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Jihua 3542: Strengthening The Chain To Promote The High Quality Development Of Xiangyang Textile Industry

2021/4/3 11:52:00 0

Jihua 3542Strengthen ChainXiangyang TextileHigh Quality Development

-- Xiangyang supply chain innovation and application excellent enterprise practice case

Jihua 3542 Textile Co., Ltd. (hereinafter referred to as "Jihua 3542" or "the company") is located in Xiangyang City, Hubei Province. Founded in 1987, Jihua 3542 Textile Co., Ltd. is a large-scale textile and home textile enterprise invested and built during the Eighth Five-Year Plan period. It ranks 36th in the list of top 100 competitive enterprises in the national cotton textile industry in 2019. Since Xiangyang City was approved as a national supply chain innovation and application pilot city in October 2018, under the guidance and support of the municipal Party committee and government, Jihua 3542 has actively participated in the urban pilot work, actively acted and took various measures simultaneously. Through vertical integration of industrial chain, strengthening R & D innovation, implementing industrial base upgrading, promoting green and global development, the textile industry of Xiangyang has been promoted Quality development provides an excellent enterprise practice case for Xiangyang supply chain innovation and application pilot work.

-- vertical integration of industrial chain to improve the "printing and dyeing short board" of Xiangyang textile industry

The textile industry chain of Xiangyang City is relatively complete, covering the subdivisions of lint processing, chemical fiber, spinning, weaving, printing and dyeing, clothing, home textile, shoes and hats, accessories and industrial textiles, with a total output value of more than 60 billion yuan, ranking first in Hubei Province, province and Prefecture for many years. However, at the same time, there are some problems such as unbalanced industrial structure and low added value. The industrial structure is "top heavy". The output value of yarn and grey fabric at the front end accounts for more than 80%, but most of them are sold to Guangdong, Zhejiang, Jiangsu and other places as semi-finished products; the back-end clothing and home textiles need to be purchased, which has stagnated for many years, accounting for only 11.5%. The city produces 800000 tons of yarn every year, less than 12% of which are locally woven into cloth, and less than 18% of which produce 2 billion meters of grey cloth. Xiangyang printing and dyeing short board problem is very prominent. Dyeing and finishing is one of the most prominent technical barriers in the textile and garment industry chain. Due to the limitation of environmental capacity and the poor management of printing and dyeing factories, before the pilot work, the production level of Xiangyang dyeing and printing link was relatively backward, and the technology and products were not closely connected with the market. The operation of printing and dyeing enterprises was facing difficulties, and it was urgent to make up the weakness of the industrial chain.

Deeply aware of the great driving effect of printing and dyeing on the textile industry, Jihua 3542, as one of the leading enterprises in Xiangyang textile industry, absorbed and merged Hubei Jihua new four five printing and dyeing Co., Ltd. on November 28, 2018, which not only completed the establishment of the whole industrial chain of spinning, weaving, printing and dyeing, and home textile products, but also became one of the few total products in the cotton textile industry Industry chain textile enterprises, at the same time, enhance the "printing and dyeing short board" of Xiangyang textile industry.

After the merger, Jihua 3542 adopted the innovation driven strategy, increased R & D investment, established the "printing and dyeing engineering technology research center", and developed 16 new printing and dyeing products. The project of "complete set of digital automatic dyeing technology and equipment" has achieved digitalization and system automation of the whole process, reduced production costs and improved the intelligent level of printing and dyeing links through three major innovations in dyeing process, equipment and system. The project won the first prize of national science and technology progress. In addition, extensive use of new materials, reduce production costs, improve the level of green printing and dyeing. Among them, the low-temperature refining agent with new materials is used in the printing and dyeing process, and the energy consumption and cost of pretreatment can be saved by more than 30%; the reasonable high sunlight disperse dyes can ensure the sunlight fastness and reduce the cost by more than 5%; the appropriate waterproof agent can reduce the production cost by more than 10%. By 2020, the revenue of functional printed and dyed fabrics has accounted for about 25% of the total operating revenue of the company.

-- strengthen R & D and innovation to create a new engine for enterprise development

Jihua 3542 implements the innovation driven development strategy, actively builds a scientific and technological innovation platform, carries out industry university research cooperation, develops new materials, new processes and new products, and creates a new engine for enterprise development.

