Analysis Of Four Reasons Why Small And Medium Enterprises In Spinning And Clothing Making Are Not "Machine Changing"

When we enter the color TV production workshop of TCL multimedia manufacturing center, it is not a crowded scene, but a busy scene on the automatic production line.

Automatic guided pport vehicle, automatic lock screw machine, automatic module turnover machine, automatic packaging machine.

All kinds of machines on the assembly line take turns, and a TV set automatically completes assembly, testing, packaging, and quick passing.

If a worker wants to do good, he must first use his tools.

Nowadays, more and more large and medium-sized manufacturing enterprises in Huizhou adopt fully automated production lines, replacing manual labor with automatic machine equipment at different stations, thus increasing production efficiency.

Behind this is a new round of technological pformation in Huizhou in recent years.

In the first half of this year, the city completed the investment of 18 billion 190 million yuan for industrial technological reform, up 147.5%, and ranked the top of the whole province.

However, unlike the electronic information and auto parts enterprises that have made automatic and intelligent pformation, Huizhou's traditional manufacturing industries, such as shoemaking,

Clothing and other industries, especially small and medium-sized enterprises, are short of funds.

The higher threshold factors, and lack of local example demonstration and promotion, are not enthusiastic about "machine substitutions".

Compared with the surrounding cities, the enthusiasm of Huizhou enterprises to carry out technological pformation is also low.

In the face of the new situation of innovation driven development, enterprises will not advance and retreat, and market competition will usher in a new round of "shuffle".

How to solve the existing problems through technological pformation and innovation research and development, and how to solve the existing problems, so that many enterprises, especially small and medium-sized enterprises, "machine substitutions" action to speed up, and thus enhance their innovative strength, is a difficult problem to be solved in Huizhou's industrial pformation and development for a period of time.

Highlights: many large enterprises spend hundreds of millions of yuan to promote technological pformation.

As one of the pillar industries in Huizhou, the electronic information industry is a major area of technological pformation.

In fact, in recent years, with the consumer electronics products on the production technology and quality technology to put forward higher standards, coupled with rising labor costs and "labor shortage", in the past, relying on the "human sea tactics" low-end processing mode is no longer the scenery, Huizhou's electronic information enterprises are also promoting the "machine replacement".

It is found that leading enterprises such as TCL group, DESAY group, Huayang Group, overseas Chinese group and so on have made great efforts in technological pformation in recent years, and invested tens of millions of yuan or even more than 100 million yuan. The main purpose is to build automation and information integration intelligent chemical plant by taking full automation production line as a breakthrough point.

Lu Bin, director of the manufacturing center of the overseas Chinese group's mobile phone production company, overseas Chinese Electronics Group, introduces that since the second half of 2013, the company has invested hundreds of millions of yuan in the R & D and promotion of the automatic production line, whether in the production process of high-speed patch, chip encapsulation, self sealing glue and other links, or optical inspection, testing, assembly and other links, all introduced some standards for automatic upgrading.

Lu Bin said that the company has 8 advanced SMT (surface mount technology) high speed production lines, all of which are used.

SIEMENS's production equipment.

Through these measures, we can recruit nearly 1000 workers, and the quality of products has also been greatly improved.

Wang Bingchun, deputy chief financial officer of overseas Chinese group, revealed that the group plans to invest 300 million to 500 million yuan in the past two or three years, and has completed the pace of automatic updating of its subsidiaries.

The trend is developing towards the goal of "smart factory".

Also in mobile phone manufacturing, TCL communication has been put into automation equipment in large scale in recent years.

In the past, a 30 person mobile phone assembly line had 10 people to conduct product quality testing. But when TCL communications invested more than ten million yuan in automatic MMI (human-machine interaction) test equipment last year, each line only needs 4 people.

The TCL multimedia manufacturing center has invested nearly 40 million yuan in promoting color TV production automation projects around the establishment of intelligent factories. The application of automation equipment has greatly saved manpower costs, and it is estimated that the annual cost savings will be nearly 30 million yuan.

