Editor's Note: At present, China has become a major manufacturing equipment country. The output value of many industries such as machine tools, molds, stamping and sheet metal ranks among the top in the world. Promoting China's transformation from a large manufacturing country to a powerful country has become the "Twelfth Five-Year Plan" period. Key tasks, restructuring and transfer methods will become the top priority for the equipment industry to achieve scientific development. The overall idea for developing high-end equipment manufacturing industry is to meet the needs of industrial transformation and upgrading and strategic emerging industries, focusing on the development of intelligent manufacturing, green manufacturing and service manufacturing, which has become the biggest task for the equipment manufacturing industry.
Equipment manufacturing is booming, and the momentum of stamping sheet metal is not diminished.
According to Luo Baihui, head of the International Association of Mould & Hardware Plastics Industry Suppliers, since 2010, the growth of the main industry has become the main driving force for the growth of the machinery industry. In 2011, the equipment manufacturing industry ushered in a new development period, equipment manufacturing. The business climate will be steadily improved, and production will be expected to maintain an increase of 21% year-on-year. At the same time, the industry sales scale will continue to expand, but the increase in sales revenue and corporate profit growth will also slow down significantly. Benefiting from the adjustment of industrial structure and the improvement of technological innovation capability, the profit margin of enterprise sales should be able to increase to more than 7%. Subject to the risk factors of RMB appreciation, the enthusiasm for enterprises to expand exports will be restrained, and the growth rate of export value will not increase much.
Due to the high priority of technology applications such as automation and intelligent control, and the emergence of the Internet of Things industry, the instrumentation industry will usher in a new dawn, starting with the 30% growth in 2011, and will continue to flourish.
It is expected that the machine tool industry will maintain a growth rate of more than 30% in 2011. The machine tool is the mother machine of machinery manufacturing. The development of the industry mainly relies on the fixed assets investment of the machinery industry. At the same time, the machine tool industry is also an important part of the high-end equipment manufacturing industry and will be supported by the national development policy. In 2011, China's auto industry investment will shrink, but benefit from the development of strategic emerging industries, energy conservation and environmental protection industries, new energy industries, new energy vehicles and new materials industries, especially aviation equipment, marine engineering, rail transit and other high-end equipment. Investment in the manufacturing industry will continue to increase, and investment in these industries will still drive the market demand for machine tools, and the machine tool industry will still perform well in 2011.
It is estimated that the output value of the automobile industry will increase within 10% in 2011, while the output value of the internal combustion engine industry will also be less than 10%. The output value of the agricultural machinery industry will increase by about 14%, and the output value of the cultural office equipment industry will increase by 20%. The increase rate is about 24%, the food packaging machinery industry has reached 26%, the petrochemical general industry has increased by 28%, the electrical and mechanical industry output value has increased by about 28%, and the construction machinery industry will still maintain a 30% growth rate.
Stamping and sheet metal production involve all aspects of the manufacturing industry. It can be said that the surface area is wide and the shape and process are very different. It is expected that the annual growth rate of the stamping and sheet metal industry will be higher than 10%, and the mold and accessories industry will increase by 24%.
Three bottlenecks in stamping sheet metal, advanced model is worth learning
In the past ten years, with China becoming the world's manufacturing center and consumer power, the stamping and sheet metal industry, one of the manufacturing industry's basic industries, has also achieved unprecedented development. According to Luo Baihui, there are about 40,000 production enterprises in the stamping industry in the country, 2 million employees, annual production of 28 million tons of stampings, total sales of 400 billion yuan, annual consumption of less than 3 mm of thin steel sheet more than 40 million tons, procurement The stamping die costs 40 billion yuan, and the newly purchased stamping equipment costs 20 billion yuan. China's sheet metal and production industry has 30,000 enterprises, 1.8 million employees, annual production of sheet metal parts of about 42 million tons, total sales of 500 billion yuan. However, compared with the counterparts of the United States and Japan, there are some problems in the stamping and sheet metal industry in China, which are summarized into three points:
1. Raw materials and related technologies are backward
Due to the poor quality and variety of domestic steel used in fasteners, chains, springs, bearings, molds, etc., it directly affects the quality of stamping parts. Mechanical basic parts are generally produced in batches, in large quantities, and also have many varieties and high processing precision requirements. Therefore, the production process and equipment are required to be high and the investment is large. High-efficiency and high-precision special planes, production lines or flexible lines are used in foreign countries to achieve efficient and automated production. However, some basic parts enterprises in China are restricted by funds, and the input is not strong. The self-reformability of enterprises is poor, and the advanced equipment is small and unsuitable, which affects the quality of products.
