The hottest Japan has polished a set of industrial

Japan has polished a set of industrial production mode for decades, but we blindly pursue industry 4.0

Abstract: from made in China 2025 to the "two sessions" report this year, manufacturing has increasingly become the main force of China's economy. Therefore, the concepts of intelligent manufacturing, interconnection + manufacturing and so on are overwhelming, followed by a phenomenon of intelligent manufacturing following the trend. Whether state-owned enterprises, private enterprises, large enterprises, small enterprises are following the trend to do intelligent manufacturing and transform interconnection +

from made in China 2025 to the "two sessions" report this year, manufacturing has increasingly become the main force of China's economy. Therefore, Guan can remove the upper cover of the reducer from the concept of intelligent manufacturing, and the concepts of interconnection + manufacturing are overwhelming, followed by a phenomenon of intelligent manufacturing following the trend. Both state-owned enterprises, private enterprises, large enterprises and small enterprises are following the trend to do intelligent manufacturing and transform interconnection +

a year has passed, how is the situation? It seems that the tide has faded a little, and some enterprises are embarrassed. The projects they have done have not achieved much. Let's discuss this issue

take Sany group as an example to see the mode of intelligent manufacturing of large enterprises:

Sany Heavy Industry, which is familiar to everyone, is a representative of the manufacturing industry and has strong manufacturing capacity. According to our understanding, Sany can produce an excavator every 5 minutes and a windmill every 1 hour. However, Sany's business model does not end when it is sold out. After sales services also include maintenance, fault response, spare parts, inventory, etc

recently, it has cooperated with Tencent cloud to jointly build an industrial Internet platform. On this platform, more than 300000 heavy machinery and equipment in the world are connected, and more than 10000 parameters are collected in real time. In this way, in case of equipment failure at any place, you can immediately perceive it, arrive at the scene in 2 hours, and solve the problem in 20 hours

even its business model has changed from manufacturing to service. For example, some construction units may not be able to afford such large-scale equipment. It doesn't matter. You can rent it. It has also driven the leasing service industry, and even brought some supply chain finance. Therefore, after the real-time connection of Sany, a traditional manufacturing information technology, its production relationship with customers and business model will change

I. reasons for the success of Intelligent Manufacturing in large enterprises

1 This kind of enterprise itself is the leader of the industry. It has rich resources. From raw material supply, to production, to service and finance, it can quickly integrate to form an intelligent industrial chain of the industry

2. The enterprise itself has a large number of customer groups. After the transformation of Internet + intelligent manufacturing, it can be quickly applied to the original customer groups. Sany is like this, and so is Haier's IOT smart appliances

3. For the scale effect of large enterprises, the scale of the enterprise itself is large enough, and the cost sharing advantage is obvious. In particular, the information system only needs a set of monitoring video display system around the stolen location, which can be applied to many product categories, so it can share the investment cost of intelligent manufacturing to a large extent; Large enterprises also have sufficient funds, so there is no need to worry about the cash flow required for investment in intelligent manufacturing, in which material science ranks first

4. In order to maintain the leading edge of "oligarchy", large enterprises must spare no effort to explore new directions. It can be said that transformation is also imperative

5. Large enterprises do not lack talents, and can attract enough excellent talents in technology, production, marketing and other fields, which is also a main reason why large enterprises are easy to transform and succeed

II. The trouble of implementing intelligent manufacturing in small enterprises

1 With the change of human's role and role in production and manufacturing, intelligent manufacturing has higher and higher requirements for employees' professional level; Pay more attention to technical professionalism. In order to introduce intelligent production mode, enterprises need more information-based talents, software and hardware talents, high skilled talents in operation management and marketing. In the process of transformation and upgrading of traditional manufacturing industry, more and more enterprises are facing the embarrassing situation of "easy access to systems and equipment, and difficult access to talents". Nearly 40% of the enterprises surveyed are worried that the existing talents cannot match and adapt to the new process of Intelligent Manufacturing in the future. Enterprises have purchased new equipment and systems, but there is no talent to implement them, leading to investment failure

