In 2020, under the influence of the epidemic, many enterprises are facing the situation of no one available after returning to work. The labor shortage phenomenon further stimulates and promotes manufacturing enterprises to increase the awareness of machine replacement, and improve the level of enterprise intelligence. Industrial robots not only act as “labor force” in the production line of manufacturing enterprises, but also are widely used in various scenes during the epidemic period, becoming “service providers” in the front line. Machine replacement is being carried out by more and more industries, and unmanned application is also being gradually promoted in various factories.
China is the largest market of industrial robots in the world, accounting for more than 30% of the total sales of industrial robots in the world, with a market scale of 40 billion in 2019. However, the density of industrial robots in China is only 140 sets / 10000 people, which lags behind other industrial countries. If it reaches the level of 327 sets / 10000 people in Japan, it will be a market with an annual scale of 100 billion. In the future, under the background of the disappearance of demographic dividend and the rise of labor costs, China will enter the steady growth stage of industrial robot industry, and the CAGR will reach 22% in the next three years.
Manufacturing enterprises have said that the positive impact of the epidemic is to accelerate the development of “machine replacement”. If the factory realizes a high degree of automation, it can effectively deal with the labor shortage.
From UFIDA’s experience in serving 460000 industrial enterprises, it can be concluded that there are three main paths for industrial enterprises to go to the industrial Internet: the first is to improve production efficiency by replacing people with machines; the other two are to improve collaborative efficiency by running errands on the Internet; and the algorithm changes brain to improve decision-making efficiency.
What else should manufacturing enterprises consider to solve the labor shortage and realize industrial interconnection and intelligent manufacturing through “machine replacement”?
Machine replacement, improve production efficiency
With the increase of labor cost, the impact of the rapid development of artificial intelligence and the increase of market options, manufacturing enterprises are forced to transform and upgrade to achieve automation to adapt to market competition. The combination of artificial intelligence and machine production brings both opportunities and challenges: while industrial robots replace low-end labor, they also create new employment opportunities; this is a good time for industrial workers to transform themselves, and also points out the development direction and future prospects for manufacturing enterprises. This is what we see, “machine for man” brings to manufacturing enterprises.
“Machine replacement” can improve production efficiency mainly in the following four aspects:
1、 The production and processing link is equipped with automatic production equipment such as industrial robots to improve the processing efficiency
The cost “scissors gap” formed by the weakening demographic dividend, the rising average wage of manufacturing employees and the falling average price of robots is gradually expanding, which forces enterprises to speed up the automation transformation. According to the data of the National Bureau of statistics, China’s aging population aged 16-69 continued to decrease from 2013 to 2018, with a year-on-year decrease of 0.6 percentage point in 2018, and the total amount and proportion continued to decline for five consecutive years. On the contrary, the wages of employees in the manufacturing industry maintain a rapid growth. From 2008 to 2018, the average wages of employees in China’s manufacturing industry increased from 24400 yuan / year to 72100 yuan / year, with an annual growth rate of 11%.
The economic impetus brought by demographic dividend is gradually disappearing. In addition, the industrial robot technology is gradually mature, and the cost is gradually reduced due to the localization of core parts. The willingness and cost performance of enterprises to carry out automation transformation are gradually strengthened.
Traditional manufacturing enterprises often need to spend a lot of manpower to carry and turnover in the process of product production, especially the enterprises using machine tools. In the process of processing workpieces, the previous machine tools often need a machine tool with a worker responsible for loading and unloading, not only the processing efficiency is low, but also prone to improper operation of workers, resulting in machine damage or personal injury. Through the implementation of “machine replacement”, enterprises can not only greatly improve production efficiency, save a lot of labor costs and equipment occupied area, but also reduce the logistics time between processes and the secondary bumps in workpiece turnover.
Time is money. The implementation of “machine replacement” not only greatly improves the production efficiency of enterprises, but also greatly reduces the labor cost and production cycle of enterprises.
2、 AVG, WMS and other automatic logistics equipment are replaced in logistics transportation to improve logistics efficiency
With the change of market demand and manufacturing mode, in order to better complete order delivery and optimize customer service experience, manufacturing enterprises continue to improve and enhance the efficiency of factory logistics execution. From the perspective of resource occupation and activity cost, picking operation has always been the bottleneck of improving logistics efficiency. In traditional factories, picking operation consumes more workers, takes up a large area of picking area, and has high intensity and low efficiency. In this context, intelligent warehousing and logistics solutions are more and more favored by the majority of manufacturing enterprises.
Traditional forklift and trailer operations need to be driven. In addition, forklift and trailer drivers need to drive to the charging room for charging when they work for a certain period of time, resulting in less than 70% of the actual working load; As an automatic material handling equipment, AGV can be charged online and operated at full load for 24 hours, which has incomparable advantages over manual operation.
Manufacturing enterprises can effectively use AGV robots to replace people in the logistics distribution link of manufacturing industry. At the same time, combined with WMS warehouse logistics integrated management, with the help of MES information management platform, they can efficiently, accurately and flexibly complete the logistics handling task, and improve the logistics efficiency of production and the competitiveness of enterprises.
3、 The quality detection link is replaced with automatic detection equipment such as image automatic detection to improve the detection efficiency
Looking around the world, industrial product appearance testing instruments are a huge market, with a scale of about 300 billion. The domestic market is almost blank. At present, only one or two large manufacturing enterprises are using related products, and most of them still rely on labor.
