Intelligent Manufacturing Can Promote High Quality Development Of Nonwovens Industry.

The intelligent manufacturing development plan (2016-2020 years) clearly pointed out that by 2020, the key areas of traditional manufacturing industry will basically achieve digital manufacturing. By 2025, the intelligent manufacturing support system has basically been established, and the key industries will initially achieve intelligent transformation and fully implement the "made in China 2025". At present, China's nonwoven industry is vigorously implementing intelligent manufacturing, using modern equipment technology and network information technology to enhance the fine manufacturing and operation capabilities of enterprises, improve product quality, reduce resource consumption, improve operational efficiency, achieve product and business mode innovation, and push the industry towards high quality development.

In August 9th, the conference on Intelligent Manufacturing of 2019 China nonwovens industry was held in Chuzhou, Anhui. It systematically summarized the achievements of the industry in intelligent manufacturing, demonstrated the solution of intelligent manufacturing integrated suppliers, and exchanged experiences from industries and enterprises in the field of intelligent manufacturing, and promoted the development of intelligent manufacturing industry to a higher level. The conference was hosted by the China Association of industrial textiles, hosted by the people's Government of Langya District of Chuzhou, CO sponsored by Hunan Zhongnan Intelligent Equipment Co., Ltd. and Hongda Research Institute Co., Ltd.

Vice president of China Federation of textile industry, Li Lingshen, vice president of China Industrial Textiles Association, Yao Zhi, deputy director of Chuzhou Municipal People's government, Sun Ximin, vice chairman of China Textile Industry Association, Hou Xi, vice chairman of China Textile Industry Association, vice chairman of Langya Textile Machinery Association, Zhou Dongmei, deputy director of Langya District, vice chairman of the CPPCC National Committee, director of science and Technology Bureau, director of Langya Economic Development Zone Management Committee, Secretary General of China Science and technology automation alliance, Dean of Intelligent Plant Research Institute, director of standardization room of mechanical industry instrument and technology comprehensive technology economy institute, and other leading guests attended this meeting.

The meeting was chaired by Zhang Chuanxiong, Secretary General of China Industrial Textiles Association.

At the meeting, Li Lingshen was awarded the demonstration of the nonwoven intelligent manufacturing pilot enterprise (the second batch) and the nonwoven intelligent manufacturing integrated supplier.

Promoting intelligent manufacturing and fostering new competitive advantages

After more than 10 years of rapid development, China's nonwoven industry already has a complete industrial chain system and innovative system, and has developed a mature application market with obvious cost advantages. It has become the world's largest producer, consumer and trading country of nonwovens. Intelligent manufacturing is an important way to upgrade China's Nonwoven Industry in the "13th Five-Year" period and even for a long time to come.

Li Lingshen, vice president of China Textile Industry Federation and President of China Industrial Textiles Association, pointed out that in the first half of this year, the output of Enterprises above Designated Size in the nonwoven industry increased by 11.41%, and the main business revenue increased by 6.84%, but the total profit decreased by 5.91%. On the export side, although the export volume of the US decreased by 18.66%, the total export volume still maintained a 4.04% growth. Although industry development shows strong resilience, structural adjustment and industrial upgrading, transformation of growth mode and cultivation of new competitive advantages are urgent tasks for the industry in the future.

After years of training and practice, the industry's understanding of intelligent manufacturing is more rational and pragmatic. Li Lingshen puts forward the following suggestions on how to promote the intelligent manufacturing of the nonwoven industry: first, the intelligent manufacturing of productive enterprises focuses on the intellectualization of the production process. Two, the practice of intelligent manufacturing of enterprises should attach importance to the construction of industrial Internet. The three is to attach importance to the application of big data in the industry. Intelligent manufacturing is a data driven mode of production, and data is the key to achieve intelligence. Four, the intelligent manufacturing system of enterprises should be embedded into the corresponding systems of suppliers and customers to achieve the synergy of the entire supply chain, maximize the value of the entire industrial chain, and cultivate new business models.