Jihua 3542 has nine science and technology innovation platforms, including two national level scientific and technological innovation platforms, including "national enterprise technology center", "postdoctoral research station", Hubei provincial high-tech high-density and high-grade home textile fabric Engineering Technology Research Center, Hubei Key Laboratory of new environmental protection composite surface material, and lake of functional fiber application and high-quality textile production technology There are four provincial-level scientific and technological innovation platforms, including the North provincial engineering research center, the new environmental protection composite fabric industrial design center, and three municipal scientific and technological innovation platforms, including academician expert workstation, home of scientific and technological talents, and printing and dyeing engineering technology research center.

Since Xiangyang City pilot work was carried out, the company has invested more than 90 million yuan in science and technology in two years, accounting for more than 4% of the main business income. A total of 25 science and technology projects have been implemented, more than 500 new products have been developed and more than 40 traditional processes have been innovated. Among them, 26 kinds of new materials were used; 173 new varieties of yarn, 164 new varieties of grey fabric fabric, 16 kinds of new printing and dyeing products, 96 kinds of new sample processing styles of home textile were developed (more than 20 models were put into production); 98 times of innovation in sizing technology were carried out, and 181 times of home textile process identification were completed.

With its leading R & D capability, perfect quality assurance system and advanced equipment and technology, Jihua 3542 has created seven series of famous brand products, which are respectively rated as "best-selling products in China market" and "famous brand products in Hubei Province". The yarn quality level reaches the level of 5% - 25% of the 2019 Uster report; the grey cloth can achieve 1800 pieces / inch 2, which is in the international leading level.

In addition, from 2018 to 2020, a total of 331 patents were applied, including 142 invention patents; 23 national, industry, group and local standards were presided over or participated in.

-- upgrade the industrial base and realize the transformation from "manufacturing" to "intelligent manufacturing"

Jihua 3542 has upgraded its industrial base, introduced international advanced equipment, built an information management system, and combined with information technology such as the Internet of things, realized the transformation of production mode from "manufacturing" to "intelligent manufacturing".

The company adheres to the concept of using the best equipment to produce the best products, takes intelligent manufacturing as the development direction, pays attention to the introduction of international advanced equipment, vigorously promotes the upgrading and transformation of spinning, weaving, printing and dyeing, finishing and home textile equipment from automation to intelligent and humanized, and establishes an intelligent manufacturing demonstration line covering the whole production process, which greatly improves the production efficiency and quality stability Sex. Among them, the spinning factory has realized automatic combing roll changing, roving automatic doffing, coarse and fine coupling, fine winding, spinning automatic doffing, bobbin automatic tube changing and automatic packaging scanning and warehousing, etc.; the printing and dyeing factory implements the project of "digital automatic dyeing complete set technology and equipment", and realizes the whole process digitization and system automation through three major innovations of dyeing process, equipment and system The project has won the first prize of national science and Technology Progress Award; the weaving factory has improved the production efficiency by introducing international advanced warping machine, sizing machine, automatic reeding machine, high-speed air-jet loom, APR automatic weft finding system and modular hanging machine system; the finishing factory has realized the intellectualization of semi-finished rapid winding inspection through the automatic winding machine system; the home textile production factory has introduced the full-automatic Iraq The application of CAD design system and home textile ERP system ensures that the development, design and production of home textile products are more accurate, efficient and fast.

Jihua 3542 has 479 sets of high-speed air-jet looms, with an average of 80 online varieties every day. There are many models, varieties, and many modified sets, which lead to the problems of equipment management, variety quality traceability, output copying workload and labor cost. Based on this situation, the company has carried out an integrated application project based on online monitoring of weaving equipment and ERP system. The project adopts Internet, Internet of things and other information technologies, integrates ERP system, online monitoring and acquisition system, intelligent textile equipment, and builds an integrated management and control information platform. The project has completed the development and application of online monitoring and acquisition system of weaving department, networking monitoring system of air compressor, temperature and humidity acquisition system of workshop, electric energy centralized reading system, ERP contract review and order scheduling system. It is committed to building a digital workshop, promoting intelligent production, making R & D and design networked, production process automation and intelligent, and management process informatization, realizing the transformation of production mode from "manufacturing" to "intelligent manufacturing", improving the comprehensive competitiveness of enterprises and promoting the overall technical level of the industry. The results of the project are at the leading level in the industry and won the first prize of scientific and technological innovation achievements of China Equipment Management Association.

