Wen Lisheng: The Construction of Clothing Ultra-Flexible Manufacturing Mode (I)

Summary

Personalized custom flexible production is the necessary direction for the transformation and upgrading of garment manufacturing enterprises. Based on the premise of the integration of new generation information technology and manufacturing industry, based on the main content and characteristics of flexible production, the concept of achieving ultra-flexible manufacturing mode of clothing is proposed for the first time in the apparel industry. And build methods and content. Through the modularization of clothing products and the modularization of garment production stations and production lines, a dynamic modular production unit is constructed to form a production scheduling model without fixed pipelines, so as to realize an ultra-flexible manufacturing mode of intelligent clothing. Finally, it proposes to form a perfect intelligent manufacturing space for man-machine integration from three aspects: intelligent decision-making layer, manufacturing execution layer and equipment execution layer.

About the Author

Wen Lisheng is a professor at Donghua University, deputy head of the expert group of China's garment intelligent manufacturing technology innovation strategy alliance, deputy director of China Garment Engineering Technology Center, director of China Textile Industry Machinery Association's Garment Machinery Expert Committee, and Shanghai Sewing Association expert. His major works include "foreign clothing machinery", "clothing technology and culture", and "China Encyclopedia (second edition)". Expertise: clothing machinery, sewing machinery , industrial washing equipment, clothing engineering technology and other disciplines. At present, he is mainly engaged in research consulting, teaching and training in the intelligent manufacturing engineering technology of garment enterprises.

With the influence of cultural factors, social factors, personal factors and psychological factors, the traditional clothing consumption market has undergone tremendous changes, mainly reflected in the characteristics of the dispersion, differentiation and variability of purchasing behavior. The conflict between personalized consumption patterns and traditional production methods. In order to meet the individual needs, the production method should have three important links in flexible manufacturing: 1 should have the flexibility to adapt to market changes; 2 should have flexible technical support; 3 should have flexible manufacturing process. This flexible production mode has the ability to effectively cope with environmental uncertainties, and has great practical significance and research value in improving production efficiency and enhancing enterprise competitiveness, and gradually gains attention from production in various industries, among which dynamic scheduling algorithm model Digital twinning technology and virtual production simulation technology have received extensive attention.

" Made in China 2025" is a new generation of information technology and manufacturing industry, and further promotes the national strategy of intelligent manufacturing in all walks of life. With the core technologies, development concepts and manufacturing models of the new generation of intelligent manufacturing in the world. Constant changes in other areas, such as the United States proposed "advanced manufacturing partnership program", Germany proposed "Industry 4.0 strategic plan", Britain proposed "Industrial 2050", France proposed "New Industry France Plan", etc., hoping to reshape the development of manufacturing Path and industrial ecology. The system's integrated and intelligent manufacturing system and intelligent equipment gradually penetrate all aspects of the manufacturing process such as “design, production, management, service”, with deep self-awareness, intelligent self-decision, precise control self-executing system, and cross-enterprise, Cross-industry and cross-industry multi-dimensional interconnection will become more popular.

In order to achieve high production efficiency, high quality, low cost and high satisfaction of the "three high and one low" requirement, companies choose the smart way to flexible manufacturing is the inevitable result of how the theory of flexible production into the enterprise production Establishing an ultra-flexible production line with stable product quality, rapid mold change and flexible adjustment is an urgent problem to be solved in the current apparel industry.

I. Advanced Manufacturing Model and Intelligent Manufacturing Maturity Evaluation of Garment Enterprises

Since the 1980s, due to the severe decline in manufacturing industry around the world, the rise of consumer market consumption and the penetration of information technology into manufacturing, a number of advanced manufacturing models have emerged, such as lean manufacturing (LP) and agile manufacturing. (QRS), Computer Integrated Manufacturing (CIMS), Flexible Manufacturing (FMS), Mass Custom Manufacturing (MC), Modular Manufacturing (MP), Network Collaborative Manufacturing, Cloud Manufacturing (CM), Green Manufacturing (GM) In the face of these advanced manufacturing models, industrialized developed countries have completed the transition from mass production to flexible manufacturing models in the past 40 years, in addition to manufacturing ( 3D printing ), intelligent manufacturing (IM) and so on.

