Introduction
In the process of digital transformation and construction, the difficulty for machinery manufacturing companies is the design of intelligent workshops. With the development of 5G technology, a large number of smart devices with network interfaces are put into use, making the implementation of smart workshops possible. This article puts forward requirements for the design of workshop MES execution systems from the aspects of workshop production planning and scheduling, process control, equipment management, quality management, energy consumption management and logistics warehousing. At the same time, it also puts forward four precautions for the process of enterprise implementation of MES.
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introduction
With the further development of network information technology, Industry 4.0, Industrial Internet, Internet of Things , big data, cloud computing and artificial intelligence have gained stronger basic support. On this basis, many enterprises have carried out large-scale digital transformation construction. After years of hard work, many companies have successfully completed the initial stage of digital transformation, and advanced management methods such as office assistance systems, enterprise resource information management systems, computer 3D design and 3D printing have become standard equipment. The informatization level of enterprises has been significantly improved.
Digital transformation puts forward all-round requirements for enterprises. Moreover, in some enterprises, although information transformation has been implemented, due to limitations in understanding, level and basic conditions, various information systems often work independently and are not coordinated with each other, resulting in physical isolation of information. , corporate information has not really circulated. The reason is that on the one hand, the foundation of enterprise informatization is not solid enough and there is a lack of interconnected platform systems; on the other hand, some complex processes, such as workshop production management of machinery manufacturing companies, are difficult to describe digitally, and many devices lack information. Interoperable interfaces, etc., coupled with the previous reasons that the network transmission speed was slow and was greatly affected by environmental factors, many machinery manufacturing companies did not dare or were unwilling to do this work.
With the development of information technology, 5G network technology has made a qualitative leap in terms of transmission rate, coverage and depth, signal delay, terminal access volume, etc., and has gradually become a new generation of wireless network technology. This makes the digital construction of manufacturing workshops possible. This article discusses how to establish an intelligent management system for manufacturing workshops in a 5G environment.
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Requirements for enterprise information management platforms To establish intelligent manufacturing workshops, enterprises must first build an enterprise digital management integration platform including product data management system (PLM), enterprise resource planning system (ERP) and office automation system (OA), as shown in the figure 1 shown. Digitization of business management is realized through various business systems and interconnection between various systems is realized.
Use 5G network core equipment and access equipment to build a dedicated 5G communication network to form a full 5G network transmission atmosphere for enterprises, achieve ultra-low latency and ultra-large bandwidth requirements, and build a good network infrastructure environment for more 5G smart manufacturing applications. Construct a 5G private network frequency band to achieve 5G signal guarantee and provide 5G end-to-end connection. In order to ensure the security and reliability of enterprise digital networks, it is best for enterprise 5G networks to provide dual redundant signals to ensure public cloud platform data storage and data security. Only when a strong 5G network environment is established will the construction of smart workshops become easier to achieve.
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Machinery manufacturing enterprises based on 5G environment
Design of smart workshop MES
The core of the construction of smart workshops is to establish a manufacturing execution system (MES) in a 5G environment. Use this system to realize data management such as workshop production planning and scheduling, production process control, equipment management, quality management, warehousing management, energy consumption management and on-site civilized production. At the same time, the system must also be able to integrate data between various modules in the workshop to achieve The workshop's comprehensive data platform and report visualization platform allow data to empower business, realize the improvement of production management visualization to intelligent decision-making, promote the comprehensive upgrade of smart workshops, and enhance the comprehensive competitiveness of enterprises. Based on this, the MES execution system framework for the intelligent workshop of a machinery manufacturing enterprise is designed, as shown in Figure 2.
3.1 Workshop production plan management
Through the interconnection between MES and ERP, the scheduling of intelligent workshop production plans is realized. MES interprets the production management plan MRP in the ERP system and turns it into the workshop production plan. The master production plan in the ERP system is relatively extensive and cannot effectively guide the specific production of the workshop. However, the MES must be able to quickly prepare the main production plan according to the product processing process and product assembly BOM in the PLM system after receiving instructions from the ERP system. Technical documents such as workshop production requirements are converted into digital instructions that can be executed by the workshop. At the same time, MES accurately transmits the production plan to processing personnel and processing stations based on the production capacity of workshop personnel, intelligent equipment, and the work rhythm of the assembly line. Logistics, processing, parts processing progress, product assembly and warehousing and other information enter MES through 5G+ related equipment. At the same time, processing quality information data is synchronized into MES through 5G+ testing equipment, realizing the transition from ERP master production plan to MES . Comprehensive docking and two-way transmission of planning and scheduling, and ultimately the integration of MES and ERP. Through integration, enterprises can realize the circulation of workshop processing data throughout the system, ensure the traceability and application of information, and realize digital and visual progress management of enterprises.
3.2 Workshop production process control and management
MES runs through the entire process of production and manufacturing. Through MES, a traceability system for important parts is established. Specific equipment such as laser engraving machines are used to mark QR Codes on defined parts to trace raw material batches, processing work orders, manufacturers and processing Personnel etc. Intelligent devices are interconnected, and various processing parameters, part measurement data and alarm information of machine tool operation are collected through various sensor technologies, data acquisition cards, etc., and the data are fed back to MES and PMC. Workshop managers can understand the processing status in real time and analyze the OEE value of machine tools through the equipment interconnection page. In the event of an alarm, the system can send a message to prompt relevant personnel to handle it.
