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China's mold manufacturing industry specializing in the production of the road is still long
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Edit£º Read£º1232 Date£º2017/5/10
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With the mold manufacturing technology continues to improve, the future of the mold will be more and more rich. Any mold enterprises can not fully grasp these technologies, so the future of the mold manufacturing industry is bound to be a highly specialized industry.
According to statistics in 2014 Germany die per capita output value of about 200 million yuan.
Over the past decade, China's mold manufacturing technology has been a qualitative leap, mold industry from small to large, the rapid rise of the world mold manufacturing power, we can put this stage is the first time in China die takeoff. With the development of China's auto industry, independent brands to enter the high-end, the rise of new energy vehicles, the market has given us a new demand, requiring us from the low-end mold into high-end mold, from the mold to the mold power, The second takeoff of the mold. How to achieve from low to high, from big to strong change, how to achieve the second leap in China mold, is worth every Chinese mold factory, each Chinese mold people think about the problem.
At present, China, the United States, Japan, Germany, South Korea, Italy, the six die-making countries die mold output value occupies the absolute position of the world, China's mold output value is the world's most.
China's mold manufacturing industry specializing in the production of the road is still long
The United States, Japan, Germany and other developed countries in the mold manufacturing industry in the production and operation has the following characteristics:
(1) staff streamlining, Europe and the United States and Japan die most of the small scale, the number of employees more than 100 people less mold enterprises are generally 20 to 50 people. Enterprise configuration of all types of personnel is very streamlined, a multi-skilled, one more people, the enterprise can not see idlers.
(2) the use of specialization, product positioning prospective. Most mold factories are around the automotive, electronics and other industries on the needs of various types of molds to determine their product positioning and market positioning. In order to survive in the market competition, and development, each mold manufacturers have their own advantages of technology and products, and have adopted a professional production methods. Europe and the United States most of the mold business both a long-term cooperation of the mold users, in the large mold company around a number of mold production collaboration manufacturers.
(3) advanced management information system, to achieve integrated management. Europe and the United States die enterprises, especially the larger mold enterprises, basically to achieve the computer management. From the production plan, process development, to quality inspection, inventory, statistics, etc., the widespread use of the computer, the company can be shared through the computer network information.
(4) advanced process management, a high degree of standardization. And the domestic mold factory to take mostly to fitter or fitter contracted production organization model is different from Europe and the United States die manufacturers rely on advanced technology equipment and process to ensure the accuracy of parts and production progress. Europe and the United States die enterprises advanced technology and advanced management, to produce large, sophisticated, complex mold, to promote the automotive, electronics, communications, home appliances and other industries played an extremely important role, but also to the mold business has brought good Economic benefits.
American mold industry
The United States has about 7,000 mold enterprises, 15 people accounted for 60%, 15-50 people accounted for 30%. Due to the highly developed industrialization, the US mold industry has long been a mature high-tech industry, in the forefront of the world. US mold specialization division of labor is clear, each mold factory has its own advantages of products, are basically specializing in all the way to the United States we have worked together Synergis mold factory, for example, they are specialized to do chassis sub-frame mold, do Progressive die and multi-station mold. We have worked together to build a vehicle sub-frame, respectively, 3 copies, one in the Americas, one in Europe, one in Asia. We are responsible for processing, assembly, to achieve the initial acceptance of the delivery, by the United States mold factory responsible for the final debugging. This cooperation is beneficial to both sides, we also large-scale multi-station mold design and manufacturing to learn a lot of things.
The United States Ford mold factory processing side of the mold, the manufacturing cycle only 8 weeks. It was a miracle in our point of view, but they did it. Mold pre-process, the design is not in the mold factory, in the research and development departments, mold factory is only responsible for the foam from the beginning of the manufacturing process. As the early work done well, very little change in processing, which gave mold manufacturing save a lot of time. Mold factory processing out of the bubble to send casting, casting back to start CNC machining, because it is more automatic conversion table, 24 hours without stopping, processing efficiency is very high. And because of pre-work such as rebound, deformation and other considerations are more detailed, coupled with actuarial technology, so the processing of the mold directly on the press debugging, the first pass rate can reach 85-90%, which shows the US specialization High processing technology.