2. The degree of specialization is low, the scale is not large, and the economic benefits are poor.
Compared with the mainframe, the metal stamping parts require relatively little investment in the initial capital technology. After several times of economic development in the country, a number of private production enterprises have sprung up, but because of the market demand, the batch size is small. Not economic scale. Most of the stamping parts processing enterprises themselves are large but small or complete, with low specialization, low equipment level, unstable quality and low economic efficiency. For example, the annual output of micro-motors by three large-scale backbone enterprises in China's motor industry is less than 50% of a famous foreign company. In the past two years, thousands of stamping parts factories have been built in some areas of China, but there are only a few of them with an annual output of more than 300,000 pieces. The main products are agricultural machinery. The German Rexroth Company produces 1.3 million pieces of various stamping parts per year, and Japan Oil Research Co., Ltd. also produces more than 600,000 pieces per year. The per capita output value of mold enterprises in industrialized countries is about 150,000 to 200,000 US dollars, and China has only 40,000 to 50,000 yuan. Luo Baihui pointed out that in recent years, with the implementation of the common development policy of multiple ownership systems, the hardware industry is experiencing a process of decentralization to gradual integration.
3. Insufficient capital investment, weak research and development strength
In the stamping parts processing industry, a number of foreign advanced technologies were introduced earlier in the late 1970s and early 1980s, but there was insufficient investment in hardware and software for digestion and absorption. According to foreign experience, the ratio of funds required for the introduction of technology and digestion and absorption is about 1:7, while China has a late understanding of this, and the digestion and absorption steps are slow. Market competition actually competes with technical strength. Foreign countries attach great importance to this and have increased their investment and occupied the commanding heights of technology. The funds used by major famous companies for research and development account for 4% to 5% of their sales, and the key areas are 10%. At present, although there are many colleges and universities in China engaged in scientific research, many theoretical research, scientific research results, and patent papers are quite high, but they are not tightly integrated with production, and are particularly slow to convert into commodities. Controlling the unsafe state of the equipment requires strengthening the daily inspection of the equipment (including inspection of its safety devices), promptly identifying various hazards and improving them, and ensuring that the safety devices are functioning properly. Each equipment development department should also develop and replace equipment with higher safety performance in a timely manner.
Luo Baihui said that as a basic manufacturing industry indispensable for the manufacturing industry, the metal stamping and sheet metal processing industries will need to continuously improve and adopt advanced manufacturing processes in the future to achieve scale, batch and even individualized production.
American model: automated production is safe and reliable
First, the automated production of closed-loop control used by US companies is safer and more reliable, facilitating the maintenance of the entire production line. The company has its tooling mold maintenance workshop. Various sensors are installed or embedded in the mold, such as sensors for detecting whether the punch passes through the slab, and sensors for detecting whether the slab has reached the station. The application of these sensors greatly improves the safety and reliability of the entire production line.
Secondly, the US stamping and sheet metal companies have a high level of safety awareness. The safety machine is installed on the press. When the worker is too close to the press, the pressure machine automatically stops, thus ensuring the safety of the workers.
Again, US companies have their own management information systems. The materials supplied by the raw material suppliers are all barcoded, and when scanned, all kinds of raw materials are automatically entered into the production database. As the raw materials enter the processing process, the computer host of each processing step will automatically input the processing information into the database, and this information will always be attached to the final product.