Yao Zhi, vice mayor of Chuzhou, said that 2019 China's nonwoven industry Intelligent Manufacturing Conference was held in Chuzhou. Many industry experts and industry leaders gathered together to exchange ideas and wisdom to collide. This will further promote the technological progress of the industry and help promote the high quality development of the nonwoven industry. In recent years, Chuzhou has actively grasps the major opportunities such as "one belt along the way", the integration of Yangtze River Delta and the construction of Jiangbei new area in Nanjing, so as to fully promote the development of high quality, and the economic and social development presents a good situation with good situation, good momentum and good trend.

Yao Zhi pointed out that last year, the main economic indicators of the city ranked the first phalanx of the province, and the growth rate was expected to be faster than that of the whole province. In the first half of this year, economic and social development continued to maintain a good momentum, of which 96 billion 60 million yuan of GDP was achieved, an increase of 9.4% over the same period last year, and the growth rate ranked second in the province. The growth rate of industrial added value, residents' disposable income and total import and export volume all rank the first in the province. In recent years, the vitality of Langya's economic and social development has been highlighted, especially the new material industry represented by Jin Chun non-woven fabrics.

Zhu Jian, director of the Investment Promotion Bureau of Langya District, Chuzhou, Anhui, said that Langya has a long history and profound cultural background, and the Langya economic development zone is a provincial-level economic development zone approved by the provincial government. It has superior location, preferential policies, excellent service and beautiful environment. The planned area of the development zone is 10.9 square kilometers, and the development area is 6 square kilometers. The infrastructure such as water, electricity, gas and communication is improving day by day, and the public facilities such as commerce, residence, school, bus and so on are well matched. As the main city zone of Langya, Chuzhou district has the advantages of eastern location, western resources and central cost. It has convenient transportation, abundant resources and industrial agglomeration. The development zone has now formed four leading industries: nonwoven materials, automobiles and parts, medicine, food packaging, and trade logistics. Especially in the nonwovens industry, it is "China's nonwoven material industry undertaking transfer demonstration base", and is the "new functional textile material industry gathering development base" in Chuzhou.

The beauty of digital empowerment

Wang Jian, Secretary General of the China Science and technology automation alliance and Dean of Intelligent Plant Research Institute, take the theme of "data intelligence achievement manufacturing beauty" as the theme, and vividly illustrate how to make technology and intelligent manufacturing become visual beauty through a small video. Wang Jian said that the beauty of manufacturing can be embodied in the beauty of the final product, but its connotation is the beauty of the manufacturing process. The evolution of manufacturing process, from orderly process, efficient process, ecological order, ecological efficiency to efficient process + ecological efficiency, process intelligence + ecological efficiency, process intelligence + ecological intelligence, can not be separated from intelligent manufacturing and industrial Internet empowerment. The data intelligence is deeply embedded in the manufacturing process, which effectively integrates, analyzes, processes, and utilizes data. The purpose of industrial big data is not to analyze, but to predict and prevent, to identify hidden problems and unknown variations from visible to invisible, from solution to prevention, to timely early warning, to avoid failures and create value.

Wang Jian believes that pursuing the beauty of products and the beauty of manufacturing process is the foundation for sustainable development of enterprises. But this is far from enough. We should also realize the beauty of innovation, start with automation of innovation, build a new management framework with innovation as the core process, and enable enterprise management to be automated, efficient and intelligent. In the future, we should use big fiber as the starting point to make fiber intelligent, efficient and green, and integrate fiber into the main battlefield of national economy.

Liu Xiaojing, director of the standardization room of the Institute of integrated technology and economics of the mechanical industry, explained the national standard "general technical requirements for digital workshops". He believes that the basic requirements of digital workshop are mainly reflected in: Digital requirements, digital workshop assets and manufacturing process information should be digitalized. Network requirements, the digital workshop should have interconnected network, which can realize the information interaction between equipment, production resources and systems. System requirements, the digital workshop should be built with manufacturing execution system or other information production management system to support the function of manufacturing operation management. Integration requirements, digital workshop should realize the information integration between execution layer and foundation layer, execution layer and management system. Safety requirements, digital workshops should carry out risk analysis and risk assessment, put forward workshop safety control and digital management plan, and implement digital production safety control.

