Machining industry information solutions

 

Current problems in the machining industry

(1) Production level

1. Production needs to know equipment test standards;

2. Lack of automation, assembly flexibility, productivity and better reliability of the automatic assembly system;

3. On-site production management is difficult, from raw material input to the final process to complete output, difficult to manage the intermediate process;

4. Production information can not be timely obtained, it is difficult to achieve effective production control;

5. The variety and quantity of installation parts increase further, and new requirements are put forward for parts reception, storage, supply, assembly operation guidance, etc. 

6. For processing, power, testing equipment machines, high degree of structural and technical complexity.

(2) Storage level

1. Warehouse material, quantity is large, can not master real-time accurate warehouse data;

2. Raw materials, semi-finished products, finished products, waste products frequently in and out of storage objects complex;

3. Warehouse location management is not clear, the warehouse administrator needs a lot of time to confirm the location of materials and products;

4. Abnormal situations are not dealt with in time, lack of effective early warning mechanism;

3. In the case of saving inventory, easy to appear out of stock phenomenon; 

Planning direction

• In flexible manufacturing system, such as agile manufacturing information as the construction goal, sensor technology, wireless communication technology, computer network technology, intelligent digital technology, the Internet of things application service platform technology and other modern technology, make comprehensive demonstration platform based on Internet of things, build a base for a demonstration application.

• Buy a way to promote advanced, scientific and forward-looking modern production.

• Promote production coordination by promoting intelligent scheduling and production data tracking through information technology.

• Promoting lean production through information visualization improves the problem solving ability of management process, and achieves the effect of problem prediction and problem prevention. Visualization includes:

• Visualization of production schedule: Tracks production schedule in real time, excavates production bottlenecks and improves delivery control. 

• Production quality visualization: analyze bad problems in production process, sum up the causes, sort out solutions and improve production quality.

• Automatically visualization of abnormal information: Improves the response speed to abnormal situations, ensures smooth production process, and improves production efficiency. 

• Invest in an information-based process, which allows production scheduling and process to be highly automated, to standardized and simplify production processes.

• According to the principle, the system reduces labor costs and improves device coordination through information and intelligent.

• According to the Internet of Things technology, equipment data is automatically collected, and equipment data and production data are automatically reported to work.

• Lent provides a variety of statistical analyses to provide decision-makers with sufficient data to base their decisions on.

Solution

Different from process manufacturing enterprises, the capacity and quality of discrete manufacturing enterprises largely depend on management level and reasonable allocation of production resources. In the face of these challenges, discrete manufacturing enterprises need to advance to high-end products and services if they want to achieve the improvement of enterprise benefits. On the one hand, enterprises need to provide more value-added services in the value chain and carry out innovation; On the other hand, it is necessary to improve the internal operation efficiency of enterprises through information and lean means to achieve cost reduction and efficiency increase.

1. Production planning and scheduling

 ERP integration

Because the enterprise has multiple management systems, including ERP and PDM. Some functions of MES are overlapped with some functions of ERP. In order to avoid repetitive work of employees, MES system needs to be integrated with ERP system. In terms of production planning, MES system needs to read the production master plan and delivery date information of ERP system, and then MES system performs detailed task decomposition according to the master plan obtained from ERP.

Production task decomposition

The main function of this module is to further decompose the main plan read from ERP, and according to the process route or process standard of the product, decompose the task to the workshop or production line.

Assignment of production tasks

The main function of the module is that the front-line managers of the workshop can perform further detailed decomposition according to the tasks of the workshop or production line under MES system, which can be specific to people, quantity, station, equipment, time, etc.

Assign workers to repair tasks

This module is mainly used to re-assign tasks to the products that are not qualified and need to be repaired in the production process or after inspection, and can send workers to the original production personnel or designate other personnel.

Production task management

You can manage production tasks, such as suspending, restarting, or shutting down tasks. Different tasks in different states have different impacts on the production process.

2. Device data acquisition and management system

 Remotely monitor device status

A single computer can monitor the real-time status of more than 256 machines simultaneously, viewing the status of all machine tools (running, idle, down, shutdown, maintenance, etc.) at any time in the form of electronic screen.

CNC equipment processing information

Real-time information of the current operation of each equipment, the current number of production, but also to further collect the current alarm or fault information, machine tool spindle power, machine tool information, machine tool rate, machine tool coordinate information, machine feed speed and spindle speed.

For high-end machine tools with network cards, more real-time information can be easily obtained: coordinate information, real-time feedback of the tool's coordinate, including absolute coordinates, relative coordinates, residual movement and so on. Machine tool operation information, real-time display of the current state of the machine tool, such as editing state, automatic running state, MDI state, trial running state or online processing state. The spindle speed and feed speed can be fed back in real time. Alarm information, such as alarm number, alarm content, etc.

PLC equipment information collection

For automated production lines or devices with network interfaces, the MDC system directly exchanges data with the PLC of the device over the network to collect the following production data: At the same time, the MDC system can manage the production data with the upper layer to monitor the underlying equipment and make the workshop transparent.

• Working status of production line or equipment (manual, automatic, running or stopping, etc.;

• Operation parameters of production line or equipment;

• Fault and alarm information of production line or equipment;

•  Other relevant production information, such as production quantity, production cycle/beat, times and time of downtime; And so on;

• can form an intuitive graphical interface to provide on-site real-time information for managers; Provide effective help for maintenance engineers to quickly locate and analyze on-site faults and determine solutions;

• can display the key process parameters of the production line or equipment in real time, realize the digital monitoring of the processing process, for the management personnel to analyze the production process parameters;

 

3. Production site management

Viewing Production Tasks

The main function of this module is that it is used for workshop processing personnel to check the production tasks of the day, clarify the work objectives of each processing personnel, check the material ratio, part drawings and process content, arrange logistics personnel to mix and feed materials in time to improve production efficiency.

Employees swipe their cards to view their work tasks and submission progress, and each person can only see their own tasks.

Production schedule submission

The module mainly realizes the real-time submission of production progress, and the processing personnel check their work tasks and submit the work progress through swiping card in the station terminal. It can be submitted multiple times or all at once.

Process graphic view

The employee can check the process text of the product according to the task product at the station terminal, and confirm the latest version by comparing their own version, so as to reduce the product scrap caused by the process description version problem.

Production schedule tracking

The main function of this module is: the manager or the planning department can know the progress of the current production order in real time in the office PC, which process the order is in, how much it is produced, qualified rate, scrap rate and so on. It can also see whether the current order is delayed, providing data for managers to arrange follow-up production and judge product delivery date.

4. Exception Management

When there is a problem in the workshop site, the staff often cannot find the person to deal with the problem or do not know which department to turn to to deal with the problem, which leads to the production delay.

The module is based on without exception types to set in advance of call process, when the exception occurs, the system will automatically by SMS, E-mail or inform the relevant departments or screen way to someone when untreated or unresolved within the given time will report step by step, improve the response speed and the efficiency of solution to solve the problem.

5. Quality management

After the completion of key process production, conduct process inspection as required, submit quality inspection data according to the task, and submit the treatment method of unqualified products, such as repair, scrap, etc.

6 .screen management

This screen mainly provides the progress of all the current production tasks for the planning team, so that the planning team can know the progress of each production task in real time without going to the workshop, and regulate the workshop production according to the progress information.