In addition, although the size of the US companies is relatively large, but the product line is not very large, they have fixed buyers, such as Delphi, Ford, the production of large quantities of products is their common feature.
Japanese model: process equipment is shocking
Japan's stamping parts production specialization, high degree of automation, large scale of production, high product precision, humanized management, systematic, basically have mold development, design and processing capabilities, and generally with its Japanese host factory users to China to establish The branch factory.
In particular, the various production know-how and process equipment accumulated by Japanese companies in production can be described as the perfect combination of modern advanced manufacturing technology and human traditional wisdom, which is shocking to all visitors, including many from Europe and the United States. Old peers.
Stone of other mountains: introduction of advanced manufacturing industrial equipment
In recent years, China's sheet metal industry has been greatly developed, but most enterprises are still in the low-productivity situation of hand-workshops, and they are fiercely competitive in low-end products. They must be able to adapt to the needs of national economic construction and participate in international competition. The sheet metal industry must avoid vicious competition and achieve differentiated production; management talents must go out and come in; technology should be constantly updated and changed, existing process equipment should be improved, hard work should be done, product quality should be improved, product quality and product quality should be met. Supply requirements continue to increase market demand, and under the premise of ability, try to use advanced manufacturing processes and equipment, establish a sound quality assurance system, improve the level of precision, specialization, automation, information manufacturing, to meet large quantities And flexible production requirements.
Develop service-oriented creation and green manufacturing
The importance of service-oriented manufacturing is being more and more widely recognized and accepted, and it has become the trend of the development of stamping sheet metal manufacturing. After the baptism of the financial turmoil, many enterprises have carried out profound reflections and made corresponding adjustments to the future development strategy. From the production and operation-oriented enterprises to the comprehensive service-oriented enterprises, almost reached a consensus. For stamping and sheet metal companies, we will strive to cultivate a total solution and manufacturing expert system centered on improving the supply capacity of complete sets of technology and automated production lines. Specifically, it is necessary for enterprises to comprehensively improve the quality and scope of services, and to infiltrate services into all aspects, including technical consultation, customer training, financial settlement methods, logistics work, product technical services, assisting customers in secondary development, and satisfying customers. Personalized needs and other aspects. At the same time, try to solve the problem in the shortest time for the customer to meet the needs of any customer, and maximize the response speed.
In Luo Baihui's view, the development of China's stamping and sheet metal industry must conform to the design, manufacturing and consumption concepts of low-carbon, environmental protection, energy-saving and material-saving, and develop towards precision, efficiency, specialization, scale and globalization. Luo Baihui pointed out that Chinese enterprises have a long way to go and will develop and transform from six aspects in the future.
First, the use of advanced manufacturing processes and equipment, establish a sound quality assurance system, improve the level of precision, specialization, automation, information manufacturing, to meet the needs of large quantities and flexible production;
The second is to improve the production, marketing and management level of enterprises, reduce management costs, and improve the overall competitiveness of enterprises. Enterprises should constantly improve and improve the level of production and sales, continuously reduce their own management costs, truly achieve quality, efficiency, and improve the overall competitiveness of enterprises.
The third is to attach importance to the construction of a talent team. While continuously introducing the high-quality talents required by enterprises, we must also pay attention to the re-education and training of the existing workforce, and keep its technology and management level in sync with the times. Luo Baihui pointed out that the great challenge in the future of stamping sheet metal industry will be the lack of high-quality laborers and the enormous labor cost pressure. Therefore, enterprises must pay attention to technological transformation and personnel training, and must pay attention to cultivating workers' teams suitable for their own production characteristics. .
The fourth is to strengthen international exchanges and cooperation, to view the development of domestic and foreign industries, to collect important industry intelligence, to broaden the cause of decision-making leadership, and to improve the forward-looking decision-making of leadership.
The fifth is to establish a concept of good faith, establish a good reputation of the company, and strive to be a century-old enterprise.