Enterprise intelligence

Topic 1: 5G technology and intelligent factory

Zhang Jen, chief engineer of Polytron Technologies Inc communications planning and Design Institute of Guangzhou, made the 5G technology and intelligent plant construction report. He said that the changes and values brought by 5G were reflected in the equipment sales becoming full life cycle management services, from simple after-sale maintenance to daily management of equipment, including monitoring of equipment status and early warning of failures. The value of services increases in proportion to revenues, improving customer experience and resource utilization efficiency. Service innovation, based on data and platform to provide post market services, the Internet of things helps enterprises to capture and predict market demand more effectively, and create new service types such as dynamic, personalized intelligent services, advisory services, data services, Internet of things, finance and insurance. The transformation of production mode lies in the transformation from mass production to mass customization production / flexible manufacturing. From centralized production to networked collaborative production in different places (de centralization), informatization and industrialization are deeply integrated (physical factory + virtual factory). Vertical industry's platform enterprises are born, providing a variety of software services and building ecological system. Core competitiveness is reflected in the software service capability on the platform, rather than the platform itself, improving the labor environment and creating value.

Jing Wong, general manager of Ji'nan Yongxin new Mstar Technology Ltd, made a detailed report on the "spunlaced nonwoven intelligent factory". According to Jing Wong, the company's main business is the development, production and sale of high-end non-woven fabrics and products for medical and health care products. Its products are exported to Japan, South Korea, Russia, the United States, Egypt, Mexico and Brazil, and are well received by foreign customers. At present, the "90 thousand tons of biomass fiber nonwoven new material intelligent manufacturing" project is being implemented. The first intelligent production line was put into operation in April 19. At the same time, the group standard of the spunlace nonwoven intelligent factory is now in the group discussion stage, and the first draft has been completed.

Jing Wong said that the company plans to implement all the four production lines this year, the whole process of intelligent manufacturing system integration and verification implementation; in 2020, six new production lines will be put into full operation, the whole process intelligent manufacturing system will be fully covered, so as to realize the intellectualization, networking, information, digitalization and greening of production management in the nonwoven field. 2020-2025 years, the new mode of intelligent manufacturing will be popularized and applied in 3-5 enterprises, so as to give full play to the guiding significance of the standard of spunlaced nonwovens intelligent plant group standard.

Zhang Xingyun, director of Tian Ding Feng (Chuzhou) nonwovens Co., Ltd., introduced the intelligent plant project of the company on the theme of "breaking through innovation and opening up a new intelligent channel". Zhang Xingyun said that Tian Ding Feng, as the "global tire base production leader enterprise", is leading the direction of the industry development. In response to the positive national call, the company declared the first batch of intelligent manufacturing demonstration enterprises, set up the intelligent manufacturing project department, determined that all production lines were automated, and built the MES plant as the center.

Zhang Xingyun introduced that in the automation production aspect, the company completed the fully automatic closed coal boiler project in 2018, completed automatic transportation of starch and automatic dispensing from 2018 to 2019, completed the automatic roll down equipment in 2018, completed commissioning and operation of the automatic down coil equipment in 2019, and completed the installation and operation of all automatic production equipment in all production lines in 2020 and 2020. In terms of MES system, it is expected to complete the investigation of MES system in 2020, and complete the commissioning and operation of the MES system by 2021, and realize the interconnection and interconnection between the SAP system and the WMS system. In terms of database, we plan to establish the database of Tian Ding Feng in 2022, and realize the management center of resources and energy, so as to realize sharing and sharing and statistical analysis.

Topic two: intelligent devices and systems

The intelligent coupler of nonwoven equipment developed by Kunshan Industrial Automation Co., Ltd. focuses on high-end logistics equipment. Based on the Internet platform and the Internet of things information system management and control platform, it controls the automatic flow of data of production factors to solve the uncertainty of complex processes, and realizes interconnection to create a smart world with "signs". The equipment can be used in workshop, military industry, auto parts, furniture, AI application and so on. Zheng Weijun, deputy general manager of the company, introduces that the equipment can be used in the factory building. Based on the Internet, the Internet of things, artificial intelligence and industrial big data technology, the flexible linkage of three levels of equipment between workshop and workshop, between the workshop area and the equipment in the region can be gradually realized, ensuring that the right materials can be delivered to the right place at the right time through appropriate equipment, so as to achieve the deep integration of information flow, production flow and material flow, so as to achieve intelligent "perception", "precise interconnection" and "efficient implementation", and ultimately achieve technological innovation driven management innovation. In the field of AI application, the AI self learning monitoring system is used in the detection stage of the screen equipment. It adopts AI vision technology plus automatic control technology instead of manual operation to improve efficiency, accuracy and stability.

