1) Japanese mold industry
At present, Japan's mold manufacturing technology is still in the leading position in the world. According to the industry statistics of Japan's Ministry of International Trade and Industry, there are about 65,438+00,000 mold factories in Japan, of which more than 965,438+0% have less than 20 employees. In other words, the Japanese mold industry is dominated by small and medium-sized enterprises, and mainly relies on specialized division of labor to complete high-quality mold design and processing. Due to the better specialization in Japan and the higher overall manufacturing level of small and medium-sized mold enterprises, "Made in Japan" mold has become a symbol of brand and quality. In recent years, the number of plastic molds, powder metallurgy molds and die casting molds in Japan has greatly increased, while the number of stamping molds and forging molds has shown a relatively decreasing trend. According to Bright Lo, Japanese molds are facing five major problems-shortening delivery time, reducing manufacturing cost, improving mold quality and accuracy, insufficient labor force and meeting the challenges of Asian countries. In view of this situation, many Japanese mold manufacturers are actively expanding equipment investment. In machining, a large number of unattended machining units are used, or online control is carried out through computers. Almost all design and manufacturing departments use CAD/CAE/CAM technology for motion simulation analysis and DNC (Direct Digital Control) machining. The technological development of molds mainly develops in high precision, high speed, long life, complexity, large scale, integration and high performance.
2) American mold industry
There are about 7,000 mold enterprises in the United States, more than 90% of which are small enterprises with less than 50 employees. Due to the high development of industrialization, the American mold industry has become a mature high-tech industry, which is at the forefront of the world. American die steel has achieved standardized production and supply. CAD/CAE/CAM technology is widely used in mold design and manufacturing, and equipped with advanced equipment for processing technology and inspection. The development of large, complex, precise, long-life and high-performance molds has reached the leading level.
However, since the 1990s, the American economy has been facing great adjustment and changes in the post-industrial era, as well as strong international competition-from cost pressure, time pressure and competitive pressure.
3) German mold industry
Germany has always been famous for its exquisite processing skills and the production of precision mechanical tools, and its mold industry has fully reflected this feature. For the complex industrial field of molds, after years of practice and exploration, German mold manufacturers have formed a kind of * * * knowledge: that is, the whole industry must coordinate, work together, tap the development potential, * * * carry forward the spirit of innovation, * * * with the technological progress, learn from each other's strong points and give full play to the overall advantages, in order to achieve the success of the industry. In addition, in order to meet the needs of rapid development of new products, not only large companies have established new development centers in Germany, but many small and medium-sized enterprises have also done so, taking the initiative to do research and development work for customers. Germany has been very active in research, which has become an important foundation for its invincible position in the international market. In the fierce competition, the German mold industry has maintained a strong position in the international market for many years, and the export rate has been stable at around 33%.
According to the statistics of German die and mould industry organization-German Machinery Manufacturers Association (VDMA), there are about 5,000 die and mould enterprises in Germany. In 2003, the output value of German dies and moulds reached 4.8 billion euros. Among them, 90 mold enterprises are members of the German Machinery and Manufacturers Association (VDMA), and the output value of these 90 key mold enterprises accounts for 90% of the German mold output value.
4) Singapore mold industry
Singapore is a small country with a population of only 3 million. In the 1980s and 1990s, the government attached importance to and supported the development of precision molds and issued many policies, which made the mold industry grow rapidly and promoted the rapid development of Singapore's economy.
Singapore has more than 1000 enterprises related to various molds and precision machining, with an annual output value of over 4.5 billion RMB, which has a very important influence and role in the mold industry in Asia. There are more than 10 listed mold enterprises. More than 65% of the molds produced by Singapore enterprises are for electronic related industries. The molds produced are not big, but they are all high-precision and high-level molds.
Singapore mold enterprises mainly focus on semiconductor frame/packaging mold, metal stamping mold, plastic mold, silicone rubber mold and other fields.
2. General situation of China mold industry
Since 1997, the state has successively listed molds and their processing technologies and equipment in the Catalogue of Industries, Products and Technologies Encouraged by the State and the Catalogue of Industries Encouraged by Foreign Investment, and implemented the preferential policy of VAT collection first and then refund for some key professional mold factories. 1999 the state has listed relevant mould technologies and products in the "Guide to Key Areas of High-tech Industrialization with Priority Development in China" issued by the State Planning Commission and the Ministry of Science and Technology. The above measures have effectively promoted the rapid development of mold industry in China.
1) The total volume of the mold industry is growing rapidly.
In 2005, the total output value of China mold industry jumped to the third place in the world, reaching 6 1 billion yuan, and in 2006, the total output value of mold industry reached 72 billion yuan. The total output value (average annual growth rate is above 16%), the number of enterprises, the number of employees and the labor productivity of all employees in China are increasing year by year.
2) The proportion of import and export is more and more reasonable, but it is still a big net importer of molds in the world.
