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Looking at Foxconn's "Millions of Robots" Plan on Electronic Transformer Inductors

Time:2012-05-08 09:26

   In the initial period of reform and opening up, the Yangtze River Delta and the Pearl River Delta have become the places where almost all the well-known labor-intensive enterprises in the world have settled. Migrant workers from all over the country flocked to find work here. At that time, the relative surplus of labor resources greatly satisfied the active choice of employing people. The cheap labor market is an indispensable factor for China's “factory of the world” name, and as a result, China’s manufacturing has quickly occupied the international low-end product market, and it has also stimulated the rapid development of China’s foreign trade companies. However, after the clock was allocated to the 21st century, the situation of workers entering the cities seems to have reversed.


   Relevant data show that at the beginning of 2012, the total number of missing workers in Guangdong Province was about 800,000, and the gap in the demand for manufacturing workers was the largest, accounting for 20% of the current employment. The first three industries in which the clothing, electrical and electronics, and food manufacturing industries are separated. According to the "2011 One-hundred-meter Private Enterprise Follow-up Survey Report," it shows that 79.4% of private entrepreneurs think that recruiting in 2012 is "more difficult" or "difficult". At the end of 2011, Lin Pingfan, a researcher at the Guangdong Provincial Academy of Social Sciences, once stated in the media that the problem of recruitment difficulties has existed since 2005. The advantages of human resources in the coastal areas have gradually weakened, the demographic dividend has become smaller, and the cheap labor force is also rapidly decreasing. . In such circumstances, it is difficult to make a turn for the better. The problem of recruitment difficulties and labor shortage will become more and more obvious.


   From "The Demographic Dividend" to "Growth Pay"


   As mentioned above, nowadays, enterprises in the coastal areas of China are trying to maintain their employment advantage. The central government's support for the policies of the Mainland has accelerated the investment in capital and technology from the "great western development" to the "revitalization of the northeast," and "the rise of central China," and other major strategic directions. The process of urban-rural integration is also accelerating. . Inland economic development is closer to that of coastal areas. Some local enterprises along the coast are also taking advantage of the lower labor force inland and have shifted some production units to the hinterland of China. Of these, Foxconn may be the most representative company. In addition to Guangdong, Shandong, Henan, Sichuan and other places continue to inward their industrial destinations. As the first element of productivity: people gradually return to their hometowns. From a certain perspective, it seems that the coastal and inland areas are playing a "competition for migrant workers' war."


   The domestic-scale production of network pulse transformer manufacturers, general manager of Dongguan Ming Pu Industrial Co., Ltd. Jing Liang said that the recruitment of Ming Pu in Dongguan in normal time is still normal, but the high turnover rate before and after the Spring Festival, is more difficult to recruit people . Although the recruitment pressure of personnel is still not large, he also said that the gap between the wages in the Mainland and Dongguan is also gradually narrowing, and the attractiveness of the coastal workforce has diminished. During the interview, the reporter saw Ming Pu's recruitment notice in front of the company posted in the most eye-catching position, in the plant upstairs, a banner of more than ten meters long is also printed: a large number of female production workers, a monthly salary of up to 2600.


   East China large-scale high-frequency transformers, inductors filter manufacturer Jiangsu Chenyang Electronics Co., Ltd. Vice President Jiang Jianping revealed to reporters, Chenyang employees this year's salary has reached 2,500 yuan, compared with the same period last year rose nearly 500 yuan.


   From "Made in China" to "China" Smart & rsquo; Made & rdquo;


   Although the recruitment difficulties and labor shortages that emerge every year have brought business production to a passive situation, the “Made in China” dominance is still difficult to break on a global scale for a short time. The industrial chain formed over the past decades has been relatively well-established, and the quality of products has been continuously linked with international standards. What's more important is that the scale advantages that Chinese companies have have taken over from the international industry giants.


