"Big and small" and agile and flexible, both high-end manufacturing equipment products and common daily necessities.
"Smart" is sweeping more industries here
Reading tips. Through the introduction of intelligent and visual systems in the production line, the smart factory can monitor the production process parameters in real time, comprehensively record the production data, and adjust the production plan at any time according to the real-time feedback data, so as to greatly improve the product qualification rate and ensure that the goods are delivered to customers with high standards.
The robotic arm is flying, the huge workshop is empty, the production information on the screen is updated in real time, and customized products are constantly producing ...... from the flexible assembly lineDo these sci-fi images still exist only in movies? In fact, such a "factory of the future" has gradually entered our daily life.
The main direction of industrial technological transformation and optimization and upgrading lies in intelligent manufacturing, and smart factories are the main position and battlefield of digital transformation. Recently, the Shanghai Municipal Commission of Economy and Information Technology announced the list of municipal smart factories to be selected in 2023, and a total of 77 enterprises are to be selected. In this list, you can see not only heavy industrial manufacturers that produce "big country heavy equipment" in high-end manufacturing fields such as aerospace, electrical equipment, and auto parts, but also brands that produce seasonings, Chinese patent medicines, potato chips and other daily necessities in people's daily lives.
"Size" and smart and flexible smart factory, what kind of production scene is inside, how various equipment operates, the reporter recently visited a number of enterprises, after all.
Solve the problem of scheduling management.
The engineer clicked the mouse in the workshop, and the production line not far away immediately received instructions: welding, painting, filming, packaging, ......As the yellow robotic arms flew up and down the production line, after a while, the structural parts used for elevator assembly were newly rolled off the production line, waiting to be shipped out of the warehouse. At the same time, the A** trolley transporting materials keeps shuttling between the production workshop and the three-dimensional material warehouse, continuously replenishing raw materials for the production line. On the large screen in the central control room, the temperature, humidity, production scheduling, raw material reserves and other parameters of the entire factory are displayed in real time, and the staff can easily grasp the overall operation of the factory.
Such a scene can be seen everywhere in the Hitachi Elevator intelligent factory located in Qingpu District, Shanghai.
Customer order management and scheduling is a more tedious daily information flow work in the manufacturing industry, and the traditional manual scheduling process is inefficient and prone to errors. According to the person in charge of the factory, Hitachi Elevator has automatically generated a variety of scheduling plans by introducing advanced algorithm models into the smart factory to form a detailed production operation plan. In addition, through the sensors arranged on various equipment, the production line can be monitored in real time, and the real-time feedback of production data can also allow production managers to quickly make production decisions and continuously optimize the production process.
At present, Hitachi Elevator's intelligent production scene is being "copied" by more factories.
According to the relevant person in charge of the Shanghai Municipal Commission of Economy and Information Technology, Shanghai has built a total of 19 national-level smart factories and 100 municipal-level smart factories, completed the promotion and implementation of more than 1,000 intelligent manufacturing scenarios, and the evaluation rate of smart factories of industrial enterprises above the city's scale exceeded 70%, of which Pudong, Jiading and Songjiang took the lead in achieving 100% full coverage. The production efficiency of the city's smart factories has increased by more than 50% on average, and the operating costs have been reduced by more than 30% on average, driving the cumulative reduction of energy consumption per unit of added value by 138%。
Intelligent robots, the "standard" of smart factories, are also constantly consolidating the digital foundation. Through the release of the recommended catalogue of intelligent robot benchmarking enterprises and application scenarios, Shanghai has driven 10,000 new robots into the smart factory, and has become the first robot density city in the country, with a robot density of 3.83 million people in key industries, reaching the international first-class level.
Digitalization has led to a significant improvement in product quality.
The manufacturer behind the medicines that are commonly available in the family medicine cabinet, such as Musk Baoxin Pills, Choning Tablets, and Zhengqi Tablets, is Hutchison Pharmaceutical. Since 1958, the company has gone through 65 years since the merger of four century-old pharmacies in Shanghai, Lei Yunshang, Hu Qingyu, Tong Hanchun and Cai Tongde.
However, there is no smoke in this "old" Chinese medicine pharmacy, and now, the factory area of Hutchison Pharmaceutical has been fully intelligentized. Relying on the industrial Internet platform and Internet of Things sensors, the Chinese patent medicine factory here has realized the digital control of the whole life cycle of drugs: relying on the effective combination of smart factory construction and actual business, the whole life cycle control of drugs is realized; Through digital production process control, the quality of proprietary Chinese medicines is guaranteed to be stable and uniform; Through the quality management system and quality inspection system, the production efficiency and product quality have been greatly improved.
Not only pharmaceuticals, but also food production needs to rely on intelligent assistance.
Founded in 1913 and formerly known as an egg processing factory, Yimin Food No. 1 Factory has been actively engaged in the intelligent transformation of its production line since 2019. By introducing an intelligent and visual system in the production line, the company monitors the production process parameters in real time and records the production data comprehensively, so as to greatly improve the product qualification rate and ensure that the goods are delivered to customers with high standards.
Not only that, the improvement of the intelligent level of the production line has also greatly shortened the cycle of product research and development, and the production side will adjust the production plan at any time according to the real-time feedback data, so as to provide consumers with richer and more diverse product choices.
At present, Shanghai is promoting the high-quality development of advanced manufacturing industry with intelligent transformation. According to statistics, among the more than 1,000 enterprises in the city that have carried out intelligent technology upgrading, the application of intelligent equipment such as digital equipment and industrial robots accounts for about 35%, and the investment accounts for about 54%. By accelerating the cultivation of a number of world-class intelligent manufacturing integrators, the total output value of the city's intelligent manufacturing system integration industry has exceeded 60 billion yuan, and the scale of the intelligent manufacturing equipment industry has exceeded 100 billion yuan.
The parts on the production line can be manufactured by themselves.
Don't underestimate the seemingly simple process of "potato chips", the "intelligent" content in it is not lower than that of the tablet computer that netizens often "in the same frame" with them when chasing dramas. In recent years, PepsiCo Foods (China)**, located in Songjiang Economic and Technological Development Zone, Shanghai, has continued to increase investment in the research and development of intelligent production lines, and has built an intelligent potato chip factory with 8 production lines, an annual design capacity of about 8 tons, and an automated three-dimensional warehouse.
Relying on the advanced process control system, through modeling data analysis, real-time optimization and control technology, the company has created an accurate automatic detection and selection system for potato raw materials and a fully automatic potato chip packaging, weighing and packing system, realizing the intelligence of the whole process of potato chip production.
What's even more amazing is that PepsiCo has innovatively applied the industry's leading 3D printing technology, so as to achieve the purpose of saving production costs and shortening the delivery time of spare parts. Through 3D modeling technology and reverse scanning technology, customized parts that meet the production scene can be designed and printed, which not only reduces the production optimization cost of the production line, but also improves the ability of the production line to cope with customized production requirements.
This year, more intelligent factories that break through imagination may be launched one after another. The relevant person in charge of the Shanghai Municipal Commission of Economy and Information Technology said that in accordance with the national smart factory construction standards, 70 new municipal-level smart factories will be built this year. Focus on key industries, implement the "smart factory +" action, promote the system optimization and comprehensive improvement of the whole life cycle of products, the whole process of production and manufacturing, and the whole link of the first chain, and strive to achieve demonstration (L3 level) and benchmarking (L4 level) in the new smart factory this year The proportion exceeds 70%, so that intelligent manufacturing becomes one of the core competitiveness of enterprises.
*:Worker**.