Huayang Group is also pushing forward "machine substitution" in LED, automotive electronics manufacturing and so on.

In August 2014, Huayang photoelectricity officially put into use the fully automated production line, from automatic parts feeding, automatic thread cutting, automatic installation of lamp holder, automatic turning, automatic tin soldering, automatic test and so on.

"By replacing robots with robots, the production efficiency of only one LED ball production line can be increased by about 600%, and the number of direct workers is reduced by 75%."

Deng Huiqing, assistant general manager of Huayang Photoelectric Technology Co., Ltd.

Huayang Universal Electronics Inc is modeled on the German industrial 4 and the American smart factory. In December last year, it planned to invest 100 million yuan to build Huayang smart factory project, which will create the world's first-class production base for vehicle electronic products.

Technological pformation has brought benefits to enterprises.

Through semi automation and automation pformation, Huayang Group can reduce manpower by 1000 to 1500 per year.

According to the plan, the group will increase investment in technological pformation this year, continue to introduce robots, promote integration of information technology and intelligent production, and create "intelligent factory".

Automation upgrading is only one aspect of strengthening technological innovation and development. Now many large enterprises in Huizhou are increasingly willing to spend money on R & D.

Taking TCL group as an example, the total R & D investment in the first half of 2015 is expected to reach 1 billion 620 million yuan, an increase of 22.1% over the same period last year.

Secret worry: this year, only 10% more companies are interested in technical pformation.

In recent years, Huizhou's technological pformation investment has been increasing.

From 2011 to 2013, investment in industrial technology pformation in Huizhou increased by 61.5%, 48.1% and 44.4% respectively.

In 2014, Huizhou's investment in industrial technology pformation completed 16 billion 80 million yuan, the total Pearl River Delta third place, the province's fourth place, an increase of 54.5%, an increase of fifth of the Pearl River Delta, and eleventh of the province.

Despite the high growth in investment in industrial upgrading, the situation in Huizhou is not particularly prominent from the whole province.

Compared with the high enthusiasm of the "big rich handsome" large enterprises, the small and medium sized enterprises with "bad money" appeared relatively calm or even cold in the face of the industrial 4 and the "machine substitution" craze.

The lack of enthusiasm for technological pformation is a hidden trouble faced by Huizhou's industrial technology pformation.

Official data at the end of last year showed that only 236 of the surveyed enterprises in Huizhou had more than 50 million yuan in the main business, and only 236 of them had the intention of technological pformation.

According to the recent data from the Ministry of information, there are 249 enterprises in the 1801 Industrial Enterprises above Designated Size in 2015 who intend to carry out technological pformation. Although the planned investment is relatively large, it is about 18 billion yuan, but the proportion of enterprises is only 13.8%.

The proportion of small and medium-sized enterprises with the intention of technological pformation is lower. The atmosphere of "technological pformation, technological pformation, technological pformation and technological pformation" has not yet formed.

In contrast, many cities in the Pearl River Delta have more enthusiasm for technological pformation.

Take "world factory" Dongguan as an example, data from 441 enterprises surveyed by Dongguan bureau last year showed that 66% of Dongguan enterprises began to implement "machine substitution" in nearly 5 years, and 92% of enterprises indicated that they would continue to increase investment or prepare for related work in the next two years.

At present, Dongguan is implementing 505 projects of "machine substitution", and the first "unmanned factory" has been built.

Actually,

Foshan and other Pearl River Delta cities released a strategic plan for machine replacement last year. Under the encouragement of a series of policy support and higher special fund subsidies, the manufacturing enterprises in these cities have a strong atmosphere for technological pformation, competing for the introduction of intelligent equipment such as industrial robots, and pforming into intelligent production.

In Zhongshan, the intention of technological pformation is higher.

According to the previous data of the city's Information Bureau, Zhongshan's main business revenue exceeds 50 million yuan, and the rate of technical pformation feedback is 96.5%, and the investment intention rate of technical pformation is 68.2%.

