How Much Do You Know About The Status Quo Of The Textile Industry?

With China's economic development entering the new normal, the textile industry has sprang up the "machine replacement" craze with automation and intelligent equipment instead of manual labor.

What has this craze brought to the industry?

What's the problem?

Is there a trend of change in the workforce of industrial workers?

In order to gain an in-depth understanding of the status quo of "machine substitution" in the textile industry, the China finance and trade textile and tobacco trade union recently went deep into the key areas of textile industry development in Jiangsu, Fujian, Henan, Tianjin, Shanghai and Shandong, and selected representative enterprises such as spinning, chemical fiber, weaving, clothing and so on to carry out thematic research, and clarified some basic situations of "machine substitution" in the textile industry.

Difficult recruitment, expensive labor force forced the textile industry "machine substitutions"

Traditional textile industry is labor-intensive industry. With the gradual disappearance of demographic dividend in China, pformation and upgrading is urgent.

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 report shows that rising labor costs and long-term structural lack of jobs in the industry have become one of the main drivers of "machine substitution" in the textile industry.

In recent years, the growth rate of labor remuneration has been accelerating.

Every year, enterprises should increase the wages of 1~2 workers, and enterprises obviously feel the pressure of employment increases.

The development of textile industry needs a large number of textile skilled workers and skilled talents.

The eastern part is a traditional labor force inflow province. There is a gap in the supply of local labor, and the return of skilled workers in the central and western provinces of migrant workers has led to textile enterprises, especially the eastern textile enterprises, generally facing the "labor shortage" dilemma.

At the same time, because the textile industry has strong work intensity and the mobility of workers is large, especially after the 85 and post-90s young workers are mostly unwilling to engage in monotonous duplication and labor intensive work, the front-line workers can not get effective supplement, and many textile enterprises have long been short of work, forcing enterprises to replace machines with machines.

Take some textile enterprises in South of Jiangsu as an example, enterprises face about 10% of the shortage of workers every year.

At the same time, the upgrading of textile industry and the realization of high quality development have created demand for intelligent manufacturing. "Machine substitution" has become the trend of the times.

The survey shows that the quality of textiles is the competitiveness of enterprises, and the development of textile quality in China is not optimistic. The instability of quality not only exists between different enterprises and different regions, but also exists among different batches of products within the enterprise, which directly affects the market competitiveness of products.

In promoting product stability and quality and achieving high quality development, intelligent robot production has unparalleled advantages in manual production.

The report points out that at present, the strategic plan of "China made 2025" and "industrial 4", as well as the "national textile industry 13th Five-Year plan" and the corresponding incentive policies of the state and local governments that support the upgrading of equipment, constitute a big background for the textile industry to realize the "machine replacement" intelligent manufacturing.

Due to the issue of labor costs and the impact of the p Pacific Partnership Agreement (TPP), manufacturing powers such as Europe and the United States have shifted their focus to India, Vietnam, Bangladesh, Pakistan and other countries. Whether it is human capital, equipment or technology, Chinese textiles have been challenged by Southeast Asian countries. At the same time, although many enterprises have introduced advanced foreign equipment, they still can not change the relatively backward technological situation of the industry.

Therefore, "machine substitution" is imperative.

"Machine substitution" for energy efficiency in textile industry

This research has made a thorough investigation of the effect of machine substitution in some segments of the textile industry.

The report shows:

1. cotton spinning industry.

The technical pformation of blowing carding and simple blowing carding, high efficiency, coarse and high efficiency tight spinning long car and automatic winder are carried out on a large scale, and the yarn quality indicators and the average employment, energy saving and consumption reduction of the 10000 spindles reach a new level.

In particular, the application of the spinning intelligent doffer can greatly reduce the labor intensity of the spinning workers, and the employment can be reduced by more than 4.

Taking Changyuan textile company of Changle, Fujian as an example, the original 10 spinning workshop has been technically pformed, and the automatic production line has been introduced. The number of workers has decreased from 504 to 317, and the average monthly salary has increased by 1000 yuan.

2. chemical fiber industry.

