Due to the intrusion of Alibaba“Rhinoceros Factory“, the smart clothing manufacturing industry Transformation has once again become a hot topic in the industry. In fact, starting from the popular trend of international brand clothing“fast fashion“, it meets the needs of multiple varieties and small batches. , quick response to production needs, has become a unique skill for each clothing manufacturing factory to ensure that it can win in the fierce competition.
Jifa Group has built a flexible intelligent manufacturing workshop that integrates weaving, dyeing and sewing and can handle orders for only two or three pieces of clothing.
As a company As an old textile enterprise with a history of 65 years, seizing every opportunity given by the times is the magic weapon for Jifa Group’s long-term prosperity. Since 2016, Jifa has used its subsidiary Qingdao Guihua Knitting Co., Ltd. as a pilot project to carry out intelligent transformation, using informatization to open up the entire process from weaving, printing and dyeing, to Garment cutting and sewing……All links in the entire industry chain have established a supply chain model of agile manufacturing and flexible production.
Today, the delivery time for Guihua’s large-scale knitting orders has been advanced from the normal 42days span>14days, fast return orders (orders within 2000pieces) arrive in advance7 span>days. Thanks to such a quick response, Guihua Knitting quickly came out of the trough after the epidemic. Since 5 months, its operating income has continued to grow against the trend, and domestic and foreign orders have been fully booked. Production schedule before the end of the year.
Intelligent manufacturing workshops open up the entire industry chain
Weaving, printing and dyeing, and garment cutting and sewing are three important links in the upstream and downstream supply chain of clothing production. From an industrial perspective, it is an industrial chain. However, in Guihua Knitting’s production workshop, through intelligent transformation, flexible intelligent manufacturing has been formed, and weaving, dyeing and sewing have become one process after another.
Weaving workshop, an orange flat-panel robot less than 1 square meters shuttles back and forth along the track to transport yarn; dyeing and finishing workshop , several small color mixing cylinders automatically color and mix colors according to established procedures; in the garment workshop, wireless radio frequency technology collects workers’ production information and work performance in real time; in the central control room, a set of ERPThe system includes all data from all nodes of weaving, dyeing, and garment making, as well as the entire chain, and has become an important carrier for real-time monitoring of all aspects of production operations and interaction of equipment information…This is the reporter coming soon Scenes seen in the flexible intelligent manufacturing workshop of Guihua Knitting Co., Ltd. of Fa Group that integrates weaving, dyeing and sewing.
Jifa Group Intelligent Information PlatformRFIDWorkshop Product Inspection Terminal
Guihua Knitting1993Since its establishment in 1993, it has focused on producing knitted garments for overseas brands (OEM). Following the trend of international brand clothing, since the beginning of this century “fast fashion“ has surged, and companies have used information to Turn it into the core and try to solve the problems of small batch, multi-batch and fast delivery orders.
Sun Weifa, general manager of the company, introduced, “I could only receive no one in the past year40 orders, one order has hundreds of thousands of pieces; but now there are nearly 6000 orders every year, and one order is several times more Thousands of pieces, sometimes only hundreds of pieces, and some even one piece, and customers require shipment within one or two weeks.”He said,“If we follow the past manufacturing methods, we would not be able to accept these orders. Under the smart manufacturing model, not only can we accept them, but our operational efficiency has also improved3030%.”
Jifa Group’s intelligent transformation has been launched since2016. Over the past few years, Jifa Group has been experimenting with��Factory Guihua Knitting uses informatization to open up all links of the entire industrial chain, establishes a supply chain model of agile manufacturing and flexible production, and realizes weaving, dyeing and sewing in one factory and one industrial park “One-stop“ to quickly meet the market demand for multiple varieties, small batches, and quick response orders.
“Every link is a digital collection of information. Each employee’s work is connected to a digital card. There is no information attenuation in different industrial links, minimizing the The enterprise’s human error costs and inventory pressure have improved the enterprise’s ability to resist risks and reduce costs.”In Sun Weifa’s view, the power of information technology can be used to form a new model in operation management. Flexible and intelligent manufacturing, they have therefore taken on more customers who are demanding.
