Our reporter Chen Yu reported from Shenzhen, Zhuhai and Foshan

May 22 near the noon, the rainy day in Pingshan New District, Shenzhen rarely shine. R & P (002577, stock bar) (002577.SZ) is located in the headquarters of the plant, dozens of orange-red small robots (300024, stock bar) distributed in a variety of production lines, working with workers in blue overalls produce.

In 2011, Pyramid purchased 75 "IRB120" industrial robots from ABB, one of the four major robot manufacturers in the world, and began the reconstruction of the production line.

This is a near-adventure attempt. The automation and transformation of Raboar Technologies Inc., including the purchase of ABB robots, cost more than 30 million yuan. After the domestic mouse and keyboard industry, there was no successful experience in using robots. But now, Pyramid has already achieved initial success on this road and is used by the industry as a model for lightweight robots.

Replacing labor with industrial robots is already a major trend in the domestic manufacturing industry. However, according to numerous interviews with 21st Century Business Herald reporters, under the careful consideration of cost-benefit, most enterprises have not broken through at the critical point of “not on robots”; the critical points of subdivided industries such as 3C, construction machinery, and logistics have been Gradually approaching, it is expected to be the first to achieve explosive growth on the demand side in the coming years.

Artificial replacement cost threshold

Leibo Technology mainly produces wireless peripheral products such as mouse and keyboard, ranking first in the domestic wireless mouse and keyboard industry. In the workshop where keyboards are assembled, Rayberg Senior Manager Sun Qinggen pointed to a robot that is operating flexibly. This workshop originally required 105 workers, but today, the user has only 3-4 in an upgraded production line built by seven small robots. Workers can.

“We had 3,200 workers in 2011 and currently about 1000.” Deng Qiuwei, deputy general manager of Leibo Technology, told the 21st Century Business Herald reporter that it is estimated that the increase in labor costs will only make the company decide to use robots. In three years, the factory has raised salary for four times, and each time the rate has exceeded 10%. At present, the average cost for a worker has to be five or six thousand yuan. From the perspective of company investment income, the reform is worthwhile.

Deng Qiuwei revealed that the robot is only the foundation, and more importantly, it is based on the robot reconstruction production line, so the company can save so much labor. For R & B Technology, as long as the production line can recover the cost within five years, the company believes that there is a replacement value, the current replacement has completed 70%, and 30% of the space can be done slowly. "If you look at it for five years now, it may be five years after two years."

“I'll tell you a change in numbers. When we achieve more than 80 billion yuan (operating income), we are 96,000 people. Now we have 120 billion, but only 80,000.” Gree Electric (000651) ) (000651.SZ) Chairman and President Dong Mingzhu told the 21st Century Business Herald reporter.

Also choosing to change is Mao Shuo Power (002660, stocks it) (002660.SZ), this is also located in Shenzhen LED drive power industry leader, is currently planning a new production line.

The company’s fundraising project was the Huizhou Maoshuo Power Drive Production Plant. The deputy director of the president’s office in charge of the planning and construction of the new factory’s smart production line told the 21st Century Business Herald reporter that the two experimental production lines had been designed and commissioned by the manufacturer. Each line is 6 robots and a total of 12 robots. The original production line required about 60 workers, and now only one-third of them are needed.

"The power industry has not yet done such an attempt by the company." The deputy director said that the company is very cautious about this. It has carried out many investigations and planning work in the early stage. After calculation, the upgraded production line can reduce two-thirds of labor. This reduced labor cost expenditure can cover the expenses for upgrading within two years, which is equal to the recovery cost within two years.

From this, it can be seen that the direct factor in considering the robot application production line is the labor cost. "In 2015, our workers' wages (preparation) will increase by 15% to 20%." Fang Hongbo, chairman and president of Midea Group (000333.SZ), said.

A person in charge of Gree Electric’s robot supplier told the 21st Century Business Herald reporter that Gree Electric Appliances had changed from the original 96,000 to the current 80,000. The future goal will be reduced to less than 60,000 people.

In contrast, the cost of using industrial robots is gradually falling.

Professor Zong Guanghua, deputy head of the Intelligent Robot Thematic Group of the former National 863 Program and professor of Beijing University of Aeronautics and Astronautics, told the 21st Century Business Herald reporter that currently the cost of robots has dropped by an average of about 4% each year.

The gradual approach of these two cost curves is a process of warm boiled frogs, and in certain types of trades or subdivided industries, the two lines already intersect.

Segmentation industry breakthroughs

In general, the field of replacing manual labor with industrial robots includes: In areas where labor costs are high and precision is very demanding, people cannot go through or perform work that is detrimental to health by humans.

The most significant industry is the automobile, which is a mature industry that uses robots for manufacturing. A brokerage analyst familiar with the robot industry chain believes that the 3C industry (computer, communications, and consumer electronics) is the next big industry that replaces artificial space with working robots.

China concentrates 70% of the world's 3C product capacity. The 3C industry still has a low degree of automation, which constitutes a special Chinese robot market that other countries can not learn from. At present, the parts that have achieved robotic automation production mainly include shells, glass, and lids. Board and final assembly stage.

"It is expected that the demand for robots in the logistics, food and beverage, pharmaceuticals, plastics, sanitary ware, stamping, and grinding industries will grow faster in the future," said the analyst.