Through intelligent technology pformation such as flexibility technology, energy saving and consumption reduction, product differentiation level, quality performance and production efficiency are significantly improved, and the number of employment is reduced.

Take Fujian Bai Hong group as an example, after the implementation of "machine replacement", the automatic wire cutting process reduces labor consumption by 70%, automatic packaging process reduces labor consumption by 80%, and automatic packaging equipment renewal costs can be recovered in 3 to 4 years.

3. functional textiles.

A large number of high performance automatic warp knitting machines, flat knitting machines, large round machines and matching finishing equipment have been introduced by enterprises to develop various kinds of functional knitted fabrics, such as garments, shoe materials, home textiles and industrial, which have adapted to the market demand trend at home and abroad.

Taking Huayu Weaving Co., Ltd. of Jinjiang, Fujian as an example, the introduction of 400 automatic warp knitting machines at one time, from more than 800 to more than 200, from 1 to 2 per capita management to 5 machines per capita; monthly wages increased by about 4000 yuan per person, and the best skilled workers earned monthly wages of nearly 10000 yuan.

4. making shoes and clothing.

Focusing on design concept enhancement and intelligent manufacturing, clothing function, art and fashion design have been continuously strengthened, and the design and sewing processing and finishing levels have made remarkable progress.

Such enterprises as Qipai, Qipai, qipawang and Jin Ba adopt robots instead of manual cloth laying, and carry out logistics process automation, which greatly reduces labor intensity and improves production efficiency.

5. printing and dyeing industry.

From the experience of advanced regions, after printing and dyeing enterprises implement "machine substitution", the water consumption per 10000 yuan of industrial added value has dropped by more than 15%, energy consumption has dropped by more than 17%, industrial wastewater discharge has dropped by more than 10%, water reuse has reached 52.7%, and labor cost has been saved by nearly 60%.

Small and medium-sized enterprises are facing difficulties in changing machines.

The report shows that "machine substitution" has an incomparable advantage in replacing manual productivity improvement, but there are still many difficulties for textile enterprises, especially small and medium-sized enterprises.

First of all, the "machine substitution" has a high one-time investment. Because of the tight funds and financing difficulties, enterprises prefer to maintain the status quo and are unwilling to invest huge sums of money.

More than half of the enterprises surveyed were over 10 million yuan, and the highest was over 100 million.

In addition, in recent years, the financing cost of enterprises is rising and financing is difficult and other factors, so that enterprises, especially small and medium-sized enterprises, are deterred by "machine substitution".

At the same time, the layout of factory buildings and production lines of some old enterprises and small enterprises can not provide enough space for upgrading the equipment of "machine replacement", and the pformation, expansion and even construction of the plant will further increase the cost of "machine substitution".

At present, the state is pushing deleveraging to reduce leverage and reduce the overall debt ratio. Banks can significantly reduce loan quotas and raise the cost of financing.

In order to maintain normal operation and ensure cash flow, enterprises are unwilling to invest in large equipment and high technology equipment.

Second, the government's supporting policies need to be further refined.

For example, the survey shows that Henan province has promulgated the "three year action plan for intelligent manufacturing and industrial Internet development in Henan" (2018-2020 years), which will promote the "machine replacement" plan in the coal, chemical, food and other industries, and plans to build 50 provincial intelligent factories annually.

However, the Henan provincial government has no specific supporting policies for the textile industry, and municipalities have no definite support policies.

The lack of policy and financial assistance has led enterprises to have a strong desire to replace machines.

Thirdly, the level of domestic textile machinery is still unable to meet the needs of high quality textile production. Import machinery is expensive, extending the recovery cycle of capital input and increasing the maintenance cost of daily equipment.

Research shows that the upgrading of equipment digitalization and intellectualization is not as simple as extensive technical pformation in the past, and can be completed through imitation or commissioning trial production.

Instead, enterprises need more cooperation with universities and automation equipment research institutes to integrate the process from the whole process to the whole production process. There are many uncertainties in the process of R & D.

Fourth, the cultural and technological level of textile workers 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.

Fifth, the wage level of textile workers in the central and western regions is relatively low.

