Lanxi, Zhejiang: Traditional textiles become intelligent “weaving” manufacturing
Fully automated production lines, intelligent package yarn packaging, and loom data sharing. In the huge weaving industry factory, one person inspects thousands of machines, and the “smart brain” controls it on one screen… In Lanxi, Zhejiang, the “City of Weaving” , the once picture of “thousands of people wearing gauze and thousands of people making cloth” has become a thing of the past. The old industrial base Lanxi and the traditional textile industry are riding on the wings of digital reform, focusing on the digital transformation of the weaving industry, and exploring a transformation and upgrading of intelligent “weaving” manufacturing. the road.
Pathfinding: Digital reform is imperative
Lanxi, known in ancient times as “the confluence of three rivers”, “the waist of six rivers” and “the thoroughfare of seven provinces”, set off a manufacturing boom of “industrial learning from Lanxi” in the last century.
Lanxi has a strong textile industry base and was once known as “China’s Famous Weaving City”, “China’s Textile Industry Base” and “Zhejiang Province’sCotton Textile Finishing Advanced Manufacturing Base”. According to statistics, there are more than 500 textile companies in Lanxi (of which more than 140 are listed above). The output of denim and the output of pure cotton elastic casual fabrics rank first in the country, and the output of pure cotton casual elastic fabrics accounts for the national market share 80%.
However, behind the production scale and market share, there is the practical problem of “every company is its own company”. The weaving machines of small and medium-sized enterprises come from various countries – different models and poor information. Coupled with the influence of various factors such as market environment and factor costs, the profit margin of the textile industry once shrank, the extension of the industrial chain was blocked, and the development prospects were confused.
In the past, a machine was an independent individual, data was not shared, and information was not communicated. “If the information is not mastered, the boss will look like a ‘half-blind man.'” Qiu Haibin, chairman of Zhejiang Xinhai Textile Co., Ltd., said frankly.
Qiu Haibin’s confusion is the epitome of many weaving companies in Lanxi. To this end, the Lanxi Municipal Party Committee, the government and enterprises began to seek a way to “break through” and explore the development path of digital “weaving” with the construction idea of ”reform first” and “reform later”.
In 2017, the Lanxi textile industry was included in the first batch of provincial pilot projects for the transformation and upgrading of traditional manufacturing industries in Zhejiang Province; in 2018, the Zhejiang Province Intelligent Manufacturing Expert Committee (hereinafter referred to as the “Zhejiang Intelligent Special Committee”) selected the textileprinting and dyeing industry intelligent manufacturing expert steering group to settle in Lanxi; in 2019, the Lanxi Municipal Party Committee decided to “create intelligent manufacturing in the textile industry” Demonstration City” to explore the digital transformation experience of small and medium-sized enterprises, and the textile industry accelerates the pace of optimization and upgrading; in 2021, the national “14th Five-Year Plan” proposes to “accelerate digital development and build a digital China”, Zhejiang comprehensively deploys digital reform, and the Lanxi textile industry is digitized Incorporated into the city’s key implementation plan, the city’s focus on digital economic development has become clearer and more vigorous.
Exploration: The “4+X” model has achieved good results
If the textile industry wants to transform, informatization, dataization, and intelligentization are the only way to go. “The first step is to let machines talk to solve the problem of ‘deaf, dumb and blind’.” Chen Fengqi, secretary of the Lanxi Municipal Party Committee, said that this step is the most critical and the most difficult step to take. At the same time, Lanxi City has also formulated an overall linkage reform idea of ”government + experts + enterprises” that includes government guidance, expert guidance, and enterprise leadership.
In 2018, the “Zhejiang Intelligence Special Committee” selected an expert team to station in Lanxi to provide comprehensive and full-process guidance on the digital transformation of the textile industry. So far, the expert group has provided 14 complete diagnostic transformation plans for enterprises, provided technical consultation and reviewed digital manufacturing plans more than 50 times. Through regular and irregular lectures and consultations by experts, entrepreneurs’ management ideas gradually changed from competing for equipment to competing for data applications, and the consensus and atmosphere for digital transformation in the city continued to improve.
Lanxi City, based on the recommendations of the “Zhejiang Intelligence Special Committee”, clarified the work path of “testing a batch and taking it forward”. After multi-party evaluation, the first batch of 9 pilot enterprises was determined, and then expanded to 30 enterprises. The benefits of the enterprises participating in the pilot were significantly improved. Among them, Zhejiang Xinlan Textile Co., Ltd., which achieved the best results, achieved an improvement rate of 36.5%.
