How much do you know about the status quo of "machine replacement" in textile industry?

With China's economic development entering a new normal, textile industry has risen to replace manual labor with automated and intelligent equipment - ldquo; machine replacement - rdquo; upsurge. What does this upsurge bring to the industry? What's the problem? Is there a trend change in the industrial workforce? In order to get a better understanding of the textile industry-ldquo; machine replacement-rdquo; current situation, China Finance and Trade Light Textile Tobacco Trade Union has recently gone deep into key areas of textile industry development, such as Jiangsu, Fujian, Henan, Tianjin, Shanghai and Shandong, and selected representative enterprises such as spinning, chemical fibre, weaving and clothing to conduct a special survey, clarifying the textile industry-ldquo; machine replacement-rdquo; and some basic information.
Difficult recruitment and expensive labor force Textile Industry & ldquo; machine replacement & rdquo;
The traditional textile industry is a labor-intensive industry. With the gradual disappearance of the demographic dividend in our country, it is urgent to transform and upgrade. Mechanization, automation and intellectualization have become effective ways to transform traditional industries, promote industrial transformation and upgrading, reduce staff and increase efficiency, and alleviate recruitment difficulties, thus opening the curtain of textile industry-ldquo; machine replacement-rdquo; and so on.
The report shows that rising labor costs and long-term structural labor shortage in the industry have become one of the main driving forces driving the textile industry backward: ldquo; machine replacement & rdquo; and so on.
In recent years, the growth rate of labor remuneration has been accelerating. Enterprises have to raise the wages of their employees one or two times a year, and they obviously feel that the pressure of employment is increasing. The development of textile industry needs a large number of textile technicians and skilled personnel. The eastern part is the traditional labor force flowing into the provinces, and there is a gap in the local labor supply, while the skilled workers in the central and western provinces who go out to work appear the phenomenon of reflux, resulting in textile enterprises, especially the Eastern Textile enterprises, generally facing the dilemma of & ldquo; shortage of employment & rdquo; and so on. At the same time, because of the high intensity of work in the textile industry and the great mobility of workers, especially the young workers after 85 and 90 are not willing to engage in monotonous and repetitive work, the front-line workers can not be effectively supplemented, which also makes many textile enterprises long-term absence of work, forcing enterprises to “ machine replacement ”. Take southern Jiangsu textile enterprises as an example, enterprises are facing about 10% shortage of jobs every year.
At the same time, the upgrading of textile industry and the realization of high-quality development demand for intelligent manufacturing, & ldquo; machine replacement & rdquo; has become the general trend. The survey shows that the quality of textiles is the competitiveness of enterprises, and the development of textile quality in China is not optimistic. The instability of quality exists not only between different enterprises and different regions, but also among different batches of products within enterprises, which directly affects the market competitiveness of products. Intelligent robot production has incomparable advantages in promoting stable product quality and achieving high-quality development.
The report points out that at present, & ldquo; Made-in-China 2025 & rdquo; & ldquo; Industry 4.0 & rdquo; Strategic deployment, as well as & ldquo; National 13th Five-Year Plan for Textile Industry & rdquo; and the corresponding national and local incentive policies for upgrade and replacement of supporting equipment constitute the background of realizing & ldquo; Machine replacement & rdquo; Intelligent Manufacturing in textile industry. Because of the labor cost problem and the influence of the Trans-Pacific Partnership Agreement (TPP), European and American manufacturing powers have shifted their focus to India, Vietnam, Bangladesh, Pakistan and other countries. Whether it is human capital, equipment or technology, Chinese textiles are challenged by Southeast Asian countries. At the same time, despite the introduction of advanced foreign equipment by many enterprises, they still face challenges. Can not change the industry's relatively backward technology status quo. Therefore, & ldquo; machine replacement & rdquo; is imperative.
& LDquo; Machine Replacement & rdquo; Energy Saving and Efficiency Increasing for Textile Industry
This survey has made a thorough understanding of the results of the LDquo, machine replacement and rdquo, which are the subdivisions of the textile industry. The report shows that:
1. Cotton spinning industry. Large-scale technical renovation of blowing-carding unit, simple blowing-carding unit, high-efficiency roughening, high-efficiency compact spinning slender car, automatic winder, etc. has been carried out. The yarn quality index, average employment of 10,000 spindles, energy saving and consumption reduction have reached a new level. Especially the application of spinning intelligent doffing machine can greatly reduce the labor intensity of spinning workers, and the labor can be reduced by more than 40%. Taking Fujian Changle Mayor Changyuan Textile Company as an example, the original 10 spinning workshops were technically reformed and fully automatic production lines were introduced. The number of workers decreased from 504 to 317, and the average monthly wage increased by 1000 yuan per capita.
