Impressions of China Textile Machinery Exhibition 2020?
China Textile Equipment Exhibition 2020 and ITMA Asia exhibition is the first exhibition after two years of the epidemic. Affected by the global epidemic, the exhibition business scale and popularity value are not as popular as expected. However, the enthusiasm of the viewers is not falling. Many textile enterprise owners are running to pursue the task of reducing labor and transforming new projects“The situation that it is difficult to recruit, expensive to employ and unable to retain "has consumed a lot of energy of the management, and even can't recruit employees at some price, which seriously constrains the sustainable development concept of the company. Therefore, the management from the bottom of my heart wants to accelerate the progress of intelligent automation technology transformation.This paper will briefly analyze the textile enterprise labor shortage, textile machine transformation problems and how to solve them.
Social factors of difficult recruitment
First of all, let's take a look at the average age of the staff in small and medium-sized textile enterprises. Most of the production and manufacturing technical backbones in many textile mills are old employees aged 40-55. The age structure is generally over 40 years old. Because there are no professional and technical personnel to recruit, many who have already retired can only be employed again, and the labor force is in the embarrassing link of no successor.In order to deal with their concerns better, the college students who have been recruited have everything from housing, central air conditioning, salary and position to the confidence that they will leave other industries.Shandong Province is a large enterprise far ahead of the rest in terms of wages and salaries. However, since a company engaged in electronic industry was called in, countless employees, including a large number of technical backbones, were attracted. In the past, the boss only had a strong smile and had no power to resist.The range of management methods of grass-roots personnel can not be mastered. If the words are heavy, they are worried that they will stop working.
What happened?Old employees are used to the boring, repetitive and simple physical work in the processing plant.However, the social development of young people has gone through a good time, and they can't resonate with the old people who have gone through difficult years in terms of Three Outlooks and ideals and beliefs. Since China's reform and opening up to the world, overseas study, vacation tourism, staff getting along with each other, and popularization on mobile phones, etc., have expanded their horizons and will no longer stick to the old rules.After getting rid of the golden rice bowl, it is unlikely to hang on a tree, and the sense of employment has changed greatly. Therefore, it is impossible to integrate into the team atmosphere of textile factory, which is relatively simple and boring, noisy and smoky.At the exhibition, the general manager of a textile enterprise sighed anxiously that none of the more than ten college students who went in last year wanted to enter the production workshop.Generally, young people seem to respect and enjoy life, and care about the quality of life. The three shift work style has been resisted by some companies and even groups.Young people prefer new freelancers such as takeout, delivery companies, live broadcasting rooms, we media platforms, etc.The textile machinery is also facing the dilemma of labor force and employment shortage. Compared with capitalist countries, the intelligent production and manufacturing of textile machinery is lack of relativity, lack of both personnel and assets.A general manager sighed that no suitable skilled workers had been recruited so far after the Chinese New Year.
In the past, the textile industry was a hot commodity. If you want to enter the factory, you have to rely on the relationship. Now it has become a "nobody's business" field. What's more, the authoritative experts have already sent out warning information in the past two years: demographic dividend is about to take place, and "wolf is coming" has been yelled for two years, but everyone is not satisfied.With the increasing trend of aging in China, the demographic dividend has been exhausted.At this stage, what level is it expensive to recruit workers?The author's real experience, in Changle, Fujian Province, roving workers see three sets of roving salary of nearly 9000 yuan.At the exhibition, a general manager of Jiangxi textile enterprises talked about recruiting an electric welder who knows how to make a full-automatic connector of rotor spinning ad car. The asking price is 18000 yuan per month. No matter how expensive it is, you have to recruit. If you let foreigners repair it, the cost will be too much.
The general trend of environment oppresses China's manufacturing industry
The spread of the epidemic has disrupted the layout of the world economy, high-tech and financial industries. The United States has attacked China's economy, trade, high-tech, financial industry and national defense in many ways. The idea of anti globalization has promoted European and American countries, Japan and South Korea and other relatively developed countries to rethink the rational layout of the whole industry chain all over the world,Preferential policies have been issued to encourage the company to move the processing and manufacturing industry back to the country.Not long ago, the G7 conference promulgated an existing policy on China's "one belt and one road" and launched an American version of the "belt and road" to compete for cheap human capital and resources.The monthly salary of employees in Southeast Asia, East Asia, central and Western Asia ranges from several hundred yuan to 12000 yuan. It is obvious that if the belt and road initiative is really promoting local transportation and freight logistics, it is highly likely that the processing and manufacturing industry, especially the medium and low-grade textiles, will migrate to the above regions. The influence of China's "manufacturing industry" may be challenged in the next five years.To deal with the labor problem is not only the problem of production and operation of simple manufacturing enterprises, but also the strategic problem of the cornerstone of the people's groups in weixie countries, which can be ignored.
