Depth: How to achieve the subversion of LED packaging under the transformation of big data?

In recent years, with the increasingly fierce competition in the LED market, corporate mergers and acquisitions have become increasingly fierce, and product prices have fallen and fallen. In the case that many companies have not fully established their high-end brand image, the profit margin of the company has further narrowed and the price has been narrowed. The madness of war and the sharp decline in net profit have brought new challenges to the development of LED enterprises. In the future, the LED industry will further concentrate on development.

From the data income of LED listed companies in the past two years, it can be found that the current LED enterprise performance differentiation phenomenon has become increasingly fierce and even extreme. Although some enterprises have increased their revenues, the proportion of LED business contribution has declined, and some are no longer even the main business. Another part of the company's revenue decline doubled, it can be seen that the decline in corporate profits is related to the decline in income caused by price fights.

With the continuous decline of gross profit, international lighting giants such as OSRAM, Philips and GE have handled the general lighting business and turned to the development of high-profit intelligent lighting. The domestic lighting companies such as Feile Audio and Mulinsen continue to attack the city and seek for cooperation. Heng, to seize the industry's commanding heights to lead the industry development pattern. Small and medium-sized enterprises are turning to the LED market segment to seek new development space. With the continuous development of the LED industry, the market structure is gradually evolving.

House seemingly endless rain. While the internal environment has evolved, the external environment has also undergone tremendous changes. The emergence of China's manufacturing 2025 and Internet+ has brought about new changes in the external environment. The traditional artificial model has been difficult to adapt to the development of the post-era of the industry. This has also put forward new requirements for the manufacturing industry, requiring future manufacturing. The industry is to liberate labor and achieve intelligence.

As the LED industry in the manufacturing industry, its packaging field has basically formed a cluster, and most of the processes realize mechanical intelligence. There are still some non-intelligent links, which makes the entire LED packaging process unable to realize intelligent closed loop.

The main reason for the formation of this situation is that the current glue-binding process is still using manual operation, which increases the glue error rate. Because of this, the whole link can not be intelligent, and it is precisely because there is such a gap, the inability to form a closed loop has caused many packaging companies to fill a lot of money in this gap, and also suffered a lot of losses.

As far as AB glue is concerned, it is not found in the entire production and shipping process. It will only be discovered after the customer has used the finished product and used it for a period of time. The consequence is not only the enterprise itself. The loss of production investment, but also affects the company's brand, credibility and even the brand credibility of customers, is a problem that all companies are not willing to see.

This is only one of them, and because there is still a lot of staffing of the current glue, which increases the labor cost, and because it is the uncontrollable operation of the personnel, it not only brings the mistakes in the above operation, but also There is waste in raw materials in the actual rubber mixing process.

Of course, the effect of the glue-binding process on the finished package is far more than that. There is also a problem of the stagnation of the inventory due to the problem of the bin rate, which makes the cost of the enterprise rise again. Of course, it takes too long for the personnel to develop the formula. , the loss of delivery and delays caused by the delivery of the customer can not be timely feedback.

Therefore, in the current environment surrounded by the price war of LED packaging, the industry is becoming more and more concentrated, and the packaging enterprises are finally fighting for enterprise competitiveness. In the context of enterprises, they must be reformed and upgraded. These inputs should be large, and the most risk-free links should be optimized by uncontrollable factors. At the same time, cost control should be optimized to better adapt to current LED packages. The big environment.

In fact, the current packaging companies fight for competitiveness is the price and time. Simply put, the price of the same quality, the price of the same price, and of course the after-sales service and brand. That means, under the premise of brand and after-sales guarantees, it is necessary to optimize the time-consuming and cost-effective links in the existing packaging process.

If the artificial operation of the glue in the packaging process can be made intelligent, and the controllability and traceability can be realized, at least the risk of the reverse reaction of the AB glue can be greatly reduced or even eliminated.

What's more worth mentioning is that it has not only cost a lot of R&D personnel, but also takes a long time. However, if you can receive the customer's order demand through intelligent equipment, you can immediately find similar formulas through the intelligent processing of the equipment and then fine-tune the concentration, quickly get the results, reply to the customer in time, and at the same time can carry out small batch testing, and then directly Entering mass production will significantly shorten the delivery period.

