Digital transformation is a must-answer for the high-quality development of the textile industry, and these companies have already tasted the “sweetness”
Recently, the Shandong Provincial Department of Industry and Information Technology issued the “Opinions on Accelerating the High Quality Development of the Textile and Garment Industry” (hereinafter referred to as the “Opinions”) ). The “Opinions” proposed that one of the goals of promoting the high-end textile industry is to promote the digital transformation of the industry and promote the in-depth application of new generation information technologies such as industrial Internet, big data, cloud computing, artificial intelligence, blockchain, and 5G in the textile and apparel industry. For spinning, weaving, printing and dyeing and other fields, promote the construction of a number of greenintelligentfactories in large enterprises, and promote the implementation of a number of intelligent technology transformation projects in small and medium-sized enterprises. , gradually realizing intelligent production processes, intelligent control systems, online monitoring informatization, and green manufacturing processes.
It can be seen that digitalization has become a mainstream trend for enterprises’ transformation and upgrading. Focusing on the present, many spinning companies in our country are also practicing this, and many of them have already tasted the “sweet” fruits of digital transformation.
Daiyin Group
Solving the difficulties in producing differentiated products
In recent years, Shandong Daiyin Textile and Garment Group (hereinafter referred to as “Daiyin Group”) has spared no effort in intelligent transformation, actively promotes intelligent spinning transformation, and creates flexible manufacturing production lines for differentiated products.
“Textile enterprises can reduce labor and improve efficiency by adopting advanced scientific management and digital, automated, and intelligent spinning equipment. Currently, the most advanced production lines can maintain between 15 and 25 people per 10,000 spindles. In terms of labor costs, Compared with other enterprises, it has huge advantages. In the next 5 to 10 years, the trend of ‘machines replacing people‘ will become more obvious. Manufacturing enterprises will improve their technical content and use It is an inevitable trend for machines and technology to replace simple manpower and realize automation.” said Zhao Huanchen, chairman of Daiyin Group.
Zhao Huanchen introduced that Daiyin Group invested 200 million yuan to gradually upgrade the existing 100,000-spindle spinning production line with intelligence, carefully build a flexible manufacturing production line for differentiated products, and achieve order-driven, intelligent cotton allocation, and traceability management. , unit monitoring, status management, and quality online intelligent manufacturing, after the project is completed, can effectively solve the difficulties existing in the production process of differentiated products, and can meet the needs of Precise R&D and manufacturing of various types of special yarns ranging from 10,000 tons to tens of kilograms, the production efficiency is increased by 25%, and the product quality is more stable.
In addition, in order to provide convenient and efficient personalized advanced customization services to different types of customers and groups around the world, Daiyin Group has invested 150 million yuan in recent years to promote the implementation of Renault suit intelligent manufacturing and international advanced customization projects. Promote the transformation and upgrading of clothing production and operation models. Relying on this project, the company actively develops the global advanced customization business of Renault suits. The market extends from domestic to overseas, and the business has expanded to the United States, Canada, the Netherlands, New Zealand, Australia and other countries.
Wansheng Textile
Improve production efficiency and reduce energy consumption
In the workshop of Hangzhou Xiaoshan Wansheng Textile Co., Ltd. (hereinafter referred to as “Wansheng Textile”), rows of intelligent machines are running at high speed, and a stream of data information scrolls across the screen.
It is understood that as early as 2014, Wansheng Textile started the pace of intelligent transformation. According to the relevant person in charge of the company, the company eliminated a ring spinning workshop that year and introduced 8 sets of Japanese Murata vortex spinning equipment, coupled with the most advanced pre-spinning equipment. After several years of operation, the contrast between the vortex spinning workshop and the ring spinning workshop is very obvious. The vortex spinning workshop not only has a good environment and easy management, but the production efficiency is also significantly higher than that of the ring spinning workshop.
In 2020, Wansheng Textile invested more than 40 million yuan, determined to build an intelligent digital factory, covering three aspects: intelligent digital workshop planning and hardware upgrades, digital platforms, and intelligent technology platforms. “We have introduced 8 sets of 870EX spinning equipment and upgraded the equipment introduced last time. The workshops have all realized automatic transportation, automatic bagging, automatic weighing, automatic palletizing, automatic temperature and humidity control, and have also installed various sensors, Control devices, data acquisition devices, and smart chips.” The relevant person in charge of the company said that through “machine substitution” and the operation of a series of industrial software and a set of production intelligent decision-making systems, Wansheng Textile has achieved a new life, not only significantly reducing It reduces labor costs and uses digital twin technology to improve product quality.
On the mobile management software, the modules such as “Production Management”, “Quality Management”, “Environmental Monitoring” and “Warehouse Management” are clearly visible at a glance. Click to view relevant real-time information. “After digital transformation, the fire hazards and production safety accidents that we were most worried about before have basically been solved. The advanced equipment has a high degree of automation, low failure rate, and intelligent management, so we can rest peacefully at night.” Related to the workshop the person in charge said.
Data shows that since the implementation of the overall transformation project for one year, the production efficiency of Wansheng Textile Workshop has increased significantly.�Increased by more than 20%, energy consumption per unit output value is reduced by 20%, product defective rate is reduced by half, and operating costs are reduced by 40%. Digital transformation has also brought about land space savings, and 1/3 of the remaining factory buildings have been vacated.
Mingren Textile
In line with world sewing thread production standards
“We have carried out technological transformation and capacity expansion to build a modern, standardized and technological sewing thread industry base. Currently, we have led 5 peers to carry out intelligent upgrades and transformations of production lines.” Hubei Mingren Textile Technology Co., Ltd. (hereinafter referred to as ” Wu Jian’an, chairman of Mingren Textile Co., Ltd. said.
Mingren Textile is a provincial high-tech enterprise mainly engaged in the production of polyester yarn. It is also the “hidden champion enterprise” in the textile industry of Hubei Province. It currently has 20 spindles. Thousands of pieces, 150,000 thread spindles, with an annual output of 38,000 tons of various high-grade pure polyester sewing threads. In order to enter the European and American markets, in October 2020, the company launched the construction of a 100,000 spindlepolyester yarn thread smart factory project.
Currently, all cables, water and other energy supply facilities in the newly built factory have been installed. “The new factory uses world-class sewing thread production equipment and an intelligent management system to achieve intelligent production processes, automated production equipment, and digital monitoring of relevant processes and machines in real time. After it is officially put into production, the company’s production capacity will increase by 1/ 3. The number of employees per 10,000 spindles will be reduced from more than 100 to more than 20.” Wu Jian’an introduced that the project is in line with the world’s sewing thread production standards and uses a double-story 40,000-square-meter single factory. Its constant temperature and humidity workshop reaches It meets the requirements of high-end intelligent manufacturing in the Industry 4.0 era and can greatly improve the quality of sewing thread products.
From manual wiring to automatic machine production, technological transformation and capacity expansion not only ease the work intensity of textile workers, but also increase production efficiency. “In the past, we had to do manual splicing, and we had to walk around. Later, the workshop staff sat on the car and slid on both sides. Now the workshop is fully automatic spinning. If we want to make the current output, we used to have at least a dozen people, but now one person can do it. Two machines.” Zhu Xiaohong, a staff member of the workshop, lamented that the intelligent transformation and upgrading has allowed the spinning workshop to get rid of the “low efficiency and high labor demand” hat.
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