Want to "gun and gun"? Enterprise transformation intelligent manufacturing, we must pay attention to...

In the past 40 years of reform and opening up, China's manufacturing has risen rapidly and become a beautiful international business card, but it has also entered a crossroads where transformation is necessary. Under the multiple pressures inside and outside, the transformation of "smart manufacturing" has become the active choice of more and more manufacturing companies, and a large number of enterprises rely on transformation to revitalize their vitality.

At the 14th China International Manufacturing Forum held in Tianjin recently, industry insiders said that China's manufacturing industry is facing "high-pressure and low-end", high-tech ecological industry has not yet formed, and professional and technical talents are lacking. The industry is facing the risk of “hollowing” in the process of “intelligent manufacturing”. At the same time, the level of digitalization of China's manufacturing industry is uneven, and it is necessary to be alert to the blind accumulation of intelligent hardware and industrial software, bringing problems such as “data islands”.

Traditional manufacturing companies are actively transforming

In recent years, in the fierce market competition, a large number of traditional manufacturing enterprises rely on the transformation of "smart manufacturing" to revitalize.

Hu Guangmin, chairman of Shandong Huaxing Textile Group Co., Ltd. told reporters that Huaxing Textile has a history of 30 years. In the early days of reform and opening up, “short economy” helped enterprises to earn “first barrel of gold”; with the market saturation, enterprises can still improve Management is further developed; while the current market homogenization competition is severe, and the production capacity is seriously overcapacity, only transforming intelligence can survive.

“The cotton spinning industry has many processes, difficult management, unstable production efficiency and poor digital foundation.” Hu Guangmin introduced that the company combined with 30 years of production experience, together with professional software developers and equipment manufacturers to build an intelligent system to transform the traditional workshop. Into the "smart spinning production line"; the business process is driven by "full data" to achieve the "order-driven" production model.

“After the transformation of intelligent spinning, our superior product rate has increased by nearly 30%, the efficiency has increased by 30% to 40%, the production cost has been reduced by 20%, the working capacity of Wanling has been reduced from 80 to 15 and the order delivery cycle has been greatly shortened. Hu Guangmin said.

Huaxing Textile is a microcosm of the active transformation of China's textile enterprises. According to Yan Yanwei, deputy director of the Information and Statistics Department of the China National Textile and Apparel Council, in recent years, some spinning companies have taken the lead in building a digital production line with a high level of application, forming a tie-tie effect. At present, there are dozens of enterprises in the construction of spinning digital workshops in China, and the new projects have basically reached the level of digital workshops. The construction of the digital workshop has greatly increased labor productivity, and the amount of work for ten thousand spindles has dropped to about 15 people.

Similar to the cotton industry, there is also a bearing manufacturing industry. As an important part of the industry, bearings are called "joints of manufacturing."

"In the past, the high-end part of China's bearing market was monopolized by foreign giants, and thousands of bearing companies of independent brands competed at low prices in the low-end market." Meng Wei, chairman of Wafangdian Bearing Group, told reporters that as the first industry in China. The old state-owned enterprises of the bearings, after continuous technological transformation, their key manufacturing equipment has reached the world's advanced level, and the level of intelligence has been significantly improved. With the opportunity of “shuffle” in the international market, Wazhou acquired the 100-year-old KRW company in Germany in 2013.

Meng Wei introduced that with the acquisition of KRW in Germany as a starting point, the Wazhou Group began a large-scale “acquisition of the external brain”. Not only have a number of technology centers been established in Europe and the United States, but also local talents have provided intellectual support for the “intelligent manufacturing” transformation of the tile axis. Today, Wazhou Group not only becomes the leader of the domestic bearing market, but its high-end products are trusted by many internationally renowned manufacturers.

The development of "smart manufacturing" has also made the national automobile brand deeply feel that "guns and guns are changed", and they are more confident in the face of market competition.

