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"Industrial redesign" should become the core driving force of "made in China 2025"

on the way to "made in China 2025", we are not only facing the external challenges of the two ends of the squeeze between the developed countries and emerging economies, but also facing the more serious problem that China's industrial products lack demand-oriented and systematic product forward design and innovative manufacturing processes and other key factors. "Industrial redesign" reconstructs the system design concept and function realization path of product R & D and manufacturing based on the innovative precision casting process, and leads to disruptive innovations in product performance improvement, weight reduction and load increase, material requirements reduction, cost reduction, energy conservation and environmental protection. "Industrial redesign" has quietly started on the line of "made in China 2025", and is beginning to show signs, which will play a huge role in the strategic task of "made in China 2025". "Industrial redesign" should become the core driving force and innovation source of "made in China 2025", which requires the high attention and active promotion of academia, government, enterprises and industry promotion institutions

first, "industrial redesign" is a system methodology for the integration of forward product design and precision manufacturing

transcendence stems from innovation, and innovation stems from forward design and system philosophy. In the development process of enterprises, reverse design is a stage that must be experienced, that is, digestion, introduction and absorption, tracking and imitation of related products, and obtaining market space. However, only by tracking and imitation, it is doomed to fall into a dead cycle of "introduction, backwardness and re introduction". When the external technology supply and market pattern change, enterprises will be vulnerable. Only enterprises seeking to surpass can become evergreen in the industry, and "positive design" relying on "systematic thinking" will be the solution. Systematic thinking emphasizes the organic organization of objects according to concepts, properties, relationships and structures, studies the functions and behaviors of the system, and focuses on revealing the various relationships between the elements within the system and between the system and the environment as a whole. Figure 1 describes the relationship between product requirements, functions, structures, and behaviors. Structure is the carrier of function, behavior is the effect of structure, and function is the abstraction of behavior, which is the objective relationship between function structure behavior

we believe that "industrial redesign" refers to the process of realizing the qualitative change of product functions through structural interpretation and behavioral simulation, which is oriented to product requirements. It is a scientific methodology towards the integration of forward design and precision manufacturing. The essential core of "industrial redesign" is the sublimation of industrial simulation application, the engineering of forward design technology, and the combination of advanced design technology and precision manufacturing technology. While improving the performance of industrial products and upgrading products, we should make them integrated, lightweight and intelligent

the overall process of "industrial redesign" is divided into three important links: traceability, innovation and optimization, and physical experiment. (1) Trace the source and obtain the design indicators and boundary conditions. The initial stage of redesign is based on the current understanding of the structure, and the boundary conditions and index data are obtained through experiments or simulations to carry out product redesign. After maturity, the original requirements of the product can be traced, and the boundary conditions and index data can be obtained by using the forward design process for deep-seated redesign. (2) Innovative optimization, innovative design and verification are carried out by means of design innovation, parameter optimization, topology optimization and virtual test technology. In the process of design, engineers can completely break the shackles of process, rely on the concept that products can be manufactured no matter how complex the product structure is, and release great design potential. They can only focus on needs, and can design products of any structure without considering the limitations of manufacturing process. The disappearance of process constraints has brought about the overturning of the barrier between product design and production. The integrated industrial product design system of design and manufacturing will be established, the traditional product design mode will be fundamentally overturned, and product design will truly realize simulation driven. (3) The innovative design scheme is confirmed and iterated by using precision manufacturing and physical test technology. With the support of precision manufacturing technology, it can realize rapid iteration, redesign and finalization as soon as possible, and launch the final innovative products

second, the crux of the outstanding problem of made in China lies in the lack of systematic thinking of positive product design, green design and process innovation

at present, the industrial developed countries are still rapidly extending and sublimating the new industrial revolution. Germany, the United States, Japan and the United Kingdom have been planning a new round of scientific and technological revolution and industrial revolution, with the intention of seizing and extending the forefront of its new industrial revolution and maintaining its leading position. There are three prominent problems in China's manufacturing industry: prominent product quality problems and homogenization problems, weak core technology and innovation ability, and serious problems of high energy consumption, high pollution and high cost. The deep-seated reason is the lack of systematic thinking, such as positive product design, green design and innovative technology

(I) the copying mode has not formed a positive systematic thinking of design from academia to industry.

design determines the gene, process and manufacturing of industrial products, and shapes the physique of industrial products. The decades long copying mode based on "reverse design of Surveying and mapping imitation" and "Introduction and digestion" has resulted in the theory and practice of product forward design and innovative design methodology based on systematic thinking and functional views that have rarely been formed in China from academia to industry, resulting in serious separation and opposition between design and process, design and manufacturing, Ignoring the development of complex products and equipment and even the improvement of the whole manufacturing industry is a systematic engineering, which is not only the so-called local problems such as materials or processes, but also the systematic support of a system. For example, in the whole process of the development of complex products and equipment such as aeroengines (including technology research and development and product development), due to the lack of understanding of the collaborative interaction, the lack of early research and exploration, and the relatively serious systemic problems in the development, there are "heart disease" afflictions in military and civil aircraft and large ships in our country

