After absorbing the first robot for 9 years, Highly Group has tasted a big sweetness: in 2015, the cost of using a robot was less than 60,000 yuan/year, and the cost of using a worker was nearly 100,000 yuan/year. The Haili Group, which produces the “heart†of air-conditioning – the compressor, owns one of the largest robot factories in Shanghai. In Haili's view, the compressor manufacturing industry can still be retained on the banks of the high-cost Huangpu River. Because of the “recruitment†of robotic employees, it has won a strategic space for Highly.
In fact, in addition to the industrial robots used in manufacturing, intelligent robots have replaced labor, and more and more play the role of customer service in the financial and other fields. CCB and China Merchants Bank have thus saved 9000 manual customer service.
"Science Fiction" workshop: 3 workers + 8 robots
The "iron arms" are everywhere, and the workers are sporadic. Flip, swing, grab, drop... 600 degrees Celsius high temperature, the robot's "iron arm" of the bumblebee color moves freely, as long as 10 seconds, three or four pounds of silver-white metal coils are taken from the next to the next The station and the process are called “stable and fastâ€. After a pipeline process, the end is filled with a molded "outer" casing. Each robot here is in a fixed position and can operate two or more devices.
This is not the scene in the sci-fi blockbuster, but the real scene of the sheet metal workshop of the Highly Group Shanghai factory.
At the plasma welding station, several workers are scattered among them. Their role is either "supervisor" or "doctor". The work of regulating robot equipment, sampling and testing products is done by workers.
As early as before the robot “joinedâ€, this compressor shell production line required about 15 workers to complete the production task. Since 2007, after the “recruitment†of robots, the current staffing structure has changed to: 3 workers + 8 units. robot.
The compressor is the heart of the air conditioner and refrigerator. The task of the sheet metal workshop is to process the steel plate into a compressor casing. At present, there are 22 robots in this workshop, and the number of workers has been reduced from 144 in 2007 to 20, which means that the work of 124 workers has been “made†by robots and “reduced†by workers. %.
In addition to sheet metal, the rest of the "arms partners" are handling, baling, and even screwing in the final assembly. Up to now, the entire Highly Group has owned 480 industrial robots. Since 2007, it has replaced 357 first-line positions, equivalent to nearly 1,000 front-line employees.
Cost two accounts: robot price drop 5% annual labor cost increase 10%
The compressor industry is a labor-intensive industry, and many jobs are done manually. However, with the gradual disappearance of the demographic dividend, the problem of “difficult recruitment and labor shortage†appeared as early as a few years ago.
At the Highly Group Shanghai plant, labor costs accounted for 47% of total manufacturing costs. In response to rising labor costs, Haili walked out of Shanghai in 2007, established new plants in Nanchang and Mianyang, and India's manufacturing base was completed. At present, the Shanghai base accounts for less than 60% of the Group's total production capacity.
"We have a large number of employers in this type of manufacturing industry, and almost every employee has lost some employees after the long holidays such as the Spring Festival. And some of them are not willing to go to the production line for heavy-duty operations after the 80s and 90s." Zheng Min, general manager, told the reporter: “The peak of departure from February to March is exactly the peak of our production. The average 33% turnover rate will interfere with normal production. At the same time, the frequent replacement of first-line workers will affect product quality and increase equipment damage rate. And safety hazards."
Of course, when recruiting the first robot in 2007, Highly Group did not hesitate: Take the Shanghai factory as an example. At that time, the labor cost of first-line workers was about 37,000 yuan per year, and the annual cost of robots was 73,000 yuan. , almost doubled.
At the same time, however, labor costs have risen at a rate of around 10% per year, while the price of robots has fallen by about 5% per year. The chairman of the then general manager, Shen Jianfang, thought about the sustainable development of Highly, and established the strategic vision of “the world's number one supplier of air-conditioning compressorsâ€, proposing the next step of competition with multinational companies, which must further develop technical capabilities and manufacturing capabilities. Innovation and improvement. To transform and upgrade, enterprises need not only the development of new products, but also the level of intelligence of production systems. So, we saw the "running" of the later Haili application robot.
In fact, by 2011, the cost of using a robot was lower than that of using a worker. The Shanghai factory is still an example. The former costs 63,000 yuan per year, while the latter costs 67,000 yuan. Moreover, this group of "scissors difference" is still expanding. By 2014, the advantages of robots have become more apparent. This set of numbers has changed to 56,000 yuan and 92,000 yuan.
“Recruiting†robotic employees has won a strategic space for Highly. In Haili's view, even in the high-cost Huangpu River, the compressor manufacturing industry can still be retained.
“HR IIâ€: What is the level of robots used to track the number of robots used by Haili?
In mid-2015, IFR (International Robotics Federation) counted the density of industrial robots in the world, with a maximum of 437/10,000 industrial workers in South Korea, followed by 323/10,000 industrial workers in Japan and 282/10,000 in Germany. Industrial workers, while the world average is 66/10,000 industrial workers, and China has only 36/10,000 industrial workers, which is below the world average.
Zheng Min said that the Shanghai factory has reached 569 units/10,000 industrial workers, which has surpassed the highest level in Korea and is at the world's leading level.
