"Machine replacement" helps China's manufacturing intellectualization gradually approaching
Abstract: in the development process of the past few decades, although China has become a "large manufacturing country" and the scale of manufacturing industry ranks first in the world, there is still a large gap between the overall level of manufacturing industry and advanced countries
in the global environment of digitalization, intelligence and networking, "manufacturing must move towards intelligent manufacturing" has become the consensus of all countries in the world. Germany is promoting the "industry 4.0" plan, the United States is promoting the concept of "industrial interconnection", and China has also timely launched the "made in China 2025" and other development plans, striving to promote the upgrading of traditional manufacturing to intelligent manufacturing and comprehensively improve the production quality of manufacturing
in the development process of the past few decades, although China has become a "big manufacturing country", and the scale of manufacturing industry ranks first in the world, there is still a large gap between the overall level of manufacturing industry and advanced countries. The action program of "made in China 2025" is the action program for China to change from a "manufacturing power" to a "manufacturing power", and the construction of smart factories is one of the important tasks. From 2015 to 2017, the Ministry of industry and information technology supported more than 500 intelligent manufacturing integrated standardization and new mode application projects, and designated 110 projects as "intelligent manufacturing pilot demonstration projects", including the Cosmo intelligent factory operating system with independent intellectual property rights of Haier Group
the construction and promotion of intelligent factories is the necessity of social and economic development, the development of science and technology, and the necessity for enterprises to obtain competitive advantages for sustainable development. We believe that smart factories in the future will bring more surprises to the world
if you don't watch it on the spot, you can hardly imagine that in the factory covering 87000 square meters, the actual number of employees is less than 400
this is the scene seen during a recent visit to Haier's central air conditioning interconnection plant located in the Sino German Industrial Park in the West Coast new area of Qingdao, Shandong Province. This plant is already Haier's eighth interconnection plant so far
why is the factory "empty"
with such a large space, spacious environment and electronic machine operation, it was almost impossible to see factory employees working within two hours of the visit
domestic enterprises are increasingly looking to Australia and African countries. Liu Xiaobo, director of the quality department of Haier central air conditioning interconnection factory, said that at present, most of the workers in the factory are responsible for supervising and checking whether there are problems in the links, and the factory has basically achieved "intelligence"
in addition to the small number of workers, Yang Weixin, head of Haier central air conditioning interconnection factory, also said that before the establishment of the factory, 169 interventions were eliminated by using 3D simulation technology. It is by virtue of optimizing the process before building the plant that the plant has been running for 9 months since its completion, and no equipment has been moved
"at present, the factory mainly produces magnetic levitation centrifuges and other central air-conditioning products. Liu Xiaobo told that in such a large factory, it is difficult to see people walking in the factory, but on the contrary, there are many robot manipulators.
a fully equipped carrier car drove past the factory, approached the small car, the carrier car immediately stopped and flashed the red light, then retreated, and the carrier car immediately" resumed "the route and continued to move towards the production line
the construction cost of smart factories is obviously expensive. Yang Weixin said that the construction of Haier central air conditioning interconnection plant began in January 2016, with a total investment of 500 million yuan. In the past five years, the production capacity of the plant has achieved double-digit growth, which is expected to increase by 70% this year. If nothing unexpected happens, the cost can be recovered next year
how to realize "private customization"
after visiting Haier's smart factory, we found that Haier's innovation comes from paying more attention to the feelings of consumers. On the one hand, it realizes interactive docking through scientific and technological innovation, and on the other hand, it improves the user experience through smart home
when talking about the difference between smart factories and traditional factories, Wang Hongtao, the operation director of cosmoplat of Haier, said: in the past, it was a factory of inventory, but in the future, it will become a factory of users
in the exhibition hall of Haier central air conditioning interconnection factory, the staff touched the screen with their fingers to demonstrate the process of realizing the customer's "private customization". The user has 11 options for customization, including refrigeration capacity, capacity and other information. After the user selects and clicks confirm, an order number will be generated. After ordering goods, users can also watch the subscription of their ordered products through remote video at any time
"the power of one plus one is always greater than two. If enterprises want to get orders, they need to start from the perspective of customers, first solve the pain points of users, and then produce similar products that can save 80% energy. The following figure shows the components of natural fiber reinforced composite vehicles, which are the new trend in the future." Wang Hongtao introduced