According to statistics, in 2014 the United States die per capita output value of about 1.27 million yuan.
Japan mold industry
According to the Japanese Ministry of International Trade statistics, Japan, a total of about 10,000 mold production plants, of which more than 20 people accounted for more than 91%, the Japanese mold industry to small and medium enterprises, mainly by specialized division of labor, complete high-quality mold design, Processing. As Japan's professional division of labor done well, small and medium-sized mold enterprises to create a higher level of the overall, so that the Japanese mold in the world mold market occupies a higher share.
I went to Japan in 1988 mold factory, real casting field study, mold factory only processing large pieces of the main pieces, the rest are assigned to the following small factories to process, design a special design company, lack of steel plate, a phone soon It is processed, sent to the designated location. Lack of screws or nails, but also a call quickly sent to the designated location, division of labor system, supporting system is perfect.
However, due to the rise of China and South Korea die, by virtue of the price advantage of Japan caused a great impact in the middle and low technical content of the mold market has become Japan's small and medium mold enterprises main competitors. It is precisely because of this, the Japanese mold enterprises have to focus on high-end mold production and technology upgrades to avoid price competition. That is, small and fine, small and technical accumulation as a source of competitiveness, to promote small and medium enterprises continue to innovate, and create a sustainable development environment. Japan, many mold manufacturers are actively expanding investment in equipment. In the processing, a large number of unattended processing unit, or through the computer for online control. Mold technology development mainly to high precision, high speed, long life, complex, large, integrated and high-performance aspects of development.
According to statistics in 2014 Japan's per capita output value of about 1.2 million yuan.
German mold industry
Germany is one of the earliest countries in Europe to mold production, its mold manufacturing technology, mold quality by the global user's recognition, in the world renowned, is the world's most important supplier of high-end die. After years of practical exploration, the German mold manufacturers formed a consensus: that the whole industry must be coordinated, team work, technological innovation, learn from each other, common progress, play a good overall advantage in order to obtain the success of the industry. In addition, in order to meet the rapid development of today's new products in Germany, not only large companies to establish a new development center, and many small and medium enterprises have to do so, take the initiative to do research and development work for customers. Germany has always been very active in research and has become an important foundation for its unbeaten international market. In the fierce competition, the German mold industry for many years to maintain a strong position in the international market, the export rate has been stable at around 33%. According to the German Machinery Factory Manufacturing Association (VDMA) data show that the mold manufacturers about 5,000 or so, but the country's mold industry is still small and medium-sized enterprises mainly: 20% of the following 80%, 20-100 people accounted for 19%, 100 More than 1% of people.
According to statistics in 2014 Germany die per capita output value of about 200 million yuan.
Taiwan mold industry
Taiwan's mold industry is basically small and medium enterprises, professional division of labor, production coordination work closely, the customer is relatively stable. Each enterprise only produces a certain type of mold, each has its own high-quality products, is conducive to the technical excellence, to survive in the fierce competition and development. Mold factory required mold parts are purchased, and some parts of the processing industry by other cooperatives co-production.
Mold enterprises with pieces of production more common, Taiwan mold industry focus on mold and product integration, mold and product complement each other, promote each other. Is conducive to the development of mold enterprises.
Follow the main product needs development mold, pay attention to open up overseas markets. Taiwan mold industry is developing rapidly. Among them, followed by the main product needs to develop, manufacturing mold is also an important factor. In recent years, the rapid development of the electronics industry and the automobile industry has led to the development of Taiwan's mold.
At present, 76% of Taiwan's die output value comes from electronic products and automobiles.
I have visited Taiwan's CNC machine tool plant, the OEM is only responsible for assembly and some finishing (local scraping research). The bed is welded steel, a dedicated factory is responsible for cutting, and then sent to the welding plant, welded to the annealing plant, after annealing to the processing plant, after processing to the main assembly plant. In addition to the larger size of the main plant, the scale of other plants are very small, each plant is only responsible for a process, we can see Taiwan's manufacturing division of the fine, coordinated closely.