In the process of industrial manufacturing, the final pass of the product on the production line is to check whether it is qualified. This work must be done by experienced employees who are very familiar with the products, so the manpower is insufficient and the efficiency is relatively low.
According to the person in charge of a number of mobile phone manufacturers, “take the production of mobile phones as an example. Foxconn, which works for them, needs to check the appearance of each finished mobile phone one by one. It takes 7-8 seconds for each mobile phone to be tested. If the testing work is completed by the machine, then seven or eight mobile phones can be tested in one second.” After the “machine replacement” is realized, not only the manpower is saved, the detection efficiency is doubled, but also the detection rate of manual detection is increased from more than 90% to more than 99%.
4、 Remote control devices such as IOT box are installed in the field service to improve service efficiency
At present, more and more manufacturing enterprises regard service as an important means to obtain market competitiveness, increase the value of their core products by improving the quality of customer service, and expand the economic and social benefits of enterprises. As a new industrial form, service-oriented manufacturing has become an inevitable trend of the development of manufacturing industry.
In theory, the equipment manufacturer is the preferred unit for equipment maintenance. However, due to the problems of untimely maintenance information, long service distance and high maintenance cost, it can not get the income of later maintenance, and part of the maintenance income is often controlled by small maintenance companies around the manufacturer. For the equipment manufacturer, the afterservice market of equipment maintenance is a deep pain; The daily maintenance is not in place, resulting in high failure rate, lack of operation and maintenance skills. These maintenance status are also the problems that affect the production safety and economic benefits of manufacturing enterprises.
For example, the traditional distributed photovoltaic power station is usually located in remote areas with a long way to go. The operation and maintenance mode is to ensure the normal operation of the photovoltaic power station through customer feedback or regular on-site inspection by service engineers. This will cause high operation and maintenance costs, problems are not handled in a timely manner, customer complaints, and even security risks due to not handled in a timely manner. By adopting UFIDA’s “manufacturing cloud device service”, photovoltaic enterprises can install IOT box on site, and realize remote online monitoring of devices in combination with IOT IOT service, so as to focus on real-time control of the whole life cycle of devices. The distributed photovoltaic power station has realized unmanned, mobile, remote and intelligent. Through on-site installation and delivery, IOT IOT service, operation data monitoring, intelligent diagnosis and prediction, after-sales service and other all-round closed-loop management and data precipitation, it integrates AI and intelligent algorithm capabilities to help photovoltaic enterprises realize the transformation of manufacturing enterprises to service and improve service efficiency.
In the process of machine replacement construction, improving the efficiency of production and service is the primary goal of manufacturing enterprises. However, the unified planning and construction of intelligent factory should also be considered, and the interconnection of MES system, intelligent warehousing and transportation system, product traceability system, equipment service system and other information systems should be considered. Otherwise, the isolated island of equipment will be formed, which will not give full play to the maximum efficiency, but will lead to enterprise production failure The problem of efficiency decreasing instead of increasing.
Practice and exploration of industrial Internet under the mode of “machine replacing people”
The biggest convenience of “machine replacement” for manufacturing enterprises is to greatly improve the production efficiency and product quality.
Xinpeng Lianzhong realizes intelligent production for medium-sized discrete manufacturing enterprises. Through the construction of supplier online collaboration system, cloud MES system, and large-scale replacement of welding robots and AGV, mobile applications are fully implemented. On the premise that the output increased by 22%, 1095 workers were saved directly, the per capita output value increased by 79.8%, and the defect rate decreased from 3 ‰ to 1 ‰;
Atlantic group has introduced a series of intelligent equipment, such as AGV, RGV, shuttle car, park rail car, pneumatic transportation line, robot, three-dimensional warehouse, etc. in the manufacturing process. Atlantic group has basically realized that the R & D cycle has been increased by 20%, the inventory has been reduced by 20%, the excellent rate has been increased by 2% – 3%, the production personnel has been reduced by 50%, and the energy consumption has been reduced by about 20%.
Shuangliang group, through the establishment of intelligent operation and maintenance platform, combines Internet of things products with internet communication and cloud computing technology to create a full life cycle service of “expert + housekeeper + Internet”. Through remote monitoring, cloud data backup and big data analysis, it provides predictive equipment diagnosis and analysis, and realizes intelligent remote diagnosis and troubleshooting. Shuangliang’s service profit has increased from 2 million yuan to more than 30 million yuan, saving 20% – 50% of energy for different users, extending the service life of the equipment for 5-10 years, and reducing the management cost by 15% – 30%.
Since UFIDA started to deploy industrial Internet in 2017, it has served 460000 industrial enterprises, covering 39 industrial categories and 18 application fields. The platform integrates 570000 sets of industrial equipment and 1949 industrial apps, and has established cooperation with 28 home appliance business platforms, 15 logistics platforms and 120 financial institutions. At the same time, as one of the top ten cross industry and cross domain industrial Internet platforms in China, UFIDA Jingzhi has completed the deployment of regional industrial Internet platforms in Hunan, Hubei, Jiangxi, Guizhou and Chongqing.
After the impact of the epidemic, it is bound to accelerate the pace of machine replacement of manufacturing enterprises to improve the production efficiency of enterprises. At the same time, UFIDA will continue to make efforts on the industrial Internet to provide perfect “infrastructure” construction and effective landing path for the digital and intelligent transformation of manufacturing enterprises.
Editor in charge: yyx