Fasteners: Innovation Drives Transformation and Development
In 2011, the total output of the fastener industry reached 6.8 million tons, a year-on-year increase of 9.7%, and sales revenue reached 66 billion yuan, a year-on-year increase of 10%, again setting a new high in the history of the industry. Although China’s fastener production volume and scale have long been ranked first in the world, there is still a big gap between industrial strength and competitiveness and the world’s forefront of the same industry, “big but not strong†and “fat but not strong†Is often used to describe the terms of our fasteners. In the process of China's new industrialization, in the “12th Five-Year Plan†development of the national economy, the transformation and upgrading of fasteners in China will still have a large space for development, but the task of transformation and upgrading is very arduous. The "12th Five-Year Plan" is a crucial period for the transformation and upgrading of fasteners in China. During this period, fasteners must take a solid step in the process of becoming stronger and stronger.
Technological development trends, changes in the world's landscape, and domestic economic trends will all have a major impact on the transformation and upgrading of fastener manufacturing. In the process of accelerating technological change, the fastener industry can only accelerate the pace of innovation, absorption, and integration of various new technologies so as to maintain its vigorous development.
The financial crisis since 2008 has had a huge impact on the challenge of forming fasteners in China. In the coming years, the development trend of fasteners in China is of great concern to every leader, engineering technician, and manager who works on fasteners.
Innovative fastener technology is the technical support for the development of fasteners. The development trend of technology determines the development direction of the industry to a considerable extent. Grasping the direction of industrial development is not only an important guarantee for realizing the transformation and upgrading of fasteners, but also it is crucial for fastener companies to compete in fierce market competition and win competition.
At the end of last year, the “China Mechanical Engineering Technology Roadmap†prepared by the China Mechanical Engineering Society was published. The “roadmap†summarizes the development trends of future mechanical engineering technologies: green, intelligent, extraordinary, integration and service. These 10 words are also The future development of fasteners.
1. The direction of development of fasteners In the current fastener market in China, some small and medium-sized fastener enterprises manufacture a large number of ordinary standard parts and do not really bring core competitiveness to the company, but are subject to conditions such as raw materials and labor costs. The changes, from 4.8 to 6.8 low-strength, or 8.8 to 12.9 high-strength fasteners, summed up as low-grade products flooded with leading markets, lack of value-added services in the value chain, production processes and equipment Flexibility, greenization of products and manufacturing processes, not to mention technical services to solve mechanical fastening solutions, and digitalization of products, design, manufacturing, and management.
Combining the “Road Mapâ€, we can think that the future development and transformation of fasteners in China will be in the direction of green manufacturing, smart manufacturing, integrated manufacturing, service-oriented manufacturing, and ultra-normal manufacturing.
1.1 Green Manufacturing The development of China's fastener industry is increasingly pressured by resources and the environment. An important way to ease resource constraints is to develop green manufacturing. Green manufacturing is a modern manufacturing model that comprehensively considers resource efficiency and environmental impact.
With the least input and the use of the most rudimentary equipment, the production and management of fasteners in workshops has led to a decline in product quality and increasingly serious production pollution. The economic benefits of sacrificing energy, sacrificing the environment, and relying on cheap labor are not in harmony with the economic principles of sustainable development. The ensuing environmental problems have also become our eternal pain. It now appears that the extensive fastener development model of the past has indeed come to an end.
In the production process of fasteners, the emission of waste gas, waste water, waste slag, dust, noise and electromagnetic radiation, which are responsible for the production of workplaces and the surrounding environment, and the environmental pollution of the atmosphere and water quality, must be controlled in a controlled manner.
The entire process from design, manufacture, packaging, transportation, use to end-of-life disposal must consider the least waste, the lowest emissions, the highest resource utilization rate, and the least environmental impact, so that the corporate benefits and social benefits can be coordinated and optimized.
On the one hand, fastener companies must adopt non-polluting and less polluting processes in their own production processes to reduce emissions and minimize the negative impact on the environment. On the other hand, more importantly, the products provided to users Should be energy-saving, water-saving and material-saving products, low-carbon, low emissions and low pollution products, and easy recycling and manufacturing.
