Abstract: With the rapid transformation of the textile industry from extensive to refined, labor-intensive production
is developing towards less or even unmanned production, modern mechatronics, automation, intelligence,
high efficiency, and continuous mass production, which is unstoppable.
Recently, at the 6th China Safety Protection Textile and Garment Industry Innovation and Development Forum,
Academician Yao of the Chinese Academy of Engineering pointed out that the textile industry
has reduced from 365 workers per 10,000 spindles and three shifts per day in the 1980s to less than 30 workers now,
which is the biggest feature of the textile industry's transformation from labor-intensive to intelligent.
Improving production efficiency and reducing the number of workers per 10,000 spindles is the goal that
many cotton spinning companies have been pursuing. In recent years, through the purchase of
automated textile machinery equipment and the optimization of textile machinery configuration,
some cotton spinning companies have reduced the number of workers per 10,000 spindles to a
rare low level in the industry.
China's leading cotton spinning enterprise employs 20 people for every 10,000 spindles
In a Chinese factory's precision spinning workshop with 135,000 spindles, the staffing is about 270 people,
with an average of about 20 people per 10,000 spindles, making it the workshop with the least workers.
In addition, the three old spinning workshops employ only about 30 people per 10,000 spindles,
which is only 1/3 of other spinning mills in the same industry, or even less.
The highlight of their spinning mill's employment is to reduce employment,
which is also the most positive and effective way to solve the contradiction of enterprise employment.
The factory has the following main ways to reduce employment:
1. Management innovation: promote the employment system, change to a two-shift system,
implement refined quotas and quotas, and work at full capacity; improve the efficiency of maintenance work;
reform and innovation of the labor organization structure. In order to mobilize the enthusiasm of
employees and achieve a full-load working state, the effect of stabilizing employment is achieved
by improving the living environment of employees and improving the quality of life of employees;
by implementing the last-place elimination system, the income of employees with outstanding work
is increased, thereby mobilizing the enthusiasm of employees for production.
2. Through the shift system reform, from the initial four shifts and three operations, three shifts and three operations,
and three shifts and two operations, the current two shifts and two operations rotation system has been adopted.
The highly flexible shift system not only meets the individual needs of employees born in the 1980s and 1990s,
but also meets the production needs, and finally reaches the full load working state of employees. In addition,
the equipment is chartered to the person, and the effective labor is chartered to the person, which enhances
the responsibility of employees and re-establishes the concept of maintenance work.
3. Technological innovation: Deepen the "integration of industrialization and informationization"
and improve the automation of production lines. In traditional labor-intensive industries, the most effective way
to improve labor productivity is to actively carry out technological innovation and improve the level of
mechanization and automation. The spinning workshop introduces advanced equipment in important
processes, and a large number of sensors are used in the equipment to improve the informatization and automation
of the equipment. Automated operation expands the workers' viewing area, and large packages reduce the
frequency of workers' daily work, thereby reducing labor.
Operation operation method reform: break the routine, study new operation methods,
simplify operation procedures and technical requirements. For example: spun yarn joints are a relatively
difficult job in the operation position, and workers need a lot of time for training to master the technology.
In response to this difficulty, Yimian changed the traditional "top tube" jointing method and adopted sleeve jointing to
reduce the technical difficulty and make it easy for workers to get started, thus shortening the training cycle.
Through this reform of jointing operation, workers are only required to connect the yarn firmly, without requiring theirjoint quality.
The electric cleaning device of the winding equipment automatically detects and removes it, and then
re-joins it with an automatic twister. This not only ensures the joint quality, but also reduces the technical difficulty of
the spinning stopper, shortens the jointing time, increases the viewing area of each worker, and reduces the number of
workers employed by the spinning value turner.
4. Process optimization and reform: The spinning process adopts super-large drafting, and the quantitative
increase of coarse yarn increases, thereby increasing the coarse yarn output and reducing the opening of the coarse
yarn car, achieving the purpose of reducing labor. At the same time, super-large drafting also improves the
quality level of yarn, coarse and fine details, and cotton knots.
5. Product transformation and upgrading: Expand high-quality boutique production lines;
implement brand standard strategy T0~T5 to meet the needs of different customers. In the face of increasingly
fierce competition in the textile industry, instead of competing on price and raw materials, it is better to find new ways
out and continuously develop and produce high-end products. In this way, while reducing competitive pressure,
we can occupy more market share and create a world-class yarn brand. The expansion of the ultra-high-count yarn
production line has reduced the requirements for total output, thereby reducing the workload of workers.
Based on the principle of full-load workload, the number of employees has been greatly reduced, which better adapts
to the current external environment of "labor shortage".
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