Winning in intelligence is not the fault of "intelligent manufacturing".

From pen and paper to computers, from stand-alone computers to networks, from "internet plus" to "Smart Plus", the development speed of science and technology is amazing. In China, people are more receptive to concepts such as network and intelligence than most countries in the world. It seems that as long as it is related to intelligence, it will enter the ranks of the tall.

For the manufacturing industry, the word "intelligent manufacturing" is as hot as the scorching sun in midsummer. All kinds of "smart" companies have been launched here, and several "smart" companies have quietly closed down there. As a result, many public media and self-media follow the trend like mindless beasts without investigation, and their comments are uneven and irresponsible, which affects or even disrupts the progress of manufacturing industry, especially equipment manufacturing industry, on the road of digitalization, networking and intelligence development to a certain extent.

In fact, in the course of the development of things, at that time, few people could tell right from wrong with certainty, and it was not wise to kill them with a stick or a stick. On-the-spot investigation, calm thinking, prudent implementation and timely rectification are the proper actions of equipment manufacturing practitioners in the industry.

In the past two years, Mr. Shen Liechu, former vice minister of the Ministry of Machinery Industry, has repeatedly voiced the problems existing in the field of machine tools and related manufacturing, which has caused considerable influence in the industry. Recently, Minister Shen authorized Machine Tool magazine to publish the article "Winning a huge loss of intelligence is not the fault of intelligent manufacturing", which is different from the article "Thinking caused by visiting Siemens Automation (Chengdu) Co., Ltd." published at the end of last year (WeChat article titled "What is the difference between intelligent manufacturing in China and Germany? ) echo each other, deeply analyze the reasons behind the success or failure of intelligent manufacturing, and put forward their own views.

Winning in intelligence is not the fault of "intelligent manufacturing".

Recently, there have been many reports and posts about Jin Shengzhi's huge losses. For example, from 2065438 to April 26, 2009, China Economic Weekly official Weibo released "Last year's huge loss of 2.866 billion". Can the unmanned factory go on? Jinsheng Intelligent: Please read the announcement carefully. Paragraphs 1 and 2 of this article are as follows:

On April 23, Jinsheng Intelligent (300083. SZ) Disclosure of annual report. In 20 18 years, Jin Shengzhi realized an operating income of 5.507 billion yuan, a year-on-year decrease of14.25%; The net profit attributable to owners of the parent company was-2.866 billion yuan, a year-on-year decrease of 72 1.88%. During the reporting period, the gross profit margin of the company's sales was 65,438+02.54%, down by 65,438+04.03 percentage points over the previous year, and the net profit margin of sales was -52.08%, down by 59.25 percentage points over the previous year.

Jinsheng Zhineng is a "star enterprise" and a "national intelligent manufacturing demonstration unit" in Dongguan. In particular, the "unmanned chemical plant" built by Jinsheng Zhineng in Dongguan Dongcheng is the first batch of intelligent manufacturing projects of the Ministry of Industry and Information Technology and the only intelligent manufacturing demonstration project in 3C field.

First, the event background review

2065438+On July 24th, 2006, the national intelligent manufacturing pilot demonstration experience exchange meeting was held in Dongguan, Guangdong. The main leaders of the Ministry of Industry and Information Technology attended and presided over the meeting. Leaders from China Academy of Engineering and Guangdong Province, leaders from economic and information committees/industry and informatization departments of all provinces, municipalities and autonomous regions, and leaders from key industries, universities and research institutes were invited to attend the meeting. The main leaders of the Ministry of Industry and Information Technology pointed out in their speeches: "It is necessary to deeply understand the arduousness and urgency of intelligent manufacturing", "it is an important embodiment to promote the supply-side reform of manufacturing, an inevitable choice to build a new manufacturing system, and an important measure to promote manufacturing to the middle and high end and build a manufacturing power". "Promoting intelligent manufacturing is a complex and huge system engineering, which requires constant exploration and trial and error. It is difficult to achieve it overnight, and it must be persevered and systematically promoted.

2065438+September 2006, the then industrial leader of the State Council inspected Dongguan Jinsheng Intelligent Components Co., Ltd.

