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Coating enterprises try to reduce the cost and expand the capacity of intelligent factories in response to rising raw material prices and weakening demand

coating enterprises try to reduce the cost and expand the capacity of intelligent factories in response to rising raw material prices and weakening demand

November 1, 2018

under the condition of low industrial concentration, the rise in raw material prices is not the key to the problem, and how to reduce the cost and expand the capacity is an issue that enterprises need to consider

"in the past, people thought that the more people there were in the factory, the larger the scale was. Now, the less, the better." On October 30, at the opening ceremony of Nippon Paint (Hubei) Co., Ltd., zhongzhonglin, President of Nippon China, said that China paint

it is learned from the emulsion paint production workshop of the above factory that the staff can place orders on demand through the emulsion paint automatic production system, and the intelligent system will issue material preparation instructions to the automatic storage tank equipment according to the requirements of the production order. According to the fine instructions, the intelligent system automatically generates the batching list by floor, and automatically feeds, mixes and produces according to the requirements of the production list. After the semi-finished products pass the quality inspection, the intelligent system will notify the production department to enter the finished product packaging link. The cost is to deliver the products to the three-dimensional warehouse through the driverless logistics vehicle in the factory. All materials are transparent and traceable in every link from incoming to outgoing

latex paint automatic production line

"at present, the production capacity of the latex paint factory is 150000 tons. From the tank car connecting to the pipeline and automatic feeding to the subsequent production process, only three workers are required, two of them are responsible for measuring and mixing (instructions) in the central control room, and another employee is responsible for inspecting the machine on site." The staff of Nippon told that through the previous investigation on the production and operation of ICBC in factories in Shanghai, Fujian, Guangzhou and other places, workshops with the same capacity generally need 80 people to complete the above workflow

putty powder workshop

"Nippon coatings has entered the Chinese market for 25 years. From comprehensive investment to plant construction, Hubei intelligent factory can be said to be Nippon's third generation plant in China. In the process of coating production, from the pipeline transportation of powder and injection agent to the automatic lower cover and automatic capping, and then to the construction of automatic warehousing and logistics system, intelligence not only ensures quality control, brings efficiency improvement, but also meets the needs of environmental protection." Zhong Zhonglin said

at the beginning of promoting the intelligent production of coating manufacturers, the above two schemes need to change the structure of raw machines. The intention is not to show off the technology, but the actual problems existing in the development process of the industry, such as the rising price of upstream raw materials, shrinking market demand, tightening environmental protection policies and so on. Under the above background, coating enterprises attempt to test the water of intelligent manufacturing to complete cost control and efficiency improvement, and introduce new service modes to increase consumer stickiness, so as to create "Refresh" demand in the stock market

since 2018, with the rising prices of raw and auxiliary materials, coating enterprises have faced great cost pressure. According to incomplete statistics, from early March to September, Nippon, PPG, AkzoNobel and other coating enterprises have set off five rounds of price increases this year

"the price of raw materials today is actually not high compared with that ten years ago. The difference is that although the prices of raw materials and coatings were high ten years ago, the market was still in a state of short supply." Zhongzhonglin pointed out that the current problem is that the prosperity of the industry is much worse than before, the market demand is insufficient, the supply of coating products exceeds the demand, and the life of large and small enterprises is difficult

therefore, when the industrial concentration of coatings with certain consumer properties is low, the rise of raw material prices is not the key to the problem. How to reduce costs and expand capacity is a problem that enterprises need to consider

Zhong Zhonglin believes that under the above circumstances, enterprises need to compress their management to make it compact. For example, strengthen the trend of unmanned production process and optimize energy efficiency management in water, electricity and heating. It is particularly important to control the inventory, production cost and transportation radius of raw materials

it is understood that the international top coating manufacturers, including Xuanwei, PPG, AkzoNobel, Masco, Nippon, Asia coatings, RPM, Jotun, Easter and BASF, have made some arrangements for intelligent production. However, throughout the coating industry, the real intelligent factory is still rare, and there are still pain points in the transformation from automation to intelligence

"the problems solved by the previous generation of factories are more automation. In the process of realizing intelligent manufacturing, it is necessary to get through all single points. It is not only an indispensable basic production link for a large number of industrial and agricultural products." Zhongzhonglin believes that there are still many breakpoints in the current automation, such as feeding automation, packaging automation, etc., but if these processes are not continuous, such a system is like being strangled and cannot play a real role. "

at present, small and medium-sized enterprises are usually in the "brown field" stage, that is, there are some old equipment that need to be connected and updated. In addition, these enterprises are also constrained by the lack of IT resources, professional knowledge and cash flow, and cannot wait for the return on investment after 5 to 10 years. The system displays "C1", indicating zero point detection

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