Incorporate flexibility into management concepts
The smaller the order, the harder it is to do it. This is a consensus in the clothing industry. According to statistics, from 2003 to 2013, in this 10In one year, the average order for Guihua Knitting was only6,000 pieces, one SKU (single style, single color, single specification) only about 500 pieces. Sun Weifa believes that some domestic orders are now even 2 pieces, 3 pieces, and a single major overseas sports brand SKUOnly128pieces, which is completely in line with the requirements of small batches, multiple batches, and fast delivery. Enterprises must pursue efficiency, which ultimately means improving competitiveness. If you can take orders that others cannot, this is your advantage. Sun Weifa said, “We rely on the transformation, optimization and improvement of intelligent manufacturing models, which is also conducive to the long-term development of the enterprise.”
Zhibian One step ahead, the advantages of Guihua Knitting are even more prominent under the epidemic“Big Exam“. “Guihua’s operations have been making steady progress in recent years. ”Sun Weifa said that due to the shift in the global textile industry chain and the impact of the global epidemic, relying on high-quality manufacturing capabilities and riding the digital express, companies are heading towards“domestic and international dual cycles“The goal is accelerated. At present, the products have been adjusted from the past 90% to 60% of exports, both domestic and foreign markets. Gradually move towards equilibrium. “Even if they are both OEMs, foreign and domestic companies have many differences in standards and requirements. The only constant is rapid response to fashion trends. ”In Sun Weifa’s view, the OEM needs of brand companies can be accurately transmitted to the production side, and manufacturers can communicate with the market more accurately, thereby promoting companies to move from mass production to large-scale production in the past. Customization, this is the direction that Guihua Knitting is rushing in the Internet era.
On 4month16day, Guihua Knitting received a 3000The order was successfully delivered on29. “This batch of orders is in small quantity and requires 7 colors, 1 It takes 12hours to dye only one color, 7colors3 days, we still need to complete various processes such as weaving and printing, and the final delivery can be done in 13 days. It reflects the flexibility and agility of enterprise production.”In Guihua Knitting, the delivery time for large-scale orders has increased from normal42 Days in advance14days, express return orders (orders within 2000pieces) arrive in advance span>7days.
“Without enterprise transformation and without Internet thinking, this would definitely not be possible.”Sun Weifa said, Internet thinking requires collaboration to implement the concept of 7day delivery into every process. Small closed loops form a large closed loop to integrate flexible manufacturing. Flexible manufacturing is like a piece of dough. You can knead it in any way you want. No matter how big the order is, you can take it in and make it.
He said that flexibility is not only reflected in the concept of manufacturing process transformation, but also must be incorporated into the company’s management philosophy. “Apparel enterprises70% of the work must be done on a piece basis. Workers are definitely willing to work on large orders. Flexible manufacturing is beneficial to management. The requirements are extremely high, and they are prepared step by step in a short period of time.”Sun Weifa said that clothing manufacturing is still a labor-intensive industry. For example, automatic feeding equipment in the dyeing and finishing workshop improves process accuracy and product quality. However, in some production links, it is still impossible to completely eliminate labor. It is inevitable and necessary for the industrial Internet to develop to the present, but the industries are different and the realm of entry is different. It needs to be combined with the current enterprise situation, do it step by step, and do it actively.
There is a consensus within Jifa Group: the factory is the clothing manufacturing industry“Qingshan”. After 65 years of development, Jifa has owned 30 multiple companies and branches, 2A large enterprise with more than 10,000 employees. In 2019, the operating income will be 112. 29 billion, demonstrating the “new vitality” of an old industry. . Nowadays, a series of improvements in digital capabilities are opening up greater room for imagination for the development of this old textile enterprise.
>He said that flexibility is not only reflected in the concept of manufacturing process transformation, but also must be incorporated into the company’s management philosophy. “Apparel enterprises70% of the work must be done on a piece basis. Workers are definitely willing to work on large orders. Flexible manufacturing is beneficial to management. The requirements are extremely high, and they are prepared step by step in a short period of time.”Sun Weifa said that clothing manufacturing is still a labor-intensive industry. For example, automatic feeding equipment in the dyeing and finishing workshop improves process accuracy and product quality. However, in some production links, it is still impossible to completely eliminate labor. It is inevitable and necessary for the industrial Internet to develop to the present, but the industries are different and the realm of entry is different. It needs to be combined with the current enterprise situation, do it step by step, and do it actively.
There is a consensus within Jifa Group: the factory is the clothing manufacturing industry“Qingshan”. After 65 years of development, Jifa has owned 30 multiple companies and branches, 2A large enterprise with more than 10,000 employees. In 2019, the operating income will be 112. 29 billion, demonstrating the “new vitality” of an old industry. . Nowadays, a series of improvements in digital capabilities are opening up greater room for imagination for the development of this old textile enterprise. </p
