China's textile economy has experienced 30 years of rapid development. Cheap human resources and abundant natural resources are our advantages. As one of the mainstays of economic development, the manufacturing industry is facing the problem of transformation and upgrading. With the disappearance of the demographic dividend and the increase in production costs, a new generation of migrant workers pay more attention to their own rights, and the development of China's textile industry is facing reforms.
Although China has become a major textile machinery manufacturing country, the level of textile machinery manufacturing is not high, so enterprises must accelerate their transformation and improve technical performance. The status quo of low-end products with low technical content, low added value, high labor cost, and low production efficiency no longer meets the current market needs and does not meet the future development of enterprises. The transformation and upgrading of textile machinery products is the general trend.
The direction of China's textile industry transformation is undoubtedly to achieve transformation and upgrading through technological progress and improvement of labor quality. By improving production efficiency and increasing benefits, enterprises can catch up with or exceed the increase in production costs. This is the meaning of transformation and upgrading, and "machine substitution" is one way.
Relevant persons in the industry said that the use of high-speed, intelligent and large-capacity textile machinery equipment by textile enterprises can reduce labor and improve efficiency. Due to the current shortage of raw materials such as cotton in the world, textile machinery and equipment can make full use of fibers and increase the added value of products. In the next 5-10 years, this demand trend will become more apparent.
The replacement of textile machinery is an inevitable trend of industrial development
Recently, an upsurge of “machine substitutions” in which smart equipment replaces labor input is sweeping across developed manufacturing areas such as Zhejiang, Guangdong, and Jiangsu, arousing attention from all parties. It is reported that Jiaxing City, Zhejiang Province alone will implement 800 "machine substitution" enterprises and 800 technological transformation projects this year, reducing the number of workers employed; Guangzhou City, Guangdong Province recently made a plan to make industrial robots widely used within a few years More than 80% of manufacturing enterprises in the city.
A month and a half ago, Shaoxing Jinhui Textile’s 30 million-meter-a-year polyester fabric technical renovation project was launched. The newly purchased 260 new-type water jet looms, 9 skewer cars, 26 winder cars, and 260 two-for-one twisters were all put into use. It is estimated that the annual sales will increase by 200 million yuan and the net profit will increase by 5%.
Among the 100 "machine substitution" enterprises scheduled at the beginning of the year in Nanxun District, 80 have already begun to renovate and 40 have already been put into use. At present, "machine substitution" has covered five major industries including elevators, motors, magnet wires, textiles, and wood industry. Through technological transformation and equipment updates, these companies have gradually realized automated production, reduced labor and production costs, and improved product quality and production. effectiveness. According to statistics, from January to April, the district invested 2.806 billion yuan in industrial production, 1.569 billion yuan in industrial technological transformation, and 1.11 billion yuan in equipment investment.
It is predicted that the "Twelfth Five-Year Plan" period will be a critical period for the development of China's industrial robot industry, and market demand will increase at a rate of 15% to 20% per year. The provincial economic work conference held at the end of last year proposed that our province will accelerate industrial transformation and upgrading and promote "machine substitution". In May of this year, the Municipal Economic and Information Technology Commission issued a special action plan for the city's "machine substitution", and at the same time announced the first batch of "machine substitution" demonstration enterprises and 28 pilot enterprises.
There are many hidden worries under the benefits of textile machinery substitution
A few days ago, Liu Zhibiao, president of Nanjing University of Finance and Economics, said that for my country’s manufacturing industry, the realization of machine substitutions faces three major problems:
1. Whose machine is used.
my country has a comparative advantage in the production of general consumer goods, but the advantage of the equipment manufacturing industry is not obvious. At present, machine substitutions mainly use foreign machines to replace people. The fundamental reason for this market gap lies in the gap in the technological level of my country's equipment manufacturing industry.
