MES project import-case analysis-XC-MES achieves high efficiency and collaboration

XC-MES projects are designed for the integration of material, scheduling, process, production and other supply chain, lean manufacturing, information sharing, quality traceability of the flying wool leg Smt. The project covers wireless warehousing, auxiliary scheduling, process setup, manufacturing, equipment management, and other full-Process Management of manufacturing.

   Currently, information sharing between management departments, production lines, warehouses, and processes involved in the production process is completed through ERP or manual reports. However, information in specific operation processes cannot be controlled and shared in real time, in order to grasp the correct and timely information of the production process, improve product quality, efficiency and reduce costs, reduce the management bottleneck caused by rapid changes in production status, and introduce the XC-MES project.

   XC-MES System for the factory site production information collection and integration system, from the perspective of the overall operation of the enterprise, it is connected to the upper tiptop ERP system and production, warehouse field operations, provides real-time and accurate sources of actual production data. From the perspective of on-site management, it integrates the data of various units in the factory manufacturing field, so that each unit can quickly obtain the information required for the operation, through information sharing and collaborative operations, to improve production efficiency, product quality and customer satisfaction.

   XC-MES is the execution system used in the factory workshop, mainly through the computer, intelligent terminal, bar code and other equipment combined with network communication, software and database technology, real-time collection of on-site information, provides real-time and accurate production conditions, and integrates various materials (materials, production management, manufacturing, quality control, and database management) of all units on the site, improve manufacturing competitiveness by controlling all factory resources, including personnel, equipment, materials, production processes and operation procedures, it provides a way to systematically integrate functions such as quality control, document management, production scheduling, and automatic control on a unified platform, thus greatly improving the production quality and efficiency. SCUD-MES collects all kinds of information on the production site, and automatically organizes and analyzes the data, to provide managers with correct and real-time information, to assist managers in correct management decisions. Effectively tracks and manages in-process products, raw materials, equipment conditions, pre-production conditions of processes, and actual production results in manufacturing activities to meet requirements from customers and manufacturing sites in real time, to help the management unit make correct decisions, its main research contents and functions are as follows:

● Real-time production information collection and sharing, paperless on-site operations, automated data collection and transmission, improving on-site operation efficiency and reducing costs.

● Help to arrange and adjust production schedules accurately and quickly.

● Process anti-stay (production factors such as automatic controllers, machines, materials, methods, and rings ).

● Fast tracking and query of product, material and supply, production, inspection, maintenance, and product inspection records.

● Standardized material classification and precise batch management are achieved, which greatly improves the efficiency and accuracy of product line material supply and inventory material management.

● Automatic Generation of various statistical reports and flexible and efficient analysis and query at any time, saving a lot of manpower and improving the efficiency and accuracy of information processing.

● Through detailed operation records, personnel can be precisely managed to precisely analyze and develop personnel operation efficiency and propose targeted improvement measures, and responsible personnel can be quickly determined for precise performance assessment.

● Remote system management using the network.

● Integration with the existing tiptop ERP interface and some industrial control equipment.

   Through the joint efforts of the project team members, the XC-MES system has developed a manufacturing execution system that is suitable for the flying leg enterprises, especially the SMT industry. Its innovation lies in the rare application of enterprises in MES projects. The main innovations are as follows:

   1. Introduce the WMS storage management subsystem. Incorporate the barcode information system into the process management; Save the production preparation time while preventing errors in the preparation, and improve the operation efficiency. The material dashboard realizes the error message and improves the Coordination Efficiency of the Department.

   2. Efficient material preparation and distribution mechanism. The Warehouse Manager uses a hand-held PDA to prepare materials. The picking process strictly controls materials and data according to the content of the stock preparation ticket to prevent the product line from receiving wrong materials; the material splitting process is displayed based on the ordering order and the feeding point information of each material, which serves as a reference for the data splitting of the Warehouse Manager, thus greatly saving the production time and improving the production efficiency.