Guangzhou CNC Equipment Co., Ltd.'s main business includes industrial robots, its products used in handling, arc welding, coating, cutting, painting, scientific research and teaching, machine tool processing and other materials. A person in the company told the 21st Century Business Herald reporter that spraying, handling, and loading and unloading in the machinery industry are all types of jobs that currently require high replacement.

“The workers in the machinery industry are relatively tired. Generally, they are not very willing to do this kind of work after the 90s.” The above-mentioned sources introduced, especially with regard to loading and unloading, the cost of the technicians in this piece was too high. It was difficult for the Pearl River Delta to attract people and stamping. It is also a high-risk type of work. There are many work-related accidents each year. The work is too tense and boring, and it is repeated.

In 2011, Gou said that after Foxconn employees frequently jumped from buildings, Foxconn will produce 300,000 robots at a rate of 1,000 units per day for monotonous and dangerous jobs to improve the company’s automation level and production efficiency. One million robot arms will be assembled by 2014. In April of this year, Terry Gou stated: "Many of our factories have already turned off the light production, and we don't need personnel. We rely entirely on robots and robots."

Appliance companies are also one of the replacements.

21st Century Business Herald reporter learned from Midea Group that since 2010, Midea’s Home Air Conditioning Division has been widely used in various workshops for various types of three-axis and four-axis robots. At present, in the production line robot application, Midea's home air-conditioner injection molding production line has invested a total of nearly 200 units and completed assembly of more than 100 units of finished products. There are nearly 200 other electronics and assembly and assembly robots. The company estimates that due to the automation upgrade in 2013, U.S. air-conditioning direct labor costs have decreased by more than 8 million.

“The cost recovery time is the most considered factor for the company.” The aforementioned Guangzhou CNC person told the 21st Century Business Herald reporter that when doing the program for the customer, we must calculate the cost. “Generally, it can be recycled in one and a half to two years. It is more than willing to do it. Because the time is too long, companies are afraid that the production of the product will change, and the cost of upgrading the production line will be partially wasted."

Localization pain

Statistics show that currently foreign robot manufacturing companies account for about 90% of China's market share, and Fanuc, Yaskawa, Kuka, and ABB four companies together account for about 65% of the market share.

Domestic robot companies are at the initial stage of development. Among them, Shenyang Xinsong Robot, Anhui Eft, and Guangzhou CNC are the first echelons of domestic robot manufacturers.

As a local robot manufacturer, Li Jun, head of marketing at Shenzhen Fushi Industrial Technology Co., Ltd., told the 21st Century Business Herald reporter that the biggest problem facing domestic robots is that the core components cannot be produced. "We now purchase spare parts such as speed reducers and servo motors from foreign countries, which is more than three or five times higher than the cost of self-produced foreign companies."

The reducer accounts for about 35% of the cost of a robot. Deng Qiuwei said that because the cost of the core components of domestic manufacturers is significantly higher than that of Japanese companies, it is difficult to compete on the cost of the overall robot.

Chen Chaopeng, a senior analyst at the Institute of Advanced Industrial Science and Technology, points out that at present, domestically produced robots are mostly non-standard robots, that is, according to the specific needs of the downstream SMEs to do customized production, and several foreign companies are more standard robots for mass production. Non-standard robots can adapt to the complex and ever-changing environmental needs of domestic small and medium-sized enterprises. However, due to the difficulty of mass production, this model can hardly produce giant companies in the industry.

In about 10% of the market gap, hundreds of domestic robotics companies competed fiercely. An interesting phenomenon is that many domestic robot buyers are gradually making their own robots and even becoming new sellers.

The automotive industry has precedents. At the end of 2012, Chery Motors announced that 200 robots independently developed by Chery have been put into use one after another. Chery will build an industrial robot industrialization base that will take shape in the next three years.

The above-mentioned robotics industry person who understands Foxconn stated that Foxconn will bid for some robot replacement projects, but the company itself attaches great importance to nurturing its own robotics department.

“Compared with other industries, the household appliance industry is not willing to pay for anything else. A robot application tender can allow more than a dozen robot companies to quote and report on the program. After choosing the cheapest, they generally choose the cheapest, after small-scale purchases. , I learned to produce robots myself.” The industry sources said, “The final estimate of home appliance manufacturers is to do their own robots, such as Gree, the United States.”

Pyramid Technology is a typical example from buyer to seller. The deputy general manager Deng Qiuwei printed another title entitled "General Manager of Pyroban Robots."

Deng Qiuwei told reporters in the 21st Century Business Herald that the company has established the department of Leibo Robots and now has a team of more than 50 people to form the company’s experience in robotic applications into other business models, including consulting or sales. robot. At present, there are more than 10 mobile phones, remote controls and other industrial customers, all of which are lightweight robots used in the assembly field, mainly in Shenzhen, Zhuhai, Heyuan, and Dongguan. In addition to ABB, Yaskawa and KUKA also cooperated with the company. The company's external sales of robots use these companies.

“The progress is faster than expected.” Deng Qiuwei said, “But it's really annoying to be a robot myself because it doesn’t make quick money. Every project (one link on a production line) is different, it’s not easy, it’s very In-depth thinking, a project will take five or six months.

“Industrial robot industry is an industry encouraged by the state. Now that everyone is surrounded by it, it is feared that the result will become a problem similar to photovoltaic.” The aforementioned robotics industry is not without worries.

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