Zhu Libo, assistant general manager of Hunan Zhongnan Intelligent Industrial Technology Co., Ltd., as a report on "intelligent equipment to boost the textile industry's intelligence upgrading", said that the company relies on independent innovation and technology introduction, taking industrial robot technology as the core, and devotes itself to the whole industry chain intelligent manufacturing products and services, so as to provide the best intelligent solutions for different application fields. Zhongnan intelligent mainly aims at the development of an automatic robot system for the nonwovens winding and packaging transportation. It realizes the functions of automatic winding, automatic generating, automatic winding, automatic paper feeding, automatic measuring, automatic sampling, automatic weighing, automatic labeling, automatic packaging, and so on. Digital twins can support the data needs of various application scenarios in the product lifecycle, and enterprises can acquire and analyze all kinds of data at various stages in a timely manner and reapply to production resources. To achieve "interconnection, controllable, transparent, lean, intelligent" digital production and operation, so as to achieve the goal of improving quality, reducing efficiency and increasing efficiency.

Xu Xianhe, an engineer of Zhengzhou Textile Machinery Engineering Technology Co., Ltd. introduced the "intelligent management system of nonwoven equipment". He introduced it from four parts, including the digital transformation of traditional industries, intelligent manufacturing, intelligent manufacturing three levels, non-woven "intelligent manufacturing" solutions, and product cases. He said that the problem of China's industry in the digital transformation of traditional industries is the irrational industrial structure, high energy consumption and high pollution, relying on demographic dividends and lack of independent brands. The domestic development trend of nonwoven equipment is large scale, high yield and high speed. The single line production will continue to improve, and will gradually move towards modular design, intelligent manufacturing, energy saving and emission reduction, high yield and wide range, a variety of process combinations, suitable for processing special fibers, composite materials, simulation and other directions.

Gao Shijun, regional director of Shaoxing smart Polytron Technologies Inc, introduced the "landing plan of industrial textiles MES system". Gao Shijun said that MES is the best carrier for intelligent manufacturing, and the two main theme of industrial 4 is intelligent factory and intelligent production. The goal of MES is to realize the transparency and digitalization of the production process, and to solve the three problems of delivery capability, quality and cost. Intellectualization is embodied in visualization, quantification and early warning. The structural units of the system include workshop production process management system, process data acquisition and monitoring system, Kanban management system, energy management system, equipment management system, and mobile office system. It can realize intelligent scheduling, improve production efficiency, production data online collection, visual production management, transparent process control, production resources traceability, process quality management, problem traceability analysis, real-time Kanban and intelligent early warning command, equipment management OEE analysis, maintenance APP guidance, optimize energy management, energy saving and consumption reduction; big data analysis BI, provide multi-dimensional decision-making basis; APP mobile office, operation at any time.

Topic three: intelligent manufacturing practice and new mode

An Haojie, general manager of Hongda Research Institute Co., Ltd. introduced the "spun bonded nonwoven intelligent production line". He said that the market demand of spunbonded equipment is that spunbonded nonwovens are directly woven into cloth after spinning into the net, and carding nets are made of natural fibers or chemical fibers. Spunbonded nonwoven technology has the characteristics of short flow, high yield and convenient development of new products. Special products have been widely used in the field of disposable products such as personal care and medical protection. To maximize the characteristics of spunbonded technology, reduce the cost of producing spunbonded nonwovens and make use of new processes to produce differentiated products are the key requirements of users for equipment and process discovery. The competition in the market of personal care and medical protective products is increasing. The new application field puts forward new requirements for the performance of spunbonded products. Only by further opening up new applications and reducing production costs and improving the competitiveness of coil production enterprises can the spinning and fusion equipment maintain its superiority in the equipment market. At present, the two-component composite spinning and production intelligence is the landmark requirement of the market for the advanced evaluation of spinning equipment and technology.

