How artificial intelligence saves money for manufacturing

As artificial intelligence begins to explore the pain points in the factory, the future of manufacturing begins to change.
A report by Accenture shows that artificial intelligence will have an economic impact on China's 15 industries, with manufacturing gaining the most.
Guess, which department is the highest cost of a ceramic company?
The answer of Foshan Ou Shennuo Ceramics Co., Ltd. (hereinafter referred to as "Ou Shennuo") is: IT department.
The company was founded in 2000, and the initial market situation is very good. But Chen Jiawang, president of Ou Shennuo, remembers that the 2008 financial crisis was a turning point - labor costs soared and export speed dropped significantly, and the way to reduce costs became a daily management theme.
"We now have automated factories in Foshan and Jingdezhen. As long as the machine is opened, how much can be produced, the key is that consumers should like it and sell it." Chen Jiawang told the Southern Weekend reporter that after 2008, intelligent production began. Has a profound impact on the manufacturing industry.
Since 2014, Ou Shennuo has formed a team to develop intelligent online systems and implement strategic transformation by using technologies such as big data capture, visual recognition and VR experience. The aim is to achieve large-scale personalized production.
“The market is forcing you to move forward. There is no way. This is a change that must be made.” Chen Jiawang said that on the smart platform, consumers choose their favorite tiles online according to the type of house, and match the style of furniture. Match, create a three-dimensional decoration renderings online. After the inspection is correct, the order will be placed, and the door will be delivered and installed automatically.
Each of these links is inseparable from the technical support of artificial intelligence and data analysis.
Now, such a wave of intelligence is bringing profound changes to traditional manufacturing industries such as white goods and furniture.
Huang He, chairman of China Intelligent Manufacturing System Solution Providers Alliance, analyzed the Southern Weekend reporters. 15 years ago, the main advantage of Chinese manufacturing was the low cost of human resources, the denser the labor in the production process, and the more advantageous the advantages.
After 2005, the cost of production factors accelerated and the manufacturing enterprises began to enter a new competition cycle. Enterprises are eager to expand their scale and dilute their costs, which has led to a rapid expansion of production capacity in a short period of time.
After about 2012, large-scale production has entered the bottleneck, and refined and personalized has become the only way for enterprises to survive. Manufacturers have begun to pay attention to details. At this stage, artificial intelligence has ushered in a golden period of development in the manufacturing industry.
"Large technology like Alpha Dog is not necessary at all. Some basic technologies can solve many problems." Huang He said that the manufacturing industry understands artificial intelligence technology, and intelligent manufacturing companies explore the pain points in the factory. Many technical problems in the factory can be solved quickly. This process will change the future of manufacturing.
Accenture, the world's largest consulting firm, also analyzed in a report that artificial intelligence will have an economic impact on China's 15 industries. Among them, the manufacturing industry has the most benefits, followed by agriculture, forestry, fisheries and retail. By 2035, artificial intelligence will drive annual growth rates of the three major industries to 2%, 1.8%, and 1.7%, respectively.

More possibilities for production methods Around 2015, China's ceramics industry's overcapacity reached its peak. Bai Mei, vice president of the Foshan Ceramics Industry Association, said in an interview with the Southern Weekend reporter in 2015 that the national ceramics market has a scale of at least 10 billion square meters, and the production capacity has reached an astonishing 14 billion square meters.
After the extensive application of artificial intelligence, the product line of Ou Shennuo has been compressed from less than 300 kinds in the peak period, which greatly shortens the turnover period. "In the past, it was based on production and sales, and now it is based on sales." Chen Jiawang said.
"Which place are you, which district, what is the type of apartment, all of us in the system." Xue Guanheng, product manager of Ou Shennuo, introduced that all new and old communities are included in the country as long as they are covered by offline brand stores. Their database.
At the beginning, they launched the offline store owner to collect, organize, and upload the floor plan of the newly developed community in the local area, but it was time-consuming and labor-intensive, and there were always some omissions and slow updates.
In fact, “crawlers” grab data, and the IT industry has long been a mature technology widely used. The IT department has found cooperation with Internet professional companies, and soon purchased this application, and made parameter improvements to be applied to the real estate website. Data combing.
When consumers select their own units for DIY matching, the system must be able to accurately identify based on the graphics. Xue Guanheng said that visual recognition in artificial intelligence is also not a particularly advanced technology, but identifying floor plans is still a blank area in the industry, so some improvements in data model technology are needed.
Leaping over the threshold of data capture and graphic recognition, it is a barrier to realizing the intelligent upgrade of this traditional manufacturing enterprise. It is a 2D to 3D rendering technology. They consulted many artificial intelligence companies and can only support them in local details. The core methods can only rely on independent research and development.
When the consumer selects the apartment type, the tile of different styles and specifications can be arbitrarily selected. On the basis of the two-dimensional floor plan, the system automatically converts into a 3D rendering with a 720 degree rotation.
Xue Guanheng introduced that in the entire intelligent system, the technical difficulties that are really difficult to overcome are only one link. Others are living and learning in the field of artificial intelligence. "It is not how advanced technology is, the key lies in application."
Personalized customization like Ou Shennuo can also be achieved in the furniture manufacturing industry.
Zhao Fang, brand manager of Guangzhou Sophia Home Furnishing Co., Ltd. (hereinafter referred to as “Sofia”) told Southern Weekend reporters that before 2007, their production methods have always followed the “mass production – dealer delivery” model. With the increasing demand for personalized consumers of the new generation, from 2007 to 2012, the innovation of Sofia standard parts with non-standard parts has greatly shortened the production cycle and increased the product category.
At present, Sofia handles about 8,000 orders per day in the country's five production bases. The products specified in these 8,000 orders vary widely, requiring approximately 500,000 pieces of assembly to be completed, and each plate has color, texture, size and thickness. With all kinds of data, these different parameters are combined, and the Information and Digital Center needs to process more than 4 million sets of data every day.
The new equipment for the bottom door automatic assembly machine, intelligent hardware sorting system, automatic old door panel automatic color correction system, line automatic cutting machine, CNC door reaming machine, etc. on the production line, as well as the full-process data acquisition system, In the case of changing the mold, it is possible to produce personalized cabinets of different thicknesses, different colors, different volumes and different shapes.
“The contradiction between individualized demand and large-scale production has been greatly solved.” Zhao Fang said. According to official data, Sofia's main business income increased from 1.221 billion yuan in 2012 to 4.53 billion yuan in 2016, and net profit increased from 173 million yuan in 2012 to 664 million yuan in 2016.

