How Can Cotton Enterprises Absorb And Assimilate The Essence Of Foreign Advanced Technology?

The development of cotton textile enterprises is facing a severe test this year. However, the equipment purchased by many enterprises with huge sums of money is difficult to really play a role, even under increasing cost pressure. Advanced equipment does not make first-class products, resulting in a great waste of resources.

As an experienced textile expert, Miu Dingshu, chief engineer of Xuchang Yufeng Textile Co., Ltd. has written out in recent years in the production line, and has problems in cotton spinning equipment itself, problems in marketing and the use of cotton spinning enterprises.

At present, the decision-makers of textile enterprises think the most, the most realistic is how to further reduce costs, optimize the internal resources of enterprises, and become strong and solid enterprises.

Many entrepreneurs say with emotion: they can no longer spin low-grade products, otherwise they will only have to look for death.

So, is it possible to spin high quality products with advanced equipment? The general phenomenon that I understand is that China's "95" development plan has spent hundreds of billions of years on the introduction of a large number of complete sets of cotton spinning equipment and components, such as blowing carding, automatic winding, combing machines, etc. so far, why only a few high quality and high quality products have been produced in China so far. The reason is that besides the business decision, market and management reasons, individuals feel that this idea has penetrated into the minds of quite a few decision-makers in the minds of quick success and instant benefit, and there has been no great effort and effort to implement how to digest and absorb the essence of foreign equipment and equipment, resulting in waste of resources and increased cost.

The present situation and existing problems of the imported and imported equipment in the textile machinery factory

Running in period usually refers to failure rate, reliability and quality stability.

There are several reasons why the running in period of domestic equipment is higher than that of imported machine.

The first is the key parts.

For example, although the domestic carding machine also adopts the suspended cover conveyor belt, but the key parts tooth profile is not wearable, and the tooth shape has the impact of the intolerance of the studs. (the design of the rig breaking device on the cover plate pmission system abroad) as long as the cover plate is not brushing or accumulating, it will cause the cover plate to arch and break the convex nail, and this convex pin is difficult to repair after breaking, causing the production stop and the cost of material to increase.

Two, it is mechanically copying components from foreign equipment and failing to really understand them.

The three is the unstable performance of the equipment.

For example, a domestic high-yield carding machine is more sensitive to temperature and humidity. The speed of the machine can be 160~170m/min (quantified 5 grams / M) in the spring and autumn season, but in the summer and winter season, it is high temperature, high humidity or low temperature and low humidity (especially in the middle of the night). The doffer speed is generally 150m/min, and the side door of doffer must be opened to make up the wind, otherwise it will increase the breakage.

The reason may be related to the lack of accuracy due to the lack of accuracy of the steel cover plate due to the accuracy of the doffer leakage.

The four is that the relevant technology is not in place with the matching process, so that the technology can not really get on the bus for a long time.

The most typical is the carding machine parts processing accuracy and installation accuracy can not reach the international standard of similar products, resulting in the use of units can not guarantee the accuracy and stability of the process.

There are abnormal phenomena in textile machinery market.

1, spare parts and equipment are shoddy.

Although significant progress has been made in the digestion and absorption and innovation of imported equipment, the rapid development of domestic textile machinery has also appeared to compete with each other.

For some high-end equipment and equipment, to ensure the performance and requirements of the equipment, it is necessary to purchase accessories, equipment and electronic components according to the international purchasing standard.

But what I see is that some textile machinery factories in order to cater for the textile factory's pursuit of the so-called "cheap and fine quality", regardless of the strict standard of high-end equipment, some defective spare parts and equipment are disposed.

I saw with my own eyes that the cots and aprons equipped with long spinning spindles (with automatic doffing) could not be used in only 4 months.

In the previous two years, a factory's high quality carding machine was still equipped with ordinary curved rail material.

The gap of tin Lin cover can not be guaranteed, while the track produced by the same product, TL tschille, is adjusted according to the FEM analysis method, and the 6 point gap is adjusted by using the gradual change of the track inclination.

Therefore, we hope that the machinery factory and the cotton mill should further coordinate and communicate with each other and avoid the unreasonable practices of the low-grade components or equipment in the high-end equipment configuration. Cotton mills should not take the goods at least three or cheaper ways in price, thus affecting the overall performance and the best effect.