Huang Yiyang, senior project engineer of innovation center, Heng An International Group Co., Ltd., he shared experience in making new models for Heng An group. He said, Heng An lean "four can" management system, can be measured, everything in terms of data, based on data, trends, analysis, the ability to analyze problems, find the problems (Principles), improve, have countermeasures, feasibility, implementation (SMART principle), replicability, standards, systems, processes, standardization, repeatable implementation and promotion; Heng an "four can" production management system is established within the organization, to achieve the goal of constant security system production management mode, is a strategic decision of the organization. It combines resources with processes, manages by PDCA management method, and selects several system elements according to the characteristics of enterprises. It generally consists of processes related to management activities, resource supply, product realization, measurement, analysis and improvement, and duplication activities. It can be understood as covering the requirements of planning, implementing, monitoring, correcting and improving activities in the whole process of determining customer needs, designing, developing, producing, testing, selling, and delivering. It is a requirement of internal production management in documents and tabular ways.

Liang Bin, deputy general manager of Limited by Share Ltd information center of Ogilvy medical products, shared "Ogilvy's intelligence manufacturing practice". He said that Ogilvy was founded in 1997 and mainly produces and sells medical dressings. Ogilvy has the largest export market in the country for nine consecutive years. Ogilvy & amp; Co. implements the integration of the two systems and forms an intelligent manufacturing propulsion system. In 2018, it obtained the certificate of the two integration system of the Ministry of industry and commerce. In 2018, we entered the list of national intelligent manufacturing pilot demonstration projects (medical dressings intelligent manufacturing pilot demonstration). He said that intelligent manufacturing and information technology is the top priority project. The top-level design of information system is very important, and planning is greater than everything. Intelligent manufacturing is a systematic project. Talent, capital, technology, equipment, management, and the upstream and downstream businesses are indispensable. It is a long-term project and can not be pinch. Only through gradual improvement of each link and landing of each item one by one, can qualitative change lead to qualitative change and eventually reach the stage of intelligent manufacturing. Data standardization is a prerequisite for intelligent manufacturing, and information security is a necessary condition. Looking forward to the future, intelligent manufacturing will be of great value under the combined influence of many factors such as land, personnel, resources and market diversity.

Reporter's notes

Interview with Li Jibin, director of the administrative committee of Chuzhou Langya Economic Development Zone

"The development prospect of nonwoven industry is very good." Li Jibin believes that from the perspective of industrial development space, the industry has good market prospects, and non-woven products are widely used in industry, engineering, medical and health, new energy, aerospace and other fields. At this stage, China's economy is developing rapidly, and the demand for nonwoven industry has not been fully released. For example, maternal and infant supplies demand for hundreds of thousands of tons annually. From the perspective of Chuzhou's industrial base, the nonwoven industry started late but developed rapidly, and in a short span of more than two years, the industrial development system of "1+2+X" has initially formed. That is to say: with the golden spring non-woven fabric as the leader and the China's nonwoven material industry transfer demonstration base as the main bearing platform, the non-woven industrial cluster based on Tian hang maternal and infant supplies, Xing Xing Cai and Tian Ding Feng, the base scale and radiative power are constantly expanding.

Li Jibin pointed out that since the listing of the industrial park, the target has attracted more than 100 million yuan related enterprises 30, of which, more than 1 billion yuan and 5 projects, and strive to create tens of billions of industries. Up to now, there are 16 new base materials for nonwoven materials industry. A total of 31 production and construction nonwoven production lines have been put into operation, with an annual capacity of more than 200 thousand tons. In 2018, the gross output value of the nonwoven industry reached 2 billion yuan, and the tax revenue was about 100 million yuan, basically forming a non-woven material industrial chain in the fields of mother and infant, medical treatment, vehicle use and so on. At the same time, it was listed in the key development industry of Chuzhou. Li Jibin said that in order to make the nonwoven industry bigger and stronger and gradually form an industrial cluster with strong influence and competitiveness at home and abroad, the Park welcomes a number of leading enterprises and high-quality projects with high technology content, good economic returns and large investment scale, so as to realize the great improvement of the nonwoven industry in the park.