Production Capacity, Labor Costs Are Better Than The Domestic Average Level! Lanxi Textile Industry Takes The Lead In "Intelligent Express"

In the workshop of Wanzhou holding group, the processes are orderly, and an AVG forklift works freely in the workshop. Only one person is left to record the packing workshop, which originally required 15 people. The whole packing process is automatically completed by the machine.

"Textile is a very traditional industry. When we started the intelligent manufacturing transformation, we always thought that the harvest was not big, but after the transformation, it was really different from before." Zhejiang Wanzhou Holding Group Co., Ltd. party secretary, executive vice president Xu Jianzhong said.

In recent years, Lanxi adheres to the strategy of "strengthening industry and revitalizing the city", focusing on the digital transformation of the cotton textile industry, vigorously explores the path of traditional industrial transformation, and promotes the industrial economy to improve quality, efficiency and stability. After more than two years of hard work, we have found a "4 + X" intelligent manufacturing way suitable for large-scale promotion in small and medium-sized enterprises.

Finding the way

Digital reform in textile industry

The textile industry is the pillar industry of Lanxi. Since the establishment of Lanxi cotton textile factory with state-owned investment in the 1960s, Lanxi textile industry started and gradually became the pillar industry. The output of white cloth and denim ranked first in China. The city has more than 500 private textile enterprises, but the overall scale of enterprises is small, all of them are small and medium-sized enterprises. Affected by multiple factors such as external market environment and factor cost rise, the profit margin of Lanxi textile industry once shrank and the extension of industrial chain was hindered.

In recent years, Lanxi municipal Party committee, government and enterprises have begun to seek the way to break through. In 2017, Lanxi textile industry was listed in the first batch of provincial pilot projects for upgrading traditional manufacturing industry in Zhejiang Province; In 2018, Zhejiang intelligent manufacturing expert committee selected the intelligent manufacturing expert guidance group of textile printing and dyeing industry to settle in Lanxi; In 2019, Lanxi Municipal Committee decided to "create a textile industry intelligent manufacturing demonstration city" to explore the digital transformation experience of small and medium-sized enterprises; In 2021, the digitalization of Lanxi textile industry has been incorporated into the overall deployment of the state and provincial Party committee and the key implementation plan of Lanxi City. The city's focus on digital economic development will be more clear and energetic.

explore

Traditional industry digitization has formed "Lanxi experience"

In the face of various difficulties faced by the digital reform, Lanxi has made clear the work path of "trying to form a batch and bringing up a piece". Nine pilot enterprises were identified in the first batch, and then promoted to 30 enterprises, forming an overall linkage force of "government + experts + enterprises".

In July 2019, Lanxi sounded the "charge" for the establishment of intelligent manufacturing demonstration city in the textile field, organized and held a mobilization meeting of 1000 people, formulated and issued the decision on creating an intelligent manufacturing demonstration city in the textile industry and the implementation plan for Lanxi City to create an intelligent manufacturing demonstration city in the textile industry. It is clear that Lanxi will pass through about three years, Establish the textile industry intelligent manufacturing demonstration city. By the end of 2021, Lanxi will achieve an industrial output value of over 35 billion yuan, with an average annual growth of more than 15%; The local contribution and profit margin of the industry have doubled; There are more than 16 enterprises in the national top 100 cotton textile industry.

Symposium on Intelligent Manufacturing of Lanxi textile industry

In the process of establishment, Lanxi gave special fund subsidies to pilot enterprises according to 50% of the investment in software, hardware and cloud, with a maximum subsidy of 5 million yuan, and innovated the financing mode of intelligent manufacturing to provide more "financial water" for textile enterprises. At the same time, in order to solve the enterprise's problems, Lanxi invited the expert group of the provincial intelligent manufacturing expert committee to settle in. According to the actual situation of the pilot enterprises, Lanxi provided complete diagnosis and transformation scheme, technical consultation, intelligent manufacturing scheme review, and regularly carried out training and on-site teaching to guide the owners to change their thinking from equipment competition to data application and data communication.

In terms of breaking the wait-and-see mentality of enterprises, Lanxi has held more than 20 symposiums, training and on-site meetings to promote the concept of intelligent manufacturing and boost the confidence of enterprises in transformation and upgrading. Nowadays, a number of old textile enterprises, such as Jinsuo printing and dyeing, Xinlan textile, Qijin textile, Weichen textile and Xinhai textile, have set off an upsurge of digital transformation under the guidance of experts. Batch after batch of intelligent production lines, intelligent workshops and intelligent projects have been launched.

results

"Tailor made" promotes intelligent manufacturing to achieve great results

In the quality inspection workshop of Zhejiang Qijin Textile Co., Ltd., located in Lanxi Economic Development Zone, Chen Wei, an expert assigned to Lanxi by the provincial intelligent manufacturing expert committee, is installing the grey fabric quality analysis module on the grey cloth coiler“ In the future, the machine will automatically record the defect points on the grey cloth, and there will be no need to manually count them one by one. " Chen Wei.

As one of the traditional textile enterprises, Qijin textile has speeded up the development of "fashion textile" in recent years, but it has also encountered problems such as labor difficulties and rising factor costs. On the same day, after the quality analysis module was installed, Chen Wei also established Qijin textile production data monitoring system according to the needs of enterprises. With this system, the operation status of each equipment in weaving workshop is clear at a glance“ Next, we will further optimize Qijin textile intelligent manufacturing cloud platform. " Chen Wei said.

After in-depth enterprise research, the expert group of provincial intelligent manufacturing expert committee has customized the "4 + X" intelligent transformation mode for the majority of small and medium-sized enterprises. It is understood that "4" is the content of general intelligent reform, that is, to get through the basic data between production equipment (including facilities, instruments, etc.), solve the problem of "deaf, dumb and blind" and eliminate the information island; Through the application data of the whole process of production and operation, realize the interconnection and interoperability between production equipment and software, ERP and MES, and lay the foundation for enterprise digital manufacturing; Through the real-time, visual and paperless operation data, install Kanban (intelligent terminal) system from decision-making level, management level to operation level, and import enterprises into digital management; Through the collaborative data between employees and machines, materials, processes, etc., training on the knowledge and skills of intelligent manufacturing is carried out for all employees, so as to realize human-computer cooperation and ensure the effectiveness of intelligent manufacturing. In strict accordance with the standard system construction, the expert group also matches the personalized x application, namely: stereoscopic warehouse or virtual warehouse management.

Many measures have been taken at the same time to achieve remarkable results. In 2020, the city's total industrial output value above Designated Size will reach 66.4 billion yuan, including 21.7 billion yuan of textile output value, accounting for 33%. In addition, there are more than 160 textile enterprises, and Lanxi textile industry has more than 30000 looms, which can produce 2.2 meters of white cloth per kilowatt hour, which is far higher than the average level of 0.7 meters in the same industry in China; Less than 30 people are employed per 10000 spindles, which is far lower than the average level of 80 employees in the same industry in China.

(source: Lanxi News)