1.2 Intelligent Manufacturing Intelligent manufacturing is also a new manufacturing mode for fasteners. It is an inevitable result of the development of automation, digitalization, networking, and intelligentization of mechanical manufacturing. With the continuous increase of labor costs and the continuous improvement of product quality requirements, the diversity of demands has become increasingly prominent. The demand for intelligent manufacturing in the fastener industry has become increasingly urgent. Intelligent manufacturing includes the intelligentization of manufacturing processes and the intelligentization of equipment. Intelligent manufacturing has greatly improved the productivity and efficiency of fasteners, reduced labor costs for enterprises, improved workers' working environment and labor intensity, and improved product quality and reliability. The intelligentization of the manufacturing process requires the development of various types of smart manufacturing systems, automated or intelligent production lines, and the construction of digital workshops, digital factories and digital companies. The technical problems that fasteners will focus on over the next few years include: cold heading machine technology and equipment for large-size fasteners, sophisticated molding technology for complex-shaped fasteners, automated and intelligent cold heading precision molding technology, automated logistics equipment, and automated heat treatment Production line.
1.3 Service-oriented manufacturing China's fastener manufacturing is currently based on production, sales as the main production-type manufacturing, this type of industry is subject to more and more constraints of resources, the environment and other factors, the profit space is squeezed. Fastener manufacturing at home and abroad has transformed into a service-oriented manufacturing that integrates products and services. Service-oriented manufacturing provides customers with not only physical products, but also value-added services relying on products, fastens the overall solution, and even focuses on services, and the products become carriers of services. Service-based manufacturing has greatly eased the pressures on resources and the environment, expanded the profitability of fastener companies, and has enabled China's fastener value chain to upgrade from the low-end to the high-end. The transition to service-oriented manufacturing is an important progress for fasteners in our country, and it is also a long-term evolution. This change is achieved by accelerating the development of modern manufacturing services. This change is not the shrinking of fasteners, but the leap forward of fasteners. The key lies in focusing on the entire product life cycle, exploring various value-added service models, and bringing value to customers. Currently, fastener companies have carried out and explored various service activity modes, from providing single sets of fasteners to providing mechanical fastening solutions, customized services, remote monitoring, etc., and future service in the sales revenue of fastener manufacturers. The proportion will gradually increase.
1.4 Fusion Manufacturing Fusion is a trend in the new era. Interdisciplinary fusion of multiple disciplines, compounding of multiple processes. The integration of machinery manufacturing technology and information technology and various high and new technologies, the integration of machinery and materials, and the fusion of technology and culture have constantly injected new vitality into the development of fasteners. The integration creates new fastening components; new manufacturing processes, new processing equipment and new systems greatly enrich the fastener product system and expand the product's functionality. Fusion-type manufacturing is not worth mentioning is the process of compounding, process integration is that a variety of existing processes, a variety of processes integrated into a single device, greatly reducing the process links, reduce site occupation, improve work efficiency, and thus improve Product quality. Integrated innovation is an important approach to converged manufacturing, and is the main type of innovation in current fastener technology; integrated innovation is an innovative activity that transforms various kinds of integration into scientific and technological achievements and into productive forces. It can be expected that in the near future, there will be many innovations in the integration of fasteners.
1.5 Ultranormal Manufacturing With the expansion of people's living space, the rapid development of technology, the requirements for fasteners are getting higher and higher, and beyond the normal state, great, very small, ultra-high temperature, ultra-low temperature, ultra-high speed and ultra Fasteners used at low speeds are endless, and the process technologies used to make these fasteners are quite different.
Supernormal manufacturing includes two aspects: one is to create fasteners that are used in an unconventional situation, and the other is to manufacture the processes and technologies for manufacturing these fasteners. It is unthinkable that ultra-precision manufacturing, ultra-high-performance product manufacturing, and extraordinary forming processes gradually become accustomed to being a symbol of the level of manufacturing of fasteners.
2. The future of fastener companies through the investigation of some fastener companies found that companies in the business are concerned about the following topics: 1 how to improve the high value-added fastener products, effectively organize the company to ensure economic efficiency; 2 in the production of international In the era of globalization, how to organize flexible and flexible production systems to improve international competitiveness; 3 to operate fastener companies under the conditions of provincial resources, energy conservation and emission reduction, and protection of the global environment; 4 How to ensure personnel training and fastening The inheritance of technology and skills.
According to the results of the survey, the author summarized the current status of the fastener companies and estimated the technical research and development of the fastener companies after 10 years (Table 1) for the reference of fastener enterprises in their operations.