   According to reports, in February, Hitachi announced that by the end of September this year, the TV manufacturing business will be fully transferred to overseas manufacturers such as China. In other words, Hitachi is gradually divesting its TV manufacturing business since 1956. In the future, Hitachi will reduce costs and strengthen its income structure in the form of overseas OEMs. Japanese companies such as Sony, Sharp and Panasonic also plan to gradually increase the proportion of overseas OEMs. According to IHSiSuppli's data, OEM production accounts for 34% of the 100 LCD TVs in the world. In this large-scale single-agent contract, the OEM companies in China and the Taiwan region share the same business. The cheap and labor-intensive enterprises with their advantages still remain the main factor in receiving overseas OEM orders.


   Although man is the first element of productivity, the most important primary productivity is: technology. Also Foxconn, the representative labor-intensive company, soon afterwards, put forward the “Millions of Robots” plan, which is to invest 1 billion yuan in three years to acquire one million robots. It means to reduce the number of workers, reduce the rising cost of employment, and improve the company's level of automation and production efficiency.


   First manufactured, then "intellectual" made. Foxconn's approach may also reflect the development of the manufacturing industry in the east coast.


   Industrial upgrading and transformation lead to automated production


   Twenty-three years have been set up to accumulate a profound history of the industry. Dongguan Intime Electronics Co., Ltd., which specializes in manufacturing EI-type low-frequency transformers, said that the general manager of Peng Ri said that although Inley has not yet reached a very passive position this year, most factories As such, there are also problems with recruitment difficulties. Yin Li will not plan to move inwards in the short term and will upgrade the industry on the eastern coast. He is also concerned about the situation of automation equipment. He said that starting from semi-automatic is better. Currently, about 30% of the factories on the market are in the order of an average of thousands to tens of thousands of orders per month, and the proportion of hundreds of thousands of orders is still relatively small. The equipment that the automation equipment factory mainly produces which process, the size of the product can not be changed and so on. Manager Peng said that the owner of each factory has a certain understanding of automation equipment. No one would say that he does not need automation, and he only wants to use people.


   Taiwan-listed companies mainly producing and developing network filters, module power supplies, converters, and other magnetic components, and Han Han Electronics (Guangzhou) Co., Ltd., which is wholly owned by Taiwan Han Han Co., Ltd., and Mr. Lin, who is responsible for IT information, said that this year Han arranged people according to the order quantity. Although the number of existing employees can basically meet the production requirements, they have been recruiting people since the holidays. In the environment of "employ people", people will find it difficult to recruit workers. At this stage, we are considering the streamlining of personnel through the form of production automation to achieve the purpose of reducing costs, management, and labor costs.


   Mr. Tong Yangwei, general manager of Huizhou Aode Electronics Co., Ltd., which specializes in the research and development of transformers and inductors automation equipment, spoke of a story. When the pressure on labor costs in 2009 was not yet highlighted, a customer with a good relationship with Australia and Germany had multi-axis automation. In the selection of both the winding machine and the single-shaft winding machine, 1000 sets of single-shaft winding machines were purchased. However, less than two years later, due to rising labor costs, the company's labor expenditures surged. He realized that it needed to switch to an automated production model. He joked that he would leave behind 300 machines and buy 700 units of corresponding automation equipment.


   Any aspect of the industry should have a sense of danger in times of peace. Australia and Germany have also been adhering to this concept throughout their development. During the first two years of the financial crisis, Australia and Germany had done equipment "trade-for-news" activities, so long as customers can make up the difference in the original equipment, they can continue to use the new equipment in Australia and Delhi. Perhaps this concept can become a marketing tool that equipment companies can learn from.


   Is the product produced simple


   Even though all electronic transformers and inductor companies are positive about automated production, they also expressed different concerns and doubts about the automation equipment on the market at the current stage.