"Four major events" transformation is the key to reduce the number of people
In order to better development, textile machinery enterprises have made four technical reforms, which are automatic management machine, automatic doffing machine, automatic packaging of cylinder yarn, and automatic inserting (inserting) machine.
▎ automatic management machine
Among the four reforms, the most rapid progress is automatic management machine. Due to its moderate price, relatively simple structure, convenient use and maintenance, more than 50% of textile enterprises can be transformed. Jiangyin Kaiye and other enterprises have launched relevant management machine equipment for enterprises to choose from.
▎ automatic doffing machine
The second is automatic doffing. Since there are at least ten types of spinning frame short cars in China, which form should be adopted?A few years ago, there was no clue. At the historical stage, China's original Songbao intelligent doffing car appeared to simulate manual pulling and doffing, which was welcomed by textile enterprises.In addition to the large investment, the narrow space is also a factor. The transformation of short car is reversed in 2019 Shanghai textile machinery exhibition, and textile machinery enterprises such as Nantong Jinchi, Jiangsu Haima and Changzhou Jichuang have achieved success in the translational collective doffing transformation technology.Compared with the traditional swing arm type, the translational type is horizontally retracted and retracted, which is not affected by the span size of the middle wall panel foot, which solves the problem that the swing type collector cannot operate in the case of small spinning frame spacing. At present, the transformation of this type of collector is in progress.
▎ automatic package of tube yarn
The third is the automatic packaging of smart yarn. It has been only two or three years since the sample came out to mass promotion, which can be regarded as a miracle. For example, Qingdao Huanqiu and Qingdao Shuangqing are relatively mature in automatic packaging of smart tube yarn, which technically solves the problems of paper tube identification, weighing and counterweight, and customized personalized layout.In terms of after-sales service, the training of equipment use and maintenance system is carried out, so that textile enterprises can learn to manage, use and repair new technology and transform equipment.
▎ automatic feeding (inserting) machine
One is the automatic feeding (inserting) machine, which has been paid close attention to by peers in the industry.I remember that in 2018, a textile machinery enterprise exhibited in Shanghai Textile Machinery Exhibition for the first time, which attracted high attention in the industry. Now two years later, the self winding yarn feeding transformation has not been widely promoted in the market, and the R & D of the spinning machine manufacturers is not so smooth, and some even switch production. What are the reasons?
It is not as simple as expected to change the manual inserting yarn into the tray or the robot feeding yarn in the yarn storehouse. This is based on the fact that the tube yarns provided for spinning enterprises are not uniform. The fact is that the yarn head on the surface of the tube yarn is not standardized due to the spinning model, doffing form, winding forming and density, count thickness, equipment model, process parameters and variety category,In particular, manual doffing has a great impact on yarn change and insertion, which affects winding efficiency, including poor management level of many small and medium-sized spinning enterprises, and difficulty in controlling temperature and humidity on site.Winding is a process of finished products, which makes the whole body move. It is also the reason why textile enterprises are afraid to place orders easily.
It is estimated that more than 25000 sets of yarn library type self winding are in use. If it is updated, the financial pressure of small and medium-sized textile enterprises will be too great and unrealistic.The old man of a textile enterprise in Dongying, Shandong Province, finally made an account. He went to Murata company to consult the pallet type automatic winder. A set of 60 spindles costs about 1.8 million yuan, and 70 spindles is close to 2 million yuan. Moreover, there is no stock, and it will take a year to get the equipment.If the yarn storehouse is transformed into one set for about 300000 yuan, the money for purchasing one set can be transformed into six sets, which can be recovered in less than three years.In fact, the textile enterprises have a strong willingness to reform themselves, and the key is to make people feel relieved and reliable performance.
From sample to product
In this exhibition, Kaiye / Kairui kylt500 and Tongling Songbao tfm18 finally launched products that can meet the requirements of textile enterprises, which can replace manual change and yarn feeding.The reason for this is that the two enterprises have carried out seven or eight times of product design, transformation and upgrading according to customer opinions. At present, the operation, maintenance, failure rate and efficiency of the products are relatively stable.The difficulty in the transformation of the doffing frame is the tube yarn of manual doffing (spindle bar bending, machine component function failure, difficult yarn drawing, nonstandard operation, etc.), especially after doffing, the tail yarn of the tube yarn is entangled together, which makes the self winding frame disordered and affects the head finding and feeding of the doffing frame.In order to improve the performance of the products, Kaiye Textile Machinery Co., Ltd. has put forward hundreds of pertinent opinions to Kaiye textile machinery from product design and development to sample production to final product. It took nearly six years to optimize Kaiye textile machinery around four major requirements of reliability, stability, convenience and practicability. It realized that in order to complete the above requirements, it is necessary to integrate the transformation of additional system and self-healing system,Improve yarn feeding efficiency in all directions.