China mold industry
China's mold industry started late, since the mid-80s of the 20th century, China's mold industry has undergone great changes, especially in the past 10 years, the change can be said to be earth-shaking, and now has become the world's mold production power. In most areas, Chinese molds have occupied a considerable share. But in the high-end mold, still a large number of imports from abroad. From the mold industry as a whole, the overall level of China's mold is still dominated by middle and low molds.
From the history of China's mold factory development, after the founding of the PRC, China has no professional mold factory, five or sixties with the establishment of the automobile factory, and gradually established a subsidiary factory tool factory, the basic reference to the Soviet model The establishment of large and complete tool factory, with the development of the automotive industry, these tool factories gradually to mold factory.
I have worked in the Beiqi, for example, the sixties called the North steam tool factory, the establishment of the eighties Beijing jeep, called the tool shop. The main production measuring tools, cutting tools, die, forging die, casting-type core box, die-casting mold, injection mold, rubber mold and all kinds of fixtures, the late 90s gradually into stamping die factory.
Since the 90's, the rise of private mold factory, the introduction of a large number of CNC machine tools, CAD, CAE, CAM the gradual implementation of the mold industry to flourish, China has become a mold manufacturing power, but most of these factory production methods are large or full Small and complete, the basic manufacturing are low-end mold, the mold in the high-end, we basically in the low-end market vicious competition.
What hinders us to do strong, do it, do it fine? One of the biggest obstacles is our large, full or small and complete production methods, our mold production is not specialized division of labor or specialized division of labor is not sufficient.
At present, China's mold factory about 30000, of which about 5% of state-owned enterprises, joint ventures accounted for about 10%, about 85% of private enterprises, employing about 100 million people, annual output value of more than 20 million enterprises about 5,000 The 2015 die output value of about 170 billion yuan, enterprises own mold output value of about 40 billion yuan, add up to 210 billion, the per capita output value of about 210,000 yuan mold. According to China's mold Association statistics in 2014, 82 key enterprise information, these enterprises in 2014 die output value of 9 billion yuan, a total of 26,800 employees, per capita output value of about 335,000 yuan.
From the mold per capita output value comparison, the Japanese mold is 1.2 million yuan, the US mold is 1.27 million yuan, the German mold is 200 million, that is the mold per capita output value of the United States, Japan is China's 3-5 times, Germany is China's 5- 9 times.
There are two main reasons for the low per capita output value. First, the vast majority of our molds are low-end molds with low added value. Second, we have low production efficiency. Our equipment is not worse than them, why low value-added, low efficiency? A very important reason is that we do not "special". The so-called sophistication, "expertise" to technology. "Special" can be a boutique, "special" can be efficient. People professional division of labor is good, so the mold quality and efficient high. We are big but not strong, wide and not special, what are dry, what are not fine, which resulted in our technology to enhance the slow, slow quality improvement, slow to improve efficiency. Therefore, mold production specialization, intensive mold enterprises to enhance technology, improve quality, improve efficiency, to large and strong, specifically the inevitable transformation of the road.
From now the big and full, small and all of the mold manufacturing model, and gradually to the big and strong, special and fine change, the formation of a large band to the point of the specialization, intensive production mode. That is, a mold center, driven by a number of small mold factory and a number of process processing plants, the formation of large and strong, small and specialized production situation, the center has a professional focus, such as the side of the mold factory, door mold factory, beam Mold factory and so on. There are many rules of market segmentation, some will be divided according to different molding materials; may also be in accordance with the type of mold to points; some will be in accordance with the inner board, the outer plate and even the body of the assembly to be classified and so on.
A flower alone is not a spring, thousands of purple is the spring, is willing to China's mold garden magnificent flowers, fragrant flowers, green verdant, a life, flourishing. China's professional production of mold is a long way, as long as we insist on going down, you will see the dawn of the power of mold, which is the dream of several generations of our mold!
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