自1913年福特汽车公司开发出世界上第一条流水线，生产均衡化、同步化、标准化、扁平化使得工厂效率大幅度提升。但文明的进步，技术的发展，使得劳动力市场对工厂的生产环境、工作方式、技能掌握有了更高的追求。数字化转型网www.szhzxw.cn
工业4.0是世界制造业新的发展趋势，但有业内专家认为，工业4.0不是新的工业革命，而是很多类先进技术不断进步和相互融合的结果，是对工厂数字化生产的改造，让工人不再在流水线上重复单调的工作，产品质量不再单纯地依靠人力因素决定。
中国，作为一个人口大国，在制造业的人口红利随着人力成本的增加逐渐消失，如何提升制造工艺和生产效率，是中国这个全球制造强国必须面对的课题。安防行业作为传统的制造产业，在生产方式和组织机构方面均遵循着制造业所规范的标准。
深圳，作为中国改革开放的桥头堡，在世界接轨与电子产业链上的优势是其他内陆城市所无法比拟的，世界各行各业的大牌外资企业也将工厂放在深圳，世界知名品牌可视对讲企业罗格朗便是其中之一。
罗格朗的产品口碑，在业内好评如潮，这不仅仅是用心制造的结果，更是对生产方式和工艺的持续改进与创新。从简单的流水线生产车间，到工业4.0数字化的制造生产系统，罗格朗走在了中国工厂生产模式的前列。洞察行业市场，挖掘产业价值，a&s媒体在安防行业的担当，让我们走进了罗格朗在深圳光明的生产工厂，在数字化的生产车间，你会感受到一家实力企业的价值呈现和市场期望。
一、巡视路线规划图
罗格朗深圳工厂坚持研发生产一体化的制造模式，在5楼的工厂大门之外，Plant Tour Way —5/F Start的地标指示开始了a&s的探访之路。数字化转型网www.szhzxw.cn
每一天，工程师都会从起点开始，沿着指定的路线进行巡视。“罗格朗深圳工厂制造中心PE部经理李晓明是本次探访的负责人，他指着墙壁上的指示牌说，”在巡视的过程中，重点生产区域会设置巡视点，绿点表示关键业绩指标（KPI）的检查，红点代表生产及消防安全的检查，根据不同的划分区域，划分的点都是有意义的，这是罗格朗集团公司指定的企业生产文化。”
在PPMS生产进度看板的屏幕上，正在实时显示着生产报表上的变动数据，上面清楚地显示着标示编号的生产线的工作内容，包括工单数量、当日产出、生产状态、不良数、品质状态等。在生产状态一栏，绿色的色块是达标的，红色的色块表示不达标。
二、防静电无尘车间
防静电生产车间，是罗格朗为了过滤来自材料和外来因素对产品的影响，在冬天时会发生静电的现象，给消费者带来困扰的特殊生产区域。所有人进入车间均需要套上一次性的薄膜鞋套，是车间严格执行生产规章制度的体现。忙碌的车间工人正在按照严格的生产环节进行工作，而他们所有的工作状态和成果，都会实时准确地呈现在第12个巡视点的显示屏幕上。数字化转型网www.szhzxw.cn
巡视工程师可以点击屏幕查看在线工人的工作报表数据，包括车间的SMT时段生产数据、月/周效率、机器/目标/警戒效率等关键数据，从这些数据中可以找到车间的负责人、工人的效率和白夜班的运营效果等详细的有价值的参考数值。例如，按照工厂的生产效率要求，今天设定的KPI数值为93.2，如果实时的运行线低于这个数值，那生产效率没有达标，证明生产线出了问题，相关人员必须要做出分析和改进。
三、PCB板的测试
从产品研发的论证，到来料检测，到半成品检测，到最后的成品检测，是罗格朗贯穿整个产品生产的制定流程。在罗格朗深圳数字化的生产车间，我们看到了PCB板的全机器检测过程。李晓明介绍，百分百的PCB板都要采取机器检测，因为要将所有不同规格的零散的元器件装配到PCB板上，对于组装的产品物料、工艺、效果都要进行及时的检测，以达到罗格朗的要求，所以在这个关键点环节上，罗格朗也设置了机器测试——ICT和FVT测试机制。而机器检测和传统的人工检测相比，最大的优势是准确和快速，保障了罗格朗的生产水平和效率。
四、精益化组装车间数字化转型网www.szhzxw.cn
组装车间是将来自不同生产车间的半成品由工人组装成成品，在传统的工厂生产车间，两边长长的流水线是标配的工作方式，但是在罗格朗深圳组装车间，我们看到了小组模式的组装方式。
“罗格朗的生产车间采用最先进的精益生产方式（柔性化生产布局），一切最大化符合Lean production 的原则。我们的精益生产组装线，能快速适应多批次、小批量的市场订单需求。”李晓明指出，”过去传统的生产线，是大量的工人坐在流水线两边作业，看着好像很紧密，有条不紊的， 而实际上工人的工作方式很单一乏味，在效率、质量以及响应多变的市场交期方面都没有这种精益生产方式好。罗格朗现在的生产U-CELL单元，一般由三到五个人组成，最大不超过十人，要求工人能完成全部组装内容，因而对工人的作业技能水平要求高，比如要会掌握操作、装配、测试、 质检、包装等多工种的技能，这对工人自身技能的提升也有帮助。另外，我们的制造技术水平和手段一直保持在同行前列，但我们知道，现在的市场需求变化多端，技术水平日益提高，我们与欧洲集团专家们保持紧密的联系，不断的探索新的制造技术，一旦成熟，我们将会推出下一代更先进的制造技术，满足需要”。
