What Changes Does Machine Substitutions Bring To Quanzhou'S Manufacturing Industry?

From thousands of enterprises in Quanzhou, Fujian "

Action investigation

In Fujian Quanzhou (Nanan) optoelectronic information industry base, the crystalline silicon solar cell production line of sun Zhongke company is roaring, and workers are busy ordering.

According to Chen Limei, assistant director of the company, the company just started construction in 2016, and the enterprise has already completed the whole line of production. At present, the order has been discharged to 2017.

Located in Jinjiang, Quanzhou, the intelligent production and modern storage base of Heng An, Hang Heng, Jinjiang, Heng An family household goods company presents a busy production scene.

Pan hope food and beverage workshop.

(information photo)

Recruitment difficulties and labor shortage are the topics that China's traditional manufacturing industry can not keep away from in recent years.

In order to solve the "recruitment difficulties", many manufacturing enterprises accelerate the pace of pformation and development, especially through the implementation of technological pformation, improve automation level, and achieve "machine substitution" to reduce employment demand.

Quanzhou, Fujian, where private economy is more developed and manufacturing industry cluster is already in scale, takes intelligent manufacturing special action as an important starting point, vigorously promotes "machine substitution", and guides nearly 1000 traditional manufacturing enterprises and labor-intensive enterprises to apply numerical control technology and products.

Where does the power of "machine substitution" for thousands of enterprises in Fujian Quanzhou come from? Where does the "machine substitution" bring about changes to the manufacturing industry in Quanzhou? After "machine replacement", can the employment problem of manufacturing enterprises be fundamentally solved? Recently, the reporter came to Fujian Quanzhou to conduct research and interview.

"Recruitment difficulties" forced "machine substitutions"

Hua Fei is located at Hua Fei industrial park, Shishi Keng East Development Area, Quanzhou, Fujian.

The brand of "garment digital rapid manufacturing engineering" at the doorway of garment manufacturing company is particularly eye-catching.

Yu Liang ya, vice chairman of Hua Fei Garments Co., Ltd., told reporters that every link of Hua Fei's clothing production workshop has been computerized automatic control, so the company has become one of the demonstration bases for rapid manufacturing National Engineering Research Center.

Entering the workshop, the reporter saw that

The automatic cloth loom is arranged in an orderly way. The production process of different links is connected to each other by automatic lifting system. After each process is completed, the semi-finished products are directly pferred through the hoisting system to the next stage.

"In 2015, we invested nearly 7 million yuan to purchase these automation equipment, greatly improving the automation level of the entire production workshop."

"For private enterprises, 7 million yuan is not a small sum," he said.

But overall, the investment is still very cost-effective.

In the clothing industry for more than 20 years, he told reporters that in recent years, enterprises obviously felt the pressure of employment increased.

On the one hand, the wages of workers are constantly rising. "Now the wage level of workers has doubled as compared to 10 years ago". On the other hand, because of the "labor shortage", workers' demand for capital is getting higher and higher. Enterprises should provide workers with free dormitories and subsidized canteens, and often engage in recreational activities that young people like to participate in, otherwise it will be difficult to retain people.

"If we do not automate the pformation and reduce the number of workers, the pressure on enterprises will be even greater."

He said that in order to build a large scale in the future market competition, enterprises can no longer rely on past "human sea tactics", but must constantly improve labor productivity.

In recent years, thousands of traditional manufacturing enterprises in Quanzhou have accelerated the intelligent pformation like Hua Fei company.

Sun Zhenhan, director of technological progress and investment section of Quanzhou Municipal Commission of information technology, told reporters that during the "12th Five-Year" period, the total technological pformation of enterprises in Quanzhou amounted to about 255000000000 yuan, with an average annual growth of 29.9%.

Among them, equipment investment accounted for more than 6.

Chen Jianxing, deputy director of Quanzhou science and Technology Bureau, said that after more than 30 years of reform and opening up, Quanzhou has developed into a huge manufacturing system, and has successfully created many traditional industrial clusters such as textiles, clothing and shoes.

However, the traditional manufacturing enterprises in Quanzhou generally have the problem of "low, scattered and short". Most of them are labor-intensive enterprises, which rely on low cost expansion for a long time. Most enterprises still use small and low-end production equipment, lack of high-end technology support such as numerical control and intelligence.

"With the gradual tightening of the macroeconomic environment, the traditional manufacturing industry is facing new challenges.

