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The following is a summary of the speech by Secretary General Zhang Jin of China Forging Association at the meeting:
I mainly talk about three issues. The first question: the current situation. I mainly talk about big forgings. The second question: to inform the industrial policies of several countries. It is mainly five industrial policies related to our industry. The third question: the future development path of our industry, and several guidelines in the development process, we cannot give up. We must have certain rules in the forging industry. Everything has its own rules. If you do it in violation of the law, you must take a detour.
The first question: We now have nearly 350 presses, plus nearly 100 presses for ring forging, and more than 400 hydraulic presses with more than 1,000 tons in China. In the early days of reform and opening up, we added more than 70 presses to steel mills. Of course, the use of free forging hammers has been greatly reduced. Compared with the composition of forging equipment in the early days of our founding, the presses have now surpassed the number of forging hammers of more than 3 tons. With so many presses, how many forgings can be produced in a year according to normal production capacity? It can produce 9 million tons of forgings. Our annual forgings production is growing at a rate of 20% to 30%. We calculated the forgings of 600,000 tons of hammers based on the base of 1.9 million tons of forgings, leaving 1.3 million tons of hydraulic forgings, which is the figure for 2007. According to this base, we can probably produce 2 million tons of hydraulic forgings this year. And our production capacity is 9 million tons of forgings. Everyone thinks about the current situation, why the order is there for a while, and not for a while. The market is now volatile and very unstable. So we can see that we have so many presses, together we can only produce more than 100 full-load machines, and more than 100 are semi-loaded. Other equipment may stop there if we hit a few hundred tons of forgings a year. It is. Engage in free forging large forgings, the two shifts are to make money, hit a stop and stop, certainly not making money.
The second situation is the grade of domestic hydraulic presses. It can be said that after another 5 to 10 years, more than 100 presses will be eliminated. Because it does not meet the manufacturing level of free forging hydraulic presses. We now have a lot of hydraulic presses that can't be called hydraulic presses. They can only be called a combination of hammer and hydraulic press. In addition, heating and heat treatment are not compatible. In order to look good, the stoves are built to be generally large, which is not scientific. Generally speaking, China is now 1 to 2, and a heating furnace is equipped with 2 heat treatment furnaces. This is not enough. According to the practice of European developed countries, one heating furnace should be equipped with 3 to 4 heat treatment furnaces. Construction.
Third, the current development direction of forgings is to say where our big forgings are going, why have they been in the past few years? In recent years, electricity has mainly driven the development of our entire industry. Every one of our free forging companies, I believe, has something to do with wind power. The rest is shipbuilding, petroleum, and chemicals. However, in order to develop for a long time, the three markets of electricity, petroleum and chemical industry will have good development with the improvement of people's living standards. This choice is no problem. However, in the shipbuilding market, because the volume of international trade is limited and the growth rate is limited, the shipbuilding industry will not expand indefinitely.
At present, the forging industry needs to solve three problems: the first is to upgrade the grade of the product. I said that the upgrade is not to say that this product is not dry, to do another product, of course, it is good to choose high-value-added products, but on the other hand, can we control the margin of free forgings within the tolerance of plus or minus 5? , including the ring. It is to improve the precision of free forging and rolling rings. According to the current pursuit, it is necessary to control at 1 mm. The best control of American presses can be plus or minus 1 mm. Therefore, upgrading the product to reduce the margin, reduce the burning loss, reduce energy consumption, this is our only way. The second technology is going to improve. In the past, we talked about the combination of production, study and research for many years, and now it has become the conscious action of many of our companies. The third labor productivity. First of all, the boss must change his mindset and, in the case of increasing labor productivity, must raise the wages of key workers. It was wrong to not raise wages and only make fixed investments. Japanese forging workers can earn one or two thousand a month, and China has only one or two thousand, and the corresponding product quality will not go up. Now entering nuclear power, the forgings are required to be replaced for 60 years. Some people in our company dare to shoot the chest and say that my product is guaranteed for 60 years? Don't dare! Therefore, the price of our products certainly cannot go up. If the above three problems are solved, our company will take a big step forward.
Second question: Communicate several policies and documents that are relevant to our industry. I estimate that these documents will be implemented one after another after the end of the two sessions. The first "Industrial Structure Adjustment Guidance Catalogue", which contains related equipment, technology and so on. This is formulated by the state. For example, if the equipment you want to import is just in the limit or elimination of products and technology, Customs will not let you buy it.