Yin Tongyue, chairman of Chery Automobile Co., Ltd., believes that China has the world's largest auto market, the largest number of Internet users, and the most open-minded consumers, giving car manufacturers a rare opportunity. In terms of "smart manufacturing", Chery spent six years overthrowing the original development system, rebuilding the platform and modules, reducing the development cycle by half, and reducing development investment. Chery Automobile has developed from the initial manual production line, semi-automatic production line and fully automatic production line to the current digital intelligent production line. The effects of digital factory, virtual manufacturing, intelligent logistics and production cloud platform are obvious.

Some manufacturing companies are actively transforming “smart manufacturing” through lean management. Shi Qingsong, deputy general manager of CRRC Puzhen Vehicle Co., Ltd., introduced the company's transformation of lean production and lean logistics, which greatly improved the efficiency of production and logistics, saving more than 10 million yuan per year. The company is about to build a “dictionary” virtual electronic data warehouse, which stores and manages data according to functional modules. "In the future, all storage, query and retrieval can be realized by QR code." Shi Qingsong said.

At the same time, a group of Chinese enterprises are exploring the use of “sharing economy” to transform traditional industries into “intelligence”. Liu Bin, deputy general manager of Tianjin Huizhi Ruida Technology Co., Ltd. believes that the garment manufacturing industry is undoubtedly a traditional industry, but through the network platform to achieve the "capacity sharing" of the garment manufacturing industry, open the channels for ordinary consumers to contact the manufacturing industry, the traditional industry It can also be revived.

"Smart Manufacturing" started well

Industrial ecology has not yet formed

The industry believes that China's manufacturing transformation "smart manufacturing" has a good start, but it also faces multiple challenges.

Zhu Hongren, executive vice president and chairman of the China Entrepreneur Association, believes that the deep integration of the new generation of information technology and manufacturing has brought profound changes to the R&D, manufacturing, industrial form and business model of the manufacturing industry. At present, China has initially formed the overall layout of intelligent manufacturing work with the guidance of “Made in China 2025” on “Developing Guiding Opinions on Deepening the Integration of Manufacturing and Internet”, Intelligent Manufacturing Engineering, Pilot Demonstration and Standard System Construction; The multi-level system promotion pattern of guidance, local linkage promotion, industry reinforcement coordination and enterprise active practice. The four major intelligent manufacturing industry clusters in the Pearl River Delta, the Yangtze River Delta, the Bohai Rim and the Midwest have gradually formed, and a number of industries have formed intelligent manufacturing development alliances.

Zhu Hongren introduced that in 2017, 19.3% of the country's enterprises have achieved comprehensive integration, and 22% of enterprises have good conditions for business integration, and it is expected to enter the stage of integration and upgrading in the short term. 63.2% of the enterprises popularized the digital R&D design tools, 34.1% of the enterprises realized the numerical control of key processes, 30.1% of the enterprises realized networked collaboration, 22.3% of the enterprises carried out service-oriented manufacturing, and 6.7% of the enterprises carried out personalizedization. custom made. A number of smart manufacturing pilot benchmark projects have been produced. After intelligent transformation, the production efficiency has increased by an average of 30%, the operating costs have been reduced by more than 20%, and the product development cycle has been shortened by an average of 35%.

Huo Jinjie, president of IDC International Data China, believes that in recent years, digital transformation has reached a high consensus in China's manufacturing industry. 84.9% of the respondents indicated that they are undergoing digital transformation, especially using digital technologies and capabilities to drive organizational business model innovation and business ecosystem reconstruction, leading them to smart manufacturing. By 2020, 40% of China's manufacturing companies will gain new business value through integration of supply chain, plant operations, and product and lifecycle.

At the same time, the industry generally believes that China's transformation of "smart manufacturing" process is also facing severe challenges.

First of all, the international competition is fierce, which makes China's manufacturing industry face “full pressure” in the middle and high-end industries.