我们在组装小组看到了一个测试员的工作内容。她将产品放进机器测试指定的位置后，按下检测健即可对产品进行检测，检测机器会按设定的流程对产品进行检测，在对话框实时显示产品是否合格，在机器测试过程中，她还参与了其他产品标签粘贴的工作。这不仅充分利用了工作时间，还提升了整个生产小组的效率。数字化转型网www.szhzxw.cn
对于数字化程度如此高的生产车间，操作工人的掌握情况如何，是否存在操作难的问题，对此，我们在现场找到了车间负责生产的一线单元的线长李琼，就相关问题对她进行采访：
Q：显示屏上的信息难不难理解，操作困难比以前困难吗？
李琼：不难理解，操作上线长都是简易化操作，都是做成模块的，有些操作比以前更加的简单。
Q：对新入职的员工要培训多久？
李琼：如果是新员工入职，到掌握一个生产小组的所有工序，大概需要一个月左右的时间，如果是单技能的工位学习，需要一个礼拜左右的时间。
Q：现在的操作流程严不严格？
李琼：当然严格，必须的严格，我们的员工在掌握操作技能的过程中，就有专人对他们进行严格的培训，一切的生产工序都要按车间规定的要求去执行。
五、OQC检验
从组装车间完成的一件产品，还不能交付客户推向市场，需要对产品进行成品检测，车间也会划分不良品放置区，将有瑕疵的产品留下。为了保证每一件推向市场的产品都是合格的，每个产品都会有专属的条形码。李晓明拿出一个PCB板，指着上面的条形码介绍：“通过罗格朗的系统，扫描条形码即可知道这个PCB板的状况，比如生产时间、软件版本、测试情况等都可以看到。”他又指着一件产品介绍，“如果内部扫描这个产品，也可以知道是谁购买这个产品，销往区域是哪里，以及其他关键参数等信息。”
在巡视路线最后一站，是罗格朗深圳工厂OQC检验间，即出货品质检验工作。这是所有生产工序完成后的最后一道检测，工厂会在产品入仓，准备送去给客户的时候进行的品质检测，罗格朗希望对推向市场的产品进行最后的检测，如果产品符合要求就出货，不符合就提出整改或返工生产。在OQC看板上，显示着房间里面抽检产品的状况，任何抽检到的品质问题都会显示出来。工程师每天巡视到这里的时候，如果不达标，则会提出相关的要求。
六、罗格朗总经理的视角数字化转型网www.szhzxw.cn
作为具有欧洲精工制造传统血统的企业，罗格朗在深圳的数字化工厂的建设和生产，承担着罗格朗集团在全球市场的产品交付能力和品质保障，因此，罗格朗的产品采取什么样的生产方式和达到怎样的生产效率显得尤为重要。
深圳市视得安罗格朗电子有限公司总经理 杨春平
对此，深圳市视得安罗格朗电子有限公司总经理杨春平向我们介绍：“罗格朗现在的生产体系叫罗格朗的生产方式，这种生产方式代表了罗格朗集团对百年制造工艺和产品质量的独特理解。以产品质量来分析，可以分三个阶段理解：第一、在研发阶段，研发部有一套完整的流程来保障设计阶段产品的可靠性；第二、进入生产阶段，针对供应商，罗格朗又有一整套要求流程，例如不允许用童工，企业的生产符合当地环境保护要求等，这些集团每两年都会派遣专员对供应商进行抽查，罗格朗的每个材料都有检查清单，这些来料要符合行业标准和产品研发阶段提出的各项性能指标；第三、在生产制造阶段，影响微电子产品质量的主要问题出在元器件上，比如出现虚接的问题，为了改善这种状况，罗格朗引进的SMT自动化生产模式，利用机器代替人工生产环节因为人的因素所造成的产品质量问题，这套系统可以控制产品的不合格率在百万分之一左右；第四、成品检验出了质量检测，还包括不同区域气候的检测，以及各个国家不同标准的检测，以满足罗格朗全球出口的产品要求。”
七、展厅展示
在罗格朗深圳数字化工厂的最后一站，我们来到了罗格朗的产品展厅。在陈列的展品世界里，我们看到了罗格朗在1993年推出的中国首台可视对讲室内机SD900，也亲身感受了智能家居控制终端对各类家电、家居产品的统一管理和控制。
凝视着这些代表各个时期的优秀产品，让人仿佛看到了时光穿梭的脚步，在各色各样的墙上，正挂着一台小小的罗格朗对讲机，连接着内外的两个世界。
八、采访后记数字化转型网www.szhzxw.cn
科学的管理，严格的操作流程，人性化的生产方式，在罗格朗深圳数字化生产工厂，我们看到了一家百年企业的制造水准和品质管控。在工业化4.0和中国制造2025的大背景下，深圳作为世界电子产业的制造中心，罗格朗向我们诠释了什么是用心制造。中国有偌大的安防和电子消费品市场，但在中国工业化三十年的进程中，事实已经证明最终能够沉淀下来的品牌，不是宣传上的夸大其词，而是生产制造上的精益求精和持续创新改进，工业4.0不是工业史上的革命，而是对工业生产持续的创新。安防工厂的效率提升，也不是依靠一批先进的机器手，而是以人为核心的精细化管理。
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翻译：
Since 1913, Ford Motor Company developed the first assembly line in the world. Production equalization, synchronization, standardization and flattening have greatly improved factory efficiency. However, with the progress of civilization and the development of technology, the labor market has a higher pursuit of the factory’s production environment, working mode and skills.
