After the application of the intelligent system for chemical fiber filament production, the per capita output of xinfengming Group Co., Ltd. has increased by about 250%, and the labor expenditure of the whole factory can be saved by about 600 million yuan compared with the previous one.
At the recently held 2018 textile and garment intelligent manufacturing solution promotion and textile intelligent manufacturing system solution supplier docking meeting, vivid examples reflect that intelligent manufacturing has played an important role in improving production efficiency, improving product quality, improving market rapid response ability, alleviating labor shortage and environmental constraints.
Textile and garment industry has a long chain, many production processes and various types of equipment, which leads to long production cycle, low efficiency and high labor cost. With the increasing cost of various production factors in China, textile and garment enterprises have an urgent need to reduce labor, reduce labor intensity, improve product quality and production efficiency“ Since the 12th Five Year Plan, textile and garment enterprises, equipment software suppliers, system integrators and scientific research institutes have developed and applied different levels of intelligent manufacturing equipment and workshops. At present, the new intelligent manufacturing mode has basically covered six fields of textile and garment manufacturing. Enterprise representatives and experts from chemical fiber, spinning, weaving, printing and dyeing, nonwovens, clothing and other fields, as well as representatives of intelligent manufacturing solution suppliers, gathered together to introduce their practice in intelligent manufacturing, put forward the future demand direction, and shared their thoughts on intelligent manufacturing.
Value and significance:
Promote innovation, green, coordinated, open and shared development
According to Hou Xi, Secretary General of textile industry sub League of China Intelligent Manufacturing System Solutions Alliance and Deputy Secretary General of China Textile Machinery Association, there are typical intelligent manufacturing cases in chemical fiber production, spinning processing, weaving processing, dyeing and finishing, nonwoven production and garment production. From the intelligent spinning demonstration project of Xinjiang Yida Textile Co., Ltd., which employs 15 people per 10000 spindles, to the whole process digital workshop of Changling spintronic intelligent weaving, from the integrated solution of finishing and weft finishing of Changzhou Hongda Electric Co., Ltd. to the pure cotton spunlaced nonwovens production digital workshop of Hengtian Jiahua nonwovens Co., Ltd, All of them reflect the value and significance of intelligent manufacturing achievements in the industry.
Shandong Jinan Yongxin New Material Technology Co., Ltd. is a domestic R & D and production enterprise of high-end medical and health biomass materials. Its products have good development prospects in the fields of high-end medical and health care, health care for the aged, maternal and infant care, etc. with the characteristics of antibacterial, hemostatic and moisturizing. According to Wang Jing, general manager, the company has initially built a new production mode of flexible and intelligent spunlaced nonwovens driven by orders, covering "one center, three platforms and four standard systems". As the brain and nerve center of the intelligent factory, the intelligent manufacturing central command and dispatch center under construction can uniformly dispatch the data of the whole process of production and operation, realize data collaboration with MES and ERP, open up data isolated island, and realize data interconnection of the whole plant; The intelligent equipment monitoring system under construction can integrate a series of high-sensitivity sensing devices and high-precision quality on-line detection system to realize accurate detection, real-time feedback, on-line diagnosis and intelligent correction of equipment status and product quality under high-speed production conditions. In the next development stage, Yongxin company will continue to develop customized ERP system, develop and apply multi joint industrial robot, develop and apply whole process intelligent Spunlaced production line and intelligent warehousing and logistics equipment system.
Han Lixin, deputy chief engineer of Beijing Machinery Industry Automation Research Institute Co., Ltd., believes that intelligent manufacturing is a big concept, a deep integration of new generation information technology and advanced manufacturing technology, which runs through all links of product design, manufacturing, service and other whole life cycle, as well as the optimization and integration of corresponding systems, aiming at continuously improving the product quality, benefit and service level of enterprises, Reduce resource consumption, and promote innovation, green, coordinated, open and shared development of manufacturing industry. The architecture of intelligent factory is mainly composed of enterprise life cycle management and product life cycle management, and life cycle management needs R & D platform, production operation platform and service platform. When talking about the construction of intelligent factories, he said that the three key points of planning first, laying a good foundation and doing a good job in integration should not be ignored.
