Manufacturing is the main body of the national economy, and it is the foundation of the country, the instrument of rejuvenating the country, and the foundation of a strong country. Since the reform and opening up, China's manufacturing industry has continued to develop rapidly and has built a complete, independent and complete industrial system. Today, China is the world's number one manufacturing powerhouse, with more than 200 industrial manufactured goods ranking first in the world. However, compared with the world's advanced level, Chinese manufacturing has always faced the problem of “big but not strongâ€. Automobile equipment, aero engines and other products rely heavily on foreign countries, and even a lot of production has long been the world's number one product, such as refills, stockings, etc., consumers are also eager to go abroad to buy.
The "Made in China 2025" issued by the State Council recently proposed that we should focus on improving quality and efficiency, and realize a historical leap from a big change to a strong manufacturing industry. From the big to the strong, what are the gaps in China's manufacturing? What is the cause behind the gap? Where should I focus? Starting today, this edition will launch a series of reports, from the phenomenon of enterprises and people around, to explore the direction and countermeasures of China's manufacturing from big to strong.
Swiss ABB seven-axis handling robot, Italy Coma welding robot, Japan Panasonic arc welding robot, Germany Nimak welding tongs... Into the Geely Ningbo Chunxiao factory, the most automated press line in China, composed of 112 robots Welding lines, the world's most advanced inspection system...all visitors are praised. However, in addition to the five eight-bar linkage mechanical presses produced by Jinan No. 2 Machine Tool, Shanghai Xiaoao's fixtures and several sets of domestic conveying equipment, the core equipment of Chunxiao Factory is almost all foreign high-end brands.
Chunxiao Factory is just a microcosm of China's automobile equipment relying heavily on “foreign brandsâ€. According to estimates, during the “Twelfth Five-Year Plan†period, China’s automobile equipment market was nearly 300 billion yuan, of which 70% of the key automotive equipment market share was occupied by foreign brands.
Purchasing "foreign equipment", domestic car companies have difficulties
“In order to make Geely Borui the highest level of self-owned brand mid-to-high-end cars, Chunxiao Factory not only competes with European-style joint venture vehicles in the level of product tooling, but also achieves luxury car standards in some processes.†CEO of Zhejiang Geely Automobile Group And President An Conghui told reporters that as the first iconic product of Volvo's anti-growth Geely, Geely Borui not only borrowed Volvo's design philosophy and technical standards, but also spared no expense in the construction of the factory.
“Equipment, tooling (including molds, fixtures, etc.) and management are great tools to improve the manufacturing process of the whole vehicle. Among them, the stability and precision of the equipment are the premise and basis. For this reason, Chunxiao Factory has to use a large number of foreign high-end equipment. Ling Shiquan, general manager of Geely Automobile Chunxiao Base, takes the welding workshop as an example. Geely Borui has a complex body structure. In order to ensure the strongest body rigidity, the total number of welding points of the car is more than 5,700, which is higher than that of the German car company. A large number of high-tensile steel plates and double-sided galvanized plates of 270 MPa or more are used. The ordinary domestic welding tongs can not meet the technical requirements, and only the German Nima welding tongs can be used.
The Chunxiao factory also encountered the same problem in the selection of handling robots in the press shop. As the person in charge of the major special project of stamping automation of the Ministry of Industry and Information Technology, Ling Shiquan once worked together with domestic equipment companies such as Jinan No. 2 Machine Tool and Beijing Automation Research Institute. “The research team has repeatedly visited domestic robot companies. The domestic handling robots can't meet the design requirements in terms of load capacity, repeatability and control stability.†Ling Shiquan said that this is also the final choice of ABB seven-axis handling robot in Chunxiao factory stamping workshop. Cause.
Coincidentally, SAIC General Motors also considered domestic brand welding robots a few years ago. Jia Yongquan, manager of SAIC GM Shenyang Beishengyu body shop, told reporters that they conducted in-depth inspections on domestic brand welding robots. The evaluation results are good in accuracy and reliability, but because the key components depend on imports, the price is 70 higher than foreign products. %—80%.
Breaking through the “blockade lineâ€, the big challenge needs to be dealt with
Into the Jinan Second Machine Tool Assembly Workshop, nearly 20 stamping production lines will be delivered, and the tall and spacious workshop will be crowded. The "US Ford CP7" assembly work list hanging on a press that is being tested has attracted the attention of reporters. It is the seventh fully automatic fast press line that will be delivered to the Ford Detroit facility.
“Since 2011, Ji Er has successively won orders for eight large-scale fast press lines from Ford's US factory, six of which have been put into production. Previously, Ford stamping equipment has always been the world of German brands.†Director of Jinan Second Machine Tool Group Co., Ltd. Chang, general manager Zhang Zhigang told reporters that in the country, Ji Er also took over the "position" of the past multinational companies. Since 2010, the domestic market share of the large-scale rapid press line of Ji'er has exceeded 80%, and it has equipped almost all independent auto companies and joint ventures such as the US, Germany, Japan, France and Italy.
