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Smart manufacturing: a new sample of Dongguan transformation and upgrading

robots work on rails in Jusheng electronics workshop. The robot production line has made Ju Sheng taste the sweetness, reduced labor costs and won large orders. Photo by sun Weifeng

as a product of the high integration of informatization and industrialization, the word "intelligent manufacturing" is becoming a high-frequency word in newspapers and government documents. Recently, the provincial Symposium on the in-depth integration of industrialization and industrialization held in Guangdong announced that a special action document on Provincial smart manufacturing was imminent. In Dongguan, Songshan Lake robot industry base and other projects have also received strong support from the municipal government

recently, a series of reports in smart manufacturing found that although Shunde, Foshan, is not under the halo of the Ministry of industry and information technology's only deep integration of industrialization and industrialization of equipment and intelligent manufacturing pilot, Dongguan has now launched a new round of manufacturing revolution. Industrial robots, information software systems, IOT technology and other advanced technologies are bringing Dongguan manufacturing from the labor-intensive era to the era of smart manufacturing. Therefore, the production management and competition pattern of enterprises have changed dramatically

robot intrusion acceleration

if many enterprises were still waiting for the labor shortage in 2008 and 2009, many enterprises have resolutely chosen to apply industrial robots on a large scale through technological transformation in recent years

recently, a questionnaire survey conducted by Dongguan foreign trade and Economic Cooperation Bureau on top 500 import and export enterprises showed that enterprises reported that production costs rose by 14.1%. Among them, the largest increase in labor costs is 9%

in the face of soaring labor costs, Dongguan Xuji food company finally made up its mind to introduce equipment to replace some workers on the production line of xufuji ShaQima, a fist product. At present, 17 of the 18 processes in this production line have been fully automated

60% of the workers are in the last big packaging link. We are debugging a set of equipment and replacing most of them. It is truly fully automated. Said Jiabin, head of xufuji ShaQima workshop

from the replacement of small-scale machines at the beginning of the establishment of the factory in 2003 to the acceleration of technical transformation in 2008, the average number of workers per process is reduced by threeorfour per year. While the output of this production line increases, the number of workers is reduced from 1300 to 700

in sharp contrast, since 2006, the salary of xufuji front-line workers has increased by about 15% every year, from slightly higher than the monthly salary of 1000 yuan (excluding provident fund, social security and bonus) to more than 2600 yuan

not only is labor expensive, but the problem of recruitment is also serious. In Dongguan, dust, harmful gases and high-intensity labor are constantly harming the health of workers in the painting of furniture, polishing of hardware and various handling and stacking work. When young workers strongly demand a more comfortable working environment, business owners often have to deal with it and pay huge hidden costs beyond workers' paychecks

more and more entrepreneurs have changed the view of labor availability in Dongguan and began to buy a large number of automation equipment, which has also been confirmed in Dalang Town, the capital of wool weaving in the world

in 2005, when the shortage of migrant workers first appeared, Dalang town began to encourage wool weaving enterprises to introduce CNC looms to replace traditional mechanical looms to reduce labor. At that time, the total number of CNC looms in Dalang town was less than 1000. In 2008, it increased to 4800, but now, Dalang CNC machine tools have soared to more than 40000

it is estimated that a CNC loom can replace eight workers, and one worker can control the machine. According to this calculation, Dalang CNC loom has liberated nearly 300000 industrial workers. The monthly salary of a sewing master is still rising as high as yuan. After the introduction of CNC looms, the labor cost of weaving pieces alone has been saved by 80%. Some textile enterprises said so

in the eyes of Huang Junqin, general manager of Alfa company, a leading enterprise in Dongguan automation machinery, Dongguan has started the third round of robot boom in the past two years. Among them, the first wave of machine replacement was after the shortage of migrant workers in the early 21st century, some labor-intensive enterprises began to increase equipment and reduce jobs, and then the second wave appeared after the 2008 financial crisis

Huang Junqin believes that with the continuous progress of technology and the decline of the average price of robots at a rate of 4% per year, industrial robots are increasingly playing a role in replacing manpower in spraying, welding, stacking and high-risk working environments. Their characteristics of precision and self-discipline, strong induction recognition, high efficiency, long working hours and low-cost operation are becoming more and more popular among enterprises

this also makes the business of equipment manufacturers such as Alfa prosperous. At the beginning of entering Dongguan in 2001, the company had only more than 30 customers. By 2007, it had 1500 customers, and now it has soared to more than 4000 customers, most of which have increased in recent three years. In 2011, Alfa's sales revenue reached 217 million yuan, a year-on-year increase of 47.81%

in the past, we focused on injection molding robots and peripheral automation equipment. Now there are more and more replacement parts on production lines in all walks of life, and we have to change to popular applications, such as preparing to act as an agent for Japan's advanced robots. Huang Junqin said that in the past, there was only a large demand for robots in the middle and high-end electronic industry and automotive industry. Now hardware products with low unit prices have also begun to introduce industrial robots, which caught them a little unprepared

competition mode changes

as customers have higher and higher requirements for product quality consistency and standardization, coupled with the unpredictable market, the introduction of industrial robots can seize the opportunity, reduce costs in advance and improve quality. This has also led to changes in the mode of competition among enterprises

whether to introduce robot production lines is changing the competitive pattern of production enterprises and even deciding whether to live or die. Yin Xiaolin, general manager of Dongguan linwangda shoes industry, has a deep understanding of this