2. Chemical fiber industry. Through flexible technology, energy saving and consumption reduction and other intelligent technological transformation, the product differentiation level, quality performance and production efficiency are obviously improved, and the number of employees is greatly reduced. Taking Fujian Baihong Group as an example, the implementation of “ machine replacement ” after that, the automatic filament dropping process reduces the labor by 70%, the automatic packaging process reduces the labor by 80%. The cost of automatic packaging equipment updating can be recovered in 3 to 4 years.
3. Functional textiles. Enterprises have introduced a large number of high-performance automatic warp knitting machines, knitting flat knitting machines, large circular machines and supporting finishing equipment, and developed various functional knitted fabrics for clothing, shoes, home textiles and industries, which meet the market demand trend at home and abroad. Taking Fujian Jinjiang Huayu Weaving Co., Ltd. as an example, 400 fully automatic warp knitting machines were introduced at one time, and the turning worker was reduced from more than 800 to more than 200 people; from 1 to 2 machines per capita management to 5 machines per capita management; the monthly wage was greatly raised from about 4000 yuan per capita, and the monthly wage income of the best skilled workers could reach nearly 10,000 yuan.
FourShoes and clothing manufacturing. Attention should be paid to the improvement of design concept and intelligent manufacturing. Clothing function, art and fashion design have been continuously strengthened. The level of design, sewing, processing and finishing has made remarkable progress. Advantage enterprises such as Qipai, Seven Wolves, Jiumuwang and Jinba adopt robots instead of manual paving and implement automation of logistics process, which greatly reduces labor intensity and improves production efficiency.
5. Printing and dyeing industry. From the experience of advanced regions, printing and dyeing enterprises implement ldquo; machine replacement rdquo; after that, water consumption per 10,000 yuan of added value of industry has decreased by more than 15%, energy consumption has decreased by more than 17%, industrial wastewater discharge has decreased by more than 10%, water reuse rate has reached 52.7%, and labor cost has been saved by nearly 60%.
Small and Medium-sized Enterprises & ldquo; Machine Replacement & rdquo; Difficulties
According to the report, & ldquo; machine replacement & rdquo; has incomparable advantages in replacing manual labor to improve productivity, but there are still many difficulties for textile enterprises, especially small and medium-sized enterprises.
Firstly, & ldquo; machine replacement & rdquo; has a high one-time investment, and enterprises are short of funds and difficult to finance. Enterprises prefer to maintain the status quo rather than invest heavily. More than half of the enterprises surveyed have invested more than 10 million yuan, the highest even more than 100 million yuan. In addition, in recent years, the rising cost of enterprise financing, financing difficulties and other factors, so that enterprises, especially small and medium-sized enterprises to & ldquo; machine replacement & rdquo; stand back. At the same time, the layout of factories and production lines of some old and small enterprises can not provide enough space for the upgrade of equipment, while the cost of renovation, expansion and even new construction of factories will be further increased. At present, the state is promoting de-leverage to reduce leverage and overall debt ratio. The amount of loans available to banks has been greatly reduced, the financing cost is high, and only the amount has no funds. In order to maintain normal operation and ensure cash flow, enterprises are reluctant to invest in large-scale equipment and high-tech equipment.
Secondly, the supporting policies of the government need to be further refined. For example, according to the survey, Henan Province has promulgated the "Three-year Plan of Action for the Development of Intelligent Manufacturing and Industrial Internet in Henan Province (2018-2020)", which will promote ldquo; machine replacement & rdquo; in coal, chemical, food and other industries, and plans to build 50 provincial-level intelligent factories every year. But the Henan provincial government has no specific support policy for the textile industry, and there is no clear support policy for each city. The insufficient support of policies and funds leads to the lack of willingness of enterprises to change people.
