A few days ago, the Shandong Provincial Department of Industry and Information Technology issued the “Opinions on Accelerating the High-Quality Development of the Textile and Apparel 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. In the fields of spinning, weaving, printing and dyeing, we will promote the construction of a number of green and intelligent factories in large enterprises, and promote the implementation of a number of intelligent technology transformation projects in small and medium-sized enterprises to gradually realize intelligent production processes, intelligent control systems, Online monitoring informatization and green manufacturing process.
It can be seen that digitalization has become a mainstream trend in enterprise 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 solves difficulties in the production of differentiated products
In recent years, Shandong Daiyin Textile and Garment Group (hereinafter referred to as “Daiyin Group”) has made great achievements in intelligent manufacturing. Spare no effort in industrial transformation, actively promote the intelligent transformation of spinning, and create 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 employees per 10,000 spindles. , compared with other companies in terms of labor costs, it has a huge advantage. In the next 5 to 10 years, the trend of ‘machine substitution’ will become more obvious. Manufacturing companies improve their technical content, use machines and technology to replace simple manpower, and realize Automation is already an inevitable trend,” said Zhao Huanchen, chairman of Daiyin Group.
Zhao Huanchen introduced that Daiyin Group invested 200 million yuan to gradually upgrade and transform the existing 100,000-spindle spinning production line into intelligent products, carefully build a flexible manufacturing production line for differentiated products, and achieve order-driven and intelligent distribution. Intelligent manufacturing featuring cotton, traceability management, unit monitoring, status management, and quality online, after the project is completed, can effectively solve the difficulties existing in the production process of differentiated products, and can meet the needs of products ranging from 10,000 tons to tens of kilograms. Precise R&D and manufacturing of special-type yarns increase production efficiency by 25% and make product quality 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. Customized projects, fully 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 improves production efficiency and reduces energy consumption
In the workshop of Hangzhou Xiaoshan Wansheng Textile Co., Ltd. (hereinafter referred to as “Wansheng Textile”) , rows of smart machines run 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 and 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, which has not only significantly reduced 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 show that since the implementation of the overall transformation project one year ago, the production efficiency of Wansheng Textile Workshop has increased by more than 20%, the energy consumption per unit output value has been reduced by 20%, the product defect rate has been reduced by half, and operating costs have been 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 meets world sewing thread production standards
“We carry out technological transformation and capacity expansion to build a modern, standardized and technological sewing thread industry base , has currently led 5 peers to carry out intelligent upgrading and transformation of production lines.” Hubei Mingren Textile Technology Co., Ltd. (hereinafter referred to as “Mingren Textile Technology Co., Ltd.”)Wu Jian’an, chairman of the Hubei Textile Industry Association, said.
Mingren Textile is a provincial high-tech enterprise mainly engaged in the production of polyester yarns. It is also the “hidden champion enterprise” of Hubei Province’s textile industry. There are 200,000 yarn spindles and 150,000 thread spindles, with an annual output of 38,000 tons of various high-end 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-spindle polyester yarn 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 an intelligent and intelligent production process. Automate production equipment and digitally monitor 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 ingots will be reduced from more than 100 to more than 20 people. “Wu Jian’an introduced that this project is in line with the world’s sewing thread production standards and uses a double-layered 40,000-square-meter single factory building. Its constant temperature and humidity workshop meets the high-end intelligent manufacturing requirements of the Industry 4.0 era, which can greatly improve the quality of sewing thread products.
From manual wiring to automatic machine production, technological transformation and capacity expansion not only eased the work intensity of textile workers, but also improved production efficiency. “In the past, we had to walk around to make joints by hand. Later, in the workshop Workers ride on both sides of the car and work. Now all workshops are fully automated. If we want to produce the current output, at least a dozen people were needed in the past, but now one person can operate two machines. “Zhu Xiaohong, a staff member of the workshop, lamented that the intelligent transformation and upgrading has allowed the spinning workshop to take off the label of “low efficiency and high labor force”.
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