How To Move The Robot In The Textile Industry?

Robots replace workers

On the agenda, can robots replace workers to win?

Textile industry is a labor-intensive industry. With the gradual disappearance of demographic dividend in China, pformation and upgrading is imperative.

Mechanization, automation and intellectualization have become an effective way to pform traditional industries, promote industrial pformation and upgrading, reduce staff and increase efficiency and ease recruitment difficulties.

The plan is effective and the industry responds positively.

Zhejiang province is the first province to implement the "machine substitution" plan. In early 2013, the government of Zhejiang launched the "four exchange" project that fully implemented the "cage changing birds, machine replacement, space exchange, and electricity supplier changing the city", which opened up a new pattern of economic development.

According to the Zhejiang Provincial Commission of information, the project has achieved great results over the past year.

First of all, the cost of employment and production and operation is reduced.

According to the survey, 61.5% of enterprises have reduced the number of front-line employees by more than 10% after the replacement of machines, and 68.9% of the enterprises have reduced production costs by more than 5%. When other conditions remain unchanged, the reduction of enterprise cost by one percentage point implies an increase of 1 percentage points in corporate profits.

Secondly, it improves the efficiency of labor production.

After 27.3% of the enterprises surveyed, the labor productivity increased by more than 30% after the "machine substitution"; 16.6% of the enterprises' labor productivity increased by 20% to 30%; and 29% of the enterprises' labor productivity increased by 10%~20%.

Third, improve the quality of products.

Because machine operation has the inaccuracy and accuracy of manual operation, the role of machine substitution in improving the quality and quality of enterprise products is also very obvious.

The survey showed that nearly 98.3% of the enterprises changed their products, and the quality of products improved to varying degrees.

Fourth, reduce energy consumption.

In the survey enterprises, up to 86.3% of enterprises said that after the "machine substitution", the energy consumption decreased.

The textile industry has played an important role in the machine change.

According to the Keqiao Economic Information Bureau, 661 technical renovation projects completed in the 1~9 months of this year have invested 24 billion 63 million yuan.

Among them, the investment in textile projects was 15 billion 342 million yuan, accounting for 63%.

Lanxi is a gathering area for weaving characteristic industries.

The production is the first in the country. In the light of the present situation of the production of dyed fabric, the machine replacement in textile industry is launched in a timely manner. The main content is to introduce automation equipment such as wear, reed, knot and so on, instead of manual labor, to encourage enterprises to purchase automatic equipment for enterprises listed as "machine substitutions". The government gives certain subsidies, mainly through policy guidance, and encourages enterprises to replace manual labor with highly automated equipment, so as to achieve the purpose of "machine substitution".

There are hundreds of weaving enterprises in Lanxi, where more than 70 enterprises have been selected (including 10 demonstration enterprises and 60 promotion enterprises). First, the implementation of "machine substitution" project has been started. These projects require all of the projects to start in the year, and the commissioning rate will be 85%, and more than 90% of the investment plan will be completed.

From the perspective of the pformation of printing and dyeing industry, Shaoxing started the project of "machine substitution". They carried out automatic information pformation and "machine substitution" for the weak links of printing and dyeing industry informatization and energy management, and achieved fairly good results.

Great room for implementation and resistance

The spinning process is complex and changeable. Only from cotton to yarn, it has to go through many processes such as cleaning, combing, blending, coarse and fine.

Continuous and intelligent become the continuous demand for the development of enterprises. At present, although some achievements have been made, textile enterprises, as traditional industries, still have much room for improvement in intellectualization.

Taking the automatic doffer as an example, the relevant data indicate that the enterprises that still use the artificial doffing method at present still account for more than 97% of the total textile enterprises in the country, while the enterprises using hand push (or electric) oblique pulling doffer are less than 1% of the national total, basically belonging to the edge of being eliminated.

In Europe and the developed countries, the number of automatic doffing instead of artificial doffing can reach more than 85%. According to this trend, the demand for automatic doffer is expected to be "blowout" in the coming years.

Machine substitution has an unparalleled advantage in replacing manual productivity improvement, but there are still many difficulties for textile enterprises, especially small and medium-sized enterprises.

High cost,

Difficulties become the biggest stumbling block for changing machines.

According to a survey conducted by the Zhejiang Economic Commission, about 71.1% of enterprises believe that the primary problem facing the current "machine change" is the high cost.

According to a survey of enterprises that have completed the "machine substitutions", more than half of the enterprises have invested more than 10 million yuan.

This is not a small sum, and in recent years, the rising cost of enterprise financing and the difficulty of financing make the enterprises prohibit the substitution of machines.

Secondly, maintenance investment is also a big problem.