Hou Xi said that among the intelligent manufacturing projects implemented in the field of textile and clothing, automation and digitization have been realized, most of them have been networked, some of them have intelligent equipment and functions, and some of them also use big data and artificial intelligence technology. This fully reflects the characteristics of parallel promotion and integrated development of the three paradigms of Intelligent Manufacturing in China.
On this basis, the intelligent manufacturing of textile and clothing will develop in the direction of more intelligent. At the same time, it will expand to other fiber raw materials such as acrylic fiber, spandex fiber, wool and hemp fiber, to other processing technologies such as cloth dyeing, needling, spinning and melting, and to the fields of home textile and industrial use. Finally, the digital network intelligent manufacturing will be applied in the field of clothing, clothing and clothing Home textiles and industrial textiles will be promoted in an all-round way.
Practice and feeling:
Act according to one's ability, not for intelligence
In recent years, Shandong Lutai Textile Co., Ltd. has actively applied intelligent production system solutions such as cheese dyeing intelligent control system, spinning e system, personalized shirt customization system, etc. Liu Zhengqin, assistant director of the Research Institute of Lutai company, introduced Lutai's practice and experience in promoting intelligent manufacturing with the deep integration of industrialization and industrialization. Liu Zhengqin believes that the informatization of data is the basis of intelligent manufacturing, the integration of informatization and informatization is the key of intelligent manufacturing, and people-oriented is the original intention of intelligent manufacturing. Lutai integrated and integrated the data of technology, enterprise management and customer information in the past 30 years, and built a six dimensional intelligent big data platform including planning and production, production collaboration, quality control, resource management, interconnection and decision support. based on the big data platform, mobile Internet technology, intelligent logistics and cloud computing, the integration of the two technologies is realized to boost the realization of intelligent production, transform from large-scale manufacturing to mass customization, and achieve the goal of rapid response and accurate delivery. With the cooperation of intelligent machines, we can give full play to human potential and make manufacturing enterprises more attractive and attractive. According to the introduction, the idea of Lutai's intelligent work at this stage is to develop data analysis and decision-making software to collect, analyze and make decisions on process, process and management data; Positioning logistics to lay the foundation for the realization of Internet of things; Modular development, segmented implementation, acting according to one's ability, not intelligent for the sake of intelligence.
Xiang Zhong, associate professor of School of machinery and automatic control of Zhejiang University of technology, said that the development trend of Zhilian network weaving is to build textile and weaving machinery interconnection platform, large-scale personalized product customization platform and network collaborative manufacturing platform. Textile and weaving factories should promote the combination of mobile Internet, cloud computing, big data and Internet of things, Help enterprises to expand international and domestic markets. It is worth noting that at present, the development of domestic Zhilian network weaving is facing difficulties in market, production, cost, resources, environmental protection and other aspects. There are also problems in the industry, such as weak standardization, poor information, random process, chaotic planning, overstocking of raw materials, unfounded decision-making, and poor quality control.
Xiang Zhong believes that the construction of textile weaving equipment information model is the foundation and core of weaving process digitization. The standardization construction of Zhilian network weaving construction scheme and the construction of intelligent manufacturing workshop should focus on solving the problems of interconnection and interoperability between different brands, types, models and other equipment. For example, in the future, the intelligent manufacturing solution of circular machine will realize machine replacement through interconnection of circular machine equipment, online detection and marking of fabric defects, flexible logistics distribution, development of industry-specific robots, etc., build a factory interconnection platform, realize online information collection, online quality inspection, and realize big data mining through factory informatization and digitization.
Demand and conception:
Network collaboration and customized production can be truly implemented
Although the textile and garment manufacturing has developed intelligent manufacturing equipment and system solutions for different fields, there are still many pain points and difficulties to overcome one by one.
