In the impression of most people, spinning industry is a traditional labor-intensive industry. In the era of intelligent industry, intelligent machines are replacing workers, and textile workers will also enter the position of competing for work opportunities with intelligent machines.
The latest results of Cees survey conducted by Wuhan University Institute of quality development strategy, Chinese Academy of Social Sciences, Stanford University and emerging market Institute of Hong Kong University of science and technology show that, in view of the fact that the actual salary has more than doubled in the past 10 years, manufacturers are adopting automation technology, investment research and development, and new products with higher added value.
Recently, the reporter in Suzhou Zhenlun Cotton Textile Co., Ltd. biomass recycled fiber material intelligent production workshop also happened to see that the spacious and tidy workshop, maintain a constant temperature and humidity working environment, a high-speed operation of automation machine instead of the original row of textile women workers back and forth busy scene, some just a few workers in the inspection and simple operation, All of these have subverted the impression of the traditional textile industry.
According to Wu Jiankun, vice general manager of the company, benefited from the investment of intelligent equipment and process transformation, the original work of more than 100 people now only needs 20 people, not only the production efficiency is greatly improved, but the stability of product quality is also higher.
"If a worker wants to do good, he must first use his tools." The enterprise must develop continuously, and it can not be separated from the products of "intelligent tools". The biomass fiber workshop introduces a large number of intelligent equipment with online monitoring functions, such as Germany carding and drawing machine, fine winding type Qingze spinning machine, Japan fine winding automatic winding machine, etc., which realizes automatic control of parallel feeding, rotating speed, spinning speed, viscosity, self winding cylinder joint and transportation. Intelligent workshop is integrated with digital information technology, and management systems such as MES and ERP can realize the perfect integration of intelligent workshop information and ERP data.
In the intelligent workshop, "automatic production process", "intelligent control system" and "online monitoring information", Wu Jiankun introduces that every spindle will be connected with sensors. The system can monitor the situation of each spindle in the production line in real time, greatly saving manpower and improving efficiency. The whole process keeps high continuity, reduces the chance of manual contact with yarn, and the yarn quality is further stabilized and improved, which greatly improves the production efficiency and labor productivity.
Shenpeirong, chairman of the company, admitted that the labor price is rising and the market competition is becoming increasingly fierce. If we still do it according to the old methods, it will inevitably lose the market competitiveness and even be eliminated from the market. Such a situation makes the high-level of Zhenlun cotton textile realize that intelligent manufacturing is the breakthrough of the development of traditional industries, automation, intelligence and information technology are the only way for the development of enterprises“ It's not that you want to do it or not, but the market and the environment force you to do it. Reducing costs and finding a way out for intelligent manufacturing can double the production efficiency. It is hoped that intelligent hedging of high labor costs will be made, and "less people use and more money" will become an unavoidable reality in the textile industry. In the future, there will be fewer professional workers in the textile industry, and there is no way out to reduce the employment and improve the production efficiency. This is the foundation of transformation and upgrading, There is no other way. "
The benefits of this game are all-round. "In 2005, the company employed 130 people for 10000 ingots, 35 for biomass, and 15 for eddy current spinning," Shen said. The actual labor cost per 10000 ingots is about 3.5 million yuan per year. Before, the process of drawing the gauze pipe needs manual operation. Now, every machine is equipped with a manipulator, which can pull all 1200 spindles of yarn pipe down at one time, and plug all empty tubes in one time by the manipulator. "
"The equipment update also drives the progress of the process. Before, our products are mainly ring spinning. Now, we are following the development trend of spinning technology and adopting Siro compact spinning technology. The same viscose yarn, compared with the yarn of ordinary ring spindle, the yarn of Siro compact spinning can sell more than 3000 pieces per ton. The products are exported to the high-end textile market around the world. Many domestic and foreign first-line brands are long-term customers of Zhenlun. " Said Wu Jiankun.
Since 2008, Zhenlun cotton textile has put more than 100 million yuan into production equipment transformation every year for several years. It has introduced advanced spinning equipment from Germany, Japan, Switzerland and other countries, and built a smart workshop for Zhenlun biomass.
After several years of deep cultivation, Zhenlun cotton spinning has basically realized the workshop automation, intelligence and information. At present, Zhenlun is building a sample factory for digital and automatic intelligent production of the whole process of domestic chemical fiber industry. The company's spider web system monitoring software will be put into use. This system is like spider web, which connects all machines and platforms. The production process can be fully online inspected and tested, and a visual intelligent master control system is established to realize data exchange and integrated management between machines. The company aims to build an intelligent spinning factory with the interconnection of production equipment, real-time scheduling of production process, automatic material transmission, traceability of product information, intelligent monitoring of workshop environment, intelligent monitoring of resource consumption, design and development and production linkage.
Shen said that the textile industry has entered a new historical period. The company takes intelligent manufacturing and green development as the important grasp, accelerates the cultivation of new kinetic energy and core competitiveness, and walks out a path of transformation and upgrading supported by intelligent technology and equipment.