The import volume of mould products in China decreased year by year, while the export volume increased year by year. The proportion of import and export decreased from 65438+6.6: 1 in 099 to 2: 1 in 06. The export molds are still dominated by middle and low grades, and the imported molds are dominated by middle and high grades. The main gap is concentrated in high-tech molds such as precision, large size, complexity and long life.
3) The technical level is constantly improving, but there is still a big gap compared with foreign countries.
During the Eleventh Five-Year Plan period, China's mold technology developed rapidly. At present, China has been able to produce precision multi-position progressive dies with an accuracy of 2 microns, and its service life is1~ 200 million times. In terms of large-scale plastic molds, we can now produce plastic shell molds for 48-inch TVs, plastic molds for large-capacity washing machines, and molds for automobile bumpers and integral dashboards. In terms of precision plastic molds, China has been able to produce camera plastic molds, multi-cavity small module gear molds and plastic packaging molds. In terms of large-scale precision and complex die-casting molds, China has been able to produce die-casting molds for integral pedals of escalators and rear axle gearboxes of automobiles. But compared with foreign countries, there is still a big gap. China's manufacturing industry is in urgent need of sophisticated stamping dies, plastic dies, automobile panel dies, electronic connectors and other electronic product dies, and still relies heavily on imports.
3. Brief introduction of major domestic mold production areas
The main domestic mold production bases are in Guangdong, Zhejiang, Jiangsu, Shanghai and Anhui.
Major provinces and cities and their characteristics.
Guangdong, the leading mould market in China, is dominated by foreign-funded enterprises.
There are more than 1 10,000 mold manufacturing enterprises in Guangdong province with 300,000 employees, ranking first in the country in terms of the number of enterprises, employees, total industrial output value and total export value. Guangdong is the most important mold market in China and the largest mold import and export province in China. More than 40% of the national mold output value comes from Guangdong, and the numerical control rate, equipment performance, mold processing technology, production specialization level and standard level of mold processing equipment are ahead of other provinces and cities in China.
Zhejiang-Plastic molds account for a large proportion, with private enterprises as the main body.
Zhejiang mold industry is mainly concentrated in Ningbo and Taizhou. Ninghai, Yuyao, Cixi and Yinzhou in Ningbo mainly produce plastic molds, Beilun mainly produces die-casting molds, and Xiangshan and Zhoushan mainly produce casting and stamping molds. The main mold manufacturers in Taizhou are concentrated in Huangyan and Luqiao, and plastic molds account for the majority.
Shanghai-The information industry and the automobile industry are dominated by molds.
There are more than 2,000 mold enterprises in Shanghai with 654.38+million employees, with an annual output value of nearly 6 billion yuan, with an average annual growth rate of more than 20%. Shanghai mold industry will face six major industries and key industries, especially information (IT) industry and automobile industry, and vigorously develop precision magnesium alloy die-casting molds, precision injection molds, automobile panel molds, large-scale parts die-casting molds and precision stamping parts multi-position progressive molds.
Jiangsu-Foreign capital and private enterprises are the main forces.
Jiangsu molds are mainly concentrated in Suzhou and Kunshan. At present, there are more than 65438+ 10,000 mold factories and 65438+ 10,000 mold processing points in Suzhou, and the annual sales of molds are about 5 billion to 6 billion yuan. Mold industry has become one of the emerging industries in this city. There are many wholly-owned and joint ventures in Japan, South Korea, Singapore, Germany, the Netherlands, the United States, Taiwan Province Province and Hongkong, as well as many private mold enterprises.
Anhui, a New Rising Force
At present, Anhui Province has a number of well-known domestic mold products, such as washing machine, large-scale injection mold for air conditioner, plastic foaming mold for refrigerator, high-speed progressive die for punching stator and rotor of motor, and some products have a market share of over 30%. Mold standard parts and mold material library have also been formed.
In addition, Shandong, Fujian, Tianjin, Liaoning, Chongqing and Hebei have also developed well in recent years.
2) The geographical distribution of enterprises with an annual output value of over 100 million yuan.
During the Tenth Five-Year Plan period, the Pearl River Delta region, the Yangtze River Delta region and the Bohai Rim region will be the first. At present, about 80% of the country's molds are concentrated in these three areas.
According to Bright Lo, at present, mold enterprises with an output value of over 100 million yuan are mainly concentrated in the field of automobile panel molds. During the "Eleventh Five-Year Plan" period, the "leading" enterprises of various molds gradually formed. For example, FAW Mould Manufacturing Co., Ltd. for automobile panel moulds, Wuxi Precision Mould Co., Ltd. for precision stamping moulds, Haier Mould Co., Ltd. for large plastic moulds, Tongling Sanjia Technology Co., Ltd. for plastic profile moulds (the first mould), Guangdong Julun Mould Co., Ltd. for rubber tire moulds, Jieyang Tianyang Mould Co., Ltd., Honglong Group for mould standard parts and Industry (Dalian) Co., Ltd., etc. Among hundreds of millions of mold enterprises, foreign capital accounts for a considerable proportion.
