The reporter visited a number of factories in Jiangsu: the key to machine substitution is "people"

The origin is the news that the reporter got in an interview: The Foxconn factory in Kunshan has reduced the total number of personnel from 80,000 to 40,000 in more than a year, and the output value has doubled. The main reason is technological transformation and transformation and upgrading, and the machine replaces people.
Before hearing this news, the reporters frequently heard in recent years that the processing factories in the Pearl River Delta and the Yangtze River Delta include large-scale factories, or closed down overnight, or moved factories to the central and western regions, and even the Southeast Asian countries with cheaper labor; Yes, because of the reduction in foreign trade orders, the phenomenon of a large number of workers working overtime during the Spring Festival may no longer occur. Today, a large number of factories have been on holiday early...
Is “machine substitution” the only way to transform the traditional “Made in China”? Can a representative labor-intensive processing plant such as Foxconn successfully transform and stay in a more economically developed region through “machine substitution”? To this end, the reporter should be employed in the Kunshan Foxconn factory for a few days as a front-line operator, and successively visited a number of factories in Suzhou. The following is what the reporter saw and thought.

What the robot doesn't have - "feel"
In the north of Kunshan City, the scale and population are comparable to the Foxconn Park in the small towns. The workshop is difficult to exhaust.
The reporter was assigned to a grinding workshop. The so-called "grinding" is a mobile phone or a notebook computer case that is punched out by a punching machine, and is subjected to deburring, fine grinding, polishing, and the like.
What I saw at first was disappointing. The reporter wants to come to see the robot, but it is divided into the most traditional manpower position - "deburring", eighty-nine people wearing masks and gloves, sitting at a long table without a conveyor belt, passing from left to right rough In the bottom case of the laptop, each person should use a trowel to grind a few knives in the designated part to remove the metal burrs remaining after the stamping. According to the workers, "It is an individual who will do it."
Can't talk, can't play mobile phone, rest every 10 hours for 10 minutes, people become robots.
The reporter asked an old engineer in charge of safety supervision in the factory: Can I not replace the machine in this position? The other party answered, theoretically, but the investment is too big, no need. In addition, he mentioned the “feeling”: some burrs, the human eye knows at a glance, and there is no scraping, but for the machine, it requires high accuracy, precision and intelligence. He said that most of the robots in the factory can't find mechanical anomalies. If the molds are not placed properly or the thimbles are not reset, the robots will not be mistaken. If they go on, they may be tens of thousands or even millions of losses.
The word "feeling" was heard several times in a multi-inquiry by reporters. This is also an important factor in the fact that robotics cannot temporarily replace artificial labor. For example, a master said that a brand of mobile phone aluminum alloy shell is extremely weak, inevitably scratches the product, but some scratches are very shallow and very thin, different shapes, compared to machine testing, the human eye is easier to find.
Dai Jiapeng, general manager of Foxconn Automation, explained to the media the difficulty of “machine substitution”. He also mentioned “feeling”: people have various feelings, and they have good flexibility. They can quickly switch to another job, robot There is no such flexibility.

Should part of the automation of "satisfaction"?
Perhaps because the reporter is always asking the robot, maybe the reporter is a newcomer to the burr is too low efficiency, two hours later, the reporter was transferred to do the "water mill" - no longer pure labor, but the use of mechanical arms.
"Water mill", or "polishing." Facing the console, put the bottom case of the laptop with the burrs removed on the mold table, open the faucet and pour it, then press the start button, the arm will automatically start to polish, and it will be black and The magnesium alloy casing of the diamond stamping stamp is ground to a bright white color, and it takes 45 seconds to grind.
It may not be fully automated. What the reporter has to do is to pick up and drop the outer casing, and after each two shells are finished, replace the two sanding discs on the robot arm, and blow the dry water on the outer casing with a compressed air gun. And neatly packed. The reporter can count about 40 pieces in one hour. After 4 hours, the waist and legs are sour.
The gap between the materials, the reporter did not give up, and asked the problem of the long line robots - changing the shell and sand, as well as drying, packing, can not be automated? The line has been working at Foxconn for several years. He said that he is content with it. Four or five years ago, it was all artificial. He said that he was wearing rubber gloves, drenched with water, and hand-polished with a hand gun. Although the grinding time is almost the same, but people can't stand it for a long time, especially in winter, cold water is pressing. According to the line leader, in recent years, many hard-working, no-will-do jobs have been replaced with robotic arms, such as the water-grinding and polishing done by journalists, such as lathe processing and rough grinding, and the dust is loud and noisy. Gradually use the robot.
To see more comprehensive automation, Foxconn also has a "model house." In May of this year, Kunshan Foxconn opened its factory to the media for the first time in 22 years. The responsible person took the reporters to visit the “lighting workshop”. Why are you "turning off the lights"? The degree of automation is high, and fewer people can turn on or even turn on the lights. The roof of the plant is covered with 6 megawatts of solar panels. The workshop warehouse uses a lot of robots. The production process uses IoT control, such as in the pulse. The assembly process of heating and reflow soldering has reduced the number of employees from 1,500 to 300 people for the most time. According to statistics at the time, Kunshan Foxconn Plant has invested 300 million yuan in automation transformation in the past five years, using more than 2,000 independent research and development robots. According to Foxconn's announcement, most of its factories have not yet completed the entire automation, but the factories in Chengdu, Shenzhen and Zhengzhou are in the transition period from “production line automation” to “whole plant automation”.
Yu Xiangfu, general manager of Foxconn Technology Group, has announced that in the future, Foxconn will recruit people who will be able to hire the most advanced automation equipment technicians or engineers, with a bachelor's degree and special expertise.

