1Smart factory design ideas
1.1 Smart factory construction goals
In order to actively respond to the country’s five development concepts of “innovation, coordination, green, openness, and sharing”, implement the “Made in China 2025” and the “Steel Industry Adjustment and Upgrade Plan”
(2016-2020)”, “Guiding Opinions of the State Council on Actively Promoting the “Internet +” Action” and the relevant policy requirements, combined with the current situation, production status and existing problems faced by steel enterprises themselves, as well as the needs for future development plans. Its technological process, green environmental protection, intelligent manufacturing and other aspects have been fully optimized and upgraded, and the company has become a domestic first-class, green and intelligent production base, realizing the double improvement of quality and efficiency.
After the enterprise builds a smart factory, the entire production line from raw materials to finished products realizes centralized scheduling control, intelligent flat management, simple and efficient production organization, comprehensive and stable energy consumption and pollutant discharge standards, and greatly improved product quality stability and reliability. , The cost per ton of steel in the whole process is reduced, which improves the company’s competitiveness. The goals of smart factory construction are as follows:
(1) Through enterprise informatization, introduce advanced management models to realize modern enterprise management.
(2) To achieve a highly standardized and scientific management process based on a streamlined and efficient business structure, guided by a rational and smooth management process, and based on standardized and advanced management standards.
(3) Realize refined management, standardized operation, and just-in-time production, realize real-time, observable and controllable dynamics of the whole process of production and operation activities, improve the enterprise's responsiveness and adaptability, and comprehensively improve the overall comprehensive market competitiveness of the enterprise.
(4) Through the improvement of the enterprise information system, gradually establish a "digital smart factory" that integrates the two technologies.
1.2 Overall design concept of smart factory
Based on the construction concept of "green and smart", in accordance with the construction ideas and goals of the "Guidelines for the Construction of National Intelligent Manufacturing Standard System", while drawing on the construction ideas of Germany's "Industry 4.0" and the United States' "Smart Manufacturing Ecosystem" Informatization overall planning.
The intelligent manufacturing system adopts the overall design concept of "one center, one map, one platform".
Figure 1 -Architecture diagram of intelligent manufacturing system for iron and steel enterprises
A center: refers to the basic support platform that provides enterprise information and intelligent systems, including enterprise management and control centers, cloud data centers, and network centers.
The management and control center realizes the intelligent scheduling and management of the main production and operation business of the enterprise. With the large monitoring screen of the management and control center and the intelligent information system as the carrier, it realizes the flat and centralized business of various businesses such as enterprise production, energy, equipment, and logistics. Company-level control.
The cloud data center will make full use of cloud technology and virtualization technology to realize the hardware support for the intelligent factory information system, and provide the server resources required by each intelligent information system.
The network center will realize the unified management of all the company's intelligent system networks, and ensure the interconnection, safety and reliability of the company's overall information network and the Internet of Things.
The above three centers (control center, cloud center, network center) will eventually be merged into one center in the company-level control center building. This center will serve as the core brain of the company’s daily production and operation. The company’s management and control personnel will Here we coordinate and manage the daily production and operation information of the entire company.
Figure 2 -Smart Factory Dispatching Monitoring Center
A map: It is the foundation of the entire intelligent manufacturing system framework. It fully combines the three-dimensional BIM technology to establish a three-dimensional digital factory map with the same scale as the actual factory, focusing on the plant building information, equipment information, pipe network information, etc., to build the final Lay the foundation for a digital operation management and control platform.
The 3D digital factory map starts from the planning stage of the enterprise and runs through the entire life cycle of planning, design, construction, completion and delivery, operation and maintenance, and realizes digital full life cycle management.
A map cooperates with the digital factory management system to realize dynamic full-process operation management and control, intelligent equipment operation and maintenance management, etc., effectively improving the efficiency of enterprise management and scheduling. Realize the comprehensive digital management of iron and steel enterprises through a map, including factory digitalization, workshop digitalization, equipment and pipeline digitalization. By creating the same virtual factory as the actual factory, the three-dimensional comprehensive display of the whole life cycle of the factory and the whole process production control are realized. , Intelligent equipment operation and maintenance management, intelligent pipe network safety monitoring management, immersive operation training and assessment management, and emergency drill simulation management. Innovatively improve the traditional working methods of steel enterprises, establish new concepts of asset management, effectively optimize the operation management system, and improve the efficiency of accident handling.
