Dongguan Footwear Industry Is Actively Seeking New Ways To Upgrade And Upgrade

< < p > near Japan Daily's "intelligent manufacturing" series reported that although unlike Shunde, Foshan, which was the only one of the Ministry of industry, "the two integration of equipment industry and Intelligent Manufacturing Pilot", Dongguan has now launched a new round of manufacturing revolution.

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< p > advanced technology such as industrial robot, information software system and Internet of things technology is bringing the "made in Dongguan" from the labor-intensive era to the era of "intelligent manufacturing".

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< p > < strong > robot "invasion" accelerated < /strong > < /p >.

< p > If 2008 and 2009 many enterprises are still waiting for the "labor shortage", in recent years, many enterprises have resolutely decided to adopt technological pformation and large-scale application of industrial robots.

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< p > recently, a survey conducted by the Dongguan Municipal Foreign Trade and Economic Cooperation Bureau on the top 500 enterprises of import and export showed that the cost of production increased by 14.1%.

Among them, the largest increase in labor costs is 9%.

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< p > in the face of soaring labor costs, Dongguan Xuji food company has finally made up its mind to introduce equipment to replace some of the workers on the production line of xufok ch.

At present, 17 of the 18 processes of the production line have been fully automated.

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< p > > "60% workers are in the final big package. We are debugging a set of equipment, replacing most of the people with real automation."

Xu Fu Ji Shakima workshop director Jia Bin said.

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< p > from the small machine replacement at the beginning of the factory in 2003, the average annual reduction in each process was three or four people by 2008. The production line increased from 1300 to 700 at the same time.

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"P" is a sharp contrast. Since 2006, the wages of front-line workers in Hsu Fu Chi have increased by about 15% per year, slightly higher than 1000 yuan wages (excluding provident fund and social security, bonus) to more than 2600 yuan.

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< p > not only expensive labor, but also difficult recruitment.

In Dongguan, furniture, painting, polishing, polishing and all kinds of moving and stacking work, dust, harmful gas, and high intensity labor are always affecting workers' health.

When young workers are demanding a more comfortable working environment, business owners often get tired of coping with huge hidden costs outside their payroll.

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< p > more and more entrepreneurs have changed the view that Dongguan's labor force is easy to get, and have begun to purchase large quantities of automation equipment. This is also confirmed in Dalang town of the world's wool weaving city.

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In 2005, when the "shortage of migrant workers" first appeared, Dalang town began to encourage wool weaving enterprises to introduce numerical control looms instead of traditional mechanical looms to reduce employment. P

At that time, the total number of CNC looms in Dalang town was less than 1000.

It increased to 4800 in 2008, and now Dalang CNC machine tool has surged to more than 40 thousand units.

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< p > it is estimated that a numerical control loom can replace 8 workers, and one worker can control 6-8 machines.

By this measure, nearly 300 thousand industrial workers were liberated in Dalang CNC loom.

"A sewing machine master's monthly salary of up to 3000-5000 yuan is still rising. After introducing the numerical control loom, only the weaving process saves 80% of the labor cost."

People with textile business say so.

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< p > in the eyes of Huang Junqin, general manager of Dongguan automation machinery leading enterprise, Alfa company, Dongguan has started the third round of robot boom in recent two years.

Among them, the first wave of machinery replaced the labor force in early twenty-first Century, and some labor-intensive enterprises began to increase equipment and reduce jobs. Then the second wave appeared after the financial crisis in 2008.

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< p > Huang Junqin believes that with the continuous progress of technology and the decline in the average price of robots at the rate of 4% per year, the role of industrial robots in replacing human beings in spraying, welding, palletizing and high risk working environments is becoming more and more apparent. Its characteristics of precise self-discipline, strong induction and recognition, high efficiency, long working hours and low cost operation have been increasingly welcomed by enterprises.

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< p > this also makes the business of AI FA and other equipment manufacturers prosperous.

At the beginning of the 2001 in Dongguan, the company had only more than 30 customers. By 2007, there were 1500, and now it has surged to more than 4000 customers, most of which have increased in the past three years.

In 2011, its sales revenue reached 217 million yuan, an increase of 47.81% over the same period last year.

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< p > "before, we focused on injection molding manipulator and peripheral automation equipment. Now there are more and more substitutions on each production line, so we have to change to popular applications, such as preparing advanced Japanese robots."

Huang Junqin said that in the past, only the demand for robots in the high-end electronics industry and automobile industry was relatively large. Now, the low priced hardware products also began to introduce industrial robots, which made them somewhat unprepared.

