The integration of Chinese manufacturing and industrialization is the main line, and intelligent manufacturing is the main direction
On June 8th, the Made in China 2025 Innovation Summit with the theme of "Smart Manufacturing for the Future" was held in Ningbo. Cai Ying, President of the APSS Advanced Planning and Scheduling Research Association, delivered a keynote speech titled "The Future of Manufacturing Industry under New Models and Technologies" at the conference.
The elimination in the manufacturing field is accompanied by the arrival of Industry 4.0
Currently, China's manufacturing industry generally lacks innovative brand value, resulting in the loss of manufacturing cost advantages, poor flexibility from design to production, and opaque production efficiency and safety management. In the view of Cai Ying, who has more than 20 years of practical experience in production and manufacturing, material planning, industrial engineering, and cost control management, the manufacturing industry has been in a sub healthy state for a long time, leading to the occurrence of the "three highs" situation, namely high delivery time, high inventory, and high cost.
The production mode of multiple varieties and small batches according to orders has become the norm, "Cai Ying specifically elaborated on the various problems that enterprises with the production mode of multiple varieties and small batches often encounter in practice: personalized customization of orders requires the use of different processes for each order; Short R&D cycle; Multiple varieties in parallel; Resource sharing is prone to bottlenecks; There is uncertainty in order changes and production cycles; Plan and schedule contingency; Equipment and production lines are difficult to flexibly cope with; The quality process cannot be iterated reliably; Costs cannot be scaled up and refined, making it difficult to monitor order progress; The changing material requirements have led to severe shortages and procurement delays.
How to face the challenges of new technologies in China's manufacturing industry has become an urgent problem to be solved. With the advancement of Industry 4.0, the era of elimination in the manufacturing field is coming.
In the future, the manufacturing industry will definitely need to face a personalized, multi variety, and small batch consumer market, and establish a highly intelligent and flexible production model. Cai Ying believes that the future manufacturing model scenarios are very attractive and require eight technologies to support: first, modular design, modular automated production, and modular logistics; The second is intelligent planning, production scheduling, APS, optimization algorithm embedded design, equipment, and process CPS; The third is the M2M of industrial Internet of Things; The fourth is industrial big data; Five is cloud computing; Sixth, scenario based and distributed computing decision-making; Seventh, self combination and adaptive response to multiple varieties and small batches; The eighth is socialized (unstructured data) big data.
In the face of flexible production, it is necessary to quickly respond to customer needs
In fact, looking at the world, Germany has proposed the concept of "Industry 4.0" due to its strong foundation in automated production. Based on the rapid development of Internet and big data, the United States proposed the concept of "industrial Internet". On the basis of integration of industrialization and industrialization, China proposed "Made in China 2025" in combination with "Internet plus industry". It is worth noting that the key to these measures cannot be separated from the keyword 'intelligent manufacturing'. In Cai Ying's words, it is necessary to face flexible production and respond quickly to customer needs in order to have intelligence.
According to Cai Ying, intelligence refers to the perception and understanding of dynamic and complex environments, the ability to make autonomous decisions and optimize in such environments, and the ability to learn and adapt based on empirical data. Especially, learning ability is a typical intelligent behavior. Intelligence is built on a continuous connection, a powerful optimization algorithm engine, and a closed loop of live data, "said Cai Ying.
Cai Ying believes that in terms of consumption, "Industry 4.0" is a big network that weaves together production materials, smart factories, logistics and distribution, and consumers. Consumers only need to place orders with their mobile phones, and the network will automatically send orders and personalized requirements to smart factories, which will purchase raw materials, design and produce them, and then deliver them directly to consumers through network distribution.
In Cai Ying's view, the three pillars of Industry 4.0 intelligent manufacturing are personalized customization, flexible supply production, and CPS information physical systems. To achieve Industry 4.0 intelligent technology, it is necessary to use intelligent networks, vertical integration, end-to-end integration, and horizontal integration, as well as industrial big data. This includes five key words, namely connection, data, integration, innovation, and transformation. Realize the connection between devices, devices and products, people and devices, devices and knowledge, etc., so that machines, working parts, systems, and humans can continuously maintain digital information communication through the network.
Regarding the definition of intelligent manufacturing, Cai Ying provided his explanation. He believes that it needs to be explained through three dimensions: first, from the dimension of the supply chain, namely cost. Next is the research and development dimension, which means that the products developed should be intelligent. Finally, there is the engineering dimension.
At the meeting, Cai Ying vividly explained intelligent manufacturing with a running little character. The APS of the brain command center, including artificial intelligence, is a major aspect. Our blood is logistics, it's the supply chain. Bones are connected to each other, just like devices are connected to each other. Sensory organs such as smell and hearing require sensors, namely the Internet of Things. And human memory relies on big data training to run faster
The ultimate goal of intelligent manufacturing is to prioritize user needs
When it comes to the future of intelligent manufacturing, Cai Ying believes that the integration of the two industries is the main line, and intelligent manufacturing is the main direction. The characteristics of Made in China 2025 are innovation leadership, improving quality and efficiency, green development, deep integration of industrialization and informatization as the foundation, and intelligent manufacturing as the breakthrough point
"Manufacturing+Internet", in Cai Ying's view, can realize product personalization, production intelligence, manufacturing service, organizational decentralization and cloud manufacturing resources.
According to statistics, digital factories can increase production capacity by 20% -30%, shorten material preparation cycles by 40% -50%, improve equipment utilization by 25% -35%, and reduce operating costs by 20% -30%.
In fact, Cai Ying pointed out that the value of intelligent manufacturing lies in meeting the personalized needs of humanistic care, having flexible and dynamic business processes, supporting optimal decisions through industrial big data, effectively producing equipment, bringing greater value to customers through intelligent services, responding to changes in population structure, and conducting better humanized work and life, forming competitiveness for high-value enterprises. "Whether it's' Internet plus' or digital factory, the ultimate goal is to actively embrace users."
Regarding the transformation and upgrading of the manufacturing industry under the new model and new technology in the future, Cai Ying pointed out that the following points should be paid attention to: first, the business model, that is, flattening the bottom of the value smile curve and extending the value chain to services; The second is the management mode, namely C2B, C2M, multi-variety and small batch customized production. Third, technological innovation, intelligent research and development innovation platform; Fourth, brand, Internet fan marketing; Fifth, reduce costs through lean management; sixth, capital, namely Internet finance and crowdfunding; seventh, quality, which can improve the quality of monitoring through industrial big data; eighth, technology, namely digital networking, knowledge base, simulation technology, robots, etc. Nine is talent, that is, the training of new talents.
"In fact, intelligent manufacturing is a system engineering, and enterprises gradually realize it according to their own conditions. The goal of intelligent manufacturing is to maximize customer service level and minimize total cost of ownership." Cai Ying said.
(Source: News Center of China Equipment Manufacturing Industry Association)
