Digital factory solutions for automotive industry

Current problems in the car manufacturing industry

(1) Production level

• It is difficult to make production plan and serious phenomenon of shutdown and waiting for materials.

• The production cycle is long, the production process is complex, and the on-site production management is difficult.

• It is difficult to manage the intermediate process from raw material input to final process output.

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

• Production data collection is not timely, unable to control the production status in real time.

(2) Storage level

• Warehouse materials are multifarious and numerous, so real-time and accurate warehouse data cannot be mastered.

• Warehouse location management is not clear, the warehouse administrator needs a lot of time to confirm the location of materials.

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

• Unable to track the real-time status and quantity of incoming and outgoing materials in the warehouse.

(3) Equipment level

• Existing equipment automation degree is not high.

• The equipment is at war with each other, without interconnection, production scheduling can not be unified control.

• Lack of equipment file management, can not automatically form equipment failure warning, maintenance reminder and other information.

• Lack of device and human interaction ability, unable to make full use of device resources.

(4) Management level

• The management process still adopts the original form transfer method, the management cycle is long, and uses a lot of manpower.

• Lack of production process control nodes, resulting in the production process can not be planned link by link implementation.

• Employee appraisal lacks scientific data basis.

Planning direction

Stamping: mass production (reduce mold change, improve equipment utilization)

Welding: assembly line (to ensure coating production and reduce model change)

Coating: assembly line (ensure final assembly queue, reduce color change)

Final assembly: assembly line (to ensure delivery time and balanced production)

• Flexible manufacturing: to achieve a variety of models, a variety of configurations at the same time production scheduling and mixed line production, maximize the enterprise's flexible manufacturing capacity.

• High production efficiency: reduce line outage caused by improper operation, provide basis for continuous improvement for related management personnel, and increase daily output of single shift based on original personnel and equipment.

• Lean production: Batch, lead, build and SPS distribution modes are realized through BOM and synchronous calculation, so that the logistics system of each workshop runs more smoothly and reduces the risk of material shortage and line shutdown.

• High product quality: comprehensive and perfect quality management, including quality monitoring and traceability of parts, WIP, finished product and key parts, as well as quality platform establishment.

• Transparent production: master the implementation of the plan in real time, track the moving position of the body at any time, transfer the information of the body in real time, so as to ensure the accurate assembly of parts of the flexible production unit.

• System integration: break the isolated island of information system, connect ERP, PMC, AVI, ANDON and other information and automation systems, comprehensively manage equipment, improve the return on investment.

Solution

Stamping shop design

MES stamping workshop production management module will be mainly through the coil, sheet metal, stamping homemade pieces of information as well as for ins and outs of the press line of production information and quality information to record, and when, accurate summary and analysis on the various data within the workshop, so as to improve the level of workshop visualization, provide objective and reliable basis for managers production decision.

• Plan breakdown and analysis

• Costing Coil inventory management

• Buying sheet stock management

• Input production information on the production line

• Input quality information on production line

• Management of self-built parts inventory

• Virtual Gateway Manages sheet metal manual repair

• Quality Problem library and quality picture maintenance

• Cost Analysis of device Efficiency (OEE/MTTR etc.)

Welding workshop design

For the actual production business process of welding workshop, MES function covers the whole process from production plan preparation, delivery, to execution, tracking and statistical analysis, and at the same time. Through the integration of MES and AVI system, as well as the recording of quality and material data in the production process, managers can always have insight into various business activities in the workshop and provide a strong guarantee for the continuous improvement of production.

• Check welding of front floor of engine room

• Maintenance and printing of production instruction tickets

• Gate area line construction material single printing

• Costing a first and final quality check

• Log and query defective products

• Buy quality data entry and analysis reports

• Queue Queries the production queue

• Static Route control WBS

• Fixed production monitoring

• Mechanism Analysis of device efficiency

Painting workshop design

For coating workshop actual production business process. MES functions cover planning management, quality management, system integration, job instructions, statistical reports, abnormal situation processing, etc. Through the integration with AVI system, the vehicle queue from WBS to completion of painting can be understood in real time, so that coating managers can have insight into various business activities in the workshop at any time, and help improve production efficiency and product quality.

• Arrange production plans

• Functions To trace production information

• Buying quality information input and analysis

• Maintenance and printing of production instruction tickets

• Fault Management of a vehicle is abnormal

• Fixed production monitoring

• Mechanism Analysis of device efficiency

• Car body tracking and routing control

• Purchase Painting work-in-process query

• Buy a WBS/PBS vehicle query

Final assembly shop design

In view of the actual production business process of the assembly workshop, MES functions cover planning and issuing, operation instructions, car body tracking, quality management, statistical reports, abnormal situation processing, etc. Meanwhile, IT is integrated with AVI system to master the real-time information of PBS vehicle queue and realize system integration with various types of automation equipment. So that the final assembly staff can always understand the business activities in the workshop, improve assembly efficiency and quality.

• Management of production plans

• Queue Job instruction ticket, bar code printing

• Queue information release (synchronous production)

• Assembly fault prevention and key component traceability

• Input and analysis of auto body quality information

• Virtual Gateway Abnormal vehicle information is displayed

• Fixed production monitoring

• Mechanism Analysis of device efficiency

• Lent Car body tracking

• Spends time analyzing reports