Information, Data And Intelligence Lanxi Intelligent Textile "Weaving" Into The New Future Of The Industry

Walking into the workshop of Zhejiang Xinhai Textile Co., Ltd. in Yongchang street of Lanxi City, more than 1500 air-jet looms are operating at full capacity. In such a large workshop, several employees patrol back and forth to check the operation of the machine in real time.

"Intelligent manufacturing can reduce labor costs for enterprises. For example, an automatic reeding machine can replace 20 workers, and the rate of return on investment is very high; MES production execution system accurately records the data in the production process, which helps enterprises analyze the order situation and scientifically arrange the output." Qiu Haibin, chairman of the company, said.

Textile industry is the traditional advantage industry and important pillar industry of Lanxi. "Thousand people's yarn and ten thousand people's cloth" is people's old impression of traditional textile industry. However, in Lanxi, with the help of Dongfeng, a demonstration city of Intelligent Manufacturing in the textile industry, the textile industry takes digital transformation as the direction, vigorously promotes the intelligent transformation of "machine for human", and realizes the comprehensive optimization and upgrading of production equipment, process technology, product innovation, enterprise management and sales channels. Textile, the former labor-intensive industry, is undergoing great changes.

Planning for digital "butterfly change" in textile industry

At present, intelligent manufacturing has become the strategic direction to promote the high-quality development of manufacturing industry in the new era, and is the key to build the future competitive advantage of manufacturing industry. Lanxi textile industry has a deep foundation, but in the process of high-quality development, it still faces challenges such as low profit margin, weak innovation, insufficient talent support, rising factor cost and hindered industrial chain extension.

"Lanxi textile industry to take the road of intelligent transformation is not a multiple-choice question, but a must answer question, is a rush to answer the question." Lanxi City Party committee chief responsible person said. In June last year, Lanxi launched the establishment of textile industry intelligent manufacturing demonstration city. It is planned to gradually realize the networking of textile enterprises' equipment, data visualization, paperless documents, process transparency, fewer workshop personnel and service platform, so as to solve the problems of difficult recruitment, high energy consumption, slow turnover and low efficiency of textile enterprises, and build a number of intelligent production lines and intelligent workshops Intelligent engineering, basically realizing "enterprise digital manufacturing, industry platform service".

Before the establishment of the demonstration city, the provincial intelligent manufacturing expert committee dispatched an expert group to Lanxi and conducted a half year investigation on the textile enterprises of the city. After investigation, the first batch of 9 furniture enterprises and the second batch of 21 furniture representative enterprises were selected as the pilot.

Wisdom empowers traditional industries with "digital brain"

Entering the "data center" of Zhejiang Xinlan Textile Co., Ltd. in Lanxi Economic Development Zone, how many products are currently produced, which team is on duty now, and what is the production efficiency today When you enter the system, you will know. Moreover, through the application of 5g network, the massive data of all workshops, all equipment and all products can be transmitted to the large screen in real time, and the whole process is smooth and easy, with almost no delay. Not only that, with the help of 5g bandwidth, ultra-low delay and other characteristics, staff in the field can also directly access the server in the mobile terminal.

"5g has brought high speed, large capacity and low delay, and the intelligent manufacturing of Lanxi textile industry will also usher in great development opportunities." Xinlan textile staff said. Originally, Xinlan textile local server data transmission slow, storage demand, and a large number of data access, there is a big security risk. With the advent of 5g era, the problems of network delay, slow transmission and storage are solved thoroughly. After testing, the uplink speed of 5g of Xinlan textile is as high as 150Mbps, and the downlink speed is more than 800Mbps, which is nearly 10 times faster than the original, and will continue to improve in the future.

"Information, data and intelligence are the only way for textile industry to develop." Looking at these intelligent devices, Huang Youhong, chairman of Xinlan Textile Co., Ltd., who has been engaged in textile industry for decades, feels a lot. "The result of intelligent transformation is unexpected, the effect is very obvious, saving time, labor, less errors, good efficiency, and great market influence!" He said that after tasting the sweetness of intelligent production, the enterprise will unswervingly take the road of intelligent transformation and further expand and strengthen.

The output value of Lanxi Economic Development Zone, which takes textile industry as the leading industry, accounts for nearly 50% of the total output value. The output value of 52 Textile Enterprises above the designated size in the area from January to September this year is 8.25 billion yuan. Therefore, Lanxi Economic Development Zone vigorously supports the intelligent manufacturing reform of the textile industry. In the next step, it will accelerate the construction of fashion textile town, promote the intelligent and digital production of the textile industry in the Development Zone, and further open the golden lettered signboard of Zhelan textile.