Equipment innovation, advocating a hundred schools
Which feeder is suitable for modification?If the new technology highlights of this exhibition, it should be two intelligent yarn inserting robots, one is Shanghai Tianfu industrial intelligent yarn inserting robot, the other is Shenzhen weiai intelligent, yarn inserting robot demonstration is both.What is amazing is that Shenzhen weiai is a high-tech enterprise that provides intelligent AI solutions. The core team is returned doctors and scientists. The advertising planning is unique and full of scientific and technological content. It can not help but shine at the textile people who are used to the traditional spinning technology.Like spinning intelligent car, the inserting robot is a transitional product, which is in line with the national conditions of our country. As long as the self winding reliability production is solved, it is really realized that one person can manage multiple winding machines, and multiple sets can be used on a single winding machine at random, so as to meet the purpose of reducing labor and improving production efficiency.Moreover, the car adapts to the small space transformation of the old factory, which really adds a choice to the production scheduling of semi worsted, color spun, blended and other varieties.
Seize the opportunity to win the transition time
The employment problem can not wait to die. Enterprise decision makers should have a higher vision and mind, judge the future trend of their own enterprises from the global industrial chain layout, and treat young people's career choices more leniently. Labor transfer is the inevitable process of industrialization, and strengthening itself is the "hard truth".Mobilize resources and wisdom, liberate the employees from the complicated physical labor, create a comfortable and relaxed working environment, and attract more young people to the automated and intelligent textile mills.It is not that some textile enterprises try their best to save electricity in order to reduce costs, and do not turn on air conditioning in summer, resulting in high temperature in spinning workshop and poor working environment.Secondly, one of the reasons why many old factories are unable to recruit more and more people is that there is no plan for the technological transformation of cotton spinning enterprises, which not only obviously lags behind other industries, but also lags behind in the textile industry.It is undeniable that the cotton textile industry has experienced the impact of the market ups and downs in the past few years, and the profits of textile enterprises are meager. Coupled with the epidemic, it is not easy to survive.
Fortunately, the geomancy turns around in turn. China is a country controlled by this rare new coronavirus epidemic in history. Since the second quarter of last year, orders from all over the world have poured into China in large quantities, and the opportunity is for well prepared enterprises.Those enterprises that improve the quality and efficiency through technological transformation have taken the lead in the market competition.Shandong Sanyang Textile Co., Ltd. attaches great importance to technical innovation and seeks market benefits through digitalization and intellectualization. The labor force for ten thousand spindles of pure cotton compact spinning is only 30 people, and the profit margin has reached 20% since May last year.
The way out to resolve the bottleneck of employment
The textile industry is not the same as it used to be. It is a realistic demand for the textile industry to transform from the traditional labor-intensive mode to the mode of modern elements such as high efficiency, intensive, ecological, environmental protection, network, intelligence, etc.How to solve the problem of recruitment difficulty, can not retain the short board of people, less people is a development direction of intelligent manufacturing, intelligent automation should be step by step, do not pursue the high-end intelligent in a short time.
Based on the problem of capital investment, the cotton spinning mill focuses on solving the above four major technical transformation in the form of "short, easy and fast".However, considering the overall situation, to solve the problem of excessive labor in cotton spinning equipment, continuous, automatic and intelligent process is the direction. Can the transformation of blowing carding unit and coarse and fine connection in policy, encourage enterprises to speed up the process.Enterprises can adapt measures to local conditions to carry out digital workshop transformation, see the benefits, and then decide as appropriate.It can be predicted that: less labor, lower production costs and higher profits;Intelligent automation + Internet of things has greatly improved production efficiency and enhanced development potential;Only when enterprises have the conditions to increase personal salary, reduce work intensity, improve the environment, pay no less than that of other industries, keep the staff and resolve the contradiction of recruitment naturally.
The textile industry is in the transition to "new products, quality and brand", focusing on big health, functionality, green and sustainable, cross-border cooperation and intelligent application.From the current situation of cotton textile enterprises, there are many varieties, small batches, many models and old models, so it is difficult to carry out the intelligent process in an all-round way!
* this article only represents the author's personal views
Source: new media of cotton textile technology
Reprinted from the author: Miao Dingshu