   For fully automatic concerns, Mr. Jing Liangcai, general manager of Dongguan Mingpu Industrial Co., Ltd., told reporters that many of the power transformers are customized and often require the production of different non-standard products. If you use a fully automatic line change, it is not easy. Second, if a fully automatic equipment fails, then the entire production process will be suspended and the customer will be unable to explain. Some automated equipment requires technical personnel to perform maintenance and repairs. When faced with frequent occurrences, the cost of technicians is higher than that of general workers.


   Despite this, Mr. Jing pointed the solution to a semi-automatic form. He said that in the semi-automatic, first, compared with simple artificial, the efficiency is relatively fast, and the input cost is not very high; secondly, after semi-automatic investment, we also hope to achieve "modularization". That is, in this device, if the product is changed for the model, as long as the corresponding part is removed, the replacement of the docking module can continue production. After importing the concept of "modularization", for enterprises, one can produce quickly, and second, investment costs are not high.


   He said that Ming Pu's evaluation of the machine was able to get back in half a year to a year, and he invested in this project. In addition to the “cost-saving” assessment indicator, it also involves the time-saving assessment of the product man-hours, and converts the man-hours saved to the required labor costs. Ming Pu began to gradually upgrade semi-automated production methods in 2009. In 10 years and 11 years, it saved more than 400 employees. In addition, if the customer can be satisfied with the equipment when they visit, it is also an invisible advantage. He said that the two most visible uses of automation are to reduce the pressure on labor costs; secondly, to improve product quality and satisfy customers.


   Jiangsu Chenyang Electronics Co., Ltd. Mr. Jiang told reporters that Chenyang just bought a batch of fully automated winding machines in March. In response to this purchase, Mr. Jiang said that mainly based on the production and customer's needs for goods, purchase some automated equipment to test the water, and see how the production efficiency. The semi-automatic equipment has already been used before, and this time the main attempt is a fully automatic winding machine.


   Mr. Lin of Hao Han Electronics stated that although some technical problems were encountered in the process of automated production, the process and small processes of a product can only be completed by partial automation. For the time being, the automation of all processes cannot be realized. However, many years ago, Haohan began to produce through automation. Especially after the financial crisis in 2008, it also increased the intensity of automation.


   What can be seen is the improvement of production efficiency. The countless number is the streamlining of personnel (Ming Pu's semi-automation has saved more than 400 people so far in 2009), and it is the improvement of the productivity; the automation is also for electronic transformers and Inductor companies have brought their customers' approval: a company that owns automation equipment production and a manufacturer that lacks mechanical operations have undoubtedly positioned the former in the ranks of advancing with the times in the eyes of customers. The subtle influence of corporate image. The impact of hidden benefits on manufacturers must not be underestimated.


   The domestic manufacturer of electronic transformers, inductors and power adapters, Dongguan Dazhong Electronics Co., Ltd. Professor Jin said that if there is an automated machine in the future, there can be an interface between the E-chip and the I-chip, press in, cancel. Welding procedures are improved in the process, which can provide an opportunity for automation. Professor Jin told reporters that Dazhong prepared to introduce some 8-axis, 10-axis, and 12-axis winding machines to produce simpler products with large output, such as high-frequency inductors. A machine responsible for a high-frequency multi-axis winding machine is used to reduce labor and increase production.


   From the above views of several transformers and inductor companies, it can be seen that as the most labor-intensive manufacturing industry in China, manufacturers of electronic components also hope to improve production efficiency and reduce the increase in the number of equipment. Manpower recruitment and cost pressures. However, due to the inherent nature of transformers and inductors, whether non-standard product orders can be produced through large-scale production of machinery has also become a common concern in the industry.


   To this end, the reporter has specialized in the production of transformer coil winding equipment, multi-axis automatic winding machine, unmanned automatic assembly line design and manufacturing, enjoys the "Taiwan winding machine production originator" Dezhou You Electronics Co., Ltd. Yuyu Co., Ltd. learned that Dezhou Youdian is now the most popular DSW-4208P-TP 8-axis automatic winding machine, which is characterized by one-time completion of a variety of angled foot function, rapid replacement Winding fixture function design, with a complete winding and wrapping tape function, automatic cable management and waste line elimination function, no residual line and so on. The price of each unit is about 200,000; it is suitable for customers of high-frequency transformers, stepping motors, relays, solenoid coils and inductors.