The project landed in Dongguan Jinsheng Intelligent Components Co., Ltd. (referred to as Jinsheng Precision), the predecessor of Guangdong Jinsheng Intelligent Group Co., Ltd. (referred to as Jinsheng Intelligent). This company is mainly engaged in the OEM of metal and non-metal parts of mobile phones, and it is a "foundry". Intelligent workshop with 10 automatic drilling and tapping production line; Including 180 domestic high-speed and high-precision CNC drilling and tapping center, 8 1 domestic robots, 30 RGV, 10 AGV trolleys, an automatic parts inspection system, and national industrial software systems, including cloud CNC platform, CAPP, APS advanced scheduling system, MES production management system and production control center, three-dimensional simulation of production process. There is also a popular automatic drilling and tapping lifting line, a robot polishing line, an intelligent production line for cultivating intelligent manufacturing talents, the application of "intelligent perception subsystem" based on Internet of Things technology to adapt to the manufacturing site, the transformation and upgrading of existing intelligent systems, the establishment of a visual integrated control center for the whole manufacturing process, and the latest domestic software and hardware and information architecture. Technically, the project has the characteristics of "three countries", "six modernizations" and "one core". The "Three Kingdoms" all adopt domestic CNC machine tools, domestic CNC systems and domestic industrial software; "Six modernizations" means equipment automation, process digitalization, production flexibility, process visualization, information integration and decision autonomy; "One core" is the "big data center" for building a smart factory. Intelligent unmanned (few people) chemical plant should be said to be the "great treasure" representing the highest technical level in China at that time, and it is the scientific and technological achievement of cooperation between government, production, research, learning and users. According to the author's understanding, foreign countries are also rare and should be cherished.

In addition, Jin Shengzhi can take this opportunity to transform intelligent manufacturing. In order to transform, Jin Shengzhi can acquire Chuangshi, hold Jiacan Precision and invest in Wuhan Aipu Chemical. These three companies provide CNC machine tools, MES systems and automation integration in intelligent manufacturing production lines, so that Jin Shengzhi can accumulate software and hardware technologies according to his own experience and lessons, and become an integrator that can provide all-round software and hardware solutions for other manufacturing enterprises in the future. This is a correct strategic choice.

Second, thinking and enlightenment

Why can Jin Shengzhi, a well-known domestic intelligent manufacturing demonstration enterprise, suffer huge losses in just a few years? Therefore, it is a difficult problem for Jin Shengzhi to quit the mobile phone OEM industry and then quit the consumer electronics manufacturing industry. How to deal with the huge losses and the existing equipment of unmanned (few people) chemical plants?

The news shocked some colleagues from all walks of life in manufacturing industry. Last year, a number of Lenovo OEM enterprises of consumer electronics, especially mobile phones, suffered losses one after another. For example, the listed company Orid suffered losses of 65.438+0.7 billion yuan, and the industrial technology losses were also very serious. Therefore, the market sales of CNC machine tools and other equipment have also declined. The entry barriers of CNC high-precision and high-speed drilling and tapping machines used by these foundry enterprises are low, and many machine tool enterprises adopt assembly mode to produce CNC drilling and tapping machines with a full set of functional components imported from abroad, which has led to a major reshuffle of such machine tool enterprises and even caused the capital chain of some famous enterprises to break! This lesson is worth thinking about by all enterprises in the industrial chain.

I have heard of the Jinsheng Intelligent Project before. Although I didn't have a direct chance to study and check it, I have some doubts about this plan. In order to solve the puzzle, I asked experts from the Institute of Comprehensive Technology and Economics of Machinery Industry Instruments (hereinafter referred to as the Institute of Instruments) to conduct an investigation, but I only focused on the technical level and did not carefully study the characteristics of deep-level consumer electronics production, especially the rapid market changes in the mobile phone industry. New technologies and materials not only change rapidly, but also have the characteristics of "fashion", which leads to rapid iterative updating of products. At present, the intelligent manufacturing mode of OEM cannot meet the changing needs of the user market. Shocked, I asked Liang Yu, editor-in-chief of Machine Tool magazine, to dig out the 200-page annual report of Jinsheng Intelligent 2065438+2008, and draw some superficial revelations as follows. Deep-seated problems need professionals to analyze.

(A) "intelligent manufacturing" can not correct people's major decision-making mistakes.

Jin Shengzhi's huge losses are not the fault of "intelligent manufacturing", but may be caused by incomplete human decision-making of enterprises. At least to the current level, the so-called "intelligent manufacturing" can not correct the decision-making of major human mistakes.

I have been studying "intelligent manufacturing" for several years, and I have been using the methods of practice theory, contradiction theory, engineering cybernetics and system engineering theory to analyze and study the opinions expressed by scholars at home and abroad. On the other hand, it is necessary for enterprises to understand the unbalanced and inadequate development of China's manufacturing industry. I have always believed that most manufacturing enterprises in China, especially small and medium-sized enterprises, are still in the era of industry 1.0 and industry 2.0. Industry 3.0 only exists in some powerful and far-sighted large and medium-sized enterprises, which have an international vision and participate in international competition and division of labor in various ways. Starting with CAD, CAM and CAPP, it gradually promoted digitalization and networking, mostly with a history of twenty or thirty years. For example, Changshu Switch Co., Ltd. has a history of 28 years since 199 1 introduced CAD technology. Others, such as Gong Lin, Wendeng Crankshaft, Wei Chai and Xugong, have a history of more than 20 years or even longer. Compared with developed countries such as the United States, Germany and Japan, their enterprises began to introduce lean production, just-in-time management and other scientific management methods from the era of Industry 2.0, constantly optimized their own technological processes, accumulated a large amount of data, and established data centers. From the era of Industry 2.0 to Industry 3.0, probably in the 1960s and 1970s, the author inspected the manufacturing enterprises in these countries. Most of them have local area network, private network and intranet, and many enterprises have begun to adopt computer management, which means that a large amount of data has been introduced into computer management, and the real data accumulated by enterprises in all aspects is the premise of computer management.