3. Conclusion The core technology of fasteners is not only to speed up the research and development of special steel grades, but also to gather technical details and know-how of fastener manufacturing, inspection and heat treatment. In short, the transformation and upgrading of fasteners in China will proceed in the five directions of greenness, intelligence, service, integration, and supernormal. In the right direction, it will reduce detours and reduce errors. It is expected that China's fastener companies, research departments, and experts and scholars will work together to reach the advanced level of foreign service in 5 to 10 years, and reach the level of foreign advanced technology by 10 to 15 years. What is most needed now is changing ideas and technological innovation.
Technological development trends, changes in the world's landscape, and domestic economic trends will all have a major impact on the transformation and upgrading of fastener manufacturing. In the process of accelerating technological change, the fastener industry can only accelerate the pace of innovation, absorption, and integration of various new technologies so as to maintain its vigorous development.
The financial crisis since 2008 has had a huge impact on the challenge of forming fasteners in China. In the coming years, the development trend of fasteners in China is of great concern to every leader, engineering technician, and manager who works on fasteners.
Innovative fastener technology is the technical support for the development of fasteners. The development trend of technology determines the development direction of the industry to a considerable extent. Grasping the direction of industrial development is not only an important guarantee for realizing the transformation and upgrading of fasteners, but also it is crucial for fastener companies to compete in fierce market competition and win competition.
At the end of last year, the “China Mechanical Engineering Technology Roadmap†prepared by the China Mechanical Engineering Society was published. The “roadmap†summarizes the development trends of future mechanical engineering technologies: green, intelligent, extraordinary, integration and service. These 10 words are also The future development of fasteners.
1. The direction of development of fasteners In the current fastener market in China, some small and medium-sized fastener enterprises manufacture a large number of ordinary standard parts and do not really bring core competitiveness to the company, but are subject to conditions such as raw materials and labor costs. The changes, from 4.8 to 6.8 low-strength, or 8.8 to 12.9 high-strength fasteners, summed up as low-grade products flooded with leading markets, lack of value-added services in the value chain, production processes and equipment Flexibility, greenization of products and manufacturing processes, not to mention technical services to solve mechanical fastening solutions, and digitalization of products, design, manufacturing, and management.
Combining the “Road Mapâ€, we can think that the future development and transformation of fasteners in China will be in the direction of green manufacturing, smart manufacturing, integrated manufacturing, service-oriented manufacturing, and ultra-normal manufacturing.
1.1 Green Manufacturing The development of China's fastener industry is increasingly pressured by resources and the environment. An important way to ease resource constraints is to develop green manufacturing. Green manufacturing is a modern manufacturing model that comprehensively considers resource efficiency and environmental impact.
With the least input and the use of the most rudimentary equipment, the production and management of fasteners in workshops has led to a decline in product quality and increasingly serious production pollution. The economic benefits of sacrificing energy, sacrificing the environment, and relying on cheap labor are not in harmony with the economic principles of sustainable development. The ensuing environmental problems have also become our eternal pain. It now appears that the extensive fastener development model of the past has indeed come to an end.
In the production process of fasteners, the emission of waste gas, waste water, waste slag, dust, noise and electromagnetic radiation, which are responsible for the production of workplaces and the surrounding environment, and the environmental pollution of the atmosphere and water quality, must be controlled in a controlled manner.
The entire process from design, manufacture, packaging, transportation, use to end-of-life disposal must consider the least waste, the lowest emissions, the highest resource utilization rate, and the least environmental impact, so that the corporate benefits and social benefits can be coordinated and optimized.
On the one hand, fastener companies must adopt non-polluting and less polluting processes in their own production processes to reduce emissions and minimize the negative impact on the environment. On the other hand, more importantly, the products provided to users Should be energy-saving, water-saving and material-saving products, low-carbon, low emissions and low pollution products, and easy recycling and manufacturing.
1.2 Intelligent Manufacturing Intelligent manufacturing is also a new manufacturing mode for fasteners. It is an inevitable result of the development of automation, digitalization, networking, and intelligentization of mechanical manufacturing. With the continuous increase of labor costs and the continuous improvement of product quality requirements, the diversity of demands has become increasingly prominent. The demand for intelligent manufacturing in the fastener industry has become increasingly urgent. Intelligent manufacturing includes the intelligentization of manufacturing processes and the intelligentization of equipment. Intelligent manufacturing has greatly improved the productivity and efficiency of fasteners, reduced labor costs for enterprises, improved workers' working environment and labor intensity, and improved product quality and reliability. The intelligentization of the manufacturing process requires the development of various types of smart manufacturing systems, automated or intelligent production lines, and the construction of digital workshops, digital factories and digital companies. The technical problems that fasteners will focus on over the next few years include: cold heading machine technology and equipment for large-size fasteners, sophisticated molding technology for complex-shaped fasteners, automated and intelligent cold heading precision molding technology, automated logistics equipment, and automated heat treatment Production line.