For example, in Anyang, Henan, there is a minimum wage of 1600 yuan and a minimum wage of 15 yuan per hour. There is basically no shortage of labor in the local area. Even if the labor force is occasionally strained, if wages are properly raised, people will be able to find enough manpower.

"Machine substitution" will change the employment structure of the industry

Since the first industrial revolution, machinery has become an irreversible trend.

In modern manufacturing, "machine substitution" is directly turning the machine into a labor force. Has it affected the traditional labor market and the employment of enterprises?

According to the survey report, the characteristics of labor intensive in the textile industry will not change in the short term.

According to investigation, at present, "machine substitution" is not implemented in the whole production process of an industry or a certain enterprise, but is applied in a certain industry or enterprise in some production links.

That is to say, robots will only replace manual operation in individual industries and links. In the short run, they will have a positive impact on production efficiency and product quality, and will not change the characteristics of high labor intensity in the textile industry, nor will they cause serious unemployment problems.

The survey results show that the textile industry is relatively stable.

The textile industry did not cause workers to lay off because of "machine substitution", but because they could not find workers to seek "machine substitutions".

Behind the "machine substitutions" in textile industry is the fact that textile talents are seriously insufficient and enterprises are struggling to fight for workers. At present, there is no hidden trouble for a large number of front-line workers to lay off.

Most of the workers who were streamlined by the "machine substitution" were pferred to the original enterprises, and some of them moved to other enterprises. The workforce was relatively stable, and the pressure of the laid off workers' social placement was relatively small.

Research Report also pointed out that "machine substitution" will change the employment structure of the textile industry.

For labor-intensive textile enterprises, the "machine substitution" will reduce the proportion of front-line workers and optimize the personnel structure.

Low skilled or even part skilled workers are replaced by robots, while the technical positions of debugging, maintaining and controlling robots will increase.

"Machine substitution" will put forward new requirements for labor skills.

In the past, it was "single type labor". In the future, it will be "digital labor", and human labor will be more and more combined with electronization and intellectualization.

The enhancement of workers' technical skills is a strong support for enterprises to implement and popularize "machine substitution", and is also an inevitable choice for the application of human-machine interaction technology to achieve the coordinated production of manpower and machinery. It is also a powerful guarantee for enterprises to reduce costs and increase efficiency.

"Machine substitution" will generate new jobs.

Although machine substitution has squeezed the employment space of workers with low and medium skilled level, it does not reduce the total number of workers.

"Machine substitutions", while curbing or eliminating some old capacity and traditional posts, are also giving birth to new employment and entrepreneurial space and developing kinetic energy.

The report points out that the employment difficulty of older and low skilled workers will increase.

With the use of advanced machinery and equipment and the increase of production efficiency, the proportion of personnel with lower comprehensive ability will be reduced, generally between 50%-90%. Under the same circumstances, the employment rate of young, educated and skilled personnel is high, and the employment rate of people with a relatively large age and low skill level is reduced.

"Machine substitution" still needs government assistance.

The report suggests that the government should actively guide enterprises to carry out technological innovation to help enterprises solve the difficulties encountered in the process of "machine substitution".

First, strengthen the textile industry "machine substitutions" technical force.

Encourage and support domestic and foreign universities, research institutes, multinational companies and textile enterprises to build R & D centers, strengthen the construction of Enterprise Engineering (Technology) centers, expand various channels for enterprises to enhance the technological strength of automation pformation, and combine all kinds of advantageous resources to jointly develop the various technologies needed by enterprises to "machine substitutions".

We should increase the input of "machine substitution" in industry university research cooperation, set up a special project of "machine substitution", and give priority to financial support and talent introduction, so as to promote the rapid implementation of production, teaching and research.

By selecting the representative enterprises in key industries, we will help enterprises build a "machine changing" demonstration line, and lead the textile industry to carry out the "machine replacement" in an all-round way.

The two is to ease the pressure of "machine substitution" in textile enterprises.

We should increase financial subsidies for textile enterprises to replace machines with machines and replace the special allowance for "machine substitution" from "ex post subsidy" to "ex ante subsidy".

A special reward fund is set up to give special rewards to the industry's first "machine substitution" demonstration line.

