Automation revolution of the hottest sanitary ware

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The automation revolution of a bathroom enterprise

after seeing off several workmates who had worked together for 8 years, Luo zhaoqiu (a pseudonym) seemed a little lost. This was the second batch of workmates he had sent away in half a year. In the glaze spraying workshop of Foshan Faen Sanitary Ware Co., Ltd. (hereinafter referred to as Faen sanitary ware), where he works, the number of employees has decreased by 2/3 in the past year

not only in the glaze spraying workshop, but also in other corners of this sanitary ware enterprise, a revolution of machine generation is being staged at the same time. Since the high-pressure grouting robot was imported in 2010 and the glaze spraying robot was imported in 2011, farn sanitary ware has started the dream chasing journey of the machine generation

when the time is approaching 2015, this sanitary ware enterprise has nearly completed the automation transformation of key production processes, and is now moving towards the goal of automation transformation of the whole production process. Behind this, getting rid of dependence on imported robots and focusing on localization of robots has become a clear path for enterprises

machine generation impulse

driven by profit seeking instinct and society

farn sanitary ware took the lead in applying robots to automatic production in the glaze spraying process, which is not only from the profit seeking instinct of enterprises, but also to meet the increasingly stringent environmental protection requirements and safety production requirements

on December 26, 2014, in the farn sanitary ware glaze spraying workshop in Gaoming Cangjiang Industrial Park, three robots clearly extended their arms. Only one handling robot sent the ceramic embryo that had been dedusted and wiped dry water into the glaze spraying room through the automatic transmission belt, and the other two glaze spraying robots then carried out glaze spraying, dust removal, cleaning, recycling and other processes, and one ceramic embryo completed the glaze application

the whole process takes less than 1 minute, which used to take 20 minutes or even longer by manual operation. Huozhuopung, deputy director of the general manager's office of farn sanitary ware, said that such a production line with three glaze spraying robots can spray glaze on up to 1000 ceramic tiles a day, while the manual glaze spraying cabinet with two workers can only spray 80 products a day

the improvement of production efficiency is only one of the driving forces of Faen sanitary ware application automation production line, and the other main driving forces are the improvement of product quality and the reduction of production costs. Huozhuopung said that the use of glaze spraying robots instead of manual work makes the glaze thickness of products uniform and the qualified rate high, which largely avoids the quality problems caused by manual errors. For example, the waste rate of glaze spraying process in many ceramic sanitary ware enterprises is 3% and 6%. Using glaze spraying robots can achieve zero waste rate and save about 10% of glaze volume, which alone can save about 800000 yuan a year

more importantly, after the replacement of machines in the glaze spraying process, each glaze spraying production line can save 2/3 of the manpower. This will allow enterprises to expand in the case of insufficient production capacity caused by difficulties in recruiting other enterprises, and allow enterprises to have enough confidence to accept large orders. Huozhibiao, director of arrow brand sanitary ware general office, said: Although the one-time investment in using glaze spraying robots is relatively large, it will bring rich returns in reducing staff costs and improving product excellence. It is expected that the cost will be recovered in one and a half to two years

arrow brand sanitary ware and farn sanitary ware are two brands of the same enterprise group, and Huo Zhibiao is in charge of the market promotion of the two brands. He said that after obtaining stable operation experience in Gaoming factory, the glaze spraying robot will be extended to other factories of the company distributed all over the country

in fact, farn sanitary ware took the lead in applying robots to automatic production in the glaze spraying process, which is not only from the profit seeking instinct of the enterprise, but also to meet the increasingly stringent environmental protection requirements and safety production requirements to make its physical properties different from metals

it is reported that glaze spraying is a very important process in the production of sanitary ware ceramics. In the past, manual glaze spraying would produce a large amount of dust, which would not only affect the environment, but also lead to occupational diseases such as pneumoconiosis. Occupational diseases have serious consequences for employees and enterprises. Robots can prevent this risk, which is very touching to us. Huo Zhibiao said that the improvement of enterprise automation level has an obvious effect on cleaner production and safety production, and is conducive to the harmonious development of employees and enterprises, enterprises and the environment, brands and society

Luo zhaoqiu has direct experience in this regard. In the past, the mask, hair and work clothes would be covered with a thick layer of white smoke after manual glaze spraying in one morning. Now, with robot glaze spraying, we just do some auxiliary work, and the work clothes are very clean at the end of the day

based on the same purpose, farn sanitary ware is still developing and applying high-pressure grouting robot technology, and some equipment has been installed and debugged. Huozhuopung said that similar to glaze spraying, grouting blank making is also an extremely important process in the production of sanitary ware ceramics, which has an impact on the environment and employees. High pressure grouting is more safe than traditional grouting. The latter can only produce 10 products a day, aggravating the wear and tear of cutting equipment, while the former can produce 48 products a day

the path of machine substitution

from import to localization

compared with import, the price of glaze spraying robot after localization has decreased by half, but the work efficiency has doubled. The cost performance of localization will be available to more and more small and medium-sized enterprises, and will eventually promote the progress of the whole industry. After the overall progress of the industry, it will put forward higher requirements and inject stronger impetus into the improvement of production automation level, thus forming a virtuous cycle