The second Ministry of Industry and Information Technology recently issued the "Technology Progress and Technology Transformation Investment Direction of Equipment Manufacturing Industry". That is to say, it lists a lot of things, such as what machine you do, what parts it will give you support. This is a very important guide to the 12th Five-Year Plan. If you invest, it happens to be the project it supports. For example, if you are doing a nuclear pump casing, the pump will not be replaced after 60 years. If you can do this kind of product, you don't have to do more. You can do a few pumps a year, which is hundreds of millions of sales. We are all imported now.
The third is that the country is launching a “Machinery Industry Circular Economy and Cleaner Production Technology Policy – ​​List of Circular Economy and Cleaner Production Technologies for the Forging Industryâ€. Among them, there are 15 research and development technologies in the forging industry, 10 in the promotion and application technology projects, 3 in the restricted technology, and 3 in the elimination technology.
The fourth is “Research on the development of anti-fatigue manufacturing and long-life critical infrastructure componentsâ€. This special project is currently being pursued. I hope that this project will be carried out during the 12th Five-Year Plan. It is planned that the country will spend 15 to 20 years developing anti-fatigue manufacturing technology. Anti-fatigue manufacturing mainly involves materials, forging and heat treatment. The main purpose of anti-fatigue manufacturing is to solve the problem of the life of forgings and parts. That is to say, the life of the machine is 10 years, and the life of the parts is preferably 10 years. In short, it is best to achieve the use of the machine without replacing key parts.
The fifth is the revitalization of four industries in the “equipment manufacturing adjustment and revitalizationâ€. To be clear to everyone, our VAT policy is gone. Now we are striving for the revitalization policy of the four industries in the national revitalization plan. According to our requirements, the strength of support is basically the same as before, but the way to go and the way to support it are different. This has something to do with our large and small forgings. More related to small forgings. Large forgings have another policy “Special for large key castings and forgingsâ€. In fact, there are two special items. In this sense, one is the support of small and medium-sized forgings, and the other is the support of large forgings. Large forging support may be more targeted at large state-owned enterprises. Our company still has to take the revitalization policy of our industry in the "equipment manufacturing adjustment and revitalization".
At this time, our association will plan to bring these documents together and compile them into a booklet. We will give you a special meeting to explain the content of these policies and strive for support. In fact, there are still some policies in the country that we don't know or don't understand. We won't say it here. Of course, some of the documents or policies mentioned here have already been written in the implementation, and some are still under development. Our industries and enterprises must constantly and actively pay attention to these policies.
The third question: the direction of enterprise development. Free forgings are divided into two categories in foreign countries, one is called small and medium-sized free forgings, and the other is called forgemaster. The translation of forgemaster into Chinese means the master of forging. It is the top of forging. The concept of "master" must be remembered, starting with materials, not with forging. The series from materials to finished parts is called forgemaster. Raw materials are an important part of our large forgings. The second is to work with universities and colleges to establish research institutes, develop new technologies, and actively transform results. The third enterprise can engage in mergers and acquisitions, and do not invest in new equipment. If it is invested, it must also invest in auxiliary equipment, furnace reform, heat treatment furnace addition and transformation, and forging machining. Fourth, improve the treatment of employees, retain talents, and do not emphasize the war of people. We must improve the labor productivity of personnel and improve the salary of personnel. The fifth is to improve efficiency. Sixth attention to the environment. The development of any enterprise in the future is not to say that there is any good equipment, a good market, but the environment will not let you do it. Especially in our region, after 10 years in our forging factory, the biggest problem will be environmental protection. Environmental issues must be mentioned on the agenda.
The development of a company, like people, requires three things: IQ, EQ, and interpersonal relationships. We will find a strange phenomenon in the society. Especially smart people do not have the achievements of ordinary people. Some companies look particularly hot, but not necessarily better than the development of the company. As a company must have a flexible mechanism, the market response is very sensitive. The second is to judge the matter very accurately. In addition, we must do a good job in three major relationships, suppliers, users and government departments. Any one of these three relationships is not good, and the company has no hope.
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Free forging industry situation and development
On February 27, 2010, “Wuxi Forging Association 2009 Annual Meeting and New Year's Eve†was successfully held in Wuxi. Mr. Zhang Jin, Secretary General of China Forging Association, Mr. Han Mulin, Deputy Secretary General of China Forging Association, and Mr. Zhou Dazhao, Secretary General of Wuxi Forging Association attended the meeting. The Secretary-General of each association made a keynote speech on “current situation and our missionâ€. Discussed the current situation and development trend of the forging industry.