From "Cotton" To Cotton Spinning, From Weaving To "Intelligent Manufacturing", How Will The Intelligent Development Of China'S Textile Industry Be?

At the end of the industrial safety series in March, the fourth phase of April will focus on industrial intelligence to see how manufacturing can upgrade to "intelligent manufacturing" from the perspective of different industries.

As an important part of manufacturing industry, the rise and fall of textile industry is closely related to people's livelihood security, which directly affects people's basic living needs.

This week, we will use the textile industry to open the "China's Intelligent Manufacturing" series: starting from the cotton textile industry and taking textile printing and dyeing as an example, we will explore the future development of the upgrading of "intelligent manufacturing" of textile.

　　01、 Xinjiang cotton, favored by sunshine, is the foundation of China's cotton textile industry

Recently, some foreign brands have published false statements that maliciously slander Xinjiang cotton, so the topic of "Xinjiang cotton" has aroused widespread concern in the society. This series of rumors, not only some brands do not have a clear understanding of their own brand, and force the chemical fiber fabrics such as "polyester fiber" used by their own brands to seek a sense of existence in Xinjiang cotton, the deeper reason is that some countries are unwilling to take the lead in China's cotton textile industry and then lead to market crowding.

China is a big cotton textile industry in the world. As the main cotton production area in China, Xinjiang has a long sunshine time and unique natural conditions suitable for cotton growth. It not only produces high quality cotton, but also is the only long staple cotton production area in China. Xinjiang long staple cotton, together with Egyptian cotton and horse long staple cotton, is well-known in the world.

According to official statistics, China's cotton output will be about 5.91 million tons in 2020, of which, Xinjiang's cotton output will reach 5.161 million tons, accounting for 87.3% of the total cotton output in China and 20.8% in the world. By the end of 2020, Xinjiang's total cotton yield, unit yield, planting area and commodity allocation have ranked first in China for 26 consecutive years. Now, in the sparsely populated Xinjiang, the cotton industry has long been highly mechanized. According to statistics, by 2020, there will be about 4800 cotton pickers for picking, and the mechanization level of cotton picking will reach more than 80%.

As the world's largest cotton consumer and the second largest cotton producer, Xinjiang cotton with high quality and large output is the foundation for the vigorous development of China's cotton textile industry. It can be said that "the world's cotton looks at China, China's cotton looks at Xinjiang"!

"One cotton", from the cotton field to the cotton mill, completes the transformation of form and realizes the regeneration of value. Xinjiang cotton not only promotes the local agriculture to upgrade towards automation and mechanization, but also attracts a large number of cotton textile enterprises by virtue of its advantages of origin, thus driving the overall development of local economy.

　　02、 From "weaving" to "intelligent manufacturing", the textile industry needs to be upgraded

China's textile industry has the most complete industrial chain and the most complete categories. The "Xinjiang cotton" mentioned above is the main raw material of the cotton textile industry, and other textile categories with hemp, silk, chemical fiber and wool as raw materials are also included. Textile is not only the largest traditional industry in China, but also a characteristic advantage industry with a long history. No matter the "Silk Road" in the Western Han Dynasty or the "belt and road" today, textiles are important commodities in circulation.

After years of development, the textile industry has become one of the five leading manufacturing industries in the world. Different products have significant competitive advantages in the international market. According to statistics, by 2020, China's total fiber processing accounted for about 50% of the world's total, chemical fiber production accounted for about 70%, and total export accounted for about one-third, which had a great impact on the international textile market.

However, manufacturing power is not equal to manufacturing power. As a typical representative of the traditional manufacturing industry, most textile enterprises are facing the same industry dilemma: complicated process, many ineffective processes, inefficient production scheduling, difficult personnel management and control, difficult progress tracking, etc. With the advent of industry 4.0 era, the application of Internet of things, big data and other technologies in industrial production is becoming more and more popular. For the textile industry, actively using high-tech to make up for the production shortage, optimize the production process and improve the production management and control system can accelerate the upgrading of "intelligent manufacturing", which is the necessary means for the industry to adapt to the development rhythm of the new era.

Of course, in the process of upgrading and transformation, there are a variety of optional technologies, among which "extracting location data of production factors for reprocessing" is an important application of location-based Internet of things technology.

