Introduction: On the whole, China's manufacturing industry is still not strong enough. In particular, traditional basic materials, basic technologies, basic processes and technology platforms. And smart manufacturing requires integration with information technology, new problems like sensors, industrial software, industrial Internet and industrial big data or bottlenecks for future development.
In mid-July, Chengdu, hot and rainy, is located at the Siemens Industrial Automation Production and Research and Development Base (SEWC) 22 kilometers northwest of the city center.
Even in the workshop, only the faint sound of the machine's rotation was heard. Several workers from time to time touch the computer screen in front of the workbench and operate the buttons on the workbench.
At the same time, in the material between the workers and the ground floor, the materials carrying the barcode are neatly placed on the automated assembly line. They climbed into the workshop along the underground conveyor system with the help of four up and down lifting devices. After three-dimensional transfer library and other equipment, it is assembled and packaged on the assembly line, and finally transported to the warehouse by the logistics trolley.
The factory of about 450 workers produces less than half the size of a standard football field. More than 2.5 million SIMATIC industrial automation products are produced each year, supplying China, the world's automotive, pharmaceutical, power and other industrial industries and infrastructure. Here, about one product is born every 10 seconds, and less than 10 of the one million such products are defective.
SEWC is the sister factory of Siemens' first digital plant, the Amberg Electronics Manufacturing Plant (EWA), and the first digital company established outside of Germany by Siemens. Behind the two digital factories is Siemens' overall solution for digital factories developed by the German government's Industry 4.0 strategy.
In response to the wave of global manufacturing revolution and the transformation and upgrading of the domestic manufacturing industry, the German government proposed the national strategy of Industry 4.0 in 2013. China released the "Made in China 2025" action plan in 2015.
If Siemens is the benchmark, it is clear that the Chinese companies are not small. "Compared with top industrial companies such as Siemens, China's manufacturing industry, especially China's home appliance industry, still has a big gap." Liu Changzhong, director of Sichuan Changhong Planning Department, said, "China's manufacturing industry is still in the industrial 2.0 stage. Part of it reaches the level of 3.0. It is necessary to plan for Industry 4.0, but also to make up for the lack of foundation, and eliminate backward and surplus production capacity as soon as possible to achieve leap-forward development."
Seamless data interconnection of a factory
After completing industrial automation, industrial enterprises are faced with transformation problems such as meeting the individualized needs of consumers and the model innovation brought about by the penetration of new technologies.
For Siemens, this series of challenges is reflected in the reality, how manufacturing companies can shorten the time to market, improve flexibility, production efficiency and product quality.
Perhaps you can see the ambition of this 169-year-old industrial company from nearly 50 companies that Siemens has acquired since 2007. Since the purchase of UGS, the company that produced the product software product Teamcenter, Siemens has been out of control. Most of the companies that look at it are mainly software companies. At the same time, Siemens continues to expand its software business portfolio and eventually proposes the concept of “digital factoryâ€.
According to Jan Mrosik, CEO of Siemens AG's Digital Factory Group, the digital solution provides a seamless workflow across the entire lifecycle by covering the entire value chain from product design, production planning, manufacturing engineering, production execution to service. . Optimize all aspects of engineering with hardware and software devices such as a unified database to ensure that products are delivered to the market efficiently.
To this end, Siemens has launched a comprehensive digital product portfolio that combines hardware, software, industrial expertise and data to drive the convergence of the real world and the virtual world.
At the Hannover Messe 2016, Siemens introduced the industrial cloud Mind Sphere. As an open platform for industrial data, various digital factories can connect their key equipment and even the entire plant data to Mind Sphere through a data gateway to monitor their equipment fleet for preventive maintenance, energy data management, and plant resource optimization.
In China, Siemens established the digital factory SEWC to implement the above solutions. The plant has digitized the entire process from management, product development, production to logistics. In the development process of the “data chain†of the digital factory – R&D engineers use the product development solution NX software of Siemens PLM (Product Lifecycle Management Software) to simulate and assemble new products.