We should speed up the reform of the credit system, enhance the credit support for "machine substitutions" enterprises, lighten the financing burden of enterprises, reduce the cost of credit, and enhance the strength of financial services for the real economy.

We should optimize the tax and fee system and lighten the tax burden of the "machine substitutions" enterprises.

Three is to do well in the textile industry "machine replacement" guidance and service work.

We should make good plans and guidance for "machine substitution", and formulate a long-term strategic plan for the development of textile industry "machine replacement", and guide enterprises to use domestic automation equipment to revitalize the local intelligent equipment manufacturing industry.

We should actively promote the construction and improvement of the "machine replacement" system in the textile industry, including the examination and approval system, the project promotion system, the supervision system, the appraisal system, the reward and punishment system and so on.

The organization will establish a comprehensive service platform for "machine replacement" to provide technical intermediaries, organization and coordination services for various units and collectives involved in "machine change".

Trade unions take the initiative to do three things well.

The report suggests that trade unions should give full play to their advantages and take the initiative in the process of "machine substitution".

One is to promote the government to train "machine exchange" for all kinds of talents and improve the skill level of the staff and workers.

We should fully seize the opportune time for the flow of talents to the emerging countries, and actively introduce the advanced equipment and technology professionals in developed countries.

To promote the government through macro guidance, co-ordination and financial support to enable enterprises and higher vocational colleges to jointly implement the "machine replacement" order training program.

We should speed up the establishment and improvement of the public service platform for the construction of industrial workers, improve the professional skills appraisal system, and create a favorable institutional environment for the construction of reasonable and high-quality industrial workers.

Two, we should actively guide and urge enterprises to set up the concept of human resource management that attaches importance to the development of industrial workers.

We should explore and establish a long-term mechanism for developing, training, using, evaluating and encouraging industrial workers, and give full play to the key role and dominant position of enterprises in promoting the reform of industrial workers' ranks.

At the same time, through technical exchanges, skills competitions, post training, and other forms, the promotion of industrial workers to become talents; through the labor model innovation studio, "teachers with disciples", migrant workers "dream of learning action", and staff education and training demonstration base and other platforms, provide broad space for industrial workers' skills upgrading and personal development.

The three is to protect the legitimate rights and interests of workers in all aspects.

Enterprise trade unions should take an active part in the management of enterprises, and fully understand the direction of enterprise development through democratic management forms such as the system of workers' Congress and so on. They should grasp the post adjustment information ahead of time, do well in organizational mobilization, psychological counseling and job pfer training, so as to help workers quickly adapt to new jobs.

"Machine substitution" will change the working hours, labor intensity and labor mode of workers. When trade unions conduct collective bargaining, they can strive for greater benefits for workers in terms of wages, overtime, rest and vacation, occupational health and so on.

At the same time, local trade unions should do meticulous and re employment assistance actions, lay laid-off and unemployed people into the employment and entrepreneurship service and related employment and entrepreneurship policy support scope, find out the employment demand, and strengthen targeted career guidance and job introduction.

afterword

- to take the opportunity to achieve the goal.

Xi Ping

In recent years, in order to ease the problem of labor shortage and rising labor costs in China's textile industry, "machine substitution" has become the trend of the times in some economically developed textile developed areas.

The highly automated production has brought about the improvement of product quality and efficiency, the decrease of unit energy consumption and the saving of labor cost. At the same time, there has been a new strong demand for highly skilled post operation talents, and some enterprises have formed a phenomenon of "reducing people" and "finding people".

On the one hand, there is a shortage of front-line operators, and all kinds of skilled personnel are in urgent need.

The new and old changes of equipment also put forward higher requirements for the quality and level of personnel in the industry. As mentioned in the report, "machine substitution" will change the employment structure of the industry, and the relative number of skilled jobs will increase, giving birth to new employment space and developing kinetic energy.

This change gives us an inspiration: the future of textile industry will shift from labor-intensive to technology intensive development.

The industry should actively guide and accelerate the training and promotion of industrial workers, and provide a broad space for the development of employees. At the same time, it also reminds the younger generation to change their mindset: the textile fashion industry in the intelligent age will be more competitive and attractive, and become a new gathering place for attracting talents.