Galanz 40 years: a 'Made in China' upgrade sample

Recently, in order to speed up the implementation of 'Made in China 2025', encourage and support local exploration of the new path and new mode of real economy, especially manufacturing transformation and upgrading, the State Council decided to launch the 'Made in China 2025' national demonstration zone. Xin Guobin, Vice Minister of MIIT Said that this move will be more conducive to the development of manufacturing industry, and the preemptive pilot policies and systems will further release the creative vitality of the market players and speed up the manufacturing industry's quality and efficiency.

The transformation and upgrading have always been an important issue for manufacturing in China. Take the Pearl River Delta as an example. Many factories in the Pearl River Delta, once relying on labor-intensive start-ups, are facing an embarrassing situation of industrial upgrading and demographic dividend disappearing. Shows that labor costs in China have risen five-fold in the past decade. The increasingly expensive labor force has forced manufacturing enterprises to open new avenues and try to 'liberate their hands through automation and upgrading.' In recent years, Guangdong has driven its innovation-driven growth step by step. In Foshan, Zhongshan and other Pearl River Delta, the traditional industrial gathering area, gradually emerged a number of 'machine replacement' boom.

In a decade, China's manufacturing industry has undergone tremendous changes. The number of workers in smart manufacturing factories has plummeted, replaced by a single machine, which has brought with it efficiency improvements, quality improvements and significant cost reductions. Seems to be the only way China factories and even made in China.

The birth of the first robot

'These components were originally used by workers to plug them in. The electrical control panels with more than 100 components used to require 20 workers, and now they are switched to machines and a single production line takes only 6 people.' At Galanz, Liao Hualin, vice president of electronic components manufacturing department to reporters showed an AI automatic plug-in machine, which is only a small Galanz EDC production workshop, however, this machine costly, priced at 1.4 million or so, the entire workshop A total of 29 units.

In addition to plug-in, SMT placement machine also plays an important role, due to the high precision SMD components, the entire link must be completed by the machine, a control board from the earliest all the plug-in gradually improved to patch and plug-ins Combination, greatly reducing the cost of the entire board design.

After the completion of the plug-in and patch, AOI automatic identification detector and on-line detector of the product appearance, performance and function of checks, to ensure that the finished product 100% qualified in such a seemingly small workshop, a total of 43 The production line, mass production of 15-20 million electronic control panels.These electronic control panel covers microwave ovens, ovens, refrigerators, air conditioners, washing machines, rice cookers and other Galanz appliances electronic control package.

In the electric control workshop, each production line has a high level of information and automation. Each electronic control board is marked with a two-dimensional code. The product is tracked by infrared scanning to track each production process and will be recorded into the production line On the server.

It is precisely because of alternating jobs of machines and workers, the labor volume reduced by two thirds than in the past.Liao Hualin told reporters, '95% of the automation is already an ideal state, companies must consider the cost and utilization of the machine, according to the industry supporting And design needs to make each job a replacement for the machine.

Galanz entered into a strategic partnership with robotics giant Fanuc in 2016. In the same year, Galanz Electrical Parts Company's technological transformation group developed the first six-axis robot independently, on the one hand to reserve technical personnel and on the other hand Robots will be heavily used in the plant after their technology matures, and in the view of Galanz, more mechanics will be behind the scenes in the future. In the 4.0 era, companies must provide internal retraining to improve worker skills so that they can be used for future automation and unmanned plant ' be prepared.

Zhang Jianfeng, deputy secretary-general of China Household Electrical Appliances Business Association, believes that under the background of China's manufacturing transformation, manual operations are turned to automation and production processes are improved to cope with labor disputes that may arise in the future. This shift reflects that Chinese enterprises are beginning to engage in more advanced Higher value-added manufacturing. "According to the International Robot Association data, it is estimated that by 2017 China will replace the EU and North America as the world's largest industrial robot using economy.

'Buying equipment is better than making equipment'

Galanz factory in Shunde was established in 1978, the factory has 39 years of history, in the electrical parts shop more than 90% of the equipment is produced by Galanz.

'Make products is not difficult, the difficulty is to do the equipment.' Galanz electrical accessories manufacturing director Huang Zhaohua told reporters that the workshop can be seen everywhere tiny parts rolling on the machine, composed of the shaded pole motor, turntable motor, micro-switch , Timer, DC five major components in the birth of this, before the workshop by another on the raw materials for stamping and injection molding.

Galanz internal process equipment and technical transformation collectively referred to as 'tooling technical transformation', the so-called 'tooling technological transformation' is to upgrade the existing manufacturing equipment. In 1993, Galanz's first microwave oven came out, in one fell swoop to break the industry monopoly by foreign brands Since then Galanz's development has gone through several difficult stages, from the introduction of imported equipment to purchase domestic equipment to their own R & D and production equipment, with a full 20 years, now Galanz has been able to do their own research and development, design, production , Manufacturing equipment, and complete including microwave ovens, air conditioners, rice cookers and other white parts of the core mass production.

