[How to transform employees in smart manufacturing②] "Mix and match", the boundary between blue-collar and white-collar is becoming more and more blurred
Our reporter Fang Dafeng and Wang Xin
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Where do the engineers come from?
Where do skilled workers go?
This is the proposition of the "new industrial revolution".
Some "new workers" created in the transformation of enterprises seem to provide a solution to the problem.
Intelligentization is not to eliminate employees, but to make employees and the company better together.
Some companies let high-achieving students and their masters on the same field, engineers and skilled workers "mix and match", the boundary between blue-collar and white-collar workers has become more and more blurred; there are also companies that use intelligent production lines for every new production line from design, construction, and debugging. The surplus skilled workers are embedded in the early stage, and these old-style workers have new capabilities after they are put into production.
This team of "new workers" accelerates the intelligent transformation of production processes and empowers "robots."
Sany Group Changsha Headquarters Base No. 18 has visitors every day.
In the front hall of the plant, there is an exhibition wall of corporate history close to 100 meters. One of the panels depicts the company's "target" by 2025: 300 billion yuan in sales, 3,000 industrial workers, and 30,000 engineers.
Many visitors will fall into contemplation here and be curious about the goal of the "Three Threes".
The group currently has 17,000 industrial workers and 3,000 engineers, the former will be reduced to 3,000 in the next few years, and the latter will grow to 30,000.
The ratio of industrial workers to engineers is 1:10, which is an unimaginable scenario for people familiar with the current situation of China's manufacturing industry.
At the "Lighthouse Factory" site, it has been difficult to tell who is the worker and who is the engineer.
"Chinese lighthouse companies are becoming more'warm'. They keep their original intentions and push transformation and innovation to a new breadth and depth." said Hou Wenhao, head of the Tsinghua McKinsey Digital Capability Development Center.
"New Workers" Stepping Out of School
Last year, when the No. 18 factory was revised and upgraded, a large number of young people were "dropped" on site, and they experienced transformation and growth together with the masters of the workshop.
These young people are mostly graduate students from 985 and 211 colleges and universities.
"Ashamed, I heard that I was going to the factory. At first, I was a little bit reluctant." Hong Kong Polytechnic University graduate student Yuan Hang is a newly promoted electrical engineer of Sany Pumping Company. The shameless new worker".
Get along with the busy teachers at the scene and call each other Liu Gong, Li Gong, Yuan Gong... "In the process of measuring and adjusting parameters, the workers often have some opinions of their own. I am not afraid of being laughed at if I have problems. Discuss with each other and learn from each other." Yuan Hang said.
In the Sany Crane Ningxiang Industrial Park, the "new workers" who have just walked out of the school gate rotate in different workshops such as boom welding, assembly, turntable welding, and machining, and are familiar with the technological process and production process of each key structural part of the crane .
"Everywhere you can see debuggers debugging welding robots, programmers programming, installing, and debugging AGV carts on site..." Huang Xin, a postgraduate student at the School of Materials Science and Engineering of Hunan University, just walked out of the school and felt the "harmony" with frontline workers in the intelligent scene , "Front-line workers are very enthusiastic about us newcomers."
Senior students and teachers are on the same field, engineers and skilled workers "mix and match", this kind of "new workers" team accelerates the intelligent transformation of production process and empowers "robots."
Chen Zhen, a pumping process engineer, was assigned to record the processing beats on the outrigger shaft production line on the first day of joining factory No. 18 last year.
The forming process of a leg shaft requires the close cooperation of 4 lathes.
He found that the processing time of the last finishing lathe was too long, so he kept discussing the feasibility of adjusting the process with the responsible worker. The accumulated experience of skilled workers eventually became "parameters", which improved the "intelligence level" of the processing robot.
Where do the engineers come from?
Where do skilled workers go?
This is the proposition of the "new industrial revolution".
The "new workers" created by Sany Group during its transformation seem to provide a solution to the problem.
According to Long Dinghua, deputy director of human resources of Hunan Chutian Technology Co., Ltd., allowing traditional skilled talents to maintain the proportion of 5% upgraded to process engineers is an important mechanism for companies to maintain process innovation, transformation and upgrading.
He is a welding master himself and has been a human resource executive responsible for improving the skills and quality of employees for many years.
A "race" against the machine
The border between blue-collar and white-collar workers in the "Lighthouse Factory" has become increasingly blurred.