4. Problems existing in China mold industry.
In recent years, the structure of China mold industry, whether it is enterprise organization structure, product structure, technology structure, import and export structure, is developing towards rationalization. In order to update and improve the equipment level, mold enterprises need to import several billion yuan of equipment every year. Bright Lo believes that the investment in innovation and development is still insufficient, and the improvement of comprehensive R&D capability of the mold industry has seriously lagged behind the improvement of production capacity. The main problems are as follows.
1) weak innovation ability;
2) The overall efficiency is low;
3) Low degree of specialization, standardization and commercialization, and poor cooperation;
4) Die materials and die related technologies are backward;
5) The organizational structure, product structure, technical structure and import and export structure of the enterprise are not reasonable enough;
6) Compared with the international advanced level, the management of mold enterprises is even behind the technology.
5. Development trend of mould industry in China.
In the next decade, the development trend of China mold industry is: mold products will develop in the direction of large-scale, precision, complexity, economy and high speed; The technical content of the mold is constantly improving, and the manufacturing cycle of the mold is constantly shortening; Mold production is developing in the direction of informationization, drawing, refinement and automation; Mold enterprises are developing in the direction of technology integration, sophisticated equipment, product branding, management informationization and internationalization.
The development of mold technology mainly focuses on the following aspects.
1) The die structure is becoming larger, more precise and more complicated, and its service life is constantly improving;
2) The wide application of CAD/CAE/CAM technology in mold design and manufacturing;
3) Popularization and application of new mould design and manufacturing technology;
4) Improve the standardization level of molds and the utilization rate of standard parts of molds;
5) Develop high-quality mold materials and advanced surface treatment technology;
6) Develop new molding processes and molds, and cultivate new ideas and new models.
Chuzhou's household appliance molds have a long-standing reputation in the country. In recent years, Chuzhou household appliances supporting enterprises have developed rapidly. At present, it has become the largest refrigerator product manufacturing equipment and mold production base in China; The production of key main equipment, such as refrigerator box, door foaming line and plastic suction molding die, accounts for 70% of the domestic market. Due to the impact of the financial crisis, it is inevitable that the mold industry will be hit. Bright Lo, CEO of Die & Mould Network, suggested that die & mould enterprises should face up to the difficulties positively, recognize the situation clearly, pay attention to a series of relevant policies recently issued by the state, such as "home appliances going to the countryside", "plans for revitalizing nine industries, such as electronic information, steel and automobiles", formulate strategies, adjust the structure, and take active measures to cope with the difficulties.
Second, the development status of Chuzhou mold industry
There are more than 70 mold manufacturing enterprises in Chuzhou, and more than 20 enterprises above designated size, mainly manufacturing vacuum forming molds and foaming molds for refrigerators. In recent years, non-standard mold equipment production line, injection mold, stamping mold and other fields have developed rapidly.
The manufacturing of vacuum forming mold and foaming mold for refrigerator is the characteristic of Chuzhou mold industry, which occupies more than 70% market share in the field of refrigerator mold production in China. There are more than 20 manufacturers of refrigerator molds in the city, among which 5 are enterprises above designated size/kloc-0, mainly located in Chuzhou city, and some are located in Nanqiao District, Quanjiao County and Lai 'an County. According to Bright Lo, Chuzhou refrigerator mould industry is currently an important refrigerator mould manufacturing base in China. Representative enterprises include Anhui Kunpeng Equipment Mould Manufacturing Co., Ltd. (formerly China Yangzi Group Chuzhou Equipment Mould Manufacturing Co., Ltd.), Chuzhou Hongda Mould Manufacturing Co., Ltd., Chuzhou Jingwei Mould Manufacturing Co., Ltd., Chuzhou Kechuang Mould Manufacturing Co., Ltd., Chuzhou Bojing Mould Equipment Manufacturing Co., Ltd. and so on. Non-standard mold equipment production is another successful field developed by mold production enterprises in our city. A number of mould manufacturers, represented by Anhui Kunpeng Equipment Mould Manufacturing Co., Ltd., Chuzhou Ailite Refrigeration Equipment Co., Ltd. and Chuzhou Xinlong Electromechanical Co., Ltd., have occupied more than 80% of the domestic market share in the production of complete sets of non-standard equipment for refrigerators, freezers, washing machines and solar water heaters.
In addition, there are other enterprises in Chuzhou, such as Anhui Tianda Group Mould Company, Chuzhou Dimond Mould Manufacturing Co., Ltd., Anhui An Lan Mould Co., Ltd. and Chuzhou Phoenix Refrigeration Parts Co., Ltd., which mainly produce injection moulds, and there are mould production branches represented by Shousu Precision Mould Company, which mainly produce supporting products for this enterprise. According to Bright Lo, in 2008, the mould industry in Chuzhou achieved a sales income of more than 300 million yuan, with 6 provincial-level enterprise technology centers and 6 municipal-level enterprise technology centers, and established an independent innovation system jointly tackled by universities and research institutes at home and abroad in Industry-University-Research, and independently researched and developed more than 200 new products, technologies and new processes every year, forming a domestic leading product standard in the development of household appliance molds and the provision of complete sets of equipment.