Digital transformation has become the only way for manufacturing enterprises to enhance their competitiveness and achieve sustainable development. As the core carrier of digital transformation, smart factories integrate advanced information technology, automation technology, data analysis technology, etc., to achieve intelligent, efficient and flexible production processes. This solution aims to provide enterprises with a comprehensive guide for smart factory planning and MES (Manufacturing Execution System) project construction and implementation.
For more reference, the public account: Preferential Think Tank
First, the three goals of intelligent manufacturing in manufacturing enterprises
Realizing the overall goal of "three modernizations" of intelligent manufacturing, that is, flexibility, platformization and transparency, is the key direction of manufacturing transformation and upgrading.
- Flexibility:
Background and challenges: As the demand for personalized customization becomes more and more prominent, multi-variety, small batch, and short delivery time have caused great difficulties to production management. Therefore, flexible production has become an important means to meet these challenges.
Definition: Flexible production refers to the ability of the production line to adapt to the production needs of a variety of products, to achieve rapid switching and flexible adjustment.
Implementation method: build a flexible and automated production line, including processing unit, storage system, handling system, fixture management and other parts. Realize customized production, and meet individual needs through measures such as mass customization and flexible production. Adopt a progressive smart factory construction route, starting from single-point automation, gradually promote integration and digital transformation, and finally achieve intelligent improvement.
- Platformization:
Definition: Platformization refers to the construction of a unified, open and scalable intelligent manufacturing platform, integrating various resources and data, and realizing information sharing and collaborative manufacturing.
Advantages: The platform can improve production efficiency and product quality, reduce energy consumption and raw material utilization, and optimize production processes and resource allocation.
Implementation method: build a unified digital management platform to realize the unified management of equipment, personnel, materials and other resources. Through cloud computing, big data and other technical means, real-time data collection, analysis and processing are realized. Strengthen cooperation with other enterprises and suppliers, build a collaborative manufacturing network, and achieve resource sharing and mutual benefit and win-win results.
- Vitrification:
Definition: Transparency refers to the visualization and transparency of the manufacturing process through digital management, so that every link in the production process is clearly visible.
Advantages: Transparency can improve the controllability and traceability of the production process, reduce production costs and risks, and improve product quality and customer satisfaction.
Implementation method: Adopt digital middle platform, equipment OEE and other technical means to realize real-time monitoring and data collection of the manufacturing process. Apply digital twin technology to build a digital model of the plant to support decision-making and optimize production processes. Through the application of industrial machine vision technology, behavior monitoring and alarm, etc., the safety and stability of the production process are improved.
Second, the construction of digital factories based on intelligent manufacturing
The digital factory based on intelligent manufacturing realizes seamless information interconnection by integrating multiple systems such as PLM (Product Life Cycle Management System), NX (Full 3D Digital Design and Analysis), ERP (Enterprise Resource Planning), MES (Manufacturing Execution System), TIA (Totally Integrated Automation) and WMS (Warehouse Management System), so as to build a transparent digital factory environment. Here's a detailed explanation of how these systems work together to enable the digital factory:
1. PLM (Product Life Cycle Management System)
Function: The PLM system centrally manages various data of the product, including design drawings, process documents, BOM (bill of materials), etc., to ensure the accuracy, consistency and completeness of the data.
Purpose: Provide a reliable data foundation for the digital factory and support the collaborative work of product design, process planning, production execution and other links.
2. NX (Full 3D Digital Design & Analysis)
Functionality: NX provides full 3D digital design and analysis tools to support the design and optimization of complex products.
Function: Carry out product design, analysis, simulation and verification through 3D models, reduce the production and testing of physical prototypes, and improve design efficiency and quality.
3. ERP (Enterprise Resource Planning)
Function: ERP system to manage the core business of the enterprise, such as finance, human resources, material management, production planning, etc.
Function: Provide comprehensive enterprise resource management functions for digital factories to ensure the rational allocation and optimal utilization of resources and reduce production costs.