the glaze spraying robot, which is now making great achievements in farn sanitary ware, entered the glaze spraying workshop in 2013. Earlier, arrow sanitary ware imported a set of high-pressure grouting robots from Italy as early as 2010, and a set of glaze spraying robot equipment in 2011, hoping to automate the original manual production line

at that time, it was also an important indicator of material strength The introduction of Dali spent nearly 9million yuan, but the effect was not ideal, resulting in an increase in the cost of robot automatic production instead of a decrease. Huo Zhibiao said that the main factor is that the maintenance cost of the equipment even exceeds the procurement cost. For example, key parts and maintenance personnel have to come from Italy, which is expensive and delays the production plan of the enterprise. In addition, imported equipment has particularly high requirements for raw materials, which is incompatible with the production habits of domestic enterprises, resulting in difficulties in material and machine coordination

therefore, arrow brand sanitary ware began to seek cooperation with scientific research institutions and robot equipment manufacturers in China, and committed to developing domestic glaze spraying robots with independent intellectual property rights. After two years of research and development and commissioning, the first domestic glaze spraying robot in the ceramic sanitary ware industry passed the test in arrow sanitary ware at the end of 2012, and was put into production and application in farn sanitary ware in September 2013

compared with imports, after the localization of the glaze spraying robot, the price has decreased by half, but the work efficiency has doubled. Huo Zhibiao said. Therefore, this R & D project has also been supported by the National 863 project and major projects of the national development and Reform Commission

the economic and Technological Promotion Bureau of Gaoming District has a high evaluation on this. The person in charge of the Bureau said that at present, only a handful of enterprises in the region use robots for automatic production, while only farn sanitary ware uses self-developed domestic robots. The company's practice has led the trend of transformation and upgrading of Gaoming enterprises, and also brought important enlightenment to enterprises. Copying foreign technologies comprehensively will often lead to acclimatization, and self-developed technologies not only meet the actual needs of production, It can enhance the competitive strength of enterprises

Huo Zhibiao also believes that the successful localization of glaze spraying robots is of great significance. The difficulty in recruiting workers and the increase in labor costs have made it a trend to continuously improve the level of production automation in the ceramic sanitary industry. He said that the one-time investment of the robot production line is much larger, and in the process of production management, it will reduce the human cost and management cost. Therefore, in the long run, the investment in automation is profitable, and the success of localization has greatly accelerated the process of enterprises from investment to income

more importantly, the cost performance of the domestic glaze spraying robot will enable more and more small and medium-sized enterprises to use it, and will eventually promote the progress of the whole industry. After the overall progress of the industry, it will put forward higher requirements for the improvement of production automation level, inject stronger power, and then form a virtuous circle. This is far more expensive than robots, which only a few large enterprises can afford to use. Because new technologies are updated quickly, only relying on the power of groups can we keep up with the trend of the times

in other words, when the price of robots is low enough, the capital strength gap between enterprises will no longer be the obstacle to the large-scale application of robots. Facts also confirmed Huo Zhibiao's judgment. After the news that farn sanitary ware was launched as a domestic robot came out, several other sanitary ware enterprises in Foshan took the initiative to contact and purchase

as the localization of robot glaze spraying has accumulated experience and established confidence, since 2013, farn sanitary ware has continued to cooperate with relevant scientific research institutions to start the R & D and production process of localization of high-pressure grouting robot, of which the first set of localization equipment can be put into use as soon as January 2015

looking back on the process of robot equipment from import to localization, Huo Zhibiao believes that we must always adhere to market-oriented and enterprise oriented, especially to allow enterprises to participate in R & D and innovation from the source, so that the new intelligent production line can be implemented quickly and have good results

machine generation the next step

will be to carry out the whole process automation transformation of the factory

farn sanitary ware will increase the investment in the level of automation, and carry out appropriate automation transformation for the whole production process from raw materials entering the factory, processing, glazing to molding, packaging and leaving the factory, from the previous labor-intensive pure manual production to the semi manual and semi automated production pattern

robot automatic production has been realized successively in key processes such as glaze spraying and high-pressure grouting blank making. The management of arrow sanitary ware and farn sanitary ware has constantly strengthened this understanding: under the background of rising labor and raw material costs, using technology to reduce production costs and improve production efficiency is a good way

based on this understanding, farn sanitary ware is also beginning to use robot equipment in hardware polishing, bathroom cabinet painting and other processes. Generally speaking, robot automatic production starts from the key processes that affect employees and gradually extends to other processes. Huo Zhibiao said that the sanitary ware industry has long been out of the era of profiteering. In the long run, it is said that the composition of this material is very simple to develop. The core competition is the quality and production capacity of products. On the one hand, automation can improve the yield, on the other hand, it can greatly improve the production capacity of products

looking forward to the future, Huo Zhibiao said that farn sanitary ware will increase the investment in automation level, and carry out appropriate automation transformation for the whole production process from raw materials entering the factory, processing, glazing to molding, packaging and leaving the factory, so as to comprehensively improve the automation level of the whole factory. After successful experience is obtained, it will be copied to branches all over the country

although the whole process automation transformation of the factory will significantly reduce the labor demand, Huo Zhibiao said that this does not mean that enterprises no longer need front-line production workers. Many industrial robots need to be fully integrated with people to maximize their role. We hope to adopt the worker + robot model

Copyright © 2011 JIN SHI