2. Who will be replaced and who will operate the machine?
The machine is replaced by an operator who sells his energy, but it does not mean that no human is needed. Those who know how to operate machines are still skilled workers. If there is a lack of skilled workers to operate and maintain these machines, it will be difficult to achieve true transformation and upgrading in the end.
3. Where do the replaced people go?
Due to the replacement of machines, there will be a surplus of workers traditionally engaged in manual labor, and there will be structural unemployment in the manufacturing industry. Therefore, in the process of machine replacement, industrial upgrading and employment expansion must be considered as a whole, so as to minimize labor pains and increase employment channels. Both the manufacturing industry and the workers need to realize their own transformation and upgrading.
1. Judging from the reality, these three problems do indeed exist. Diet, president of the Asia-Pacific region of consulting firm Solidiance, predicts that the six major Japanese companies account for half of China’s industrial robot sales, while the four major domestic robot equipment manufacturers add Together they only account for 5% of the Chinese market share. In the Chinese robot market, foreign robot giants are in a monopoly position. Although China's robot industry has developed rapidly in recent years and domestic robot companies are catching up, they are still in a weak position.
A study from Tsinghua University shows that there is still a big gap in competitiveness between local brand industrial robots and foreign brands. In 2012, the four giants of FANUC, Yaskawa Electric, KUKA, and ABB accounted for 53.8% of the market.
In the entire robot industry chain, among the three major upstream key components, midstream equipment manufacturers, and downstream industry applications, domestic companies are currently mainly concentrated as system integrators to achieve downstream applications, that is, by purchasing robots from abroad, Design corresponding schemes for downstream customers to realize profits. However, the upstream of the industrial chain has no support from core component manufacturers, and the key components are still far behind foreign companies, so they are subject to long-term constraints.
An industry insider told reporters that domestic companies generally rely on imports for the key components of the joint of the robot, the reducer. "The reducer is an important factor restricting the cost of domestic industrial robots. Research on the reducer requires more than good equipment. , And more importantly, there must be good materials and craftsmanship, and the materials need to be wear-resistant. These are not capable of catching up with foreign technologies in a short while."
2. Difficult running-in between man and machine
In 2007, Huang Jianping, chairman of Aesthetics, went abroad for a round of inspections and was amazed at the automated production lines in the West. After returning, he spent more than 4 million to import seven or eight automation equipment, but he encountered opposition from some middle-level managers.
"A machine can range from a few hundred thousand to five to six hundred thousand, and it would be impossible to reduce a few people." The director of the production workshop at that time also had this complaint. What’s more difficult is that some workers like Dai Chaozhi don’t want to, and some don’t know how to operate the machine: “I’m so full of energy. Why do I have to do things that are so troublesome to handle things that I can do with just one lift and one move?”
Zhong Weiqiang said that when the new production line was just started, the "old card" had to be shut down for maintenance. The kiln of the ceramic tile factory cannot be stopped 24 hours a day, and one minute of empty kiln operation costs more than 5,000 yuan in energy and equipment maintenance costs. Over and over again, the workers returned to the original state of "all by themselves" from "automatic". The machines were left idle and had to be dismantled in less than a year, and more than 4 million machines were put into the "cold palace". .
Chen Wuqin told reporters that when the robot first entered the production workshop of Aomei Hi-tech, workers would be afraid to approach it because they were worried that they would damage the new technology because of improper operation. Moreover, the codes for manipulating robots are close to heaven for workers, which increases the distance between each other.
However, after nearly half a year of running-in, the relationship between the two has become closer. Although the degree of automation of the production line has been greatly improved, the efficient operation of robots is still inseparable from the cooperation of people.
3. Where do the replaced people go?
However, a problem has emerged: after the introduction of equipment and technology, many manual tasks will be replaced by machines, which means that a batch of surplus labor will be produced. According to the expectations of the company's management, more than 50 employees will be cut at one time, which is close to one third of the total number of employees. It is precisely because of this that the disputes between the company and employees that occurred some time ago due to the replacement of machines have been triggered.
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