In the large factory, there are only more than a dozen workers operating different equipment on the assembly line, and the spare parts are transferred between the automated production line, which is a robot… This is not a movie shot, but the production scene of the safety shoe forming digital workshop of Senna Group Co., LTD.

CIMR-P7U45P5 In November last year, Sena Group launched the construction project of safety shoe forming digital workshop to explore the way of “intelligent manufacturing” to reduce the dependence of traditional shoe enterprises on labor, in order to achieve the purpose of innovation-driven, reducing staff and increasing efficiency, the project was shortlisted in March this year Ruian City’s first batch of intelligent manufacturing pilot projects in the shoe industry. Recently, the reporter came to Sena Group to explore this set of intelligent, automation and information technology in a digital workshop.

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CIMR-P7U45P5 Automated production line PK traditional production line

Production efficiency increased by nearly 50%

Sleeve shaping, injection molding, finishing and packaging… The shoes can be made in a few minutes, and the qualified rate of the finished products is 99.9%.

CIMR-P7U45P5 This is the production efficiency of the shoe-making line in the digital workshop of safety shoe forming of Sena Group. Recently, this assembly line has been put into trial operation, and through the innovation of process technology, people and machines have formed effective interaction.

Zheng Yizhao, deputy general manager of Sena Group, is the person in charge of the project. Under his leadership, the reporter entered the digital workshop to visit. I saw different “tall” equipment formed a ring assembly line, with only a few workers on the side for auxiliary operation, and on the other side, multiple robots waved long arms for “fancy” operation: Surface drawing, spray glue, steel plate, intelligent shoe last handling and other processes originally operated by manual operation are all completed by robot workstations, stereotyping, molding, finishing, packaging into the box, each process of semi-finished products will be used in a short time by the next process, ring by ring, orderly, with a feeling of one step. “The finished upper becomes a pair of finished safety shoes in just a few minutes, compared to about three days under the old production process.” Zheng Yizhao introduced that the traditional production line to produce a pair CIMR-P7U45P5 of safety shoes needs to go through different workshops such as punching, stitching, shaping, molding, finishing and packaging, and these workshops are located on different floors of the plant, and the shoemaking process is long. The automated production line put into trial operation will open up all the production processes with intelligent means, and realize the integration of upper surface shaping, injection molding, and shoe finishing and packaging, greatly reducing the time and labor costs spent on secondary handling.

It is worth mentioning that the automated production line is no longer responsible for handling workers, but replaced by robots. “We let the robots do all the heavy lifting.” Zheng Yizhao told reporters that in the past, handling needed to occupy a lot of manpower, and now an automated production line has invested 2 AGV handling robots, saving a lot of labor costs.

CIMR-P7U45P5 According to the preliminary budget, after the project is officially put into operation, the production efficiency will be increased by nearly 50%, and the annual standard production capacity of a single line will be 297,000 pairs, with an annual output value of 10.3752 million yuan.

Intelligent control of production process

Millions of dollars saved in labor costs

CIMR-P7U45P5 In stark contrast to the nearly 50% increase in production efficiency, more than half of the labor is saved. “By replacing manual labor with mechanical equipment, it is estimated that an assembly line of 27 people can be reduced to 12 people, and the labor cost of a single line can be saved by one million yuan.” Speaking of the benefits brought by automated production lines, Zheng Yizhao is full of joy.

Taking the continuous injection molding process as an example, this process process is more complex, the manual operation needs at least four to five workers at the same time, and now after the automatic and intelligent transformation of the equipment, no workers can be arranged to complete the operation, and the mono-station working time is shortened from the original 28 seconds to less than 20 seconds.

In the specific production links, another change in the digital workshop is that workers can use the on-site visual electronic kanban to centrally monitor the information interconnection of production and processing equipment and the entire production process, so as to achieve visual, transparent and paperless management of the production process.

CIMR-P7U45P5 Chen Yuanfeng, general manager of Sena Group, introduced that the digital workshop not only realizes the automation of the production process terminal, but also realizes the automatic transmission and management of information and data in the product manufacturing process. The RFID identification system is used to collect production data such as shoe type and shoe size, and realize the mixed production of multi-sizes and multi-styles on the production line. And through MES manufacturing execution system, on-site visual electronic Kanban management, machine networking and equipment data collection to achieve the digital control of the production line, effectively solve the previous production links, each workshop in their own information island problem, better control product quality and production progress. “The automatic transformation of this whole set of equipment is independently developed by the company’s research and development team. After the completion of the digital transformation of the production workshop, the next step is to implant business orders, procurement and other processes into digital management to realize the intelligent manufacturing of the whole process.” Chen Yuanfeng said that for the traditional labor-intensive footwear industry, the transformation and industrial upgrading of enterprises has been urgent, and the completion of the safety shoe forming digital workshop will lay a solid foundation for the development of digital factories and comprehensively promote the intelligent manufacturing of the shoe industry, “with the large-scale deployment of automated assembly lines, the shoe industry manual workshop production scene will become a historical lens.”