Manufacturing Execution System of process enterprises (steel enterprises)

Manufacturing Execution System of process enterprises (steel enterprises)

1Definition and classification of modern process Enterprises

Modern process industry usually refers to the industry that realizes value-added through continuous production processes from raw materials to finished products with both physical and chemical changes. This definition only divides the service industry and some processing industries, and classifies the production enterprises according to the logistics conditions in the production process, that is, they can distinguish different types of enterprises, it can also implement scientific management methods from macro control to micro-coordination in the Process of accurately reflecting the value-added production conditions.

2. the "v" type logistics shows that it features few raw materials, similar processing routes, and various types of final products, enterprises with the majority of "V" logistics in the production process, such as steel and refining. One of the corresponding process industries is "A" type logistics-oriented enterprises, such as shipyards, which have many raw materials, complicated processing routes, and fewer final products. Between the two is the "T" type logistics-oriented enterprises, such as automobile manufacturing plants, assembly plants, is characterized by a large number of common materials, processing routes, the final product types are not too many.

According to the above statement, most of the process enterprises in a strict sense are mainly "v" type logistics, which basically belongs to the basic industry and is a typical capital-intensive industry, increasing the enterprise scale within a certain range can effectively reduce costs. The technology and material technology are already quite mature, and the technology rigidity is large, at present, process enterprises in China usually have some weaknesses, such as low implementation of economies of scale, low technical equipment, excessive production capacity, and a small proportion of high value-added products. Implementing mes helps improve the current situation from the management method and technical aspects.

Figure2Enterprise Classification Based on logistics Characteristics

2. Process Enterprise Supply Chain Model

Any production system should achieve economic significance, that is, the optimal processing of the logistics, capital flow and information flow of the production system, with the lowest resource consumption to produce products that meet market requirements. Therefore, the research on modern process industrial production starts from the analysis of its logistics, capital flow and information flow characteristics. Take steel enterprises as an example.

1) Logistics features: multi-part production, multi-part transportation, multi-part Storage, multiple types of logistics, multiple processes and different forms, accompanied by a variety of raw materials. Products and finished products include: iron ore, powder ore, raw coal, Piron, scrap steel, molten steel, molten steel, final products (plates, tubes, coils, wires, and models ). All devices are large, with high costs, complex operations, tight process connections, strong operation continuity, and high time requirements. There are not only time balance and temperature balance problems, there is also a balance between resource capabilities and logistics.

2) features of capital flow: capital flow is difficult to control due to the huge investment, frequent capital flows, complicated logistics features, and Financial Analysis for a large production scale, only by complying with the strict accounting system and implementing flexible fund management can enterprises accurately and timely reflect their operating conditions and effectively control them. The lag of financial data, such as funds, and the real-time requirement for controlling capital flows, are useful for network databases.

3) Information Flow Characteristics: production and operation activities require a large number of feature values to describe, covering content from traditional information management fields such as finance and personnel to production management. Production should be performed according to orders, reasonable production plans should be formulated, and all-round quality management should be implemented. The production process should also be monitored comprehensively and data collected to meet the real-time requirements of production management, continuously updated personnel, materials, products and other information, comprehensive and detailed statistics help managers to publish the most reasonable control information, so as to perfectly achieve the business objectives.

After analyzing these features, we can get the basic supply chain model of steel enterprises. 3:

Figure3Typical Process Enterprise Supply Chain Model

3.Steel Enterprise Integration Model

After obtaining the external supply chain model of an enterprise, you also need to design a functional model for the enterprise based on the internal analysis needs, and divide the system into "layers" according to the function ", the implementation should be divided into different levels by computer and network systems ". The Operation and Management of steel enterprises can be divided into three layers, which are achieved through seven levels.

1. Planning layer: including business decision level and enterprise plan level. Main function modules: production and operation decision-making; preparation of long-term and mid-term production plans; financial management; human resource management; procurement and distribution; Cost Management; inventory management; order processing; auxiliary decision-making.

2. Execution layer: including workshop production level and production scheduling level. Main function modules: Production Scheduling and operations; quality management; personnel and equipment management; material tracking and Product tracking; analysis of the operation process.

3. control layer: including process control level, device control level, and detection driver level. Main function modules: monitoring of production line scope; adaptive control; equipment control; various signal detection on site. Integration Model Level 4:

Figure4Hierarchical Structure of typical process enterprise integration models

4. Enterprise Operating System (BOS).

After the hierarchical structure of the external supply chain model and integration model of the Process Enterprise has been determined, a detailed functional module of the enterprise operating system (Bos, Business Operation System) can be defined, 5 (BPS is the planning layer-business plan system, business planning system; PCs is the control layer-process control system, process control system ).

Figure5: Enterprise Operating System (BOS).

The Manufacturing Execution System (MES) consists of eight modules:

Production Plan: Generate an optimized shop-level plan based on cost objectives for orders associated with processing properties, and retain original order data for easy control.

Workshop scheduling: Dynamically coordinates personnel, materials, and equipment on Site Based on Real-time production data and historical cases to optimize production as much as possible.

Job plan: Batch Combination Plan and production sorting plan based on a small unit of time to maintain the efficient operation of the workshop.

Personnel Management: Detailed records of behaviors are not only associated with personnel compensation, but also can provide a basis for production analysis, facilitate management and effectively improve productivity.

