In August, new cotton is about to enter its maturity stage, but the cotton spinning market is still sluggish and deserted. Many yarn company owners lamented: “Will there be spring in the yarn market this year? The difficult days are so difficult that we can hardly survive.”
In 2020, affected by the COVID-19 epidemic, most textile companies have experienced sluggish production and sales and difficulty in capital turnover. Some textile companies have stagnated. However, in the overall sluggish market environment, we It can also be seen that there are still spinning companies whose orders have been scheduled for two months, and there are still spinning companies that continue to innovate and develop new yarns to further open up the domestic market. So, how do these companies do it?
Zhengkai New Materials:
Intelligent traceability system ensures rapid response
Since this year, due to the impact of the epidemic, the overall market of the textile industry has shrunk, but in the textile industry of Shandong Zhengkai New Materials Co., Ltd. located in Zhong District, Zaozhuang City There are 200,000 spindles of yarn in the smart factory, and functional yarn orders have been scheduled for two months.
Shandong Zhengkai New Materials Co., Ltd. Product R&D Center Director Wang Yanyong said that the full order schedule is due to their rapid market response ability of “small batches and multiple varieties”. The order-taking model of “multiple varieties and small batches” allowed Zhengkai to successfully break through and receive orders. However, the probability of errors in the production workshop also increased accordingly. “There are dozens of varieties being produced in the workshop. With so many materials, if the wrong barrel is delivered, it will be a big quality accident, and the economic loss can be millions of yuan.” The first branch of Zhengkai New Materials Co., Ltd. Factory director He Shengjun said.
In order to solve this problem, Zhengkai New Materials Co., Ltd. has launched China’s first intelligent barrel traceability system, which realizes the tracking of tooling equipment by installing radio frequency identification devices and smart chips. Product information interconnection.
Taking variety identification as an example, Shen Delong, director of the Information Department of Zhengkai New Materials Co., Ltd., said that in the past, it was necessary to find out the yarn varieties needed by customers from the warehouse for production. Relying on existing experience, but because of the wide variety of yarns, “looking for a needle in a haystack” is not only a waste of time, but also prone to mistakes. Sometimes, after a batch of yarn is produced, it is discovered that it is not the variety that the customer needs. Work equipment is now equipped with FRID smart chips, which can record machine variety information in real time. “Each of our barrels has a unique ID card information, which is identified through the white box. When the materials carried by the tooling are put on the machine, the system verification can be automatically triggered. Once the materials on the machine do not match the actual production varieties, , the machine will automatically alarm and shut down. In the past, we would look at each barrel one by one, but now we can detect problems in time as soon as the red light on the barrel turns on. In this way, we can avoid mis-weaving from the source and stabilize the product. Quality.”
This year, Zhengkai New Materials Co., Ltd. has launched a new round of technological transformation, installing self-levelling and online detection devices, and through spinning production The data management platform controls quality and the number of employees is reduced from 4,000 to 800. “Our investment in technological innovation accounts for about 1/3 of the output value, and we increase added value by developing some high-end, functional and fashionable yarns.” said Ding Changjin, deputy general manager of Zhengkai New Materials Co., Ltd. FRID intelligent identification, material traceability, online quality inspection and control… Here, with internationally advanced automation equipment, smart spinning has moved from a dream to reality.
Yudahua Group:
Stabilize product quality and eliminate returns
“In January this year, our yarn orders were already scheduled to June. The products were sold out as soon as they came out, and the current inventory is not to 10 days,” said Wei Jiang, general manager of Yudahua Textile and Garment Group Company. After building an intelligent spinning workshop, the product quality of this traditional textile company has been greatly improved, and the supply of products exceeds demand.
In the Yudahua spinning workshop, rows of spinning machines roar, tens of thousands of spindles rotate at high speed, transport, Roll changing, splicing, inspection…all processes are carried out in an orderly and automatic manner. There are only a few workers in the huge workshop. It is not the traditional impression of a “ten thousand people factory” at all. In a conference room behind the workshop, there is a large screen, which clearly displays information such as the number of orders in the workshop, how much yarn is spun, how much electricity is used, etc. A large number of sensors, industrial robots, AGV handling trolleys, etc. are also installed in the workshop, creating a unique new model of spinning production. Most processes do not require manual participation, and night shifts can be unattended, turning it into a “black light factory.”
It is reported that in 2018, Yudahua invested 330 million yuan in intelligent transformation to build a “100,000-spindle full-process intelligent spinning project” and introduced domestically independently developed intelligence. Systems such as spinning, smart logistics, and smart warehousing have greatly improved production efficiency. “In the past, textiles were a labor-intensive industry. For example, when transporting yarn between different processes, workers carried it on their shoulders, which was very labor-intensive. Now all transportation robots are used, which is not necessary at all.�Requires manual operation. “Wei Jiang introduced that after the intelligent transformation, the number of workers in the 10,000-spindle yarn production line was reduced from 53 to less than 15 in the past, a reduction of 71.7%, and the operating cost was reduced by 14.85%.