In addition to these, it is also possible to improve the yield rate and make the main color area more concentrated. This is where the current packaging companies need to optimize, and the competitiveness of subsequent concentration increases again. If this is achieved, then this wave of price increases will show higher profits than peers and higher sales than peers.

This used to be the idea of ​​LED packaging people for many years, many equipment companies have been thinking for many years, but it has been fruitless. Nowadays, when LED enterprises enter the mature stage, the industrial concentration increases, and the scale effect becomes more and more obvious. The need for such products is even more urgent.

Its appearance can be described as right at the time, it is the "Xingluo" ultra-high-precision LED intelligent rubber powder matching machine of Shenzhen Target-matching Technology Co., Ltd. - a package of enterprises that are currently the pain point of the package, and also realize the closed-loop intelligentization of the packaging link. key.

Because it doubles the process stability of the current mainstream manual dispensing, the drop rate of the main color zone is increased by 3%-6%, while the personnel is reduced by 50%, the auxiliary material is saved by 2%, and zero error is achieved. Said to solve the current and future pain points of the packaging company.

Borrowing an exaggerated network of hot words, this is the power of the current packaging companies.

Customer A usage

Customer B usage

Customer C usage

In recent years, with the support of national policies and various efforts, China's big data industry has developed in a sequential manner and its application has been deepened. Big data has become one of the hotspots in the economic and social fields.

Regardless of whether Industrial 4.0 or Industrial Internet is a smart Internet, it is inseparable from big data. The main purpose is to make the manufacturing industry based on big data by making full use of information and communication technology to integrate products, machines, resources and people. Intelligent transformation based on analysis and application. The arrival of the era of intelligent manufacturing also means the arrival of the era of industrial big data. With the advent of the era of big data, it represents the transformation of traditional manufacturing to customization, and enterprises have higher requirements for flexible production.

In intelligent manufacturing, by integrating the data of the equipment and control layer of the workshop with the enterprise information system, the production big data is transmitted to the cloud computing data center for storage and analysis, forming decisions and in turn guiding production.

In the past, during the operation of the equipment, due to the artificial participation, there were many uncertainties in the production of the product. However, due to the development of information technology and Internet of Things technology, it is now possible to monitor the data in real time through the management system, knowing whether the product line is working properly, what is the fault, and where the feeding is needed, so that these factors in the production process can be precisely controlled. Achieve intelligent production. Therefore, to a certain extent, whether the equipment in the workshop can be intelligent directly determines the future of the manufacturing enterprise.

For the current LED packaging manufacturing enterprises, with the increasing concentration of the industry, the use of machines is getting larger and larger, the labor costs are getting higher and the scale is becoming faster and faster, and the competitiveness of the traditional model is gradually increasing. The micro-modification and intelligent transformation has become a problem that must be solved by current packaging enterprises, and it is also a problem that must be solved. The target machine is to meet the current situation of LED packaging enterprises, helping enterprises realize the intelligentization of LED packaging, which is also its core. The value lies.

The value of the bullseye is not so simple as the intelligentization of the small part of the packaged rubber and powder. Its greater value is to help the enterprise build a smart factory together with the enterprise MES system, and to change productivity through automated informationization. It also changed the production relationship.

Light raw materials and formulas have always determined the light results, and the consistency of the light results is determined by the comprehensive ability of the three processes of powder mixing, stirring and dispensing. In the past, the use of artificial rubber blending powder has increased many uncertainties. However, the use of the bulls-eye ratior not only accurately completes the powder distribution, but also records the data of each job in real time, and the correlation of these real-time matching data with the spectral result data makes the intelligent control packaging process possible.

With the improvement of the intelligent trend, the refined management of packaged enterprises, the role of centralized management in business operations is growing. The existing production line management system has certain limitations. From material to finished product production, it is impossible to complete the real-time tracking of the product in real time, and data interruption occurs, which makes the accounting management lack strong data support. In order to improve the management process, clearly grasp the material flow, and realize the material consumption corresponding to each product and corresponding to the market demand, it is very necessary for the LED packaging enterprise to reform the entire production process system of the product.

As far as the current packaging process is concerned, from the perspective of the whole process of encapsulation, such as solid crystal bonding, welding line, glue filling, testing, and spectrometry, in the glue filling process, it is not only impossible to make materials because of artificial participation in the rubber mixing process. Real-time monitoring of the machine also increases the cost of LED packaging companies and brings great uncertainty and security.

