Since mid-April this year, every once in a while, a train full of cargo will depart from Yiwu West Railway Station to Ningbo Zhoushan Port, and then be connected by sea and sold overseas. The goods transported are not traditional small commodities in Yiwu, but photovoltaics.
Photovoltaics refers to products that use semiconductor materials to directly convert solar radiation into electrical energy. “The company’s Yiwu production base broke ground in May last year, and the module workshop was put into production at the end of September.” Wang Fanggang, the head of the digital information department of JA Solar’s (002459.SZ) production base in Yiwu, told the China Business News reporter. With the establishment of the Yiwu base, the company will connect its self-developed digital production management system “Jingleopard” and MES (Manufacturing Execution System) to Dingding, and will fully apply it to 40 production lines of JA Yiwu.
In March 2020, JA Solar Technology (002459.SZ) announced an investment of 10.2 billion yuan to build a photovoltaic intelligent manufacturing base in Yiwu. The project covers an area of about 700 acres, mainly for the construction of 10GW solar cells and 10GW solar modules. Not only JA Solar, but in recent years, Yiwu has introduced photovoltaic companies such as Aixu (600732.SH), JinkoSolar (JKS.NYSE), Trina Solar (688599.SH), and Orient Risen (300118.SZ). , Has formed a large scale of production capacity in the battery and component links.
The “Yiwu Photovoltaic Industry Development Plan” proposes that the overall strategic positioning will be to build a “bright capital of the world”. By 2025, the total output value of the photovoltaic industry will reach 100 billion yuan, and 5 leading enterprises with an output value of more than 10 billion yuan will be formed. , A group of growth-oriented enterprises with over 1 billion yuan.
Let data drive productivity
Digitization and intelligence have become a consensus for the improvement of enterprise production efficiency and automation.
A reporter from CBN recently saw at the second component factory of JA Yiwu production base that there are 14 automated production lines in the field, 38 AGVs (automatic navigation devices) realize automated logistics handling, and the operation of all production lines will be in the factory area. The area composed of large digital screens is updated in real time, including MES cockpit, AGV operation system, production grid management system Jingbao, hourly production capacity indicators, safety indicators, process flow introduction, real-time monitoring, etc.
Taking Jingbao as an example, if there is a problem in any process, the corresponding location on the visual map in the system will light up warning lights of different colors according to the type of failure, and give a warning of the severity of the failure at all levels. The blue light indicates that the fault affects the current position, the yellow light indicates that the fault affects the current production line, the orange light indicates that the fault affects the same position on all production lines, and the red light indicates that the fault affects all production lines.
Failures of varying degrees will bring losses to the production workshop. If the equipment or product failures in one position are not discovered in time, the products will automatically flow to the next production line, and continue to process the defective products until all processes are completed Only when it enters the quality inspection link will it be discovered as a product quality problem, which will cause waste and inefficiency in the production process.
In front of a screen inside the second component factory, the reporter can click on any production line section to view the operation status of the welding machine, stitch welding, lamination, rework, lamination, curing, testing and other areas at any time, and can display problems The location information, problem description, on-site photos, scope of influence, call scope, follow-up personnel and other information.
“What really troubles the manufacturing industry is to report for repairs, solve abnormal problems, and find the right person. A problem may require the assistance of multiple departments such as process, equipment, quality, IT, power, etc. The personnel attending different departments are constantly changing every day. Yes, the previous model was to find the right person, and then call or WeChat to make group communication. The cost of communication for companies is often higher than the cost of actual operations. Every day they call and look for resources. In fact, it is very short to solve a problem. Liu Haibo, the production supervisor of the second component plant of JA Solar’s Yiwu production base, told Yicai.com that there was a material problem during the night shift and the site could not be put into production. It involved multiple departments such as operation, quality, and craftsmanship. Everyone spent four After many hours of communication and confirmation, the production line has been at a standstill.
After the Jingbao system is launched, for example, the welding machine stops working, the welding machine itself has an operation interface that will report the abnormality. If the on-site personnel cannot analyze the cause and solve the problem, just take a picture and upload it to the alarm record. Will automatically match the corresponding personnel for processing.
In order to improve efficiency, JA Solar’s Yiwu production base integrates Jingbao on Dingding platform. Any abnormal production line will be reflected on Dingding in real time: the relevant person in charge will receive task notifications on the Dingding APP of the mobile phone. More than 3 Hours of production line exceptions will be pushed in the business group and reminded on the top. The relevant personnel can also open the corresponding fault alarms at any time on DingTalk, create a fault tracking group with one click, automatically associate fault problems, and pull in products that can handle related problems. Collaborative processing by line employees.
“These trouble tickets are all production black boxes that affect productivity and efficiency. The traditional way is to log in to a specific system to view abnormalities. Now Dingding robots will automatically push to the group, and Aite to specific people.” Wang Fanggang said.
In fact, China’s manufacturing industry generally has problems such as data lag and untimely response, which are prone to internal friction.
To this end, in August 2018, Yiwu City issued “Several Opinions on Promoting the High-Quality Development of the Real Economy (Trial)”. Among them, in order to accelerate the promotion of smart manufacturing, Yiwu has Its network software and hardware are subsidized at 30% of the actual investment, and the maximum is not more than 3 million yuan; its production equipment technological transformation subsidy standard is increased by 3 percentage points on the basis of the current policy. For those recognized as provincial and national intelligent manufacturing engineering projects (industrial strong base engineering projects, green manufacturing engineering projects, high-end equipment innovation engineering projects), 500,000 yuan and 5 million yuan will be given on the basis of the above subsidy policy. reward.