly improved the production efficiency.
The reason why Compina created a fully automatic package yarn dyeing production demonstration line is not only the need for the development of Compine, but also the performance of Compine's fulfillment of social responsibility. At the beginning of this century, in the face of the low dyeing efficiency of the traditional printing and dyeing workshop, the waste of resources, the low sample rate, poor production efficiency and poor product quality of the traditional package yarn dyeing, Compina decided to change the status quo of the industry through its own efforts. In order to improve product quality, first of all, we must eliminate the impact of human factors on products as much as possible, and the automatic production line replaces manual operation with robots, which greatly reduces the impact of human factors on product quality.
The fully automatic production line not only improves product quality and reduces production costs, but also makes a great contribution to environmental protection. For example, in traditional printing and dyeing enterprises, the water consumption of one ton of yarn dyeing is about 120-130 tons, while in the smart factory of Compine, the water consumption of one ton of yarn is 80-85 tons. It is estimated that if about 1/3-1/4 of the domestic printing and dyeing industry enterprises use such production lines, it will save 10-11 West Lakes of water every year.
Industry-university-research to enhance the core competitiveness of enterprises
In the domestic textile industry, there has been a saying: Chinese enterprises will always lag behind the technology of foreign advanced enterprises. In 2003, in order to break this curse, Compina began to explore, in line with the principle of "mutual benefit and win-win", and reached a cooperative relationship with the Chinese Academy of Sciences and other scientific research institutes, and since then embarked on the road of transformation and development with the theme of scientific and technological innovation. The R&D expenses of the Campina Group account for more than 5% of sales revenue every year.
In the construction of the scientific and technological talent team, Kangpina has always adhered to the concept of "gathering wisdom for development, gathering talents for one thing and one discussion", and selected 12 young outstanding personnel to be appointed as assistants to the chairman to support the on-the-job education of employees. According to the intelligent dyeing factory plan, a professional project team is formed, and professional talents are introduced and trained to ensure the supply of talents. According to the plan, each intelligent dyeing factory needs 20 management and technical personnel, 50 intelligent dyeing factories are completed and operated, 50 new management teams and 1,000 management and technical positions are added. Focusing on the main line of the industry, Kangpina expands the scope of industry-university-research cooperation and enhances new advantages in market competition. Guided by market demand, with each module of the intelligent dyeing factory as the carrier, strengthen the talent recruitment and training of various professional teams, promote the construction of professional teams, improve the market distribution mechanism, form a construction mode of assembly line operation, ensure the quality and efficiency of construction, and improve the quality of market services; Adhere to process innovation, expand and improve the construction of smart factory industry chain, and lead the technological progress of the industry; Adhere to model innovation, achieve standardized, large-scale, and intensive production, and promote industrial upgrading.
Share factories and form a community of interests
After the completion of the complete set of digital automatic dyeing technology and equipment for package yarn, the company originally planned to vigorously promote and sell the energy-saving and environmental protection equipment throughout the country, but after a period of promotion, the sales team found that the equipment could not be sold at all. After some investigation, it was found that there are three reasons: first, the textile industry is a continuous large-scale production industry, and each time a new equipment is installed, it must be stopped for a year and a half to complete the installation and commissioning, which is impractical for small enterprises with only one production line; Secondly, after the outbreak of the financial crisis, the textile industry has become a restricted development industry, and financial institutions no longer give financial support to enterprises; Third, domestic textile enterprises are dominated by private capital, and the willingness of private entrepreneurs to invest in the textile industry is low.