   When it comes to the recovery time of the cost of automation equipment, in Shenzhen, an employee's salary is about 3,000 yuan. With the DSW-4208P-TP as an example, the machine's service life is about 10 years. If a product type in the EE16 series is produced, it is generally 3~5 windings, and each winding can be corresponding to a DSW-4208P-TP automatic wrapping machine. One person, one machine, 1200 / hour production. The passing rate of the current test standard is 99.2%, and the failure rate range is only within 0.8%. Non-automated manual operations require three individuals instead, skilled and the average pass rate is only 95%. After calculation, it can be known that: According to the machine's 10-year use cycle, the daily use fee is about 56 yuan, and the production capacity is 1200 pieces per hour; if it is done by skilled employees within the same unit hour, it can produce up to 400 pieces in an hour. This also includes a 3% to 5% failure rate. The daily expenditure of each employee is more than 100 yuan.


   At the 2012 China (Shenzhen) International Winding Equipment Exhibition, reporters learned from the most renowned Japanese Tanaka Seiki engineers of the world's automated winding machines that they exhibited a 6-axis automatic winding model MX3606 at the show. machine. The price of the machine is about RMB 250,000. If the switching power supply transformer EP14/15 is used as the winding target, the unit output can reach 1500 units within an hour, which can replace 8 manual operations with the same output. And the pass rate of the product has also been increased to 90%, or even higher, compared with only 60% to 70% artificial production pass rate is 20% higher. And the machine has a conservative life of at least 5 years or more. The machine is suitable for liquid crystal display backlight high and low voltage coils, fire high and low voltage coils, sensor coils, solenoid valve coils, automotive injector coils, automotive ABS, charger coils, small communication coils, printer nozzle coils, stepper motors, mid-week tuning Coils, automotive instrument coils, relays, camera lens drive motor coils, switching power transformers, EE transformers, EI transformers, I-shaped inductors, small chip inductors.


   If in the Pearl River Delta region, the company’s expenditures on employees, including social security and other expenses, are calculated at 3,000 yuan/person/month, the following table shows:


   The person further pointed out that this machine's daily simple maintenance such as wiping and doing the right way of use, basically does not appear too much trouble. Even if the problem arises, it can provide the appropriate technical personnel to solve the support.


   The world-famous leading enterprise of automated winding and the head of the customer service center of Japan's special engineering company, Mr. Rong Rong, said that the special equipment has a certain attraction in the mass production of winding products and has attracted the attention of the market. At the same time, Nike also attaches great importance to the requirements and ideas from customers, and in this way, it combines R&D equipment and procedures. He continued to say that, from the feedback from customers, it was learned that automated production has indeed improved product output and quality, and that personnel can also achieve cost reductions.


   Mr. Wing also showed to reporters and introduced a special automatic equipment for multi-turn inductor winding. I saw this device from the winding, soldering, detection and discharge, a series of processes are completed smoothly under the unmanned operation. Efficient automation increases productivity and the number of products.


   Structured design meets the needs of multiple types of products


   What the transformer needs to do is to change the size of the voltage in and out. If the voltage input and output do not change, the structure will not change much. Therefore, due to the consideration of the design cost of the entire circuit board, there are few manufacturers that will make large adjustments to the transformer structure.


   De Yu You Yu Yu proposed that according to the different products, design different components to be installed in the automation equipment. A machine as a whole does not change the configuration of the surrounding, can be achieved by changing different components. Mr. Yung, a Japanese special-day mechanical engineering company, said that now automated machinery can be customized to a large extent according to the needs of customers' products.


