The automation transformation can increase the efficiency of the digital transformation production line of the power system by up to 30%~60%, which is the core technical means to reduce costs and improve efficiency in the current field of power equipment production. Firstly, the core manifestation of efficiency improvement is the enhancement of production efficiency
Automated production lines replace manual repetitive operations (such as component insertion and cabinet assembly), reducing single station operation time by more than 50% and overall production cycle by 25% to 30%;
The equipment utilization rate has increased from 65% for manual operation to over 90%, and non production time such as standby and debugging has been reduced by 40%;
The accuracy of capacity matching has been improved, the delivery cycle of orders has been shortened by 15% to 20%, and the response speed to small batch and multi variety orders has been increased by 30%. (2) Quality and operation optimization
The integration of online automated testing (such as partial discharge testing and insulation resistance testing) has increased the product qualification rate from 91% for manual operation to 98.5%, and reduced rework losses by 70%;
The full chain digital collection of production line data has shortened the fault location time from 2 hours to less than 10 minutes, and reduced unplanned downtime by 50%. (3) Reduced labor costs
The demand for operation and maintenance personnel for a single core production line has decreased from 12-15 to 3-5, reducing labor costs by over 60%;
The management processes such as data statistics and report generation are fully automated, resulting in an 80% increase in management efficiency. 2, Adaptation conditions for efficiency improvement (1) Hardware foundation of production line
Reserve digital interfaces such as Profinet and Modbus for industrial Ethernet to ensure the networking and collaboration of automation equipment;
The renovation of old production lines prioritizes covering core processes such as welding and final assembly, and the input-output ratio of full line replacement is lower than that of core process renovation. (2) Personnel and supporting facilities
Frontline personnel need to master the operation of digital tools, and the certification rate after training should reach 85% or above;
The edge computing unit is required to process the real-time data of the production line and upload it to the control platform, otherwise the data cannot be converted into efficiency gains.
