1. Introduction
Gear, as a crucial mechanical component with teeth on the rim for continuous meshing to transmit motion and power, plays an indispensable role in various industries. With the continuous development of the automotive, mechanical manufacturing, and aerospace industries, the demand for gear products has been steadily increasing. This has led to the active production of gear products in China. However, in the context of China’s efforts to reduce overcapacity and adjust the industrial structure, the production of gear products has also been affected to some extent. Despite the challenges, the gear industry’s output value has been on the rise, indicating its growth potential. Nevertheless, there is still a significant gap between the domestic gear products and the international advanced level in terms of power density, reliability, and service life. Therefore, it is essential to explore the development model of the gear manufacturing industry and improve its development level to promote its sustainable growth.
2. Gear Manufacturing Industry Development Status
2.1 Classification and Market Share of Gear Products
Gear products can be classified into vehicle gears and industrial gears based on their application scenarios. Vehicle gears account for approximately 62% of the entire gear market, while industrial gears make up around 38%. The dominance of vehicle gears is closely related to the booming automotive industry, which has a high demand for gears in transmissions and drivetrains. Industrial gears, on the other hand, are widely used in machinery manufacturing, power generation, and other industries.
2.2 Production and Output Value Trends
From 2016 to 2021, the total output of the industrial gear industry in China showed certain fluctuations: 274.01 million tons in 2016, 257.99 million tons in 2017, 217.89 million tons in 2018, 237.17 million tons in 2019, 245.67 million tons in 2020, and 228.16 million tons in 2021. Although the output has been affected, the output value of the gear industry has been increasing. For example, from 2016 to 2020, the output value of China’s gear industry was 220.5 billion yuan, 236 billion yuan, 260 billion yuan, 280 billion yuan, and 300 billion yuan, respectively. This indicates that the revenue scale of the gear industry in China is continuously expanding.
| Year | Industrial Gear Output (million tons) | Gear Industry Output Value (billion yuan) |
|---|---|---|
| 2016 | 274.01 | 220.5 |
| 2017 | 257.99 | 236 |
| 2018 | 217.89 | 260 |
| 2019 | 237.17 | 280 |
| 2020 | 245.67 | 300 |
| 2021 | 228.16 | – |
3. Gear Manufacturing Industry Development Problems
3.1 Manufacturing Process Optimization Required
3.1.1 Low Standardization and Standardization
The lack of uniformity in manufacturing processes among different enterprises leads to inconsistent product quality. This not only affects the performance and service life of gears but also undermines the overall image and reputation of the industry. For example, in the production of high-precision gears for aerospace applications, the inconsistent use of process parameters can result in significant differences in gear quality.
3.1.2 Limited Automation
Although advanced manufacturing technologies such as CNC machines and robots are available, their application in some gear manufacturing enterprises is insufficient. This limits production efficiency and quality improvement. In contrast, enterprises that have adopted automated production lines have achieved higher productivity and better product quality.
3.1.3 Inadequate Precision Control
Precision is crucial for gear performance, but some enterprises have difficulty in strict precision control during manufacturing. The use of low-precision machine tools and simple measurement tools leads to larger gear tooth profile errors and undetected fine errors, resulting in quality issues. For instance, in the manufacturing of gears for high-speed trains, even a slight deviation in tooth profile can cause vibration and noise problems.
3.2 Technical Talent Shortage
3.2.1 Insufficient Talent Supply
The demand for highly skilled technical personnel in the gear manufacturing industry is increasing, but the supply is limited. The small-scale training of gear manufacturing majors in universities and vocational schools fails to meet the industry’s needs. This shortage restricts the industry’s technological innovation and development.
3.2.2 Severe Talent Loss
High-tech enterprises often attract technical talents with high salaries, but the lack of talent cultivation and long-term incentive mechanisms in some companies makes it difficult to retain them. This leads to a loss of valuable technical expertise and experience.
3.2.3 Unreasonable Talent Structure
The age structure of technical personnel in the gear manufacturing industry is often skewed towards the elderly, with a relatively small proportion of young talents. This imbalance affects the industry’s innovation ability and long-term development potential.
3.2.4 Imperfect Talent Training System
The current talent training system in the gear manufacturing industry is relatively weak, lacking practical training and innovation ability cultivation. This results in a shortage of high-quality technical talents.
3.3 Low Brand Building Capacity
3.3.1 Lack of Brand Value Awareness
Some gear manufacturing enterprises view brands merely as logos or names, neglecting their value and significance. This leads to a lack of differentiation and competitive advantage in the market.
3.3.2 Ambiguous Brand Positioning
Many enterprises lack a clear brand positioning strategy, making it difficult to define their market position and target customer groups. This confusion affects market competitiveness and brand building.
3.3.3 Insufficient Brand Promotion and Communication
Enterprises often rely on traditional sales channels and underutilize modern brand communication channels such as advertising, publicity, and social media. This limits brand awareness and recognition.