Liu Xiangju, deputy director of the Intelligent Manufacturing Research Institute of Factory No. 18, felt the most about this.
Wearing a safety helmet and holding a laptop in hand, Liu Xiang held up and down the welding island to debug the robot.
"This is my most common job status. It is more appropriate to call me a'new worker' rather than a process engineer." On the road of transformation, everyone is racing and helping each other.
"Gong Liu, we are going to produce a batch of new parts today, please tell me how to write this program." "Xiao Liu, the new robot has been connected to the three-wire network, hurry up and pair up."...In 2019, the 18th factory building will be a critical period for upgrading the lighthouse factory. Liu Xiangju Every day, nearly 40 robots move between the turret, the turntable, and the four welding islands of the front and rear outriggers. After the pump truck turret is changed to robot welding, there are always bottlenecks such as "low pass rate and too long cycle time".
"Working" with the workers every day, in-depth analysis of each welding seam and trajectory, Liu Xiangju re-organized the welding procedures and framework, and also "one-to-one, face-to-face" to the robot operator to explain the communication programming key, so that Get familiar with and get started at the fastest speed to achieve technical collaboration.
The collaborative research of process engineers and skilled workers has greatly optimized the welding process of the turret robot. The production cycle of a single set has been shortened by about 75%, and the overall production efficiency has increased by 34%. The welding island has reached and stabilized production.
"The construction of the'Lighthouse Factory' is completely different from the traditional factory model. Both workers are required to be engineers, and engineers are also required to be'new workers.' Only by exploring and experimenting together can we overcome all difficulties." Liu Xiangju said.
Letting skilled workers participate in the whole process, rather than just letting technicians "work behind closed doors", is considered not only beneficial to the intelligent transformation of the factory, but also beneficial to the "homeopathic transformation" of workers.
"In order to let the skilled workers surplus from the smart production line quickly integrate into the new environment of smart manufacturing, each new production line of the company will embed them in the whole process of design, construction, and debugging. Ability." He Meng, deputy director of the manufacturing center of Sunward Intelligent Co., Ltd. introduced.
Intelligentization is not to eliminate employees, but to make employees and the company better together. Enterprise upgrades also need to help front-line skilled workers become versatile talents.
The company's human resources director Xiao Wei provided a piece of data. Five years ago, the company had about 2,000 people. Now, the company's size has doubled five times, and the number of employees has exceeded 4,000.
Let employees "more money, more valuable"
"Insist on people-oriented, the'Lighthouse Factory' has always paid attention to inclusive growth in the process of promoting the transformation of the fourth industrial revolution, encouraging employees at all levels to participate in the restructuring of the industry, and jointly create an innovative and creative future. The "white paper" written by the World Economic Forum and McKinsey, after analyzing the global "lighthouse factory" sample, believes.
"Intelligent manufacturing will profoundly change human society and the world." In August of this year, Sany Group Chairman Liang Wengen issued the "Sany Group's Certification Incentive Measures for Robot Programming Languages", and the company paid a huge amount of over 80 million yuan. Reward, encourage employees to improve themselves, accelerate their transformation into "new workers", and make employees "more valuable and richer."
"Robot programming" has become a "hot word" often mentioned in employee chats.
The certification work is led by the Sany Intelligent Manufacturing Headquarters and will be carried out for more than 1,200 robot operators, more than 200 team leaders, more than 800 craftsmen and more than 360 center directors (deputy directors) in the production system of the whole group.
Pass the corresponding elementary, intermediate, and advanced certifications, you will enjoy a cash reward of up to 100,000 yuan, and your salary will be raised by one level and you will enjoy a monthly allowance.
In order to help more ordinary workers transform into "new workers", Sany Group invested another 10 million yuan to build the first "robot programming training base" in the domestic industry in Sany Institute of Technology, and the first batch of 6 robots purchased by the base It has been deployed in place and officially launched at the end of September. It will focus on new job training for students in the "industrial robot" specialist class and existing workers in the company.
"Without the successful transformation of industrial workers, the intelligent manufacturing transformation of manufacturing enterprises cannot be successful." Guo Lifu, deputy secretary of the Party Working Committee and director of the management committee of the Changsha High-tech Zone, said when talking about the strategies of enterprises under the trend of intelligentization.