From Quality Improvement to Multi-Benefits of Order Growth - Shuangjiao Textile's Experience in Digital Transformation

Lanxi Shuangjiao Textile Co., Ltd., established in 2005, is located in Shuitingwu Village, Shuiting Township. The factory covers an area of 12,000 square meters and employs 230 people. It owns over 200 textile machines and produces more than 7,000 tons of yarn annually. In 2022, the company expanded its international presence, achieving an export value of 44.25 million yuan, an increase of 85.31% compared to the previous year, and contributed 1.76 million yuan in taxes. The company represents a typical example of small and medium-sized spinning enterprises in the city. Due to limited space, outdated equipment, complex management of numerous employees, and the need for cost reduction and efficiency improvement, the company embarked on a digital transformation journey in 2022. Through four steps of "introduction, integration, upgrade, and application," it comprehensively monitored and managed its production processes, achieved integrated workshop control, significantly enhanced product quality, doubled its export sales orders, and improved production efficiency by 7%-10%.

Introducing Digital Systems to Enhance Management

The company introduced ERP, MES, and energy management systems to accurately monitor every detail of the production process, improving efficiency and avoiding cost wastage and human errors. The digital systems also streamlined employee management. Managers can access historical orders, production volume, and employee productivity through a mobile app, enabling them to promptly identify areas for improvement and establish more effective employee training and production plans. Management can now monitor production status in real-time even when outside the company, and each worker can oversee 6-10 fine yarn machines. The company reduced its workforce by 60 employees, saving over 3.5 million yuan in personnel costs annually. The level and capability of management significantly increased, yielding noticeable management benefits.

Integrating Production Data to Enhance Product Quality

The company introduced data collectors for fine yarn machines, utilizing real-time data collection and monitoring to prevent incidents such as yarn breakage caused by hasty shift changes. By adding fine yarn single-spindle detection systems and electronic lifting systems, the company could monitor yarn breakage and weak twisting in real-time, increasing the weight of each spool by 20%. Real-time data collection and consolidation led to further reduction of production waste and losses, lowered product costs, improved quality, and enhanced stability. Previously, yarn quality relied on customer feedback, but now the company can monitor and query abnormal spindle positions through the system, reducing quality feedback time from two weeks to real-time. Quality issues can be traced back to specific operators, providing valuable time for process improvements.

Upgrading Product Variety to Expand Market Orders

Quality improvement led to an upgrade in product variety. Through systematic control, the company transformed its downstream yarn products from simple socks to underwear and T-shirts, broadening its customer base and increasing order volume, consequently boosting profits. The company can now conveniently manage historical orders, real-time production volume, and employee work hours, which helps them better understand production status, match customer needs, elevate service quality, and subsequently increase orders and profits. With the same fundamental management approach and production mode, Shuangjiao Textile achieved an 85.31% increase in foreign trade exports in 2022, more than double the growth of the untransformed Shuangding Chemical Fiber Factory, a member of the same group.

Applying Maintenance Modules to Ensure Production Stability

Real-time monitoring and assessment of equipment operation status, coupled with automated equipment maintenance records and prompts, standardizes and enhances equipment maintenance efficiency, ensuring normal equipment operation and reducing downtime and maintenance costs during production. Previously, manual inspection was required for the entire factory's 27,500 spindles, taking two weeks. Now, the maintenance module sends daily reminders to mobile phones for required upkeep tasks, accurately evaluating maintenance needs and significantly improving maintenance effectiveness.

The achievements of the company's digital transformation have provided confidence and motivation for the next-generation leader of Shuangjiao Textile, Teng Tao. In the future, he plans to utilize digital twin technology, create data models, and establish a digital "cloud factory" to enhance the company's overall image, enabling foreign customers to comprehensively and vividly understand the company's production and business operations and further expand the market."