Intelligent manufacturing is the direction in which the tire industry has been transformed and upgraded. This has become the consensus of the industry. But how to promote the pace of smart manufacturing in the tire industry under the pressure of domestic and foreign markets, and achieve global resource sharing in the development process? On September 28, at the Tire Intelligent Manufacturing Forum hosted by Soft Control Co., Ltd., a peak dialogue was held on the topic of “The Opportunities and Challenges of Tire Smart Manufacturingâ€, focusing on the pain points, implementation schemes, and intelligence of current smart manufacturing. In terms of manufacturing vision, etc., the company explored the road to transformation and upgrading of the tire industry in the context of global smart manufacturing, and conspired to build tires with “smart†manufacturing upgrades.
What problem does smart manufacturing solve?
At present, China's tire industry faces two pressures at home and abroad: First, tire exports frequently encounter foreign "double reverse", China's tire exports account for about 40% of production, frequent trade friction caused great pressure on China's tire exports. Second, the lack of growth in the domestic market, especially in the iron and steel, coal, cement and other industries to increase capacity, also has a greater impact on the rubber industry. Against this backdrop, why are many tire companies still investing heavily in building smart factories?
Shi Wei, general manager of Hefei Wanli Tire Co., Ltd. stated that Wanli Tire Hefei Project invested 220 million yuan in automation, information, and intelligence. It took so much money to mainly solve three major problems: First, solve people's problems. Now that China’s demographic dividend has disappeared, the traditional factory model is no longer applicable. It is estimated that it will be difficult to recruit workers after the 1980s and 1990s if they are recruiting in the original way. This will cause great difficulties for the enterprises, and the factory production is after all Is the biggest factor. The second is to solve the problem of serious product homogeneity. The homogenization of products has led to fierce competition. There is no profit for enterprises and there is naturally no room for growth. If we want to change this situation, we must create a new production model, achieve quality breakthroughs and cost reduction through intelligence, and build Chinese brands. The third is to solve the problem of inefficiency. Low efficiency will inevitably lead to high costs. In this regard, domestic costs are relatively higher than those in foreign countries. If Industry 4.0 is achieved, compared with the same industry, the per capita output value of Hefei Wanli will increase by three times, the comprehensive energy consumption will be greatly reduced, and the product consistency will be greatly improved. Therefore, tire manufacturers are forced to implement smart manufacturing, and they must come out of traditional production.
Shi Wei said that the project of Hefei Wanli is currently undergoing full debugging. It is the first full-line intelligent factory in China, and it is fully automated and intelligent from raw materials entering the factory to finished products. After production, labor costs will drop by 62.4%, and the investment in MES and automated logistics will be withdrawn in less than three years.
Yang Hongwei, the director of engineering of Continental Horse Tire (China) Co., Ltd., introduced that the Continental Group is confident in the future of smart manufacturing, and has devoted great efforts in areas such as smart car driving. They believe that the dialogue between people and cars in the future is mainly about changing tires. Therefore, it is hoped that the entire process of tire products from ordering to product manufacturing and logistics can be intelligentized. But this is the direction of the future. He believes that the most difficult of intelligence lies in tire manufacturing factories, such as the automation and information transformation of factories, and the transformation of processes.
How does smart manufacturing land?
In the wave of intelligence, companies that are becoming intelligent are also springing up, and companies have many solutions. As a traditional tire industry, how to make intelligent manufacturing landing?
Mr. Robert, president of Rockwell Automation Asia Pacific, believes that the tire industry is now facing the challenge of overcapacity, but there are opportunities, which is to improve tire production efficiency through smart manufacturing and improve the company's strength in the competition. As for how to implement smart manufacturing, Robert said that if it is a new factory, it can be done in one step, but more is to face the existing factory, and the situation is different in each factory. In the implementation of automation in the old factory, the most important thing is to analyze which problems need to be solved first, and implement it step by step when formulating the plan. In the past, many tire companies have laid a good foundation in automation. Now that they can add informationization capabilities to existing projects, they can quickly realize basic smart manufacturing goals.
Yang Qiang, deputy director of the Institute of Mechanical Science and Research, believes that different factories have different paths, and it should first establish what objectives to achieve, such as the goal of production efficiency, and then optimize production lines. The transformation of the existing factory must first solve the short board, and then link up with the market.
Yang Hongwei believes that there are many tire companies and they have different situations. He is more concerned about the faster transformation of tire equipment. At present, the stability and reliability of domestic tire equipment are still facing greater challenges. The equipment should be made more intelligent and greener. On the one hand, the degree of automation should be improved. On the other hand, the gap in the management capabilities of tire companies can also be bridged. .