Thirdly, the domestic textile machinery production level is still unable to meet the needs of high-quality textile production. The imported machinery is expensive, which prolongs the recovery cycle of capital investment and increases the maintenance cost of daily equipment. Research shows that the digital and intelligent upgrading of equipment is not like the simple and extensive technological transformation in the past, which can be accomplished by imitation or commissioning trial production. Instead, enterprises need to cooperate more with universities and research institutes of automation equipment to integrate the whole production process from process flow. There are many uncertainties in the process of R&D.
Fourthly, the cultural and technological level of workers in textile enterprises is relatively low, and there is a serious shortage of technical personnel. After the introduction of automation equipment, the demand for all kinds of technical personnel will increase dramatically. Textile enterprises need to train or introduce high-level technical personnel, which is undoubtedly a greater burden.
Fifthly, the wage level of textile workers in the central and western regions is relatively low, and the subjective willingness of enterprises to carry out ldquo; machine replacement rdquo is not strong. For example, Anyang City, Henan Province, implements the monthly minimum wage standard of 1600 yuan and the hourly minimum wage standard of 15 yuan. There is basically no shortage of labor in this area. Even if there is occasional shortage of labor, it is generally possible to find enough people after properly raising wages.
& ldquo; machine replacement & rdquo; will change the employment structure of the industry
Since the first industrial revolution, it has become an irreversible trend for machines to replace human beings. Modern manufacturing industry & ldquo; machine replacement & rdquo; is directly turning machines into labor force, whether it has had a greater impact on the traditional labor market and enterprise employment?
According to the survey report, the characteristics of labor-intensive textile industry will not change in the short term. According to the survey, at present, & ldquo; machine replacement & rdquo; is not implemented in the whole production process of an industry or an enterprise.Instead, it is widely used in certain production links of an industry or enterprise. That is to say, robots only replace manual operation in individual industries and links. In the short run, robots mainly have a positive impact on productivity and product quality. They will not change the characteristics of high labor intensity in textile industry, nor will they cause serious unemployment.
The survey results show that the staff of textile industry is relatively stable at present. The textile industry is not laid off because of & ldquo; machine replacement & rdquo; but because it can not find workers and seek & ldquo; machine replacement & rdquo;. There is a serious shortage of textile talents and the fact that enterprises are striving to compete for workers. At present, there is no worry that a large number of front-line workers will be laid off in textile enterprises. Because of & ldquo; machine replacement & rdquo; most of the workers who have been streamlined are transferred and retained in the original enterprises, a small part of them are transferred to other enterprises, the workforce is relatively stable, and the pressure of social resettlement of laid-off workers is relatively small.
At the same time, the research report points out that the employment structure of textile industry will be changed. For labor-intensive textile enterprises, & ldquo; machine replacement & rdquo; will greatly reduce the proportion of front-line workers and optimize the personnel structure. Low-skilled and even part of skilled workers are replaced by robots, while the number of technical jobs in debugging, maintenance and control of robots will increase relatively.
& ldquo; machine replacement & rdquo; will put forward new requirements for labor skills. In the past, & ldquo; single labor, & rdquo; in the future, & ldquo; digital labor, & rdquo;We should include laid-off and unemployed people in the scope of employment and entrepreneurship services and related employment and entrepreneurship policies, identify employment needs, and strengthen targeted vocational guidance and career introduction.
afterword
- Far-reaching results can only be achieved by taking advantage of the situation-
Jie Xi Ping
In recent years, in order to alleviate the labor shortage and the rising cost of human resources in China's textile industry, & ldquo; machine replacement & rdquo; has become the general trend in some economically developed textile areas. Highly automated production has brought about the improvement of product quality and efficiency, the decrease of energy consumption per unit, and the saving of labor cost. At the same time, it has also created a new strong demand for highly skilled post operators, which has formed a phenomenon of coexistence in some enterprises: ldquo; reductions & rdquo; and & ldquo; finding people & rdquo; and so on. On the one hand, the number of front-line operators has been reduced, while the demand for all kinds of skilled personnel is urgent. As mentioned in the report, & ldquo; machine replacement & rdquo; will change the employment structure of the industry, and the number of technical posts will increase relatively, which will give rise to new employment space and development momentum.
This change brings us an enlightenment: the future of textile industry is bound to shift from labor-intensive to technology-intensive development. The industry should actively guide and accelerate the training and promotion of industrial workers to provide broad space for the development of employees; at the same time, it reminds the younger generation to change their ideas: the textile fashion industry in the intelligent age will be more competitive and attractive, and become a new gathering place to attract talents.