In daily life, wearing strippers is a piece of cake. However, as early as in nineteenth Century, quite a lot of people had broken their brains. At that time, boots were popular in Europe and America, but there were more than 20 buttons on the boots, which took a lot of time to wear. Women's clothing became more complicated and even needed assistance. Is there any tool that can make the clothes beautiful and convenient to wear? Out of consideration of this problem, the prototype of the zipper was born. Then, after hundreds of years of iteration and evolution, there are now exquisite, beautiful, colorful and functional zippers. From aviation to military, from medical treatment to civil use, small zippers are often neglected, but they play an important role beyond imagination. As the largest producer of garments and bags in the world, China is currently the world's largest manufacturer and exporter of zipper products, with an annual output value of about 50 billion and about 3000 domestic zipper manufacturers. The industry employs nearly one million people. Traditional zipper production is a typical labor-intensive industry with high labor cost and low added value. However, in Chengdu, known as "the land of abundance", there is such a high-tech enterprise specializing in R & D and production of zipper dyeing production line. Schneider electric Subverting traditional cognition with innovative solutions and realizing seamless link between digitalization and light industry. Chengdu R & C Automation Technology Co., Ltd. 。
Active change:
From "device" to "service"
In the past, people's requirements for zippers were limited to performance. Nowadays, with the continuous improvement of quality of life and aesthetic standards, consumers are more and more aware of the style, color and design of clothing. Therefore, dyeing as an important part of the zipper production process also directly determines the aesthetics of the zipper products. He has worked hard in zipper dyeing field for many years, and has been working hard to provide world-class zipper dyeing equipment and services for Chinese zippers. At present, the company has formed a strong technological R & D team, not only to provide the most complete zipper dyeing production line in the industry, but also has independent core technology in the fabric shaping process, which can help the zipper enterprises to greatly improve the product quality and effectively solve the quality problems such as deep light color, color flowers, indentation, specifications and so on. When it comes to the industry competition pattern, General manager, Mr. Said: "zipper supporting equipment in the field of imitation is more serious, industry competition is very fierce. The cost of dyeing equipment developed by us is relatively high, so the main target customers are large zipper manufacturers at home and abroad. However, the demand of large companies is always limited. Simply selling equipment is easy to touch the ceiling of the top industry. Under the background of the deep integration of the two industries of China's advanced manufacturing industry and modern service industry, we respond positively to the call. Active opening of the transformation from "equipment" to "service". " From a long time ago, he began to actively explore the business model of providing services to customers. This makes the business mode of the company different from the traditional OEM manufacturers. It not only provides customers with a full set of production line equipment for zipper dyeing, but also needs to produce products on the spot in the customer workshop, and then hand over the finished zipper products to customers. This unique business model determines that the company is both a device manufacturer and a line operator. It should consider both the one-time delivery of the whole equipment and the long-term operation of the equipment. Because of its dual status, it also faces both challenges in manufacturing and operation. Facing challenges directly:
From "manufacturing" to "intelligent manufacturing"
In a zipper factory located in Fujian, because of its low automation level, the dyeing production line must also rely on manual operations for loading and unloading. After receiving the order, the operator will use the trolley to transfer the bobbin from the raw material storehouse to the belt winding machine. The weight of a bobbin is less than 60~70 Jin, and more than 300-500 Jin. It needs at least one hundred times a day to move up and down. It not only has great labor intensity, but also affects the production efficiency. And dependence on labor also brings difficulties in recruitment. Over reliance on manpower is only a representation, which reflects the lack of digital system support in the production and operation of factories. Data can not be synchronized with the management mode, which easily leads to errors in material transfer. Secondly, it makes the logistics inside the plant not easy to manage, and the finished products and semi-finished products are often unable to locate. Thirdly, managers can not understand the specific implementation of production for the first time. Take the material link as an example, the cloth used in the zipper actually has many kinds of woven patterns, but it is difficult to distinguish the naked eye. The employees only distinguish the materials by the naked eye, which easily leads to the mistake of the material, which affects the quality of the finished products. In addition, RX needs a mature dyeing management mechanism. Color formula is the core of the dyeing process. If we can solidify the relevant knowledge and experience in the system instead of relying on the teacher to record the prescription on the book, it will help the long-term development of enterprises and the inheritance of technological knowledge. The challenges from cost, efficiency and management have prompted the urgent need for digital restructuring. On the way from "manufacturing" to "green intelligent manufacturing", he hopes to have a strong technical and experienced partner to work together. Based on the previous demonstration project with Schneider electric, he has highly recognized the strength of Schneider electric, so the two sides have continued to work further together. "Schneider electric provides us with a complete EcoStruxure machine solution, covering the hardware system of M258, M241, M218, M200 PLC, ATV 320 inverter, Lexium 26 servo, GXU touch screen and low-voltage distribution products," said ran. It ensures the stability of the production line equipment, including AVEVA system platform and industrial APP. Software products such as EcoStruxure machine consultants provide support for long-term operation of production lines. The complete solution of Schneider electrical hardware and software integration helps us to realize the one-off delivery of the whole equipment and the long-term digital operation of the production line based on intelligent machine and intelligent logistics. "
Gorgeous Transformation:
Efficiency, energy saving and optimal management
Digitalized baptism makes Zhejiang's new zipper dyeing line look like new. The factory realized zipper dyeing from the order to the production of fully automated production, greatly improving the production efficiency, product qualification rate and prescription management efficiency, reducing the raw material consumption, labor intensity and human error rate, and all of these are inseparable. "Zipper dyeing scheduling system" The "military division" is in the central government to co-ordinate the overall situation. The system is developed jointly by AVEVA and system based on Schneider system, including order management, scheduling, erect management, quality inspection and so on. Thanks to the good openness and expansibility of the AVEVA system platform, the system with powerful functions has been developed in only 2 months. Whenever there are new orders from customers, the zipper dyeing scheduling system will become an intelligent "housekeeper" who is smart and smart, and automatically arrange production according to order priority, equipment status and order date, so as to ensure that equipment is not idle, production will not conflict, and orders will not be delayed. As the system reasonably arranges the connection between orders and orders, it reduces the airlift of the equipment, reduces the loss during the production line waiting period, and further saves energy consumption. After the production is completed, the employees can receive raw materials from the raw materials warehouse according to the job information automatically generated by the system. At this time, the system is like a strict "customs inspector". Each material needs to be identified through two-dimensional code, so that it can smoothly exit the library and eliminate the mistake from the source. At the same time, the system will also inform the AGV car to move the bobbin from the vertical warehouse, and automatically up and down the material, thus greatly reducing the labor intensity of the operator. After the preparation of all processes, the dyeing of raw materials will start. In this process, the system can also carry out statistics on raw materials, semi-finished products and finished products such as storage, storage, product quantity and so on, and automatically collect all the data in the production process, so that all paperless management can be realized, so that managers can grasp all the production conditions. In daily operation and maintenance, operation and maintenance personnel can also achieve better equipment maintenance through industrial APP EcoStruxure machine consultant. The system can timely push the corresponding solution manual to the field engineer when the equipment fails, and provide online after-sales module to facilitate the end users to accurately and efficiently repair. Ran Hao gave high praise to the project results: "since the application of Schneider Electric's digital solution, our overall production efficiency has reached 10%-20%, and production energy saving is 20%. This result makes us truly feel the efficiency and convenience brought by digitalization and intellectualization." In the future, the two sides will also collect data from each field based on the function of EcoStruxure machine consultant's analysis center, and create an algorithm model. The model will be integrated into the platform to achieve real-time monitoring, prediction and feedback. When production deviations occur, workers will be scheduled for on-site work.
