Investigation Report On Machine Substitution: Progress Of Intelligent Process At Foot

At the central economic work conference held at the end of 2018, high quality development, manufacturing power, structural adjustment, optimization and upgrading became the key words of industrial development. Sun Ruizhe, President of China Textile Industry Federation also mentioned in the subsequent interpretation that the central economic work conference not only set priorities for 2019, but also pointed out the direction for pformation and upgrading of textile industry and high quality development.

In 2019, strengthening the construction of science and technology will continue to be an important job in the industry. The intelligent manufacturing process, which is composed of product intelligence, manufacturing intelligence and operation intelligence, will continue to accelerate.

After several years of development, the concept of "machine substitutions" emerged from the "12th Five-Year" period, from the concept to the positive practice, has been the only way for the pformation and upgrading of the textile industry.

"Machine substitution" forms a new driving force for development?

Textile enterprises taste the sweetness

Looking back in 2018, the intelligent manufacturing of textile industry went further. In the Jiangsu and Zhejiang provinces, the textile industry was densely populated. The effect of "machine substitution" was remarkable, and the development momentum continued to 2019.

Taking Shaoxing city of Zhejiang as an example, the "machine substitution" was used as the key project plan for the 2018 technical pformation, including the new technological pformation project of Shaoxing Xing Ming dyeing and finishing Co., Ltd., the production line renewal and the plant renovation project of the Zhejiang Fu Li Li home textile Limited by Share Ltd.

Among them, a total of 97 projects in Keqiao district were included in the key project plan of "machine replacement", 26 projects were included in the key project of Intelligent Manufacturing in the city, and 18 projects were included in the provincial "four hundred items" key technology pformation demonstration project plan.

In the intelligent printing and dyeing production and processing base of Shaoxing Xing Ming dyeing and finishing Co., Ltd., each piece of white cloth has bar code, which records the process needed to process the grey cloth.

The employee only needs to sweep the corresponding bar code on the computer terminal, and the whole process digital dyeing control system enables the machine to finish processing automatically.

In the past, most of these operations were done manually. The efficiency of the machine changed greatly and the number of employees decreased.

In Zhejiang Shaoxing Yongli printing and dyeing Co., Ltd., the automatic yarn winding machine workshop of Italy, the automatic intelligent winding machine of the province only needs 1 people to operate on each line, compared with the original equipment, the production capacity is increased by 4 times, and the yarn tightness is uniform, which greatly improves the next dyeing efficiency.

Technology Kone, the color measuring instrument is testing and analyzing the color matching and color matching of the customers. The most reasonable formula is calculated. The imported automatic drip drier in Italy is in accordance with the formula issued by the computer and runs in an orderly way.

Close to the workshop next to the technology department, the white gauze with uniform texture and neat arrangement is grabbed from the track by the mechanical claw of the Italy automatic yarn loading machine. It is quickly and accurately placed in the frame, and is ready to dye the cylinder in the next step.

The dyed yarn is automatically dehydrated to the corresponding yarn rack through the mechanical claw of the Italy automatic yarn unloading machine, and the yarn dehydrated is pferred to the assembly line for further automatic drying.

The low end of the production line for high-end, machinery for digital, single set replacement, artificial intelligence, comprehensively improve the production and operation of automation, digitization, networking and intelligent level, effectively reduce the number of labor force use, improve labor productivity, is Shaoxing Keqiao area "machine for others" brings huge results, to upgrade traditional industries and help industrial pformation and upgrading plays an important role in promoting.

In addition to Shaoxing Keqiao textile cluster "machine substitution", Rongsheng, Sheng Hong, Hengli, Tong Kun and other leading enterprises are spending money on importing the most advanced equipment in the world, trying to get a new way to reduce staff and increase efficiency under the background of the loss of labor cost dividends.

Hengli Group is one of the earliest enterprises exploring intelligent manufacturing. It is gradually changing the mode of enterprise development from "demographic dividend" to "technology dividend" through "machine for labor", "automatic replacement of machinery", "complete sets of replacement units", "intelligent data exchange" and so on, so as to ensure the sustainable development of enterprises.

At present, the work of artificial silk stacking in filament production workshop of Jiangsu Heng Ke New Material Co., Ltd. has been handed over to the robot. More than ten robots have been waving "arms" for 24 hours to arrange rows of silk cakes neatly and swiftly.

