In the past few days, in the printing and dyeing workshop of Jiangxi Yiyang Textile Group, workers are stepping up production and catching up with orders.
Aiming at the goal of energy saving and emission reduction, we are equipped with energy-saving printing and dyeing equipment such as ultra-low liquor ratio overflow dyeing machine, gas-liquid dyeing machine, and high-precision press setting machine. At the same time, the production process is controlled by the self-developed ERP (Enterprise Resource Planning) system, all equipment is networked, and the product type, raw material entry and exit, equipment operation status and so on are clear at a glance, achieving the goal of low energy consumption, high quality and increasing production capacity. Liu Zhuhui, chairman of Yiyang Textile, told reporters.
Yiyang Textile, located in De'an County, Jiujiang City, Jiangxi Province, is an enterprise integrating spinning, weaving, printing and dyeing, and garments, and its knitted fabrics and garments are sold to many countries and regions. In recent years, the company has been committed to building a leading textile full-chain intelligent manufacturing base by building an industry-leading 5G+ smart factory, transforming and upgrading from "weaving" to "intelligent manufacturing". In 2023, Yiyang Textile will be selected as a "5G + Industrial Internet" application demonstration enterprise in Jiangxi Province, and will obtain the AA-level "two-in-one" integration management system implementation certification.
Build a smart factory.
In recent years, the textile and garment industry has continued to promote transformation and upgrading and structural optimization through equipment upgrading, process upgrading, technology upgrading and other means. In Liu Zhuhui's view, if enterprises want to win an advantage in the competition, they must accelerate the in-depth application of a new generation of information technology and dare to be the first person in the industry to "eat crabs".
In the face of traditional warehousing goods storage difficulties, low efficiency, high cost, and manual quality inspection is difficult to unify.
1. With the pain points of the industry such as low yield and uneven quality of fabrics, Yiyang Textile invested more than 30 million yuan and signed a cooperation agreement with China Mobile and Megvii Technology to jointly build a new 5G+ smart factory, build a high-density single-roll automated three-dimensional warehouse, and obtain 15 intellectual property patents.
In the Yiyang textile factory area, a smart warehouse covering an area of 3,500 square meters, up to more than 30 meters, and with more than 50,000 cargo spaces is particularly eye-catching. In the warehouse, there is no one, and bundles of finished cloth are continuously sent into the warehouse through the high-altitude bridge conveyor system, and then sent to the designated cargo location through the seamless connection between the automatic guided vehicle and the stacker. "Each piece of cloth is affixed with ***4 double-deep stacker cranes running between 16 rows of shelves, back and forth, with a daily throughput of up to 5,000 rolls. Tan Yurong, deputy general manager of Yiyang Textile, said.
The biggest feature of this smart warehouse is that it realizes the automatic storage of single rolls of fabric. In the past, fabrics were selected by workers and transported by forklifts. Tan Yurong said. The smart warehouse project uses 5G + artificial intelligence, big data, Internet of Things and other new-generation technologies, with the Hetu-WMS system as the core, and uses intelligent logistics equipment such as stackers, conveyors, and automatic guided vehicles to complete handling, sorting, distribution, inventory and other work. At the same time, through the unmanned operation of warehousing and intelligent handling and scheduling system, the goods can be smoothly shuttled in the weaving, printing and dyeing, and garment workshops, and multiple processes such as spinning, weaving, dyeing, and garment can be opened up to realize unmanned warehousing and unmanned logistics applications.
The operation of the smart warehouse is all 'unmanned', which realizes intelligent management, green warehousing, and efficient distribution. Compared with before, the storage capacity has been increased by 9 times, and the daily throughput has increased by 15 times, the locking time has been reduced from 30 minutes to 5 seconds. The quality inspection work is carried out by replacing people by machines, and the detection rate is more than 90%, the detection speed is twice that of traditional manual inspection, and the product qualification rate is close to 100%. Tan Yurong said.
Through intelligent transformation, digital transformation, information construction and other methods, Yiyang Textile has achieved fine management, lean production, cost reduction and efficiency increase, and its market competitiveness has been significantly enhanced. In 2023, the output value of Yiyang Textile will exceed 200 million yuan, a year-on-year increase of 80%.
Promote cleaner production.
