Hundreds of enterprises promote “4+X” digital transformation, Zhejiang Lanxi Textile Industry embarks on the road of smart manufacturing
As one of the first batch of pilot enterprises, Zhejiang Xinlan Textile Co., Ltd. has comprehensively improved its production management and services since 2019. According to statistics, the company’s comprehensive efficiency of looms has increased by 5 percentage points year-on-year to more than 97.1% in the past two years, operating costs have dropped by 10% year-on-year, comprehensive energy consumption has dropped by 5% year-on-year, labor employment has dropped by 16.6%, and order delivery times have been shortened by more than 7 days. .
Rely on intelligent visual cloth inspection equipment and its functions such as automatic statistics and classification of fabric defect information to avoid missed inspections due to visual fatigue… Not long ago, a reporter from Science and Technology Daily visited Zhejiang Wanzhou Holding Group Co., Ltd. (hereinafter referred to as Wanzhou Zhou Holdings) learned that the company’s workshop cloth inspection speed has increased from 25 meters/minute two years ago to 60 meters/minute, and the manual inspection fee per 10,000 meters of cloth has been reduced by 100 yuan, saving more than 90% of labor costs.
“In addition, there are AGV trolleys in the workshop that can automatically drop cloth to improve the transportation efficiency of the cloth workshop. All process equipment has been connected to the Internet, and the data dashboard can monitor in real time.” The relevant person in charge of Wanzhou Holdings introduced that in the past two years, the company has The overall efficiency increased by about 13%, the error rate dropped to 1%, and water and electricity consumption also dropped significantly.
In 2019, Jinhua Lanxi City decided to create a “Textile IndustryIntelligent Manufacturing Demonstration City” to explore the digital transformation experience of small and medium-sized enterprises. There are 39 textile companies including Wanzhou Holdings The enterprise completed the digital pilot transformation.
On July 7, at the Intelligent Manufacturing into the Park·Lanxi Station and 2021 ChinaTextile Industry Intelligent Manufacturing on-site meeting, Lanxi Municipal Party Committee Secretary Chen Fengqi said that after more than two years Through exploration and practice, the local area has formed a “4+X” model suitable for the digital transformation of small and medium-sized textile enterprises. The first batch of 9 pilot enterprises have increased their efficiency by an average of 12.3%, and the digital manufacturing 100 enterprise promotion activities have been fully launched.
Digital transformation is imperative
Since the 1960s, the Lanxi cotton textile factory was built, and the Lanxi textile industry began and gradually became a pillar industry in the local area, with white gray cloth, Denim production has recently ranked first in the country. There are more than 500 local textile companies, 147 of which are above designated size, and 11 are shortlisted for the top 100 companies in the national cotton textile industry.
“In the past few years, affected by multiple factors such as the external market environment and rising factor costs, the profit margin of Lanxi’s textile industry once shrank, and the extension of the industrial chain was blocked. Conflicts such as difficulty in recruitment, high labor costs, large production capacity, and thin profits have become increasingly prominent. .” The relevant person in charge of the Lanxi City Economic and Information Bureau told reporters that many business executives lamented that “the days of relying on equipment, cost reduction, and price wars are gone forever.”
In 2017, 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. Changing the previous extensive management and operating model and improving technology and management have become the consensus of more and more enterprises. Lanxi Municipal Party Committee, Government and enterprises have begun to seek the path to digital transformation.
“With a strong foundation in the textile industry, companies also have strong needs for transformation. Some companies even take the initiative to test digital manufacturing. However, in order to explore an experience model that can be replicated and promoted, the pragmatic and accurate strategic guidance of an expert team is crucial. “The person in charge said.
In 2018, the Zhejiang Provincial Intelligent Manufacturing Expert Committee (referred to as the Zhejiang Intelligent Manufacturing Expert Committee) sent an expert team to Lanxi to conduct a half-year survey of the city’s textile enterprises, visiting more than 100 enterprises to comprehensively identify difficulties, blocking points, Pain points, providing diagnostic reports and technical support to relevant companies.
Under the guidance of the Zhejiang Intelligence Special Committee, Lanxi City proposed the goal of creating a “Textile Industry Intelligent Manufacturing Demonstration City”. The municipal government issued a “three-year implementation plan” to form a team with the mayor as the team leader and the deputy mayor in charge. The deputy leader of the establishment work leading group and city leaders will investigate the progress of the pilot enterprises every half month, coordinate and resolve blockages and difficulties in a timely manner, and ensure the smooth progress of the pilot.
“For the first batch of nine pilot enterprises, the decision-makers have firm determination, have relatively clear statements and needs for the problems to be solved by intelligent manufacturing, and have a certain foundation for internal management.” Xu Jiping, deputy director of the Zhejiang Intelligent Industry Committee, said, Lanxi The city started with a lightweight smart transformation model that costs less, is easy to implement, and solves many obvious problems, effectively putting enterprises on the track of smart manufacturing.
“4+X” transformation is advancing despite the epidemic situation
“For local enterprises, facing digital transformation, there are difficulties in raising costs, interconnecting software systems, maintaining information systems, collecting production equipment data, and recruiting informationtalents Five major problems include difficulty in recruitment.” Xu Jiping introduced.
