On February 25, the 2019 Intelligent Manufacturing Enterprise Training and On-site Exchange Conference jointly sponsored by the Municipal Industry and Information Technology Bureau and the Municipal SME Bureau was held at the Guanlan International Conference Center in Lingang District. Weihai Adike Electronic Technology Co., Ltd. sent representatives to participate At this meeting, we had friendly exchanges with Secretary General Yu of Weihai Intelligent Electronics Association and President Zhang Guangrui, Executive Dean of Shandong Intelligent Manufacturing Research Institute, hoping to provide more exquisite products and services in the intelligent transformation of enterprises.
At the exchange meeting, the three companies of Vida Group, Klett Fan, and Expansion Fiber showed up to share their useful exploration and vivid practice in intelligent transformation.
"This is also a concrete action for us in the transformation and upgrading of enterprises, promoting the high-quality development of the industrial economy, and forcing enterprises to solve the problems of labor difficulty and labor cost. By setting up a platform and solving problems for enterprises, we help enterprises solve transformation puzzles and mobilize enterprises to vigorously promote. Intelligent transformation to accelerate the conversion of new and old kinetic energy." said the main person in charge of the Municipal Bureau of Industry and Information Technology.
Machine substitution can save more than 10 million yuan in labor costs
On February 25th, when I walked into the new workshop of Weida, it was impressive that 2 automatic assembly lines and 21 automatic assembly lines, and the products were quickly formed on the assembly line. On both sides of the production line, only a few employees maintain it.
"We didn't have this posture before. These three or five people are not enough for one production line." Wang Hongtao, director of the engineering department of Shandong Weida Machinery Co., Ltd., looked at the prospects and sighed.
Before 2013, the Vectra workshop still used the old-fashioned production lines for production, assembly, inspection...Each production line was surrounded by six or seven workers, and human participation was indispensable in every link. "Manpower is definitely indispensable, but under this production model, it is difficult for the company to make breakthrough progress in its efficiency." Wang Hongtao said.
These accustomed lives have quietly changed since 2013. That year, the wind of the conversion of new and old kinetic energy blew into Vectra. Yang Mingyan, chairman of Weida Machinery Co., Ltd., took the lead and acquired Jinan Machine Tool Co., Ltd., which was once known as one of the "18 Arhat Plants" in the domestic machine tool industry.
Jinan Yiji regained its vitality under the banner of Weida Machinery. Since then, Vectra has boldly embarked on the road of intelligent manufacturing, acquired companies such as Suzhou Demeco, and quickly grew into one of the better intelligent manufacturing system integrators in China; actively implemented the machine substitution project, and the transformation and upgrading of the company became more and more. Go wider.
The data records the pace of Vectra's transformation: the construction of 50 intelligent automated production lines, the original 110 traditional production lines employ 715 workers per shift, and now there are no more than 65 workers per shift, and annual labor costs can be saved by more than 10 million yuan.
Nowadays, in the automated assembly intelligent production line of Weida Machinery Headquarters, more than a dozen parts are placed one after another, and the robot hands automatically grab the parts and automatically assemble them. Each production line now only uses one person.
"Enterprises go to the cloud" to create a "transparent factory"
"The transformation to intelligent manufacturing is the inevitable development of the enterprise, and it is the general trend." "Intelligent manufacturing is not only as simple as introducing a set of equipment and production lines, but more importantly, changing ideas and changing models."... February 25, Weihai Klett Sheng Junling, general manager of Feier Fan Co., Ltd., took the stage to speak with the topic of "Thinking about Tradition and Innovation", and talked about the major events of the enterprise's wisdom transformation.
Looking back on the road to transformation and upgrading, Sheng Junling summed it up with five words "growth pain".
2015 is an important node for enterprise transformation. In the previous four years, the labor costs of enterprises have risen rapidly, the shortage of talents has become increasingly obvious, and the prices of raw materials have risen, and corporate profits have always been unable to rise.
