Lanxi Textile Intelligent Manufacturing Takes The Lead In China

Storage and extraction of warp shafts In the workshop of Wanzhou holding group, each process is in good order. An AVG forklift works freely in the workshop. As a result, only one person is left to record in the packing workshop, which originally required 15 people. The whole packing process is automatically completed by the machine. Spinning industry is a traditional labor-intensive industry. In the era of intelligent industry, intelligent machines are replacing workers, which not only greatly improves the production efficiency, but also improves the stability of product quality.

"Textile is a very traditional industry. When we started the intelligent manufacturing transformation, we always thought that the harvest was not big, but after the transformation, it was really different from before." Zhejiang Wanzhou Holding Group Co., Ltd. party secretary, executive vice president Xu Jianzhong said.

In recent years, Lanxi has built an intelligent manufacturing demonstration city of textile industry by combining the government and enterprises and taking various measures to promote the transformation of textile industry. Through more than one year's transformation and improvement, the average benefit of 30 pilot enterprises has increased by 12.3%, the networking rate of production equipment has reached 98%, and the average consumption of water, electricity and steam per 10000 meters cloth has decreased by 9.8%, 4.1% and 5.6%, respectively.

"Government + expert + enterprise" linkage set off the upsurge of digital transformation

Textile industry is one of Lanxi's traditional superior industries and important leading industries. It has formed a relatively complete industrial chain of spinning, weaving, printing and dyeing, colored cloth, jeans, towel, clothing and industrial cloth. The total textile industry has accounted for one third of Lanxi's industrial economy, 80% of all cotton leisure elastic fabrics are produced, and one seventh of the country's denim fabrics are exported“ China textile industry base city ".

However, behind the boundless scenery, there is an unknown sadness. After years of development, Lanxi textile industry is still facing difficulties and challenges, such as low profit margin, weak innovation, lack of talent support, rising factor cost, hindered industrial chain extension and other difficulties and challenges, hindering the high-quality development of the industry.

The sustainable development of enterprises is inseparable from the products of "intelligent manufacturing sharp tools". Lanxi people, who dare to break through and dare to fight, began to think about change. In 2008, Lanxi textile introduced the world's most advanced high-end intelligent production equipment, such as Toyota air-jet loom in Japan and Bigelow loom in Belgium, which took the lead in setting off a wave of "machine replacement".

In July 2019, Lanxi took the lead in creating an intelligent manufacturing demonstration city in the textile field, organized a mobilization meeting of thousands of people, formulated and issued the decision on creating an intelligent manufacturing demonstration city in the textile industry and the implementation plan for Lanxi City to create an intelligent manufacturing demonstration city in the textile industry. It is clear that the demonstration city of Intelligent Manufacturing in the textile industry will be established in about three years, until 2021 By the end of the year, the annual average growth rate of industrial output value above Designated Size of the textile industry will be more than 15%, and the local contribution and profit margin will be doubled; more than 16 enterprises will be shortlisted in the top 100 cotton textile industry in China. In the process of establishment, Lanxi will also give pilot enterprises special fund subsidies according to 50% of the investment in software, hardware and cloud, with a maximum subsidy of 5 million yuan. It will also innovate the intelligent manufacturing financing mode, popularize and apply the supply chain financing modes such as the core enterprise's own authorization letter and the core enterprise's upstream and downstream authorization mode, so as to provide more "financial water" for textile enterprises.

Through "machine replacement", Lanxi has more than 30000 international leading looms. Because these machines and equipment come from different countries, different models and different communication protocols, there is no "dialogue" between machines, and they will only "work alone". How can they "talk" to each other? Last year, Lanxi insisted on the pilot project first, with the direction of digital transformation, and vigorously promoted the intelligent transformation of "machine replacement" in the textile industry. At present, more than 10000 textile machines have realized data sharing, and the working efficiency of looms has been improved and the power consumption has been reduced.

In the data center of Zhejiang Xinhai Textile Co., Ltd., a large data screen covers the whole wall, on which the equipment operation of each machine in the loom workshop flashes, and the staff can access the real-time data of any machine at any time; in the cloth inspection workshop of the company, the cloth inspection machine is equipped with high-speed cameras, through which the cloth information is collected and uploaded in time Go to the server to compare and look for errors. At present, click on the customized mobile phone app, gently scan the bar code on the finished cloth, and you can check the detailed information of warping, sizing, weaving, inspection and other production steps. "After the intelligent transformation, our enterprise has improved the production efficiency and reduced the labor cost. This gives us full confidence in the future development of the enterprise. " Qiu Haibin, chairman of the company, said.

"Standard + personality" tailored to promote the implementation of intelligent manufacturing

In the quality inspection workshop of Zhejiang Qijin Textile Co., Ltd., which is located in Lanxi Economic Development Zone, the expert group dispatched by the provincial intelligent manufacturing expert committee is installing the grey fabric quality analysis module on the grey cloth coiler. "The machine will automatically record the defective points on the grey cloth, so it is not necessary to make statistics one by one manually." Introduction of the expert group.

