In fact, since the Fashion trend of international brands tends to be "fast fashion", to meet the production demand of multiple varieties, small batch and quick response has become a unique skill for garment manufacturers to ensure that they can win from the fierce competition.
· December 08, 2020 9:40:27 Source: Qingdao Daily/Sea View News author: Liu Lanxing 2.7W
Serve the net
That is, hair group to create weaving dyeing joint integrated flexible intelligent production workshop -
We can take orders for only two or three pieces of clothing
Due to the intrusion of Alibaba's "rhino factory", the intelligent transformation of clothing manufacturing industry has once again become a hot topic in the industry.In fact, since the fashion trend of international brands tends to be "fast fashion", to meet the production demand of multiple varieties, small batch and quick response has become a unique skill for garment manufacturers to ensure that they can win from the fierce competition.
As an old textile enterprise with a history of 65 years, seizing the opportunity given by each time is the magic weapon for Jifa Group to prosper forever.Since 2016, We have taken Its Qingdao Guihua Knitting Co., Ltd. as a pilot company to carry out intelligent transformation, making use of information technology to get through the process from weaving, printing and dyeing, to tailoring and sewing of garments...All the links in the whole industrial chain have established the supply chain mode of agile manufacturing and flexible production.Now, the delivery time of Guihua knitting scale order has been advanced from 42 days to 14 days, and the quick return order (order within 2000 pieces) has been advanced to 7 days.Thanks to such rapid response, Guihua knitting has come out of the trough quickly after the epidemic. Since May, guihua knitting has realized a continuous growth of operating income against the trend, and domestic and foreign orders have been fully scheduled for the production schedule before the end of the year.
Intelligent manufacturing workshop through the whole industrial chain
Weaving, printing and dyeing, tailoring and sewing of garments are three important links in the upstream and downstream supply chain of the garment production end, which is an industrial chain from the perspective of industry.However, in the production workshop of Guihua knitting, through intelligent transformation, flexible and intelligent manufacturing has been formed, and weaving, dyeing and sewing have become a series of processes.
In the weaving workshop, an orange flatbed robot less than 1 square meter shuttles back and forth along a track, carrying yarn.Dyeing and finishing workshop, several small color mixing cylinder according to the established procedure automatic color matching, color mixing;Clothing workshop, radio frequency technology real-time acquisition of worker production information and work efficiency;The central control room, a set of ERP system includes all the data of each node and the whole chain of weaving, dyeing and garment, which has become an important carrier for real-time monitoring and equipment information interaction in all links of production and operation...This is the reporter in the hair group Guihua knitting Co., LTD. Weaving dyeing joint flexible intelligent production workshop to see the scene.
Since its establishment in 1993, Guihua knitting co., LTD has been focusing on overseas OEM knitted garments.Following the fashion trend of international brands, since the beginning of this century, the trend of "fast fashion" has emerged. With information as the core, enterprises try to solve the problem of small batch, multi-batch and fast delivery order.Sun Weifa, general manager of the company, said, "In the past year, we only received less than 40 orders, one order was hundreds of thousands of pieces;But now there are nearly 6,000 orders a year, from thousands to hundreds to even one, and customers are asking for delivery in a week or two.""If we had done it the way it used to be done, we wouldn't have been able to do it," he says. "With smart manufacturing, we would have been able to do it, and our operations would have been 30% more efficient."
Jifa Group's intelligent transformation began in 2016.In recent years, the group in pilot plant your China knitting, with all the information through the whole industry chain and establish the agile manufacturing, flexible production mode of supply chain, in a factory, an industry garden to realize seam taimei "dragon", to quickly meet many varieties, small batch, fast reaction order of the market demand."Every link is digital information collection, and every employee's work is connected to a digital card. There is no information attenuation in different industrial links. *** reduces the human error cost and inventory pressure of the enterprise, and improves the anti-risk ability and cost reduction ability of the enterprise.In Sun Weifa's view, with the help of information power in the operation management to form a flexible intelligent, they therefore undertake more "demanding" customers.
Incorporate flexibility into management philosophy
The smaller the order, the more difficult to do, this is the consensus of the clothing industry.According to statistics, from 2003 to 2013, in this 10 years, the average order of Guihua knitting only 6,000 pieces, a SKU (single style, monochrome, single specification) only about 500 pieces.Sun Weifa believes that some domestic orders are even 2 or 3 pieces now, while a large overseas sports brand only has 128 pieces of single SKU, which is a requirement of small batch, multi-batch and fast delivery time.Enterprises to pursue efficiency, in the final analysis is to improve competitiveness, others can not take the order you can take, this is the advantage."We rely on the transformation, optimization and improvement of the intelligent manufacturing model, which is also conducive to the long-term development of the enterprise," Sun said.
Wisdom change a step ahead, Guihua knitting advantage in the epidemic "test" under the more prominent."Guihua's business these years is steady progress."Sun weifa said that due to the impact of the global textile industry chain transfer and the global epidemic, relying on high-quality manufacturing capacity and riding the digital express, the enterprise is accelerating toward the goal of "domestic and international double cycle".At present, the export of products has been adjusted to 60% from 90% in the past, and the domestic and foreign markets gradually tend to be balanced."Even if the same OEM, foreign and domestic enterprises have many differences in standards and requirements, and the only constant is the rapid response to fashion trends."From Sun Weifa's point of view, guihua knitting is surging in the trend of the Internet age to deliver the OEM demand of brand enterprises to the production end precisely, and the manufacturer can more accurately talk about the market, and then promote the enterprise from the previous mass production to mass customization.
On April 16, Guihua Knitting received an order for 3000 pieces and successfully delivered the goods on April 29."This batch of orders is very small and needs 7 colors. It takes 12 hours to dye one color and 3 days to color seven colors. It also needs to complete various processes, such as weaving and printing, and finally can be delivered in 13 days, which reflects the flexibility and agility of production."In Guihua knitting, the delivery time of scale order has been advanced from 42 days to 14 days, and the quick return order (order within 2000 pieces) has been advanced to 7 days.
"Without corporate reinvention, without Internet thinking, this can't be done."Sun weifahe said, the Internet thinking needs to be coordinated, the idea of 7-day delivery into each process, a small closed loop into a big closed loop, integrated flexible manufacturing.Flexible manufacturing, like a piece of dough, can be kneaded any way, no matter how big the order, can be taken in to do.
He said that flexibility is not only reflected in the concept of manufacturing process transformation, the enterprise management concept should also be incorporated into the flexibility."Seventy percent of the work in garment enterprises requires piecework, and the workers are certainly willing to take large orders. Flexible manufacturing has particularly high requirements on management and can be prepared in a short time step by step."'Garment manufacturing is still labor-intensive,' Mr. Sun said.Such as dyeing and finishing workshop automatic feeding equipment, improve the process accuracy and product quality.However, in some production links, it is not possible to completely eliminate labor.It is inevitable and necessary for the industrial Internet to develop to the present stage. However, different industries and different levels of entry require us to take into account the current situation of enterprises, and do it step by step and actively.
There is a consensus within JIfa Group that the factory is the "green hill" of clothing manufacturing industry.Over the past 65 years, Jifa has become a large enterprise with more than 30 companies and branches and more than 20,000 employees.In 2019, the company achieved operating revenue of 11.229 billion yuan, demonstrating the "new vitality" of an old industry.Nowadays, the improvement of a series of digital capabilities is opening up more imagination space for the development of this old textile enterprise.
