August 18，CCTV News Channel《New discoveries in China's economy》A series of reports focus on“Lighthouse factory”，Two consecutive broadcasts, focusing on Sany，From New Technologies in Intelligent Manufacturing、New application，Discover the new driving force of China's economy、New growth。
“Lighthouse factory”Be known as“The most advanced factory in the world”，Selected by the World Economic Forum，It represents the highest level of intelligent manufacturing in the world，Full automation of the production process、Precision and optimization，It guides the new direction of digital transformation of global manufacturing industry.。
Our country is the world“Lighthouse factory”Most countries，At present, there are 11 batches of 153 companies in the world.“Lighthouse factory”Medium，There are 62 Chinese factories.。Since this year，“Lighthouse factory”As the representative, the growth of high-tech manufacturing industry has accelerated.。According to the latest data，July，The added value of China's high-tech manufacturing industry increased by 10 percent.0%，1% faster than last month.2 percentage points。
So“Lighthouse factory”What the hell？What are the new changes this year?？What role does it play in China's economy?？
AIThe system simulates learning with careful calculation.“Tailor”
Sany Group，Praise 56
At“Lighthouse factory”In the evaluation criteria.，Use automation、Digitize、5GCommunication and other technologies are an important indicator for enterprises and industrial chains to reduce costs and increase efficiency.。Reporters found in the survey， Each “Lighthouse factory”Behind，They all have one“An intelligent brain”Robots and workers on the command line work together.，Let every production link use the least material.，Do the fastest work.。
A family in Changsha, Hunan“Lighthouse factory”It mainly produces pump Trucks in construction machinery.。The head of the factory told reporters.，A pump Truck can be assembled in 45 minutes at the fastest.。
The production of a pump Truck begins with the cutting of spare parts，How many steps are there in cutting a steel plate?，The answer is one click.。
Guo Pengxiang, Cutting and Forming Engineer of Intelligent Manufacturing Headquarters of Sany Heavy Industry：Once we get the nesting order，Click a smart typesetting in the screen.，The whole intelligence“ Brain ”It will be based on the optimal utilization，Generate a nesting diagram，The robot is ready to cut.。
How to make the best use of it，It has been a headache for enterprises before.，Draw the shape of the parts on the steel plate by hand and then cut it.，Low efficiency，A lot of waste。
Guo Pengxiang, Cutting and Forming Engineer of Intelligent Manufacturing Headquarters of Sany Heavy Industry：Around 2019，The average utilization rate of steel in the whole group is only 70.8%Left and right，Even an experienced programmer.，It is also impossible to achieve the optimal utilization rate of the nesting map.。We preserve the best nesting results in history.，Let's startAIAutomatic learning。
AIThe system not only increases the number of spare parts on each steel plate，It also matches the spare parts of other construction machinery and equipment through data.，And guide upstream enterprises to provide more accurate size of raw materials.，Reduce waste。
Guo Pengxiang, Cutting and Forming Engineer of Intelligent Manufacturing Headquarters of Sany Heavy Industry：Originally, I only produce spare parts for pump trucks here.，Now it can also produce fire engines.、Accessories for towing pump，The utilization rate of steel plate increases by one point，The procurement cost can be saved by 20 million yuan per year.。
AIAfter the system is online，The steel utilization rate of enterprises has increased by 11 percentage points.。
Guo Pengxiang introduced to reporters.，In addition to the nesting link，The welding robot in the factory can control the welding seam at the millimeter level.，Use 1/The rotary table of the pump truck is welded out in 6 hours.，Blanking robot andAGVThe car can travel at a speed accurate to the second.，Send the spare parts of each link to the workstation.，In the baking room，The robot can dynamically control the baking power according to the current room temperature.，Reduce energy consumption。
In constant learning，Intelligent brain gradually exerts the highest efficiency and reduces the most cost of the factory.，The automation rate of the plant is close to 80 percent%，Production capacity increased by 123%，Personnel efficiency improvement 98%，29% reduction in unit manufacturing cost%。
Yao Zhiheng, Director of Sany Heavy Industry Pump Road Intelligent Manufacturing Technology Institute：Our system is not only used to optimize the production process.，We also connect all the devices we sell to the Internet.，Through this system.，Research and development、Manufacture、Sale、After-sales，Can all work together on this.。
Flexible production line industry exports to participate in global competition
Sany Group，Zan 19 The construction machinery industry is highly cyclical.，There are many kinds of products，Features of small batch，Enterprises must adjust the production plan at any time according to the demand of market orders.，Resolve market risks。
At“Lighthouse factory”Li，Intelligent、Application of digitization，Make flexible production possible。While reducing costs and increasing efficiency，Help enterprises easily adjust production plan，And expand its business to overseas markets。
In this room“Lighthouse factory”Li，The reporter saw，Pump truck turntable being welded by robot，It is not the product of its own enterprise.。
Ke Xiangen, Deputy Director of Sany Heavy Industry Pump Road Intelligent Manufacturing Technology Institute：This is the 47-meter turntable of Putzmeister we produced.，The debugging has just been completed，It will be mass-produced next month.。
2012，Sany acquired 100% of Germany's Putzmeister%Equity，The two companies tied the knot，In research and development、Deepening cooperation in marketing and other aspects，However, the production lines of their respective products are not combined into one.。The pump trucks produced by Putzmeister are mainly sold to the high-end markets in Europe and America.，Assembly plant is located in Turkey，Previously, it had been ordering parts for product assembly in Europe.。
Ke Xiangen, Deputy Director of Sany Heavy Industry Pump Road Intelligent Manufacturing Technology Institute：The cost of their purchased parts is relative to our self-made parts.，The cost is more than twice as high.，The standard applied by Putzmeister is the European Standard.，High requirements for welds and refinement。
High raw material and labor costs，Let Putzmeister look east to his partners.。“Lighthouse factory”The flexible production line can not only meet the enterprise's own production.，Intelligent、The technology of automation is also fully adapted to European standards.。
Ke Xiangen, Deputy Director of Sany Heavy Industry Pump Road Technology Institute：We use arc tracking technology for turntable welding.，The accuracy can reach millimeter level.，You can switch programs to produce different models at any time.。Production cost plus transportation cost，20% lower than local production in Putzmeister%。
The head of the factory told reporters.，Not only“Lighthouse factory”Able to produce foreign equipment，Enterprises will also“Lighthouse factory”The model is replicated overseas.。In Indonesia，The first overseas company in China's construction machinery industry“Lighthouse factory”，It is working steadily at the rate of producing 3000 Excavators a year.，12 processes、Full network connection and unmanned production of more than 500 robots，The first overseas systematic export of intelligent manufacturing in China's construction machinery industry has been completed.。
Yao Zhiheng, Director of Sany Heavy Industry Pump Road Intelligent Manufacturing Technology Institute：We are now talking about globalization from the export of products to the export of industries.，Leading the allocation of resources through Chinese enterprises，Better serve global customers。 Later “Lighthouse factory”It's not just an independent factory.，But with“Lighthouse factory”To form a system based on intelligent decision-making and highly flexible manufacturing.，So as to help Chinese enterprises better participate in the global competition.。
Source：CCTV News