small and medium-sized enterprises need to change their thinking
unlike high-cost goods such as electronic products, household appliances have become indispensable "relatives and friends" in families. Although household appliances have been upgrading, due to the lack of creativity of products, "one use to the end" has become the purchase principle of the public
in this regard, Wang Hongtao believes that compared with other developing countries, whether Germany or the United States, their technological advantages are relatively superior to China. Therefore, China's household appliance enterprises urgently need to improve the automation level to meet the higher-level needs of consumers
Wang Hongtao believes that made in China has been facing many problems in the process of intelligent transformation, including "inconsistent standards, unclear directions, chaotic means and modes"
as early as 2015, China issued the guidelines for the construction of national intelligent manufacturing standard system. "The state has defined the five major standards of Intelligent Manufacturing in China, namely 'openness, interconnection, flexibility, intelligence and visibility', which provides guidelines and landing standards for Chinese enterprises to transform to intelligent manufacturing. Therefore, we believe that building an integrated, digital and intelligent service platform to better meet the personalized experience of users is the new direction of enterprise transformation and upgrading." Wang Hongtao said
"the main directions of various countries are different. The United States has done a great job in Internet and software, and Germany has done a great job in technology application, but China has a broad application market." Wang Hongtao believes that only by connecting the upstream and downstream of the platform can we better drive the upgrading and transformation of enterprises
transformation to Intelligent Manufacturing: harmony but difference
the report shows that China's intelligent manufacturing industry is still in the primary development stage, most enterprises are in the research and development stage, and only 16% of enterprises have entered the application stage of intelligent manufacturing. From the perspective of the economic benefits of intelligent manufacturing, 52% of the enterprises' existing change experiments can only record semi quantitative indicators such as the number of twist turns. The contribution rate of intelligent manufacturing revenue is less than 10%, and 60% of the enterprises' intelligent manufacturing profit contribution rate is less than 10%. The reason why the majority of small and medium-sized enterprises have a low degree of intelligent manufacturing is that the cost of intelligent upgrading inhibits the demand of enterprises
in recent years, as enterprises pay more attention to scientific and technological innovation, they are committed to building intelligent factories and deepening the field of robots, trying to start with intelligent manufacturing and strive to be the leader of the industry
Midea Group has acquired Germany KUKA group, one of the world's four largest robot companies, to realize production automation in general industrial fields and aim at the future home robot market. It is reported that Midea has invested 1billion yuan in the field of intelligent manufacturing, and the number of robots has reached 562, saving 22000 labor
on the one hand, machines save labor. On the other hand, areas lacking labor can also use "machines" to achieve efficient production and operation
Dongguan, Guangdong, which has geographical advantages, has also done its best. The first private "unmanned factory" has been put into construction in Dongguan, marking a new stage of the local "machine replacement" strategy. Dongguan Songshanhu Changying Precision Technology Co., Ltd., which built the factory, is a high-tech enterprise that produces and sells a series of connectors, shields, ultra precision hardware terminals and molds
Ren Xiangsheng, executive deputy general manager of the company, introduced that in the past, the product processing of manually operated CNC machine tools was often prone to safety problems, product quality, and our plastic matrix was renewable, and the stability of biopolymers was relatively poor
with the rapid development of science and technology, machines are gradually helping people "save labor". Due to many personal subjective factors, manual production has no advantage in realizing product standardization, and it is no longer the "first choice" of enterprises. According to Ren Xiangsheng, the company has made up its mind to establish an intelligent unmanned factory, replace manual labor with hardware manipulators, and then establish a highly intelligent software control system for network remote control. "These will greatly improve the work efficiency and product quality of the factory." Ren Xiangsheng said
"with the increasingly serious labor shortage in some areas, the demand for robots will gradually increase, which will also force robot research and technology to achieve more breakthroughs and more localization." Li Yuewei, marketing director of Shenzhen zhongweixing Technology Co., Ltd., believes that
"with the gradual advancement of machine replacement, China's robot industry will develop rapidly, and the era of Intelligent Manufacturing in China is coming." Hu Wen, chief financial officer of Liqun Automation Technology Co., Ltd., believes that
Dr. huangyanghua, assistant researcher of the Industrial Development Research Office of the Institute of industrial economics, Chinese Academy of Social Sciences, believes that with the promotion and implementation of the "machine replacement" strategy, China's robot market will rapidly develop to the trillion order of magnitude, and the "bigger cake" will stimulate more market players to enter this industry