The domestic automotive welding robot market, which has been monopolized by international giants such as ABB and KUKA for 30 years, has now appeared in Anhui Efte. It is reported that the welding automation production line using nearly one hundred Eft industrial robots has been running smoothly in the sixth plant of Chery Automobile for more than two years.
However, domestic auto equipment companies have really broken through the “blockade line†of multinational companies, and they still need to cope with the big challenges. One of the challenges is that the core components have long been dependent on imports, which has greatly increased the cost of domestic equipment. Take the 165 kg six-axis joint robot as an example. At present, the total cost of foreign products is about 169,000 yuan, and the cost of domestic robots is as high as 299,000 yuan.
The second challenge is technical iteration. “Ji Er’s eight-bar linkage mechanical press is in line with the world’s leading level of fast-moving double-handed lines.†Ling Shiquan said that in order to counter the Chinese brand, foreign companies have launched servo presses in recent years, focusing on energy-saving cards and stealing some orders. . Although a joint research and development, a servo press developed by Jiji has been put into use in Guangzhou Automobile passenger car, but the cost of imported servo motor is high, spare parts are difficult, service response speed is slow, and the whole line control technology needs to be improved. There is still a gap between the comprehensive competitiveness and foreign products.
The acceleration of the localization of the full value chain by multinational corporations is the third challenge facing domestic equipment companies. Gu Chunyuan, chairman and president of ABB (China) Co., Ltd., said that in 2005 ABB set up a robot R&D center in Shanghai and the only spray robot production base in the world. Up to now, ABB has realized the localization of industrial robots from R&D, production, sales, engineering, system integration to customer service full value chain. It is reported that the robot factory invested by KUKA and Yaskawa Electric in China has also been put into production. Localization has not only significantly reduced the cost of foreign brands, but also the short-term response to slow after-sales service.
Support the "first set", policy escort should be added
"To break through the market monopoly of high-end equipment of multinational corporations, it is inseparable from the independent research and development of the company for two years, and it is also inseparable from the strong support of enterprises such as Guangqi Honda and SAIC General Motors for their own equipment." Zhang Zhigang said with emotion.
Ji Er has always been proud of his fast-pressing lines with his arms. The first "eat crab" is SAIC General Motors. Zhao Jinrong, deputy general manager of Jinan No. 2 Machine Tool, said that the No. 4 press line of SAIC-GM Dongyue Factory, which passed the acceptance in October 2010, was the first full-time contractor for the system integration. “At the time, due to the problem of matching the Siemens motor and the drive, the commissioning time was extended, but SAIC General Motors still firmly supported it, and handed the order for the No. 5 press line to Jiji shortly after the acceptance.â€
"On the premise that technical standards, quality, reliability are not reduced, and costs are not increased, we certainly hope to drive the domestic equipment industry technology level." Wang Xiaodong, executive vice president of SAIC General Motors Manufacturing Engineering, said Dongyue No.4 After the problem of debugging the line, the pressure on the company was also great. SAIC General Motors not only gave the time for the rectification of Jiji, but also mobilized relevant experts from GM and Siemens and other suppliers from Siemens to solve the problem.
Of course, the rise of domestic equipment is entirely hopeful that a responsible user will give the stage and give the opportunity, which is not realistic. The relevant person in charge of the Ministry of Industry and Information Technology said that users, especially decision-makers, have more concerns about the first set of equipment, fearing that design and manufacturing will not meet technical requirements, affecting normal production, and being held accountable; in addition, there are discriminatory provisions and "hidden rules" in bidding. "Phenomenon, etc., also made the first set of equipment in a disadvantaged position in the market competition for a long time.
The implementation of the first pilot of major technical equipment insurance compensation mechanism will undoubtedly accelerate the promotion and application of major technical equipment. In this year's "First (set) major technical equipment promotion and application guidance catalogue" forming processing equipment, industrial robots, dual-beam laser welding equipment, large-scale full-servo automatic stamping production lines are all in the line, which means adoption The “first set†of major equipment enterprises can insure relevant insurance, and in the three-year pilot period, the central government will subsidize at a rate of no more than 3% and 80% of the annual premium.
“Last year, SAIC-GM's Wuhan plant ordered a Jiji full servo line in the second phase, and put it into production in 2017. This is the first set of domestic large-scale full-servo automatic stamping production line.†Wang Xiaodong said that this line is completely in line with the country. The first set of major technical equipment insurance compensation pilot requirements, Ji II has been in contact with insurance companies.
"We look forward to the first set of pilots to land as soon as possible, and hope that the state will give more encouragement and support to enterprises supporting domestic equipment." Zhang Zhigang said.
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