Industry 4.0 is a new development trend of the world’s manufacturing industry. However, some industry experts believe that Industry 4.0 is not a new industrial revolution, but the result of continuous progress and mutual integration of many kinds of advanced technologies. It is the transformation of the digital production of factories, so that workers no longer have to repeat monotonous work on the assembly line, and product quality is no longer simply determined by human factors.
As a populous country, China’s demographic dividend in manufacturing industry is gradually disappearing with the increase of labor cost. 数字化转型网www.szhzxw.cn
How to improve the manufacturing process and production efficiency is a task that China, a global manufacturing power, must face. As a traditional manufacturing industry, security industry follows the standard of manufacturing industry in terms of production mode and organization.
Shenzhen, as the bridgehead of China’s reform and opening up, in the world and the advantages of the electronic industry chain is incomparable to other inland cities, the world’s all walks of life of the big foreign enterprises will factory in Shenzhen, the world’s famous brand visual talkback enterprise is one of them.
The reputation of the products of Leglan, in the industry is highly praised, which is not only the result of careful manufacturing, but also the continuous improvement and innovation of the production method and process. From simple assembly line production workshop to Industry 4.0 digital manufacturing production system, Leglan is at the forefront of Chinese factory production mode. Insight into the industry market, mining industrial value, a&s media in the security industry, let us into the production factory in Shenzhen Guangming, in the digital production workshop, you will feel the value of a strong enterprise and market expectations.
Patrol route planning map
Shenzhen Plant adheres to the manufacturing mode of integration of R&D and production. Outside the factory gate on the 5th floor, the Plant Tour Way — 5/F Start landmark indicates the start of the a&s visit road.