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

Hengli relevant responsible person said that the group's automatic packaging production line introduced 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 6 years, most of the robots in the workshop have been redeveloped.

An intelligent automatic packaging robot can top several workers.

Taking the initiative to adapt to the new technology development trend of big data, cloud computing and artificial intelligence, Sheng Hong Group has been actively implementing the "Internet +" manufacturing industry in recent years, creating automation, intelligence and intelligent chemical plants, and promoting the innovation and development of enterprises.

The group's wholly-owned subsidiary company, Guo Wang Gao's spinning workshop and bomb packing workshop, has been fully automated, and realized the full-automatic packaging function of silk car on-line, outgoing, warehousing, wrapping, opening, packing, labeling, sealing, packing and palletizing.

It is understood that "machine replacement" and IOT technology enable Sheng Hong to save 15 million yuan a year, a production line can save 127 workers, reduce the labor rate by 34%, reduce the failure rate by 55.9%, increase the production per person by 29.8%, and increase the production capacity by 33%.

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

It is understood that Rongsheng started intelligent construction 5 years ago, and the machine replacement equipment 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.

On the one hand, we should lay out intelligent production lines, strengthen the development of textile digitalization and intelligent equipment, promote the construction of intelligent workshop (production line), foster the development of large-scale customization, on the other hand, promote the innovation of manufacturing mode and business mode, and form a new driving force for the development of textile economy. The textile industry reform effect is remarkable in the new period.

"Machine substitution" causes unemployment?

This pot is not backed.

In November 2017, when CCTV interviewed Shandong Ruyi group, it talked about the pformation of the intelligent equipment in the spinning workshop and the automation level. The number of employed workers from 10000 yuan to 200 workers dropped to 15 yuan.

The number of workers in the workshop has dropped by 92.5%, even if it is only a demonstration workshop.

In the future, all kinds of jobs are becoming more and more automated, more and more intelligent. A lot of manual labor and repetitive labor will be replaced by machines, and a large number of jobs may disappear.

I can't help asking questions. What about so many workers?

What is the overall situation of the whole country?

Today, "machine substitution" is irresistible, becoming the only way for the industry to adjust its structure and optimize and upgrade its enterprises, especially in the labor-intensive fields that are more sensitive to labor costs rising.

On the one hand, it is a choice that enterprises must make. On the one hand, it is a panic that causes unemployment. Whether machine substitution is the blessing of industrial upgrading or the disaster of laid-off workers?

In addition, from the employment figures of the second industry in recent years, we can see that the number of employment in the second industry in China began to decrease after reaching the peak of 232 million 410 thousand in 2012, 231 million 700 thousand in 2013, 230 million 990 thousand in 2014, 226 million 930 thousand in 2015, 223 million 500 thousand in 2016, 218 million 170 thousand in 2017, and 14 million 240 thousand in five years.

Not only that, the decline rate also showed an increasing trend. In 2013 and 2014, the decrease was 710 thousand compared with the previous year. In 2015, 4 million 60 thousand people dropped sharply, 3 million 430 thousand in 2016, and 5 million 330 thousand in 2017.

Over the past few years, it has been the process of "machine substitution" from exterior to interior, from shallow to deep. In fact, intelligent manufacturing is essentially technological progress, and people always intuitively believe that technological progress - factories start machine replacement and artificial intelligence - repetitive labor is replaced - a large number of low-end jobs disappear and bring unemployment.

This is why, with the rise of machine substitutions and artificial intelligence, more and more articles say that the tide of unemployment is coming.

However, the fact is that machine substitution and artificial intelligence are taking place objectively, but this is only a small factor for large-scale layoffs and unemployment. In fact, it should be considered in many ways.

One of the most important reasons for the elimination of excess capacity and low end capacity is the "step by step" of production capacity and the tightening of environmental policies.

In 2015, China put forward a policy of "three down, one down and one subsidy", of which the capacity of production has become a key point. The policy has been focused on the central economic work conference for three consecutive years, and the various surplus capacity industries have become the object of "priority care".

Then, in 2017, in order to cooperate with the production capacity, our country started "environmental protection storm", and implemented strict environmental protection inspection and renovation.

Take Hebei as an example, in the first 11 months of 2017, Hebei Province found 10.9 "scattered pollution" enterprises, and completed 10.2 million renovation projects, including shutting down 6.9 enterprises with no license and no license.

