本书是专为中小企业量身打造的自动化实战指南。作者聚焦制造业"招工难、人力不稳、效率低下、质量波动"四大困局，以奇思等企业的真实转型案例为样本，系统提出以"价值评估一工艺标准化一人机协同"为核心的7步模型(详见书中路线图)，涵盖自动化产品识别、工艺体系构建、人才组织变革等关键环节。书中提供丰富的实战场景与工具模板，独创"奇思自动化双平台模型"，帮助企业实现生产效率最高提升约51%、人力优化率超过50%的突破，堪称一本可落地、可复制、可量化的自动化转型行动手册。

杨廷旺基克纳CEO、西交利物浦大学校外导师、浙江水利水电学院客座教授、江苏省企业信息协会特聘精益专家、法国国立路桥学校智能制造管理博士、西安交通大学产业经济学博士研究生、西安交通大学管理学院专业学位研究生校外导师。

第1章 为什么推行自动化（“四难困局”如何破）··································1
1.1 我们为什么必须走向自动化？··················································2
1.1.1 招工难：年轻人不愿来工厂············································2
1.1.2 留人难：“95后”“00后”平均在职仅7个月······················2
1.1.3 提产难：员工熟练度决定产出效率···································3
1.1.4 质控难：人眼判断，错误难免·········································4
1.2 自动化，带来怎样的改变？·····················································5
1.2.1 破解招工难：机器人“员工”永不疲倦·····························5
1.2.2 稳定生产团队：告别人员波动困扰···································5
1.2.3 提升产能稳定性：精准控制的优势···································6
1.2.4 提升质量管控水平：从人控到智控···································6
1.2.5 增强客户信心，赢得更多订单·········································7
1.2.6 提升员工技能和待遇······················································9
1.2.7 建立低成本高效率的竞争优势·······································10
第2章 衡量自动化成功的4个标准···················································12
2.1 降低成本：自动化如何系统性重塑制造业成本结构？··················12
2.1.1 人力成本：从“人海战术”到“智能无人化”的深度变革···13
2.1.2 质量成本：从“救火式返工”到“零缺陷生产”的革命性 突破·········································································13 2.1.3 工序排布的效率革命：从传统“孤岛”到智能流线化·········14
2.1.4 场地利用最大化：从“粗放使用”到“高效集约”的空间 革命·········································································16
2.2 长期复用：构建可持续的自动化资产体系·································17
2.2.1 整线复用：从“专用陷阱”到“柔性通用”的战略转型······17
2.2.2 单机复用：模块化设计理念的深度实践···························19
2.2.3 模组复用：标准化与柔性化的完美结合···························21
2.2.4 关键零部件复用：构建精益供应链体系···························22
2.3 快速回报：自动化投资的价值实现艺术····································24
2.3.1 投资回报周期的战略意义·············································25
2.3.2 人工成本的快速下降机制·············································26
2.3.3 质量成本的即时改善····················································27
2.3.4 效率提升的快速实现····················································28
2.3.5 投资回报的持续优化····················································29
2.3.6 风险管理与回报保障····················································30
2.4 减少风险：构建稳健的智能制造体系·······································32
2.4.1 产品质量风险的系统化控制··········································32
2.4.2 人员安全风险的全面防控·············································34
2.4.3 运营连续性风险的防范·················································36
2.4.4 数据安全与网络安全防护·············································36
2.4.5 业务连续性风险防范····················································38
2.4.6 风险管理的经济效益····················································39
第3章 推行自动化的困难和误区·······················································41
3.1 推行自动化的困境及突破······················································41
3.1.1 项目发起困境：当商业现实遭遇技术理想························41
3.1.2 技术实现困境：当理想照进现实····································43
3.1.3 突破困境：在迷途中寻找出路·······································45
3.1.4 在困境中孕育新生·······················································47
3.2 推行自动化的三大认知误区···················································47
3.2.1 误区一：产品设计完成后再做自动化设计························47
3.2.2 误区二：未做精益化直接推自动化·································49
3.2.3 误区三：片面追求自动化率··········································51
3.2.4 从误区走向智慧··························································52
第4章 自动化7步模型··································································54
4.1 选择有自动化价值的产品······················································54
4.2 选择适合自动化的动作·························································55
4.3 工艺标准化········································································55
4.4 设备标准化········································································55
4.5 面向自动化的产品设计·························································56
4.6 为自动化配置人才·······························································56
4.7 为自动化调整流程·······························································57
第5章 什么产品有自动化的价值·······················································58