Changed the machine, the same workers could not stay
With the reporters, the workers who entered the Foxconn work with the secondary school and junior high school diplomas obviously could not enter the "lighting workshop" for the time being. Although some of them are experienced, there is no technical accumulation.
The 26-year-old Wang Pengpeng has entered Foxconn for the third time and entered the electronics factory for the fifth time. He has worked in the Foxconn factory in Yantai for more than a year and spent two months at the Foxconn factory in Zhengzhou. In Yantai, he is responsible for detecting and repairing the mobile phone, as long as the instrument is plugged in and out; in Zhengzhou, he assembles the mobile phone on the assembly line, and screws the screw day after day; he also worked on CNC machine tools every 7 to 8 minutes. The mobile phone case was taken in the machine... Zhao Shuanghu, 26, had worked at the Foxconn factory in Beijing. He also worked on the assembly shop day after day to screw the screw. He also worked in the garment factory and the home power plant.
Together with the reporters, they were assigned to the grinding shop. After doing it for less than an hour, Zhao Shuanghu took off his gloves and went indignantly. The reason for his departure is: water splashes all over the body, wet, cold, bitter, boring. He said that he would continue to find a job and find a good job. What is good living? He can't answer, but at least it's easy, can sit and go to work, not cold.
Wang Pengpeng persisted, but he also sighed privately: it is not as simple as screwing on the assembly line, you can sit and think about nothing. He also felt that this was a temporary worker and the salary was too low. He plans to mix in Foxconn and wait for the rest day to go to the nearby Lujia Town. There are many labor agencies there, and you may find a better and easier job.
Today, in traditional processing factories like Foxconn, more and more young people leave after two or three days of employment. This week, during the “finding jobs” and “work”, the reporter heard many similar stories in the local area –
An infant products factory recruited 400 employees a day, and ran more than 300 people the next day, because the factory did not have a canteen without meals, and the surrounding snack bar had a meal for ten yuan, not worthwhile; a large-scale electronic processing The factory is recruiting a lot in the vicinity of the talent market every day. The workers who transport a whole bus to the factory every day can run out almost the next day, so they simply recruit the “one-day temporary workers” to do the simplest and most difficult jobs. Turning back to the reporter, this group of workers entering Foxconn was assigned to 7 people in the grinding workshop. Only one person remained on the third day...
Many people say that it is a machine that has replaced a large number of workers with simple labor. This phenomenon of “machine substitution” has not only appeared in manufacturing factories but also in white-collar workers in various service industries. However, the new generation of industrial workers are generally afraid of hardships, grinding and polishing, bitter coating, bitterness to the burrs, and where to eat and burn in the noise and dust in the early years. In the opinion of the reporter, “machine substitution” is of course the active choice of the factory for transformation and upgrading. At the same time, it is also the last resort of the factory after the living conditions of the workers are generally improved and the labor costs are rising.
The words of Foxconn automation implementer Dai Jiapeng also confirmed the reporter's thoughts. He said that when the automation was first introduced, the factory supervisors were not happy. Before and after 2008, some work types with poor working conditions began to be difficult to recruit and more difficult to retain. Therefore, the supervisors took the initiative to ask for the use of robots instead of labor. .

