From precise control of production processes to optimization of whole-process management, printing and dyeing companies activate their “digital brains”

The digital transformation of traditional industries is the only way to go, and this has become a consensus in the textile industry. However, how can digital transformation be implemented so that enterprises can truly reduce costs, increase efficiency and improve quality?

As a leading enterprise in the textile printing and dyeing industry, Huafang Co., Ltd. (hereinafter referred to as “Huafang Co., Ltd.”) is an “old factory” with a history of 47 years . However, when you walk into the factory, you can really feel the new vitality that digitalization has brought to the enterprise: in the printing and dyeing production line, the dye auxiliaries will automatically complete the weighing and transportation after an instruction is issued; in the fabric and home textile workshops, wired , wireless networks are connected vertically and horizontally; in the data monitoring center, various operational indicators of the factory are displayed in real time…

These are the fruits of the “Research and Application Demonstration of Digital Control Technology for the Whole-Process Printing and Dyeing Process”.

Dye auxiliaries can be automatically weighed

With Huafang Co., Ltd. as the main completion unit, the “Full-process Digital Control Technology Research and Application Demonstration of Printing and Dyeing Process” project won the 2022 China Textile Industry Federation Science and Technology Awarded second prize. Among them, realizing accurate and intelligent distribution of dyeing and chemical auxiliaries is one of the key points of this achievement.

It is understood that Huafang Co., Ltd. has used the creation of intelligent chemical distribution equipment and control systems to achieve automatic, efficient, and precise measurement and transportation of dyes and auxiliaries in the printing and dyeing production process, reducing workers’ labor intensity, improving metering and batching efficiency, and stabilizing Productquality and achieve clean production.

Li Chunguang, deputy chief engineer of Huafang Co., Ltd., said that the system is simple and convenient to operate. Just scan the QR code, and the system will automatically identify the chemical material requirements and automatically transport the preset storage tanks for backup. “By establishing a mathematical correlation model between controllable production parameters, we can accurately control parameters such as the type of chemical base liquid, feed amount, and stirring time. Through the collection and analysis of historical operation data, we can accurately control different dyestuffs and chemicals Agents, using different supporting parameters, can effectively collect, process, store and feed back relevant information. It can ensure that the concentration and viscosity of auxiliaries and dye solutions meet expected standards, improve the accuracy of dyeing and chemical auxiliaries at the source, and effectively Improve overall equipment efficiency.”

It is worth mentioning that the project also developed an intelligent distribution control and management program for dyeing and chemical additives. This program digitizes operating equipment and parameterizes operating nodes to achieve unified management, effectively unifying various parameters used in the auxiliary distribution system. Through digital configuration, the system has both good independence and scalability.

“After the program is run, it effectively solves the current situation that the distribution modules of dyestuffs and chemical auxiliaries are relatively scattered and independent. It organically integrates information between modules, improves the real-time information interaction between modules, and effectively cooperates with the automatic control program to improve the efficiency of auxiliaries. In order to improve the efficiency and accuracy of slurry transportation, different distribution methods are adopted to reduce the loss of slurry during the transportation process. In view of the characteristics of many types of slurry, small dosage, easy to bond, settle, and pile up, etc., Li Chunguang said.

Management decision-making data has the final say

In fact, realizing intelligent distribution of dyes and chemicals is only the first step in the digital transformation of Huafang Co., Ltd. What is more important is the “digital brain” hidden behind it.

In the monitoring center of Huafang Co., Ltd., various operational indicators of the factory are displayed in real time on large screens, such as real-time collection of machine operating parameters, production process parameters, cloth cart/cloth axis operation stations, workshop environment and other key Parameters are dynamically displayed to production managers in a graphical manner, making it easier for managers to have a horizontal and overall understanding of the production operation of the workshop. At the same time, it supports the historical storage and retrieval of parameters, and displays the changes of selected parameters of interest in the form of trend charts to facilitate managers to conduct in-depth longitudinal analysis of a certain parameter.

“For example, we use radio frequency identification (RFID) technology. Managers can trace quality information back to processing machines, gray cloth batches, process flows, operating parameters of each machine when processing the cloth, etc., to facilitate the identification of the causes of product defects. Search and improve product quality. The energy management module accurately records the energy consumed in each process during the production of each order by installing water, electricity, and steam metering instruments with remote transmission functions on the machine. “Li Chunguang said.

When data are collected, managed and analyzed, they become like “managers” and “guides” who come alive.

When will you start preparing materials? How much quantity should be prepared? When will production start? How to do warehouse management? When do you ship? What happens when the design changes? What to do if the delivery date is delayed… Every link in the production process has been managed and optimized; when changes occur in one link, other links can be quickly adjusted.

Li Chunguang introduced the design and production scheduling process to the reporter of China Textile News in detail: “ERP sends a week’s production orders to the MES system, and the MES system automatically generates production task orders after receiving the production orders. The APS system starts fromAfter obtaining the production task order in the MES system, select the appropriate production task order according to the corresponding rules, obtain the corresponding process in the process database, including the process, processing time and dwell time of each process, and then obtain the processing status of the current machine. , including available processing periods, key/bottleneck processes, etc., and plan and schedule the production task order after obtaining all parameters required for production scheduling. After the production schedule is completed, each machine picks up materials for processing according to the production card. ”

Digitalization becomes core competitiveness

Management is constantly iteratively upgraded, and digitalization has become the core competitiveness of Huafang Co., Ltd.’s development.

From traditional production lines to intelligent factories, not only the production methods have changed, but also the production efficiency has been significantly improved. Under the guidance of the digital transformation strategy, Huafang Co., Ltd. has achieved remarkable transformation results – the collection rate of key parameters of equipment for printing and dyeing products is 100%, the fault diagnosis accuracy rate is 94.5%, and the product first-time accuracy rate is 98.4%. The average energy consumption of the product is reduced by 25%, and the water consumption is reduced by 31%…

Sheng Shouxiang, chairman of Huafang Co., Ltd., proudly said: “The results of ‘Research and Application Demonstration of Digital Control Technology for the Whole Printing and Dyeing Process’ are based on the company’s years of management and technology accumulation, as well as the deep integration and innovation of information technology accumulation. It has greatly improved production efficiency, reduced various costs, and effectively improved overall benefits.”

It is understood that this technology has been promoted and applied in three units including Binzhou Oriental Carpet Co., Ltd. and Binzhou Rentai Textile Industry and Trade Co., Ltd., with a cumulative increase of 440.84 million yuan in sales and 28.649 million yuan in new profits in three years. The research results have outstanding effects and significant economic, social and environmental benefits, and have played a good demonstration role in promoting the development of the printing and dyeing industry.

Chen Zhihua, President of the Printing and Dyeing Industry Association, said that Huafang Co., Ltd.’s transformation of traditional enterprise production and operation models not only grafts Internet thinking into production technology, but also applies it to the management level of enterprises, enabling enterprises to step out of the A development path based on textiles but also beyond textiles. “The times are constantly changing, and digitalization is constantly being given new definitions. Only by truly embracing digital ideologically and letting digital dominate business development and company operations can an enterprise achieve true digitalization.”

AAA

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