In the face of rising costs, the manufacturing industry in the Pearl River Delta is experiencing significant differentiation: high-end manufacturing throughautomationThe organic combination with informatization pursues intelligent production to reduce labor input and improve production efficiency; the middle and low-end manufacturing industries are relocated to reduce production costs, and the scale of the remaining factories tends to be miniaturized as a window for receiving orders , to meet customer research and development proofing needs.
Automation + Informatization Improve Production Efficiency
A production line is automatically identified, detected, and assembled by a robotic arm, while a production line is manually identified, detected, and assembled. The final product is a walkie-talkie, but there are big differences in quality, cost input and production efficiency.
At Hytera’s global manufacturing base located in Longgang District, Shenzhen, you can see traditional production lines, automated production lines andindustryThe coexistence of intelligent production lines in 4.0 makes it a good model for observing the transformation and upgrading of the manufacturing industry.
Visually, the intelligent production line is much longer than the traditional production line. Factory director Che Guyong explained: “Because people have complex thinking ability, a person can do multiple actions. On the contrary, machines can only do the same action repeatedly.”
The first phase of this intelligent production line invested 12 million yuan, integrating 29 sets of radio frequency identification (RFID) equipment, 11 sets of six-axisRobot, 34 sets of testing instruments and other hardware equipment. Che Guyong said: “This is only the visible hardware part, but in fact, for an intelligent production line, the most important part is the invisible software part, that is, the information investment. Figuratively speaking, automation allows machines to have Hands, and informatization allow machines to have brains, thinking and judgment capabilities.” This intelligent production line integrates 18 sets of systems and programs independently developed by Hytera, involving 6 patents.
Che Guyong said: “With informatization, the machine can judge and communicate independently. For example, in the automatic feeder, how does it know that this tray of materials has been taken out and needs to be replaced? That’s because when this tray is When the last of the trays is taken, a message is sent to the feeder ‘you should take the next tray out’.”
In Che Guyong’s view, informatization is also the key to realizing mixed-line production. With the diversification of orders, if a production line can only produce one product, it will lead to waste of capacity. Traditional production lines rely on people to identify product categories and make production adjustments. In the intelligent production line, the jig on which the product is placed has a radio frequency identification barcode. Once it is scanned, you can know what product is on the jig and where it should stop. Communication between the machine and the product is realized.
For the same production of walkie-talkies, compared with the traditional production line, the number of employees per shift of the intelligent production line can be reduced from 25 to 12, a reduction of 52%, and the output per hour is increased from 65 to 90, an increase of 38%.
Zeng Hua, Senior Vice President of Hytera said: “In the process of rising costs, we also considered moving, but the accumulation of technology and talents may be wasted. We have observed that German companies rarely rely on moving factories to solve rising costs. The problem is to meet the challenges through technological innovation and upgrade to Industry 4.0. We feel that the German model is more suitable for us, so we choose to make efforts in the direction of Industry 4.0.”
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