Figure 3 -Smart Factory Operation Management Platform
One platform: the establishment of a centralized digital operation and control platform for company-level production, energy, logistics, equipment and other major businesses, which integrates the data information of the enterprise's information system at all levels, and uses a three-dimensional digital factory map as the basis for company-level management Kanban provides management information at all levels of the company's key production indicators and is the core of the operation and management of smart factories.
The digital platform will serve as the company's all-round operational data source, integrating and extracting business data from operations, production, energy, equipment, logistics and other business data, and providing all-round data support for building the company's big data management and analysis system.
Figure 3 -Smart factory operation management and control platform
1.3 Smart factory system architecture
Based on the principles of "intelligent manufacturing, big data, Internet+" and "centralized, simple, direct, continuous, smooth, and efficient", a stable and reliable equipment control system and high-level Automated process control system, continuous and efficient lean production system, centralized and unified ERP system, scientific and rigorous decision support system, and collaborative network office system to achieve an integrated planning system for supply, production and marketing, an integrated execution system for supply, production and marketing, Supply, production and marketing integrated tracking system, supply, production and marketing integrated balance system, interactive and quick win-win marketing system, sincere and win-win enterprising service system, dynamic, efficient and transparent monitoring system, scientific and precise decision-making system.
(1) Key points of the company's management model
1) Efficient composite management and control mode that adapts to group operation management and control.
2) The company implements a centralized management and control model for core business units.
3) The core business unit is set up according to the three-level management structure of "company-professional factory-operation area" to implement management.
4) The company is the production and operation control center; each professional factory is the cost center, which is mainly responsible for the implementation of the production plan, while ensuring the realization of various technical and economic indicators such as variety, output, quality, cost, safety, and equipment operation.
5) Build an information system that develops simultaneously with the enterprise. Through the construction of an information system covering all fields of the company, while the company's management mode in all fields is promoted, the company's information system is implemented as a supporting tool to provide effective support for the company's modern management.
(2) The overall architecture of the intelligent factory system The functions of the intelligent factory management system are divided into:
Level 5 Business Intelligence System (L5);
Level 4 Enterprise Resource Planning System (L4);
The third level production management system (L3);
The second level is the process control system (L2);
The first level is the basic automation system (L1).
Figure 3-1 The overall functional architecture diagram of the smart factory system
The fifth layer is the business decision-making layer , which is mainly the enterprise decision support system. It uses information technology to extract important data on corporate procurement, sales, and production and operation to provide support for corporate decision-makers;
The fourth layer is the enterprise resource management layer , aiming at the management of the company’s business level, including the company’s ERP, office automation OA, e-commerce platform, etc., to achieve information processing on R&D, technology, finance, cost, personnel, assets, and customers; in modern Under the guidance of enterprise management theory, advanced management concepts and methods are solidified through information systems to systematically and efficiently integrate and manage the internal and external supply chains of the enterprise.
The third layer is the intelligent manufacturing layer , which is mainly responsible for the entire manufacturing execution process of the company’s various business production units, from the factory accepting product orders to the product warehousing management of the entire production process. The focus is on production management, which is between enterprise informatization and process automation. The core connection layer.
The second layer is the process control layer , which is the key to connect the production management layer and the basic automation layer
The control layer mainly realizes the functions of plan management, tracking and data collection, set value calculation, shutdown management and quality management, and is an effective means of unit control.
The first layer is the basic automation layer , which is the control layer directly facing the equipment. It mainly completes the set value setting of each unit, various parameter control, data acquisition, quality control and equipment diagnosis systems. It can be independently produced and is the production process Important link in the
4 Application system functions
4.1.2 Enterprise Cooperative Office (OA) System
The collaborative office system realizes the information processing of official documents, personnel, assets, customers, etc. on a unified enterprise information platform, completely eliminating the problems of information expansion, information islands, unstructured information, and non-individualized information that exist within the enterprise. The collaborative office system provides a collaborative and integrated office environment, so that all office staff are in the same and personalized letter
Work in the information portal, get rid of time and geographical constraints, and realize collaborative work and knowledge management. The main function:
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- Enterprise internal portal;
- Send and receive documents;
- Meeting management
- knowledge base;
- Work flow management;
- Instant messaging.
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Collaborative management proposes effective solutions to the three island problems of information, business and resources with "information synergy", "business synergy" and "resource synergy".