Fan Rende, Honorary President of the China Rubber Industry Association, gave advice on how to upgrade the tire industry. He believes that the most important thing in the industry is to change concepts, cross-border thinking and extraordinary thinking. One is the shift from single thinking to cross-border thinking. Smart manufacturing emphasizes the deep integration of manufacturing and the Internet. In the past, the rubber industry focused more on the research and application of the industry's own technology and equipment. However, there is little research on informationization, especially on the Internet, and it must be changed. The way of thinking is to achieve deep integration with the Internet. The second is to replace the current traditional thinking with extraordinary thinking. In the new era, the scientific and technological achievements of industry are changing with each passing day, and the influence of the Internet is also more than ordinary. In the past, companies could not have both cost, efficiency, on-demand customization, etc. Now, through smart manufacturing, Wanli, Sen Qilin and other factories can achieve it.
Fan Rende said that because different factories are not the same and their foundations are different, they should choose the path of smart manufacturing according to their own conditions. The new factory can follow the intelligent manufacturing model in one step to realize the curve overtaking; the old factory gradually transitions to intelligent manufacturing from 2.0, 3.0 or the most basic lean production according to demand conditions. He believes that there will be more factories such as Sen Qilin, Double Star, Wanli, Race Wheel, and soft control, which will contribute to the smart development of the industry. He believes that the Chinese tire industry will become an active promoter of smart manufacturing in the world.
When can I achieve smart manufacturing?
Fan Rende said that in 2015, the China Rubber Industry Association released the “Study on the Development Strategy of China's Rubber Industry Powerâ€, which is in line with the “China Manufacturing 2025†national development strategy and has become the goal and fundamental task of the rubber industry. For the "China Rubber Industry 4.0" prototype. In the “Study on the Development Strategy of the Powerful Country of China's Rubber Industryâ€, the goal and strategic measures for building a strong rubber industry are proposed. By 2025, the intelligent manufacturing of tires will be realized. He said that in 2015, the rubber industry's sales revenue will reach 1 trillion yuan, and the goal of the 2025 plan is to double. If smart manufacturing can be achieved, this goal may be achieved. “Our development goals are not the goal of production, but we must achieve the highest production efficiency, the highest efficiency and price, and we hope that the industry will work together to achieve this goal.â€
Yang Hongwei believes that the tire industry as a traditional industry, to achieve intelligent manufacturing is a great challenge for all companies, this should be a long-term task, but I believe this day will come. However, he personally thinks that the time for smart manufacturing needs to be longer, because it is necessary to respect the needs of the industry's high-end products while satisfying the need for personalization.
Yang Qiang from the soft control and other suppliers to see the current development, that the tire industry should be ahead of 2025 to achieve some intelligent manufacturing.
Robert also believes that the tire industry will achieve smart manufacturing more generally in the next 10 years. He said that in the next five years, more investment will occur in the tire industry. It is predicted that in the next 10 years, there will be many revolutionary changes in tire production processes, materials, and equipment.
Shi Wei said that currently the rubber industry is mostly semi-automatic and manual. With the arrival of Industry 4.0, companies will be eliminated if they do not reach this step. In the next 5 to 10 years, the Chinese tire industry must be able to survive. There is a brand-new situation. If it cannot keep up with the pace of the times, it will be eliminated. The development of the tire industry must be green manufacturing and intelligent production, so that the resources and energy consumption reach the province, and it is in line with the international market, and it has achieved its due status in the world.
Zheng Jiangjia, president of the Summit Dialogue Host Software Co., Ltd. concluded that in the context of global smart manufacturing, tire companies have chosen to integrate into this wave and strive to be at the forefront. Although the smart manufacturing of the tire industry faces many difficulties and challenges, everyone is full of visions for the future. Each tire company is facing different status quo, it is necessary to find its own transformation and upgrading road based on its own foundation and conditions, and to increase the survivability and competitiveness of the enterprise through investment in intelligent manufacturing.
Zheng Jiangjia said, “Today's forum, Hefei Wanli and Qingdao Sen Kirin all display many valuable information on tires' intelligent manufacturing. This is also a kind of resource sharing.†In the future in the case of big data and cloud services, sharing should not It is leaked and copied, but it should be respected. Looking forward to the future, with the development and application of new technologies, we will fully respect each other and, on the premise of protecting intellectual property rights, fully share valuable equipment, technologies, data, etc., and let smart manufacturing be launched in the tire industry and promote mutual development. Tire industry transformation and upgrading.
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