Green | what do you know about smart production in the Chinese manufacturing industry?

In the past two years, intelligent production has gained wide attention in the manufacturing industry. What is intelligent production? What does it contain? These are important topics for enterprises. Today, let's talk about smart production.

First, let's look at the main concepts of smart production:
Man-Machine Integration System Consisting of intelligent equipment, sensors, process control, intelligent logistics, manufacturing execution system, and information physical system;
In terms of process design, implement Intelligent Production, efficient scheduling, automatic material distribution, status tracking, optimization control, intelligent scheduling, equipment operation status monitoring, quality tracing and management, and workshop performance throughout the manufacturing process;
Correct judgment and handling of production, equipment and quality exceptions;
Implement integration of Manufacturing Execution and operation management, R & D design, and smart equipment;
Finally, the integration of design and manufacturing and management are realized.

Throughout the domestic manufacturing market, the manufacturing industry has a very strong demand for smart upgrade and has made rapid technological advances in recent years. However, in general, the foundation of China's smart manufacturing industry is very weak. Most enterprises, especially the majority of small and medium-sized enterprises, digital Manufacturing transformation has not yet been completed.

The following problems exist:

1) The digitization and intelligence of production equipment are not high, and the network connection rate is low, which seriously hinders the construction of digital and intelligent workshops.

2) The level of automation and intelligence of logistics is low. There are not many factory logistics and automated warehouse, and the automation level of material distribution at the production site and material transmission between processes is lower, which is basically the manpower used.

3) The MES ratio in the workshop is very low, resulting in extensive workshop production operation plans, uneven equipment load, and poor coordination of material supply. There are also chaotic Workshop material management and poor job progress monitoring.

4) Some enterprises purchase a considerable number of numerical control machine tools or automated production lines, but the system integration is poor.

5) data collection is serious and insufficient. The production process progress, quality status, equipment running status, material distribution status, and other information cannot be reported in a timely manner. The transparency and visualization of the entire production system are not high, the scientific nature of production scheduling is greatly reduced.

For manufacturing enterprises in China, using automation and information technology to improve factory production methods and seeking opportunities for industrial upgrading has become a common consensus of enterprise managers. Intelligent Production systems can be divided into three levels:

Intelligent equipment and Control System

Intelligent equipment and control system is the basic equipment of the Intelligent Production System. It consists of several Flexible Manufacturing Systems (FMS. According to the definition of national military standards: "A flexible manufacturing system is an automatic manufacturing system consisting of numerical control processing equipment, material storage device, and computer control system. It includes multiple flexible manufacturing units, it can be quickly adjusted based on changes in the Manufacturing task or production environment, and is suitable for multi-variety, Small and Medium batch production."

Smart warehousing and logistics system

From the perspective of lean production, we hope that the smaller the inventory, the better, but sometimes the inventory is necessary due to factors such as supply quantity, supply radius, transportation cost, and so on. Building an intelligent warehousing and logistics distribution system is an important part of smart production.

The smart warehousing and logistics system consists of the warehousing and logistics information management system, automatic control system, and logistics facilities and equipment system.

Intelligent Manufacturing Execution System

Manufacturing Execution System (MES) is a concept proposed by AMR in 1990s. Amr defines MES as a management information system at the workshop layer between the upper-layer Planning Management System and the underlying industrial control system ", it provides the operator/manager with the execution and tracking of the plan and the current status of all resources (persons, equipment, materials, customer requirements, etc.

MES can monitor the running status of underlying devices in real time, collect the status data of devices and instruments, analyze, compute, and process the status data, and trigger new events, in this way, the control system is linked with the Information System conveniently and reliably, and the production status is reported to the planning layer in a timely manner.

At the same time, the MES system is also responsible for integration with Enterprise Resource Planning ERP, R & D and design systems CAX/PLM, etc. Through integration, MES transmits the information to the intelligent equipment and control system and the intelligent logistics system to achieve comprehensive integration from the underlying equipment to the management, R & D and design system.

① Integration with ERP System

Information transmitted by the ERP system to the MES system includes the production task, procurement (outsourcing) in transit, inventory information, and material distribution plan. Information transmitted by the MES system to the ERP system includes the production completion status, material re-production, material distribution status, exception information, and quality of the production process.

② Integration with the R & D and Design System

The information transmitted from the CAD, Capp, cam, and PLM systems of the R & D and Design System to the MES system includes the material master data, material list, design documents, process documents, numerical control procedures, and technical changes, achieve integration of design, process and manufacturing. The MES system reports process exceptions and design exceptions to the intelligent design system.

③ Integration with the smart Service System

The MES system transmits product quality traceability information to the intelligent service system for product recall and claims. The intelligent service system sends user feedback to MES.

However, we found that although some enterprises have upgraded production, the results are not satisfactory. In fact, manufacturing enterprises of different industries and sizes should proceed from their own strategic direction and management level, combine the core elements of intelligent manufacturing to develop digital and intelligent transformation approaches.

1. Starting from the strategic direction, find the enterprise's own shortcomings, build its own smart manufacturing blueprint, small steps, long-term planning, and pay attention to information-based investment benefit analysis.

2. define your own vision and vision. Assess whether the implementation conditions are met, objectively assess the current and future situation, and consider the implementation path from the unit (point) and production line (line) to the factory (area.

3. Benchmarking world-class enterprises based on industry trends, and formulating implementation goals and plans based on their strategic needs and current management level. It builds a foundation based on the framework and gradually deepens. It solves the problems of optimizing the enterprise management process through digital intelligence, and ultimately achieves intelligence.

Digitalization and intelligence are only technical means. The core goal of intelligent manufacturing is to enhance the competitiveness of enterprises. To achieve intelligent production, enterprises do not have to worry about it. They can implement the overall planning and small steps based on the status and capabilities of the industry.

Green | what do you know about smart production in the Chinese manufacturing industry?