Only by implementing the innovation driven development strategy and comprehensively promoting the technological innovation of numerical control and intelligent manufacturing can we promote the pformation and upgrading of traditional manufacturing industries.

Chen Jianxing said that in promoting the construction of the "numerical control generation" application demonstration project and the development of intelligent manufacturing, we encourage enterprises to carry out "machine substitution", which is to further enhance the core competitiveness of enterprises, speed up the pformation and upgrading of manufacturing industry, and promote the development of high-end manufacturing industry and the supporting role and service ability of pillar industries and special industries.

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Reducing labor costs in Enterprises

When the reporter came to Pan Pan food group in the Cai Cai Industrial Zone, Anhai Town, Jinjiang, Quanzhou, Cai Jinchai, CEO of the company, was convening management meetings.

The content of the conference is to arrange and push ahead with the commissioning of Pan food's automation equipment in the new production line in the field.

"Now the cost of labor is rising everywhere. To ensure that workers can stay, wages are generally 5% to 10% higher than the local average, and in some places even more than 20%."

Cai Jinchai said that only when the workers are relatively stable, the quality of products can be guaranteed and the efficiency of enterprises will become better and better.

However, in this way, the cost of labor will increase.

Cai Jinchai said that in order to further control costs and improve production efficiency and product quality, pan hope has made strategic cooperation with domestic and foreign manufacturers in the past few years to jointly invest in R & D production line equipment.

From the practice point of view, after the introduction of advanced automated production lines, not only the quality of products is guaranteed, but also the employment situation of enterprises has been further improved.

Now Pan Pan Group, 3 workers can complete the work of the past 5 workers, and 3 people get the wages equivalent to the wages of 4 people in the past.

Cai Jinchai told reporters that Pan foods currently has 19 branches and 12000 employees.

Since its establishment in the past 20 years, pan foods has been expanding almost every year by increasing the speed of a branch company.

After the implementation of "machine substitution", the size of the company has expanded, but the number of employees required has not increased significantly.

According to the plan, pan foods strive to produce more than 10 billion yuan of food and beverage output value. In the future development, pan food will continue to implement the "machine replacement" and make dividends to new and high technology.

In Hua Fei clothing company, Yu Liang Ya told reporters that with automation ancillary equipment, the factory's demand for labor decreased by 1/4 than that of the past, and the convergence of each workflow was also automated. The labor intensity was greatly reduced, labor efficiency was improved, product quality was improved, rework rate dropped by 8 percentage points, and enterprise efficiency increased by about 20%.

Chen Jianxing said that the implementation of "Quanzhou manufacturing 2025" and the promotion of Intelligent Manufacturing in Quanzhou have a great impact on the pformation and upgrading of industries and the development of innovation and development. The level of equipment and manufacturing technology in major industrial sectors has been significantly improved, and the level of production and technology of some enterprises has improved significantly.

For example, after the use of CNC spinning machines in textile enterprises, the production time is reduced from 3 to 4 hours / sweater (piece) to 40 minutes / sweater, and 1 workers can operate 5 to 10 machines at the same time, which can greatly improve production efficiency, reduce labor demand and labor costs.

In the interview, the reporter also learned that the automatic break detection technology of warp knitting machine developed by Quanzhou Huayu company and Harbin Institute of Technology can increase labor productivity by 10% and reduce the rate of defective products by 5 percentage points.

The company's spindle automatic packaging line project saves 50 people a day, and saves 2 million 500 thousand yuan per year.

Meyang company originally only produced plastic products and engaged in mold development, cooperated with the China Central University Intelligent Research Institute, developed high-speed full servo five axis manipulator, and reformed the injection molding workshop. Only 38 workers in the workshop needed 16 workers, the production capacity increased by 3 times, the labor cost reduced by 35%, and the product category increased by hundreds.

Chen Zhaoping, deputy director of the Quanzhou Municipal Development and Reform Commission, said that after the pformation of machinery manufacturing enterprises in Quanzhou, the traditional manufacturing enterprises generally reduced employment by 20% to 30%, and the efficiency increased by more than 50%, and the quality of products was greatly improved.

"Shortage of skilled workers" will be more prominent

Reporters learned in the interview that Quanzhou's manufacturing equipment is generally not fully automated, and some processes are mainly done by manual operation. For example, 70% of the stone industry is dominated by PLC low end control technology. Most of the workers in the grinding and polishing process of the plumbing industry are working in a dusty environment.