In recent years, Qijin textile has accelerated the development of "fashion textile", but in the process of development, it has also encountered problems such as labor difficulties and rising factor costs. After the quality analysis module is installed, with the "intelligent manufacturing" enabling, the enterprise's pressure resistance is stronger, and the foundation gas is more sufficient. At the same time, the expert group also set up Qijin textile production data monitoring system according to the needs of enterprises. "At present, our company produces high-end differentiated products, which require high-quality products, but the original management mode is relatively backward." Lu Ying, chairman of the board of directors, said that after the start of intelligent transformation, they can timely grasp the quality of products, and timely adjust the production of products. At the same time, from production to sales, the whole dynamic of the enterprise can be mastered, which is of great help to the development of enterprises.

In order to speed up the intelligent transformation, Lanxi invited the expert group of the provincial intelligent manufacturing expert committee to settle in and provide more than 30 complete diagnosis and transformation schemes, more than 100 technical consultation and intelligent manufacturing scheme reviews for the 30 enterprises selected as the pilot, and regularly carried out training and on-site teaching to guide the owners to change their thinking from competing equipment to data application and data communication.

After in-depth enterprise research, the expert group of provincial intelligent manufacturing expert committee has customized the "4 + X" intelligent transformation mode for the majority of small and medium-sized enterprises. It is understood that "4" is the content of general intelligent reform, that is, to get through the basic data between production equipment (including facilities, instruments, etc.), solve the problem of "deaf, dumb and blind" and eliminate information island; get through the application data of the whole process of production and operation, realize the interconnection and interoperability between production equipment and software, ERP and MES, and lay the foundation for enterprise digital manufacturing; and open up real-time It is necessary to install Kanban (intelligent terminal) system from decision-making level, management level to operation level to import enterprises into digital management; to get through the collaborative data between employees and machines, materials, processes, etc., implement the knowledge and skills training of intelligent manufacturing for all employees, realize human-computer cooperation, and ensure the effectiveness of intelligent manufacturing.

In strict accordance with the standard system construction, the expert group also matches the personalized "X" application. Xinlan textile and Qixing textile and other enterprises have developed and applied automatic storage system and virtual goods location management for pre and post finishing and post dyeing; Wanzhou textile, Ciyuan textile and other enterprises have taken the lead in deploying 5g Network + Intelligent cloth inspection system, which can double the cloth inspection speed and save 105 yuan of labor cost per 10000 meters of cloth; Xinhai textile and other enterprises use edge data acquisition controller, intelligent meter and intelligent water To achieve real-time monitoring of equipment energy consumption, the formation of water, electricity, gas and other production factors of automatic control management, prompting enterprises to reduce energy consumption by more than 10%.

"Technology + industry + industry" service to realize intelligent "civilian" Application

On January 12, this year, Lanxi held the unveiling ceremony of textile cloud platform, marking the formal launch of an information management system that can provide enterprises with low cost, quick effect and convenient implementation.

"The platform can help enterprises fine management, understand industry information, and share production resources between industries." According to Chen Wei, head of cloud platform development, in terms of enterprise management, the platform provides fine data collection for textile enterprises, which can accurately understand the operation status of production equipment, daily output of production line and product qualification rate, and "paperless" the planning table, scheduling table and purchase table of production link, so as to reduce errors and improve efficiency. At the same time, the platform will also realize the exchange of industry information, and realize the sharing of production equipment and technical personnel through various adjustment methods.

While developing the textile cloud platform, Lanxi has also built a comprehensive platform integrating intelligent manufacturing engineering technology, intelligent technology research and development, entrepreneurial service mode and intelligent manufacturing display, and introduced a number of textile intelligent manufacturing engineering technology research institutes and textile industry intelligent technology application research institutes, striving to improve the guarantee level of digital services and innovative services. Select the most powerful intelligent manufacturing general contractors such as Kangli, Tianfu and huansi to provide high-quality intelligent manufacturing supply capacity for Lanxi textile enterprises.

In order to comprehensively enhance the supply and demand capacity of the industrial chain, Lanxi improved the upstream and downstream supply chain, integrated the domestic advantageous cotton yarn enterprise resources, and built a comprehensive cotton yarn textile trading platform integrating "brand + supply chain management + trading platform + supply chain finance". Based on the all-round data of supply chain and textile cloud platform, a standardized system of credit evaluation is established by comprehensively using digital technology. The traditional mortgage guarantee is replaced by the evaluation value, so as to realize the directional risk control and accurate drainage of enterprises, and solve the financing problems of enterprises.

Many measures have been taken at the same time to achieve remarkable results. In 2020, the total industrial output value of Lanxi will reach 66.4 billion yuan, including 21.7 billion yuan of textile output value, accounting for 33%. In addition, there are more than 160 textile enterprises on the scale. Lanxi textile industry has more than 30000 looms, which can produce 2.2 meters of white cloth per kilowatt hour, which is far higher than the average level of 0.7 meters in the same industry in China. The labor force per 10000 spindles is less than 30, which is far lower than the average level of 80 people in the same industry in China.

"In the next step, Lanxi will comprehensively promote the" hundred enterprises promotion "activity, build a number of intelligent production lines, intelligent workshops (warehousing) and intelligent factories, basically realize the digital manufacturing of enterprises and industry platform services, and further standardize and modularize the common needs of the industry, and provide them with shared services to the majority of small and medium-sized textile enterprises, so as to help enterprises with low cost and zero threshold Realize the cloud of production data and equipment, reduce the cost of enterprise intelligent transformation, shorten the implementation time and improve the transformation efficiency. " Lanxi economic and Information Bureau related responsible person introduction.