In order to manage these robots, the Shanghai factory has a “Second Human Resources Departmentâ€: The Production Technology Department undertakes the human resources management of the robots.
More than 230 robots, from 2007 to the present, a total investment of 187 million yuan, 288 posts, 861 people ... Chen Jiayu, chief of the Automation Promotion Division, said that the production technology department will file a number for each robot in order to continuously track the return on investment of the robot. At present, one machine passes three working hours, which is equivalent to the output of three production employees. Based on the 2015 automation project, the average return on investment is 3 years.
On the other hand, the “Second Human Resources Department†is responsible for the “transfer†work of the robot according to the adjustment of the work station. It can be easily realized by changing the robot manipulator configuration, which reduces the difficulty and labor cost of personnel transfer and is highly versatile.
Internal re-investment can also be achieved through robotic labor savings. For example, after three years of depreciation to recover the investment, the labor cost saved by the robot continues to work, forming a pool of funds, and achieving self-circulation through reinvestment.
Increased production capacity: per capita capacity increased from 295 units to 1131 units
If there is no robot, the instability of the staff will cause production fluctuations. For example, the resignation and newcomer training make the staff's work efficiency fluctuate greatly, and the human factors such as fatigue level, worker's mood and skill proficiency will bring uncertainty.
After the robot is “on the jobâ€, it can maintain a stable and efficient operation state for a long time, achieve low output fluctuations, improve on-time delivery rate, reduce in-process inventory, and comprehensively improve on-site management.
The artificial efficiency is compared with the robot efficiency in different time periods within one shift: the personnel efficiency is up to 90%, the lowest is 0%, and the fluctuation is at any time, and the robot efficiency is stable at about 90%.
Take the Shanghai factory sheet metal shell production line as an example. Before using the robot, there are 10 operators per shift, with a capacity of 2,949 compressors, 295 per capita capacity, and 1.2 per capita operation equipment. After using the robot, each shift is reduced to 3 people. However, the capacity of the class has expanded to 3,392 units, with a per capita production capacity of 1,131 units and 7.7 per capita operating equipment.
Man-machine "dancing": worker transformation is an inevitable move
The employment of a robot does not mean that the worker is laid off. "In 2007, robots have been introduced, and there has not been a large-scale separation." Zheng Min told reporters that the first-line laborers had a certain turnover rate, and the reduction of recruitment, robots replaced nearly a thousand workers is a gradual decline process.
After the robot came, the "worker" who danced with it was also the beneficiary. “In 2005, we organized the Highly Power Academy and jointly organized with the University of Television and Radio, so that workers can read college classes and undergraduate classes.†Zheng Min introduced that after training, some workers were liberated from the original heavy physical positions, and now the scene Workers' work mainly focuses on equipment maintenance and product testing, transforming into robot managers, reducing labor intensity and increasing revenue.
The increase in income is the most visible “affordableâ€. Haili uses a large number of robots, and after the labor efficiency of the company is improved, the income of employees increases. Last year, the annual per capita cash income of the Shanghai factory sheet metal workshop rose from 37,000 yuan in 2007 to 84,000 yuan.
In terms of improving occupational health, robots can replace manual work in harsh environments such as noise and high temperatures. According to reports, the noise of high-speed rushing posts reaches 97 decibels, the sound of electric saws is 90 decibels, and the exposure to noise of 70 decibels to 90 decibels for five years, the risk of high blood pressure is as high as 2.47 times.
Workers who were originally engaged in high repetitiveness and high labor intensity can turn to positions with higher skill requirements and lower labor intensity, which strengthens the ability of enterprises to innovate and is more conducive to the realization of personal values ​​of employees.
It can be said that the use of robots is a win-win situation for enterprises and employees.
Highly Meaning: Robots Resolve Manpower Cost Pressure
To transform and upgrade, enterprises need not only the development of new products, but also intelligent and flexible production. In the face of disappearing demographic dividends and high labor costs, the exploration of Highly applied robots has sample significance for other companies.
At present, Highly Group has taken the lead in completing the international industrial layout in the industry. There are 5 world-class compressor factories and 7 technology centers in the world. The products are sold to more than 160 countries and regions. There are 1 set of 7 air conditioners in the world. The Highly Compressor is used.
As a traditional home appliance manufacturer, Highly is able to take the lead in realizing the internationalization of its industrial layout. One of the factors that has long occupied the top three in the global market is the introduction of an intelligent automated production model and the introduction of robot “employeesâ€.
As robots can effectively relieve the pressure of rising labor costs and protect the advantages of domestic manufacturing companies in other aspects, Zheng Min believes that China's "world factory" status will not be easily replaced.
Industrial robots have been used in the automotive industry for the longest time, mostly in welding, stamping and painting. But now, robots are “big-scale attacks†in various industries, from the handling of valuables such as tobacco and Wuliangye, to the brick making, food and beverage industries, and even the feed industry. In fact, more and more labor-intensive companies in China are also experimenting with robots. Zheng Min believes that Highly's robotic application model is fully qualified for replication in other mass-produced, standardized, and process-oriented manufacturing industries.
Highly is currently preparing a robot plan for 2020. In the future, most workshops in Shanghai are expected to be fully automated.
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