The sixth is to establish a global concept, establish a reasonable relationship between supply and demand of upstream and downstream, and at the same time introduce and train international talents, understand the customs, laws and regulations, language and culture of other countries, ensure unimpeded communication between enterprises and foreign companies, and improve the success of cooperation. rate.
Equipment manufacturing is booming, and the momentum of stamping sheet metal is not diminished.
According to Luo Baihui, head of the International Association of Mould & Hardware Plastics Industry Suppliers, since 2010, the growth of the main industry has become the main driving force for the growth of the machinery industry. In 2011, the equipment manufacturing industry ushered in a new development period, equipment manufacturing. The business climate will be steadily improved, and production will be expected to maintain an increase of 21% year-on-year. At the same time, the industry sales scale will continue to expand, but the increase in sales revenue and corporate profit growth will also slow down significantly. Benefiting from the adjustment of industrial structure and the improvement of technological innovation capability, the profit margin of enterprise sales should be able to increase to more than 7%. Subject to the risk factors of RMB appreciation, the enthusiasm for enterprises to expand exports will be restrained, and the growth rate of export value will not increase much.
Due to the high priority of technology applications such as automation and intelligent control, and the emergence of the Internet of Things industry, the instrumentation industry will usher in a new dawn, starting with the 30% growth in 2011, and will continue to flourish.
It is expected that the machine tool industry will maintain a growth rate of more than 30% in 2011. The machine tool is the mother machine of machinery manufacturing. The development of the industry mainly relies on the fixed assets investment of the machinery industry. At the same time, the machine tool industry is also an important part of the high-end equipment manufacturing industry and will be supported by the national development policy. In 2011, China's auto industry investment will shrink, but benefit from the development of strategic emerging industries, energy conservation and environmental protection industries, new energy industries, new energy vehicles and new materials industries, especially aviation equipment, marine engineering, rail transit and other high-end equipment. Investment in the manufacturing industry will continue to increase, and investment in these industries will still drive the market demand for machine tools, and the machine tool industry will still perform well in 2011.
It is estimated that the output value of the automobile industry will increase within 10% in 2011, while the output value of the internal combustion engine industry will also be less than 10%. The output value of the agricultural machinery industry will increase by about 14%, and the output value of the cultural office equipment industry will increase by 20%. The increase rate is about 24%, the food packaging machinery industry has reached 26%, the petrochemical general industry has increased by 28%, the electrical and mechanical industry output value has increased by about 28%, and the construction machinery industry will still maintain a 30% growth rate.
Stamping and sheet metal production involve all aspects of the manufacturing industry. It can be said that the surface area is wide and the shape and process are very different. It is expected that the annual growth rate of the stamping and sheet metal industry will be higher than 10%, and the mold and accessories industry will increase by 24%.
Three bottlenecks in stamping sheet metal, advanced model is worth learning
In the past ten years, with China becoming the world's manufacturing center and consumer power, the stamping and sheet metal industry, one of the manufacturing industry's basic industries, has also achieved unprecedented development. According to Luo Baihui, there are about 40,000 production enterprises in the stamping industry in the country, 2 million employees, annual production of 28 million tons of stampings, total sales of 400 billion yuan, annual consumption of less than 3 mm of thin steel sheet more than 40 million tons, procurement The stamping die costs 40 billion yuan, and the newly purchased stamping equipment costs 20 billion yuan. China's sheet metal and production industry has 30,000 enterprises, 1.8 million employees, annual production of sheet metal parts of about 42 million tons, total sales of 500 billion yuan. However, compared with the counterparts of the United States and Japan, there are some problems in the stamping and sheet metal industry in China, which are summarized into three points:
1. Raw materials and related technologies are backward
Due to the poor quality and variety of domestic steel used in fasteners, chains, springs, bearings, molds, etc., it directly affects the quality of stamping parts. Mechanical basic parts are generally produced in batches, in large quantities, and also have many varieties and high processing precision requirements. Therefore, the production process and equipment are required to be high and the investment is large. High-efficiency and high-precision special planes, production lines or flexible lines are used in foreign countries to achieve efficient and automated production. However, some basic parts enterprises in China are restricted by funds, and the input is not strong. The self-reformability of enterprises is poor, and the advanced equipment is small and unsuitable, which affects the quality of products.
