The Guangdong South China Sea Entry-Exit Inspection and Quarantine Bureau has conducted a special survey of the “machine-for-machine†status of the company within the city. It has visited and surveyed more than 10 representative companies and conducted 200 surveys through questionnaires. Involved in general equipment, automobile and motorcycle fittings, aluminum profiles, metal processing, electronic communications and other fields. According to the research report, through the "machine substitution", the enterprises generally obtain the good benefits of reduced production costs, improved production efficiency, improved product quality, and reduced energy consumption. However, the "substitution of machinery for small and medium-sized enterprises" still faces insufficient funds and insufficient technical capabilities. Lack of professionals and incentive policies need to be further improved.
After the "machine substitution" efficiency has generally improved
According to reports, the research team visited more than 10 Foshan manufacturing companies in depth and at the same time conducted a questionnaire survey of the 200 companies and conducted a total of 173 valid questionnaires. Among them, there are 19 large-scale enterprises with annual output value exceeding 400 million, accounting for 10.9%, 122 medium-sized enterprises with output values ​​ranging from 20 million to 400 million yuan, accounting for 70.5%, and 17 small enterprises with less than 20 million, accounting for 9.8%. According to the survey, 46% of companies use industrial robots, and 83.6% of companies use smart devices other than industrial robots.
According to the report, the biggest driving force for the "machine substitution" of enterprises is to increase production efficiency. Up to 71.1% of enterprises selected this option (multi-choice questions) among the most important reasons for the implementation of "machine substitution", and the remaining 46.8% of the respondents In order to improve product quality, 33% of companies chose high labor costs, and 16.8% of companies chose recruitment difficulties.
“This shows that the company is not passively carrying out 'machine-for-work' work, but is more actively upgrading its production efficiency and product quality,†said the person in charge of the research report. 67.3% of the surveyed companies stated that “machine substitution†has increased production efficiency by 10%-30%, 19.3% of respondents said that production efficiency has increased by less than 10%, and 8.8% of the companies stated that production efficiency has increased by more than 50%.
Labor-intensive companies would like to "machine change"
According to the survey, 33% of the enterprises chose the high cost of labor in the most important reasons for the “machine substitution†work. 16.8% of the companies chose the corresponding type of work for hardship, danger, and recruitment difficulties. These are mostly labor-intensive enterprises. "Machine substitutions" are more urgent.
According to data released by the Statistics Bureau of Foshan, from 2005 to 2015, the average monthly wage of employees on the ground in Foshan rose from 1,836 yuan to 5,151 yuan, with an annual growth rate of 10%-15%. The labor cost has forced some labor-intensive enterprises to use machinery instead of labor.
It is reported that with the gradual relocation and upgrading of labor-intensive enterprises in recent years, the labor shortage in Foshan has been largely resolved, but the trend of increasing labor costs has not changed. In addition, there are still difficulties in recruiting workers for some dangerous and difficult jobs. For example, the glaze spraying process of sanitary ware, the scene of large dust, tens of thousands of monthly salary are difficult to recruit people.
Substitution of machines allows most companies to reduce labor costs. According to the survey data, 52.1% of the surveyed enterprises stated that after the implementation of “machine substitutionâ€, the employment of enterprises was reduced by 10%-30%, and 40.4% of the surveyed enterprises had reduced their employment by 10%. For example, Guangdong Xinhe Aluminum Co., Ltd. introduced three fully automatic oxidation production lines to reduce the use of 350 people. The cost of one-year labor can be reduced by 20 to 30 million. In 3 to 5 years, the cost of technological transformation can be recovered.
Difficulties in funds constrain the "machine substitution" of SMEs
The research shows that Foshan enterprises have a high degree of enthusiasm for “machine substitutionâ€, and in particular, some demonstration companies have achieved great success through “machine substitution†and have played a good role in demonstration. The industrial robots in Foshan have shown a rapid growth trend, which has grown by more than 2,000 units in 2016 alone.
However, for some companies, especially small and medium-sized enterprises, there are still some difficulties in carrying out "machine substitution". The most prominent is that the cost of "machine substitution" is too high, and it is difficult for enterprises to invest funds. 60.8% of the surveyed companies stated that the main difficulty in restricting enterprises to carry out “machine substitution†is funding difficulties. It is reported that the price of industrial robots is generally higher, and the price of an industrial robot is as low as 100,000 yuan, and as many as a million, plus the cost of system integration and control and control software, hundreds of millions of times are needed, and one is intelligent. The production line needs more than 100 million yuan of investment, but it takes a relatively long time to recover costs.
Qiu Siming, deputy secretary-general of the Foshan Machine Industry Innovation Association, said that some business owners, especially small and medium-sized ones, are mostly people in their 50s. They lack understanding of this new type of machine substitution and have no incentive to invest in transformation. The robotics industry association has the intention to do it, but its power is limited. Government departments should also devote more efforts to propaganda and promotion of machine substitutions.
Recommendation: Take measures to solve the problem
The research report also made corresponding suggestions for the difficulties faced by the "machine substitution" of Foshan enterprises. For example, financial difficulties are the biggest obstacle to Foshan's industrial companies carrying out "machine substitutions." To solve this bottleneck, it is impossible to solve the problem by expanding government funding alone or the company’s own financing. It is necessary to take multiple measures to explore and establish a combination of industrial, financial, and fiscal policies that suit the characteristics of the region.
In addition, it is also necessary to accelerate the training of "machine substitution" personnel. For example, encourage enterprises to enhance the ability to cultivate independent talents, strengthen cooperation with universities and research institutes, establish a joint personnel training mechanism, and train a group of high-tech talents such as automation and software development. Third, guide qualified companies to accelerate the establishment of platforms such as technology research and development, engineering technology, and postdoctoral workstations. The fourth is to use government subsidies to increase the income of first-line senior technicians and attract more talents to work in Foshan.
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