â–² Matching process

If you want to solve the existing problems of the current LED packaging enterprises, the first thing you need to solve is to minimize the participation of personnel in the formula. It is best to manage only the company's decision makers or core figures, and at the same time, implement the encryption of the mature large order production formula. Into the bom table, so that the production of similar products in the future is the need to retrieve the code of the bom table, and then the core key person to send the recipe instructions to the machine, without the need for other people to operate.

Based on this goal, the bullseye ratio introduces a bullseye machine, which can receive recipe instructions sent by the computer to realize smart dispensing production. So how do you implement the closed loop intelligence?

This requires a recipe management system, which helps you to achieve remote centralized management of multi-machine network management recipes and machine operations, centralized management of recipes in the system, and then remotely distribute production recipes to the bullseye smart glue to be produced. The powder machine, and the built-in software in the bullseye machine will feed back the actual process data recorded in real time to the recipe management system.

The traditional large amount of manual data collection and computer desk productivity has been outdated, because the recipe management system will calculate the real-time data results for you. You only need to click the mouse to call out the required machine utilization rate. Information; at the same time, the real-time running status of each machine will be known through the remote monitoring center. In the future, employees can obtain operating instructions through the handheld terminal.

And the blue-thin, mushroom-like mechanized and boring operator who checks the condition of the machine will eventually be included in the smart terminal! With the implementation of the recipe management system, the front end can realize the docking with the ERP system, and the back end can implement the docking with the dispenser through barcode management. Therefore, the enterprise has broken through the LED packaging industry after introducing the bullseye intelligent rubber powder machine. To achieve the bottleneck of intelligent production, this bottleneck breakthrough has opened up the front-end ERP and factory machine remote control and real-time data traceability and real-time remote monitoring of machine operation, so that the intelligent manufacturing of LED packaging industry has countless imagination space, In the following, we will gradually elaborate on how this myriad of imagination space is realized by the combination of the bull's-eye ratio and the factory's MES system in the LED packaging enterprise.

Back to the beginning of this year, large raw materials such as coal and iron ore were the first to raise prices, and gradually passed to the industrial sector in a few months. In November, the price hike of raw materials has not declined, but it has risen steadily. The price hike has affected many fields such as steel, copper, aluminum and plastics, impacting the entire LED industry.

It is foreseeable that a wave of price increases has arrived. Under the trend of rising raw material prices, the profits of the upstream and downstream of the LED industry have been affected by price increases. However, from the past price wars of LEDs, what the whole industry lacks seems to be a collective price increase.

Of course, from the perspective of business operations, price increases are the means to maintain survival. The pressure of cost has threatened the survival of enterprises. However, the cost of LED business operations is not all raw materials, but also includes personnel costs, material waste, and inventory. And other factors in all aspects. That wave of rising prices also reflects the management cost of LED companies' management costs and production costs.

As an LED packaging company, how can we achieve the core competitiveness of subverting management costs when the price surge comes?

Since the cost of raw materials is high, what can LED companies do in addition to price increases if they want to guarantee profits? In manufacturing companies, everyone knows the profit of the company = the price-cost, the price is determined by the market (customer negotiation), and the cost is determined by the management ability of the company, so before answering this question, we may wish to see Under our main business cost component, it covers three parts: direct and indirect labor, manufacturing costs, direct materials. So, for LED packaging companies, how to find the profit of the enterprise from the breakthrough of people, technology and materials?

Looking back, we are in the "pain of the bullseye big data revolution, how can LED packaging achieve the subversion of the business? In the first two articles, the management cost is intelligent to solve the problem of packaging artificial glue, which can bring huge benefits to the enterprise, but there is no data analysis of its impact.

In fact, in the first article, the problem of the bin rate of the machine is mentioned continuously, but the expression is not specific enough, so many people see that the data is 99.8%. In fact, the two are like a pair of twins, from the surface. There is almost no difference in the situation. The bin rate is 99.8%, but the difference is very large. The main performance is that the bin rate of the main production area (ie customer demand) is different, and the bin rate of the machine will be higher than the manual. %-6%.