2, suspected of exaggerating the function of equipment.

Some spinning mills use factories to pursue high production and high speed equipment.

3, new products to the market is not standardized.

It is understood that the new equipment of the European international textile machinery exhibition will be put on the market after testing at least 2 years or so in the experimental factory and the factory it works with. For example, compact spinning frame has only been mature in the European market for many years before reaching the Chinese market.

Some textile machinery factories in Wuxi also carry out similar scale and simulated cotton spinning and weaving factories in the Ma Shan Textile Machinery experimental factory, so that customers can be assured of new products and equipment.

At present, many cotton mills reflect the fact that there are still many textile mills that directly or indirectly regard the cotton mills as an experimental factory. There is no cooperation agreement between the production equipment and the equipment. The spinning machine factory often sells the newly designed equipment that has not been tested practically below the market price as a bait. At last, it can only consume a lot of manpower and material resources, and the quality is not guaranteed, so that the risk can be pferred to the factory.

It shows that there is no good market environment and notarial institution for protecting the interests of cotton spinning enterprises in China.

Problems existing in cotton mills in the digestion of imported equipment or equipment

1, advanced equipment but no action.

After entering the WTO, the market competition has forced the powerful enterprises to invest heavily in technological pformation. These factories already have the most advanced equipment in the world or the best equipment in the country and the world's most famous equipment, such as the Swiss Graff needle clothing, and also want to sell the yarn well, but most factories still do the products of big road products.

Many factories can do well in small samples, and batch production is not too bad. Customers often complain that the quality of yarn can not really pass through.

This involves a core problem, that is, all people hope that with the world's advanced equipment, they can produce high quality yarns of international standard. In fact, many factories use the internal indexes of the evenness tester to achieve the world average level of 5% above, but the price of ordinary yarns.

The reason is very simple: our starting point is to spend a lot of money on equipment, and spend little effort in digestion and absorption, or not enough in kungfu, so that the most effective and basic work is neglected. In addition, we find that a lot of factory technicians are losing a lot of technology and still remain in the thinking of the middle and low equipment in the past. When the new equipment has been used for one or two years, when the best parts are replaced, it is possible to replace the so-called cheap parts made in China, so that the imported equipment and equipment will be tossed about.

2, the introduction of equipment is only to increase production.

I remember a few years ago, a factory in Zhejiang spent hundreds of millions of yuan to buy dozens of units. At that time, it could produce more than 30 spun spinning equipment under high production conditions (rotating speed 150 thousand revolutions / points), and the result was that the factory used to produce low-grade 8 British yarn.

The function of the original spinning high grade high count yarn is wasted.

This represents a considerable part of the decision-making and business model of private bosses, that is, short-term behavior, to get profits as quickly as possible, not to maximize profits, nor to consider long-term development planning and participation in international competition.

3, buying equipment is only cheap.

Compared with the chairman of state-owned enterprises, the boss of private enterprises is a good bargain hunter and even a foreigner. This is not a bad thing in itself. The problem is a price, and you have to consider whether the goods are up to international standards, and you must also consider the price performance ratio.

Even if the importer gradually finds out the doorway of Chinese business, after three goods, we can see that a large number of non original parts and equipment have been mixed into the imported equipment. The practice test is not the best. Some of them even counterfeit some brand products, such as counterfeit ECC card, Graff card clothing, fake SKF bearing, and so on. It is not that selling expensive does not have such problems, but there is indeed a phenomenon of no cheating and no business.

Similarly, the acquisition of domestic imitation.

4. The overall technology and management level restrict the development of high-end products.

After the "11th Five-Year plan" of cotton mills in China, most enterprises have been upgraded in quality and should be efficient, low consumption, high quality and high yield.

In fact, in recent years, China has gone through the process of enterprise pformation and reform, and the process of modernization has just begun. The management system is not perfect, all kinds of brain drain, labor shortage and cost increase restrict the maximization of resources and market interests.

Speaking of high production carding machine, cotton spinning enterprises have been basically popularized in China, but because of the overall technical level and management level of cotton spinning enterprises in China, although several years have been integrated, thousands of ingots and tens of thousands of spindles are still small. Even if they buy advanced equipment, they will be able to use cannon as gun.