(II) extensive development mode leads to the fact that China has not yet formed a green design system and concept.

at present, China's manufacturing industry is large but not strong, the development mode is extensive, the utilization efficiency of energy resources is low, and the environmental pollution is serious. In terms of energy consumption per unit of industrial added value, China's energy consumption per unit of industrial added value is 3.5 times that of the United States, 5.3 times that of Japan, 7.7 times that of Britain and 8 times that of Germany. Due to the low level of economic development and opening-up, some regions still have a vague understanding of the value and importance of green design. Green design is the premise of green manufacturing. Many domestic researches on green design of industrial products are still in the stage of academic discussion, lacking practical, comprehensive and operable systematic research, and far from forming a systematic problem-solving idea. In essence, the green design ability is based on the independent design ability of products, while China's industrial independent design ability is insufficient, especially the innovative positive design ability is insufficient, and the follow-up research and simulation model is difficult to establish the awareness and ability of green design, resulting in the genetic deficiency of green design ability

(III) the restriction of production process has hindered the process of product design and the pace of innovation to a great extent.

for a long time, the design of industrial products has been finalized based on existing processes. Due to the limitation of technology, there are unbreakable obstacles in processing and installation, which makes it more difficult to release the design potential of engineers and affect the pace of product innovation. Current products must be assembled, welded or riveted by a large number of parts. This combination has a negative impact on the performance, reliability, weight, volume, load, materials, power, cost, energy consumption, environmental protection and other aspects of the product. For example, the casting process belongs to the "long process" process. There are nearly 30 links in the whole process, and each link also includes a combination of factors such as design, equipment, tooling, materials, process inspection, whether the joint of the oil circuit system is tightened or not. The cumulative control points can reach more than 150. Too many control factors are very easy to produce cumulative quality errors, so it is easy to produce defects, unstable quality, complex processes and other problems, Traditional process is difficult to be used as the main process flow in the manufacturing process of products requiring high precision and high mechanical performance

III. "industrial redesign" can help realize the three transformations of "made in China 2025"

(I) the transformation from factor driven to innovation driven

the realization of "industrial redesign" starts from the source of product demand, and goes through the complete process of product design, such as demand development, function analysis, system design, physical design, process trial production, experimental verification, etc, "Industrial redesign" realizes design scheme innovation through "innovative positive design technology based on Knowledge Engineering", and carries out breakthrough, structural, transcendent and subversive innovative product design, which can truly form the independent research and development ability of China's industrial enterprises, enhance the competitiveness and viability of enterprises, and gradually promote the innovation driven enterprise growth mode. The innovation of design details through "digital technology based on Simulation and optimization design" and the innovation of manufacturing process through "precision molding technology" is a complete innovation driven development process, which can well realize the transformation from factor driven to innovation driven

(II) the transformation from extensive manufacturing with large resource consumption and high pollution emissions to green manufacturing

research shows that 80% of resource consumption and environmental impact depend on the product design stage. Therefore, green design is the most critical link and the most important measure to promote the green transformation and development of industry. Industrial redesign will completely abandon the "silly big black coarse" manufacturing methods that rely on resource consumption, low-cost competition, and high energy consumption and high emissions. Improve product genes through lean design and product reliability through precision manufacturing, so as to improve the quality and efficiency of manufacturing industry; Precision manufacturing realizes environment-friendly green manufacturing by saving raw materials and basically zero emissions. Realize the transformation from low-cost competitive advantage to quality and benefit competitive advantage, and realize the transformation from extensive manufacturing with large resource consumption and more pollution emissions to green manufacturing

(III) the transformation from production-oriented manufacturing to service-oriented manufacturing

Industrial redesign will solve the core problems of industrial products in the process of R & D and manufacturing. At present, relevant domestic enterprises have carried out practice and achieved great results. For example, the industrial redesign partner system led by Ansai Asia Pacific can become an outsourcer of various industrial product development enterprises in R & D and parts/machine production. In just two weeks, the enterprise affirmed the alloy composition and preparation process plan of ultra thin 3104 can body material, which can more focus on the market development in the early stage of products and customer service in the later stage, so as to realize the decentralization of R & D resources The integration of manufacturing resources and the high synergy of their core competitiveness can successfully realize the transformation from production-oriented manufacturing to service-oriented manufacturing

IV. "industrial redesign" will have great potential in the implementation of the strategic task of "made in China 2025"