in May this year, he bought more than 40 sewing robots of a certain type. Although the price of 12000 yuan per sewing machine is six times higher than that of ordinary sewing machines, he did not expect that the monthly output of the factory soared from more than 50000 pairs to 90000 pairs, and the monthly profit also rose from more than 200000 to more than 400000 pairs, with the hands and costs unchanged

this made him overjoyed. As the owner of a small shoe factory, he used to think all day about how to keep his customers and how to recruit other customers, but everyone's technology, raw materials and labor costs are almost the same, and the deadlock is difficult to break

because the stitches of the products made by the sewing robot are very standard, and the thread ends are gone, the high-quality and low-cost products moved the customer, helping him grab an extra 30000 pairs of orders every month, and the investment of 500000 yuan will be fully recovered in three months

if one of the two enterprises that also make shoes reduces the price by 2 yuan because of the reform of technology, it can firmly hold the source of customers in its hands, and the other has no market. Yin Xiaolin explains the competitive changes brought about by technology

in the field of fine manufacturing such as electronic products, the advantages brought by advanced equipment are more obvious

Jiang Shiyuan is the deputy general manager of Dongguan Jusheng plastic electronics. One of his tasks every day is to receive visitors. Since the introduction of industrial robots in 2008, the precision of the mold products has been greatly improved. Many peers have come to ask Jisheng for help in processing. This part of the steel bar bending experimental machine accounts for one third of the factory's output

after tasting the sweetness, Ju Sheng spent 100million yuan to introduce foreign equipment to develop an intelligent precision mold flexible manufacturing system for the manufacturing of the most precise mold parts. Jiang Shiyuan proudly said: the processing accuracy can be accurate to 3 microns, and the error is much smaller than that of hair

immediately, Jusheng received the mold order for the iPhone connector plug for the first time. Such small and high-precision molds are generally made by foreign manufacturers and few domestic cutting-edge enterprises. This is the first time to choose Dongguan enterprises. Jiang Shiyuan said that when foreign manufacturers visit and inspect, the robot production line can increase a high impression score

the new production line also enabled Jusheng electronics to enter the fields of medical devices, led molds and so on, winning orders from major domestic customers. Jiang Shiyuan revealed that at present, Jusheng's domestic orders are only 30% - 40%, and it is expected to reach 60% - 70% in three years

at present, Jusheng electronics plans to promote the intelligent precision mold flexible manufacturing system to more than 10 enterprises, with an output value of more than 10million yuan based on 1million yuan per system. While selling products, Jusheng has also become a technology exporter

the power of whole process management and control

in addition to the hardware substitution of machine replacement, informatization means can also achieve the same effect, especially effectively supporting Dongguan enterprises from global design and manufacturing in Dongguan to design and global manufacturing in Dongguan

Dongguan shoe industry tycoon Huajian group is a typical example. According to Zhang Huarong, chairman of Huajian, the processing and production links of Dongguan footwear industry should be transferred to the mainland and even overseas, while order receiving, research and development, procurement and so on will remain in Dongguan. At present, Huajian has four production bases in Dongguan Huabao, Dalong, Ganzhou, Jiangxi and Ethiopia

relying on a set of information management system, Huajian has realized the remote collaborative design, manufacturing and enterprise management, and can carry out synchronous processing and production. It can be said that from pre-sales customer consultation, to product research and development, raw material procurement and final goods collection, the headquarters management can control the production of each batch of orders on and iPad, and the phenomenon of late delivery has never appeared again. Liu Shiyuan, director of Huabao shoe industry informatization, a subsidiary of Huajian group, said

Hu Wei, general manager of Dongguan Kingdee management software company, believes that at present, most large and medium-sized enterprises in Dongguan have achieved information management represented by financial management system, which was born in the 1960s, and are moving towards ERP, which appeared in the 1990s. (ERP is an enterprise resource management platform integrating basic data, human and material resources, hardware and software.)

but it's a pity for Hu Wei that most small and medium-sized enterprises in Dongguan still suffer from inadequate Informatization: backward production planning and control mode, extremely poor enterprise adaptability, inaccurate cost calculation methods and a series of precipitation for a long time

a Taiwanese businessman once complained to Hu Wei that every time companies participate in exhibitions at home and abroad, they need to prepare at least six financial personnel to be on standby in the office. When a customer inquires and negotiates an intended order, the six financial departments will get busy ahead: they have to quickly calculate the quotation range, whether this batch of orders can be accepted, and so on

when you are still waiting, others hold the terminal to decide whether to accept the order in minutes. If you are a customer, which one will you choose? Hu Wei asked

the change of smart manufacturing not only occurs in the factory workshop, but also outside the workshop. With the help of information technology and IOT technology, smart manufacturing means are becoming a powerful support for the new operation mode of enterprises

in the clothing industry, soyute, urban beauty and other brands have attracted much attention because they focus on both ends of the smile curve. Since 2012, when the clothing industry's inventory difficulties and store closures have hit physical stores, urban beauty is expanding at a high speed with the 10000 store plan

Sha Shuang, vice president and chief information officer of urban beauty, said that the phenomenon of high inventory shows that the business model based on channels is gradually declining. Under the guidance of this model, it is difficult for enterprises to determine production based on demand, but they plan to determine production, but products are only sold to franchisees, and enterprises do not know whether products are sold to consumers. If the product cannot be sold, it will become

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