The hottest low-end manufacturing needs to change

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Low end manufacturing is in urgent demand. LED lighting enterprises should learn intelligent manufacturing

according to the data of the LED Research Institute of higher industry and Research (GGII), in 2016, the scale of the global LED chip market increased by 7.88% year-on-year, reaching 44.8 billion yuan. GGII predicts that the global LED chip market will reach 51billion yuan in 2017, with a year-on-year increase of 13.8%

after years of development, China has become the world's largest producer, consumer and exporter of LED lighting products. According to GGII data, China's LED chip market began to pick up in 2016, and the growth rate of chip market size reached 11.54%. Considering that chip prices remained basically stable in 2017, the productivity of domestic chip manufacturers remained at 100% and large chip manufacturers expanded their production, GGII expects the growth rate of China's LED chip output value to reach about 30% in 2017

nowadays, China has initially formed a relatively complete industrial chain, including the production of LED epitaxial chips, the preparation of LED chips, the packaging of LED chips and the application of LED products. Among them, as the LED penetration rate increases, the LED downstream application market is becoming broader and broader

according to the research data of the LED Institute of higher industry and Research (GGII), the market scale of China's LED downstream application field in 2016 was 369.7 billion yuan, with a year-on-year increase of 15.71%, the growth rate is similar to that in 2015. Among them, the display screen, backlight, lighting and other application sectors account for 12%, 11%, 66% and 11% respectively. GGII predicts that the output value of LED downstream applications in China will reach 445.1 billion yuan in 2017, an increase of 20.4%

lighting, as one of the largest LED applications on February 29, has been extremely active in recent years. From the perspective of the form of LED lighting products alone, the types of LED lamps have long been dazzling, and the structure of lamps has also changed intuitively in the process of evolution

the way of the evolution of the morphology and structure of LED lamps

due to the inherent advantages of energy saving and environmental protection, LED is widely used in all kinds of lamps. LED lamps have experienced several years of development, with increasingly diversified product forms and power

however, under the situation of declining product prices and rising costs, the product profit margin has decreased sharply. In this situation, lamp manufacturers are working hard on the selection of raw materials and product plans. With the simplification of the scheme, the lamp structure has also changed significantly

take LED bulb lamp as an example. In the past, a bulb lamp was divided into lampshade, LED light source, radiator, power supply, base and screw port, and this structure has been maintained for a long time

however, due to the steep fall in the price of bulb lamps in recent years, manufacturers cannot afford the heavy cost. Therefore, various new schemes came into being. Among them, the appearance of linear scheme has fundamentally changed the morphological structure of bulb lamp. The independent power supply in the previous bulb lamp disappeared and was replaced by the integrated form of Linear IC circuit and LED light source

nowadays, in the LED lighting industry, product upgrading is too fast. If a product does not update its appearance and materials for a year or two, it will be surpassed by its rivals. This directly leads to the low degree of standardization of LED products and the low degree of automation of LED downstream manufacturers

the low-end manufacturing of the domestic lighting industry is in urgent need of change

at present, the domestic manufacturing industry is still dominated by labor-intensive low-end manufacturing, the added value is relatively low, and the per capita manufacturing output is lower than that of developed countries; In terms of export product categories, the export volume of high-end technology intensive manufacturing in Chinese Mainland accounted for only 42% in 2014, lower than 58%, 53%, 55% and 58% in the United States, Germany, Japan and the United Kingdom

in the long run, the aging population will inevitably lead to the increase of human costs, which will weaken the cost competitiveness advantage of domestic manufacturing industry. In addition, India, Thailand, Vietnam and other countries have lower human costs, so the transformation and upgrading of domestic manufacturing industry is imperative

throughout the LED lighting manufacturing industry, at this stage, the largest load unit is installed on the moving beam driven by electromechanical drive or oil pressure. The pressure has evolved into how to improve efficiency and reduce personnel management. For this reason, since the second half of 2013, some large assembly plants in Chinese Mainland have begun to introduce automated production lines, which can reduce assembly costs by 50%

Lin Yan, vice chairman of Sanxiong Aurora, believes that the automation transformation of the production line will be divided into two stages: one is mechanization and the other is intellectualization. Simply speaking from the solution of mechanization, it can improve efficiency and save labor costs; Intellectualization is to raise a level, which can reduce the cost of the manufacturing process through intellectualization, but this process cannot only rely on equipment enterprises, and only the active participation and cooperation of lighting production enterprises can realize the optimal solution

lighting production enterprises have become the most direct beneficiaries by adopting automatic production lines. First, it can improve production efficiency and ensure quality; In addition, it can actually reduce labor costs. In the lighting industry, LED lighting enterprises such as MuLinSen, Sanxiong aurora and Yuanhui optoelectronics have invested in LED automatic production lines to fundamentally improve production efficiency. The structure should be as simple as possible to produce high-quality LED products in a few seconds, which has brought more benefits to enterprises

take the LED bulb lamp automatic production line made by xuanshuozhi as an example. If a bulb is produced manually, the production cost is about 0.5 yuan -0.6 yuan, while using automatic equipment only needs 0.1 yuan. Exclusion method: take out the damping pin, yuan -0.15 yuan. In this way, a bulb can save 0.4 yuan in production cost. Based on the hourly output of 1500 bulb lamps in automation equipment, at least 8000 yuan can be saved a day. For LED lighting enterprises, the investment cost can be recovered in half a year

nowadays, with the proposal of "made in China 2025", accelerating the development of intelligent manufacturing equipment and products, and laying out the R & D and industrialization of lighting electrical products has become a general trend, which is also one of the effective ways to upgrade the LED manufacturing industry and enhance the competitiveness of China's lighting industry

source: Senior Engineer LED

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