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【中国制造2025样本调查】我们离智能制造还有多远?

2017-05-23 22:01:40   央广网

央广网北京5月23日消息(记者杜金明 王建帆 宁波台记者吴巧 吴福明)据经济之声《天下财经》报道,假设有这样一个场景:你在网络平台看上一件衣服,下了订单,企业从接单、设计方案、分配任务开始,一直到生产、包装、物流等诸多环节,能实现人与机器人的互不干扰、完美共事,这种柔性化、智能化和高度集成化的生产、销售过程,通常就是我们所向往的智能制造,它是中国制造2025的核心。《中国制造2025样本调查》第二篇:我们离智能制造还有多远?

一进门,首先迎接记者的是人脸识别系统。跟着车间主任胡新凯,记者顺利进入到了车间里。眼前,两条生产线正在工作,只有搬运机器人在自由穿梭,没有工人;这里全天不开灯,但每条生产线每分钟能暗暗生产500节碱性电池。这就是中银(宁波)电池有限公司的“黑灯车间”。

车间里,只看到机器身上发出的星星点点的光,像跳动的一个个音符;生产线上,一节一节电池排着队,呈S形前进,然后快速下线。车间主任胡新凯说,这是世界上智能化程度最高的碱性电池生产线。“正常生产的时候不需要照明,因为没有操作工。所有的动作,包括机器人,包括设备,指令都是程序安排好的。”

按照传统的生产方式,一节电池从原材料到成品,要经过11道工序,经过7个人的手,大概耗时1个小时。如今这些工作全部交给机器人后,一条生产线减少7人,但生产效率却大大提高了,真正实现了提质增效。

不过,也有人对投入产出提出了质疑。中银的这两条生产线投入4000万元,历时一年半研发而成。传统车间里,同样规模的两条生产线需要14个操作工,按一名操作工年薪8万计算,总的人工成本才112万,只有现在智能生产线研发成本的不到3%。这笔账,感觉不怎么合算。不过,中银(宁波)电池有限公司的工程部主任常伟却算了一笔长远账:一是智能化生产提升了产品的合格率;二是机器换人解决了招工难。

常伟说:“我的质量不需要人看,我把人的眼睛取消了;我的货物的搬运(靠机器人),把人的手脚取消了;我所有的数据用我的自动化系统全部集成了。”

在以制造业著称的宁波,越来越多的企业正在向智能制造迈进。比如在宁波慈溪的先锋电器,是全球最大的取暖器专业生产企业之一。2013年,先锋电器创始人的儿子姚裕初从国外留学归来后,开始大刀阔斧“机器换人”。公司的目标是把一线工人从4000人减少一半,到2000多人,但是事与愿违,目前只砍掉了300人。原因很简单:很多环节是机器人无法替代的。

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