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In depth analysis: why should the steel industry realize intelligent manufacturing

in depth analysis: why should the steel industry realize intelligent manufacturing

China Construction Machinery Information

"the iron and steel industry should learn from the idea of 'industry 4.0' to promote 'made in China 2025'." In fact, the entry point and main direction of "made in China 2025" is intelligent manufacturing; The core of Germany's "industry 4.0" is also that the success of smart chemical enterprise M & A cannot be separated from the manufacturing of three major factors, which is suitable for industries with a high degree of automation. The steel industry is one of the most automated manufacturing industries

"whether 'industry 4.0' is applicable to the steel industry depends on whether it has the foundation of 'industry 3.0', because the former is the natural extension and development of the latter." "In this sense, the steel industry is one of the most suitable industries to learn from this idea".; Many concepts and goals of intelligent manufacturing have been explored and even achieved in steel enterprises. For example, the personalized customization emphasized by "intelligent manufacturing" is called "standard" in the steel industry+ ɑ”; The essence of the well-known mathematical model in iron and steel enterprises is CPS (information physical system) in intelligent manufacturing

promoting intelligent manufacturing in the iron and steel industry can bring many values, such as improving service levels, promoting safe production, improving product quality and resource utilization efficiency, energy conservation and emission reduction, reducing production costs, optimizing the labor environment, improving labor efficiency, and can contribute to protecting the natural environment, coping with aging, promoting people's free development and other social issues. In the "industry 3.0" industry, the gap between the overall technical level of China's steel industry and foreign advanced enterprises is relatively small. To revitalize China's manufacturing industry, the steel industry should bear a greater burden. The key is how to go in the future

personalized service should be the leading condition for intelligent manufacturing

steel is the basic raw material, and its economy is based on large-scale production. However, the uses of steel vary greatly, and the needs of users vary greatly. The contradiction between large-scale production and personalized needs has been puzzling the steel industry. This not only leads to difficulties in production organization, but also causes problems such as rising costs and inventories, declining yield and quality, and extending delivery time

"to promote intelligent manufacturing in the steel industry, we should not blindly pursue the personalized differences of the products themselves, but should emphasize" mass customization ": that is, we should use the same materials to meet the needs of different users as much as possible, and arrange the different processes as late as possible

however, it is not easy to implement this idea. First of all, we must understand the essential requirements of users for materials. This requires "personalized service" as the guide, and improve their own service ability and complete knowledge accumulation in the service. "Intensive production and personalized service" may be the key direction for the steel industry to promote intelligent manufacturing

the steel industry can embed CPS into the information platform of horizontal integration and end-to-end integration to realize intelligent R & D, service, procurement and sales. In this way, through the sharing of knowledge and information, we can break through the boundaries between departments, achieve rapid and effective collaboration, shorten the distance between enterprises and customers, and reduce the total cost of parts by 40%, so as to provide customized personalized services for users. Guo Zhaohui believes that in iron and steel enterprises, it is not only the sales and R & D departments that serve the needs of users, but the whole company

in the future, downstream users will gradually strengthen their requirements for personalized services. The basic driving force will come from two aspects: first, with the improvement of users' automation and intelligence level and the improvement of final product quality requirements, the requirements for material quality will certainly increase; Second, with the continuous development of e-commerce, steel products need to come from small and medium-sized customers more and more, and the traditional service mode will become increasingly unsustainable. Therefore, promoting "intelligent services" is obviously an important direction for the steel industry to realize intelligent manufacturing

the rise of labor costs forces the development of intelligent manufacturing.

intelligent manufacturing is a profound industrial revolution and a blue ocean of innovation. However, only with the height of "judging the quality based on five performances" can we see the full picture of the blue ocean. Guo Zhaohui believes that the purpose of intelligent manufacturing can be summed up as "serving people, helping people, replacing people, surpassing people, liberating people, and relying on people". Promoting intelligent manufacturing can also be attributed to human problems

in fact, the direct reason why Germany proposed "industry 4.0" is that Jinan new era Gold Testing Instrument Co., Ltd. Jinan experimental machine factory sincerely welcomes you. First, aging has reduced the competitiveness of its manufacturing industry, which requires technical means to extend the working age and attract young people

in China, the problem is equally serious. With the arrival of "Lewis inflection point", the labor cost rises sharply; In 2012, the total working population began to decrease, followed by China's entry into the 'new normal' of medium and high-speed development. In recent years, while facing the market downturn, capital, environmental protection and other pressures, iron and steel enterprises clearly feel the rising labor costs, difficult to find cooperative workers, unstable teams, declining employee engagement, management difficulties, frequent safety accidents, unstable product quality and other problems. Recently, a number of experts pointed out that getting old before getting rich may lead China into a "middle-income trap"

international competition puts forward higher requirements for the steel industry

at present, the per capita steel production of POSCO is more than twice the average value of this index of China's steel enterprises. Although the wage level in China is low, the total labor cost is very close. With the further rise of labor costs in China, the pressure on China's iron and steel enterprises will be increasing

however, the current differences in labor efficiency between China and South Korea are mainly caused by economic factors. With the increase of labor costs, Chinese steel enterprises will also adopt robot, unmanned driving, unmanned trolley, unmanned warehouse and other technologies to improve labor efficiency and reduce production costs. Technically, these are not inherently difficult

recently, the ultimate goal is to establish an unattended smart factory. "What I worry about is the future - if Chinese steel enterprises can't keep up now, it may lead to a new round of backwardness."

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