The Paper trainee reporter Zhou Chunling
walked into a building full of German industrial atmosphere. On the large screen on the wall, several numbers kept beating: temperature, real-time power, cumulative power generation, CO2 emission reduction... It seemed Like a master control room that controls the operation of some large systems.
This is the lobby on the first floor of the Bosch Changsha factory office building, and this large screen displays the current power consumption of the factory. Bosch uses artificial intelligence technology to optimize the management of factory production energy, improve power utilization and reduce carbon emissions based on current weather, temperature, historical status of production lines, production plans and other factors.
Since the launch of this energy management system , the factory's electricity consumption has dropped by 18%, and its production carbon emissions have been reduced by 14%.
Thanks to a series of energy-saving and emission reduction measures and the implementation of advanced "intelligent manufacturing" projects, Bosch's Changsha factory was recently selected into the Davos World Economic Forum's list of new global "lighthouse factories" in 2022.
This is the third lighthouse factory of this parts supplier in China and the world after Bosch Wuxi and Bosch Suzhou .
In this factory, robots are gradually occupying workstations that originally belonged to humans; product testing no longer relies on the experience of old masters who "look, hear, ask, and understand" but is based on quantitative standards analyzed by digital big data; there are also few queues at the factory gate. Long queues of material supply trucks because they can now make deliveries at more precise times based on big data predictions.
All this is due to Industry 4.0 and " Made in China 2025". In the "Made in China 2025" program issued by the State Council in 2015, it was mentioned that "my country's manufacturing industry faces severe challenges from developed countries and other developing countries. It must look at the world and step up strategic deployment... to seize a new round of manufacturing industry." The commanding heights of competition.”
In this context, smart manufacturing such as smart equipment and smart factories based on information systems is leading the transformation of manufacturing methods. This change undoubtedly has a profound impact on China's second largest pillar industry, the automobile industry.
As a company "born in the same year" as the inventor of the automobile Mercedes-Benz , almost every car in the world is equipped with BOSCH products, from camera sensors to ABS/ESP motors. .
It is not easy to accurately describe what Industry 4.0 is, but you can actually feel that the density of workers in the factory is getting lower. Mars Splashing KUKA robots can be seen everywhere, and the automatic feeding production lines are emitting regular and exciting information. The exciting sound of mechanical operation.
"China accepts new things very quickly, which is why our three lighthouse factories are all in China," Wei Yan, general manager of Bosch Changsha, told the media who visited the factory, "Bosch Changsha will continue to do a good job in the fourth version of industrial revolution is a pioneer and vanguard, accelerating the digital-to-intelligent transformation of China's manufacturing industry, releasing green and low-carbon potential, and jointly exploring a new future of intelligent manufacturing. "
is also a production line for ABS motors. The new production line of this factory only requires two. operators, the production cycle reaches 7.5 seconds/piece. For comparison, the old production line requires 10 operators, and the production efficiency is one-third lower, at 10 seconds/piece.
In addition to improving production efficiency, the use of big data algorithms can also make more accurate predictions about equipment maintenance timing. It used to be "Equipment breaks down - stop production - repair - resume production", now it's "predict it will break down - prepare to replace equipment in advance - quickly replace it at the lowest peak point of production - resume production".
Taking the turning process as an example, by collecting the torque , temperature, humidity and other data of the turning tool , and comparing its performance and map with the "new tool" or "old tool" parameters defined by the standard, we can get Know the current life status of the equipment.
For another example, in the production line of winding copper wire for motors, when each roll of copper wire is replaced after use, the tension of the copper wire needs to be manually adjusted again to ensure the performance and safety of the motor rotor. Now, this step is through machine adaptive adjustment, which can achieve the consistency of copper wire density, thickness, and tension, ensuring that each motor winding achieves the same performance.Through data collection, machine learning and analysis model building,
helped the factory increase the service life of consumables such as welding electrodes and turning tools by more than 30% and save 50% of replacement time.
In the field of logistics, which has a significant impact on production efficiency, the Bosch Changsha factory, from raw material supply, transportation, internal circulation to production and goods delivery, the entire process is connected by real-time data through the logistics center, abnormal monitoring and alarm, in process big data Achieve overall control with the blessing. Through the flexible scheduling of automatic guided transport vehicles , RFID/visual recognition, automated applications and intelligent reports, combined with the deep integration of cloud technology, AI technology and logistics business, the platform helped Bosch Changsha save 30% of logistics costs and 15% inventory turnover days. The truck utilization rate has increased from 30% to 90%, and the production cycle has been shortened to 64% three years ago.
These measures are not only implemented in the Changsha factory. The so-called lighthouse factory serves as a benchmark to promote advanced methods to other factories around the world.
's " digital intelligent " manufacturing will also benefit vehicle companies downstream of the industry chain. You know, among the carbon neutrality plans of major car companies, one of them is basically "creating a low-carbon supply chain." The real carbon neutral is not just that cars do not use oil and factories do not need thermal power generation, but that the entire industrial chain is "decarbonized".
editor in charge: Chen Hua
proofreader: Liu Wei
