The 2023 Year In mid-February, when spring just started, in the Yanaisi textile workshop in DATANG STREET, ZHUJI, 4 4 0 On a sewing and knitting hosiery machine, colorful silk threads are flying up and down, and the machine is running at full power to catch up with the sock’s orders for this spring.
General manager Dai Tiejiang is very satisfied with the start of this year: the order on hand has been scheduled until April. In the following May, it’s time to prepare for this year’s autumn and winter models.
in Zhejiang Province has the most complete hosiery industry chain in the world and is the largest hosiery production base in the world, accounting for about 35 %, nationwide _ 65 %. In Datang, where hosiery owners are produced, there are thousands of hosiery companies like Yanaisi that have grown from family workshops. Thanks to the efforts of the government, in the past three years 1 1 1 enterprises have gradually embarked on the road of digitalization, and the digital platform has connected thousands of enterprises and hundreds of thousands of workers in the hosiery industry.
In the past three years, the new crown epidemic has changed global economic life, and the hosiery industry is also undergoing important changes. On the user side, socks have gradually become an indispensable fashion accessory from warm products. On the sales side, e-commerce is becoming an increasingly important sales channel, and people’s demand for trendy and high-quality socks continues to increase. On the production side, hosiery factories are undergoing digital industrial upgrading based on people’s demand for high-quality cotton socks.
The latest data show that in the case of contracting international and domestic demand in DATANG Street last year, manufacturing investment was 1.62 billion yuan, a year-on-year increase of 53. 1 %, self-operated export 1 0 7.8 100 million yuan, breaking through the 10 billion mark for the first time. When digitalization enters each factory workshop, this world-famous sock town is ushering in a fundamental upgrade of the industrial chain.
Small town supplies global market
DATANG Street in ZHUJI 2019 Year 6 Yue was formed by the merger of the original Datang and Caota towns. This is a characteristic town in Zhejiang Province, a demonstration area for creating well-known national hosiery brands, a pioneering area for world-class hosiery industry clusters, and a demonstration base for intelligent manufacturing equipment and hosiery art design in China’s hosiery industry. Each year, there are approximately 25 billion pairs of socks, from Datang all over the world.
In 2022, Datang Street added a new digital workshop 48 digital demonstration enterprises 3. ZHISHEN Hosiery is one of them. As a young dark horse enterprise, the hosiery enterprise was updated last year. 1 0 0 digital integrated hosiery machines. this 1 0 0 The surprises brought by the first digitally integrated hosiery machine and intelligent management system are orders from international brands “Little Yellow Man ” and Under ARMOUR. Zhou Jianjun, the person in charge, told the first financial reporter, “Our output value was very low before, and the ex-factory price of a pair of socks was only 1 buck or 8 Dimes, now the ex-factory price of our socks is basically four or five or six yuan. ”
Not far from ZHISHEN Hosiery is YANAISI Textile, the hosiery company that has updated the most digitally integrated hosiery machines in Datang Street in the past three years. Three years ago, Yanaisi’s orders were mainly OEM and OEM, mainly for large chain supermarkets such as Sanfu Department Store and RT-Mart in China. In the past three years, with the rise of a group of cutting-edge brands on the e-commerce platform represented by Tmall, the supply volume of Yanaisi to the e-commerce platform has also greatly increased.
” The feedback from the domestic market is that the demand for mid-to-high-end socks is increasing. ” Dai Tiejiang told reporters that the first time he brought the socks produced by the digital integrated hosiery machine to Sanfu Department Store, the other party was very satisfied with the product, and the order of a big customer meant that he needed more machines to guarantee its supply. Therefore, while many hosiery companies are still waiting to see and test the water, Yanaisi decisively updated in the first year 1 0 0 A digital integrated hosiery machine.
At that time, such a large-scale update received great support from the street, except that the Economic and Trade Bureau gave a 40 % subsidy with an additional subsidy on the street. Dai Tiejiang told reporters that the update of hosiery machines can not only ensure higher-quality mass production capacity, but also speed up the factory’s rapid response to customer orders and can adjust production according to market demand more quickly. Therefore, Yanaisi respectively in 2 02 1 year and 2 02 2 In 2010, it upgraded its own factory again, and the ” small family workshop” began to improve towards the direction of a modern factory. This kind of quick reaction ability ” is the number one vitality of our domestic sales enterprise “, Dai Tiejiang told reporters.