2. The degree of specialization is low, the scale is not large, and the economic benefits are poor.
Compared with the mainframe, the metal stamping parts require relatively little investment in the initial capital technology. After several times of economic development in the country, a number of private production enterprises have sprung up, but because of the market demand, the batch size is small. Not economic scale. Most of the stamping parts processing enterprises themselves are large but small or complete, with low specialization, low equipment level, unstable quality and low economic efficiency. For example, the annual output of micro-motors by three large-scale backbone enterprises in China's motor industry is less than 50% of a famous foreign company. In the past two years, thousands of stamping parts factories have been built in some areas of China, but there are only a few of them with an annual output of more than 300,000 pieces. The main products are agricultural machinery. The German Rexroth Company produces 1.3 million pieces of various stamping parts per year, and Japan Oil Research Co., Ltd. also produces more than 600,000 pieces per year. The per capita output value of mold enterprises in industrialized countries is about 150,000 to 200,000 US dollars, and China has only 40,000 to 50,000 yuan. Luo Baihui pointed out that in recent years, with the implementation of the common development policy of multiple ownership systems, the hardware industry is experiencing a process of decentralization to gradual integration.
3. Insufficient capital investment, weak research and development strength
In the stamping parts processing industry, a number of foreign advanced technologies were introduced earlier in the late 1970s and early 1980s, but there was insufficient investment in hardware and software for digestion and absorption. According to foreign experience, the ratio of funds required for the introduction of technology and digestion and absorption is about 1:7, while China has a late understanding of this, and the digestion and absorption steps are slow. Market competition actually competes with technical strength. Foreign countries attach great importance to this and have increased their investment and occupied the commanding heights of technology. The funds used by major famous companies for research and development account for 4% to 5% of their sales, and the key areas are 10%. At present, although there are many colleges and universities in China engaged in scientific research, many theoretical research, scientific research results, and patent papers are quite high, but they are not tightly integrated with production, and are particularly slow to convert into commodities. Controlling the unsafe state of the equipment requires strengthening the daily inspection of the equipment (including inspection of its safety devices), promptly identifying various hazards and improving them, and ensuring that the safety devices are functioning properly. Each equipment development department should also develop and replace equipment with higher safety performance in a timely manner.
Luo Baihui said that as a basic manufacturing industry indispensable for the manufacturing industry, the metal stamping and sheet metal processing industries will need to continuously improve and adopt advanced manufacturing processes in the future to achieve scale, batch and even individualized production.
American model: automated production is safe and reliable
First, the automated production of closed-loop control used by US companies is safer and more reliable, facilitating the maintenance of the entire production line. The company has its tooling mold maintenance workshop. Various sensors are installed or embedded in the mold, such as sensors for detecting whether the punch passes through the slab, and sensors for detecting whether the slab has reached the station. The application of these sensors greatly improves the safety and reliability of the entire production line.
Secondly, the US stamping and sheet metal companies have a high level of safety awareness. The safety machine is installed on the press. When the worker is too close to the press, the pressure machine automatically stops, thus ensuring the safety of the workers.
Again, US companies have their own management information systems. The materials supplied by the raw material suppliers are all barcoded, and when scanned, all kinds of raw materials are automatically entered into the production database. As the raw materials enter the processing process, the computer host of each processing step will automatically input the processing information into the database, and this information will always be attached to the final product.
In addition, although the size of the US companies is relatively large, but the product line is not very large, they have fixed buyers, such as Delphi, Ford, the production of large quantities of products is their common feature.
Japanese model: process equipment is shocking
Japan's stamping parts production specialization, high degree of automation, large scale of production, high product precision, humanized management, systematic, basically have mold development, design and processing capabilities, and generally with its Japanese host factory users to China to establish The branch factory.