"You see, there is a defect here. After the computer recognizes it, the machine will stop automatically, and the specific defect location will appear on the screen. Workers can clearly see the location of the specific defect on the screen, and the operation is very convenient and fast." In the inspection workshop of Wanzhou group, Ying Xiaohua, the former director of weaving department, pointed to the defects on the screen and said that with the addition of "Tianyan", the efficiency of cloth inspection has been greatly improved.

According to Ying Xiaohua, "Tianyan" is exactly seven high-speed cameras, which can capture the defects on the surface of the white fabric in real time, and transmit the information to the server which plays the role of "brain". The system can obtain stable and clear images. At the same time, through the information comparison between calculation and database, the defects with different sizes, directions and shapes can be identified and distinguished quickly and accurately, Mark and display on the computer screen in time, the defect situation is clear at a glance.

We know that cloth inspection is an important factor to ensure the quality of finished products, but cloth inspection is a weak link in the intelligent transformation. The use of "intelligent eyes" on the cloth inspection machine can solve the problem of this pain point, and further improve the efficiency and accuracy of cloth inspection while liberating manpower. Zhejiang Wanzhou holding group is one of the first batch of textile intelligent manufacturing pilot enterprises in Lanxi City. The intelligent cloth inspection adopts the quality inspection mode of "artificial intelligence + big data", which realizes the function of on-site information collection and information synchronization resource sharing for cloth inspection, which improves the original cloth inspection efficiency by more than twice, and the accuracy rate is close to 100%. At the same time, it can also replace the manual process of marking defects. It not only reduces the labor cost, improves the detection speed and accuracy, but also gives full play to the stability of computer vision system, perfectly solves the disadvantages of traditional manual detection, and wins more orders and benefits for enterprises.

After more than a year of intelligent transformation, Lanxi pilot enterprises have achieved remarkable results, with flexible production capacity and ability to cope with external changes improved, technical reserves and talent team strengthened, and the enabling effect of industrial big data on intelligent manufacturing was further reflected.

At present, 30 textile enterprises have basically completed the acceptance of intelligent transformation pilot and surface expansion work, and the pilot effect is obvious. The average benefit is increased by 12.3%, the error rate is reduced to 1%, the loom efficiency is increased by 5%, the networking rate of production equipment is 98%, and the average consumption of water, electricity and steam per 10000 meters is reduced by 9.8%, 1.6% and 5.6%, respectively.

Strengthening the market

In the workshop of Zhejiang Jiushun Textile Co., Ltd., machines roar, showing a busy production scene, where yarn made of colored cotton is being produced.

"Look, the yarn we spun not only has color, but also has excellent antibacterial effect, which is especially suitable for the field of medical textiles. Jin Youyi, chairman of the company, confidently introduced this new colored cotton product to us.

Affected by the epidemic situation, export orders of Lanxi foreign trade and textile enterprises were seriously damaged this year, and 90% of orders were facing the risk of refund, and Jiushun textile company was no exception. How to "break the ice" transformation and upgrading in the severe trade environment has become an urgent problem for enterprises.

There are many textile and weaving enterprises in Lanxi, but most of them mainly produce denim, cotton and suitable for pants. The problems of incomplete industrial chain, low profit rate and weak product innovation are always the problems of enterprises. Therefore, Lanxi textile enterprises focus on further improving product innovation ability and strengthening the industrial chain.

Friendship is like gold in the ears. In August last year, relying on Lanxi Textile Research Institute of Zhejiang University of science and technology, Jiushun company established a technical research expert team, and made great breakthroughs in the identification of color cotton authenticity and technical transformation. In March this year, Jiushun company and China colored cotton group got married and began to produce new colored cotton products on a large scale. Because of the technical reserve in the early stage, the enterprise basically completed the technical transformation in only one week. Jin Youyi said that after more than 20 equipment debugging a week, the production efficiency of colored cotton spinning has increased to more than 90%, which is basically the same as that of white cotton. As soon as the new products came out, domestic trade orders from Guangdong, Fujian and other places poured in.

From September 16 to 17, Gao Yong, Secretary of the Party committee of the China Textile Industry Federation, and his party visited Lanxi and expressed their appreciation for the intelligent transformation of Lanxi textile industry. "Lanxi has realized the expansion of Intelligent Manufacturing in textile industry from point to area in just one year, with remarkable results. This kind of experience is worthy of promotion in intelligent manufacturing industry in China." At the forum, Gao Yong's words strengthened Lanxi's confidence and determination to speed up the intelligent transformation of the textile industry.

Intelligent manufacturing has no end. On the basis of this year's pilot expansion, Lanxi will promote the promotion of 100 enterprises, build a number of intelligent production lines, intelligent workshops and intelligent factories, basically realize "enterprise digital manufacturing, industry platform service"; create industry samples, hold pilot experience summary meeting, promote advanced experiences and practices, form replicable and referential methods, and strive to achieve a bigger industry Coverage and improvement of scope.