It is worth noting that the role of Huizhou's technological pformation investment in enterprises needs to be improved.

Although the contribution rate of automation technology is increasing for large and medium-sized enterprises at present, taking TCL communication as an example, the contribution rate of automation has increased from 2% in 2012 to 10% in 2014, but the main application is dispersed single machine intelligent equipment. There is still a gap between the leading enterprises in other cities of the Pearl River Delta and the intelligent factory integrating a fully automated equipment into a large production system.

For large and medium-sized enterprises in Huizhou, the next goal of technological pformation is to integrate single machine intelligent equipment into interconnection, integration and big data management, and realize integrated manufacturing system from intelligent parts, intelligent equipment, intelligent production line to intelligent workshop, intelligent factory and intelligent industrial chain.

Cold: footwear industry clothing industry "substitution" power shortage

It is reported that Huizhou small and medium-sized enterprises in the traditional manufacturing industries such as shoemaking, textile and clothing, building materials and furniture are not willing to make technological pformation.

Compared with the similar industries in neighboring cities, the "machine replacement" of the hot industry and the world, automation and intellectualization equipment has not been widely applied in the footwear industry and clothing industry of Huizhou, and is generally "cold".

A number of shoemaking and garment factory owners said that although they also hoped to introduce advanced technology, SMEs had limited funds and "machine replacement" power. The actual demand and enthusiasm for intelligent equipment were also lower than those of the "big tall" industry such as local electronic information, and the application of automatic production equipment was slow.

Huidong footwear industry is a microcosm.

"A hammer, a pair of scissors, a bucket of glue" family workshop production has been a portrayal of Huidong shoe factory, although in recent years by promoting standardization and mechanization, with automatic molding shoe production line of 350 (set), but small workshop situation is still more common.

By the end of 2014, there were 6380 shoe industry units in Huidong, 5515 of which were self-employed, while 85% of the employees were below 20 employees.

Faced with weak external demand, declining orders and increased production costs, local shoe companies and self-employed businesses have been hit.

According to the data provided by Huidong county government, last year, half of the shoe factories in Huidong were closed down to 372 enterprises (households), and 211 were closed down.

When a group of shoe makers shut down their own businesses, some shoe companies are developing together through technological pformation, brand alliances and innovative marketing channels, and their product processes and quality have been greatly improved.

Wang Jianxin, deputy director of the China Leather Association and executive director of Guangdong Leather Association, said that the footwear industry in Huidong, like Guangdong and even the whole country, is facing pformation and upgrading.

Some local shoe factory owners also admitted that they had considered technological pformation and introduced more automated production equipment. However, due to the small scale of single household production and the shortage of funds, it was difficult to achieve.

Not only the shoe industry, but also the textile and garment industry in Huizhou is facing similar predicament.

It is found that most garment enterprises are small in scale and low in brand awareness, and the popularity of advanced assembly lines is not high.

Take the Yuanzhou town of Boluo County as an example, the garment enterprises are everywhere. The town has more than 1000 garment production and supporting enterprises, employing about 60 thousand people, and producing 100 million kinds of casual wear annually.

Although some clothing enterprises have adopted automatic hanging system, some advanced printing equipment has been imported from abroad.

But overall, automation equipment is not yet popular.

In contrast, traditional industries such as textiles, clothing, shoes and hats and furniture in Dongguan have been blowing up a "machine changing" whirlwind in recent years, benefiting from the better equipment manufacturing industry's supporting base, and now the application of machine automation has become a climate.

For example, Dongguan Dalang Town, known for its woolen weaving industry, has basically completed the first round of "machine substitution" since its use of CNC looms was less than 600 units in 2005 to about 50 thousand units today.

Hundreds of domestic and foreign CNC loom brand enterprises set up sales organizations in Dalang, forming a "1.3 km" professional weaving street of CNC looms, making Dalang the largest distributing center of CNC looms nationwide and the most centralized area of CNC looms in the world.

