The Sadness And Joy Of Changing Machines In Wenzhou Enterprises

The sharp rise in labor costs has dominated the profit margins that the manufacturing industry did not have. "Machine substitution" has become a necessary precautionary measure. It is also an inevitable choice to promote industrial pformation and upgrading under the new normal economic situation.

As a private economy weathervane, Wenzhou enterprises are faced with the pain of pformation when they taste the sweetness: where will the equipment fund come from? How do they fit in with each other? How to make up for the gap of technical personnel?

An advanced assembly line, a row of neat manipulators, a Taiwan flower huge capital to introduce production equipment, Wenzhou boss so big investment "machine substitution" project, in fact, there is a "technology upgrade" smart account, which makes the reporter feel that the boss's smart account is making Wenzhou manufacturing industry "smart change".

The picture shows the automatic needle pressing machine assembly line in the assembly workshop of Hexing group.

Previously, 6 workers were required to complete the assembly line. After the machine was replaced, the new assembly line was put into use. Now a worker can manage three to four machines at the same time.

GA Da GA Da... "

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In the assembly workshop of Hexing group, there are a lot of rhythmic machine running sound.

In the workshop, the vibrating plates connected by three circular orbits are orderly rotating, and through the rotation of the machine, the processes such as pins, hitting, inserting, bending, breaking, testing and so on are automatically completed. Finally, they flow into the plastic bags under the machine.

"This machine is made of household electronic connectors. There are 200 thousand output per day," he said. "This amount needs 6 workers to work for a week."

Zheng Weiping, chief executive officer of Hexing group, said, "before the machine changes, all of these processes need to be done manually. The efficiency is low. Employees often get stuck with small needles on the connector. After the automation machine is put on line, a worker can manage three to four machines at the same time. After the new pipeline is put into use, it will probably reduce 130 people a year and save about about 6000000 yuan.

Employees are also feeling more relaxed. Now, just do two things: feeding and receiving, and occasionally dealing with machine breakdowns.

At the same time, in the automotive electronics workshop of Hexing group in Zhejiang, a mechanical manipulator about 1.5 meters is working in an orderly way. It sees that it grabs the metal parts on the table, quickly extends to the injection molding machine, and promptly takes out the plastic parts that are just in the injection molded car, and embeds the gold parts into the injection molding machine. The whole process takes only 20 seconds.

Zheng Weiping said: "this robot is only a small part of the equipment in the automotive electronics workshop. Because of its high efficiency and good product stability, it is mainly used for processing high-end products with high added value, which is conducive to improving the overall capacity."

It is understood that if the workshop is full load production, it is estimated that the annual output value can reach 100 million yuan.

Machine substitutions not only change quality but also change intelligence.

In the past three years, Hexing has invested 100 million yuan to carry out "machine substitution", and its production efficiency and product quality stability have been greatly improved.

The annual output value has increased by more than 10% annually, the total number of employees has decreased by 350, and the labor cost has been saved more than 15 million yuan per year.

Machine replacement is far from being "simple". It is not only "qualitative change" but also "intelligence change".

According to Zheng Weiping, in the introduction of robotics production line, Hexing introduced software, such as production management, human resource management and information management, from the very beginning, to synchronize with the hardware of the production line, instead of simply introducing an advanced assembly line.

In their view, "machine substitution" is just a formulation, the essence is "technological pformation", not only a way to introduce equipment.

For enterprises, the purchase of new equipment is a great expense, and the optimization and upgrading of existing equipment has the characteristics of small investment, good returns and fast returns.

According to Zheng Weiping, "Hexing has its own R & D team, and some automatic equipment will carry out its own technological pformation. This will not only reduce the purchase cost, but also meet the needs of the enterprise itself."

The "intelligence change" brought by "machine substitution" is not only the introduction of advanced equipment, the replacement of workers, but also the integration of advanced production technology into the whole production management system, and ultimately the realization of intelligent production and scientific decision making, and the integration of informatization and industrialization.

Such a view has been affirmed by many enterprises in the research of people's finance and economy. Machine instead of labor is the main trend of manufacturing pformation. Machines are the key, but people are the core.

Whether the choice of equipment purchase, or after the purchase of debugging, use and daily maintenance, all require high-quality workers.

If we do not have enough technical personnel to master vocational skills, we only buy a few machines. The so-called "machine substitution" is only superficial.

