Hou Xi: Intelligent Manufacturing Promotes Transformation And Upgrading Of Textile Industry

Guidance:

The future development of China's textile industry is the application of new textile materials, intelligent manufacturing and green manufacturing. The intelligent manufacturing of textile and clothing is one of the key means of transformation and upgrading of China's textile industry. It is also the key stage for China's textile and garment manufacturing to maintain the world's leading edge for a long time.

China has the world's most complete modern textile and garment manufacturing system, accounting for more than 50% of total fiber processing, exports of textile and clothing exceed 1/3, and industrial scale ranking first in the world. In 2018, the main business income of China's textile enterprises was 5 trillion and 370 billion 350 million yuan, accounting for 5.9% of the revenue of manufacturing owners' business, and the total profit was 276 billion 610 million yuan, accounting for 4.9% of the manufacturing industry. The textile industry played an important role in the national economy.

In 2018, the textile industry accounted for 11.1% of the total export volume and 71.1% of the total foreign exchange earnings. In addition, 60 of the top grade yarns account for 60% of the world's total, and the top color spinning production accounts for 90% of the world's total. The export volume of textile machinery is second only to Germany, ranking second in the world. The traditional manufacturing industry represented by textile and garment is an important part of China's modern manufacturing system. It will also play an important role in building a manufacturing power in the future.

At present, the problems faced by the textile industry are difficult employment and recruitment, and the production efficiency and product quality need to be further improved. The demand for transformation and upgrading of textile industry is urgent. Intelligent manufacturing is one of the important means of transformation and upgrading of textile industry.

Examples of textile intelligent manufacturing

The pilot project of intelligent factory covers the whole industry chain, and the breakthrough of digital textile technology, the development of textile mass customization and technology network collaborative manufacturing. Let's take a look at several specific cases.

The first case is the chemical fiber filament intelligent manufacturing solution. Taking the Bai Hong Group in Quanzhou, Fujian as an example, a workshop needs 400 employees before the transformation. The annual wage of the enterprise is 24 million yuan per workshop, and the storage link is 2 million yuan. After the transformation, the workshop saved 75% of the work cost, and the transportation, inspection and storage logistics in the whole production process achieved automation and informatization. In addition, the detection link also applied artificial intelligence technology to machine identification and detection, and now this scheme has been widely promoted in chemical fiber production. Recently, a chemical fiber factory in Zhejiang has applied industrial 5G technology on the basis of this solution, which is rare in traditional manufacturing industries.

The second is the automatic production line of spinning automation. The application effect is reduced to 15% from 10000 spindles.

The third is the bobbin dyeing intelligent manufacturing solution. The automation and digitalization of the whole process of cheese dyeing system makes China the first country to break through the whole process automation dyeing technology and realize the engineering application. The passing rate of dyeing was increased from 60% to over 95%. Such an increase is very great. In the past, the traditional mode was dyeing to bleach, which resulted in two pollution. The supplier of the system solution realized the scale through the self built cheese dyeing factory. The yarn cost per ton was reduced by 2000 yuan compared with the original dyeing production cost, so that the backward production capacity could be eliminated by means of advanced technology and cost.

At present, China's printing and dyeing technology level and equipment level are advanced in the world, but because of the large stock, the fabric processing accounts for over 60% of the whole world, and transformation and upgrading need a process. The above three systems of the complete set of equipment have been internationalized and have independent intellectual property rights. Let's take a look at a case of clothing customized intelligent manufacturing. The clothing industry has many employment and low efficiency, and often there will be a backlog of inventory. Ningbo news birds achieve mass customization by digitalization, component and intelligence. Through the adoption of intelligent beds and modular sewing machines instead of traditional processes, a large number of industrial workers have been reduced. The production mode is popularized with users as the center, and products achieve zero inventory. Consumers can participate in the design of clothing from the very beginning, and truly realize the personalized demand of one person, one edition, one garment and one garment by intelligent manufacturing. The large-scale customization of clothing has been realized.

All of these are examples of intelligent manufacturing on tall buildings. Here's a common example. In some garment processing enterprises in Shandong, there is no automation, but there is a card reader on each sewing machine, with several cards on it, one is a work card, one is a material card, a staff member starts to work, then the material is placed in the material box, through a card reader, the whole production of people, machines and materials are linked together, and the enterprise can pass the meter. The computer understands the production technology and the production situation in real time. The employee sees the card reader knows his workload and calculates the wages of that day. If a problem is found, the inspector can know which part of the problem is wrong by reading the card information.

The card reader is very low-key, but it is luxurious on every ordinary sewing machine. So we call it "low luxury of clothing production". In this case, there is no automation, the investment of enterprises is not large, but it is also an innovation, which reflects the characteristics of Intelligent Manufacturing in China, that is, parallel propulsion. Of course, to truly realize intelligent manufacturing, we also need digitalization and intellectualization.

The project of Intelligent Manufacturing in textile industry has 6 items of comprehensive standardization of intelligent manufacturing, and 20 new projects of intelligent manufacturing. In the textile industry development plan, the intelligent manufacturing demonstration lines of chemical fiber, spinning, knitting, printing and dyeing, non manufacturing cloth, clothing and home textiles have been covered in seven sub fields. The solution of systems such as chemical fiber and spinning has been widely promoted in the industry. The projects that have been implemented have been automated and digitalized. Most of them have adopted the industrial Internet. Some of them have intelligent equipment and functions. Some projects also use big data and artificial intelligence technology.

Key to advancing textile intelligent manufacturing

The textile and garment industry must be upgraded. The manufacture of textile and clothing itself is the main body. Information technology is the tool. The application of the new generation of information technology must adapt and serve the development of the textile and garment industry, and must not put the cart before the horse. While paying attention to intellectualization, we should also pay attention to the development of professional software tools, make great efforts, and make great efforts to build up a team of scientific and technological personnel. The upgrading of textile and clothing intelligent manufacturing needs the combination of hardware and software.

How to transform a large number of existing production lines into digitalized, networked and intelligent production lines is the key to the successful transformation and upgrading of textile industry, so stock is the key. In addition, large enterprises of textile and clothing have the ability to transform and upgrade intelligent manufacturing, and large and medium sized textile enterprises need to use external force to implement intelligent manufacturing, and vigorously train suppliers of intelligent manufacturing system solutions and industrial financial services institutions. Therefore, the upgrading of textile and garment intelligent manufacturing should be taken into account by both large and small enterprises.

German industry 4 strategic judgment textile is not a traditional industry, is based on new materials, energy saving, environmental protection, intelligent products to create new products and services. The future development of China's textile industry is the application of new textile materials, intelligent manufacturing and green manufacturing. Intelligent manufacturing of textile and clothing is one of the key means of transformation and upgrading of China's textile industry. It is also a key means for China's textile and garment manufacturing to maintain world leading edge for a long time. However, in order to comprehensively promote the high quality development of textile industry in the future, intelligent manufacturing, green manufacturing, new textile materials and applications should be combined.

Author: Hou Xi, vice president of China Textile Association

This paper is published in the twentieth issue of the 1/2 monthly magazine of China Industrial and information technology. This paper is based on the shorthand speech of Hou Xi, vice president of the Quanzhou in the construction of 2019 national manufacturing Power Forum (Quanzhou).