Every day, the engineer will start at the starting point and walk the designated route. “Li Xiaoming, manager of the PE department at the manufacturing center of the Shenzhen plant of Leglan, who is in charge of the visit, points to the signs on the wall.” During the inspection process, inspection points will be set up in key production areas, with green dots indicating inspection of key performance indicators (KPIs) and red dots indicating inspection of production and fire safety. According to different areas, the points are meaningful. This is the production culture designated by the company.
On the screen of the PPMS production schedule board, the change data of the production report is displayed in real time. It clearly shows the work content of the numbered production line, including the number of work order, daily output, production status, defect number, quality status, etc. In the production status column, a green color block is acceptable and a red color block is substandard.
Anti-static dust-free workshop数字化转型网www.szhzxw.cn
Anti-static production workshop is a special production area where the electrostatic phenomenon occurs in winter in order to filter the influence of materials and external factors on products. All people need to put on disposable film shoe covers when entering the workshop, which is the embodiment of strict implementation of production rules and regulations in the workshop. The busy workshop workers are working according to the strict production process, and all their work status and results will be accurately displayed in real time on the display screen at the 12th inspection point.
The tour engineer can click on the screen to view the work report data of the online workers, including the SMT time production data of the workshop, monthly/weekly efficiency, machine/target/alert efficiency and other key data. From these data, detailed and valuable reference values can be found such as the workshop leader, the efficiency of the workers and the operation effect of the night shift. For example, according to the production efficiency requirements of the factory, the KPI value set today is 93.2. If the real-time running line is lower than this value, the production efficiency is not up to the standard, which proves that there is something wrong with the production line. Relevant personnel must make analysis and improvement.
PCB board test
From the demonstration of product development, to the inspection of incoming materials, to the inspection of semi-finished products, to the final inspection of finished products, it is the development process of the whole product production. In our digital workshop in Shenzhen, we see a full machine inspection process for PCB boards. Li Xiaoming introduced that 100% PCB board should be inspected by machine, because all scattered components of different specifications should be assembled on PCB board, and the materials, processes and effects of assembled products should be inspected in time to meet the requirements of Leglan. Therefore, in this key link, Roglan also sets up machine testing — ICT and FVT testing mechanisms. Compared with traditional manual detection, the biggest advantage of machine detection is accuracy and speed, which guarantees the production level and efficiency of Roglan.
Lean assembly workshop数字化转型网www.szhzxw.cn
In the assembly workshop, semi-finished products from different production workshops are assembled into finished products by workers. In the traditional factory production workshop, long lines on both sides are the standard working mode. However, in the assembly workshop of Leglan Shenzhen, we can see the group mode of assembly.
“Our workshop adopts the most advanced Lean production method (flexible production layout), which maximizes everything in line with Lean production principles. Our lean manufacturing assembly line can quickly adapt to multi-batch, small-batch market orders.” “In the past, the traditional production line, with a large number of workers sitting on both sides of the assembly line, looks tight and orderly, but in fact, the way the workers work is very monotonous, in terms of efficiency, quality and response to the changing market delivery,” Li Xiaoming pointed out.
Currently, the production U-CELL unit of Leglan is usually composed of three to five people, with a maximum of ten people. It requires workers to complete all the assembly contents, so the working skills of workers are required to be high, such as mastering the operation, assembly, testing, quality inspection, packaging and other skills, which is also helpful for the improvement of workers’ own skills. In addition, our manufacturing technology level and means have always been in the forefront of the industry, but we know that the market demand is changing, the technology level is improving day by day, we keep close contact with the European group experts, constantly explore new manufacturing technology, once mature, we will introduce the next generation of more advanced manufacturing technology to meet the needs.”数字化转型网www.szhzxw.cn
We saw the work of a tester in the assembly team.
After she put the product into the designated position of the machine for testing, she pressed the detection key to test the product. The detection machine would test the product according to the set process, and the dialog box would display whether the product was qualified in real time. In the process of machine testing, she also participated in the label pasting of other products. This not only makes the best use of working time, but also increases the efficiency of the entire production team.
For the production workshop with such a high degree of digitalization. How are the operators mastering and whether there is a problem of difficult operation? For this, we found Li Qiong, the line leader of the first-line unit responsible for production in the workshop. And interviewed her about relevant issues:
Q: The information on the screen is not difficult to understand. Is the operation more difficult than before?