Device management: Preventive Equipment Maintenance focuses on analyzing and optimizing equipment capabilities to eliminate bottlenecks and restrict production and achieve the maximum utilization of equipment.

Quality Management: The integrated functions support various work related to quality planning, inspection and control. Dynamic Data analysis provides a basis for workshop scheduling.

Material tracking: The on-site data is collected to track material changes, which is possible for enterprises to quickly respond to changes in internal conditions and external environments.

Product tracking: The on-site data is collected to track the changes in work-in-process products. The changed product information facilitates production management and can also provide services to customers.

5.MESObjectives and design principles

The most important goal of a custom manufacturing execution system for process enterprises is to establish and improve the production management system, including formulating production plans based on customer orders, market forecasts, and internal resource conditions; optimize and coordinate the production process from the overall perspective, and dynamically adjust the production plan. At the same time, it is necessary to establish an information system to ensure quality management, including online feedback and adjustment of online material tracking and quality control, and the pursuit of zero defects in product quality. The above two objectives serve as an opportunity to build a Process Enterprise MES system to promote the transformation of production methods and management ideas. This will be a gradual process.

The Design of MES is based on software engineering standards. It mainly considers the overall situation and versatility. It not only needs to optimize the entire production process, but also provides a standardized and modular application framework; at the same time, the principle of scalability, openness and compatibility should be adopted, so that the system functions will not be affected when the production capacity changes, it also provides standard and open communication interfaces and reduces the impact of changes in the development environment and development tools. You should also pay attention to operability, visibility, and robustness, friendly and easy-to-use interfaces, monitoring and tracking simulation, and strong fault tolerance capabilities are helpful for users at all levels. Finally, real-time performance is required, only the shortest response time can be used to control and adjust the production process.

6.MESInformation Library Design

Information flowing in modern process enterprises has strong dynamic characteristics and a large amount of redundant information and missing information and information breaks coexist, whether it is the production data collected from the site or the order information obtained from the market, it may cause immeasurable consequences to the enterprise because it cannot be truly reflected, to ensure that valuable information can provide correct guidance for enterprise decision-making and operation, a variety of information databases should be built in the Process Enterprise Operation System. Different information databases have different characteristics.

Material Information Library: inventory status of enterprises and materials that require external procurement or internal adjustment. Some information is shared with suppliers. Order Information Library: requirements for products (such as steel grades, quality, and quantity, some information is shared with the contractor. Product Information Library: product catalog and the in-product status with specific contract providers. Some information is shared with distributors/users. Basic information library: enterprise personnel and equipment status, basic information of enterprise operations, such as accounting data, is used in different confidentiality levels within the system. It also includes some frequently updated external information such as policies and markets. Production Information Database: production-related information, such as real-time changes of personnel and equipment in the production process, with high dynamic requirements, as well as basically unchanged process routes, is invisible to the outside.

These databases are relational databases. The establishment of these databases reduces the data burden on workshop-level computers and reduces a series of consequences caused by data storage and operation failures. Materials, orders, and product information databases can be queried by external personnel to form strategic partnerships with suppliers. The relatively stable basic information library provides great convenience for daily management of personnel, finance, and equipment. The Production Information Library has the highest dynamic performance requirements, and a large amount of flow data is injected into other information libraries every moment. Therefore, it has the highest design requirements. Common functions of these databases include reporting, storage and backup, recovery and deletion, and passwords and permissions.

In the dynamic production information library, the parts connected to the data collection module become the top priority. It monitors the status data collection points of data collection points in the production process in real time and the equipment operation status in the main production process, to ensure that the collected data is reliable, not redundant, and sufficient without breaking.

7.MESData Flow diagram design

For a long time, the improvement of the production and operation status of enterprises has always been centered on the planning layer, while the Practical Value-Added links-production, scheduling, process control, and other links are still maintained through experience, even the imported world's advanced production lines are out of touch with the planning layer in terms of data collection and monitoring, and according to the facts of domestic enterprises, many enterprises have built ERP and other planning systems. Therefore, this article mainly discusses the data flow diagram design of MES systems that are rarely implemented by domestic process enterprises but urgently needed to be built (due to actual restrictions, the functional modules in the control layer are also taken into account ).

External Entities of the Process Enterprise Operating System are: suppliers, contractors, system maintenance, and distributors/users.

Supplier: The department that provides equipment, materials, transportation and other items or services, and provides relevant material (service) Information to the system.

Contractor: The Other Side of the production order, providing the relevant order information to the system.

System Maintenance: An enterprise member responsible for updating and maintaining the basic information library of the enterprise.

Distributors/User: Product users must provide related product information and information services.

Now, we can obtain the data flow diagram of the Process Enterprise Operating System Bos, including the top DFD diagram of the system, the first DFD diagram, and the second DFD diagram of MES. Figure 6 mainly describes the second DFD diagram of MES.

Figure6: Process Enterprise2LevelDFDFigure (MES/PCS)

Conclusion:

The role of MES for manufacturing enterprises has been very clear, but people do not know MES as well as ERP, CRM, SCM and other management systems. Due to unclear understanding, the demand will naturally become unclear, making it difficult to form a certain market scale. At present, mes in the United States is growing at a speed of 25%, while in China it is basically the Development of Local MES functions, specifically some simple data collection, logistics management, etc, in fact, these also fall into the scope of MES functions. However, with the gradual deepening of people's understanding of MES, the application of MES in enterprises will be gradually deepened.

<This article is reproduced in the AMT management lecture hall>