In order to implement the " Opinions of the Central Committee of the Communist Party of China and the State Council on Supporting Pudong New Area's High-level Reform and Opening Up to Build a Leading Area for Socialist Modernization", Pudong New Area launched the Industrial Digitalization Jump Plan ( GID ). According to the plan, by 2025 , Pudong will cultivate 30 chain-owner enterprises, build 10 digital platforms, build 100 smart factories, gather 100 digital service providers with industry influence, and drive the digital transformation of 1,000 enterprises.
From port machinery to automobile manufacturing, from ships to aircrafts, enterprises in Pudong are undergoing digital transformation according to the actual conditions of different industries.
Zhenhua Heavy Industry: Digitalization of Heavy Equipment
Since 2015 , Zhenhua Heavy Industry has carried out technical exploration of digitalization of discrete robot welding process in its smart factory. Yu Xiping, deputy director of the Process Design Institute of Zhenhua Heavy Industry Design and Research Institute, introduced that the structure of large-scale box girders is complex, the space is limited, and there are many welding positions. It is very difficult to realize autonomous welding by robots. The application of box girder intelligent workshops involves offline programming of robots, etc. technology.
For off-line programming of robots, fast programming, verification and import of robot welding programs are realized. The robot directly calls the offline editing software, and the welding programs after offline teaching and simulation can be modified, and the programs on the memory or generated by the offline software can also be modified. The program performs program management, program transformation (translation), etc., which effectively solves the problems of long online programming time of the robot and collision with components. The welding positioning of the robot is precise and the weld seam is well formed.
After the construction of this scene is completed, the programming time of each box component is shortened from an average of 8 hours to 5 hours, the programming efficiency is increased by about 40% , and the production capacity of the entire box girder workshop is increased by 30% .
Yu Xiping believes that at the product level, smart factories need to convert product data at the design end into process data at the manufacturing end, ultimately guide on-site manufacturing, open up the data flow from design, process to manufacturing, and create an integrated data platform for design, process and manufacturing.
In fact, the digital factory for box girder manufacturing is only a part of ZPMC's digital transformation. Zhenhua Heavy Industry has also built a digital and intelligent global maintenance service platform for port machinery spare parts, and an intelligent dispatching platform for the Internet of Vehicles. On the market and sales side, ZPMC’s digital intelligent port machinery spare parts global maintenance service is one of its digital value-added services.
"The ultimate goal is to reconstruct the value chain of the port machinery equipment industry from multiple dimensions such as design, manufacturing, operation, and after-sales, and realize the transformation and upgrading of port machinery equipment from product manufacturing to digital, intelligent, and service-oriented." Zhenhua Heavy Industries Yang Yuhua, general manager of the Science Technology and Digitalization Department, said.
Yanfeng: Leading the Demonstration in the Digital Factory of the Automotive Supply Chain
As the base camp of smart manufacturing in Pudong, Jinqiao Automobile Industry Smart Factory is a microcosm of the transformation and upgrading of the manufacturing industry to "smart manufacturing". Here, the two smart factories of SAIC-GM Cadillac and Yanfeng Automotive Interiors Jinqiao Factory serve as typical demonstrations, leading the pace of digital transformation of my country's automobile manufacturing and supply chain.
"Digitalization is always a means, and the key is to step on every point of the industry." Xu Tingjie, head of Yanfeng Intelligent Manufacturing Planning, believes that the most fundamental driving force for the improvement of digital capabilities in automobile manufacturing comes from market demand. Especially in recent years, the latest emerging car manufacturers have put forward strict requirements on suppliers' data delivery capabilities such as product quality testing, inventory, and delivery cycles. The delivery cycle of some products has been shortened from one year to four months.
In Yanfeng's smart factory in Jinqiao, a product rolls off the production line every 45-60 seconds. All the different technological processes of each product from purchase to shipment can be freely scheduled and clearly displayed. once a Yanfeng customer needs to know the order status, Yanfeng can connect the order logistics, inventory, delivery cycle and other data to the customer under the condition of consensus. If there is a quality problem, the detailed information on the production and processing of the product can be traced back through the QR code.
"Transfer the right data to the right people and equipment in the right way at the right time." This is the experience of Yanfeng's digital transformation. "Digital tools are essentially inseparable from the concept of lean manufacturing." Xu Tingjie said that the so-called lean manufacturing is to minimize the resources occupied by enterprise production and reduce enterprise management and operating costs as the main goal.
Digital twin technology is a new direction for digital transformation of smart factories
Digital twin technology can realize two-way data interaction and is regarded as a new direction for the digital transformation of smart factories. It is like a "digital sand table", which gathers various isolated data systems on one platform, and the ultimate goal is to allow data to flow and interact across systems more, faster, better and more economically.
Pudong enterprise Liangfengtai, which uses augmented reality ( AR ) technology in the industrial field, believes that with the support of technologies such as AR and digital twins, seamless connection and interaction between the digital world and the physical world data can be realized.