Li Qiong: It is not difficult to understand that the operation line is always simplified and made into modules. Some operations are simpler than before.
Q: How long does it take to train new employees?
Li Qiong: It takes about a month for a new employee to master all the processes of a production team. It takes about a week for a single skill to learn.
Q: Is the current operation process strict?
Li Qiong: Of course, it must be strict. In the process of mastering operational skills, our staff will have a special person to give them strict training. All the production procedures should be implemented in accordance with the requirements of the workshop.
OQC inspection
A product completed from the assembly workshop cannot be delivered to the customer for market. So the product needs to be tested. The workshop will also divide the defective product placement area, leaving the defective product behind. In order to ensure that every product brought to market is qualified, each product will have its own bar code. Li Xiaoming took out a PCB board and pointed to the bar code on it. “The condition of the PCB board can be known by scanning the bar code through the system of Leglan. Such as production time, software version and test status.” “If you scan the product internally, you can also find out who is buying it, where it is sold, and other key parameters,” he says.
The last stop on the inspection route is the OQC inspection room of the Shenzhen factory of Luelang, that is, the outgoing quality inspection work. This is the last inspection after the completion of all production processes. The factory will conduct quality inspection when the product is in the warehouse and ready to be sent to the customer. Leglan hopes to carry out the final inspection on the products brought to the market. On the OQC Kanban, the status of the sampled products in the room is displayed. And any quality problems detected will be displayed. Every day, when the engineers visit, if they don’t meet the standards, they will make relevant requirements.数字化转型网www.szhzxw.cn
General Manager’s Perspective
As an enterprise with the traditional ancestry of European precision manufacturing. The construction and production of the digital factory in Shenzhen bear the delivery capacity and quality assurance of the products of the group in the global market. Therefore, what kind of production mode and what kind of production efficiency of the products of the group are particularly important.
Yang Chunping, general manager of Shenzhen Sedeanlang Electronics Co., LTD
In this regard, Yang Chunping, general manager of Shenzhen Sedeanelang Electronics Co., Ltd. introduced to us:
“The current production system of Leglang is called the production mode of Leglang. This production mode represents the unique understanding of Leglang Group on the century-old manufacturing process and product quality. Product quality analysis can be divided into three stages: First, in the research and development stage. The research and development department has a complete set of processes to ensure the reliability of the design stage;
Second, entering the production stage, for suppliers, Rogelang has a whole set of requirements. Such as no child labor, production in line with local environmental protection requirements. These groups will send specialists every two years to carry out spot checks on suppliers. Every material of Rogelang has a check list, these incoming materials should meet the industry standards and the performance indicators proposed in the product research and development stage;
Third, in the production and manufacturing stage, the main problems affecting the quality of micro-electronic products are components, such as the problem of virtual connection. In order to improve this situation, the SMT automatic production mode introduced by Rogelang uses machines to replace the product quality problems caused by human factors in the production process. This system can control the unqualified rate of products in a million or so;
Fourthly, the finished product is tested for quality, including the testing of different regional climates. As well as the testing of different national standards to meet the requirements of the products exported by Leglan worldwide.”
Exhibition hall display
At the last stop of our digital factory in Shenzhen, we came to the product hall of our company. In the world of exhibits on display, we saw China’s first video intercom indoor machine SD900 launched by Leglan in 1993. And also experienced the unified management and control of various household appliances and household products by smart home control terminals.
Staring at these excellent products representing various periods, people seem to see the pace of time travel, on various walls, is hanging a small Roger Lang walkie-talkie, connecting the two worlds inside and outside.
Interview postscript数字化转型网www.szhzxw.cn
Scientific management, strict operation process, humanized production mode, in the digital production factory in Shenzhen. We have seen the manufacturing standards and quality control of a century-old enterprise. Under the background of Industrialization 4.0 and Made in China 2025. Shenzhen is the manufacturing center of the world’s electronics industry. China has a huge security and consumer electronics market. However, in the process of China’s industrialization for 30 years, facts have proved that the brand that can finally settle down is not exaggerated in publicity. But the excellence in production and continuous innovation and improvement. Industry 4.0 is not a revolution in industrial history, but a continuous innovation in industrial production. The efficiency improvement of security factory does not rely on a group of advanced robot hands. But on the refined management of the human core.
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