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Survey: 2012 Sino-US machine tool industry competitiveness
The world's general machinery, automotive, aerospace, energy, medical, rail transit, mold machine tools and other industries are inseparable from cutting tools and equipment. From the perspective of future development trends, the global tool market is expected to grow by 3% to 5% annually in the next five years. According to this growth rate, China is still the world's number one. From the perspective of the supply of domestic tools, domestically produced tools occupy a mainstream position, reaching 65%. In these years, we have also achieved outstanding enterprises like Zhun Drilling. Together with the original four major tool factories, there are about 10 key enterprises, all of which have entered the modern cutting tool industry from traditional tools, and have developed year after year. Ok, they have entered a period of rapid growth. This is a very good performance. The data shows that in 2010, the total production of domestically produced tools in China was 29 billion yuan. In addition to supplying the domestic market, the export tool was 7 billion yuan. In the same year, the total sales of imported tools and domestically produced tools reached 33 billion yuan, ranking first in the world. China's knives increased by 40% in 2010, and the growth in the first three quarters exceeded 50%. In 2010, the sales of foreign tool companies in China also grew very well. There is no market demand and no development can be said. Demand, this is our biggest advantage. In the 33 billion yuan sales, the imported 11 billion yuan of tools are all modern high-efficiency knives. Among the 22 billion yuan of domestically produced knives, only about 2 billion yuan of modern high-efficiency knives are used, accounting for 10% to 15%. The sales of foreign branded tools account for one-third of China's tool consumption. This shows that while China has become the world's most promising tool market, the high-end market is occupied by multinational companies. This is a big problem. In 2011, the domestic tool market still maintained rapid growth, and it is expected to create a new historical high point. Statistics show that in the first half of the year, the domestic tool market achieved a growth of 25% to 30%. Although the growth rate has slowed down since July, it can still achieve 15% growth throughout the year. In comparison, the international tool market has maintained a stable recovery in recent years, but the annual average growth rate is conservatively estimated to remain only around 3% to 5%, while the domestic market will gradually maintain its annual stability after experiencing rapid growth in the past year. The average growth rate is between 10% and 15%. Therefore, the domestic tool market capacity growth rate will be more than three times faster than the international market. China has become the world's most promising tool market, and many multinational tooling groups are also in the development strategy of the post-crisis era, without exception, expanding the sales of tools in China as the first choice, the Asia-Pacific headquarters of each company, research and development The center, training center, and logistics center have settled in China, so that China is the center of China, and it can serve customers more directly and conveniently, and better meet the special needs of customers in the Asia-Pacific region. Luo Baihui, secretary-general of the International Association of Mould & Hardware Plastics Industry Suppliers, believes that the reason why the Chinese market will receive such attention is mainly because the proportion of sales in the Chinese market is increasing in its global market share. In order to firmly grasp the Chinese market, foreign tool manufacturers are carefully studying the needs of China's equipment industry. For example, Seco Tools established the Industry Development Department this year, aiming at the industry as a research object, focusing on providing typical parts processing in the industry. solution. The technical experts of the department are responsible for a key industry, paying attention to the development of the industry, solving the technical problems of tool application in the industry, and holding tool training for customers in the industry from time to time. SteveMorency, president of the American Cutting Tool Association (USCTI), said, “From a global perspective, from North America to some parts of Europe, and most parts of Asia, the market is quite busy. At the EMO2011 machine tool show held recently, participants seem to They are looking for solutions that solve production problems, not just casual purchases. Machine tool manufacturers seem to be selling quite well at the show. Many industries offer growth opportunities – aviation (especially commercial aircraft), automotive, medical and The development of the energy industry is on the rise.†Sales data reported by USCTI member companies indicate that the recovery has been very good since the second quarter of 2009 when tool sales fell to the bottom. Although the sales growth in the first few months of 2010 was slightly stagnant, the sales value for the whole year still increased by 24%. Sales growth in 2011 was even stronger. As of August, sales increased by more than 31% to $1,134 million. However, Morency believes that there are also some problems and concerns that inhibit this optimism, one of which is "the US economic recovery is slow and the unemployment rate is high." In addition, due to tight supply, raw material prices are rising. “In the past 12 to 18 months, the price of cemented carbide has risen by 40% to 50%, and people are worried that it may rise further in the future.†Morency is optimistic about the tool market prospects. He predicted, "I am very positive about the prospects for next year. Tool sales growth should reach double digits. Unless there are major setbacks, the growth rate may be 15% to 20%. "PatrickW. McGibbon, vice president of strategic information and research at the American Manufacturing Technology Association (AMT), is quite optimistic that the US machine tool industry is unlikely to fall into another recession in the near future. He said, “This possibility is only about 20%. Now, our product prices are very competitive in the world – except for China. And China’s labor costs are rising very fast, so the American-made machine tools – exactly It is said that all products made in the US will be more competitive in the near future than Chinese products.†McGibbon said that the recovery of US machine tool manufacturers has been stronger than expected and is particularly strong in some machine tool markets. “Our three markets are automotive, construction machinery and aerospace. The construction machinery market is showing rapid growth. The annual output of the automotive industry is only 12 million, but the profit is growing sharply, compared with the previous years. For the 17 million vehicles, the industry has very little profit. Of course, the reduction in the wage rate will also help the profit.†McGibbon added, “The growth rate in 2012 may be slightly worse than in 2011, just because this year is too hot. At present, we are close to the peak level of 2007.