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< p > < strong > competition mode change < /strong > < /p >

< p > with the increasing demand for product quality consistency and standardization, and the uncertainty of the market, the introduction of industrial robots can seize the opportunity, reduce the cost and improve the quality ahead of schedule.

This has also led to changes in the competition pattern among enterprises.

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< p >! --EndFragment-- > whether to introduce robot production line is changing the competition pattern of production enterprises or even deciding whether to live or die.

In this regard, Yin Xiaolin, general manager of Dongguan Lin Da Da shoes industry, has a deep understanding.

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< p > in May this year, he bought more than 40 sewing machines, although the price of 12000 yuan was 6 times higher than that of ordinary sewing machines. Unexpectedly, the factory's monthly output increased from more than 50 thousand pairs to 90 thousand pairs, and monthly profits rose from about 200000 to about 400000, with constant manpower and constant cost.

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"P", which made him overjoyed.

As a boss of a small shoe factory, he used to think about how to keep his customers and how to dig other people's customers, but the technology, raw materials and labor cost were almost the same, and the stalemate was hard to break.

Because sewing robot products are very standardized, there are no wires. High quality and low price products have touched customers. They have robbed 30 thousand pairs of orders every month, and 500 thousand yuan has been recovered in 3 months.

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< p > "two enterprises also do" a href= "http://www.91se91.com/news/index_c.asp" > shoes < /a > enterprises. If one of them has changed the technology to reduce the price by 2 yuan, it can hold the source of tourists firmly in the hands, and there will be no market for the other. "

Yin Xiaolin explains so much about the competitive changes brought about by technology.

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< p >, in the field of refined manufacturing such as electronic products, the advantage of advanced equipment is more obvious.

Jiang Shiyuan is deputy general manager of Dongguan Shengsheng plastic electronics. One of his duties every day is to receive visitors.

Since the adoption of industrial robots in 2008, the precision of the moulds produced has been greatly improved. Many colleagues have come to ask for help in the process of machining, which accounts for 1/3 of the factory output.

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Less than P, the huge rise after the sweetness was 100 million yuan. The introduction of foreign equipment to develop an intelligent precision mold flexible manufacturing system for the most precise mold parts manufacturing.

Jiang Shiyuan said with pride, "machining accuracy can be accurate to 3 microns, and the error is much smaller than that of hair."

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< p > immediately, Kui Sheng received the order form of iPhone connector plug for the first time.

"Such small and high-density molds are usually made by foreign manufacturers and very few leading enterprises in China. This is the first time to choose Dongguan enterprises."

Jiang Shiyuan introduced that when the foreign manufacturers visited and inspecting, the robot production line could increase a very high impression.

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< p > the new production line has also enabled huge rise electronics to enter the field of medical devices, LED molds and other fields, and win the order of large domestic customers.

Jiang Shiyuan revealed that at present, the domestic orders for giant rise are only 30%~40%, which is expected to reach 60%~70% in three years.

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< p > at present, the giant electronics project promotes the intelligent precision mold flexible manufacturing system to more than 10 enterprises, with the value of 1 million yuan for each system, and its output value is more than 10 million yuan.

While selling products, giant rise has also become a technology exporter.

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< p > < strong > the whole process control is less than /strong > /p >

< p > in addition to the hardware substitution of machine replacement, information technology can also achieve the same effect, especially supporting the pformation of Dongguan enterprises from "global design, Dongguan manufacturing" to Dongguan design and global manufacturing.

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< p > Dongguan footwear giant Huajian group is a typical example.

According to Zhang Huarong, chairman of Huajian, the processing and production links of Dongguan footwear industry should be pferred to the mainland and even overseas, while orders, research and development, procurement and so on will remain in Dongguan.

At present, Huajian owns four major production bases of Dongguan Huabao, Dalong, Jiangxi Ganzhou and Ethiopia.

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Relying on a set of information management system, Huajian has realized remote collaborative design, manufacturing and enterprise management, which can be processed in the same way, and can be processed synchronously by P.

"It can be said that from the pre-sale customer consultation, product development, raw material purchase to final goods collection, headquarters management can control every batch of orders on the cell phone and iPad, and the late delivery has never appeared again."

Huajian Group subsidiary, Liu Shiyuan, chief executive of Huabao shoe industry informatization.

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< p > Hu Wei, general manager of Kingdee management software company of Dongguan, believes that most large and medium-sized enterprises in Dongguan have realized the information management represented by the financial management system in the 60s of last century, and are moving towards the ERP pformation in 90s of the last century.

