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Company Profile
GCL Solar is located in the beautiful Suzhou Industrial Park. It is the world's leading manufacturer of photovoltaic materials. Its silicon wafer products account for 70% of the domestic circulating silicon wafers, and it is in the leading position in the domestic industry. It is also at a relatively high level in terms of technology development, quality control, and automation upgrades. The corporate style is down-to-earth and humble. How to improve efficiency and improve product quality is always our responsibility. Through years of optimization of the production process, our company's production efficiency and product quality have always maintained industry leading, however, we gradually feel that with traditional methods, the optimization space is getting smaller and smaller. For our company, it is undoubtedly a huge problem how to improve the last mile of production quality. The general manager of our company's Suzhou branch once said: "The future breakthrough of Suzhou GCL will still depend on new technologies and new products."
Project Background
The rise of intelligent manufacturing has introduced big data analysis to the manufacturing revolution. By collecting and uploading production data to the cloud, real-time and long-term analysis of the data, you can monitor the production process and analyze the optimizable parts of the production process; monitor the links that affect product quality, and quantify and improve product quality Forecast equipment conditions and optimize spare parts.
Big data analysis provides a path for the last mile of production quality improvement, which allows us to see new opportunities. In 2016, our company officially cooperated with Alibaba Cloud, hoping to promote internal management upgrades through new generation information technologies such as cloud computing and big data 3. Further improve market competitiveness. The main objectives of this cooperation are transparent production, data management and yield improvement. Including:
low-cost long-term preservation GCL production process all the data
through big data analysis, yield prediction model
through big data analysis, monitoring key parameters of the model, the production process monitoring and alarm
by Ali cloud BI system for our company Multi-dimensional statistical analysis of data
Through Alibaba Cloud large-screen technology, the establishment of workshops and business departments to produce large-screen kanban and other aspects.
For example, in the production process of photovoltaic slicing, there are thousands of production parameters that affect the yield of slicing, such as mortar temperature and mortar density. Any small change in any variable will directly affect the production results. And through Alibaba Cloud's big data analysis algorithm, we can analyze all the variables collected in our company's production process and find out the most important key variables that are most relevant to the yield rate. Based on these key variables, we build a production parameter monitoring model for our company, and analyze and process these variables during the production process. Once the variables exceed the scope of the model, our company's monitoring system will promptly warn. After the implementation of the first phase of the project, tens of millions of annual cost savings have been achieved, and the small target is not far away.
solution
Data clouding guarantee:
15 days of single-shop full data batch clouding; quasi-real-time clouding of slicer, sorter, and MES data in the whole workshop
Key parameter monitoring model:
Through big data analysis of full parameters and production experience, the key parameters to be analyzed are proposed, and the monitoring model is established.
Production process monitoring and alarming:
Streaming uploading of production process data, real-time monitoring through streaming calculations. And based on the monitoring model, to achieve abnormal alarm.
Yield rate prediction:
Multivariate statistical analysis is performed on important parameters that affect the yield, to achieve yield rate prediction.
Spare parts wear analysis:
Through association rules, cluster analysis, deep learning and other methods, monitor relevant parameters to achieve early warning of spare parts wear.
Large-screen kanban design:
Implement large-screen kanbans at the level of each workshop and business division.
BI analysis:
Multi-dimensional statistical analysis of 30 topics, and supports custom time, parameters, and analysis of mathematical correlation between parameters.
The value of the cloud
with the overall Chinese manufacturing industry to conservation of the extensive, fine transition, many industries are shifted from labor-intensive to capital-intensive technology, new technologies, especially the big data analysis techniques, the manufacturing sector reform became support The backbone. As a representative of manufacturing companies pursuing excellence, our company has explored a path for the transformation and upgrading of similar companies. Big data is an important asset of an enterprise. With the help of new technologies such as cloud computing, it can realize the intelligent transformation and upgrade of the enterprise and complete the last mile to improve production efficiency and product quality.
For enterprises that have the ability to obtain factory data, they can continue to focus on manufacturing itself, and find big cloud analysis and other big data analysis companies to undertake such tasks as big data analysis. The mode of cooperation between our company and Alibaba Cloud can be directly copied, using the production experience of manufacturing companies, and cloud computing and big data analysis to provide enterprises with stable and efficient big data storage and analysis capabilities to create an enterprise-level data analysis platform. Pursuing excellence and surpassing self, China's manufacturing industry has opened a brand new chapter driven by the Internet and new technologies.
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