Zhu Hongren, professor of Shanghai Jiaotong University, Dong Ming and other industry insiders believe that at present, the United States, Germany, France and other programs have promoted the development of the manufacturing industry, aiming to establish new advantages through the "return of manufacturing industry." The Industrial Internet and Advanced Manufacturing 2.0 proposed by the United States focuses on getting hardware from software and trying to activate traditional manufacturing with the Internet. The “Industry 4.0” proposed by Germany focuses on getting through software to software and using “information physics system”. Production equipment gains intelligence and establishes a sound industrial ecosystem. At the same time, developing countries such as Mexico, Vietnam, and India have accelerated the transfer of industries and technologies, which has brought about a "two-way squeeze" situation in China's high-end and low-end manufacturing industries. China's manufacturing industry is under pressure. .

Secondly, the “low-end lock” has caused China to develop “intelligent manufacturing” with the risk of “hollowing”.

Zhu Hongren pointed out that with the continuous advancement of China's intelligent manufacturing, the demand for high-end equipment needed for intelligent transformation will grow rapidly, and there is no smart equipment provider with global influence in China, and the huge demand for intelligent manufacturing has become a minority. Foreign core technology has a feast for enterprises, and it is difficult to transform into the real risk of China's high-end equipment upgrade development strategy opportunities. At present, most domestic mechanical parts companies can only produce low-end and mid-range products, and they are still unable to meet the needs of high-end intelligent equipment development. Core components, components and key intelligent equipment mainly rely on imports, and intelligent manufacturing is in danger of “hollowing”.

He believes that the core hardware and software technology accumulation of China's equipment manufacturing enterprises is seriously insufficient. The mainstream industrial software such as CAD and CRM are almost dominated by European and American enterprises. The enterprises and scientific research institutions that can develop precision control components and intelligent manufacturing basic software systems in China寥寥Countable, domestic high-end products such as CNC machine tools and robots still use a large number of foreign key components and software systems. At present, multinational software giants are accelerating the layout of intelligent manufacturing production control and operating systems, while the key infrastructure components and operating systems and industrial software required by China's intelligent manufacturing equipment industry are seriously lacking, and become a "hard injury".

Third, a good smart industry ecology has not yet formed, and it is easy to fall back into the “technical dependence trap”.

Zhu Hongren and other industry insiders believe that it is difficult for a single system solution provider in the field of traditional industrial control or information technology to meet the needs of enterprise intelligent transformation, and it is necessary for suppliers in the industrial field, information field and industry service field to collaborate and innovate. .

In general, China's intelligent manufacturing ecosystem has not yet been formed. The pace of integration and development of industrialization, information technology and industry services has been slow. It has not yet cultivated a group of suppliers with strong international competitiveness and ability to integrate the entire system. . Leading companies in developed countries are rapidly forming smart manufacturing products and solutions based on their technological advantages, and are aggressively entering the Chinese market. If the response is not good, China may once again fall into the "technical dependence trap" of "backward-introduction-and backwardness" in the field of intelligent manufacturing.

Fourth, the level of digitization and lean management capabilities are uneven, and the “information island” dilemma is easy to emerge.

The IDC survey shows that Chinese manufacturing companies are generally experiencing the lack of digital skills and talent resources in the digital transformation. Huo Jinjie believes that the rise of emerging technologies and architecture has alleviated the traditional IT infrastructure problems in the industry. Although many companies have achieved certain information and data transformation maturity, many companies still face “information islands”.

Wang Hongyan, chairman of Aiborui Group, believes that 50% to 60% of enterprises in China are in the industrial 2.0 stage, 30% to 40% are in the industrial 2.0 to industrial 3.0 stage, and less than 5% are in the industrial 3.0 level. China's manufacturing industry is facing the dual challenge of Industry 2.0 remediation and Industry 3.0 to Industry 4.0. On the road to implementing intelligent manufacturing, the biggest "black hole" is to ignore the basic management improvement, only to upgrade hardware devices and information software, and form an "information island."