Remove routine equipment maintenance costs, as well as maintenance personnel input.

The general culture and technology level of textile enterprises is relatively low, and technical personnel are seriously lacking.

With the introduction of automation equipment, the demand for all kinds of skilled personnel will increase dramatically. Textile enterprises need to train or introduce high-level technicians, which is no doubt a big burden.

Moreover, the capital recovery cycle is longer.

According to the survey, the proportion of enterprises that have completed the "machine replacement" pformation business over 4 years is 36.8%.

In view of this, Hu Xudong, President of the school of mechanical engineering of Zhejiang Sci-Tech University, believes that textile enterprises must adjust to local conditions and do not have to go one step at the same time.

"Machine substitutions" can be very small. Generally speaking, the whole production line pformation is relatively large and suitable for large enterprises to implement. However, small businesses can also achieve the purpose of machine substitution by means of automatic pformation of one unit of equipment.

Weaker enterprises can pay close attention to some auxiliary work, such as knitting sewing, spinning and weaving plant's upper and lower cylinder, weighing, packing, pfer and other processes. Although these processes are not key jobs, they still use a large number of workers, and the process is relatively simple and easier to succeed. Secondly, some single spindle pmission equipment such as twisting, winding, and pouring cylinders, etc., use automation technology to design some self stopping devices. When broken ends or other faults, the single spindle can be automatically stopped, without affecting the whole machine production, which has little effect on productivity, so that the production of unmanned workshops can be realized, or only regular inspections and labor saving can be achieved.

Challenges and opportunities, and equal emphasis on technology and services.

Textile machinery enterprises are facing the challenge of machine switching.

Hu Xudong said, at present, the textile machinery is in a relatively low state. Machine replacement may be an opportunity for some enterprises. By upgrading the level of automation and intellectualization of the equipment, it can solve the plight of recruitment difficulties in the textile industry, and it can go out in the current downturn.

However, the upgrading of equipment digitalization and intellectualization is more difficult. It can not be completed by imitation or commissioning, unlike the past technological pformation. It needs more cooperation from universities and automation equipment research institutes to integrate the process from the process to the whole production process, so it is more challenging.

In the face of such a situation, what preparations should be made for spinning machinery enterprises?

First, continuous innovation and implementation of differentiation strategy.

Technological innovation is the core competitiveness of an enterprise, and constantly improving the differentiation of its products through technological innovation is the urgent need for the pformation and upgrading in depth.

For example, recently, the robot suture system launched by Cixing has a very large working procedure for sweater industry, and it has a higher demand for workers' age, vision and physical strength.

Cixing company first selected in this process to break through, can greatly reduce the number of workers, the application prospect is broad.

Second, enhance service awareness.

The manufacturing industry is gradually developing in the direction of private customization. Even in the same industry, the situation of enterprises is different and needs are different.

In this process, the textile machinery enterprises not only need to supply equipment, but also provide updated service mode, or borrow the accumulated experience in the past to become the best consultant for textile enterprises.

For example, Jingwei shares promotes the nanny service mode instead of the maintenance worker by the manufacturer's professional personnel in the launching of complete sets of equipment, and is gradually recognized by customers.

Or, the new requirements for front-line workers after the implementation of "machine substitution" for enterprises, help textile enterprises to train a number of operators and equipment maintenance personnel who are proficient in new technologies, new processes and new equipment.

At the same time, we should constantly improve the comprehensive quality of after-sales service personnel.

The comprehensive quality of employees reflects the culture of an enterprise and represents the image of an enterprise.

Therefore, we should constantly train and assess the professional knowledge, standard operation and communication ability of the after-sale service personnel.

Third, strengthen the technology alliance.

Technology alliance is usually an important way for many manufacturing powers in the world to form and maintain competitiveness.

Because of the shortage of funds and scientific research ability, a single enterprise can not form effective breakthroughs in technology, but technology alliance has greatly increased this possibility.

In 2011, a number of China's steel wire ring technology innovation alliances formed by several domestic steel wire ring production enterprises were co developed with the State Key Laboratory of tribology, Tsinghua University, so that the technical content and performance of products were greatly improved, and the product prices were also improved.

It can be seen that forming alliances between universities, universities and research institutes or enterprises is an effective way to improve technological level.

Fourth, enhance the awareness of intellectual property protection.

Judging from the current situation of the industry, the protection of intellectual property rights has not yet been formed.

This creates conditions for speculators and those who do nothing, so the differentiated product form can not be differentiated, and will soon be duplicated.

Therefore, enterprises must strengthen the protection of intellectual property rights such as patents and know-how.

Changing robots is not the only way to make a road.