In the face of these problems, the first choice faced by Campina is: continue to sell equipment or change the development idea based on the needs of the industry and the actual development of the enterprise? If you continue to sell equipment, although the income increases, the target customers are really few; If we change our development ideas, give full play to our technological advantages, through market-oriented operation, take enterprises as the main body, adopt a multi-party cooperation model, build an intelligent dyeing sharing factory, and create a "Compina sharing model", you can not only use your own equipment, but also get benefits, why not? After many field investigations and investigations on the development of the textile industry in Xinjiang, Jiangsu and other places, Kangpina finally decided to adopt the shared factory model to promote the equipment. At present, intelligent dyeing factories in Shandong, Xinjiang, Jiangsu and other places have been completed and put into operation - a standardized and replicable intelligent dyeing sharing factory with an annual output of 20,000 tons of package yarn has been built in Tai'an; In Xinjiang, the government provides financial support, accounting for 45% of the shares, and Kangpina provides plant and equipment, accounting for 55% of the shares; In Jiangsu, the government provides factories and land, and Kangpina "moves in". The company also plans to build 50 intelligent dyeing sharing factories across the country, and after all are put into operation, the annual sales revenue is expected to reach 30 billion yuan, and the annual social energy saving is about 889,000 tons of standard coal.
The intelligent dyeing sharing factory uses digital and intelligent dyeing technology and equipment, and the whole process of dyeing realizes digital and intelligent production, and the pass rate of dyeing is increased to more than 98%, the production efficiency is increased by 28%, and the labor is saved by more than 80%, and the effect of energy saving and emission reduction is outstanding, compared with the indicators specified in the "Printing and Dyeing Industry Standard Conditions (2017 Edition)", each ton of yarn saves 70% of water, reduces sewage discharge by 68%, and reduces comprehensive energy consumption by 45%.
Development - where to find the "fulcrum" of innovation and upgrading
As an enterprise that has been deeply engaged in wool spinning for 20 years, Kangpina has always insisted on relying on brand advantages, establishing a sound marketing system, accurately grasping the market trend, making full use of the advantages of the company's research and development of new equipment, and applying new technologies and new processes to independently develop new products. At present, Compina has launched 20 series of tens of thousands of new fabric varieties.
After a long-term market-oriented development, the domestic textile industry has entered the stage of sufficient supply or even oversupply in the market from material shortage and short supply. Due to the lack of innovation and strength, at present, the homogenization of brands in the domestic textile and garment market is serious, and the orientation of consumer behavior largely depends on the discount intensity of market promotion, and the stickiness of domestic textile and clothing brands to consumers is not enough, and the problem of low consumer loyalty to the brand is very prominent.
Campina's response strategy is to build a loyal customer base through personalized service initiatives such as one-to-one custom design, differentiated management, and focused maintenance, while establishing strategic alliances with key customer groups. For example, the sales team of Compina has subdivided the market into two sections: the international market and the domestic market, and further subdivided the international market into the European and American markets and the Asian market, and the domestic market into Beijing, Shanghai, Shenzhen, Zhejiang, Wuhan five regions, and on the basis of market segmentation, combined with the product structure brand and enterprise development strategy, to provide customers at different levels of corresponding service content. As a result, the design and production of Compina show the characteristics of product style diversity, novel and unique colors and fabrics, and fashion and speed of multi-element combinations, which are favored by many well-known clothing companies at home and abroad. At present, Campina has established long-term cooperative relations with Eland in South Korea, Hugo boss in Germany, Maxmara in Italy, Itochu in Japan, and Youngor, Joeone, Jiuzi in China, etc.
With the continuous upgrading of domestic residents' consumption and the fierce competition of foreign products, Compina is also constantly upgrading its products.
Its selection of raw materials is almost strict, such as the purchase of alpaca, camel hair, superfine wool, cashmere and other raw materials with high cost and low supply, which has laid the foundation for its high-end brand image. At the same time, Campina will also take on the challenge of developing products with complex production processes, such as personalized and unique products such as color dot yarn, TT yarn, and loop yarn in the spinning and weaving process, as well as light and thin cashmere products with unique patterns and double-sided different colors.
In addition, Campina is relentless in its pursuit of innovation in the finishing process. "Doing the familiar to the extreme" is Campina's product development philosophy. For example, its coarse wool products should not only pay attention to three-dimensionality, naturalness and leisure, but also require the product to be stereotyped and stable, and the ironing and factory fabric style and physical quality in the garment production process remain unchanged. It is precisely through a series of stringent standards that Campina has become a reliable golden signboard.