   The reporter introduced to the introduction of Japan's automated winding machine technology, design, production, sales of automatic multi-axis winding machine Dongguan Botai Automation Technology Co., Ltd. Mr. Feng learned in detail that, like the Po Thai 4216 this automatic winding machine is 16 axes, 42mm axis spacing. All products with a diagonal or diameter of less than 42mm, such as ignition coils, relays, inductors, high- and low-frequency transformers, micromotors (stepping motors, synchronous motors), are suitable for coil types. If the inductor is produced in the early stage and the relay is produced in the later stage, it may be possible to replace the loading rack device and 16 shafts in the fixture section. The loading rack device and shaft center are replaced, and the price varies from 7,8,000 to 30,000 depending on the raw materials. In addition, other major replacement parts include wire needles, each with a price of about 50 to 200 yuan. Mr. Feng also said that many automated winding machines have now been able to replace the module control with a programmable controller PLC, and the price can be made in thousands.


   As for the degree of wear, it will be determined by the different types of products. The largest axis is worn by the wearer. The number of windings around the transformer varies, and the level of shaft unloading frequency also affects the speed of wear. Other parts that are not artificially damaged can be used normally for at least 5 years or more.


   In the initial stage of production model transformation, most companies accepted or semi-automated operations. Through the replacement of modules and institutions, the production needs of different non-standard products were achieved. The high capital investment and low flexibility of fully automated production lines have become the main factor for companies not investing in the first time.


   The customer's product requirements & rdquo; is the most important and most important design basis for automated winding equipment. Non-single batch machines can be tailored to customer-specific products to make different program adjustments, and can also guarantee the production of various non-standard products for transformers or inductors.


   After-sales become an important part of ensuring production


   Mr. Yu of DeZu Youdian said that to avoid or minimize problems, equipment manufacturers must first select good materials when producing equipment, and design should also consider many details to make it less of a problem. In addition, it is also necessary to strengthen the training of the technical staff of the customer companies. If there are any problems, they can be dealt with in a timely manner.


   Enterprises using fully automatic equipment usually have very large orders and produce the same products all year round. Even if the products are changed, only some wire diameters and laps will be changed and the appearance of the products will not be changed. For example, customers such as solenoid coils and relay coils can consider fully automated assembly line equipment. But generally, the current production method of the customer is an assembly line. Each station has a worker. If the machine of a certain station is suspended, it will be artificially applied immediately.


   Mr. Feng from Dongguan Botai Automation stated that he is cooperating with a Japanese company. The R&D of the product is designed by the Japanese. The raw materials of the equipment are also shipped from Japan. High-quality protection can be achieved from technology to materials and assembly. If it is a failure within one year, you can repair it for free throughout. After the warranty period is exceeded, only the cost fee will be charged.


   Increased core competitiveness of artificially-to-automated industrial transformation companies


   After nearly a month, the Big Bit reporter visited a number of companies and learned that most of the electronic transformer inductor companies at this stage expressed their recognition of the trend toward automation, and they are also interested in learning more about automated energy belts. Benefits and cost savings. But at the same time it also shows concerns about automation equipment efficiency, cost, and diversification of production. As a device manufacturer, how can we more fully understand the market of electronic transformer inductors, close to customer needs, so that humanized research and development, tailor-made and electronic transformers and inductors are in line with each other, it is a problem that should go to multi-directional thinking.


   In a changing market, if you want to maintain a strong competitive position, it is obvious that by using a large number of labor to produce traditional products with multiple product models, large batches, and large quantities, it is difficult to keep up with the pace of industrial upgrading. . If our electronic transformers and inductors cannot break through the higher-level technology than artificial production as soon as possible, it will be difficult to expand into new markets. "Survival of the fittest" has always been the law of the jungle in the competitive market, and on the contrary has also become an effective measure for electronic transformers and inductor companies to forge ahead. We hope that more electronic transformer inductor companies can clearly understand market trends, product R&D innovations, and increase China's “creativity” by increasing the first factor of productivity: investment in technology, improving the competitiveness of enterprises. The situation.