Every new product developed has its own data information. These data information is continuously enriched in all aspects of R&D, production and logistics, and is stored in the same data center Teamcenter in real time for sharing among various departments such as quality, procurement, production and logistics. Every day, the equipment automatically records more than 10 million product information, which is convenient for workers to find out the origin of the product.
The materials required for the production process carry barcodes themselves, and through the “data dialogue†with the warehouse management software, through the material transportation link of “automatic transportationâ€, they are transported to the high-bay warehouse or the material intermediate warehouse. The assembly line staff touches the computer display on the workbench and the required materials enter the material room.
After the materials are transferred from the materials to the workshop, the workers begin assembly and packaging according to the electronic task list on the computer display. After the task is completed, he simply presses the button on the workbench and the sensor on the assembly line scans the bar code information of the product and records its data at this station. The MES (Manufacturing Execution System) will use this data as a basis for judgment and issue instructions to the control system to direct the logistics car to deliver the product to the next destination.
The factory uses flexible production. The same production line produces more than 4,000 products per day, and can produce up to four different products at the same time, and make reasonable plans for future capacity adjustment.
The entire plant is based on these data foundations, ERP (Enterprise Resource Planning), PLM (Product Lifecycle Management), MES (Manufacturing Execution System), control systems and supply chain management, all of which achieve seamless information. Interconnected, factory data can also be interconnected with German production sites and R&D centers in the United States.
China's manufacturing benchmark is in the 3.0 stage
Unlike the German Industry 4.0, which goes from the manufacturing end to the information end, in the view of Shi Yong, vice president of the Machinery Industry Information Research Institute, “Made in China 2025†mixes the concepts of industrial internet in Germany and the United States. Some leading companies are exploring the Internet. Enterprises and manufacturing enterprises strengthen cooperation and promote the integration of the two.
According to Shi Yong, SAIC and Alibaba signed the "Internet Car" strategic cooperation agreement to strengthen the application and introduction of information technology; Huawei signed a strategic cooperation agreement with KUKA in 2016 to jointly develop smart manufacturing solutions for the Chinese industrial market; Qingdao Red Through exploration efforts, it has become the benchmark for smart manufacturing in the field of garment production. These are examples of the integration of the Internet and manufacturing.
But overall, the current fundamentals of China's manufacturing industry are not strong enough. In particular, traditional basic materials, basic technologies, basic processes and technology platforms. And smart manufacturing requires integration with information technology, new problems like sensors, industrial software, industrial Internet and industrial big data or bottlenecks for future development.
Electrification popularization, automation promotion, and intelligent demonstration. This is the overall evaluation of China's manufacturing industry by Zhang Yan, deputy director of the Institute of Strategy and Planning of the Machinery Industry Information Research Institute. The data of the two indicators can be visualized: the density of the industrial robots and the numerical control rate of the equipment.
According to statistics from the World Robotics Association, the density of industrial robots used in mainland China in 2014 was only 36 units/10,000, which is less than 1/13 of South Korea, 1/9 of Japan and Germany, and 1/5 of the United States. It is 54.5% of the world average. From the numerical control rate of machine tools, the numerical control rate of machine tools produced in China is only 25%, and the numerical control rate of machine tools in Japan in 2012 has reached 88%. China's current level is only equivalent to Japan's level in the late 1980s.
“No domestic company can be used as a benchmark.†Luo Jun, CEO of the Asian Manufacturing Association and the International Robotics and Intelligent Equipment Industry Alliance, believes that even the highly respected Haier Group is still a traditional industry, far from the requirements of Industry 4.0. The gap with Siemens is very large. “We are overly concerned with the production process, and the R&D field is backward. There are no companies that really lead the development of the global industry.â€
Enterprises also have "self-knowledge." In September last year, the Ministry of Industry and Information Technology announced the list of 2015 smart manufacturing pilot demonstration projects, a total of 46 finalists, involving 38 industries and 21 regions. The demonstration projects declared by Sichuan Changhong Electric Co., Ltd. are among them.
Changhong also believes that there is still a big gap between itself and the top world industrial 4.0 companies such as Siemens. “Germany is more focused on the research and development of innovative industrial technology products, as well as the management of complex industrial processes. It has a good foundation in the equipment and workshop manufacturing industry, and has a high level of competence in the world of information technology, in embedded systems and automation. There are also very professional technologies in engineering," said Liu Haizhong, head of Sichuan Changhong Planning Department.