Not only a few loom enterprises in Dalang have launched leasing business, but also through leasing equipment to promote the technological pformation of small wool weaving mills with insufficient funds.

And shoe industry big town Dongguan Houjie's shoe enterprises are also larger scale "machine replacement", the shoe machine factory in the town also develops rapidly, shoe machine sales volume ranks the forefront of the province, shoe automation equipment to accelerate the promotion.

Yang Xia, Secretary General of Guangdong Footwear Manufacturers Association, believes that the footwear industry in Huidong should actively introduce foreign advanced technology and pform it from quantity to quality, technology and innovation.

Some experts pointed out that if Huizhou's traditional industries such as shoemaking, textile and clothing are not developing rapidly as soon as possible, but still remain on the "artificial sea tactics", it will be very difficult to compete in the competition.

Reasons: Many SMEs can not afford to use advanced technology.

The survey found that in recent years, enterprises with large scale enterprises accounted for most of the "machine substitution" enterprises in Huizhou in recent years.

The greater the strength of large enterprises, the more obvious the trend of technological pformation. On the contrary, the less financial SMEs are, the less motivated and motivated the technological pformation will be.

"Lack of money" is a "stumbling block" faced by many small and medium-sized enterprises in the process of technological pformation.

Large enterprises can invest heavily in technological pformation and R & D, such as TCL group investing billions of dollars a year for R & D, which is far from common business.

Small and medium-sized enterprises usually lack liquidity, and loans are not easy. In the face of high investment, "machine replacement" tends to be more than enough.

"The main reason is that the equipment is too expensive."

Peng Donglin, deputy general manager of Huidong Xiang Xiang shoe industry Limited by Share Ltd, said that the shoe industry abroad can be fully automated, because its output is high, and the labor cost is relatively high, and the cost of machinery is relatively lower. However, it is not very realistic for Huidong shoe industry to popularize automated production in large areas in large areas.

Data show that the current sophisticated industrial robot equipment still needs to be imported by foreign countries. The single machine operator is around 200 thousand yuan. If the whole supporting equipment is imported, a group will spend 450 thousand yuan.

Chen Yusheng, director of Huizhou Jilong osley shoe factory, said that the introduction of fully automated equipment to large-scale production is more cost-effective.

In addition, the smart equipment manufacturing industry in Huizhou has a relatively thin foundation, less autonomous production automation and intelligent equipment, small and medium-sized shoe manufacturers and textile and garment factories can not choose to purchase advanced and suitable equipment nearby, and cross regional purchase will increase costs.

Through the "machine substitution" can reduce labor costs, but the industry believes that the upgrading period of modern equipment is generally 2 to 3 years, and the cost recovery of enterprises in a relatively short period of time, the high cost of equipment acquisition is more difficult for SMEs to undertake.

"It is not that we do not want to use advanced technology, but we can not afford it.

"Machine substitutions" often cost millions of dollars to tens of millions of dollars, and the cost of recovery may be waiting for several years.

Someone in charge of the business said frankly.

"Machine substitution" may also lead to problems such as insufficient order, idle production capacity, and inadequate R & D capability.

A business owner said, "machine replacement" is a good thing, but the cost of robot is very high, after buying, the order is not enough, the business day is sad.

In addition to hardware input, the whole process of technological pformation of enterprises is not simply to buy several machines to update production lines, but also to require technicians to carry out routine operations and regular maintenance.

It is learnt that at present, SMEs generally lack such skilled personnel, which has put a greater test on their application R & D support and technical personnel training.

To be equipped with technical talents, there should be a lot of expenses for follow-up. Some small and medium-sized enterprises can only be deterrent to "machine substitution".

The chairman of a Polytron Technologies Inc in Huicheng suggested that compared with the surrounding cities, Huizhou's preferential policies for landing the machine were not enough, especially the lack of supporting implementation details.

The government should provide more special funds to support enterprises in technological pformation. At the same time, we should build a multi party joint guarantee and financing platform to open up a green channel for the financing of technological pformation of enterprises.