In the future, the customer's parameters for the lamp bead will become more and more fine, and the increase of the Bin rate will accurately meet the customer's product demand, reduce the inventory inventory risk of the packaging plant, and greatly increase the inventory turnover rate, thereby improving the LED packaging factory. Profitability.

And this reaction to actual production, when the amount of orders increases, the advantages and disadvantages will be magnified by orders of magnitude. As the concentration of current LED packages is getting higher and higher, the scale is getting larger and larger, and the drawbacks of manual operation are gradually enlarged. The following is an example of an LED device order in a main color zone of 100kkPCS.

â–² 100kPCS a main color area LED order production target machine and manual comparison

According to the chart of the case, we can see the very intuitive value of the bullseye machine:

1. The main color area has a 3.2% increase in Bin rate---allowing enterprises to serve customers' needs more accurately. On the one hand, profit from the outside, because demand = sales = business profits; on the other hand, the production of each batch can get 3.5% of the production capacity, which is equivalent to the improvement of our manufacturing process, and finally feedback to our cost structure. in.

2. Reduce the input of raw materials by 5.7kk---allow enterprises to make the best use of them, save raw materials = reduce costs

3. The edge color block inventory is reduced by 3.5%---the settlement of each batch, whether it is from the storage management or the inventory handling, the reduction of the edge color block can reduce the management cost brought by the inventory and improve the manual operation value. .

In summary, the intelligent dispensing powder of the bullseye machine allows the enterprise to obtain cost advantages from the three links of people, technology and materials, which will create new corners for the company in this price increase. Overtaking opportunities.

In today's rapid development of high technology, cloud computing, big data and artificial intelligence have achieved a trinity environment. If enterprises still maintain the traditional business model, it is equivalent to using candles in the era of inventing electric lights. Its faint candlelight, while giving up the bright fluorescent lamp. So, waiting for the fate of the enterprise is only "death."

If the company keeps pace with the times and upgrades and transforms at the right time, the days will be much better. With the bullseye seized the market of large and well-known enterprises, the general manager of the Bullseye Company, the young entrepreneur, told us with confidence: "The introduction of the bullseye matching machine is equivalent to opening the door to the intelligent transformation of the LED packaging industry."

Why do you say that? Because the details of the traditional LED packaging production process are complicated and complicated, various small links are messy, resulting in the details and hidden costs can not be simplified, resulting in many enterprises invisibly lost a large part. profit. However, the introduction of the bullseye machine has helped the enterprise to be simplified, and many of the original small-scale links have been intelligentized, and the profit details have been digitized. This value can be seen from the following two aspects.

1. The value of the data. Enterprises can use the real-time database of the built-in software of the bullseye machine to deeply analyze, mine and process the recipe information of the enterprise, and summarize the formula of the company's own formula. In this way, the company can formulate reasonable production schedules and material purchases according to the conclusions, thereby reducing the amount of production waste and the increase in inventory to meet the customer's shipment quantity, different ways, and achieving optimal control over production costs. At the same time, a little further, I want to incorporate the bullseye into the current management system of the enterprise. It is promising to realize the navigational production mode by the material replenishment and production arrangement triggered by the demand. This is the “just-in-time” thinking of Toyota’s production method. Take the required items and get them as needed when needed."

2. The wisdom of the data. In addition to the control of production costs, companies also have the control of hidden costs. If the control is not good, the butterfly effect will be triggered. As far as this price increase is concerned, the chip is the most valuable part of the lamp. It can be said that it has mastered the cost of the enterprise, but for the packaging company, the material is derived from the market, which is the external environment and cannot be controlled. However, the light result of the device is produced by the proportion of rubber powder, which is the core value of the enterprise. The proportion of the product comes from the knowledge of the internal personnel of the enterprise. Because of the limitation of the artificial rubber powder, the control of this piece becomes the blind spot of the enterprise. Due to the leaked formula and the loss of personnel, enterprises have caused considerable difficulties and caused huge losses and even bankruptcies. Therefore, after the introduction of the bullseye machine, how to give human intelligence to the R&D platform and build a system platform for the LED packaging industry on the R&D side is already a feasible solution.

Therefore, based on the value of data and the attributes of data intelligence, enterprise information construction will determine the future development status of the enterprise to some extent. Whoever has mastered the level of informationization will have the core competitiveness of smart manufacturing in the future. That's why it will overturn the traditional model of existing LED packages.

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