2. Resources and technology are insufficient, and they have no control over upstream suppliers, their own production capacity and technical capacity are also insufficient, and the back-end service capacity is even insufficient. (many enterprises only do foreign trade processing in the early stage, and their ability to transform to serve domestic consumers is relatively weak)

3. Small capital enterprises have poor anti risk ability and insufficient cash flow, so they can't invest too much in intelligent manufacturing. Even if they can do it by using various financing and investment methods, due to insufficient customer support and insufficient resource support, the investment recovery cycle is too long, which is easy to drag down the enterprise

III. how to make intelligent manufacturing transformation for small enterprises

small enterprises should be based on their own actual situation, and should not be blind or eager for success. Just like Professor Liu Qiang of Beihang's "three don't's theory": don't engage in automation on the basis of backward technology, don't engage in informatization on the basis of backward management, and don't engage in intellectualization when you don't have the foundation of digital networking "

☆ I suggest that small enterprises should do several basic work before transformation:

1 Do a good job in basic lean work

many small and medium-sized enterprises need to make up lessons first. We have participated in the diagnosis of hundreds of enterprises. Many small enterprises do not do a good job in the most basic production management. Enterprise management is very backward, and they barely survive by relying on low processing fees. In the process of diagnosis, small and medium-sized enterprises can be seen everywhere, for example, inventory backlog, unreasonable production arrangements, serious waste and other phenomena emerge in endlessly. In this case, it is necessary to speed up the process of industry 2.0 and 3.0 and reduce the D. control system: the liquid crystal rubber tensile testing machine adopts pulse command control mode to make the control more accurate, various unreasonable losses and unreasonable waste, reduce its own manufacturing cost, and improve the quality and reliability of products at the same time

when we advocate intelligent manufacturing and industry 4.0, we need to think calmly. The development of enterprises is a step-by-step process. Japan has spent decades to build a set of lean production mode in the era of industry 2.0/3.0, which is also an insurmountable development of our small and medium-sized enterprises. Therefore, there is no need to blindly follow the trend and promote industry 4.0 with great fanfare. To promote intelligent manufacturing, we need to practice the basic skills first

Japan has polished a set of industrial production mode for decades, but we blindly pursue industry 4.0

2 Introduce flexible production and manufacturing capacity

today's customer demand is gradually fragmented and personalized, so the demand for production is also gradually small batch, even single piece personalization. Therefore, production-oriented enterprises first need to establish flexible production capacity on the basis of lean, from process to partial informatization, so as to achieve flexible manufacturing capacity. But it needs to be clear that this is only part of informatization, and flexibility does not mean intelligence. Realizing this step requires process optimization, lean layout, and the introduction of erp+mes system. This investment is affordable for small and medium-sized enterprises. The building of flexible ability is not overnight, which requires a lot of basic work to support

3. Gradually build a professional enterprise with "craftsman spirit"

enterprises should first strengthen lean production, management improvement, technology improvement and other aspects to achieve industry leadership in product innovation, process quality and cost efficiency. Make yourself irreplaceable competitive in the original competition pattern. Like many small technological enterprises in Germany and Japan, they still have irreplaceable competitive advantages in the Internet era with their own technological capabilities

enterprises that build craftsmanship spirit need to meet the following conditions:

˙ Talents need talents who can devote themselves to research technology, are very persistent, and love this work very much

˙ Corporate culture, enterprises need to establish a cultural atmosphere suitable for the survival of craftsman spirit, and advocate craftsman spirit by practice, not based on oral publicity

˙ For the mining of customers' needs, the so-called craftsmanship spirit is to meet the needs of consumers in some aspects, which needs to be studied according to the precise needs of consumers

˙ Product culture refers to the integration of product design, process, production and culture to create a product with profound cultural heritage

intelligent manufacturing can shorten the development cycle of products, reduce costs, and achieve the optimization of quality and efficiency, but it can not solve the problem of product competitiveness in the market and demand. Therefore, small and medium-sized enterprises need to make a comprehensive evaluation according to their own situation, and they should not blindly follow the trend and invest. They need to carry out step by step according to their own actual situation and the development path of intelligent manufacturing