†As an important part of the equipment manufacturing industry and important process equipment in the cutting process, hardware tools determine the processing efficiency, precision, quality and cost of parts in the manufacturing industry. When it comes to the gap with advanced technology, Luo Baihui believes that from the user's point of view, there are two biggest gaps: First, the product structure of the entire industry is backward, the traditional universal standard tools still account for the majority, and the sales are very good, even There have also been so-called "low-alloy high-speed steel" blades, which have been slow to change in low-end products and counterfeit. This problem is very serious. At present, China's high and low-end sales are very good, this phenomenon is worth thinking about. Second, in general, there are still gaps in equipment, technology and services. Although some companies' equipment conditions and technologies are improving, they still cannot meet the needs of users. The problem is mainly in service. In terms of solutions, the combination of us and users is not good enough. With the premise "production, study and research", now the "production, study and research", "use" should be the first. Modern advanced manufacturing technology is led by user companies. Users in China also need to bring this head, which will drive the development of a large number of material suppliers and machine tool suppliers. According to industry analysts, the approximate cost of processing a workpiece is 30% for machine tools, 25% for fixed indirect costs, 20% for operators, 20% for raw materials, and 5% for tools. Customers who purchase tools, in addition to value whether it can complete the processing quality, pay more attention to how to reduce the cost of the workpiece and achieve higher product profit. However, from the perspective of cost savings, the cost of the tool is only about 5%, which is relatively low. Therefore, the service consciousness of the tool enterprise should shift from the tool itself to the “whole value chain†of the workpiece to greatly reduce the production cost of the customer. The focus is on the entire production process of the workpiece, including equipment run time, minimum scrap rate, increased production, and efficient personnel utilization. According to this idea, the tool company should build a brand value-added solution for all customers, starting with procurement and planning, across the entire production process itself, until the tool is disposed of and recycled. This program has four standardized service modules, including planning, production and logistics, maintenance, training and expertise. Only about 5% of the cost of the tool can reduce the production cost by 20% to 50% by continuously improving the whole process service plan, fully reflecting the value of the brand. China has begun to focus on high-efficiency and high-quality tooling. In recent years, the technological development of many high-end manufacturing fields in China has brought new requirements to tools. For example, automotive tools must be characterized by high efficiency, high stability and specialization. With the continuous development of the automotive industry, new requirements have emerged. From a technical point of view, there are mainly heavy-duty, composite, specialization, The trend of standardization, high speed and variety. In the field of aerospace manufacturing, with the wide application of difficult-to-machine materials such as titanium alloys and high-temperature alloys, how to correctly select and rationally use tools for efficient and high-quality cutting has become a very important industry topic. Near-water towers have the first month, and domestically produced tools should have the advantages of time, location and people in providing tool services for the above-mentioned manufacturing fields. But in fact, imported tools basically occupy high-end users in the machining industry, especially in automotive engine manufacturing workshops, aircraft engine manufacturing enterprise machining workshops or steam turbine manufacturing workshops, and highly efficient and high-precision machining tools are almost imported tools. Monopoly, it is difficult to see the traces of domestic knives. Domestically produced tools are mostly used in medium and low-demand customer groups, such as agricultural machinery, motorcycles, agricultural vehicles, general machinery, and low-end machinery manufacturing industries. Not only that, the extensive development of the manufacturing industry has led to an extremely unbalanced development of machine tools and tools. According to Luo Baihui, secretary general of the International Association of Molds and Hardware and Plastics Industry Suppliers, the current consumption ratio of CNC machine tools and tools in foreign developed countries is 2:1. The domestic ratio is too low, and the total tool consumption is less than one-fifth of the total machine tool consumption. Many manufacturers spend a lot of money on machine tools, but they are reluctant to buy tools. They are reluctant to buy advanced and efficient tools. The market demand for traditional tools has remained high for a long time. This is also an important reason why many domestic tool companies are reluctant to enter advanced and efficient tool production. At the same time, we must face the gap between Chinese tool companies and foreign companies, including basic technology, innovation capabilities, promotion capabilities and service capabilities. The user demand and the tool enterprise should be the innovation leader, and the leading enterprises should take the lead in demonstrating the role in technology application. However, some key domestic key enterprises and new excellent private enterprises have taken a very welcome step in the development of modern and efficient tools, such as Zhuzhou Diamond, Xiamen Golden Heron and Arno Tools. These companies attach importance to technological progress and put service first. Significant results have been achieved in related fields. In the tool industry, CNC machine tools have become the mainstream of manufacturing equipment today, shouldering the heavy responsibility of providing CNC equipment with key equipment for the manufacturing industry. The processing technology level of the manufacturing industry is greatly affected by the overall level of the tool industry, and the development of the manufacturing industry will also promote the development of the tool industry. Luo Baihui believes that in the future, multi-functional composite tools and high-speed and high-efficiency tools will become the mainstream of tool development. In the face of increasing number of difficult-to-machine materials, the tool industry must improve tool materials, develop new tool materials and more reasonable tool structures. 1. Increased application of cemented carbide materials and coatings. Fine-grained, ultrafine-grained cemented carbide materials are the development direction; nano-coatings, gradient-structured coatings, and coatings of new structures and materials will greatly improve tool performance; the application of physical coatings (PVD) continues to increase. 2. The application of new tool materials has increased. The toughness of ceramic, cermet, silicon nitride ceramic, PCBN, PCD and other tool materials is further enhanced, and the application is increasing. 3. Rapid development of cutting technology. High-speed cutting, hard cutting, and dry cutting continue to develop rapidly, and the range of applications is rapidly expanding. 4. Tool development is more targeted. The focus of tool manufacturers' research and development is no longer on generic brands and general structures. In the face of complex and varied applications and processing conditions, the development of more targeted blade geometry, grades and corresponding tools replaces common grooved, graded inserts and tools. 5. The role of the tool manufacturer is changing. From simple tool production and supply, to the development of new cutting processes and the development of corresponding sets of technologies and solutions, we provide comprehensive technical support and services. 6. The degree of informatization has increased, cooperation between tool manufacturing companies has increased, and market competition has intensified.