Since 1950s, CNC machine tools have appeared as commodities, and then the CNC era of equipment began. Especially in the 1970s, industrial control equipment such as integrated circuits, digital computers and PLC were gradually applied, not only for the design, manufacture and management of production products, but also for the integrated control of production lines. Digitalization, networking and future intelligent manufacturing must be based on advanced manufacturing technology and management. Conversely, the continuous and in-depth application of digitalization, networking and intelligent manufacturing in the future will promote the optimization and further improvement of advanced manufacturing technology and management. The two are dialectical relations and promote each other. This is what I have always stressed: the future digitalization, networking and intelligent manufacturing are only means, not ends. The purpose is to improve quality and efficiency, reduce costs, compress inventory, accelerate capital flow, shorten research and development time, deliver goods on time according to quality, and strengthen maintenance services. All in all, speed up supply-side reform, transformation and upgrading, and constantly meet the needs of users, that is, the demand side. The author thinks that only by correctly handling the dialectical relationship between purpose and means can we accelerate the development of make-up lessons industry 1.0 to industry 2.0, and then accelerate the promotion of industry 3.0. At present, it has not really reached the testing stage of Industry 4.0, because many enterprises have not yet established a correct and full-coverage database. Make-up lessons for Industry 2.0 are to supplement scientific management, establish and improve advanced technical systems and business processes, supplement digital descriptions of production factors such as people, machines, materials, methods, environment and measurement, and establish a database of production factors, laying a foundation for the operation of fully digital enterprises, and the data will be fast, effective and efficient.

In June+10 last year, the author visited and studied Siemens Automation Products (Chengdu) Co., Ltd. (hereinafter referred to as "Siemens Chengdu Factory"), which is one of the factories with the highest level of intelligence in the industry. The main base of R&D is in Germany, and the order is issued by Siemens headquarters. A small number of automation products are developed by Siemens Chengdu factory, and the sales are also transported to all parts of the world by Siemens headquarters. In essence, it also has a "foundry". This visit left a deep impression on me and gave me a lot of inspiration. After I came back, I wrote an article: "Thoughts on Visiting Siemens Automation Products (Chengdu) Co., Ltd. —— Also on the differences in understanding of" intelligent manufacturing "between experts, entrepreneurs and officials in China and Germany" (this article is attached at the end of the article, and readers can correct it if they are interested). Perhaps we can find out the differences between Jinsheng Zhineng and Siemens Chengdu factory in concept, strategy, tactics and implementation process.

The person in charge of Chengdu Siemens said: Chengdu factory is not a smart factory, and its technical level is only in Industry 3. X stage, but a fully digital factory (generally speaking). Why?

(2) Intelligent manufacturing is only a means, and the products manufactured need to have a market and be competitive.

Jinsheng Zhineng is specialized in OEM for mobile phone customers. It doesn't have its own products, and its biggest customer is Samsung. Samsung stopped ordering for two reasons. First, the domestic labor cost is too high, and the foundry moved to Southeast Asia, which gave Jinshan a great impact. Second, the development from 4G to 5G. Because 5G is millimeter wave, the material of mobile phone is changed from aluminum-magnesium alloy to glass plastic, which increases the shielding effect. At the same time, due to the "fashion" characteristics of consumer electronic products, the shape changes rapidly, and the process has changed from mold processing to mold-free processing (in fact, CNC machine tools can be used), and Jin Shengzhi can't adapt. In the annual report, Shenzhen Chuangshi Company, a subsidiary of Jinsheng Zhineng, mainly develops and produces CNC machine tools and machining centers. Although the turnover has declined, there is no loss, because it has its own main products, which can be quickly transformed (the registered capital of Genesis Company is 300 million).

(3) The superstructure must be compatible with the economic base, relations of production and productivity.

After consulting the 20 18 annual report, the author found that the shareholding structure of Jinsheng Group is very complicated, with five layers, and the interests at all levels are not exactly the same. In the past two years, due to the effect of demonstration projects, the scale has expanded rapidly, and Jinsheng Zhineng has more than 15 offspring companies. I don't know if these circumstances have a negative impact on Jin Shengzhi, only the controlling shareholder of Jin Sheng knows. Further observation and in-depth study by professionals are needed.

(D) Enlightenment of "official, production, learning, research and use"

Author: Shen Liechu 20 18 10 month