These well-known enterprises, in the view of Zuo Shiquan, director of the Institute of Equipment Industry of the CCID Research Institute, are still in the stage of digital development, which is what Germany calls Industry 3.0. They are still opening up the issue of vertical integration. Among them, very few companies are tackling the problem of network collaborative manufacturing. The Ministry of Industry and Information Technology has announced 109 smart manufacturing demonstration pilot projects in 2015 and 2016. Only the C919 aircraft network collaborative manufacturing pilot demonstration filed by China Commercial Aircraft Co., Ltd. and the textile and apparel network collaborative manufacturing declared by Quanzhou Haitian Materials Technology Co., Ltd. Pilot demonstration of two projects.
Industrial Internet has the most commercial value
How do Chinese companies meet the goals of smart manufacturing requirements?
Don't take smart manufacturing as a technical job. Chen Ming, a professor at Tongji University and director of the Industry 4.0-Smart Factory Laboratory, suggested that Chinese companies should take into account products, equipment, production, management and services. The Germans believe that Industry 4.0 must first be lean production and lean management, so that the implementation will be efficient, and German companies basically do the same.
Liu Haizhong also agrees with this view. According to its introduction, Changhong understands that intelligent manufacturing not only arms factories with robots, automation equipment, information technology and other technical means to meet the improvement of internal manufacturing efficiency. More need to stand from the perspective of consumers, the consumer demand as the highest standard of intelligent manufacturing, reverse consideration of R & D, production, sales, service and other aspects, in order to achieve a large-scale personalization of a new business model.
Chen Ming also warned Chinese companies not to be too anxious, to achieve Industry 4.0 is a gradual process. Moreover, whether in China or other parts of the world (including developed countries in Europe and America), Industry 4.0 is still in an exploratory stage, and there has not yet been a real enterprise that has achieved Industry 4.0.
Zhang Yan said that even the Siemens Amberg factory still claims to be in the industry between 3.6-3.8. According to the German Fraunhofer Institute, the organization that proposed the concept of Industry 4.0 will predict that after 15 years, the enterprise that truly realizes Industry 4.0 will appear.
However, some insiders believe that you should not be superstitious about Industry 4.0. Jinan Second Machine Tool Group Co., Ltd. mainly produces stamping equipment and CNC machine tools. The company uses Siemens systems to increase productivity, quality and reliability. However, Zhang Shishun, the company's deputy general manager, reminded the company that Industry 4.0 and “Made in China 2025†are not a panacea and may not solve the problems that enterprises are currently facing. For some problems, companies may need to start with internal management and find ways to find and solve problems.
Companies that plan to use smart manufacturing models must learn to be "high-key." Zhang Shishun suggested that domestic enterprises should systematically plan and implement them step by step, grasping the goals and the overall development trend, and “seeing is highâ€; but when it is really necessary, it is necessary to start with the most basic things, “hands are lowâ€.
This is also the advice of the Boston Consulting Group to Chinese companies, to do the basics. New technologies cannot circumvent some of the most basic things in manufacturing, such as production standardization, effective facility maintenance, and the skill level of personnel.
In Zuo Shiquan's view, the industrial Internet is the most commercial value for enterprises. Automation, digitization, and intelligence require constant capital investment. Industrial Internet is to gain revenue through value-added services. Enterprises use information technology such as the Internet of Things to help users better use products and gain more value. Although this method has to be invested in the early stage, the cost will be lower and lower in the later stage.
For example, he said that some textile machinery manufacturers in Beijing will connect the textile machinery sold to customers with the Internet of Things, pay attention to the operation of the products, reduce the maintenance and operation and maintenance costs of customers, and charge customers the corresponding fees.
In addition, manufacturing companies should pay attention to the application of emerging technologies at the product, production, service and other levels, including intelligent hardware such as robots and industrial control systems. "Whoever uses it early, whoever uses it well, will gain a favorable position in the competition." Zuo Shiquan said.
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