In 2019, It Was Hard For The Industry To Work Hard, And The Chemical Fiber Giant Had Lost The Money.

Every year before the holidays, in the manufacturing base of the Yangtze River Delta and the Pearl River Delta, enterprises will experience a wave of seasonal labor shortage due to workers coming home early for the new year, choosing to return to their jobs or job hopping.

Compared with previous years, what new changes have taken place in the labor shortage before the end of this year?

The reporter conducted an investigation.

At a textile and garment processing plant in Shaoxing, Zhejiang, the person in charge told reporters that the order had been placed in May, and that it was coming to the Spring Festival.

But in the next workshop, reporters found that only machines did not have workers.

Zhejiang Shaoxing a garment processing factory director Zhu Li: Recently, employees can not recruit, now the 500 machines have stopped.

Wages for employees are also around 5000 yuan -8000 yuan.

Because machines can't get jobs, machines can only "sleep".

It should have been a busy workshop, but it could only turn into a dusty warehouse.

Zhu Li, director of a garment processing factory in Shaoxing, Zhejiang: it's a bit urgent. It's a pity that it has changed to warehouse, and the equipment is idle.

Workers are hard to recruit, especially younger ones.

In the Pearl River Delta, some manufacturing enterprises can only take up their vacation after two years.

Shenzhen the Great Wall development Polytron Technologies Inc trainer Zhang Kesong: there are two trainers, one year after leave, a year ago.

Lack of people can also ensure production through wheel breaks.

What makes the company headache is that many workers will not come back after the Spring Festival.

Cao Shiliang, director of Human Resources Department of the the Great Wall development in Shenzhen, Cao Shiliang: back to the new year, the workers who can come back are about 80%.

In order to retain workers, many enterprises can only rely on improving the treatment of workers.

Fan Boyuan, chairman of Zhejiang smart home Co., Ltd.: every year before the Spring Festival, all the employees get good buses to send them back. After the end of the year, they go to their employees' home to pick them up. Their monthly salary is 6000 yuan -7000 yuan.

Fan Boyuan told reporters that in the past five years, the cost of garment processing materials has increased by about 10%, but the increase in labor costs has reached 35%.

Fan Boyuan began to expand the scale of intelligent manufacturing, hoping to solve the problem of worker shortage through industrial upgrading and enhance the profits of enterprises.

It is more difficult to employ skilled workers.

The employment problem is a commonplace topic in textile market in recent years, and it is also a key problem that has to be solved directly.

In 2019, the employment problem of textile enterprises will become the primary issue of the industry.

1, the relocation of water production capacity, many workers return tide.

Over the past two years, the environmental protection of looms has been improved, and a large number of water jet looms have been shut down in Jiangsu and Zhejiang provinces, and some water spraying enterprises have been put into operation in Northern Jiangsu, Anhui, Hubei and Henan.

Nowadays, the pfer of water production capacity has begun to take effect. Some enterprises in the central and western regions have developed rapidly, providing many jobs for local employment personnel. These people do not need to go to other provinces and cities remotely, and they are employed nearby in their hometown. Wages will not be much lower, consumption level is low, accommodation and home expenses will be reduced, and parents and children can also be taken into account.

In addition, the relocation of Jiangsu and Zhejiang water enterprises has also taken part of skilled workers to some extent.

A weaving company in Anhui set up factories in Anhui as early as 2011, and the person in charge told the author that at that time, almost no one was engaged in the weaving industry at that time when they went to Anhui to run factories. The workers in their factories were taken from the local area, and the bags were eaten and wrapped.

In recent years, under the backdrop of environmental protection in the water spraying industry, a large number of enterprises have moved out and workers have returned. In 2019, weaving enterprises were increasingly nervous.

2, workers return home early, resumed work late, making the employment problem before and after the Spring Festival is more prominent.

"Today's workers are not the same as they were 10 years ago.

"The previous workers were most concerned about their wages when they were looking for jobs," said the head of a coating factory.

Nowadays, when workers are looking for a job, the first thing they ask is whether there is any time for rest.

The concept of workers has changed, so there are more and more factories that have been on holiday during the past two years, and the Spring Festival holidays in factories are getting longer and longer.

In the past, factories would return to work in order to get a good start.

But now workers resume work time is getting late, factory normal start time is also postponed, now the eighth day is the time for workers to report, normal production is generally to about fifteen of the first month.

Labor shortage, for many textile owners, 19 years after the Spring Festival employment or will be a big problem.

3, layoffs or machine substitutions?

A difficult choice in textile industry

According to experts, in the future, if workers pay more than ten thousand yuan, it is possible to recruit workers to ensure the normal operation of manpower.

In the future, such a high labor cost, on the one hand, the entire chain of our textile industry will change, raw materials will rise, management costs will increase, and circulation costs will increase. Finally, all these enterprises will pay the bill, and some enterprises will also be burdened with redundancy.

And our products also need to re examine their pricing.

With the rising labor costs in China and the close employment wage in Europe, the advantage of "demographic dividend" before domestic textile enterprises has gradually decreased, and the advantage of textile enterprises has been greatly weakened.

According to reports, the International Textile Manufacturers Association (ITMF) data show that between 2008 and 2016, the yarn labor cost gap between Italy and China decreased by 30%, from 0.82 US dollars to kilograms to 0.57 US dollars / kg.

With the increase of labor costs, the number of home textile enterprises has begun to gradually reduce the number of employees. On the other hand, in the face of rising labor costs in the textile industry, young people are reluctant to engage in the plight of the textile industry. What can textile and chemical fiber enterprises do in the future to alleviate this situation?

Where is the way out?

In recent years, textile and chemical fiber enterprises have long been aware of this problem. In this respect, they are spared no expense. Rong Sheng, Sheng Hong, Hengli, Tong Kun and other chemical fiber giants are spending money on importing the most advanced equipment in the world.