Severe regulation has resulted in the reduction of state-owned low-end product lines, difficulties in private enterprises' operation and even bankruptcy.

Among them, "printing and dyeing war" let the beginning of the article Shaoxing Keqiao "loss of soldiers and soldiers", in the survival of the fittest has experienced a painful baptism.

It can be said that if we put aside the policy factors such as capacity and environmental protection storm, in the past five years, "machine substitution" or AI will not affect the employment of second industries in China.

One of China's largest clothing suppliers, and also a brand supplier of ADI, Reebok and Armani, China Tianyuan Garments Co., Ltd., in early 2018, invested 20 million US dollars in a factory in Arkansas, Suzhou, and produced 80 thousand t-shirts for Adidas every day. Due to the large number of robots used to manufacture and sew, the cost of each T-shirt is only 33 cents, that is, almost 2 yuan.

Tang Xinhong, chairman of the board, said in an interview with the media: "when the 21 full-automatic production lines are fully operational, the system can produce a T-shirt in 22 seconds, which means we can produce 80 thousand t-shirts for Adidas every day.

Looking at the whole world, even if the labor force's cheapest market can't compete with us, I'm really excited about it.

It can be seen that although the technological progress of the manufacturing industry has reduced the number of low-end jobs to some extent, it has increased the output value, so that the wages of the entire factory workers can continue to rise, allowing machines to work for people, and the overall income will go to high-end.

At the same time, it is worth mentioning that the labor intensity of workers has also been greatly reduced.

Therefore, whether it is aimed at the increase of labor shortage and labor cost, or to speed up intelligent production, machine may be the best way to solve the problem. Instead, it is imperative to improve the quality of front-line staff, whether coping with the upgrading of job skills or solving the crisis brought about by "machine replacement".

"Machine replacement" pressure front-line staff?

There is pressure to drive.

Nowadays, the voice of "machine substitution" in textile industry is more and more intense, and the scope of implementation is more and more extensive and deeper. For the front-line employees directly facing the event itself, "machine substitution" is not simply a change of job or unemployment, so simple and crude. On the contrary, it has far-reaching and positive influence on the development of the entire textile industry and the overall improvement of staff quality.

In the survey report of the textile industry front-line workers' income in Jiangsu Province in 2018, 90% sample workers supported the "machine substitution", and the overall support rate of the workers in Jiangsu textile industry was higher.

More than 80% of the workers in the support sample think that machine replacement can improve work efficiency, which is the main reason for the support. Secondly, it is believed that it can liberate human resources and reduce the cost of enterprises.

At the same time, in view of the emergence of "machine substitutions", most workers think that trade unions need to organize related skills training, including new machine operation skills training and new post skills training, and help in career planning.

The survey also shows that in the case of "machine substitutions", the actual substitution of machine substitutions is mainly for spinning workers, winding workers and sewing workers.

The workers who are replaced are mainly pferred to other types of jobs that are not replaced, followed by technicians who operate and manage new machines and equipment.

It is worth noting that in the absence of "machine substitutions" of the sample workers, there are nearly 60% employees think that enterprises should carry out internal training, in this part of the sample workers, are willing to make their own choices after the replacement of their jobs, of which 53.4% of the workers are willing to operate and manage the new machinery and equipment technicians, followed by other non replacement jobs.

This fully shows that front-line employees are positive about "machine substitutions" and are willing to accept and try new career opportunities.

As far as the employees are concerned, the positive effects of "machine replacement" are mainly included. The enterprises have carried out extensive education and training for the workers and the use of machine and equipment. It plays a very important role in improving the professional quality of the staff and workers, promoting the technological innovation of the workers and enhancing the overall competitiveness of the enterprises.

At the same time, the enterprise's awareness of staff training is constantly improved, and then the workers' awareness of education and training is raised.

In terms of individual enterprises, in the trend of innovation leading development, the continuous introduction of high-tech machinery and equipment, in the liberation of manpower at the same time, more need to use and maintenance of machinery and equipment workers, strengthen internal and external training, train high-quality talents, and generate more employment opportunities.

As far as industry is concerned, "machine substitution" promotes technological progress, not only improves the automation efficiency of local low-end industries, prevents industrial relocation, but also robs foreign middle and high-end industries to a certain extent, creating a large number of new employment opportunities for China.

