Lanxi Textile Is Reborn In The "Intellectual Change"

Weaving opportunity dialogue, cloth inspection is not eye-catching, mobile phone check progress, products can be traced With the deepening of digital transformation, Lanxi textile industry is bidding farewell to the traditional image of "thousand people's yarn and ten thousand people's cloth", optimizing and upgrading production equipment, technology and enterprise management in an all-round way, and becoming the leader of Intelligent Manufacturing in textile industry.

"Dumb" machine can talk to "intelligent manufacture" and promote great changes

On March 24, we came to Zhejiang Wanzhou holding group. In the spinning workshop of more than 50000 square meters, we saw that rows of machines were running at full power, but only more than 100 workers were sporadically patrolling among them. The automatic logistics packaging system transported the tube yarn just off the production line to the packaging workshop, stacking, handling, packing and warehousing were completed automatically. "At present, the number of workers for 10000 spindles in our spinning workshop has been reduced to about 28 (the national average of 80). The number of packing and warehousing used to be 15 people per shift, but now only one person is needed." Wanzhou group party secretary, executive vice president Xu Jianzhong said.

Xu Jianzhong, who opened a weaving factory in the 1970s, witnessed the upgrading of generation after generation of equipment, but what impressed him most was the profound changes brought about by intelligent transformation in recent years.

Entering the group's big data center, the whole wall's electronic display screen scrolls in real time the equipment operation situation from each workshop, the air compressor operation, output statistics, variety distribution, shutdown equipment, production efficiency, etc. can be seen at a glance. "For which loom, how much yarn is left and how long it needs to be renewed, the system will give early warning in advance, so that the relevant processes can be prepared and the loom will not be waiting. The system will adjust the air compressor in real time according to the needs of the loom to run. It does not need to supply the same amount of gas all day long. The photoelectric cost can be saved by 5.6 million yuan a year. " According to Xu Jianzhong, Wanzhou's weaving equipment has always been in the leading position in the industry, but in the past, a single equipment was an independent individual, working hard, and the data were not shared, and the machines were not interconnected. The advantages of the new equipment were greatly reduced. Now, after the equipment is fully connected and the data are fully extracted, the benefit is increased by more than 12%, the water and electricity consumption is greatly reduced, and the products can be traced and accounted only.

On the basis of the provincial pilot project of upgrading traditional industries, Lanxi proposed to create an intelligent manufacturing demonstration city in three years in 2019 to basically realize "enterprise digital manufacturing and industry platform service". Zhu Junfeng, member of the Party committee of Lanxi economic and Information Bureau, said that at present, the equipment networking rate of 30 pilot enterprises has reached 98%, the average efficiency has increased by 12.3%, the error rate has decreased to 0.5%, and the average consumption of water, electricity and gas per 10000 meters cloth has decreased by 9.8%, 4.1% and 5.6%, respectively, which has achieved remarkable results in cost reduction and efficiency increase.

In Zhejiang Xinhai Textile Co., Ltd., we have seen the process of using "Tianyan" instead of human eye to complete the "factory test" of white fabric. Automatic cloth inspection equipment and loom are interconnected. Seven high-speed cameras lock the cloth firmly, and inspect the fabric quality at the speed of about 60 meters per minute (3 times that of manual work). Once a defect is found, the machine will stop automatically, and the specific defect location will pop up on the screen beside it to remind the staff to check and repair the corresponding loom. "After the automatic cloth inspection system is put on line, one person can manage two machines. With the speed doubled, the output of the original five machines can be completed by one person now, and the product qualification rate is close to 100%." Xinhai textile big data management center director Jin Jiansong said.

Data links up big value industries and radiates new momentum

"Getting through the data is only the first step. The next step is to use the data to make the data produce more value. Intelligent transformation will certainly play a greater role in product innovation and management innovation. " For example, Qiu Haibin, chairman of Zhejiang Xinhai Textile Co., Ltd., used to rely on gross estimation for production scheduling. Now, after inputting relevant data, the system will automatically integrate the real-time price of raw materials, production capacity, average scrap rate and other parameters to provide decision-making reference for whether an order can be accepted or not. Such a precise grasp of the "family background" makes the company's raw material procurement and order arrangement more scientific and efficient.

At present, Xinhai textile has formulated a five-year plan for intelligent manufacturing. Qiu Haibin hopes that the follow-up data analysis can help the company accurately grasp the fabric trend and style trend, and provide data support for product innovation and new product research and development. At the same time, in the aspects of supply chain management, marketing management and internal management optimization, "smart brain" can play a more intelligent role.

As one of the leading industries, there are more than 500 textile enterprises in Lanxi, among which 158 are above the designated size, accounting for 1 / 3 of the total output value of the city. At the same time, Lanxi textile equipment is the world's leading, with more than 30000 international advanced looms. Based on this foundation, Lanxi focuses on inclusive growth and promotes the action of "100 enterprises promotion" while promoting the pilot expansion and data deepening application. By building the cloud platform of textile industry, Lanxi will send high intelligent manufacturing to "ordinary people's home", and strive to create a number of intelligent production lines, intelligent workshops and intelligent factories in the whole industry.

"The cloud platform is simply to formulate a unified solution for low-cost and lightweight transformation in light of the common pain points and difficulties in the intelligent and digital transformation of enterprises, and put it into the cloud in the form of modules. No matter the size of the enterprise, they can rent modules according to their own needs, so they can share the digital dividend without spending money on research and development. Moreover, the modules on the cloud platform will be upgraded dynamically, so that enterprises can use the latest system at the lowest cost. " Chen Wei, project manager of Zhejiang Tianheng Information Technology Co., Ltd., a participant in the platform, said that at present, the intelligent transformation of Lanxi textile industry has been in the forefront of the country, and the cloud platform is expected to become the wisdom brain of the whole textile industry and provide decision-making basis for the overall development of the industry. "At present, four enterprises are preparing to access the cloud platform pilot, and relevant details are still under discussion. Strive to go online in June and help more than 30 enterprises implement intelligent transformation within the year. "

The government and enterprises should go in the same direction, dare to lead the way, and need to run for a long time

Cloth has longitude and weft, and the evolution of a piece of cloth also has longitude and weft. In the process of intelligent transformation and upgrading of the textile industry, Lanxi has taken a road of transformation led by the government, experts and enterprises, which is undoubtedly the result of the same direction of the government and enterprises.

Lanxi has made a good start, but both government departments and enterprises should be aware that the "smart change" road of the textile industry is only "the first step in the long march". To achieve a wider range of coverage and promotion of the whole industry, we need to constantly innovate models and means.

The data magic box of textile industry has been opened. Each enterprise may have its own choice whether to embrace or reject. But for the whole industry, intelligent transformation is not an option, but a must answer question, even more a question to be answered. Lanxi must take the road of digital reform with greater courage and wisdom, adhere to the combination of crossing the river by feeling the stone and strengthening the top-level design, break through the shackles of concept, technology bottleneck and talent shortage, and make every effort to promote the "intelligent production mode, digital production form and platform industrial organization", consolidate the first mover advantages, steadily deepen the reform, and form a set of perfect, reproducible and popularized system "Lanxi experience" contributes to the high-quality development of traditional industries.