Soqian Town: Intelligent transformation turns the textile workshop into a digital factory

Rows of smart machines run at high speed, and a stream of data information scrolls across the screen. As the first enterprise in Suoqian Town to carry out intelligent transformation, there are almost no people in the production workshop of Hangzhou Wansheng Textile Co., Ltd. (hereinafter referred to as Wansheng Textile). The production efficiency has been greatly improved and the land use has been saved by 1/3. The impressive performance has made it a benchmark for intelligent transformation of the textile industry in the region. It has also accelerated thetransformation and upgrading pace.

Intelligent transformation bears “sweet” fruits

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 Japan Murata’s 870 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.

When the company relocated in 2020, it invested more than 40 million yuan, determined to build an integrated 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 A variety of sensors, control devices, data acquisition devices, and smart chips.” Through the operation of “Machine Substitution” and a series of industrial software and a set of production intelligent decision-making systems, Wansheng Textile has achieved a new life, which not only significantly reduces labor costs, but also uses digital twin technology to improve product quality.

Looking at the management software on the mobile phone of the person in charge of Wansheng Textile Workshop, I can only see modules such as “Production Management”, “QualityManagement”, “Environmental Monitoring” and “Warehouse Management” At a glance, click in to view relevant real-time information. “After the intelligent 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, a low failure rate, and intelligent management, so we can rest peacefully at night.”

Data shows that since the implementation of the overall transformation project one year ago, Wansheng textile workshop production efficiency has increased by more than 20%, energy consumption per unit output value has been reduced by 20%, product defective rates have been reduced by half, and operating costs have been reduced by 40%. The intelligent transformation has also brought about land space savings, and 1/3 of the remaining factory buildings in the factory area have been vacated.

For these remaining factories, Wansheng Textile has once again tasted the sweetness through attracting investment. At present, Zhejiang Xianglong Technology Co., Ltd. and Hangzhou Borui Electronics Co., Ltd. have settled in. This operation has become another example in Xiaoshan’s “Equal-acre-on-hero” reform.

The current industrial transformation and upgrading is gaining momentum

In order to promote the transformation and upgrading of enterprises, Suoqian Town has carried out training activities on enterprise technology and talent policies for many times, implemented the national policy opinions on accelerating transformation and upgrading, and Organize government personnel and business leaders to visit relevant enterprises inside and outside the district to study and learn from the advanced, find gaps, and transfer ideas, thereby accelerating the development of the town’s industry in intelligent manufacturing.

Wansheng Textile’s successful implementation of intelligent transformation has undoubtedly set an example and brought confidence to other companies in the area. Some companies that were originally hesitant to invest large sums of money in transformation are now beginning to start transformation.

In the view of Yu Yigang, deputy mayor of Suoqian Town Economics, on the one hand, it is the government’s continuous promotion of intelligent and informatization transformation and the introduction of relevant incentive systems; on the other hand, various enterprises have seen the practical implementation of intelligent transformation. The benefits it brought were real, especially after an on-site visit to an enterprise like Wansheng Textile, which strengthened my idea.

The industries in Suoqian Town are mainly concentrated in four industries: cotton spinning, plastics, machinery, and down home textiles. Now, many cotton spinning companies have carried out intelligent transformation in warehouses, processes, management and other aspects. Plastic companies such as Xinguang Plastics and Xiangbang Technology have also invested in transformation. In the machinery industry, Shangyan Machinery has carried out multiple rounds of equipment updates and software system implementations, built a flexible R&D, manufacturing, and delivery system for metal construction with rapid and accurate customization capabilities, and has initially acquired digital production capabilities. “The intelligent transformation of the down home textile industry is relatively slow.” Yu Yigang believes that the concepts of many business leaders have changed, and some companies are considering starting with warehouse transformation, which is also a progress.

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