'In the view of Huang Zhaohua, R & D and manufacturing capabilities of owning equipment have gradually become the core advantage of Galanz occupying the manufacturing highland of China's home appliance industry. Especially in the context of the high cost of equipment maintenance and the acceleration of product upgrading and upgrading, It is not the long-term development strategy for the core support to be produced by others. "Having mastered the core technology has mastered the lifeblood of the enterprise," said Huang Zhaohua.

As small as a rivet to a magnetron, Galanz has been able to complete the seamless convergence of the whole industry chain, from the past 'to buy parts depends on the supplier's face' to 'Indian and Japanese Galanz factories to learn from' Galanz people Technology to refresh the international awareness of Chinese-made.

In this regard, Galanz magnetron manufacturing director Zhang Wenliang feel the deepest, 'Galanz magnetron without any technology introduction, it can not be introduced.' In fact, the International Industry Coalition has long built a wall for Chinese enterprises in the past a long time Want to buy each other's key equipment, costly and without any bargain, or buy some of the equipment has been eliminated at high prices.

In 2000, Galanz initiated the development of magnetron, after a few years had been tested for magnetrons, just started, when China's home appliance industry is weak, supporting the overall backward.For example, the use of silver, copper, plating The functional electroplating of nickel products, to withstand nearly 900 ℃ high temperature hydrogen furnace test, when the general manufacturers can only do decorative plating, electroplating pieces into a high temperature hydrogen furnace, the electroplating layer has long been missing due to the large use of hydrogen, However, market resources are limited, Galanz will buy all of the Pearl River Delta can buy hydrogen, all consumed in less than two hours, how to find the matching raw materials? In Zhang Wenliang seems to do magnetron addition to not dig up the mountain Have to do anything.

In this process, Galanz must understand its own industry needs clearly, customize the raw materials and accessories with matching production factors, and even help suppliers overcome the technical difficulties. After a long period of research and development, Galanz magnetron electron emission efficiency from 70% -71% to 75% -76%, fully equipped with the core elements of the source to lead the microwave upgrade conditions. Over the past two years to complete the upgrade Galanz magnetron pipe production line, with intelligent, relatively traditional manufacturing, a new Zhizao production line to reduce the amount of 30% of the work, work efficiency increased by 25%.

In addition to the supply of basic raw materials such as plastics and steel products, we also supply key components and components, such as magnetrons, transformers and computer boards, which are self-supporting industrial chains such as injection molding, stamping, sheet metal and molds, All independently developed by Galanz design.

Real gold hit the smart

The core matching self-realization ability enables Galanz to expand the entire product line, and its products such as air conditioners, refrigerators, washing machines and electric steamers are all available one after another. Different from the traditional production line-oriented layout of the home appliance enterprises, Galanz is trying its best to create products The ecological layout, forming a complete ecological chain manufacturing system.

From microwave ovens to white goods, after the completion of the traditional layout of white electricity, Galanz has constructed a future kitchen for young people and has personally experienced the 'vitality' brought by Galanz at Galanz's Kitchen Experience Museum reporter.

From the factory to the store, Wang Shou-guo, deputy director of Galanz Institute of Appliances, showed reporters a smart refrigerator, equipped with a camera in the refrigerator to monitor the food storage date in a timely manner, and can also purchase fresh food from an external multimedia terminal. By downloading the mobile APP, Remote control ...... In addition, Galanz kitchen range hoods, micro-one machine, drum washing machines and other products can be completed on the Internet information exchange, which is fully in line with the younger generation's pursuit of quality of life.

This glorious 'kitchen' is Galanz's profound interpretation of the automation and intelligence of the entire product line.With the further development of 'Made in China 2025', Galanz has been continuously increasing its efforts to actively promote the construction of an automated factory, In recent years, Galanz invested more than 3 billion yuan to build automated production equipment such as microwave ovens, dishwashers and washing machines, and the investment in manufacturing and transformation only exceeded the sum of investment made in the past 20 years. For a company that has been in development for nearly 40 years and yet to go public, Galanz has not invested in any capital and does not intend to engage in 'sideline' business as any other home appliance business.

Liang Zhaoxian, president of Galanz Group, once admitted in an interview: "Enterprises can not always serve capital, serve investors and should serve more consumers."

'In which direction the business development which is closely related with the leadership decision-making power' Huangzhao Hua believes that not only is the equipment of real money, in the introduction and training of qualified personnel, Galanz attaches great importance.

'People are the first capital of Galanz' was impressively written on the wall of a factory in Galanz's Shunde factory. Over the past two years, Galanz has top-ranking R & D, marketing and manufacturing management personnel introduced to Europe, the United States, Japan and South Korea. Since 2004, Galanz has launched the 'Sunflower Program' for brand-name university graduates and has trained technicians and technicians with first-class specialized colleges and universities through the mode of school-enterprise cooperation such as "joint school running, job alternation, and production and teaching integration."

Source: China Business

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