(ERP is an enterprise resource management platform integrating basic data, human resources, hardware and software.

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< p > but it is regrettable to Hu Wei that most small and medium enterprises in Dongguan still suffer from insufficient information: lagging behind in production planning control, poor enterprise adaptability, inaccurate cost calculation and so on.

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< p > a Taiwanese businessman once complained to Hu Wei that every time a company was exhibiting at home and abroad, at least six financial personnel should be prepared to stand by at any time in the office.

When a customer asks for an order and talks with an intention, the six financial affairs will get a call from the front phone: they have to quickly figure out the number of quotations and whether the list can be picked up.

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< p > "when you are waiting for the phone, people will decide whether to pick up the bill by hand holding the terminal for minutes. If you are a customer, which one will you choose?" Hu Wei asked.

The change of "smart manufacturing" not only happens in the factory workshop, but also outside the workshop, with the help of information technology and Internet of things technology, intelligent manufacturing means is becoming a powerful support for the new mode of operation of enterprises.

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< p > < < a href= > http://www.91se91.com/news/index_c.asp > > garment industry > /a >, search brand, city beauty and other brands have attracted much attention due to their focus on the two sides of "smile curve".

Since 2012, when the clothing industry has been trapped in the stock market and the shops are closing in, the beauty of the city is expanding rapidly with the "Wan Dian plan".

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P, the vice president of city beauty and chief information officer Sha Sha, said that the phenomenon of high inventory shows that the decline of business mode based on channel is gradually fading. Under the guidance of this model, it is difficult for enterprises to achieve the planned production, but the planned production, but the products are only sold to the franchisees, and the enterprises are not sure whether the products have been sold to consumers.

If the product is not sold, it will become a channel inventory, and a vicious circle will follow. The next quarter will be blocked.

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"P > fashion brands respect time, parity, and fashion trends," Sha said. "The flat pattern of urban beauty has brought her advantages.

Every time, the urban beauty will put the new style into the market in small quantities, then monitor the market reaction, replenish the goods or adjust in time.

"City beauty does not have the concept of agent, and stores directly contact the company. What goods do they need to fill up?

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< p > for the urban beauty who owns more than 5000 stores, this seemingly trivial and huge project can be easily realized.

Because in 2010, urban beauty paid huge sums of money to build an information management system of "network patrol shop", so as to achieve real-time monitoring and feedback of all stores' operating data, weather conditions, display of goods and so on when the company turned on the computer.

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< p > "there is no fine plan and timely feedback and adjustment. Following the example of Zara and other fast fashion brands is not advisable, because from demand to supply is very fast, replenishment to stores does not exceed two weeks, which is very fast for the supply chain."

Sha Shuang said.

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For this reason, in May 2011, urban beauty spent tens of millions of dollars to introduce automatic sorting and WMS system for goods. The RFID RFID tags were used to realize the standardization, automation and information tracking of the commodity outgoing sorting process, reducing the rate of manual error and manpower cost at the same time, ensuring the smooth and efficient logistics flow.

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< p > Lin Lixia, Deputy Secretary General of the Dongguan Internet of things Industry Promotion Association, believes that through the application of the Internet of things to integrate the personnel, machines, equipment and infrastructure in the network, enterprises can manage production and operation in a more detailed and dynamic way, so that the market that can cope with changes in the wind and cloud can have more opportunities.

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< p > < strong > > the road of "Zhi" is /strong. < /p >

< p > Dongguan's enterprise information input accounts for only 0.3% of GDP, while Shenzhen's figure is 7%.

The first obstacle to this phenomenon is cost investment.

Enterprises that are walking on the road of "wisdom" have sprung up.

According to the Municipal Bureau of statistics, since 2009, 37 enterprises have been selected for the "two integration" 4 100 demonstration projects, accounting for about 1/10 of the province's demonstration projects.

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< p > but this is only a tip on the iceberg.

"There are a large number of foreign direct investment enterprises in Dongguan. They bring the most advanced concept of automation and information construction in the world. At the same time, there are still a large number of small and medium-sized enterprises in Dongguan, and some have not even really automated and information-based applications."

Liu Jiongxian, deputy director of the Municipal Bureau of information, said.

Hu Wei also said that Dongguan's enterprise informatization investment accounted for only 0.3% of GDP, while Shenzhen's figure was 7%.

The first obstacle to this phenomenon is cost investment.