From the current situation, the use of high-yield carding machine has the following phenomena: first, the high production of carding machine can reduce the cost, reduce the cost, and reduce the number of personnel, plus the excessive publicity of manufacturers, which can generally reach 70kg/h on the carding machine of the rotor spinning process. However, a certain number of high production carding machines in the early stage are unstable in performance, and the quality is not stable enough, and the quality fluctuates greatly. Two, the domestic high-yield carding machine manufactures to enhance the quality, most of the clothing manufacturers of international famous manufacturers, such as Graff card clothing, and the production plants are not able to keep up with the ancillary equipment and equipment, for example, they are still arguing about whether the imported needle clothing should be grinded, and how to use the auxiliary equipment and methods when grinding.

If the above problems are not solved, it will be difficult to guarantee the technology.

The quality of clothing often goes up and down in the shelf life, not to mention that it is considered blindly that the imported card clothing can work beyond the time limit without any needle clothing maintenance.

Three, many factories are short of the least testing instruments to control the long-term stability of quality.

Four, in order to ensure stable quality, some factories still use high-yield carding machines to maintain light weight and slow speed, and the output is maintained at around 35kg/h. This is undoubtedly a waste of high-quality equipment resources.

Suggestions on digestion and absorption of advanced technology

As soon as China becomes a textile power, China should focus on long-term development goals. Strategically speaking, it can neither rely on imported equipment nor keep China's textile machinery and equipment at all times maintaining a high quality and low price, but the technological level is only the established impression of the world second class level. It is necessary to have confidence to strive for the next five year plan as soon as possible and strive to achieve the world-class level of key components and parts of the equipment.

The following are my immature views:

1, through the government and market integration of cotton textile equipment and talent resources, eliminate small and medium-sized factories with large energy consumption, poor management level and lack of skilled personnel, strictly control the repeated introduction of equipment, and if introduced, they must bear the risk of repayment on schedule.

The next five year plan calls for the introduction of advanced equipment and the introduction of corresponding software.

It is emphasized that the introduction of core technology can play 42 roles.

If necessary, strengthen technical cooperation with foreign countries in key equipment and components.

We will absorb and assimilate foreign advanced technology, from imitation to self design, until innovation, and develop new generation of mechanical and electrical integration and high degree of automation with low energy consumption, high yield per unit, reliable performance and high quality.

It is hoped that the China Textile Federation will consider the production and manufacturing standards of textile machinery industry in the new situation, consider the internationalization of textile machinery as soon as possible, standardize the entry threshold of enterprises according to different product grades, optimize the existing resources of domestic spinning machines, and protect the rights and interests of cotton textile enterprises.

There should be policy restrictions for manufacturers that do not have the production of high-end equipment, and their qualifications should be banned if they do not have production conditions.

Standard setting should emphasize from raw material procurement, equipment selection and cooperation units, equipment product design, manufacture, assembly, commissioning, and the experimental cycle before the product is listed, including the overall technical evaluation of the experimental equipment, the quality level of the production products and so on.

End the good and bad phenomena as soon as possible.

2, how to digest and absorb advanced equipment and technology, in addition to policy guidance and preferential funds, the China Textile Federation will formulate relevant laws and regulations with the relevant departments of the state to create an atmosphere for digestion and absorption of advanced technology.

A large number of imported equipment has been used for many years, and cotton mill's biggest voice is the price of imported imported parts.

For example, our company has a self levelling drawing machine output detection bell mouth, weighing less than 100 grams, the price is about 20 thousand yuan.

The most used solenoid valve, as long as a change of a seal ring, up to ten or twenty yuan, but no substitute, had to spend 1000 yuan to buy a solenoid valve.

Fewer encoders are thousands, thousands, and tens of thousands, and life expectancy is not so long.

Similarly, the spring and bearing seal traps equipped with the automatic winding adapter can only be used for 3 months or so, which is much lower than the quality of the foreign products for over a year, but the foreign price is at least 3 times.