In particular, the various production know-how and process equipment accumulated by Japanese companies in production can be described as the perfect combination of modern advanced manufacturing technology and human traditional wisdom, which is shocking to all visitors, including many from Europe and the United States. Old peers.
Stone of other mountains: introduction of advanced manufacturing industrial equipment
In recent years, China's sheet metal industry has been greatly developed, but most enterprises are still in the low-productivity situation of hand-workshops, and they are fiercely competitive in low-end products. They must be able to adapt to the needs of national economic construction and participate in international competition. The sheet metal industry must avoid vicious competition and achieve differentiated production; management talents must go out and come in; technology should be constantly updated and changed, existing process equipment should be improved, hard work should be done, product quality should be improved, product quality and product quality should be met. Supply requirements continue to increase market demand, and under the premise of ability, try to use advanced manufacturing processes and equipment, establish a sound quality assurance system, improve the level of precision, specialization, automation, information manufacturing, to meet large quantities And flexible production requirements.
Develop service-oriented creation and green manufacturing
The importance of service-oriented manufacturing is being more and more widely recognized and accepted, and it has become the trend of the development of stamping sheet metal manufacturing. After the baptism of the financial turmoil, many enterprises have carried out profound reflections and made corresponding adjustments to the future development strategy. From the production and operation-oriented enterprises to the comprehensive service-oriented enterprises, almost reached a consensus. For stamping and sheet metal companies, we will strive to cultivate a total solution and manufacturing expert system centered on improving the supply capacity of complete sets of technology and automated production lines. Specifically, it is necessary for enterprises to comprehensively improve the quality and scope of services, and to infiltrate services into all aspects, including technical consultation, customer training, financial settlement methods, logistics work, product technical services, assisting customers in secondary development, and satisfying customers. Personalized needs and other aspects. At the same time, try to solve the problem in the shortest time for the customer to meet the needs of any customer, and maximize the response speed.
In Luo Baihui's view, the development of China's stamping and sheet metal industry must conform to the design, manufacturing and consumption concepts of low-carbon, environmental protection, energy-saving and material-saving, and develop towards precision, efficiency, specialization, scale and globalization. Luo Baihui pointed out that Chinese enterprises have a long way to go and will develop and transform from six aspects in the future.
First, the use of advanced manufacturing processes and equipment, establish a sound quality assurance system, improve the level of precision, specialization, automation, information manufacturing, to meet the needs of large quantities and flexible production;
The second is to improve the production, marketing and management level of enterprises, reduce management costs, and improve the overall competitiveness of enterprises. Enterprises should constantly improve and improve the level of production and sales, continuously reduce their own management costs, truly achieve quality, efficiency, and improve the overall competitiveness of enterprises.
The third is to attach importance to the construction of a talent team. While continuously introducing the high-quality talents required by enterprises, we must also pay attention to the re-education and training of the existing workforce, and keep its technology and management level in sync with the times. Luo Baihui pointed out that the great challenge in the future of stamping sheet metal industry will be the lack of high-quality laborers and the enormous labor cost pressure. Therefore, enterprises must pay attention to technological transformation and personnel training, and must pay attention to cultivating workers' teams suitable for their own production characteristics. .
The fourth is to strengthen international exchanges and cooperation, to view the development of domestic and foreign industries, to collect important industry intelligence, to broaden the cause of decision-making leadership, and to improve the forward-looking decision-making of leadership.
The fifth is to establish a concept of good faith, establish a good reputation of the company, and strive to be a century-old enterprise.
The sixth is to establish a global concept, establish a reasonable relationship between supply and demand of upstream and downstream, and at the same time introduce and train international talents, understand the customs, laws and regulations, language and culture of other countries, ensure unimpeded communication between enterprises and foreign companies, and improve the success of cooperation. rate.
Block Magnets,Permanent Magnets,Ring Magnets
SDM Magnetics Co., Ltd. , http://www.lg-magnets.com