Jinfei Carbon Fiber: Creating a New Benchmark for Intelligent Manufacturing of Digital Carbon Fiber Composite Materials

Case Description

Shanghai Jinfei Carbon Fiber Technology Co., Ltd. is a high-performance carbon fiber composite material production enterprise. As a national "specialized, refined, unique and new small giant" enterprise, the company has 73 technical patents and its products are exported to Europe, North America, Japan and other parts of the world. After introducing the Caijiang digital solution, it is like building a bridge connecting the workshop site with management decisions, making complex manufacturing transparent and visible. Whether it is financial, cost, production, or material control, each process brings long-term benefits and significant improvements to the enterprise.

Application Products

     ERP system          WMS system           MES system          Talent Craftsmanship Intelligent Data Platform (CJ-AI)

Company Profile

Shanghai Jinfei Carbon Fiber Technology Co., Ltd. was established in March 2006 and quickly rose to become an excellent supplier of carbon fiber composite material solutions in China. The company takes technological research and development innovation as the foundation of the enterprise, and is always committed to becoming a high-value enterprise in the field of carbon fiber composite materials in China. It is a leading high-tech enterprise in China that provides comprehensive solutions for carbon fiber composite material products from research and development design to mass production. Jinfei carbon fiber products come in two forms: carbon fiber composite materials and multi-purpose intermediates (carbon fiber fabrics and pre impregnated fabrics). Our business involves high barrier, high viscosity, and high value-added industries such as rail transit, civil aviation, medical equipment, and industrial equipment.

Project background

• Cost control:

1. Raw material price fluctuations: The main raw materials for carbon fiber, such as acrylonitrile, have significant price fluctuations, which affect the stability of production costs

2. High energy consumption: The production process of carbon fiber consumes a lot of energy, and how to effectively reduce energy costs is a major challenge faced by enterprises.

3. Large R&D investment: The research and development of carbon fiber products requires a significant amount of capital and time investment, and how to balance R&D costs and innovation benefits is a problem that enterprises need to consider.

4. High equipment maintenance costs: Carbon fiber production equipment is precise, and maintenance and update costs are high. How to reduce equipment maintenance costs through digital means is a problem that enterprises need to consider.

• Material flow:

1. Complex supply chain management: Carbon fiber production involves supply chain management of multiple raw materials and intermediate products. How to ensure the stability and response speed of the supply chain is a problem faced by enterprises.

2. High inventory costs: The inventory management of carbon fiber products and raw materials is complex, with serious problems of inventory backlog and capital occupation.

3. Difficulty in controlling logistics costs: The transportation cost of carbon fiber products is high. How to optimize logistics solutions and reduce logistics costs is a problem that enterprises need to solve.

• Production process:

1. Difficulty in monitoring the production process: Carbon fiber production involves multiple steps such as raw material procurement, weaving, pre soaking, curing, and cutting. If traditional management methods rely on manual recording and paper-based transmission to collect data from production processes, it is easy to form information silos.

2. Quality control challenge: Carbon fiber products have extremely high quality requirements, and ensuring consistency and stability of product quality is a challenge faced by enterprises.

Solution

• cost optimization

The refined management of costs cannot be achieved without the support of digital tools, which involve multiple aspects such as direct materials, direct labor, manufacturing costs, indirect costs, inventory costs, and quality costs. By introducing an ERP system, enterprises can track the procurement and usage of materials in real-time, thereby accurately calculating direct material costs. At the same time, the system automatically calculates employees' working hours and wages to ensure the accuracy of direct labor costs. The system will automatically generate cost reports based on the results of cost accounting, analysis, and forecasting, providing comprehensive financial information and decision support for enterprises. The integration of logistics, capital flow, and information flow of data information has been achieved, which not only improves the efficiency of cost management but also enhances the enterprise's ability to control costs.

• Material flow

By combining the Caijiang MOM system with advanced IoT technology, the company has established an intelligent material traceability system for the entire process from procurement, production to finished products. Employees assign unique identifiers to each material, allowing for full tracking of data at every stage of material flow. Any product or component can be quickly traced back to its production batch, raw materials, equipment, quality, personnel, and other information by scanning the code. Once non-conforming materials are found, the system can quickly isolate and track their flow.

• Production management

In response to the problems of multiple production processes and difficult manual operations, the company has introduced the Talent Craftsman MOM system and established strict production process control, quality control, and traceability systems to achieve highly transparent operations and stable supply to world-class customers. The inventory status, production progress, and quality of materials at every stage from raw material storage to final product delivery can be accurately and real-time recorded and monitored by the system. Management personnel only need to view visual charts on the system to intuitively understand every activity on the production line, including the progress of specific orders, the status of various operators, equipment usage status, and task progress.

Application value

1. Through the built-in automated calculation function and report analysis tools of the system, the efficiency of enterprise cost accounting has been doubled. Over the past three years, the operating costs of the enterprise have decreased by 10%. On the basis of not increasing the staffing of the finance department, the company's annual revenue scale has achieved a double growth rate.

2. By accurately recording and controlling the flow of materials, the material turnover rate has increased by 10%, further optimizing capital utilization and reducing manual errors, thereby ensuring a high level of order execution and customer service for the enterprise, indirectly promoting revenue growth.

3. Through real-time cost comparison and in-depth analysis provided by the system, potential waste and efficiency bottlenecks in the production process can be effectively revealed, helping management identify cost deviations and adjust production strategies in a timely manner. Breaking the 'black box' in the production workshop, the production cycle has been shortened by 10%.