The problem also lies in the domestic parts and components, equipment has a large number of fake and shoddy products, through abnormal channels to enter the manufacturer, bring unforeseen adverse consequences, resulting in waste of human, material and material.

People in the industry talk about it. The whole machine and prototype of the spinning machine factory can do well.

But a specific part of the machine is not willing to work hard. Even a key screw is not good enough to import.

Because I have been in the production line for a long time, it may not be pleasant to speak.

The biggest headache for the maintenance workers is that imported equipment will be replaced with domestic bearings.

Japan's digestion and absorption is worthy of our imitation. They use less than 20% of their capital to introduce hardware and equipment, but spend 80% of the money to really find out every detail and software function in the equipment, so that they can create new heights to reach the first-class level in Europe and the United States.

Therefore, the state should pay attention to the research and investment of basic components. Our core components are basically in the hands of others and the prices are controlled by others.

For example, industrial control computer, PCC (programmable computer), encoder, solenoid valve, frequency converter, electronic yarn clearer, AC servo motor, sensor and so on. Cotton spinning equipment such as blowing tools, sawtooth series, various kinds of Carding Clothing, used for drafting parts of cots, aprons, pneumatic cradles, winding part of rings, travellers and so on, need to work hard in stability, reliability, consistency and service life, so as to narrow the gap with similar products abroad, and improve product performance and market competitiveness.

3, digestion and absorption depend on talents.

It is not easy for textile machinery factories to produce similar equipment in such a short time, but the essence of real equipment is not overnight.

To play the role of industry, University and research, perhaps the market is not yet mature. How to connect the university with the market, and the results of research are turned into commodities.

Judging from the current use of imported equipment cotton mills, the overall performance, maintenance, operation and management of the system has not been systematically maximizing, and the technical strength is rather thin.

In order to make up for this defect, we hope that the machinery plant will organize technical personnel to conduct comprehensive and systematic training for the manufacturers of the equipment sold.

4. The renovation and replacement of the equipment of the textile plant should be done by the power.

Enterprises with economic strength can take a step forward, carry out large-scale pformation or integrate with the advanced international level in the introduction.

However, we should not neglect the problem of "man machine matching", that is, the relationship between staff quality, management level and the application of advanced equipment.

The high debt, big investment and market failure of the textile industry are often crushed by debt. Therefore, risk assessment and market prediction should be done as far as possible.

Enterprises with poor economic strength can choose the road of automation combined with domestic import and key parts import.

Although there is still a big gap between China's automation and industrial control technology in the manufacture of products, there is a growing maturity in the area of pformation and system integration, especially software design, which is more consistent with the reality of enterprises.

The cost of such pformation is only a fraction of the total imports, and the cost of accessories and maintenance is much lower.

In fact, many enterprises have already done so, but promotion is not enough.

Generally speaking, the textile industry takes the road of industrial automation, which is both urgent and gradual. At the same time, it must link up with the market demand and balance itself with its own strength.

Yufeng textile factory introduced the world's first class advanced equipment last year. All the equipment and product manuals have hundreds of pages, which are very comprehensive, detailed and standardized.

Each instruction manual emphasizes the importance of safety repeatedly, and that is, the instructions are more suitable for the fact that the operation skills of factory workers are falling down at the present stage. Each functional component and device on the aircraft are explained and decomposed in detail. Sometimes it seems too cumbersome, but its responsibility to users and meticulous attitude are admirable.

5, we hope that the textile machinery factory should establish close communication and interaction relationship with the plant. The new products and equipment sold to the users of the spinning machine factory should be pparent, explain the reason, win win cooperation and carry out three packages. The spinning machine factory should not exaggerate the performance of the equipment too much.

We expect the industry to have corresponding restrictions on such phenomena.

The factory is the experiencer who checks the reliable performance of new equipment. It can find the problem most. It is the source of improvement, digestion and absorption and innovative inspiration. The rise of the second generation of products in many textile factories is based on this.

China's equipment needs to solve the main gap between foreign countries and other countries in terms of stability, reliability and low failure rate. It is precisely the need to solve these minor problems in bilateral interaction and gradually enhance them.

The key is to see if you are sincere, put aside the shelf, pay attention to details, then one day your equipment will be impeccable, and will definitely enhance to the height of international brand.