Dongguan Garment Industry Change Concept Automation Becomes Bright Spot

"Even the assembly line of garment factories can achieve computerized management. I think there is no real traditional industry, only the traditional management concept."

At present, in Dongguan's furniture industry, textile industry and garment industry, automation has become a scenic line in Dongguan's industrial upgrading chain, and at the same time, it has also brought about a change of concept.

New management of traditional factories

300 people do 600 lives.

Tai Fu is a clothing manufacturer.

A Jiao is the production line female worker of this enterprise.

However, unlike the traditional clothing sewing workshop in Dongguan, A Jiao has a special type of work: feeding.

At 3 p.m., on the assembly line of the workshop, A Jiao was doing his homework easily -- the fast running smart suspension system and the cut jeans cloth.

The long metal tracks hang on the workers' heads on the assembly line, a bit like the curtains of the home curtains, and the equipment keeps running.

A group of more than 30 workers, each of whom is the same female worker, has a very coherent understanding of their suspending systems. For example, A Hua, a woman worker, is responsible for sewing jeans trouser legs. She only needs to operate sewing machines, the first sewing process is finished, the hand is loose, the suspension system takes the trousers away, and then second pairs of jeans semi-finished products are delivered to the machine automatically.

In less than a few minutes, A Jiao completed the feeding action.

At this time, the computer console at the end of the production line immediately showed: A Jiao, adding one hundred sets, no scrap!

Just as A Jiao fed, more than 30 lathe workers on the production line kept working on the locomotive sewing pants for a moment.

The sewing workers here can not move from beginning to end. Whether they are sewing trouser legs or sewing bags, they should focus on one point only when they are equipped with intelligent equipment.

And all kinds of stripes, after each link of these more than 30 women workers, turned into a complete finished jeans.

"Before I manage this group, I need to go round and round without stopping, and when workers encounter technical problems, they will stop working and ask for help, especially if the workers are running out of materials, they need to carry them to their seats, pack, untie, distribute, and do a bunch of chores."

Xiao Deng said that the realization of automation completely eliminated these problems, and the workers spent 100% of their time on sewing process.

The leader of the whole production line is the group leader. This young man who runs more than 30 turkeys is named Deng Chunhong, who has worked in Tai Fu for 8 years.

As a garment worker with ten years of service, A Jiao said that this is a completely different way of production.

For example, before a worker could only complete one thousand processes, after putting into operation, we could finish two thousand, that is to say, now three hundred workers in our workshop can do six hundred workers' work.

"All links can be solved here, digital management."

Xiao Deng said.

On his desk, more than 30 workers' names, process names, distribution of raw materials, the number of qualified products currently completed, and the number of defective products.

The number bar behind the worker's name continues to change as workers continue to work.

In fact, Xiao Deng's group is only one of the more than 20 production lines of the factory, and there are more than 20 production lines on both sides of the group.

This is the first step for Tai Fu garment factory to turn to intelligent and digitalized pformation from a familiar traditional garment factory.

Tai Fu's automation Road

Difficult to recruit workers, determined to invest 3 million yuan to update equipment.

"Everything starts with the difficulty of recruiting workers. If we go out of this step, we will make good arrangements later."

Mr. Zou, senior manager of Tai Fu garment company, admitted in an interview with our reporter that it is difficult for outsiders to feel the difficulty of this pformation, because it seems to be just an introduction of automation equipment, but for a small garment manufacturer, millions of dollars in investment means that nearly a year's profits have fallen into the invisible future.

Mr. Zou is an old employee in the garment industry, and also an elder statesman of Tai Fu company.

From the 80s of last century, it began to join the garment industry. Over the past 20 years, the wages of garment factory workers have risen from tens of dollars and hundreds of yuan to more than two thousand yuan nowadays.

On the other hand, the number of workers is decreasing year after year.

"It is the year before the start of considering the investment to purchase automated equipment, that is, when recruitment difficulties begin to show prominently."

Zou Xiansheng said that from the beginning of the discussion to the real purchase and use, as a small business, management at that time was under great pressure and he had been involved in this process.

"If we can not find workers, enterprises can not develop and even move to the outside world, but wages are rising all the way. Where can we move to the end?"

Workers are becoming more and more difficult to find, and the turnover rate of workers who are hard to find is also high.

Tai Fu management finally decided to upgrade the equipment.

At that time, the equipment dealer assured that the efficiency could be doubled.

