â–³ In the Quanzhou City (Nan'an) Optoelectronic Information Industry Base in Fujian Province, Sunshine Zhongke Enterprise's crystalline silicon solar cell production line roared, and workers were busy rushing to order. According to Chen Limei, assistant to the chairman of the company, the company has already started production in 2016, and the orders have been placed in 2017. Photo by Zhang Jiuqiang
△ Hengan intelligent production and modern storage base in Hengkeng Town, Jinjiang City, Quanzhou City – Fujian Hengan Family Living Goods Co., Ltd. presents a busy production scene. Chen Tao
Panpan food and beverage workshop.
It is difficult to recruit workers and use labor. This is a topic that China's traditional manufacturing industry can't avoid and avoid in recent years.
In order to solve the "difficult recruitment", many manufacturing enterprises have accelerated the pace of transformation and development, especially through the implementation of technological transformation, upgrading the level of automation, and achieving "machine substitution" to reduce the demand for employment.
Quanzhou City, Fujian Province, where the private economy is relatively developed and the manufacturing industry cluster has become a large-scale, the intelligent manufacturing special action is an important starting point, vigorously promote "machine substitution", and guide nearly 1000 traditional manufacturing enterprises and labor-intensive enterprises to apply CNC. Technology and products.
Where does the power of implementing “machine substitution†for thousands of enterprises in Quanzhou, Fujian? What changes have the “machine substitution†brought to Quanzhou’s manufacturing industry? After the "substitution of machines", can the employment problems of manufacturing enterprises be solved fundamentally? Recently, the "Economic Daily" reporter came to Quanzhou, Fujian Province for research and interview.
"It is difficult to recruit workers" and forced "machine substitution"
At the Huafei Industrial Park in Shishikeng East Development Zone, Quanzhou City, Fujian Province, the brand of “Fashion Digital Rapid Manufacturing Project†at the entrance of the garment workshop of Huafei Garments Co., Ltd. is particularly eye-catching.
Yu Liangya, vice chairman of Huafei Garment Co., Ltd., told reporters that every step of the Huafei apparel production workshop has achieved computer automation control, and the company has become one of the demonstration bases for the rapid manufacturing of national engineering research centers.
Into the workshop, the reporter saw that the automatic cutting machine and the automatic drawing machine are arranged in an orderly manner. The production processes of different links are connected to each other by the automated lifting system. After each process is completed, the semi-finished products are directly transferred to the next link through the lifting system. .
“In 2015, we invested nearly 7 million yuan to purchase these automation equipment, which greatly improved the automation level of the entire production workshop.†Yu Liangya said that for private enterprises, 7 million yuan is not a small amount. However, in general, this investment is still very cost-effective.
Yu Liangya, who has been in the clothing industry for more than 20 years, told reporters that in recent years, companies have clearly felt that the pressure on employment has increased. On the one hand, workers’ wages are rising. “Now the wage level of workers has doubled from 10 years ago. On the other hand, because of the “labor shortageâ€, workers’ demands on employers are getting higher and higher, and enterprises are required to provide workers with Free dorms, subsidized canteens, and often engage in cultural and sports activities that young people like to participate in, otherwise it is difficult to retain people.
"If you do not automate the transformation and reduce the number of workers, the pressure of employment will be even greater in the future." You Liangya said that enterprises must be able to make large-scale competition in the future market. Tactics, and must continuously improve labor productivity.
In recent years, thousands of traditional manufacturing enterprises in Quanzhou have accelerated the intelligent transformation like Huafei. Sun Zhenhan, head of the Technical Progress and Investment Section of the Quanzhou Economic and Trade Commission, told the reporter that during the “Twelfth Five-Year Plan†period, Quanzhou’s total investment in technological transformation was more than 255 billion yuan, an average annual increase of 29.9%. Among them, equipment investment accounted for more than 60%.
Chen Jianxing, deputy director of Quanzhou Science and Technology Bureau, said that after more than 30 years of rapid development in reform and opening up, Quanzhou has developed a huge manufacturing system and successfully built many traditional industrial clusters such as textiles and clothing and footwear.
However, Quanzhou traditional manufacturing enterprises generally have the problems of “low, scattered and shortâ€, most of which are labor-intensive enterprises. They have long relied on low-cost expansion. Most enterprises still use small and low-end production equipment, lacking numerical control and intelligence. High-end technical support, processing accuracy and product quality are difficult to guarantee, lacking continuous technological innovation.