"Human-machine integration" is the core.

As one of the earliest enterprises in Wenzhou to carry out "machine substitutions", the giant group also has great feelings.

In recent years, the problem of increasing labor costs and frequent flow has made the shoe making industry a traditional labor-intensive industry into the bottleneck of development. The introduction of advanced equipment and machine substitution has not only alleviated the employment pressure of shoe companies, but also raised the level of shoemaking technology.

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The picture shows the laser machines of the giant shoe factory. There are more than 100 sets of giant one, all of which are controlled by computers.

After the workers put the program into the computer, the laser will be in it.

It is very precise and fast to depict all kinds of complex patterns.

Laser plays a very important role in carving, punching, cutting and scribing of shoe materials.

According to the staff, "once a pair of shoes needed 382 holes, the laser machine was used in 20 seconds. It not only saved time but also ensured the accuracy of drilling."

Pan Jianzhong, President of gigantic Group Co., Ltd. disclosed that because of the fancy and perforation of the upper, if the original handwork was made, the quality of the shoes of different batches would be different because of the different technical level of each worker. At the same time, some complex shoe upper styles could not be manufactured manually, and the new laser equipment used to solve these problems.

At present, the giant one group has invested about 35000000 yuan in the technical pformation, and 30% of the 100 manufacturing processes have been automated production.

At the same time, the employment demand of the company is reduced by 20%.

Although the "machine substitution" has gradually alleviated the shortage of labor, the enterprises have encountered new challenges. As Wenzhou's various industries and enterprises have pushed forward the "machine replacement" in recent years, the demand for skilled labor has been enhanced. Therefore, the demand for skilled workers has been greatly enhanced, and the talents in this field of Wenzhou are rather weak, which has been in a tight state of supply shortage.

It is undeniable that the change of demographic dividend to the technical dividend is brought about by machine substitution, which is the adjustment of employment structure, the relatively low demand for ordinary workers, and the rapid increase in demand for skilled workers.

In the new normal research, Pan Jianzhong also admitted to the people's finance that after the "machine substitutions", enterprises can operate the imported machinery and equipment and manage the production line technicians and technicians, and become the "key talents" of the enterprises.

Equipment upgrading involves many fields, such as information technology, industrial design, software, system integration and so on. It poses new challenges to equipment management and operation workers. Previous staff skills level has been unable to meet the requirements of automated production, and the introduction of technicians has become the difficulties they face at present.

"What we can do is to absorb senior technicians on the one hand by raising wages and benefits, while speeding up training for some workers to get started quickly."

In addition, Pan Jianzhong also pointed out that although giant one group has large scale and strong strength, "machine substitution" is also larger in terms of capital input, and the price of robots with higher intelligence and systematic solutions is more expensive.

For small and medium-sized enterprises, hundreds of thousands or even tens of millions of yuan can hardly afford them.

Therefore, speeding up the pace of "machine substitution" and the high cost are also unavoidable problems at present.

According to the reporter, "machine substitution" is technically promoted by the government.

The Wenzhou municipal government pointed out in a number of opinions on "helping enterprises to strengthen industry" released last year to increase the subsidy for "machine replacement".

According to the actual facilities and value-added tax invoices, the technical pformation projects of urban enterprises with more than 5 million yuan of equipment in one year will be rewarded by the municipal finance to 15% of the international advanced import equipment, and the domestic high-end equipment will be rewarded 10%. The subsidy limit for a single enterprise will be increased from 3 million yuan to 5 million yuan.

It is not hard to see that the government's support for "machine substitution" is relatively large, but some small and medium-sized enterprises believe that there are still many difficulties in financing.

In the survey of people's finance, some entrepreneurs called for more policy support, and suggested that the government should increase support for technological pformation of enterprises, such as establishing special funds, guiding enterprises to attach importance to technological innovation and investment in science and technology, and also taking the lead of the government to set up special guarantee institutions.

For a long time, China's economic development mode is extensive, and industrial development is mainly supported by cheap labor strength.

In the face of the new normal economic development, due to the need of industrial pformation and upgrading and the increase of labor costs, it is impossible to stick to the past development mode and impossible to engage in "human sea tactics" again.

In the era of "demographic dividend" fading away, "machine substitution" has become the focus of attention of all walks of life. Some enterprises are constantly adapting to the trend of "qualitative change" to "smart change".