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< p > < --EndFragment-- > a small electronic business owner in Dongguan complained that: "production is still more dependent on manual labor than on automation, but the cost is too high, automation devices are often hundreds of thousands, hundreds of thousands, and a workshop is matched by nearly 100 million enterprises.

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< p > "the acquisition cost of robots is only a part of it. Later programming, pformation, maintenance and so on also cost a lot. Some enterprises think that the cost of investment automation is not balanced with the labor cost saved."

Huang Junqin said.

Huang Junqin explained that the reason for the high price is largely due to the fact that some key core components still rely on imports. "At least half of the cost of raw materials for an injection molding manipulator should be contributed to Japan and other countries."

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< p > not only machines, but also tens of millions of millions of millions of millions of millions of people.

"Without billions of dollars in revenue, you don't want to play private cloud and other information, but small and medium enterprises can hire cheaper public cloud platforms and other information software and services."

Hu Wei said.

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< p > but the problem is much more than that.

For example, the large-scale production of machines is based on a large number of stable orders. In the past, if the enterprises had fewer orders, they could also give workers holiday or layoffs. How did you buy the machines? For example, the machine assembly line often has problems with one node, the whole system will be affected, the relevant technology is not up to standard, the maintenance personnel is short and fatal.

Huang Junqin said.

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< p > however, in Lin Lixia's view, the problem of entrepreneur's concept and talent reserve is even more worrying.

"Entrepreneurs should have a long-term layout. It is not the introduction of single robots or the development of a set of intelligent devices that are intelligent production. If the entire production process computer and production equipment are to effectively link up, we must have talents who are familiar with production equipment and computers, and the competition in the future is the most intense."

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< p > "the problem now is that talent is so scarce that a lot of enterprises are reflecting on us. Even if they want to start some projects, they can't understand and judge whether they are good or bad after receiving the tender."

Lin Lixia said.

These questions need not be too urgent.

The market will force them to go down. In the final analysis, it depends on whether the enterprise has courage, determination and long-term vision, Hu Wei said.

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< p > < strong > synergy synergy "drive tiger" < /strong > < /p >

< p > smart manufacturing needs to be based on key industries and professional towns.

Although enterprises are the main body, the application of new technologies needs the support from all sectors of society. How can we solve the problem of popularization and application at the end of application? < /p >

< p > Liu Jiongxian, deputy director of the Dongguan Municipal Bureau of classics, believes that the next step in promoting smart manufacturing needs to be based on key industries and professional towns.

Because at present, Dongguan is widely used in the electronics industry, mold manufacturing, wool weaving and other industries. The application of ERP system and automatic robot and numerical control machinery is relatively extensive. From the perspective of the region, the two characteristics of regional integration based on the characteristics of the town are also outstanding.

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< p > Lin Lixia also believes that there are a large number of small and medium-sized enterprises in Dongguan, such as "big town" and "Humen dress", which have the characteristics of "one town, one characteristic industry". Dongguan enterprises can formulate service contents according to the characteristics of each town street and the specific needs of enterprises, and promote the application of intelligent manufacturing technology through packaging and cooperation with professional towns.

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< p > "the Internet of things can carry out cross industry cross platform resource integration through the platform strength of different industries. Dongguan can make full use of the advantages of specialized towns and gradually develop the whole industrial chain."

Lin Lixia said that based on the two aspects of government driven and enterprise needs, IOT application can find fulcrum on the public technical service platform of specialized towns.

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< p > in addition, the government, research institutes and trade associations need to play their respective functions and cooperate with each other.

Liu Jiongxian told reporters that the letter Bureau will refer to the experience of Guang Shen and Shunde, and strive to support intelligent manufacturing from many angles, such as advanced manufacturing, technology innovation, and Internet of things applications.

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Thanks to the strong support of the government, < a href= "http://www.91se91.com/news/index_p.asp" > Dongguan < /a >, P has built a number of public innovation platforms, and has been in the forefront of the country in the field of intelligent manufacturing.

Among them, Huazhong CNC Dongguan Industrial Research Institute hatched out 7 science and technology enterprises including Dongguan Xun information technology, Dongguan think Valley digital technology, Dongguan easy walking robot and so on, achieving nearly 100 billion yuan in economic benefits.

But in Songshan Lake, there are 10 research institutes like the Dongguan Neutron Science Center and the Guangdong Electronics Industry Research Institute.

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< p > Huang Junqin thinks that it may take 100 systems integration enterprises to build a robot. After tackling key technologies, scientific research institutes can attract a large number of upstream and downstream related parts production, application software and other enterprises, and their enterprises are also looking forward to Dongguan's import substitution on key parts.

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