“The cost can be recovered in the past”
When the sheet was about to bottom out, Zhang Xiaofeng patrolled the walkway. The six-axis robot arm swooped and rotated, and a thin steel plate swelled up, and along the narrow slit, it was inserted into the base of the right machine. Quietly, loose "hand", pull out, beautiful back tilt, only listen to "哐哐" two sounds, stamping closed, the iron piece is rolled out of a dense row of grooves.
The 10 machine tools are arranged in a compact arrangement, and the robots are free to move. The mechanics walk straight through the line. The production line of nearly 15 meters in the middle is empty, and the operation task is completed after unloading a tank of material at the end.
"Before a machine has at least two people, one line has more than twenty people. Now, as long as one person looks at it." Zhang Xiaofeng is an engineer of Dongling Weili Electric Co., Ltd. (hereinafter referred to as "Power Appliance"), witnessing the company's technology. Upgrade, he introduced to the Southern Weekend reporter, their workshop is responsible for the processing of microwave oven liners, forging lines, punching, scouring and so on more than a dozen processes, all of which realize the intelligent operation of the robot.
Liu Liang, executive director of Power Electric, told the Southern Weekend reporter that in the 1990s, the growth was fast and the profit was high. The space for product iteration was broad. Enterprises were eager to expand production capacity, and they did not care much about the resource consumption.
Due to the relatively mature technology, the ceiling of white goods industry is even earlier than other manufacturing industries. The overcapacity of ceramics industry has brought the chill of Ou Shennuo, and the power has been frequently taught since 2000.
What's more troublesome is that compared with the IT industry and the 3C industry, the possibility of disruptive innovation in the home appliance industry is very slim. "The current mobile phone is much different from what it was ten years ago, but you look at the difference between air conditioners and refrigerators. A lot?" Liu Liang said, "One of our most important tasks in recent years is how to reduce labor costs."
"It is impossible for every industry to have major inventions. Innovations like WeChat and Didi are still a few." In Liu Liang's view, the situation of most manufacturing companies is comparable to that of the home appliance industry. The route is moving slowly, and artificial intelligence means fine for them, which means excellence.
In the process of reducing costs, Liu Liang found that the most direct and effective means is to upgrade equipment, "machine substitution." In the home appliance industry, a skilled worker has a monthly salary of at least 4,000 yuan per person, and a person needs about 50,000 yuan in labor costs per year. The purchase of a robot requires 100,000 yuan, which is equivalent to two people's salary a year. Robots can generally operate 24 hours, at least equal to the efficiency of 2 workers, and a device can be used for at least 5 to 8 years.
"This account is still very good, and the cost is recovered in the past." He said that after 2010, they began to upgrade their intelligent equipment on a large scale. Under the continuous expansion of the company, the number of employees has decreased by 10%. Probably increased by about 30%.
At the same time that manufacturing companies such as Power Appliance are eager to reduce costs and transform processes through smart devices, more artificial intelligence technology companies that serve manufacturing companies have emerged.
The digital phase technology company founded in 2014 is one of them. This company dedicated to artificial intelligence pattern recognition is providing intelligent transformation solutions for many small and medium-sized manufacturing companies.
Wang Linna, deputy general manager of Digital Phase Technology, told the Southern Weekend reporter that a wood processing enterprise that produces flooring will classify the floor under the line according to the quality in order to improve the profit margin of the product. In the past, this link relied mainly on skilled workers to identify by the naked eye, with low efficiency and high error rate.
Wang Lena recorded a video of the worker's identification of wood and looped it to the visual robot. In a short time, the visual robot mastered the law of identifying the floor level. "Artificial intelligence will learn on its own and find the logic to act."
According to the retrofit solution provided by Digital Phase Technology, a camera can solve the problem. "On one link, you can save hundreds of thousands of yuan a year." Wang Liena said that this technology is not complicated. In the long chain of floor production, artificial intelligence can also change manufacturing in a wider range.

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