To this end, Lanxi City has introduced a bidding mechanism through the overall linkage of “government + experts + enterprises”, selected and cultivated and developed a cotton textile industry Internet platform, and invited a team of experts to provide technical consultation and digital manufacturing plan reviews for enterprises more than 100 times , and refined the “4+X” model suitable for the digital transformation of small and medium-sized enterprises.
“Lanxi Municipal Government calls ‘4’ and ‘X’ prescribed actions and optional actions, and adjusts the direction of policy subsidies.” Xu Ji�� explained that “4” includes the basic data that connects production equipment; the application data of the entire production and operation process, realizing the interconnection and interoperability between production equipment and software, and between ERP and MES; presenting real-time, Visualized, paperless, and job-based operation and operation data; and training of all employees in the enterprise on the basic knowledge of intelligent manufacturing and what they need to know and know at different levels and positions. “X” refers to the optional content of personalized smart modifications added 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.
As one of the first batch of pilot enterprises, Zhejiang Xinlan Textile Co., Ltd. has comprehensively improved its production management and services since 2019. According to statistics, the company’s comprehensive efficiency of looms has increased by 5 percentage points year-on-year to more than 97.1% in the past two years, operating costs have dropped by 10% year-on-year, comprehensive energy consumption has dropped by 5% year-on-year, labor employment has dropped by 16.6%, and order delivery times have been shortened by more than 7 days. .
It is worth mentioning that the originally step-by-step pilot plan did not come to a standstill due to the COVID-19 epidemic. The local government took advantage of the epidemic and bucked the trend to promote intelligent transformation. .
“During the epidemic last year, some companies in the second batch of pilots had the idea of ’overcoming the difficulties first, and then carrying out smart reforms.'” Xu Jiping said that the expert group recommended that companies take advantage of insufficient customer orders and partial production in the post-epidemic period. Implement smart manufacturing training for employees when lines are idle, prompting companies to seize the time to practice their internal skills and gain the initiative.
“In the early stages of smart reform, most textile companies in Lanxi held a wait-and-see attitude towards smart reform due to the concept that ‘smart manufacturing investment threshold is high and is only suitable for large enterprises’. The success of the first batch of pilot companies dispelled their concerns. “Xu Jiping said that at the same time, when a large number of orders were transferred to China due to the epidemic, Lanxi benefited from the early intelligent reform, its ability to attract orders was enhanced, and the consciousness of the enterprise’s intelligent reform was greatly improved.
Leading the overall upgrade of traditional manufacturing industry
In June this year, the list of the first batch of industry brain construction pilot projects in Zhejiang Province was announced, and Lanxi City’s weaving (cotton textile) industry brain was on the list.
“We will use the ‘4+X’ model of digital transformation built by pilot enterprises as the four beams and eight pillars to steadily promote the ‘100 Enterprise Improvement’, and with the goal of ‘based on Lanxi, covering the entire province, and serving the entire industry’, we will strive to create The industrial brain of the weaving (cotton textile) industry leads the digital reform of Lanxi.” said the relevant person in charge of Lanxi Economic and Information Bureau.
At the same time, Lanxi City proposes to use intelligent manufacturing to lead the transformation and upgrading of the traditional manufacturing industry, promote the intelligent manufacturing model of the textile industry, and combine the application of “5G + Industrial Internet” to leverage It will promote the digital transformation of traditional industries such as cement, batteries, and metallurgy and create several industry samples.
Among them, the cement industry, a key traditional industry in Lanxi, is actively building an industrial brain.
Xu Jiping believes that the reason why it is difficult for small and medium-sized enterprises to carry out digital transformation is that it is often difficult to get started. Situations such as no money to invest, no one to do it, and no ready-made experience to learn from will dissuade quite a number of business owners. “Lanxi City chose the cotton textile industry, a pillar industry, to take the lead in piloting, classifying the common and individual problems of enterprise digital transformation, and then summarized and refined sample models to alleviate concerns for other industries.”
In addition, in conjunction with “Creating a Demonstration City for Intelligent Manufacturing in the Textile Industry”, Lanxi City actively explores support models for digital manufacturing financing and provides financing services for digitally transformed companies, stimulating the enthusiasm of companies.
“The online loan product for small and micro textile enterprises developed by local financial institutions has been connected with the big data administration, industry and commerce, and tax-related data. Enterprises can apply for loans online based on the capital needs of digital transformation and operations, and borrow at any time. The person in charge said that this has also accumulated experience for promoting the digital transformation of other traditional industries.
“Lanxi is a veritable old industrial base. It was once glorious in the era of planned economy. It transformed from a trade town to an industrial town. It concentrated 70% of Jinhua’s industry and contributed more than 50% of the fiscal revenue. It became the first batch of fiscal revenue in Zhejiang. Billion-yuan County.” Chen Fengqi said that today, manufacturing is still Lanxi’s most solid foundation. Lanxi will take the lead of Zhejiang Province’s “No. 1 Digital Economy Project” and digital reform to further promote the transformation and upgrading of traditional industries and the cultivation of emerging drivers to accelerate Economic highquality development.
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