Zhu Hongren believes that many enterprises still have many confusions and misunderstandings about intelligent manufacturing, path selection, key transformation direction, and implementation strategies. "At present, everyone pays great attention to the technical characteristics of intelligent manufacturing, that is, various advanced technologies and system applications, while ignoring the most basic driving force of intelligent manufacturing." Zhu Hongren said, "The transformation of the entire industrial operation mode requires enterprises not only need software. , technical equipment, and more needs the company's operating model, management model to make profound changes."

Filling the short board to build a smart industry chain

Wang Yulin, dean of the China Academy of Ordnance Science, and other industry insiders believe that "smart manufacturing" is causing major changes in the manufacturing development concept and manufacturing model. The integration of modern information technology and manufacturing, manufacturing and service integration should improve the ability of services, product manufacturing, and the ability to quickly meet the individual needs of consumers, so that manufacturing can regain the competitive advantage.

The insiders suggest that we should vigorously develop "smart manufacturing" and realize the historic leap from China to "China's wisdom".

First, establish a system of innovation and innovation. Zhu Hongren believes that advancing smart manufacturing means that enterprises must carry out systematic changes, including profound changes in manufacturing thinking, as well as deep integration of industrialization and information construction, as well as disruptive innovations in organizational structure, operational models and management methods. It even includes the re-adjustment of labor, employee skills, and job structure. "If smart manufacturing is a wave that will profoundly affect China's manufacturing industry, then the change of manufacturing thinking is the primary, the lean thinking of employees and the impulse of innovation are the support, the upgrade of equipment and systems is the foundation, and all the links are indispensable."

Secondly, complement the hardware, software, and ecological shortcomings to build an intelligent manufacturing industry chain and innovation chain driven by market demand. The insiders suggest that China should establish the "I am the main" smart manufacturing development ideas, give full play to the domestic market demand for consumer demand upgrades and various industries intelligent transformation needs, aiming at high-end technology, equipment and software systems, led by the industry Enterprises take the lead, the government supports, use the market mechanism to form an innovative industry alliance, and jointly break through the key common technologies, equipment and software systems required for intelligent manufacturing, and promote the "high-end equipment manufacturing and software industry" in China to achieve "curve overtaking." Give full play to the role of the main body of the enterprise, based on the reality of the coexistence of Chinese industry 1.0, 2.0, and 3.0, and encourage enterprises to explore the transformation path in combination with reality.

Third, fully leverage the information technology such as “Big Data” to develop dividends. Wang Yulin believes that China's manufacturing transformation "intelligent manufacturing" needs to be closely integrated with "Internet +". It is recommended to further integrate production factors through the Internet, promote innovation and collaboration among enterprises, improve design production and service capabilities, optimize matching resources, reshape product structure and enterprise structure; make full use of the information contained in big data for analysis and establish comprehensive standard parts. , component knowledge base, and establish a shared use mechanism.

Fourth, to improve enterprise management as the starting point, to achieve technological innovation and management innovation "two-wheel drive." Wang Hongyan believes that the development of intelligent manufacturing must rely on the two wheels of “two-wheel drive” of technological innovation and management innovation to optimize the manufacturing process through lean management, thus minimizing production costs and maximizing enterprise efficiency. Bai Yingzi, director of the Enterprise Reform Bureau of the State-owned Assets Supervision and Administration Commission, believes that lean management as the cornerstone of digitalization and then intelligence is also the only way to “go global”. Bai Yingzi pointed out that multinational companies in the United States, Japan and other countries have successfully expanded overseas. The first is that their management is sufficiently lean to reduce costs, improve efficiency and added value, and enhance the core competitiveness of products. Some equipment manufacturing enterprises have repeatedly hit the wall in the process of “going out”. In addition to the lack of system solutions, the quality of more important products is not good enough.

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