“With the gradual tightening of the macroeconomic environment, traditional manufacturing industries are facing new challenges. Only by implementing innovation-driven development strategies and comprehensively promoting innovation in CNC and intelligent manufacturing technologies can we promote the transformation and upgrading of traditional manufacturing industries.†Chen Jianxing said that "CNC generation" application demonstration project construction, development of intelligent manufacturing process, we encourage enterprises to carry out "machine substitution", is to further enhance the core competitiveness of enterprises, accelerate the transformation and upgrading of manufacturing, promote the development of high-end manufacturing industry and strengthen local pillars and The supporting role and service ability of the featured industry.
Reduced labor costs
When the reporter came to the Panpan Food Group in Qiancai Industrial Zone, Anhai Town, Jinjiang, Quanzhou, the company's CEO, Cai Jinxi, was convening a meeting of management. The content of the meeting was to arrange and speed up the commissioning of Panpan Food's new production line automation equipment in the field.
“Now the cost of labor is rising everywhere. To ensure that workers can stay, the wages are generally 5% to 10% higher than the local average, and some places even exceed 20%.†Cai Jinxi said that only the workers are relatively stable, product quality Only when there is security, the benefits of the enterprise will be better and better. However, in this way, the labor costs of enterprises will increase.
Cai Jinxi said that in order to further control costs and improve production efficiency and product quality, Panpan Food has entered into strategic cooperation with domestic and foreign manufacturers from a few years ago to jointly invest in R&D production line equipment.
From the practice point of view, after the introduction of advanced automated production lines, not only the product quality is guaranteed, but also the employment situation of the enterprise has been further improved. Now the Panpan Group, three workers can complete the work of the past five workers, and the wages of three people are equivalent to the salary of the past four people.
Cai Jinxi told reporters that Panpan Food currently has 19 branches and employs 12,000 people. Panpan Foods Co., Ltd. has been expanding for almost 20 years since its establishment. After the implementation of “machine substitutionâ€, although the company's scale has expanded, the number of employees required has not increased significantly. According to the plan, Panpan Food strives for the output value of food and beverages to exceed 10 billion yuan. In the future development, Panpan Food will continue to implement “machine substitution†and dividends for high technology.
In Huafei apparel company, You Liangya told reporters that with the automation of auxiliary equipment, the labor demand of the factory has been reduced by a quarter compared with the past, and the connection of each workflow has been fully automated, which greatly reduced the labor intensity and improved the Labor efficiency has also improved product quality, the rework rate has dropped by 8 percentage points, and corporate profits have increased by about 20%.
Chen Jianxing said that the implementation of “Quanzhou Manufacturing 2025†and the promotion of intelligent manufacturing in Quanzhou have a great impact on the transformation, upgrading and innovation of various industrial fields. The level of equipment and manufacturing technology in major industries has been significantly improved, and the production level and product technology level of some enterprises have improved significantly. .
For example, after the textile company uses the CNC textile machine, the production time is shortened from 3 to 4 hours/sweater (piece) to 40 minutes/sweater (piece), and one worker can operate 5 to 10 machines at the same time, which can greatly improve production efficiency. Reduce labor demand and labor costs.
In the interview, the reporter also learned that the automatic yarn breakage detection technology project of the warp knitting machine developed by Quanzhou Huayu Company and Harbin Institute of Technology can improve labor productivity by 10% and reduce the defective rate by 5 percentage points. Baihong's automatic ingot packaging line project saves 50 people every day and saves 2.5 million yuan in labor costs per year. Meiyang Company originally only produced plastic products and engaged in mold development. It cooperated with Huazhong University of Science and Technology Intelligent Research Institute to develop high-speed full-servo five-axis manipulators and renovate the company's injection molding workshop. The 38 equipments in the workshop only need 16 workers. The cost is increased by 3 times, the labor cost is reduced by 35%, and the product category is increased by hundreds.
Chen Zhaoping, deputy director of the Quanzhou Development and Reform Commission, said that the traditional manufacturing enterprises in Quanzhou have generally reduced their employment by 20% to 30% and the efficiency has increased by more than 50% after the “machine substitution†transformation. The product quality has been greatly improved.
“Technics shortage†will be more prominent
The reporter learned in the interview that Quanzhou's manufacturing equipment is generally not highly automated, and some processes are mainly completed by manual operations. For example, 70% of the enterprises in the stone industry are mainly based on PLC low-end control technology, and the polishing and polishing process in the plumbing industry. Most of the workers work in dusty environments.
After the implementation of “machine substitutionâ€, some traditional manufacturing enterprises are equipped with more advanced equipment and systems, and the requirements for operation and maintenance of the equipment are further improved.