1.3 Service-oriented manufacturing China's fastener manufacturing is currently based on production, sales as the main production-type manufacturing, this type of industry is subject to more and more constraints of resources, the environment and other factors, the profit space is squeezed. Fastener manufacturing at home and abroad has transformed into a service-oriented manufacturing that integrates products and services. Service-oriented manufacturing provides customers with not only physical products, but also value-added services relying on products, fastens the overall solution, and even focuses on services, and the products become carriers of services. Service-based manufacturing has greatly eased the pressures on resources and the environment, expanded the profitability of fastener companies, and has enabled China's fastener value chain to upgrade from the low-end to the high-end. The transition to service-oriented manufacturing is an important progress for fasteners in our country, and it is also a long-term evolution. This change is achieved by accelerating the development of modern manufacturing services. This change is not the shrinking of fasteners, but the leap forward of fasteners. The key lies in focusing on the entire product life cycle, exploring various value-added service models, and bringing value to customers. Currently, fastener companies have carried out and explored various service activity modes, from providing single sets of fasteners to providing mechanical fastening solutions, customized services, remote monitoring, etc., and future service in the sales revenue of fastener manufacturers. The proportion will gradually increase.
1.4 Fusion Manufacturing Fusion is a trend in the new era. Interdisciplinary fusion of multiple disciplines, compounding of multiple processes. The integration of machinery manufacturing technology and information technology and various high and new technologies, the integration of machinery and materials, and the fusion of technology and culture have constantly injected new vitality into the development of fasteners. The integration creates new fastening components; new manufacturing processes, new processing equipment and new systems greatly enrich the fastener product system and expand the product's functionality. Fusion-type manufacturing is not worth mentioning is the process of compounding, process integration is that a variety of existing processes, a variety of processes integrated into a single device, greatly reducing the process links, reduce site occupation, improve work efficiency, and thus improve Product quality. Integrated innovation is an important approach to converged manufacturing, and is the main type of innovation in current fastener technology; integrated innovation is an innovative activity that transforms various kinds of integration into scientific and technological achievements and into productive forces. It can be expected that in the near future, there will be many innovations in the integration of fasteners.
1.5 Ultranormal Manufacturing With the expansion of people's living space, the rapid development of technology, the requirements for fasteners are getting higher and higher, and beyond the normal state, great, very small, ultra-high temperature, ultra-low temperature, ultra-high speed and ultra Fasteners used at low speeds are endless, and the process technologies used to make these fasteners are quite different.
Supernormal manufacturing includes two aspects: one is to create fasteners that are used in an unconventional situation, and the other is to manufacture the processes and technologies for manufacturing these fasteners. It is unthinkable that ultra-precision manufacturing, ultra-high-performance product manufacturing, and extraordinary forming processes gradually become accustomed to being a symbol of the level of manufacturing of fasteners.
2. The future of fastener companies through the investigation of some fastener companies found that companies in the business are concerned about the following topics: 1 how to improve the high value-added fastener products, effectively organize the company to ensure economic efficiency; 2 in the production of international In the era of globalization, how to organize flexible and flexible production systems to improve international competitiveness; 3 to operate fastener companies under the conditions of provincial resources, energy conservation and emission reduction, and protection of the global environment; 4 How to ensure personnel training and fastening The inheritance of technology and skills.
According to the results of the survey, the author summarized the current status of the fastener companies and estimated the technical research and development of the fastener companies after 10 years (Table 1) for the reference of fastener enterprises in their operations.
3. Conclusion The core technology of fasteners is not only to speed up the research and development of special steel grades, but also to gather technical details and know-how of fastener manufacturing, inspection and heat treatment. In short, the transformation and upgrading of fasteners in China will proceed in the five directions of greenness, intelligence, service, integration, and supernormal. In the right direction, it will reduce detours and reduce errors. It is expected that China's fastener companies, research departments, and experts and scholars will work together to reach the advanced level of foreign service in 5 to 10 years, and reach the level of foreign advanced technology by 10 to 15 years. What is most needed now is changing ideas and technological innovation.
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