After the successful implementation of the project, it provides necessary information technology support for enterprises to achieve fine management. The product process design cycle is shortened by more than 30%, the trial production cycle is shortened by more than 30%, the production scheduling capacity is increased by more than 30%, the order receiving review cycle is shortened by more than 50%, the accuracy and punctuality rate of planning are greatly improved, and the loom opening efficiency is improved; the product production rate is increased by 2% on average, the sizing cost is saved by 0.02 yuan / m, the annual power saving is 3.5%, and the annual labor cost is reduced by 2 million yuan Now order profit maximization, achieve lean production.

-- promote green development and improve the level of green supply chain in industrial chain

Implement the green development strategy, through R & D and innovation, vigorously use green materials and green technology to improve the level of green supply chain of the whole industry chain.

In 2018, Jihua 3542, as the leading unit of the project, combined with upstream and downstream enterprises and scientific research institutions, formed an integrated enterprise, University, research and application, and undertook the construction project of functional textile green design platform of the Ministry of industry and information technology of the people's Republic of China in 2018. The expected objectives of the project are: (1) to establish a green standard system. Improve the functional textile green design and evaluation system, improve the industry green design integration and evaluation standardization, formulate one green factory standard and two green design product evaluation standards; (2) use information platform as a tool to realize data integration. Promote the construction of life cycle data resources of functional textiles, break through the data bottleneck in the process of green design and evaluation; (3) realize technology breakthrough and application. Break through the key technology of functional textiles, complete the research and development of spinning, weaving, printing and dyeing and finishing technology, form a batch of core technologies and intellectual property rights, open up the whole set of spinning weaving dyeing process, establish green manufacturing industry demonstration line of new functional textile products with green environmental protection, energy conservation and consumption reduction, and verify green design technology; (4) promote green design products. Develop 7 kinds of green design products to enhance the international competitiveness of China's functional textiles. The green target of the project: the green rate of manufacturing technology is increased by 24.7%, the greening rate of manufacturing process is increased by 27.9%, and the environmental impact of green manufacturing resources is reduced by 18.2%.

In addition, through the application of new green technology and new materials, Jihua 3542 realizes ecological manufacturing, improves production efficiency, reduces production cost and reduces environmental pollution. The benefits of some new processes are as follows: (1) energy saving and short process green desizing process. It is estimated that the new process can save 50% energy compared with the original process after the full implementation of the process. (2) Low salt, low alkali dyeing process. The low salt and low alkali dyeing process of modified cotton fabric with medium temperature reactive dyes can reduce the amount of neutral electrolyte and inorganic alkali at the same time, and the dyeing temperature can be reduced by 10 degrees. Moreover, the dyed fabric has the advantages of higher color fastness and dyeing reproducibility, and can also solve the environmental pollution problems caused by the traditional high salt dyeing process with reactive dyes. (3) New technology of foam finishing. The process can not only meet the requirements of functional finishing, but also reduce the amount of chemicals by more than 40%. Due to the low liquid content of the product, the energy consumption can be reduced by about 50% during fabric drying.

- "bring in, go out" to build global supply chain

Jihua 3542 implements the globalization strategy, continuously optimizes the industrial layout, improves the global resource integration ability, actively responds to the Sino US trade friction, develops new comparative advantages, expands the global market, and constructs the global supply chain. The company's comprehensive management level and business performance have been continuously improved.

In order to meet the needs of production orders and achieve differentiated product management, Jihua 3542 makes full use of the advantages of international market resources, imports international raw materials directly, realizes the complementarity and combination optimization of international and domestic production factors, and promotes the healthy and sustainable development of the company's overall production and operation. Overseas purchasing markets mainly include the United States, Australia, Egypt, Brazil, Mexico and Israel, and the products purchased are lint. Among them, the purchase proportion of the United States accounts for more than 50%. In 2019, the company imported 1500 tons of cotton, with a total import amount of 3.78 million US dollars; in 2020, the import quantity was 1836 tons, with a total import amount of 4 million US dollars.

The company's export markets are mainly distributed in North America, Europe, the Middle East, Australia, India, Pakistan, ASEAN countries and Russia. Since the United States started the trade war in 2018, the company has actively and effectively explored overseas markets through overseas market layout adjustment, participating in overseas exhibitions and conducting target market investigation. It has achieved results in Southeast Asia, Australia, South America and European markets. The proportion of exports to the United States has gradually decreased from 80% to about 50%. The next step will focus on and Efforts should be made to develop the markets along the belt and road.

Next, Jihua 3542 will continue to ride the wind and waves, take the industrial chain logic and supply chain thinking as the guidance, strengthen innovation, opening up and collaboration, give play to the leading role of leading enterprises, and further improve the development level of Xiangyang textile industry chain supply chain.

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