   3. Dashboard mechanism. Based on the field Control and Data Collection System of the network and electronic panel, the electronic panel definition is similar to the Kanban concept in the punctual production method (just in time, JIT, through the scheduling and allocation module, the scheduler assigns tasks to workers and devices. through the computer network of the workshop, the computer in front of the device obtains the assigned tasks and presents the task list. This is an electronic dashboard. The electronic dashboard provides the tasks to be completed by workers and devices on duty. The functions of the e-Dashboard include Task Distribution display, picking registration, task progress entry, and work-hour feedback. Workers can obtain the tasks they need to complete in this shift through the electronic panel, and obtain the corresponding materials from the on-site in-product warehouse for processing, and perform the picking operation through the electronic panel, provide on-site flow information of materials. After the task is processed, the personnel input the task progress through the e-card, and then feedback the task progress and labor time information to the scheduler and scheduling level. On the other hand, in the hidden layer sense, employees can also compare the production progress of each shift through the electronic panel to motivate employees' morale.

   4. ERP interface. To realize continuous and real-time information flow of enterprises, MES must be integrated with ERP. The SCUD-MES system provides both manual and automatic synchronization mechanisms to meet the needs of daily production and emergency handling. When an enterprise's upper-level planner sends an order processing service request to the ERP interface, the ERP interface first queries the ERP server to determine which orders have been prepared for processing, then, a manufacturing order is generated on the MES server based on these orders and distributed to the Production Planner at the workshop layer through the MES system. In this process, the ERP interface can query the MES model to obtain the statistical information about the production data, quality or production capacity, and report the execution results to ERP, to update inventory information and the overall production capacity information of the enterprise.

   5. SMT loading error prevention mechanism. For the special nature of the SMT industry, its loading principle

                           

Before SMT device placement, the operator needs to put the material disk on the correct feeder, and then put the feeder on the position of the appropriate SMT device. In this process, due to the frequent use of wrong materials or the use of wrong feeder, SMT Equipment runs continuously at high speed. If this error cannot be avoided in advance, rework or decommission may cause huge losses to the enterprise, to avoid this situation, the best way is to compare the correspondence between the feeding tray, feeder used, and the loading position with the feeding table during the loading process. Introduction of SCUD-MES system loading error prevention subsystem can bring this benefit. Although the seemingly simple SMT loading operation has its own complexity, the SMT loading error prevention subsystem also supports the following features: first, during the entire production process of the SMT workshop, loading scanning can be classified into several business types, such as loading, feed/receiving, blanking, QC sampling and comparison. The loading error prevention system must first provide system functions that meet these business types, in addition, the user's work habits should be taken into account to minimize the complexity of user operations. Second, the electronic products produced by many customers involve single-panel, dual-panel, and mixed panels containing multiple products, the loading and error prevention system supports a variety of complex product structures and maintains coordination with customers' business habits to the maximum extent. 3, the loading error prevention system must collect various Tag Information scanned by the operator before comparing the materials in the table. The system considers how to prevent the operator from missing the table so that the system can play a real role, at the same time, we try our best to reduce the complexity of system operations and the resistance of frontline personnel to the system.

   6. flexible system configuration platform. Users can flexibly classify, rename, or delete existing functional modules based on their usage habits, so that the MES system is more suitable for actual use. On the basis of familiarizing yourself with the MES database table structure, you can develop custom reports under the existing table structure. You can write SQL statements at specified locations to generate the report data you need; you can use the Configuration Wizard to display and define report data in a graphical manner. the system administrator can configure the business logic of the work site and match the business logic processing content of the work site with the background business logic stored procedure. When the business logic changes, you can modify the content of the background stored procedure without changing the system. This allows you to smoothly upgrade the system.

   7. Accurate Analysis of SPC quality management. Analysis of the production straight-through rate (including the total number of patches, the total number of poor, the straight-through rate, the total number of reflux, the number of poor reflux rate, the return rate), the analysis of bad records, and the analysis of maintenance records. Through the collection of quality data, statistical process control analysis such as P, NP, U, C, and xbar-r of the SPC module is realized.

   8. Introduce the SMO client platform. The SMO client can simulate the DCT (Data Collection Terminal) Equipment of our company, instead of some on-site DCT collection equipment, which reduces the procurement cost of hardware equipment and saves space.

   9. bar code printing software. Combined with the characteristics of the company's bar code printing, developed to adapt to the flying leg bar code printing software. It includes a printing template that can be configured and edited on its own. The corresponding bar code is automatically generated according to the custom encoding rules. It also supports printing similar to various types of queries, such as order orders, BOM, and receiving orders, this improves the overall efficiency of bar code printing.

   The Development and Application of XC-MES System in feimao leg enterprise will be a qualitative leap of the informationization of feimao leg manufacturing industry. At the same time, the application and implementation in the SMT industry is also another pioneering work in the same industry in Fujian Smt.