After implementing the "machine substitution", some traditional manufacturing enterprises are equipped with more advanced equipment and systems, and the requirements for the operation and maintenance of the equipment are further improved.

However, due to the lack of numerical control technology applied talents (engineers, technicians, technicians), especially the complex technology talents who know both numerical control technology and professional knowledge, there are few and far between them, which affects the implementation and promotion of numerical control technology to a certain extent.

"At present, most of the technical workers in Quanzhou account for about 80% of the junior high school diploma, which is difficult to adapt to the operation and maintenance requirements of robots and intelligent equipment in a short time."

Chen Jianxing said.

Chen Jianxing also said that after implementing the "machine substitution", the low skilled workers in the manufacturing enterprises and even some skilled workers will be replaced by industrial robots, and the technical positions of debugging, maintenance and control of industrial robots will be relatively increased.

In the short term, robots will have an impact on the labor market. If some workers are unable to meet the requirements of robot engineers, they may eventually become the elimination of intelligent revolution.

In the interview, Cai Jinchai told reporters that after the automatic pformation of Pan Pan food, many devices need to be operated by computers.

In order to cope with the shortage of skilled workers, the company has expanded recruitment from vocational schools on the one hand, and has also selected a number of staff from skilled workers on the other hand, and is responsible for training by equipment suppliers, thereby enhancing the technical level of employees.

This will not only increase the production efficiency of enterprises, reduce the cost of labor, but also increase the income of workers and achieve win-win results.

Chen Zhaoping said that with the advance of "machine substitution" and intelligent manufacturing, "recruitment difficulties" and "shortage of skilled workers" will continue to exist in a short time.

To solve the employment problem of manufacturing enterprises, we should speed up the pformation of automation and upgrade the level of informatization and intellectualization of traditional industries from the perspective of supply side structural reform.

On the other hand, the relevant departments should also put the vocational skills training of migrant workers to a more important position, through strengthening the "school enterprise cooperation" and other mechanisms to support universities and vocational colleges and universities to set up more professional and curriculum with local industries, and pay attention to the development of "intelligent machine" blue collar.

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New employment demand arises at the historic moment

Although the development of manufacturing industry started earlier, many equipment manufacturing enterprises in Quanzhou used the imported CNC system, the price is generally 30% to 40% higher than that of the domestic system, the core technology is controlled by others, and the desire to replace the imported CNC system with the domestic CNC system is strong.

The implementation of "Quanzhou manufacturing 2025" and promoting the implementation of intelligent manufacturing have a great impact on the pformation and upgrading of industries, and the development of innovation and development. The level of equipment and manufacturing technology in major industrial sectors has been significantly improved, and the level of production and technology of some enterprises has been significantly improved.

According to Chen Jianxing, through the in-depth implementation of the "Quanzhou manufacturing 2025" and the "NC generation" demonstration project, the Quanzhou machinery and equipment industry has been promoted to the development of numerical control, automation and intellectualization. In the emerging industry of intelligent equipment such as CNC machine tools and robots, there are a group of enterprises with great development potential such as Jiatai, micro Bo and Black King Kong. They have made breakthroughs in the research and development of intelligent equipment, forming a number of automation products with leading domestic level and high cost performance.

Data show that only in 2015, Quanzhou's machinery and equipment enterprises in the city to promote the "CNC generation" demonstration products reached more than 600 units (sets), the sales amount of more than 300 million yuan.

In 2015, the output value of the equipment manufacturing industry reached 135 billion yuan, an increase of 12.5%.

"The rapid development of these equipment manufacturing enterprises has spawned demand for high-end talents supporting the development of the industry."

Chen Zhaoping told reporters that on the one hand, the development of the equipment manufacturing industry attracted a large number of high-level talents to gather in Quanzhou. On the other hand, enterprises also needed a large number of senior blue collar workers with professional skills.

Chen Jianxing said that Quanzhou will continue to rely on the platform of university research institutes and typical demonstration enterprises to further carry out training activities, and train a large number of professional skilled and skilled workers with professional skills and practical operation, so as to further provide talents for the "NC generation" demonstration project.

Reporters learned that, at present, Quanzhou has set up teaching robot demonstration points in Quanzhou Information Engineering College, building machinery and equipment major in Quanzhou Liming University and Nanan machine tool enterprises, cultivating large numbers of professional and skilled workers and skilled workers for the development of intelligent manufacturing industry.

In addition, a number of practical training points set up by Xiamen University of Technology and other universities are also under construction.