The textile industry has long processes and flexible production, and it is very difficult to achieve intelligent manufacturing. This intelligent transformation is the largest one-time equipment investment in the history of Yudahua. With the investment in the new production line, Yuda Hua has realized all-round intelligent sorting and collection of materials in all processes and parts, which has greatly improved production efficiency, reduced operating costs, and achieved traceability of product quality. In the past, product labels were manually written on paper, which was easy Lost, quality problems are difficult to trace. Now, many equipment in the workshop are equipped with chips. Through the intelligent quality traceability system, it is easy to find the root cause of the problem. “After the workshop transformation, we produced a total of 5,000 tons of yarn, and there were no returns or claims.” This situation used to occur dozens of times every year. “Introduced by Wei Jiang.
Expand production capacity in good times and focus on technological innovation in bad times. At present, Yudahua has gradually formed a raw material trade-spinning-weaving-printing and dyeing- Clothing, a complete industrial chain layout from fiber to fashion, continuously enhances the competitiveness of its own products.
Hengfeng Group:
Comprehensive innovation strategy to break through core technology
In June, at the China Cotton Textile Industry Association held In the yarn fashion trend product recommendation activity, the “environmentally friendly degradable yarn – polypropylene” produced by Linyi Hengfeng Textile was shortlisted for the “2020/2021 China yarn fashion trend products” list.
“The core point of Hengfeng’s success in realizing the leap from traditional industry to new industry is the in-depth implementation of a comprehensive innovation strategy led by scientific and technological innovation. It has a series of unique and distinctive For new and special products, we continue to increase our technological innovation capabilities, continuously develop new products, quickly achieve mass production, use new products to occupy large markets, and seek benefits from high-end products, thereby accelerating the conversion of old and new driving forces and cultivating new profit growth points. “Sun Chuanfang, Chairman of Dezhou Hengfeng Group, said that Hengfeng’s research and development has never stopped.
Sun Chuanfang believes that the main challenges faced by enterprises in terms of transformation and upgrading are Lack of professional knowledge and professional talents. In this regard, Hengfeng has increased investment in science and technology on the one hand and increased the research and development and application of new technologies, new products, and new processes; on the other hand, it has cooperated with well-known companies and scientific research institutions in the upstream, midstream and downstream of the industry. Establish a cooperative relationship, borrow wisdom and strength, and make breakthroughs in core technologies.
“In order to solve the key technical issues in achieving industrialized production of plant-dyed fibers, we have joined forces with Qingdao University and Hangcairun Technology Co., Ltd. , jointly formed a research and development team and established the Shandong Hengfeng Plant Dyeing Industrial Production Technology Research Institute. At the same time, it cooperated with Donghua University to establish a corporate academician workstation, and established a plant dyeing industry alliance with upstream and downstream companies in plant dyeing to jointly develop plant dyed clothing products. Sun Chuanfang introduced that the textile and garment industry was included in the four traditional industries, which clarified the two-wheel drive of new models and new technologies, extended the industrial chain in both directions, and promoted the textile industry to be high-end, green, capitalized, and clustered. The development idea of transformation. This is very consistent with Hengfeng’s development reality. Hengfeng Group has grasped the differentiated development strategy and is at the forefront of the country in the research and development and production of new yarns. The new fiber yarns were quickly developed and mass-produced, allowing Hengfeng to Hengfeng Group has seized the right to speak in the market time and time again.”
In the process of development, Hengfeng Group has created a unique “chairman unit” model and has established operations in Ningxia, Sichuan, Yunnan, Xinjiang and other places have stepped up the pace of expansion. There are currently 48 chairman units, which is equivalent to the construction of 48 Texas Hengfeng stores, forming a unique “Hengfeng Speed” and “Hengfeng Model”. “Technological innovation and model innovation are the two wings for an enterprise to take off. Without management and model innovation, technological innovation cannot be implemented. We have proposed the goal of ‘second entrepreneurship’ and started to promote the integration of governing units linked by property rights to make it a Economic independence, clear property rights, more operational autonomy and corporate decision-making power, and the implementation of a professional manager system under the new management structure to better stimulate the creativity and initiative of each unit. In the future, Hengfeng Group will We will work hard on the four main lines of capital operation, product research and development, Hengfeng Business, and consulting services to achieve the two-wheel drive strategic goal of ‘industry + capital’, and strive to create more than two companies listed on the Science and Technology Innovation Board by 2021 to promote Hengfeng Group To move towards an international group.” Sun Chuanfang said.
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