In the field of location-based Internet of things for many years, four phase technology provides one-stop location information service for different industries: it uses high-precision positioning system to obtain the location information of production factors, connects production factors through emapneng constant trace TM geographic information system engine, and realizes processing and analysis of location data of different production factors by emapneng constant trace TM analysis engine, so as to help enterprises achieve the goal of Automatic scheduling and decision making of production process.

　　03

Production capacity increased by 20%, four phases help textile printing and dyeing upgrade "intelligent manufacturing"

In the textile industry with complex process, different processes face different problems. For example, printing and dyeing process, as an important part of the textile industry chain, plays a key role in improving the added value of textiles and driving the overall development of the clothing industry. Facing the global textile printing and dyeing Market, Chinese products have great market competitive advantages.

However, according to our industry research data and feedback from customers, the textile printing and dyeing industry still has the following problems restricting its development at this stage:

There are thousands of material transfer trucks, each of which stores different raw materials and finished materials. Production often consumes a lot of time in searching for the corresponding material truck, which affects the production line efficiency;

The daily order task is heavy, and there is no corresponding automatic supervision and analysis system for whether the current materials in each processing station are correct;

Due to the lack of data support for production schedule and time management, the production process can not be visually controlled.

Up to now, Sixiang has reached project cooperation with many printing and dyeing enterprises to provide customized solutions on demand. Taking a large printing and dyeing factory in Zhejiang Province as an example, four phases has built a printing and dyeing production scheduling logistics tracking system based on high-precision positioning technology: through the production scheduling Kanban system, the rapid search system of material vehicles, the binding and unbinding of material vehicles and materials, and the information output of finished cloth vehicles, the printing and dyeing production scheduling, production efficiency and location IOT technology are integrated The production scheduling and logistics management system of the plant is automatic and intelligent, which can effectively save manpower, material and financial resources. The case of the company has also become an influential Benchmarking Project in the smart printing and dyeing industry.

Logistics tracking system of printing and dyeing scheduling

On site shooting of the project

System interface display

Some functions

Rapid vehicle search: through the four phase high-precision UWB positioning system, the time of thousands of material vehicles is compressed to less than 1 minute on average;

Automatic production scheduling: the positioning system is connected with the dispatch system to automatically dispatch orders according to the real-time status of the material vehicle, so as to improve the utilization rate and production efficiency of the material vehicle. When there are important emergency orders, the management personnel can issue instructions in the system to change the order of the orders according to the actual requirements;

Process confirmation: with the cooperation of vehicle label and regional electronic fence, the automatic matching of material vehicle information and processing logistics information of work order can be realized, and the correctness of logistics can be automatically confirmed to ensure the rapid and orderly production process;

Early warning and warning of transfer error: if the material vehicle is transferred to the destination or transportation route or sequence is wrong, the process confirmation system will give an alarm automatically, so as to avoid the error of some orders requiring special process and process processing, and reduce the loss of the factory.

For the whole textile industry, how will the intelligent transformation develop during the "14th five year plan" period? The latest government work report has given a clear direction:

Strengthen the application research and development of common key technologies of intelligent manufacturing such as industrial Internet, artificial intelligence, industrial robots and big data, and solve the key technical problems in key equipment, intelligent workshop / factory and intelligent service system of textile intelligent manufacturing;

Vigorously promote the construction of chemical fiber intelligent factory, unattended ring spinning factory, short process spinning intelligent factory, intelligent weaving production line, knitting digital workshop, printing and dyeing digital network chemical factory, non-woven intelligent factory, clothing and home textile intelligent factory;

Accelerate the development of textile intelligent manufacturing system integrators, establish effective innovation consortia, promote collaborative innovation of cross domain enterprises such as special equipment, automation, software and information technology, and form an intelligent manufacturing development ecology in which leading enterprises advance and a large number of "specialized and special" enterprises deeply participate.

In the future, according to the development direction of smart textile, Sixiang technology will give full play to its own technical advantages, deeply integrate the location information system into different textile production processes, and assist the factory to realize the lean production management of all factors and space-time, and complete the comprehensive upgrading from "weaving" to "intelligent manufacturing"!

Data sources:

1. Tian Xiaoming's cotton production theory and modern cotton planting technology in Xinjiang

2. China Statistical Yearbook

3. Statistical bulletin of the people's Republic of China on national economic and social development in 2020 issued by the National Bureau of Statistics

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