4.1.1 Decision Support System (DSS)
The implementation goal of the decision support system is to set the management performance goals that the company should strive for and the core goals of each branch. At the same time, it provides an evaluation basis for the achievement of the company's goals, and reports the performance to the management and shareholders. By combining company strategy and company actions, it provides support for company value-oriented management; establishes a performance management mechanism that combines financial and non-financial indicators.
DSS aggregates the data of the enterprise's ERP system and multiple business transaction systems, provides a shared view across the entire enterprise, integrates the financial and performance management processes, and makes individual goals or departmental goals consistent with the goals of the entire company.
The main function:
• Performance scorecard system;
• Strategic financial system;
• Business intelligence system.
4.3 Intelligent Manufacturing-Production Management System
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4.3.1 System Features
The intelligent manufacturing system closely links sales and production links. It is driven by sales contracts, with production orders as the main line, product specifications and metallurgical specifications as the core, and forms the information of order entry-plan-on-site execution-feedback-adjustment of the whole process Loop, implement the production and sales plan to the on-site execution, and grasp accurate and timely information for real-time adjustment and optimization to maximize production capacity and efficiency. The system has the following characteristics:
(1) Establish a unified code system
(2) Establish product specification and metallurgical specification system to realize design and production according to contract
(3) Real-time dynamic order tracking
(4) Achieve a balance between supply and demand in steel production
(5) Realize the first-level plan management of the whole process
(6) Realize the real-time dynamic scheduling system for the integration of rolling
(7) Realize the integration of supervision, management and control
(8) Realize the whole process quality management
(9) Collection of financial cost information
4.3.2 Business Process
(1) Production management business process
The main business of production management is: starting from the company’s acceptance of sales orders, including raw and fuel management, production control, production contract management, material application, production operation planning, production process control and adjustment, work-in-process inventory management, production performance collection and sorting, The warehousing management involved in production logistics until the product is released to the factory.
The general diagram of the production management process is as follows:
Figure 4-1 Production management flow chart
• Raw material management;
• Production operation plan management;
• Production contract management;
• Work in progress management;
• Production control;
• On-site operation management.
(2) Quality management business process
Quality management refers to the quality management activities that start from meeting user needs and focus on a series of processes such as design, production, service, and relationships with customers and suppliers.
The overall quality management process diagram is as follows:
Figure 4-2 Quality management flow chart
Quality control management consists of the following management services:
• Order quality design;
• Quality inspection;
• Process quality control;
• Quality judgment;
• Product manufacturing history management;
• Product quality certificate management;
• User quality objection management;
• Quality level management.
Quality system management consists of the following management services:
• Quality policy objectives;
• Product supply standard management;
• Procedure system management;
• Process audit;
• product check;
• Quality meetings;
• Quality management;
• Correction and prevention of product quality objections;
• Internal user satisfaction survey and evaluation. 4.3.3 System function
(1) Integrated quality management
• Quality standard management;
• Quality design management;
• Quality tracking management;
• Quality judgment management;
• Quality certificate;
• Quality statistics management;
• Quality analysis management.
(2) Pre-iron production management system
• Pre-iron production plan management;
• Adjustment and release of the pre-iron production plan;
• Quality tracking management;
• Raw material yard management;
• Whole plant operation management.
(3) Post-steel production management system
• Order management;
• Production planning management;
• Production control;
• Production order process management;
• Quality tracking management;
• Job management;
• Equipment status management;
• Roller room management;
• Tools and equipment management;
• Production operation statistics;
• Production cost management.
(4) Warehouse management
Warehouse management includes:
Raw and auxiliary materials, scrap steel warehouse management, billet warehouse management, finishing semi-finished products, finished product warehouse management. Including warehousing, warehouse related operations, material location, and related inventory statistics.
4.4 Intelligent Manufacturing-Professional Management System
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4.4.1 Intelligent 3D Factory
The system integrates three-dimensional BIM technology and GIS dynamic positioning technology to realize dynamic management and monitoring of energy, equipment, meters, and pipelines on the three-dimensional factory model. Users can use the system to achieve transparent management of corporate assets, efficient management of operation and maintenance, and drawings Data accuracy
Management, intelligent point inspection management of intelligent equipment and calibration instruments.
Users can monitor the energy consumption changes of energy-consuming equipment and energy-using units in real-time on the three-dimensional model; they can quickly locate equipment and meters by entering related equipment and meter numbers, so that maintenance personnel can quickly find the installation location of equipment. When the pipeline fails, the system can quickly locate the upstream instruments and valves, and prompt for shutdown.
