Digital factory solutions for food industry
Current problems in the food industry
The circulation of all production links relies on paper documents, warehousing depends on manpower confirmation, inventory count manual statistics.
In the process of weighing ingredients in the past, weighing needs to rely heavily on manpower, the weighing process has high requirements, and manual errors are easy to occur, which is not conducive to production.
Equipment data rely on manual supervision inspection, production equipment running status is not real-time monitoring.
Production process relies on paper documents for confirmation, transmission of production plans and production information communication costs are high, and the flow between production processes is inefficient, which reduces the production rhythm.
1. From the perspective of production planning, production planning of enterprises mainly determines market demand by market forecast and organizes production. If there is a large market demand for products. It is "production-based promotion" -- reducing costs and improving competitiveness through mass production.
2. From the perspective of cost budget, the parallel carry-over method is generally adopted to calculate product cost. In its cost composition, raw materials account for the largest proportion in production cost. Generally, raw materials account for a larger proportion of the cost of the product, labor costs account for a smaller proportion, and other shared costs.
3, in the workshop real-time data statistics, due to a high degree of automation of single equipment, equipment control level of a large number of DCS, PLC. In the detection drive, a variety of intelligent instruments, digital sensors have been widely used; The automatic control system based on minicomputer is widely used in process control. These automatic equipment can automatically and accurately record all kinds of production site information. For MES, the focus is on the data interface with these automation devices when the system is built.
4. In terms of equipment management, in the process of assembly line production, every piece of equipment is a key piece of equipment and cannot fail. The failure of one piece of equipment will lead to the termination of the whole process.
5. In terms of product quality management, quality inspection and management are very important. According to the nature of raw materials, near-infrared technology is used to carry out online detection on each process of production batch products, and feedback to the control platform through MES system, so as to ensure the stability and uniformity of product quality.
1) Production management
Work order management: production work order management/packing (filling) work order management, support new, modify, freeze, cancel work order
Arrange production according to capacity: integrate with ERP and other systems to realize the whole enterprise information
Production management: distinguish finished products, semi-finished products, raw materials, etc., BOM formula management
Equipment, station, workshop, production line management: predefined production process route
Production execution: production instructions, production in strict accordance with the predefined production process route, to ensure the completion of work order with "quality and quantity", real-time control of work order status, can freeze problem work order, dashboard, report, screen real-time display of production
Integration with other business systems: download production work orders from ERP systems, download BOM/ formula management from ERP systems, and upload production execution data to ERP systems
2) Material management
Material management: raw material management, container, vessel management, WIP identification
Material use execution: material transfer, adjustment, scrap, rework, merge, decompose, accept, ship, pull, material consumption, material production, rework and scrap control, WIP status management (freezing, isolation, release), finished product, semi-finished product,WIP differentiation
Dashboard and report display: WIP and inventory status, real-time display of material batch location
Integration with other business systems: Material consumption
In the process of material management, the main emphasis is the movement of materials. Every move of material will be recorded, every batch of decomposition, disappearance, creation by the system to deal with, at the same time real-time inventory information, to ensure the visibility of materials in the process of food and beverage production.
3) Quality management
Quality sampling and execution: process control setting, process sampling rules, planned sampling rules, online and offline quality sampling, HACCP
Sampling management: planned and unplanned, collection of on-line or batch quality data, collection of equipment status, early warning event data, CAPA
Deviation management: Monitor data deviating from standard values and provide visual means to monitor real-time data
Net content control: control weighing equipment, strictly follow the information shown on the label (weight, quantity, etc.)QA release management (WIP freeze, release)
Dashboard and report display: one-time pass rate statistics, KPI display
Integration with other business systems: download quality specifications and upload quality analysis data
4) Product tracking
Tracking/tracing and family tree management: tracking the use of man-machine material method, tracking based on different levels of Lot/Item/Unit, tracking abnormal processes such as rework/scrap, historical operation records of operators (manual control events)
Dashboard and report display: forward tracking, backward tracking, efficient correlation reports
Integration with other business systems: Traceability of finished products continues
Product tracking emphasizes the management of man-machine material method, each production step, through what equipment, which operators involved, what parameters will be recorded, including environmental information by the system through automated means to collect data. Therefore, after the production, as long as there is a problem with this product, the reason can be traced back to in THE MES system.
5) Manufacturing intelligence
Intelligent production: production sequencing, work order status, overall production capacity and efficiency, OEE statistics, efficiency of assembly line and packaging line, planning/capacity balance
Material estimation: inventory management, scrap reporting and rework materials
Trace/trace and family tree reports: trace forward/backward
Quality management assessment: Quality analysis index, HACC, historical data analysis and reports
Intelligent efficiency analysis: PACKAGING line OEE statistics, downtime statistics, OLAP analysis