5.1 需要规模化生产的产品：以帕累托-数量（PQ）分析确定订单 基础················································································58
5.1.1 核心逻辑：规模化是自动化的“产能基石”·····················58
5.1.2 实践工具：PQ分析与“80/20法则”的应用·····················59
5.1.3 案例验证：BD0027储液仓的自动化成效·························60
5.2 适用范围广的产品：以产品-工艺（PR）分析划分产品族·············60
5.2.1 核心逻辑：避免“单一产品绑定”的设备风险··················60
5.2.2 实践工具：PR分析与成组技术的实施方法·······················61
5.2.3 案例实践：自动化产品族的柔性生产······························62
5.3 动作重复性高的产品：以工序特性匹配自动化优势·····················64
5.3.1 核心逻辑：自动化的“天然适配场景”是重复动作············64
5.3.2 公司产品的高重复性工序识别·······································65
5.3.3 案例实践：吸阻测试工序的自动化改造···························67
5.4 自动化技术成熟的产品：以技术适配降低落地风险·····················69
5.4.1 核心逻辑：成熟技术是自动化落地的“保障”··················69
5.4.2 雾化器产品的技术成熟度评估·······································71
5.4.3 反例警示：技术不成熟产品的自动化困境························73
第6章 什么动作适合标准化·····························································74
6.1 从高频重复性动作切入：奇思一次性雾化产品自动化的实践路径····75
6.1.1 高频重复性动作定义····················································75
6.1.2 分阶段推进，构建覆盖核心工序的自动化体系··················76
6.1.3 自动化成效显著，助力企业高质量发展···························77
6.2 人工精度不可控的动作：奇思自动化进阶式发展························78
6.2.1 危机：订单激增背后的质量危机····································78
6.2.2 人工焊接困境：高投入、低产出、不稳定························79
6.2.3 破局之路：启动全自动化电池组装焊接线项目··················79
6.2.4 攻坚克难：技术攻关与设备研发全过程···························80
6.3 有连贯性的动作：奇思的集成推进之路····································82
6.3.1 三厂七楼包装线试点····················································83
6.3.2 项目实施：从装袋机上料到码垛下料的全线贯通···············84
6.3.3 首条线集成验证··························································85
6.3.4 横向铺开：从1条线到38条线，仅用40天完成全面升级···86
6.3.5 横向拓展：六厂16条线全覆盖，迈向“零人工包装车间”···87
6.4 可标准化的动作适合自动化：奇思的复用推广之路·····················88
6.4.1 为什么选择这类动作为自动化重点？······························89
6.4.2 标准化动作带来的核心价值··········································89
6.4.3 案例一：包装装盒——自动装盒机复用性的实现················90
6.4.4 案例二：雾化芯装硅胶及折引脚自动化实现标准化突破······90
6.4.5 横向复制——BD0053与XD0011的快速落地····················94
6.4.6 工艺反向驱动——自动化倒逼标准化落地·························94
第7章 工艺如何标准化···································································95
7.1 产品工艺标准化：驱动自动化制造的核心引擎···························95
7.2 第一部分：雾化芯结构件的标准化——自动化装配的“心脏”······96
7.3 第二部分：储液仓组件的平台化——自动化密封与注液的基石······97
7.3.1 碎片化的储液仓，沉重的代价·······································98
7.3.2 破局之道——构建以注液量为核心的储液仓平台················98
7.3.3 平台化储液仓的设计原则·············································99
7.3.4 平台化前的“血泪史”·················································99
7.3.5 平台化落地——B2平台的诞生与验证·····························101
7.3.6 平台化红利——全链条的价值释放·································102
7.3.7 自动化能力的质变······················································103
7.3.8 展望未来，储液仓平台化战略还将持续进化····················104
7.4 第四部分：成品组件化设计——以“乐高式”逻辑重构制造········104
7.4.1 告别“零部件堆砌”，拥抱“模块集成”·························105
7.4.2 组件化蓝图——定义三大核心“乐高积木”·····················105
7.4.3 供应链与生产准备——化繁为简····································108
7.4.4 量产爬坡——自动化与质量的双重飞跃···························108
7.4.5 组件化设计的深远红利——全链条收益···························109
7.4.6 从BD0027到未来——组件化生态构建···························110
7.4.7 结论：组件化——智能制造之“操作系统”·····················110
7.5 包装包材工艺标准化——自动化物流“最后一公里”·················110
7.5.1 下面我们从装袋工艺的演变的案例展开说·······················111
7.5.2 以“糖果袋”为突破口——公司包装工艺全面标准化及 六大包材统一规范······················································112
7.5.3 标准化：自动化时代包装新哲学···································113
7.5.4 标准化：自动化时代之战略制高点································113
第8章 设备如何标准化··································································114
8.1 CD0018全自动组装线（2022）——全自动不是“堆功能”，是 “建标准”········································································114
8.1.1 设计阶段：理想主义的“大而全”蓝图··························115
8.1.2 调试阶段：“钢铁巨兽”变成“麻烦制造者”···················115
8.1.3 试产阶段：纸面数据崩塌的开始···································116
8.1.4 转折与优化：从“堆功能”到“减麻烦”·······················118
8.2 全新一代BD系列柔性成品组装线（2024年）——标准化让设备 “听话”···········································································119
8.2.1 设计理念：从“做加法”到“讲规矩”··························119
8.2.2 调试阶段：动作平台标准化、模块化标准化、零部件 标准化带来的革命性提速·············································121
