At the end of last year, the “13th Five-Year Plan†for the scientific and technological innovation of Binhai New Area clearly stated: Combining the functional orientation of the R&D and transformation base of the new district manufacturing industry, further improving the level of intelligent manufacturing. How do manufacturing companies realize manufacturing and intellectual creation? Manufacturing companies in the new district are exploring the answer to this question at a practical level.
Promote the butterfly of traditional enterprises
The core of Industry 4.0 is to use the IOT information system to digitize and intelligentize the supply, manufacturing and sales information in production, and finally to achieve fast, effective and personalized product supply. New technologies and new production methods have given all enterprises equal opportunities, and they have also given some private enterprises the opportunity to overtake the corners. Some of them are from industry 1.0 and 2.0 directly to Industry 4.0.
Tianjin Deka Auto Parts Co., Ltd. is a 12-year-old company that assembles tires and wheels together and then supplies them to the entire vehicle company for installation. This is the business that the company is engaged in. In the first eight years of its establishment, the company used the most traditional assembly processes in its Xiqing factory. "The assembly tools we used in the early days are not much different from those of general auto repair shops. They are completely dependent on manpower. It is inevitable that some small parts and small parts of the parts are in the process of production." The relevant person in charge of the company told the reporter.
The huge transformation began in 2012, when the company won a new order from Tianjin FAW Toyota, they are going to build a new factory in Tianjin Development Zone. Simply copying past production processes is not realistic. “FAW Toyota is an orderly production, not a mass production. This means that every product on the production line may be different from the products before and after it.†Zhang Jianguo, general manager of Tianjin Dika Auto Parts Co., Ltd. told the author, the new The factory must build a new production line from the perspective of reducing costs and improving efficiency in accordance with the requirements of informationization and automation.
In order to meet the demand of Tianjin FAW Toyota's order production, the new factory built a special network to receive the order information of Tianjin FAW Toyota. The received order information was disassembled by the computer system and transferred to a highly automated production line. The reporter saw on the scene that in addition to raw material and finished product handling and individual assembly steps, other production links were automatically completed by the production line.
“After receiving the order information, the system will allocate the tires, hubs, delivery time, serial number, etc. required by the order. The workers only need to take the corresponding model and quantity of tires and wheels according to the indication system.†Zhang Jianguo introduced .
Compared with the factory in Xiqing District, the production capacity of the plant in the development zone has increased from 100,000 vehicles to 300,000 vehicles, and the number of employees has dropped from 60 to 38. Due to the order production, zero inventory, the plant area decreased from 2,700 square meters to 2,300 square meters. "In the past, we had to have a special person to receive orders, place orders, and arrange production. The products to be shipped should be sorted. At least 2 days of inventory should be prepared for inventory. Now it is not needed." Zhang Jianguo introduced.
Open a customized production chain
Actively introducing "Industry 4.0" is also the Mei Kemei home that settled in Tianjin Development Zone in the 1990s. In the intelligent production workshop of this well-known domestic high-end furniture manufacturing enterprise, advanced industrial robots are completed together with young front-line workers.
"On the basis of traditional production equipment, by introducing industrial robots, the work of the original four people has been reduced to one person now." Xu Hai, intelligent manufacturing project manager of Meike International Household Products Co., Ltd., said that the former workers had to The workpiece is machined on the machine, but now it is placed in the silo, loading, processing, and unloading, all automatically done by the robot. As long as the worker scans the document on the material, the machining program can be automatically transferred to achieve automatic machining.
The support center and the robot cooperate to complete the processing work is the control center on the second floor of the factory. "What is produced here is not determined by the workers themselves, but by the control and dispatch of our control center. Based on the control system, we produce products on the production line according to the needs of customers, making on-demand production possible." Xu Hai introduced that the most traditional hand-made robotic automation equipment not only saves labor costs, but also increases efficiency by 300%.
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