In addition, the reform pilot summarized the “4+X” “universal + personalized” smart reform experience: 4 is the “four connections”: opening up the basic data between production equipment and solving the problem of “deaf, dumb and blind” between machines problems; open up application data in the entire process of production and operation, realize interconnection and interoperability between production equipment and software, and between ERP and MES; open up real-time, visual, and paperless digital management data, and install it from the decision-making level, The Kanban (intelligent terminal) system from the management level to the operation level introduces the enterprise into digital management; it connects the collaborative data between employees and machines, materials, processes, and between front and rear processes, and provides all employees with what they need to know about implementing smart manufacturing Training to achieve human-machine collaboration and ensure the implementation of smart manufacturing. The “X” represents the addition of personalized smart modification options based on the development needs and financial strength of each enterprise, such as smart logistics warehouses, AGV trolley systems, equipment numerical control updates, smart cloth inspection, etc.
From waiting and watching to consciously participating, hoping to��The atmosphere of “intelligent reform” is getting stronger and stronger.
Imagination: “Lanxi Experience” in promoting the digital transformation of traditional industries
Rows of machines are running at high speed, and occasionally a few workers shuttle around to inspect; the electronic screen scrolls in real time the operation status of the equipment in each workshop. The operation of the air compressor, output statistics and shutdown equipment are all clear at a glance… Walking into the 50,000-square-meter spinning workshop of Wanzhou Group, the “unmanned factory” in front of you is breathtaking.
“After the intelligent transformation, the number of workers per 10,000 spindles of yarn has been reduced from 80 to more than 20, and production data has been collected, analyzed and fed back in real time.” Xu Jianzhong, Secretary of the Party Committee and Executive Vice President of Zhejiang Wanzhou Holding Group Co., Ltd. He said that the system will warn you in advance about how much yarn is left on each loom and how soon it needs to be replaced, so that the relevant processes can be prepared, “saving time and worry.”
“Textile is a traditional industry with brutal and fierce market competition. Product innovation, cost reduction and efficiency improvement, quality and efficiency improvement, staff reduction and efficiency improvement are imminent.” 2021 China held in Lanxi City Textile IndustryIntelligent manufacturing on-site meeting, Qiu Haibin, chairman of Zhejiang Xinhai Textile Co., Ltd., shared, “Intelligent reform is currently one of the best paths for enterprise transformation and upgrading.”
Lanxi’s traditional textiles have been transformed into intelligent “weaving” manufacturing, and achieved good results with an average increase of 12.3% in the efficiency of pilot enterprises. From pilots to promotion to full rollout, the “Lanxi experience” gradually explored during the digital transformation process will continue to be used.
“Focusing on the government’s achievements, focusing on expert opinions, and focusing on corporate momentum are the three keys to the ‘Lanxi’ experience.” Chen Fengqi told reporters.
Reform can continue to exert force, and it is inseparable from the government’s leadership in top-level design. Lanxi City attaches great importance to the digital manufacturing of the textile industry and has put the intelligent transformation of the textile industry on an important agenda. “City leaders investigate the progress of pilot enterprises every half month, coordinate and solve blockages and difficulties in a timely manner, and ensure the smooth progress of the pilot.” Chen Fengqi said that the reform It must be top-down and the guiding role of government departments should be given full play.
Enterprise reform is inseparable from the guidance of experts. “The digital transformation of small and medium-sized enterprises is easily restricted by factors such as capital, technology, and talent.” Wang Zhiwu, general manager of Zhejiang Seven Star Textile Co., Ltd., said that since the start of the transformation, the government has invited a team of experts to enter the enterprise. Guidance and “think tanks” help overcome blockages and difficulties, which have strengthened the confidence of enterprises in taking the road of digitalization.
“Digital manufacturing is always on the road, and we hope to use the experience of ‘Lanxi’ to deepen industry-wide promotion.” Chen Fengqi said that currently, Lanxi is promoting the expansion of pilots, deepening the application of data, and advancing the “100 Enterprises Improvement” action plan to use digital manufacturing As a fulcrum, we will leverage the digital transformation and highquality development of the city’s traditional industries.
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