Practice Industry 4.0, join hands for China Optoelectronics, Hongyan Electric Investment 50 million yuan "machine substitution"

The bright and tidy company's LED lighting production workshop has only four workers in the entire production line, and one worker is in the state of standby, but the company's lighting products have doubled in production efficiency.

Such a change will happen in Hongyan Electric Appliances - on October 28, 2015, Hangzhou Hongyan Electric Appliance Co., Ltd. (hereinafter referred to as "Hongyan Electrical Appliances") and Hangzhou Zhongwei Optoelectronic Technology Co., Ltd. (hereinafter referred to as "Zhongwei Optoelectronics"), In Hangzhou, a strategic cooperation of “machine substitution” was reached. According to the agreement, Hongyan Company has compiled a master plan for “machine substitution”. It plans to invest in not less than RMB 50 million for three years, to automate the production line and assembly line, to carry out intelligent transformation and to build a new intelligent factory. The implementation of the "machine substitution" project by Hongyan Electric will be fully entrusted to Zhongwei Optoelectronics.

The strategic cooperation agreement was signed at the Shangri-La Hotel in Hangzhou on the day of the press conference. Zhang Yue, deputy inspector of Zhejiang Economic and Information Technology Committee, Chen Yegen, member of the Party Working Committee of Hangzhou Qianjiang Economic Development Zone, and other deputy director Chen Yegen attended the signing ceremony.

Now, 60 workers can finish doing 4 or 5 people.

The lighting workshop of Hongyan Electric has a total of 8 production lines. If the “firepower is fully open”, each production line can produce an average of 300,000 LED light source products per month. However, because it is a semi-automated production line, if the production capacity is fully opened, each production line needs to be equipped with 30 workers.

"But now the workers are not good at recruiting, especially the skilled workers are very scarce," said Yu Jinsheng, the person in charge of Hongyan's lighting production. He told reporters that Hongyan Electric's salary for workers is not low, the average month. The wages can reach 4,000-5,000 yuan. However, seasonal recruitment is still difficult to happen, especially before the Spring Festival and after the summer vacation. The "labor shortage" is the most serious.

However, with the implementation of the company's "machine substitution" strategy, Yu Jinsheng's "employment anxiety" has finally been cured.

According to the overall plan of “Van Substitution” of Hongyan Electric Appliance, the current lighting production line will be automatically transformed. Each upgraded production line can realize the production capacity of 600,000 LED bulbs per month (measured by 22 hours per day). It has doubled over the original, and to complete such capacity, only 4-5 workers are needed.

The reporter calculated an account: taking 600,000 LED light source products as an example, the traditional production line needs 30 workers to work for 2 months. According to the monthly salary of 5,000 yuan/person, the company needs to pay 300,000 yuan for 2 months. Wages, but if the automatic production line is introduced and the same capacity is completed, the company pays less than 30,000 yuan, and the labor cost is greatly reduced.

3D printing meets individual needs

As we all know, fully automated production lines are more suitable for standardized products, so how to achieve niche and personalized user needs?

According to Zhang Jiliu, general manager of Hangzhou Zhongwei Optoelectronic Technology Co., Ltd., as long as it is the product demand of the customer, regardless of the order size, the new production line can be satisfied by 3D printing and flexible production. Not only that, the traditional production line is mainly based on workers' operations, and it is inevitable that there will be “manual mistakes” in the inspection products. The new production line introduces intelligent image recognition technology for the first time instead of manual visual inspection or machine positioning. On the basis of improving efficiency, the product quality is also improved. .

In fact, the new production line realizes the system solution of automatic assembly, automatic detection and automatic aging in the whole production process. The whole process does not require manual intervention, and can also realize the functions of product inspection and quality inspection, and further control quality.

Practice Industry 4.0 to seize the commanding heights of competition

The strategy of "Hongyan Electric's machine substitution" was also forced out." Wang Yancheng, president of Hongyan Electric, said.

It is understood that Hongyan Electric, which started with electrical products, was established in 1981. The company's electrician product market share has always been at the forefront of the industry. In 2010, the company began to enter the LED lighting industry and invested in eight production lines in the company's two industrial parks.

However, with the rapid development of Hongyan lighting industry, the company urgently needs to further expand its production capacity. “For example, from January to September this year, Hongyan Lighting’s revenue increased by 80%, orders increased rapidly, and it’s difficult to recruit workers. A major obstacle to development." Wang Micheng said.

If you have a problem, you must find a solution. In fact, the strategy of “substitution for people” has been brewing in Wang Micheng for one or two years.

"Zhejiang is a big province of manufacturing, but in recent years, the disappearance of the "demographic dividend" and the adjustment of the global industrial competition pattern, the low-cost advantage of China's manufacturing is no longer, so I have been thinking about it, as the manufacturing geese, the future How should we go?"

In Wang Micheng's view, Zhejiang and even China's manufacturing industry faces the challenge of “two-way squeeze” between developed countries and other developing countries. Enterprises need to step up strategic deployment, practice Industry 4.0 and “Made in China 2025” plan, and seize a new round of manufacturing. Competition is the commanding height, and “machine substitution” is one of the necessary measures for companies to cope with challenges.

Therefore, during this period, Hongyan investigated a large number of intelligent manufacturing equipment enterprises, and understood its technology and services. Finally, in October of this year, it reached a cooperation with Zhongwei Optoelectronics. According to the agreement between the two parties, the project of Hongyan transformation includes Qingshan Lake Hongyan Industrial Park. Automatic assembly line for lighting products, automatic assembly line for electrical products of Wuchang Hongyan Industrial Park and automatic production line for electronic products of Wuchang Hongyan Industrial Park.

At the same time, the two sides will also cooperate in the construction of Qingshan Lake Hongyan Industrial Park lighting intelligent factory. Nowadays, Hongyan has begun to lay out the smart home field. According to Wang Micheng's vision, Hongyan not only needs to produce intelligent products and solutions, but also to realize the intelligentization of the production process, in order to cope with external challenges and seize the commanding heights of competition. (This article is the submission of Hong Yan Electric)

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