We figured out the cost, especially the pressure on the completion of the order, and thought it would be good if we raised 50%. Let's think about it. Our factory's more than 400 people will increase the efficiency of 50%, which means an increase of more than 200 workers.

However, the purchase of equipment was not smooth, and the price of automated equipment, which was first made in Germany, was too high.

"Later, it was finally reported that the same performance automation equipment was available in the country, and the price was only 1/3 of German equipment."

Finally, the management decided to invest about 3000000 yuan at a time and bought a whole set of equipment experiments.

"For a small enterprise, the investment of about 3000000 yuan is not a small sum. The profit of a small enterprise has not been counted for a year."

Zou said that now he wants to come, actually it reflects the concept of the boss of the enterprise, and whether he has the courage to take a crucial step at the critical moment.

"Very good, the effect is much better than we imagined. It never occurred to me that this labor-intensive industry could even have a computer controlled rhythm mode."

Tai Fu management revealed that after the purchase of such equipment, the efficiency of the factory has nearly doubled.

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Workers: not only saving effort but also thinking.

Ah Xiu is an ordinary employee of Tai Fu who has worked for three years in the workshop.

She told reporters that she did not want to work too long in the factory, ready to see the world and go back to Jiangxi to marry and have children.

"The boss bought automated production equipment and solved many odd jobs for the workers.

Now, what we need to do is concentrate on the operation of the machine, what materials we need, sign up for numbers, count the pieces, turn around, pack and unpack all kinds of chores, except for going to the bathroom, our job is to operate machines exclusively.

In fact, in Tai Fu, intelligent equipment has only replaced some workers in the production workshop.

Reporters saw that the same production workshop, only half of the workers are in the original mode of operation.

Management said that according to the current strength, we can not fully realize intelligent management.

In comparison, ah Xiu revealed that the workers who worked in the intelligent workshop were 20% lower than the traditional workshops, but the total monthly salary was 10% more than that of the other.

This shows that the clothing workers enjoy the benefits of intelligent management.

"Now it seems that two years will be enough to recoup the cost of purchasing equipment, and the workers will have more profits, so that every aspect will be beneficial."

Company management Zou Xiansheng said.

Reporters learned that the use of Tai Fu is not the most advanced equipment, according to Chen Yaohua, President of the clothing association revealed that the market has a machine instead of more than 20 workers working highly intelligent equipment.

Industry insiders: psychological fear of cost investment is far beyond practical difficulties.

Chen Yaohua, President of Dongguan textile and garment industry association, said in an interview with reporters that at present, Dongguan's clothing and textile industry may be one of the most difficult industries to recruit workers. Although export and domestic sales are very good this year, it is precisely because of limited production capacity, especially for workers, that many orders among enterprises are not readily available.

Under such circumstances, enhancing management efficiency and upgrading industrial equipment will attract everyone's attention.

Chen Yaohua said that in Dongguan, the intelligent and automation of clothing industry instead of traditional manual operation has only recently begun to appear. This shows that the concept of modern enterprise management is also forced by the situation.

In the past, bosses hired a factory and hired a group of workers to make money by hand, which led them to never dare to buy expensive equipment at a high price.

In view of this, the management of Tai Fu thinks that industrial upgrading is also based on the actual situation.

For example, in the early 90s of last century, the wages of workers were only a few hundred yuan, and a set of equipment would cost millions of dollars. The cost of purchasing equipment would be enough to cover the wages of a factory worker for several years. When workers were good at recruiting, enterprises would naturally not have to do so.

Li Ke, general manager of Dongguan Fuyun Furniture Co., Ltd. believes that whoever uses high-tech to replace workers first will stay ahead of the competition.

In fortune motor furniture company, the reporter saw the largest and the most intelligent production equipment and management concept in Dongguan: a set of furniture spray equipment made in Germany, which can replace the traditional mode of operation of the 120 workers.

"The problem is not just to save manpower. Manual operation of such a scale requires a lot of venues, because workers have to spread out on different occasions to make enough space to run.

And this equipment is a link chain, spray painting, drying a few minutes can complete. "

Li Ke said that in addition to saving labor, only 90% of the land area can be saved. Of course, there is still a quick time, because artificial spraying takes time to dry naturally, and intellectualization takes only a few minutes to dry.

"Although the equipment needs about 8 million yuan, it is very cost-effective to calculate it synthetically."

Li Ke said that for managers, cost investment, psychological fear is far greater than the actual difficulties, because in Dongguan, there are very few entrepreneurs with the concept of modernization.