The key to "machine substitution" is "person"
In any case, the key to concern in "machine substitution" is the problem of "people."
A message more than two months ago is very representative: the employees of the Foxconn Chongqing factory are dissatisfied with "less overtime." Because the factory improves the operational efficiency of employees through automation and industrial engineering optimization, thus reducing overtime hours, but for many employees, less overtime is equivalent to less wages. The reporter remembers that many years ago, workers protested against working too much. The change is worth considering. What the reporter is thinking about now is, under such a background, where does "Wang Pengpeng" go?
The reporter asked Wang Pengpeng: You have been working in Yantai for more than a year. Why don't you just stay, learn some skills, and get promoted? Wang Pengpeng sighed that it is difficult to get promoted, even if it is a master, it is still these simple activities, no technical content.
So what do you think is good in the electronics factory? Wang Pengpeng said that when he was in Yantai, he was a security guard at a health care factory. It was a state-owned enterprise. All the production processes in the factory were automated. The employees only had to touch the screen and occasionally click the mouse.
That health product factory, have you gotten in? He said no to him immediately, because a good factory and a good life basically do not recruit people.
In fact, the reporter saw in Foxconn that there are welcome banners for employees to provide self-study college and undergraduate opportunities, as well as some formal workers who have been promoted many times in more than ten years. The basic salary performance plus overtime pay is at least monthly. There are six thousand dollars. If you work hard, you will have the opportunity to go to the so-called "good living" "lighting workshop". But the truth is that not everyone is willing to work hard. When the reporter was training at Foxconn, there was a lineman of the stamping workshop who came up with a person who said that although the working environment was poor, he could learn some craftsmanship and would like to do it? Twenty people in the training room did not look up. The female master on the podium said with a cold smile: "How do you guys make money on the map, don't you figure out a technology?" What the reporter can feel is that the technical life is still fragrant, but the "Wang Pengpeng" can mix and live, less and less.
Another group of people to focus on are business owners and factory managers.
In Kunshan, the reporter found a private enterprise that produces automobile cables. When entering the door, the machines on the ground are back and forth. They shuttle back and forth along the fixed track, transporting hundreds of kilograms of metal wire barrels for processing, and The finished product is transported back to the warehouse. When it is out of power, it runs to the corner to charge; several workshops, such as warehouse, logistics wire, and segment mold, basically turn off the lights, no workers; even the main production workshop, a long and complicated name "Full-automatic machine", one person operation, can top the assembly line of 12 employees a few years ago... Casting tens of millions or even hundreds of millions of yuan to "machine substitution", the boss of this company Cheng Sanrong thinks very thoroughly: "To improve the overall competitiveness of enterprises, the past people's tactics will obviously not work."
However, after careful analysis, the company's big investment has its own reasons - the basic process of automotive cable products, the update is slow, and even many years without major changes, put into a set of automated equipment and procedures, obviously can be used back In addition, this company has achieved "co-linear design" in research and development with famous European and American car companies. The two databases are synchronized, and they have the right to design and support. Looking back at Foxconn's foundry, most of the design and development of mobile phones and notebook products are not here. To truly realize automation, production lines and molds must be redesigned and reinstalled, and digital products are updated very quickly. Some products even "This week, it’s sold out, and it’s going to die next week.” Automation wants to keep up, where can it be?
Then, do you want to "machine substitution"? The bosses have their own accounts, considering the risks and overall benefits. What about the "Wang Pengpeng" who were replaced? When the reporter finished the draft, Wang Pengpeng had already exited the Foxconn gate and was looking for a job. He said that he would not enter the factory again in the future. He was considering it, and it was good to be a security guard and a chef.
Maybe we have to believe that whether it is a machine or a person, the market has its own hands.

Reporter's note that "machine substitution" needs to be adapted to local conditions
At the morning of the first day of work in the Foxconn factory, at 7:40, the reporter could see the rushing and mighty flow of people, brushing the card and rushing to various workshops; every day at noon, evening, night, and work, flocking to the canteen to eat The same is true of the flow of people. Even if the number of employees is tens of thousands, it is still a big manufacturing industry.
There are more people who have more logic. The reporter recently asked too many robot questions and heard too many answers. Some people talk about Zhengzhou Foxconn's mobile phone detection pipeline, only need a simple robotic arm when picking up the mobile phone; if you ask, why not replace it? The other party will show a cute expression - can't replace it.
Sometimes, it may not be replaced, but it is not cost-effective. Wang Pengpeng cited one example. In the assembly line of the Yankang Foxconn factory, he once produced a Japanese brand mobile phone with full horsepower. However, he did not expect this mobile phone to be on fire for more than a year, and he could not sell it completely and quickly stopped production. A large number of workers also resigned. If you put an automated pipeline for this heavy investment, isn't it a big replacement for robots and molds? He added that the mobile phone of an Internet brand is very hot now. A factory has received orders and recruited a large number of people. It is estimated that next year, this group of people will come back to find a job again... "Machine substitution" is not the same as Automation and informatization, whether to "substitute", large, medium and small factories will make their own choices based on market and risk. At the recent World Internet Conference, Foxconn Group President Guo Taiming described the "Internet +" in his heart. The reporter listened carefully, he was not talking about robot products, but more focused on intelligence and software. He said that in the future, the data of all factories will be shared and analyzed by big data to make decisions.
Therefore, "machine substitution" is something that needs to be adapted to local conditions. It is the path for China's manufacturing industry to enhance its international competitiveness in the development of intelligent and informatized plans that are in line with reality and to increase investment in technology research and development.

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