4. Gear Manufacturing Industry Development Countermeasures
4.1 Actively Optimize the Manufacturing Process
4.1.1 Strengthen Standardization and Standardization
Establishing unified manufacturing standards and quality control systems can ensure product consistency and stability. For example, standardizing material selection, heat treatment processes, and machining equipment requirements can improve product quality.
4.1.2 Introduce Advanced Technologies and Equipment
Adopting advanced machining technologies such as CNC machining and automated production lines can enhance production efficiency and quality. Collaborating with research institutions and universities can also promote technological innovation.
4.1.3 Improve Precision Control
Investing in high-precision machine tools and advanced measurement equipment, and optimizing manufacturing processes can improve gear precision. This is crucial for high-performance gear applications.
4.2 Meet the Demand for Technical Talents
4.2.1 Strengthen Talent Supply
Enhancing cooperation between universities, vocational schools, and enterprises to adjust curriculum settings according to industry needs can cultivate more practical talents.
4.2.2 Establish Long-Term Incentive Mechanisms
Providing equity incentives, bonuses, and career development opportunities can attract and retain excellent technical talents.
4.2.3 Improve the Talent Structure
Increasing the recruitment of young talents and establishing a talent echelon system can promote the growth of the technical team.
4.2.4 Strengthen Talent Training
Collaborating with the government and schools to formulate comprehensive talent training plans, including vocational training and practical experience accumulation, can provide a stable talent supply.
4.3 Increase Brand Building Efforts
4.3.1 Enhance Brand Value Awareness
Educating employees about brand value and emphasizing its importance as a core competitiveness can improve brand awareness within the enterprise.
4.3.2 Define Clear Brand Positioning
Conducting market research to understand customer needs and competitors, and formulating a unique brand positioning strategy can enhance market competitiveness.
4.3.3 Utilize Multiple Brand Communication Channels
Leveraging advertising, social media, and customer testimonials to promote the brand can increase brand awareness and recognition.
5. Gear Manufacturing Industry Development Trends
5.1 Market Demand-Driven Product Structure Adjustment
As the global economy and international trade grow, different industries have varying demands for gear products. The aerospace industry requires high-precision, low-noise gears, while the wind power industry demands large-sized gears. Gear manufacturing enterprises need to adapt to these changes by adjusting their product structures.
5.2 Technological Progress Promotes Industry Upgrading
Advancements in materials, manufacturing processes, and equipment have significantly improved gear performance. The adoption of new materials, such as high-strength alloys and composites, and advanced manufacturing technologies, like 3D printing and precision grinding, can enhance gear strength, reduce noise, and increase production efficiency.
5.3 Environmental Protection Leads to Green Manufacturing
In response to global environmental concerns, the gear manufacturing industry is moving towards green and sustainable production. This includes reducing waste, emissions, and energy consumption, and promoting the use of recyclable materials.
6. Conclusion
The gear manufacturing industry faces both challenges and opportunities. By optimizing the manufacturing process, meeting the demand for technical talents, and strengthening brand building, enterprises can enhance their competitiveness. Adapting to market trends and technological advancements, and embracing green manufacturing, will drive the sustainable development of the gear manufacturing industry.
7. Future Outlook and Recommendations
7.1 Research and Development of High-Performance Materials
Continued investment in research and development of new materials is crucial for the future of the gear manufacturing industry. Materials with enhanced strength, durability, and resistance to wear and corrosion can significantly improve gear performance. For example, the development of advanced ceramic materials and nanostructured alloys shows great potential in meeting the demanding requirements of high-precision gears used in aerospace and automotive applications.
7.2 Integration of Digital Technologies
The integration of digital technologies such as the Internet of Things (IoT), artificial intelligence (AI), and big data analytics can revolutionize the gear manufacturing process. IoT-enabled sensors can be installed on production equipment and gears to monitor performance in real-time, enabling predictive maintenance and quality control. AI algorithms can optimize manufacturing processes by analyzing large amounts of data, improving production efficiency and reducing waste.
7.3 Global Market Expansion and Competition
With the globalization of the economy, gear manufacturing enterprises should focus on expanding their global market share. This requires understanding international standards and regulations, improving product quality to meet global requirements, and building a strong international brand. At the same time, enterprises need to be aware of the intensified global competition and continuously innovate to maintain their competitive edge.
7.4 Sustainable Manufacturing Practices
In addition to the previously mentioned green manufacturing trends, the industry should further explore sustainable manufacturing practices. This includes the use of renewable energy sources in production facilities, reducing the carbon footprint of the manufacturing process, and implementing circular economy principles to maximize resource utilization and minimize waste.
7.5 Collaboration and Partnerships
Collaboration between gear manufacturing enterprises, research institutions, and suppliers is essential for the industry’s development. Joint research and development projects can accelerate the introduction of new technologies and materials. Partnerships with suppliers can ensure a stable and high-quality supply of raw materials and components. Additionally, cooperation with end-users can help enterprises better understand market needs and develop customized solutions.
In conclusion, the gear manufacturing industry is at a critical juncture of transformation and upgrading. By addressing the existing problems, implementing effective countermeasures, and embracing future trends, the industry can achieve sustainable growth and contribute to the development of the global manufacturing sector.