China's apparel industry has changed from mass production mode (MP) to mass customization manufacturing mode (MC) and computer integrated manufacturing mode (CIMS) since the 1990s. In the past two years, our apparel industry has turned to Personalized custom flexible manufacturing, network collaborative manufacturing, cloud manufacturing (CM), green manufacturing (GM), additive manufacturing (3D printing), intelligent manufacturing (IM), etc., according to the past industrialization of information technology in China's apparel industry The characteristics of integration, the focus is on the parallel development of digital, network and intelligent, and implement the technical route of “parallel advancement and integration development” to achieve catch-up with Western developed countries.

According to the "Smart Manufacturing Capability Maturity Model White Paper", the Capability Maturity Model (CMM) is used to evaluate the intelligent manufacturing level of apparel enterprises, as shown in Figure 1. The model divides relevant capabilities into low-to-high-level, planning-level, specification-level, integration-level, optimization-level, and lead-level. At present, China's garment flexible production is in the level of intelligent manufacturing, and its characteristics realize the integration and sharing of data vertically and horizontally. The manufacturing industry should move into the highest level of maturity optimization and leading level of intelligent manufacturing. As shown in Figure 1, it is necessary to push artificial intelligence technology to the highest level of artificial intelligence to achieve self-learning.

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Second, the development status and shortcomings of flexible personalized production of clothing personality

The modularization of the Flexible Production process enables rapid production of multiple varieties, multiple styles and small batches through technologies such as lean production, intelligent scheduling and intelligent human-machine ranking. Flexible production of garments refers to processing equipment based on computer numerical control to achieve highly flexible production methods of multiple varieties and small batches. It can be flexible in three aspects of market, technical support and manufacturing process, such as large-scale personality. Customization is the whole process customization through the stages of sewing, sewing and sewing.

3D-CAT+CAD+CAM operation, intelligent robot cutting, 3D-CAT measurement, digital modeling, image recognition, big data processing, etc., as well as database (style, layout, craft sheet, surface accessories) Selection, custom style selection, digital exhibition hall for customer service; in the sewing stage, "smart hanging (flow sink) + automatic flat / overlock sewing machine + automatic sewing unit system (or automatic template sewing system) + special automatic The sewing process consists of sewing machine automation; the automatic flexible ironing line with RFID technology as the core, the automatic ironing and folding packaging machine, the complete chain of automatic three-dimensional warehouse logistics distribution system and its information system.

At present, the implementation of flexible garment production is in various forms, such as the discrete enterprise intelligent manufacturing represented by Shannannanshan Textile Apparel Company; the network collaborative manufacturing represented by Shandong Dishang Group; Shandong Red Collar Group (Cool Group) ) Customized personalization for the representative, automatic data flow production; high-grade personalized custom production represented by Zhejiang Baoxin Bird and customized lean production represented by Fujian Haopai Group.

The main technology of garment flexible manufacturing production is the integration of automation, digitization and network, so as to achieve personalized customization services, such as the six demonstration enterprises selected by the Ministry of Industry and Information Technology (Nanshan, Red Collar, Dishan, Aidi, Baoji, 柒Under the guidance of the China Garment Manufacturing Alliance, the "three clothes and two pants (suits, shirts, T-shirts (cultural shirts), trousers, jeans)" demonstration enterprises, their production characteristics and models, basically in accordance with the order in a production line A single-piece production of a single piece of flow is achieved.

The core technology is to use MES as the backbone system of the digital factory to support the centralized control and scheduling concept of the flow production line. The vertical integration realizes the connection between ERP and MES, and realizes the opening of MES and sewing equipment PLC. Automatically import production orders, collect data and analyze it in the field, predict equipment failures, detect product quality or analyze equipment energy.

Therefore, the flexible production we have completed at the moment is only stuck in the integration and sharing of data (see Figure 1). There are still many shortcomings in this kind of personalized customization: 1 Personalization or limited personalization, can not be completely personalized; 2 existing production conditions can not meet the customer's dynamic changes in the custom process of the process; 3 customers can only Participating in the order and the two ends of the goods, there is opaque manufacturing process, the customer can not see all the information of the processing process and process; 4 customizing on a relatively rigid assembly line, the production flexibility is insufficient; 5 lack of network construction in the production process For the application of analog and simulation technology, the user does not get the simulation try-on service; 6 flexible customization is only customized under the conditions of automation, digitization and network, and does not reach the level of intelligence. The assembly line consisting of hanging and sewing machines in the sewing section did not realize the original intention of “ machine substitution ”. Because of this, it was proposed to change to the ultra-flexible sewing manufacturing mode. (To be continued)