8.2.3 投产表现：数据说话，标准真管用································121
8.2.4 设备标准化带来的好处················································124
8.3 如何做设备标准化······························································124
8.3.1 动作平台标准化——让每个生产工艺都有“标准”············125
8.3.2 模块标准化——每个“积木”都能拼，像搭乐高积木一样 简单········································································128
8.3.3 零部件标准化——每个“零部件”都通用························129
8.3.4 设备导入流程标准化，让价值“滚”起来·······················130
第9章 面向自动化的产品设计·························································132
9.1 设计标准的底层逻辑：从“补救思维”到“前置规划”··············132
9.1.1 设计标准的核心原则：避开那些“坑”··························133
9.1.2 设计标准要跟着产品“定位”走···································134
9.2 自动化设计核心标准：基于DFA的上料、取料与连接规范·········135
9.2.1 上料方式设计标准：构建自动化的“物料供给基础”········135
9.2.2 取料方式设计标准：确保自动化的“抓取稳定性”···········139
9.2.3 连接方式设计标准：保障自动化的“装配可靠性”···········140
9.3 设计标准的落地保障：从“图纸规范”到“产线验证”··············148
9.3.1 设计评审：把问题掐在“图纸阶段”·····························148
9.3.2 小批试产：用实际数据“说话”···································150
9.3.3 标准迭代：跟着实战“升级”······································150
9.4 总结：设计标准是自动化的“第一生产力”·····························150
第10章 如何为自动化配置人才·······················································152
10.1 自动化转型中的人才体系重构与兵力部署······························152
10.1.1 新旧体系关键岗位配置对比········································152
10.1.2 新增职能与部门调整的深层逻辑··································154
10.1.3 新旧人才体系大裂变：从“人海战术”到“精兵矩阵”····155
10.2 如何配置自动化人才·························································157
10.2.1 人才画像：先定“魂”，再画“形”·····························157
10.2.2 内部晋升：把“老师傅”变成“指挥官”······················160
10.2.3 外部引进：用“开放日”钓“大鱼”····························161
10.3 人才盘点：给自动化人才做“全身CT”································162
10.3.1 根因分析································································163
10.3.2 盘点实施框架与标准·················································164
10.3.3 科学分类与结果应用·················································166
10.3.4 人才盘点总结分享····················································168
10.3.5 破茧重生：重构人才生态的底层逻辑····························168
10.4 每类人才的赋能培训·························································169
10.4.1 培训目标································································169
10.4.2 培训对象································································169
10.4.3 培训课程体系··························································169
10.4.4 课程设计································································171
10.4.5 实训体系设计··························································172
10.4.6 教学实施流程··························································175
10.4.7 结业考核机制··························································176
10.4.8 考核结果评定与应用·················································178
10.4.9 持续优化机制··························································179
第11章 如何为自动化调整流程·······················································180
11.1 产品设计阶段···································································182
11.1.1 产品策划与自动化设计同步········································182
11.1.2 平台化组件化的产品设计···········································184
11.2 设备导入阶段···································································189
11.2.1 需求分析································································189
11.2.2 方案设计评审··························································191
11.2.3 设备采购································································194
11.2.4 预验收···································································195
11.3 设备生产阶段···································································197
11.3.1 设备试产································································197
11.3.2 设备量产································································197
第12章 自动化三不做···································································203
12.1 不为订单稀少之物：规模经济是自动化的基石························203
12.2 不为复用性极低之功：自动化价值在于重复性累积··················204
12.3 不为工艺未熟之术：标准化是自动化的前置条件·····················205
附录A 合作伙伴分享·····································································207
附录B 学习及实践感悟··································································228
后记····························································································243