Technology development has not only greatly improved the salary level of Chinese manufacturing workers, but also generated new demand after the increase in income, and combined with infrastructure and new business models, a large number of new service industries were born.

As far as the whole society is concerned, in the process of technological progress, some occupations will indeed disappear, but the essence of the economy is to satisfy people's needs, technological progress, higher social efficiency, increased middle and high income posts, and the increase of people's income will bring about a large number of new demands. People's needs will gradually expand, and from one side to many sides, the overall social employment opportunities will be more diversified, with higher incomes and lower labor intensity.

In fact, this is the case. Over the past ten years, there are more and more different kinds of jobs, industries are constantly shuffling, and employment is constantly upgrading.

The rapid development of the consumer market decides that no matter which position it is, it will constantly face new challenges and new challenges, which is the driving force for social progress and industry development.

"Machine replacement" pain and happiness?

Change will continue

In the past five years, the cost of garment processing materials has increased by about 10%, but the increase of labor cost has reached 35%.

In 2019, the employment of textile enterprises will remain one of the important problems in the industry.

To further expand the scale of intelligent manufacturing and solve the problem of worker shortage through industrial upgrading, it is the best choice for the textile industry and enterprises to enhance the profitability of enterprises.

The survey report on the income of front-line workers in the textile industry of Jiangsu Province in 2018 showed that promoting the intelligent application of machines is the most direct and effective way to alleviate the shortfall of labor shortage in Jiangsu.

Jiangsu textile industry front-line workers accounted for a large proportion of foreign workers, local workers less, and because the textile industry salary compared with other industries, there is no obvious advantage, the industry as a whole young workers less, resulting in greater employment pressure.

In addition, in addition to sustained high labor costs, the entire chain of textile industry is also changing, rising raw materials, increasing management costs, increasing circulation costs......

All these will be paid by enterprises.

Therefore, the survey results also suggest that enterprises can use the innovation driven development strategy currently implemented, introduce new machinery and equipment, replace manual labor with machines, and directly alleviate the shortfall in employment and improve work efficiency.

On the other hand, in order to achieve the goal of manufacturing power in the light of industrial upgrading and structural adjustment, "machine substitution" is also imperative.

China is still the largest producer of labor-intensive industries in the world with the doubling of labor costs. The first export power is far ahead of the world's second.

At present, China's labor-intensive industries are running through technological progress and time. In a sense, this race also determines the industrial prospects of Vietnam's developing countries such as Vietnam.

That is to say, if China successfully implements large-scale production of machines in the labor-intensive industries and makes the cost better than the lowest labor cost countries in the world, other countries, such as India, which have a large local market and can stop China manufacturing and rely on the local market to develop domestic goods through tariffs, will not be comparable to China.

Therefore, no matter in order to solve the cost dilemma or to continue to develop, the scope of "machine substitution" will continue to expand and the extent will continue to deepen.

For example, in-depth collaboration with the Internet of things.

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, if the pformation of the Internet of things is realized, the cloud management and control of some production processes can be realized, and the energy saving of the production process will be optimized. The intelligent factors will drive the factory to be more flexible, intensive and efficient.

Therefore, the advanced form of "machine substitution" in the future will be embodied in the construction of the Internet of things and the 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 reduce staff, improve quality and increase efficiency.

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.

Overall, with the weakening of China's labor cost advantage and the continuous improvement of consumer market demand, "machine substitution" is imperative and will be deepened gradually.

However, "machine substitution" is not completed overnight. There are two main factors at present: one is the restriction of the current technology level, and the robot is not capable of changing people in all manufacturing industries and all manufacturing posts. Even if the machine has the ability of human, it may not be as efficient as manual labor.

There are many kinds of manufacturing industry, and there are thousands of different posts. There are not enough matching intelligent manufacturing technology solutions to match.

The other is that even if the machine is more efficient than manual labor, it also involves the issue of return on Investment: This robot is more efficient than manual labor, saving 1000 yuan a year than manual labor, but the price of this robot needs ten thousand yuan, even if it does not consider the factors of failure and spare parts maintenance, it will take 10 years to return to the original, and the enterprise will not buy it.

Therefore, the pformation of machine substitutions and artificial intelligence can not exceed the two mountains of technology and cost.

At the same time, China's textile industry, enterprises and front-line employees will also change their position as the market changes.

Any change is bound to suffer pains. How to deal with the pain and minimize it is the key to the successful completion of the revolution.