"Difficult innovation" is a stumbling block to the development and growth of enterprises, and textile printing and dyeing enterprises that do not pay attention to research and development have been eliminated after rounds of market reshuffle. Today, the enterprises surviving in the market generally attach importance to R&D and innovation, especially in the research and development of new products, and generally have strong initiative and enthusiasm. Campina had a deep understanding of this early on, and has attached great importance to the construction of the R&D team since its inception. The innovation and hot sales of Compina woolen products are inseparable from the reserve of technology and talents. Kangpina invests tens of millions of yuan every year to cultivate technical talents and build a research and development team. At the same time, Compina has also cooperated with domestic and foreign scientific research institutes to establish a number of R&D centers, and now, Compina has an international scientific research cooperation base for textile digital dyeing and finishing equipment, Shandong Provincial Key Laboratory of Intelligent Dyeing and Finishing Equipment, Yarn Automatic Dyeing Technology R&D Center and other national and provincial R&D institutions, and its R&D strength is in a leading position in the domestic industry in the field of textile dyeing and finishing and related high-end equipment development and manufacturing.
The future is a long way to go
As a high-tech enterprise, in the course of 20 years of development, Kangpina has a deep understanding of the problem of "innovation is difficult, innovation is expensive, and the industrial transformation of achievements after innovation is even more difficult". From winning the first prize of the National Science and Technology Progress Award in 2014 to winning the China Industry Award in 2018, the award-winning project has also experienced many difficulties, and has accumulated a lot of valuable lessons along the way. What's next for Campina?
First, talent management still needs to be strengthened. Looking back at the development of Campina over the past two decades, it is not difficult to see that it attaches great importance to talent. The technological progress of Compina stems from its emphasis on the construction of scientific and technological talents, and the company has established a set of specific management methods for scientific research talents. However, the construction of the operation and management talent team is still insufficient. In the future, Compina will also strengthen the construction of management cadre training bases, and at the same time speed up the designation of relevant rules to promote the company's management to better adapt to its intelligent and shared production mode.
Second, the follow-up operation of the shared plant faces challenges. Compine's intelligent dyeing factory has completely independent intellectual property rights, and its package yarn dyeing production has realized the leap from manual mechanization and stand-alone automation to full-process digitalization and system automation, which has become a major breakthrough in the transformation of the mainland textile printing and dyeing industry to intelligent, digital and green manufacturing. The construction mode of the shared factory system is "technology-intensive + capital-intensive", so it is necessary to continue to carry out the iterative upgrading of core technologies while continuously laying out and building regional intelligent dyeing sharing factories. Therefore, the construction funds, technology upgrades and operating funds after the completion of the shared factory have become difficult problems restricting the construction and operation of the Compina shared factory system.
Thirdly, the changing market demand also poses a challenge to Campina. At present, Compina has occupied a place in the market, and the market demand continues to grow. In order to continuously meet the market demand and adapt to the development and application of new technologies and new processes, it is necessary to keep up with the market, study the technical standards of the same industry, and constantly improve the technical standard support service system that is in line with international standards and suitable for the development of wool textile enterprises, and improve the technical level of enterprises. At the same time, learn from foreign experience, continue to develop and produce digital equipment urgently needed in the domestic dyeing and finishing industry, and produce CNC machine tools in the foundry industry with low energy consumption and low pollution, so as to achieve the development goal of a comprehensive textile printing and dyeing enterprise.
In the increasingly complex market environment, from the initial wool textile industry to the manufacturing industry, to solve the market homogenization, consumer stickiness and other industry pain points, Compina has become the "leader" of China's textile industry. Nowadays, under the guidance of the country's multiple measures to develop and expand the real economy, especially the advanced manufacturing industry, and the policy opportunities to vigorously support the development of the private economy, can Compina continue to take the differentiated strategic route around the guiding ideology of innovation-led development and reform to control the overall situation? Let's wait and see.
About the Author | Wang Hongsheng: College of Economics and Management, Shandong Agricultural University;
Li Yingxia: Yantai Branch of Zhongtai Securities Co., Ltd.;
Lv Meixuan: College of Economics and Management, Shandong Agricultural University;
Chen Qi: School of Economics and Management, Shandong Agricultural University.
Editor-in-Charge | Zhou Yang([email protected])
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