From “managing workers” to “managing data” – the intelligent transformation of a textile factory

In the workshop, “5G+Ethernet machine vision” testing equipment is used to transmit production images in real time. AGV logistics robots shuttle among them. Workers can learn about the production of each machine just by staring at the big data platform. Efficiency and trend of defective products – In the warp knitting workshop of Huayu Zhengying Group located in Jinjiang, Fujian, there is no smell of sweat and noise in the air, replaced by the smell of technology.

“Ten years ago, factories were full of heavy machines and busy workers. Today, with intelligent equipment and a steady stream of data, corporate decisions are more scientific Now, the workshop is much brighter.” Su Chengyu, CEO of Huayu Zhengying Group, said with emotion.

Su Chengyu is one of the earlier batch of textile entrepreneurs in Jinjiang to transform. In 2013, the local government convened a meeting of entrepreneurs to encourage everyone to explore digital transformation. At that time, Jinjiang, which started out as a traditional manufacturing industry, was surrounded by cumbersome assembly lines and tireless workers, and the concept of “digitalization” was still vague.

After the meeting, Su Chengyu came up with the idea of transformation. At first, his idea was very simple – “It would be great if there was a machine that could replace people looking at the machine.” In 2013, with the help of the local government, the company and The scientific research team of the university joined hands and the first step was to develop a “visual inspection system” to use sensor inspection to replace the traditional “man-on-machine”.

“The biggest concern in innovation is the imbalance between input and output.” Su Chengyu said that the company took many detours at the beginning and invested a lot of money in transforming the “iron knot”, which not only failed to help, but also reduced the yield rate. . Fortunately, in the early stages of research and development, the Jinjiang Municipal Government borne more than 80% of the company’s research and development expenses through project funds, and also organized everyone to visit and study in other places, which solved the worries of the transformation.

After four years of repeated testing, this detection system was successfully implemented. As a result, the operating efficiency of the warp knitting machine has increased from 70% to 85%, and the yield rate has also climbed from 85% to 90%. “The factory produces more than 50,000 tons of products a year, and every one percentage point increase means a considerable sum of money. profit.” Su Chengyu was encouraged.

After “tasting the sweetness”, Huayu Zhengying Group has carried out a number of technical research projects with university research institutes around intelligent logistics, intelligent warehousing, intelligent cloth searching, etc. They have brought huge returns to the company. Today, the company’s sales are increasing by more than 20% every year, the product defective rate has been reduced from 25% to 5%, and the company’s sales radius has also expanded from the original domestic market to more than 40 countries and regions around the world. .

In Jinjiang, a large county with a private economy, with the implementation of AI, industrial Internet, 5G and other technologies, smart factories have sprung up like mushrooms after a rain, and many entrepreneurs are actively embracing digitalization. According to reports, currently more than 90% of Jinjiang’s companies are “connected to the Internet” and more than 1,100 companies have migrated to the cloud. It has been selected as one of the top ten counties in the country for industrial Internet development.

What impressed Su Chengyu the most was that his colleagues no longer worked behind closed doors, or even just focused on the shoe and clothing trade fairs. Instead, they actively participated in activities such as the Digital China Summit and found more ideas for their smart factories through “charging.”

　“In recent years, the technological innovation ecology, technological innovation capabilities and levels of private enterprises have been greatly improved, which has contributed to the high level of the industryQualitydevelopment has injected strong innovative vitality and momentum.” Jiang Jiaxing, director of the Jinjiang Municipal Science and Technology Bureau, said that Jinjiang will focus on building a regional innovation ecological demonstration zone and an industrial innovation transformation demonstration zone, and strive to increase the entire society’s R&D investment by 2025. It has exceeded 10 billion yuan, the output value of high-tech industries accounts for more than 30%, and 50 leading innovation and entrepreneurship teams have been introduced to create a benchmark demonstration for scientific and technological innovation in counties across the country.

AAA

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