The system can import equipment related documents, drawings and three-dimensional monomer models, combined with equipment operating parameter curve changes and point inspection and repair performance to realize the full life cycle management of equipment. For complex equipment, the system can integrate equipment animation to facilitate later Equipment overhaul and maintenance work.
(1) Energy monitoring
Based on the 3D scene, the model realizes a 360-degree self-rotation, and the basic properties and current working status of the object in the current perspective are displayed in the form of labels. The energy monitoring data of important parts can be dynamically tracked through the statistical graph display to dynamically track the energy trend and amplitude of the place. At the same time, you can view information such as different pipe manufacturing materials and media flow directions.
(2) Three-dimensional equipment model
View the 3D models of important energy-using equipment, visually display the appearance of the model, the names and functions of different parts, the operating parameter standards of the integrated equipment and the actual operating parameter change monitoring;
(3) Equipment installation
Based on the equipment model, you can control equipment disassembly and installation animation playback through buttons to help equipment maintenance personnel understand the equipment disassembly and installation steps.
(4) Equipment positioning
You can check the device number, device name, and device type in the 3D scene.
The query conditions locate the current device installation location, and the system locates the target device by switching the scene camera location.
(5) Video surveillance
The real display function of the video surveillance system in the 3D scene. Users can view the video surveillance content of the current location by clicking on the video surveillance model in different positions in the model; when a major accident occurs, it will automatically link with the video and positioning to quickly find the fault point and save accident handling Time, reduce energy waste.
4.4.2 Equipment Management System
The equipment management system is centered on major equipment management work, through spot inspection, patrol inspection, maintenance and warehouse management, standardize the corresponding operation process, improve equipment utilization and reliability to ensure the smooth progress of enterprise production.
The equipment management system establishes a unified equipment catalog of the enterprise, conducts effective analysis of equipment operation records and operating parameters, prevents and discovers hidden dangers of equipment failures in advance, and formulates reasonable inspection and maintenance work plans to ensure the safe operation and reduction of equipment The cost of equipment maintenance.
(1) Equipment technical files
• Equipment basic information management;
• Standard management;
• System and regulation management;
• Drawing file management;
• Periodic inspection equipment management.
(2) Equipment operation monitoring and management
• SCADA operation monitoring;
• data analysis.
(3) Equipment capacity and energy consumption management
• Energy consumption performance management;
• Energy production performance management;
• Outsourcing and export management.
(4) Inspection and management of equipment points
• Inspection plan management;
• Spot inspection performance management;
• Equipment hidden danger management.
(5) Equipment fault management
• Equipment failure management;
• Equipment failure statistics.
(6) Equipment maintenance management
• Maintenance work notification management;
• Maintenance work order management;
• Maintenance quality management;
• Maintenance acceptance management.
(7) Equipment lubrication management
• Lubrication plan management;
• Lubrication performance management;
• Oil recovery management.
(8) Spare parts management
• Plan management
• Warehouse management
• Outbound management
• Inventory management
• Renovation and waste management
(9) Equipment asset management
• Equipment asset depreciation management;
• Equipment evaluation management;
• Equipment storage/unseal management;
• Equipment idle/enable management;
• Equipment transfer management;
• Equipment allocation management;
• Equipment scrap management.
4.4.3 Energy Management
The energy management system targets the entire plant's energy pipeline network, directly dispatching and monitoring the supply and distribution of various energy media throughout the plant; monitoring electricity, water, gas, oxygen, nitrogen, argon, steam, compressed air and other media; monitoring The whole plant's transformation and distribution stations, self-generation, gas mixing stations, gas pressurization stations, various gas tanks and gas emission systems, and remote monitoring of energy stations that allow unattended on-site. An advanced energy management and control platform tailored for enterprises. The product combines advanced design concepts, through the establishment of single process models for iron, steel, rolling, and main public and auxiliary processes, and then dynamic simulation simulations, which can help companies find the problems and bottlenecks in the actual production of energy media in advance, thereby improving Make various emergency plans well to reduce unnecessary waste of energy. Moreover, through the flat remote control platform and rich experience in the implementation of the underlying transformation, it assists the enterprise in the transformation of various energy substations, truly realizes centralized energy management and control, and each station is unattended, which effectively reduces the number of employees and increases the efficiency of the enterprise. Lay the foundation for improving energy management efficiency.
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