Data Connectivity Activates Productivity Is Changing "Thousands Of Yarns, Thousands Of Clothes"

"Thousands of people yarn, thousands of people cloth" was a common impression of textile. On May 4, when the reporter walked into the digital spinning workshop of Xiajin Renhe Textile Technology Co., Ltd., he saw that there were few textile workers except for the sound of machine operation, and the production situation of the whole factory was clear at a glance on the general control platform. This is due to the enterprise's MES system and digital intelligent spinning online monitoring system.

Looking at the operation of each textile machine flashing on the company's data screen, Li Zongzhi, the general manager of Xiajin Renhe Textile Technology Co., Ltd., said with emotion: "Two years ago, in order to understand these data, we assigned eight meter readers for each shift. The error rate is high, and the efficiency is also low. It usually takes 24 hours to know the operation of the machine." According to him, Now the average time of doffing is reduced from 8.54 minutes to 7.41 minutes, with an annual output increase of 118 tons and an annual capacity increase of more than 30%. Under the current scale, the annual gross profit can increase by 177000 yuan; From the analysis of system data, the difference in power consumption of different machines for the production of the same variety is more than 15%. Through the screening of high energy consuming machines, the power consumption is reduced by 2% a year, saving 417600 yuan in electricity costs.

Cotton textile is the traditional industry of Xiajin County. More than 160 cluster enterprises have an annual output value of more than 10 billion yuan. Simple and efficient quality inspection system is an important guarantee for textile enterprises to improve production efficiency. How does cotton textile, as a traditional industry, integrate with digital? From the human eye to the "insight", the digital quality inspection system makes flaws nowhere to hide, and makes quality more guaranteed. Therefore, a round of accurate digital "make-up lessons" was carried out in the textile industry of Xiajin.

This round of "make-up lessons" aims to achieve human-computer "dialogue" and data interconnection, and generally does not involve equipment update. Enterprises only need to install sensors, code scanning guns, display screens, etc. to solve the "deaf, dumb, blind" problem of equipment and materials and achieve data collection; Realize the interconnection of production, purchase and sales data through software system; Then, through system application, intelligent terminal systems with different permissions are installed from the operation layer, management layer to the decision-making layer to realize the digital management of enterprises.

Data interconnection activates productivity. Data shows that the pilot Renhe Textile "Digital Intelligent Spinning Online Monitoring System" can effectively track the whole production process, reduce production costs by 12%, and is rated as a provincial "typical application scenario of industrial Internet". Xiajin Xinshixing Textile Co., Ltd. was newly launched on the platform of "Shuttle Smart Knitting MES Management System". The number of employees for 10000 spindles was reduced from 40 to 25, and the yarn quality was constantly improved. It has established long-term cooperative relationships with customers such as Feile and Youngor, and was recognized as a municipal "smart factory". Shandong Hongtai Dingxin Material Science and Technology Co., Ltd. has adopted DCS control system to effectively realize automation and intelligence, and was rated as a municipal "digital workshop".

"Such a new transformation is highly professional and needs the help of the government." Zhao Zhida, deputy secretary of Xiajin County Party Committee and head of Xiajin County, introduced that the county takes industrial restructuring as the main line, gives play to the guiding effect of "platform+funds", and promotes the improvement of quality and efficiency of traditional industries by introducing and transforming key equipment and technologies. The textile industry in Xiajin County has typical characteristics of subdividing industries. Many enterprises are equipped with similar equipment, adopt similar processes and produce similar products. This means that if you "try a batch", you can "drive a piece". At present, the equipment automation rate of textile enterprises in the county has reached more than 75%, and the employment has dropped to less than 30 people per 10000 spindles, saving more than 60% of labor costs compared with that before the transformation.

"Seeking productivity from data is the only way to optimize and upgrade traditional industries, and we must make up our minds, follow the trend, and do something." Sha Shuhong, secretary of Xiajin County Party Committee, said, "Lead enterprises to take the first step of intelligent manufacturing more easily - digital transformation, and achieve greater benefits with less investment."

(Source: Dazhong Daily)