However, due to the current lack of CNC technology application talents (engineers, technicians, technicians), especially the composite technical personnel who understand both CNC technology and related majors, there are few and far between them, which affects the implementation of CNC technology to a certain extent. Promotion.
“At present, among the vast number of technical workers in Quanzhou, junior high school diplomas account for about 80%, and it is difficult to adapt to the operation and maintenance requirements of robots and intelligent equipment in a short period of time.†Chen Jianxing said.
Chen Jianxing also said that after the implementation of "machine substitution", the first-line low-skilled workers in the manufacturing enterprises, even some skilled workers will be replaced by industrial robots, and the technical positions for debugging, maintaining and controlling industrial robots will increase relatively. In the short term, robots will have an impact on the labor market. If some workers are unable to meet the requirements of robot engineers, they may eventually become the eliminated people of the intelligent revolution.
In the interview, Cai Jinxi told reporters that after the automation of Panpan Food, many equipments need to be operated by computer. In order to cope with the shortage of skilled workers, the company expands recruitment from vocational colleges on the one hand, and selects a group of skilled workers from the other, and the equipment suppliers are responsible for training, thus improving the technical level of employees. This will not only improve the production efficiency of enterprises, but also reduce the cost of labor, and further increase the income of workers and achieve multiple wins.
Chen Zhaoping said that with the advancement of "machine substitution" and intelligent manufacturing, "difficult recruitment" and "technical shortage" will continue to exist in a short time. To solve the employment problem of manufacturing enterprises, on the one hand, we must start from the perspective of supply-side structural reform, accelerate the automation transformation, and enhance the informationization and intelligence level of traditional industries. On the other hand, the relevant departments should also put more emphasis on strengthening the vocational skills training of migrant workers, and strengthen the "school-enterprise cooperation" and other mechanisms to support universities and vocational colleges to open more professional and professional industries. The course focuses on cultivating the blue collar of “opening smart machinesâ€.
New employment demand came into being
Although the development of manufacturing industry started earlier, many equipment manufacturing enterprises in Quanzhou have used CNC systems imported from abroad. The price is generally 30% to 40% higher than that of domestic systems. The core technology is subject to people, and the imported CNC system replaces imported CNC. The desire for the system is strong.
The implementation of “Quanzhou Manufacturing 2025†and the promotion of intelligent manufacturing have greatly affected the transformation, upgrading and innovation of various industrial fields, which has significantly improved the level of equipment and manufacturing technology in major industries, and the production level and product technology level of some enterprises have improved significantly.
According to Chen Jianxing, through the in-depth implementation of the “Quanzhou Manufacturing 2025†and “CNC Generation†demonstration projects, Quanzhou’s mechanical equipment industry has been promoted to be numerically controlled, automated and intelligent, and has emerged in the emerging industries of intelligent equipment such as CNC machine tools and robots. A group of enterprises with great development potential, such as Jiatai, Weibai and Heijingang, have made breakthroughs in the research and development of intelligent equipment, forming a group of automation products with domestic leading level and high cost performance.
The data shows that in 2015 alone, the number of “CNC generation†demonstration products promoted by Quanzhou’s mechanical equipment enterprises in the city reached more than 600 sets (sets), and the sales amount reached more than 300 million yuan. In 2015, the output value of the city's equipment manufacturing industry reached 135 billion yuan, an increase of 12.5%.
"The rapid development of these equipment manufacturing enterprises has spawned the demand for supporting the development of high-end talents in the industry." Chen Zhaoping told reporters that on the one hand, the development of the equipment manufacturing industry has attracted a large number of high-level talents to gather in Quanzhou; on the other hand, enterprises also need A large number of senior blue-collar workers with professional skills.
Chen Jianxing said that Quanzhou will continue to rely on the platform of university research institutes and typical demonstration enterprises to further carry out training activities and train a large number of professional and skilled personnel and skilled workers with professional skills and practical operations to further promote the “CNC generationâ€. "The demonstration project provides talent protection.
The reporter learned that at present, Quanzhou has set up a teaching robot demonstration point in Quanzhou Institute of Information Engineering, and built a mechanical equipment specialty at Quanzhou Liming University and Nan'an Machine Tool Enterprise to cultivate a large number of professional and technical personnel and skilled workers for the intelligent manufacturing industry innovation and development. In addition, Xiamen University of Technology and other colleges and universities to cooperate with enterprises to set up a number of training points are also under construction. (Economic Daily reporter Lin Hucan Shi Wei)
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