In the past three years, not only the order value of supermarkets such as Sanfu Department Store and offline agents has increased, but the e-commerce channel of Yanasi has also gradually opened up.
Tmall ‘s top brand Mianzhuwu is also one of Yanaisi’s important customers. In the past three years, Mianzhuwu has become the dark horse brand of Tmall cotton socks, which has also strongly driven Yanaisi’s online orders to increase significantly.
Zhou Dawei, the founder of Mianzhuwu, was a Taobao operator. At the beginning of the establishment of the brand, he made it clear that Mianzhuwu would never be a brand that competes at low prices in an industry with high homogeneity. from 2 0 20 Since 2010, Mianzhuwu has changed the model of OEM enterprises’ leading products, and the products are determined by the brand. For example, in terms of craftsmanship, Mianzhu House has very high requirements for the factory, and each process of the factory socks has a very clear SOP, even setting (a process in the production process ) air pressure and pressure holding time will have strict requirements. In order to make the shape look good, Mianzhuwu requires a certain type of socks to be as wide as possible 7 . 5 to 7 . 8 cm, the error is less than ±0.2.
such technical requirements, Dai Tiejiang told reporters that in recent years, Yanaisi has witnessed the development of Mianzhu House as an OEM company, has also grown with customers, and has received more orders from online platforms. “Socks companies want to make explosive socks, and they need matching production links. This puts higher requirements on the production and order response capabilities of sock companies. ” Dai Tiejiang introduced that the current e-commerce platform has high requirements. Timeliness and high quality. Taking their company as an example, the fastest response time for e-commerce orders such as Tmall can reach 7 days, The regular online model is the fastest or even only needs 2 days. After updating the hosiery machine and digital management system, they can use more scientific tools to coordinate and guarantee the “expansion of territory ” of e-commerce enterprises.
Fewer workers, more machines
which exist almost like air in everyone’s daily life, and are made up of countless details in the eyes of the owner of the socks factory in Datang. Because the unit price is not high, they need to reduce the cost as much as possible for every link.
In Zhishen Hosiery, Zhou Jianjun’s desk is opposite two large screens, and he can monitor the operation of factory equipment at any time on this hosiery IoT management system developed by Haier. In Yanaisi ‘s factory workshop, the smart factory network management system developed by Zhejiang Dahao Mingde Intelligent Control Equipment Co., Ltd. was introduced simultaneously with the hosiery machine installation.
The digitally integrated hosiery machine and the intelligent factory network management system bring these factories not only the improvement of the process but also the substantial reduction of various costs.
Take the seam head as an example. In the traditional hosiery knitting process, the seam head is generally divided into machine seam and hand seam head. The hand seam head is also called the eye seam head or boneless seam head. The touch is obvious, and there are still threads at both ends of the seam, and the hand-stitched socks have no protrusions at the seam. Before the digitally integrated hosiery machine, traditional manual sewing needs to manually align each stitch of the sock on the machine, which is very inefficient. General traditional machine sewing can be completed per person per day 4 00 0 to 50 00 pairs, while the artificial sewing head is completed per person per day at most 7 0 0 pairs. Dai Tiejiang told reporters that just sewing a thread here brings comfort to the wearer and at the same time means that it can be sold in the wholesale market. A premium of 2 ~ 3 yuan. After upgrading to the hosiery machine, the cost of hand-stitched heads has been reduced by at least half.
On the intelligent system side, the efficiency of the machine is more quantitatively reflected on the big screen, which is clear at a glance. In the digital workshop of Zhishen Hosiery, each hosiery machine has a serial number, installed 2 2 infrared sensors, as long as a thread of any hosiery machine is loose or broken, the workshop data display screen can see that the hosiery machine is in a ” faulty ” state, and the operator will deal with it immediately, which will not be like before Produce defective socks like that and cause waste.