At that time, Sheng Junling was exposed to the concept of National Industry 4.0. She deeply understood that if she did not take this "high-speed train" of intelligent manufacturing and improve the level of intelligence of the production system, the company would inevitably be eliminated by the market.
How can I turn it? Just as Sheng Junling was wandering, a turning point came.
The former Municipal Commission of Economy and Information Technology carried out the "Introducing Intelligence and Strengthening Enterprises" enterprise diagnosis activity and organized a group of enterprises to go out to visit and inspect. Taking this opportunity, Sheng Junling followed the department to learn from the experience, and even went to the United States to participate in the "Internet +" training, learning from each other's strengths. , Not only strengthened her determination to transform, but also allowed her to find a new path for transformation and development.
Introducing digital production workshops, inviting foreign expert teams to settle in, integrating product information and data, and improving intelligent services... A series of digital transformation and upgrading have given the company a new lease of life.
"At that time, the company's annual profit was 27 million yuan. I invested 40 million yuan. It was painful, but I had to do it, and even borrow money to do it!" Sheng Junling said.
Not only is he "ruthless" in investment, Sheng Junling is also striving for excellence in lean production. "In the past, workers made money on a piecemeal basis. For example, if a worker is required to make 100 pieces a day, he can make 500 pieces. The quantity is up, but what about the quality?"
In response to this problem, last year, the company specially hired Japanese lean production experts to conduct lean consultations on the existing problems of operation management, production management and quality management in the process of intelligent upgrade. As soon as the experts came, they threw away 10 containers of "garbage". These "garbage" are products of substandard quality.
Without breaking or standing, Sheng Junling also uses "Enterprise Cloud" to realize intelligent production and open up the enterprise data flow from order to product delivery and after-sales operation and maintenance.
More than 300 workers can see who is doing what and what the progress is every day, and it is clear which material is used where, to ensure the high quality and traceability of the products. "Now, whoever owns our products has the market advantage." Sheng Junling is full of confidence.
While building the big data platform, the company has also built a "smart cloud factory" to re-adjust the company's production layout. At present, it has introduced painting, cutting robots and other equipment.
This bottom-up intelligent improvement has increased the utilization of core data by 30%, increased production capacity by 30%, and saved 70% of the company's operating costs. Klett Fan has gradually transformed from a market follower to a market leader.
"Baby" turned "Leader Goose"
"Is your production model reproducible?" "The benefits of smart manufacturing really far outweigh the costs?" ... On February 25, in the development of fiber, dozens of entrepreneurs from various districts and cities watched and asked questions.
In 2005, the domestic carbon fiber industry was in the ascendant. "The products on the market were immature at that time, and we were less utilitarian, so we could put our minds on the development of the first batch of products." said Cong Zongjie, general manager of Weihai Development Fiber Co., Ltd.
It took five or six years to develop and put a single product into production.
Because of the long product development cycle, the market has strict requirements on product strength and stability. But Cong Zongjie did not dare: "Our new products apply intelligent manufacturing!"
In 2013, expanded fiber to participate in a major scientific research project-the research and development of the second-generation T-800 carbon fiber products. To this end, Expansion Fiber not only mobilizes all staff to participate in product development, but also introduces a new MES manufacturing execution system. The experience of front-line workers and the sophisticated data feedback of the intelligent system have gradually formed a line of research and development ideas.
In the past, it is not the frontline workers who are common in the production plant, but the staff responsible for reading meters and collecting data. But now, there is no one beside the water meter and other instruments. According to Cong Zongjie, this is due to the newly introduced new MES system. Various data can be accurately calculated at all times, and abnormal data can be found in advance.
For this item alone, although more than 10 million yuan has been invested, the production cost has been greatly reduced, and the product qualification rate has been greatly increased. Today's expanded fiber has become a leader in the domestic carbon fiber industry. Its main products, T-300, T-800, T-1000, etc., occupy a large share in the domestic military and aerospace fields.
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