1, layout intelligent production line

Under the changing environment of textile industry, labor costs are getting higher and higher. Textile enterprises have been pforming, or building factories in areas where labor costs are low, or reducing the number of employees, replacing them with machines.

And strengthening the development of textile digitalization and intelligent equipment, promoting the construction of intelligent workshop (production line), cultivating and developing mass customization, promoting the innovation of manufacturing mode and business mode, and forming a new driving force of textile economic development have become one of the important goals of textile industry reform.

Take Hengli as an example, the company is one of the earliest enterprises to explore intelligent manufacturing. The group plans to gradually pform the development mode of enterprises from "demographic dividend" to "technology dividend" through "machine replacement", "automatic replacement of machinery", "complete sets of replacement machines", "intelligent data exchange", and so on, so as to ensure the sustainable development of enterprises.

At present, the work of artificial silk pancake in the filament production workshop of the Jiangsu Heng Ke New Material Co., Ltd. has been handed over to the robot.

More than a dozen robots wielded "arms" in 24 hours to row rows of silk cakes rapidly and swiftly.

Employees only need to face the screen in front of the machine, check the information, status and quality of each cake.

Its relevant person in charge said that the automatic packaging line introduced by the group in recent years has increased at least 60% of the work efficiency.

In addition, from 2013, Hengli Group started the pformation of intelligent factory.

In the past 4 years, most of the robots in the workshop have been redeveloped.

An intelligent automatic packaging robot can top several workers.

In recent years, Sheng Hong Group has taken the initiative to adapt to the development trend of big data, cloud computing and artificial intelligence, and actively implemented the "Internet +" in manufacturing, creating automation, intelligence and intelligent chemical plants to promote the innovation and development of enterprises.

It is understood that the wholly-owned subsidiary of Sheng Hong group, which is a wholly owned subsidiary of the Hong Kong Group, has achieved full automation in the spinning workshop and the bomb packing workshop. It has realized the automatic packaging function of the silk car line, outgoing, storage, wrapping, opening, packing, labeling, sealing, packing and palletizing.

The technology of machine substitution and Internet of things enables Sheng Hong to save 15 million yuan a year. A production line can save 127 workers, reduce the employment rate by 34%, reduce the failure rate by 55.9%, increase personnel production by 29.8%, and increase production capacity by 33%.

To create an unmanned workshop and achieve intelligent production has become the highlight of Rongsheng group.

It is understood that Rong Sheng started Intelligent Building 5 years ago.

Its machine replacement equipment has been put into operation since 2011, and has been basically installed and put into operation.

After the equipment is put into use, the labor force can be reduced by about 40%, and the corresponding workshop can even achieve "no man's management". According to the current salary level, the labour cost can be saved by about 20 million yuan per year.

In addition, "machine substitution" avoids the damage caused by manual handling and operation, and greatly improves the quality of products.

2, opening up the Southeast Asian market.

In addition to intelligent development, in order to save labor costs, most textile enterprises also choose to build factories in the western regions of China or in Southeast Asia.

According to the annual report of Lutai A2016, Lutai Vietnam's first stage dyed fabric project has been put into operation smoothly, and the finishing production line and Luan ready to wear shirt production line are being constructed in an orderly way.

However, after more and more textile enterprises enter Southeast Asia to build factories, wages in these areas have also risen.

According to media reports, in recent years, Southeast Asian countries such as Vietnam and Indonesia have raised their minimum salaries annually, and 2017 is no exception.

Among them, the minimum monthly salary of workers in some parts of Vietnam in 2017 has increased from 3 million 500 thousand Vietnamese shield in 2016 to 3 million 750 thousand Vietnamese shield, or about 165 US dollars, or 7.14%.

According to insiders, even if Southeast Asian countries raise salaries, they still have a big gap compared with the wage level in China.

3, pformation of the Internet of things factory

Turn on the mobile phone APP to see the energy consumption of the entire production process, without changing the host equipment, as long as the introduction of an Internet system, the overall production efficiency can be increased by 10%.

For a weaving enterprise, the pformation of the Internet of things has realized the cloud management and control of some production processes and the optimization of energy saving in the production process. The intelligent factors drive the factory to be more flexible, intensive and efficient.

The construction of the Internet of things in factories is known as the advanced form of "machine substitution". It is also an important means of "two integration" of industrialization and informatization. Now it has been accepted by more manufacturing enterprises from the original "unfamiliar vocabulary", and has become an effective way for enterprises to seek attrition, improve quality and increase efficiency.

The integration of the Internet of things and artificial intelligence of Hengyi high and new materials has given birth to the prototype of the smart factory.

In AI, the intelligent external inspection system of the enterprise realizes the judgement of intelligent product grades and avoids the mixture of different grades of products.

The detection rate of appearance defects is over 99.9%, which ensures the quality and quantity of products.

In the construction of the Internet of things, this year, with the help of the deep integration of the upper management system (ERP) and the underlying control system (DCS), the product quality traceability management system with single spindle data as the core is implemented, and the integration of production data and management data is realized.

Machine substitution is the foundation for building the Internet of things and the industrial Internet. It is also an essential step in the construction process of intelligent factories.

Hengyi hi tech material workshop D originally needed 36 workers, and only 9 employees were required after using the automatic packaging line. At the same time, the packaging efficiency increased by 20%.

Overall, with the weakening of China's labor cost advantage and the continuous improvement of product quality, the above several directions from chemical fiber to the entire textile industry is also an inevitable trend.

At the same time, Chinese workers will also change their positioning and skills as the market changes.

But any change will be painful. How to deal with the pain and minimize it is the key to the successful completion of the revolution.