High energy consumption, high emissions and high pollution are the problems that must be solved for the high-quality development of textile enterprises. Walking in the Yiyang textile factory area, everywhere is clean and tidy, there is no smell of any peculiar smell, and the neatly arranged photovoltaic panels on the roof of the factory are spectacular.
In recent years, the company has gradually embarked on the road of high-quality development of clean production, low-carbon transformation and recycling, in addition to continuously improving the level of energy conservation and consumption reduction through technological innovation and process improvement, it has also benefited from the local 'five unifications' environmental protection project for the textile industry. Tan Yurong told reporters that the "five unifications" are unified heating, unified industrial water supply, unified sewage pretreatment, unified reclaimed water reuse, and unified sludge disposal.
In the "Five Unifications" project, the sewage pretreatment adopts the anaerobic + AO combined process, the reclaimed water reuse adopts the MBR membrane and RO reverse osmosis process, and the sludge generated by the water treatment project is concentrated through centrifugal dehydration and sludge drying, and then transported to the high-temperature and high-pressure circulating fluidized bed boiler, and the final disposal is carried out by sludge coupling coal-fired blending to achieve harmless and resource treatment.
The water supply, heating and sewage treatment pipe networks are directly connected to the plant, and the wastewater generated in the production process is sent to the anaerobic sedimentation tank through the sealed sewage pipe network for sewage pretreatment, and then disposed of by the process through the reclaimed water reuse system, so as to reach the industrial water standard of reclaimed water and reuse it for production to realize the recycling of water resources. Tan Yurong said that after the implementation of the "five unifications" project, the company's manpower, management and operating costs have been greatly reduced. At present, the reclaimed water reuse rate has reached 65%, which can save more than 10,000 tons of water every year.
Broaden the space for development.
Innovation is the inexhaustible driving force and source of enterprise development and growth, and this concept has formed a consensus in Yiyang Textile. "From a piece of silk to a piece of clothing, the company has formed a complete ecological chain of textile, dyeing and finishing, clothing, etc., adding momentum and confidence to further expand and develop new space. Liu Zhuhui said that the company continues to promote the extension of the industrial chain to the downstream, and continues to make efforts in the market and R&D end.
On the market side, Yiyang Textile has actively launched its own brand from OEM to online and offline channels, relying on online and offline channels to enter the domestic and foreign markets. At present, the construction of the second phase of the project located in Yiyang Textile is in full swing. "The project plans to build an annual output of 30,000 tons of medical meltblown cloth, 250,000 tons of automatic production line for printing and dyeing cotton knitted fabrics. After the completion of the project, the company's production capacity will reach an annual output of 20,000 tons of cotton knitted fabrics, 10 million pieces of processed garments, and 50,000 tons of printed and dyed cotton knitted fabrics, and the degree of integration of the industrial chain will be higher and higher. Liu Zhuhui said.
On the R&D side, Yiyang Textile invested more than 6 million yuan in technological innovation and R&D last year, and has obtained 19 utility model patents and 2 invention patents. The company's R&D center will focus on the development of new fabrics and the research of equipment technology transformation and upgrading, and has achieved certain results, and has obtained national utility model patents in the research and development of sports fabrics with sunscreen, breathability and quick-drying functions, as well as hygroscopic knitted fabrics. Li Xueqin, head of the R&D department of Yiyang Textile, said.
Yiyang Textile also continues to explore and promote the in-depth cooperation between industry, university and research and the transformation of scientific and technological achievements. At the same time of expanding production, the company plans to use its own unique production technology, technology, and products as resource carriers to develop industrial tourism products with functions such as visiting, leisure experience, and research and popularization, so that tourists can not only understand and learn the modern production technology and technology of the textile and garment industry, but also immerse themselves in the process of weaving and dyeing fabrics.
At present, Yiyang Textile is actively cooperating with China Unicom (Jiangxi) Textile and Garment Industry Research Institute to use 5G, artificial intelligence, digital twins, Internet of Things and other information technologies to realize the networked, digital and intelligent management of all factors, processes and scenarios of enterprise production. "We will continue to build digital workshops for weaving, printing and dyeing, garment making, etc., and strive to build an industry-leading 5G fully connected benchmark factory and digital twin industrial park. Liu Zhuhui said. (Economic ** reporter Liu Xing).