4. MES (Manufacturing Execution System)
Function: The MES system monitors and manages the execution process of the production line, including production planning and scheduling, material tracking, equipment monitoring, etc.
Function: Obtain various data from the production site in real time, provide decision support for the manufacturing process, and realize the optimization and control of the production process.
5. TIA (Totally Integrated Automation)
Function: The TIA system realizes the full integration and automatic control of production equipment, including equipment monitoring, fault warning, remote control, etc.
Function: Through the TIA system, the digital factory can realize real-time monitoring and intelligent control of production equipment, and improve production efficiency and equipment utilization.
6. WMS (Warehouse Management System)
Function: WMS system manages material storage, warehousing, inventory and other operations in the warehouse.
Function: Through the WMS system, the digital factory can realize the effective management and traceability of materials, and ensure the accuracy and timeliness of material information.
In the digital factory, these systems work together through seamless information interconnection to create a transparent digital factory environment. This environment has the following characteristics:
Real-time: Through data collection and analysis technology, various data from the production site can be obtained in real time to support decision-making.
Visualization: Through 3D models, virtual reality and other technical means, the situation of the production site is displayed in an intuitive way, which is convenient for management and monitoring.
Traceability: Through PLM, WMS and other systems, the traceability and management of the whole life cycle of products are realized to ensure product quality and traceability.
Intelligent: Analyze and predict production data through artificial intelligence technology, data mining and other methods to help enterprises make decisions and improve production efficiency.
3. Construction and implementation plan of MES project of smart factory
With the rapid development of Industry 4.0 and intelligent manufacturing, MES (Manufacturing Execution System), as one of the core systems of smart factories, plays a key role in optimizing production management and improving manufacturing efficiency.
The MES project aims to realize the digitalization, networking and intelligence of the production process, and realize the real-time collection, analysis and processing of production data through the integration of various information systems and automation equipment, so as to provide strong support for production decision-making.
1. Production management
Production management is one of the core functions of the MES system, which realizes the visualization and optimization of the production process through production planning, scheduling, tracking and other functions. The system supports a variety of production modes, such as order production, predictive production, etc., and can be flexibly adjusted according to the actual production situation.
2. Material management
The material management module includes functions such as raw material warehousing, inventory management, and outbound distribution. By grasping material information in real time, we can optimize material flow, reduce inventory costs, and improve material utilization. At the same time, the system supports material traceability to ensure that the quality of materials is controllable.
3. Device management
The equipment management module realizes real-time monitoring, predictive maintenance and fault warning of production equipment by integrating equipment information, operation data and maintenance plans. Through equipment efficiency analysis, improve equipment utilization and reduce maintenance costs.
4. Quality management and quality management
The quality management module covers quality inspection, quality control, quality traceability and other functions. Through real-time collection and analysis of quality data, real-time monitoring and early warning of product quality can be realized. At the same time, the system supports quality traceability to ensure that product quality problems can be traced and solved.
5. Exception Management
The exception management module automatically identifies and handles abnormal events, such as equipment failures, production delays, etc., by monitoring the production process in real time. The system supports automatic alarm and rapid response to abnormal events to ensure the stability and continuity of the production process.
6. KPI metrics
The KPI indicator module is used to set and monitor key performance indicators (KPIs) in the production process, such as production efficiency, pass rate, equipment utilization, etc. Through real-time data collection and analysis, it provides decision-making support to management and promotes continuous improvement of the production process.
7. Production reports
The production report module automatically generates various production reports according to the set report template, such as production plan execution table, equipment efficiency table, quality statistics table, etc. These reports can help management quickly understand the production status and guide production decisions.
8. Production Kanban
The production kanban is an important display window of the MES system, which displays the real-time data and information of the production site through graphics, such as production progress, equipment status, quality status, etc. The production kanban can update the data in real time, providing intuitive and convenient monitoring and management means for the production site.
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