There are five major problems in China's mold industry
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Although China's total mold production has ranked third in the world, the overall level of design and manufacturing is much behind that of developed countries such as Germany, the United States, Japan, France and Italy. It is also much better than the United Kingdom, Canada, Spain, Portugal, and South Korea. Singapore and other countries are lagging behind. The gap is mainly reflected in the following six aspects.
The domestic self-distribution rate is less than 80%, of which the supply of medium and low-grade molds is over-demand, and the self-distribution rate of medium and high-grade molds is less than 60%. Mold is an important process basis for manufacturing. In China, mold manufacturing belongs to special equipment manufacturing. Although China began to manufacture molds and molds very early, it has not formed an industry for a long time. It was not until the late 1980s that the Chinese mold industry entered the fast lane of development. In recent years, not only has state-owned mold enterprises developed greatly, but also the development of three-funded enterprises and township (individual) mold enterprises has been quite rapid.
It can be seen from the table that although China's mold industry is developing rapidly, it is obviously in short supply compared with demand, and its main gap is concentrated in the field of precision, large, complex and long-life molds. Due to the large gap between China and the international average and developed countries in terms of mold accuracy, life, manufacturing cycle and production capacity, a large number of imported molds are required each year.
The organizational structure, product structure, technical structure and import and export structure of the enterprise are not reasonable enough. Most of China's mold production plants are self-produced tooling workshops (factories), and most of the professional mold factories are “big and complete†and “small and completeâ€. Foreign mold companies are mostly "small but specialized" and "small but fine." China's mold production ratio is as high as 50% or more, and more than 70% of foreign products are commodity molds. The proportion of large, precise, complex and long-life molds in domestic molds is only about 30%, and foreign countries are above 50%. In 2003, the ratio of mold import and export was 4:1, and the net import after import and export offset was 1.03 billion US dollars, which is the country with the largest net import volume.
The level of mold products and production technology are generally much lower than the international advanced level, and the mold production cycle is much longer than the international advanced level. The low level of products is mainly reflected in the accuracy, cavity surface roughness, life and complexity of the mold; the low level of technology is mainly in the design, processing, process equipment and so on.
The development capability is weak and the economic efficiency is not good. China's mold companies have a low proportion of technicians and low levels. They do not pay attention to product development and are often in a passive position in the market. The average annual production value of molds per employee in China is about 10,000 US dollars, while the mold industry in developed countries is mostly 15 to 200,000 US dollars, and some even reach 250,000 to 300,000 US dollars. The result is that China's mold enterprises have poor economic returns, mostly meager profits, and state-owned enterprises have overall losses and lack of stamina.
The level of mold standardization and the use of mold standard parts are low. The coverage rate of mold standard parts in foreign advanced countries is over 70%, and the coverage rate of domestic mold standard parts is only about 45%.
Compared with the international advanced level, the management of mold companies is lagging behind technology. The backwardness of management is easily overlooked. Most of the domestic mold enterprises still use the extensive management mode of the past workshops, and there are not many real enterprises that realize modern enterprise management.
There are many reasons for the above gaps. In addition to the long-term lack of attention to the mold as a product, there are several main reasons:
First, the system is not smooth and the foundation is weak.
Although the three-funded enterprises have already played a positive role in promoting the development of China's mold industry, private enterprises have developed rapidly in recent years, and state-owned enterprise reforms are also underway. However, in general, the systems and mechanisms are not yet adapted to the market economy. In addition, the domestic mold industry foundation is weak, so the industry development is still not satisfactory, especially the overall level and high-tech aspects.
Second, there are serious shortages of talents, too little investment in research and development and technological research.
The mold industry is a technology-intensive, capital-intensive industry. With the advancement of the times and technological development, there is an abnormal shortage of talents who can master and apply new technologies. Senior mold fitters and corporate management talents are also in short supply. Due to the poor efficiency of the mold enterprises and the insufficient attention to scientific research and development and technological breakthroughs, the overall investment in the mold industry in research and development and technological research is too small. The difficulty of private enterprise loans also affects the technological transformation of many enterprises, resulting in little scientific and technological progress. .
Third, the level of process equipment is low, and the matching is not good, and the utilization rate is low.
Although many domestic enterprises have adopted advanced processing equipment, the overall level of equipment is still much behind that of foreign companies. In particular, the numerical control rate of equipment and the coverage rate of CAD/CAM applications are much lower than those of foreign companies. Due to institutional and financial reasons, the introduction of equipment is not matched, the equipment and accessories are not compatible, and the problem of low equipment utilization has not been solved for a long time. The low level of equipment has brought about problems such as the high proportion of fitters in Chinese mold companies.
Fourth, the degree of specialization, standardization, and commercialization is low and cooperation is poor.
Due to the long-term influence of “big and complete†and “small but completeâ€, many mold enterprises are backward in concept, the professional production level of mold enterprises is low, the specialized division of labor is not fine, and the degree of commercialization is also low. At present, the molds produced in China are only about 45% of the molds produced each year, and the products are produced for their own use. The cooperation between mold companies is not good, and it is difficult to complete the large-scale mold set tasks, which is far behind the international level. The low level of mold standardization and the low coverage of standard parts also have a great impact on mold quality and cost, especially on the mold manufacturing cycle.
Fifth, mold materials and mold related technologies are backward.
The performance, quality and variety of mold materials often affect mold quality, life and cost. Compared with imported steel, domestic mold steel has a big gap between quality and variety specifications. The poor performance of plastics, plates and equipment also directly affects the improvement of the mold level.
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