Digital Brain Empowerment, Smart Factory Online ... Under the Epidemic, Industrial Intelligence Enhances Traditional Manufacturing's "Immunity"
The emergence of "new infrastructure" in the textile workshop, the temperature of workers is still irreplaceable
Reading tips
The firepower of intelligent machinery is fully on, artificial intelligence quality control identification, and deep transformation of data mining ... Traditional textile companies need at least 1,100 workers to produce 200,000 tons of nylon per year. In Hengshen Holding Group, this number is only 420. The "new infrastructure" with big data, artificial intelligence and the industrial Internet as the core accelerates the promotion in the textile workshop, helping traditional manufacturing industries to "counter attack" under the epidemic.
The tens of thousands of tons of raw materials arrived at the wharf can be directly reached to the factory site without loading or unloading, without using vehicles; how much raw material inventory, how much is consumed, how much catalyst is put in, and whether there are “runs and drips” ... when many textile companies are still When busy looking for workers to return to work, all links in the production line of Hengshen Holdings Group in Fuzhou City, Fujian Province, have realized the "intelligent brain" full process control. Today, the company's chairman, Chen Jianlong, has begun planning the next phase of production capacity layout and intelligent transformation of the production workshop.
With a comprehensive weighted start-up rate of 92%, an employee return rate of 97.4%, and capacity recovery of more than 110% ... Looking at the real-time jumping data on the big screen of "Smart Center", Chen Jianlong sighed: "The new infrastructure in the workshop allows Hengshen ran ahead of the epidemic! "
智能 "Smart" to solve the problem of resumption
On March 20th, in the Liheng nylon polymer production workshop of Hengshen Holding Group, three high-speed spinning and chipping production lines are operating efficiently. The production equipment in more than 5,000 square meters of workshop is controlled and monitored by operators in the central control room. At the scene, 15 workers wore masks and achieved "zero contact" using intelligent production equipment.
On the same day, in the post-spinning workshop of Hengshen Synthetic Fiber Technology Co., Ltd., which is 6 kilometers away from the Liheng nylon polymer production workshop, the yarn was "stretched, twisted, untwisted, and wound" between the machines. 30 workers Wearing anti-static clothing to shuttle back and forth, the scene of hundreds of workers sweating in the traditional textile workshop disappeared here.
恒 At Hengshen Holding Group, intelligent equipment such as automatic film wrapping machines, robotic arms, and automatic packaging lines have been widely used on production lines, which allowed the labor shortage during the epidemic to quickly fill the production gap and ensure the smooth operation of the production line.
"It is intelligence that helps us to minimize the labor demand to restore production capacity." Mei Zhen, general manager of Hengshen Synthetic Fiber Technology Co., Ltd. told reporters that traditional textile enterprises with an annual output of 200,000 tons of nylon require at least 1,100 workers, while in Hengshen Shen, this number is only 420.
At this moment, although the epidemic has not been resolved, Mei Zhen has set out to promote the acceleration of production capacity brought about by intelligence.
9 At 9:30 am, in the finished silk workshop, Mei Zhen was busy discussing with the technical staff on the side the "new infrastructure" project just established, the industrial smart camera. The industrial smart camera needs to load the quality and appearance information of millions of products to achieve centralized and integrated inspection of the product appearance to reduce a large amount of human input. In Mei Zhen's words: "The product does not pass, and no manual inspection is required. The camera will know at a glance."
According to reports, this upcoming intelligent transformation project will be used for quality control links that require a lot of manpower, such as silk cake appearance inspection. Mei Zhen calculated for the reporter that after the project is completed, annual labor costs can be saved by 4.8 million yuan, and the qualified rate of the product after the transformation is expected to increase by 0.5%, which will create benefits of more than 35 million yuan each year.
數字 "Digital brain" brings global synergy
Reverse acquisition of "World First" Fubond, promoted to the world's largest caprolactam producer; took the lead in opening up the entire industry chain of "cyclohexanone-caprolactam-polymerization-spinning-textile-warping-weaving-dyeing and finishing" ... In recent years, Hengshen, which has 21 branches and 7 R & D laboratories around the world, has become a "world factory".
However, in the face of industrial coordination problems across Asia and Europe, this local textile company started from a "mosquito net factory" does not have much ready-to-use experience.
"Even if you have the most advanced equipment in the world and use machines to replace labor, it does not mean that intelligent transformation has been achieved." In the view of Chen Jianlong, chairman of Hengshen Holdings Group, only the network of industrial collaboration can be put on the "sky." It is through the "new infrastructure" to learn from the "digital brain" that intelligent factories can have souls.
建 Chen Jianlong showed reporters the "early form" of Hengshen's "digital brain" intelligent management platform on a tablet. This set of management system based on the "SAP ERP" framework realizes the deepening of the "IoT (Internet of Things) + SaaS (Software Integration) + AI (Artificial Intelligence)" system, and integrates data from manufacturing, research and development design, logistics and warehousing. Combined into one, real-time acquisition and intelligent mining of "production, supply, sales, people, finance, and material" data are realized.
The reporter found that through the "digital brain", whether it is a subsidiary in Changle, Fujian, Nanjing, Jiangsu, or a factory in Maastricht, the Netherlands, Chen Jianlong can real-time access to production screens and production capacity, inventory, etc. Various types of data and intelligent reports are generated, which makes it possible for enterprises to adjust the capacity structure across regions, allocate production indicators, and reduce inventory consumption during the epidemic.
"In the past, the European R & D center invested about 17 million euros in research and development every year. Now through the" digital brain ", the same research and development topic only needs to invest 8.5 million euros. This is the efficiency brought by collaboration." According to Chen Jianlong, the information across the region previously Delivery will take five or six days. With the intelligent decomposition of the "digital brain", the delivery cycle has been accelerated from the previous one or two weeks to the current 4 days, and production efficiency has been greatly improved.
There is an irreplaceable worker behind the machinery
7Every morning at 7:45 am, in the Hengshen Synthetic Fiber Technology Center, the engineer Yang Yue must appear in front of the computer screen on time to check the product index data transmitted by the six rear spinning workshops in front. The data is loaded in 8 tables, which record the 22 physical parameters of the three major categories of physical properties, dyeing, and appearance of the products produced by each machine in the workshop. There are 110 post-spinning equipments owned by Hengshen Group. On average, there are more than 2,200 data that Yang Yue needs to inspect and process. He told reporters: "It will take half a day after reading and collating the data."
"The product wool rate data is abnormal. It is still high after 1 day of spinning. Check whether the mechanical parts are worn and aging?" "Frequent occurrence of stiff threads or tight points may require fine-tuning of the production process." Yang Yue should find abnormalities from these data, and analyze the data to provide abnormal causes and improvement suggestions for workers in the production workshop, and follow up the entire process.
不少 In the eyes of many colleagues, Yang Yue's role is like the brain in a "smart factory", mining the value of data in massive amounts of data. In order to improve the automation level of data mining, Yang Yue and colleagues are studying the expression rules of abnormal data, trying to develop new analysis systems, so that abnormalities on the production line can be found more quickly and efficiently, and the error rate of manual inspection can be reduced.
"Whether it is intelligent machinery or the 'digital brain', it is to help workers achieve higher quality production and labor." In Yang Yue's view, he is not worried that he will be replaced by this automated system, nor is he worried about workers Will be replaced by smart devices on the production line.
Sunda and the other two engineers in the technology center are from the production line, and monitor and organize the production data of polymerization, front spinning, and post spinning. "We can be here because we have the capabilities and experience that machines do not have." Yang Yue told reporters: "The temperature of workers is irreplaceable."