Li Hui, general manager of clothing supply chain of 361 (China) Co., Ltd., said that it is difficult to find intelligent manufacturing solution suppliers that match the project vision at present, which is the pain point of 361. In 2025, the total scale of the sports industry will reach 700 million yuan, with huge development potential. But at present, the shoe and clothing industry is burdened with three mountains: labor reduction, industrial transfer and information island. As a labor-intensive enterprise, the age-appropriate labor force is gradually decreasing. With the industrial transfer, workers need to achieve home employment. These practical problems need to be solved by network collaborative manufacturing. Business collaboration, information collaboration, design collaboration and supply collaboration are the four cornerstones to realize cross regional network collaborative manufacturing. The support of intelligent equipment, big data related technology and the combination of government, industry, University and research is essential“ Cross regional network collaborative manufacturing needs the support of intelligent devices, industrial Internet, big data and cloud platform. Through network collaborative manufacturing and big data, we can achieve the goal of low inventory and zero inventory in the clothing industry chain, and get through the interconnection of the whole industry chain with the help of brand. As a Chinese brand, we hope to unite with Chinese software suppliers and really go to the world. We have an urgent demand for big data and cloud platform in shoe materials. After truly realizing cross regional network collaboration, we have realized the chain from brand R & D and design to retail terminal, which should be in the middle of the smile curve. We need to upgrade with the help of intelligent manufacturing to achieve the so-called flexible manufacturing and retail transformation. Our goal is to achieve flexible manufacturing from brand design to store sales within 30 days, which is our challenge. The future layout of 361 company not only focuses on China, but also focuses on the world. With the efforts of all parties, cross regional network collaborative manufacturing can really be realized and become an international company. " Li Hui said.
Mei Feng, chief engineer of Jiangsu Guowang hi tech fiber Co., Ltd., analyzed the development requirements of chemical fiber enterprises, and introduced the concept of future factory for polyester filament intelligent manufacturing. Mei Feng said that the integration of the chemical fiber industry is getting higher and higher. On the one hand, enterprises use large-scale to improve efficiency and reduce costs. On the other hand, they have higher and higher requirements for the functionality of products. They need to use leading technology to achieve professional and customized production. In the future, the company will realize intelligent digital production from the whole process of product performance, function design, melt conveying, polymerization, spinning and texturing process, manufacturing, testing, logistics and packaging, and realize customized production through industrial cloud and industrial big data. It includes the construction of chemical fiber online trading platform, the construction of production process simulation system, digital intelligent processing system, the realization of online quality monitoring and management of the whole production process, the construction of intelligent logistics system, intelligent cleaning and intelligent replacement, cleaning and purging, spinneret detection and assembly system, intelligent microscopic inspection robot system. He also introduced to suppliers the current demand of chemical fiber enterprises for intellectualization: how to improve the efficiency, variety and quality simultaneously according to the overall design requirements of intelligent factory and combined with the improvement of chemical fiber process flow; Targeted breakthroughs in key processes such as spinning plate cleaning, assembly disassembly, POY feeding, etc; How to build their own big data applications and platforms.
By analyzing the case of Zhilian network weaving, Xiang Zhong puts forward six development measures of Zhilian network weaving: first, strive for special support from government policies, funds, entrepreneurship, etc; The second is to improve the hardware environment for the development of Internet textile from four aspects of network facilities, data center, public platform and logistics network; The third is to cultivate a number of "intelligent network weaving" enterprises with national influence, strengthen the development and promotion of typical application demonstration, drive social resource investment by demonstration application, and accelerate the industrial expansion from point to area; The fourth is to establish "Zhilian network weaving" industrial concentration area to highlight the industrial cluster effect and promote regional economic development; Fifthly, we should strengthen the training of Internet textile talents and gather high-end talents to lead the training and accelerate the development of Internet; Sixth, strengthen the cooperation between industry, University and research in the field of "quality network weaving" and carry out technical exchanges.
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