In process control, the workshop collects equipment and producer processing information through PLC data collection, producer input, etc. and inputs it into MES.
3.3 Workshop intelligent equipment management
5G+ equipment interconnection is used to achieve comprehensive awareness of equipment status, efficient information processing, and flexible production in the workshop. 5G network collection is performed on various smart devices (as shown in Figure 3), production lines, etc., based on the relevant buses and network interfaces, and converted into 5G signals through 5G modules, and then through the 5G dedicated line network, the collected device data is Upload in real time, and then respond and process in real time through edge computing MEC mobile. Improved real-time collection capabilities of industrial data.
Through real-time monitoring of equipment operating status, operating efficiency monitoring, equipment failure anomaly management, and equipment maintenance early warning management, we can reduce unplanned downtime caused by equipment downtime, improve equipment utilization efficiency, and extend equipment service life. At the same time, we control the outflow of defective products caused by equipment failure during the production process. Monitor equipment faults during the production process and set fault warning values, predict equipment faults in advance and monitor them in real time, shorten fault processing time, and ensure safe production.
3.4 Workshop quality management Design quality control system QMS to control workshop processing quality. According to the BOM list, the parts are identified with entity codes or batch codes. Workshop quality inspectors can obtain quality inspection data such as parts inspection, process inspection, incoming material inspection, finished product inspection and sampling inspection in QMS through 5G+IP AD, compare basic data and standards, and realize incoming material quality management and process quality management . , finished product quality management, processing of non-conforming products, and functions such as reports and signboards. At the same time, intelligent testing equipment can also detect the processing process and feed back qualified/unqualified data information to QMS through MES, thereby achieving effective control of workshop processing quality. For the management of factory products, smart signage can be realized through the relevant industrial IoT code identification system. Customers can query the key process information, material information, process information, equipment debugging records and other information of the production products through the relevant system.
3.5 The logistics warehousing management workshop organizes production according to the rhythmic production concept, the process planning is subdivided into each work station, and the relevant attributes of the materials are written into the product MBOM and process route. AGV smart cars are connected to 5G or WiFi and are used for finished product warehouses, raw material warehouses, workshop assembly line transportation, inspection line transportation and coating line transportation to realize the automation of raw material warehousing, product assembly and packaging, warehousing and other circulation, and realize warehouse logistics optimization. Establish automated warehouses (including raw material warehouses and finished product warehouses) and intelligent warehousing system WMS. Through WMS, the warehouse is managed for all locations and a digital location model is established. The distribution of materials and inventory levels are clear at a glance. According to the BOM list, materials are scanned into the material library through 5G+IPAD, and the material data is synchronized to WMS. WMS analyzes information such as commonly used materials and sluggish products based on the incoming and outgoing materials. On the basis of material usage frequency data, the warehousing principle of WMS is flexibly set to ensure that the storage location of commonly used materials is as close to the warehouse exit as possible, reducing logistics journeys and improving warehousing efficiency. Through WMS, time-sensitive materials are managed according to the outbound strategy of "first in, first out" and "first in, first out". By setting reasonable safety inventory, procurement cycle and other attributes for each material, the information flow is transformed into logistics, minimizing the purchase volume and achieving the minimum inventory, and improving economic benefits.
3.6 Workshop energy consumption management Design the production energy management module to implement data collection from metering instruments such as smart meters, natural gas flow meters, tap water and compressed air flow meters, and automatically count energy consumption at multiple management levels such as workshops, production lines and intelligent equipment. Statistics of energy consumption are based on time dimensions such as year, month, week and shift; combined with input modules such as output and output value, unit consumption measurement at each management level and time dimension is achieved. Monitor the three-phase current , three-phase voltage, three-phase power, power factor and harmonics of high energy-consuming equipment, and perform statistical analysis on the operating status and operating time of the equipment; when the equipment parameters exceed the limit, an automatic Alarm prompts; monitor the key process parameters of the equipment in real time, and combine the process parameters to comprehensively analyze the energy efficiency of the equipment. For a continuous production line composed of multiple equipment, analyze the coordinated operation of each equipment in the production line to avoid that when the main production line stops running, the auxiliary equipment is still running idling. Combine production plans and historical data of energy consumption to make monthly and annual forecasts of future energy consumption; monitor the maximum demand curve of the factory in real time, and when the maximum demand reaches the threshold, control the maximum demand by adjusting the interruptible load. Energy saving.
3.7 Workshop on-site management Since a large number of automated production lines and intelligent equipment are used in smart workshops, the requirements for on-site management and control are very strict. How to do a good job in on-site management of smart workshops, using 5G+ tools is a very effective way. Install 5G+ AI camera. Implement a security video surveillance system that collects intelligent image recognition of personnel behavior data to analyze and alarm situations such as not wearing a helmet, smoking, playing with mobile phones , fireworks, personnel staying, early warning of personnel entry and exit, and foreign objects in passages. At the same time, through intelligent AI monitoring and analysis, safety monitoring of the on-site production environment is achieved. Various types of sensors, thermostats and other intelligent equipment are used to promptly transmit unsafe factors on the workshop site to various monitoring points to achieve all-round supervision of the workshop without blind spots.
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Integration of MES with other information management systems
Implement the integration of the MES of the smart workshop with the enterprise's CRM, PLM, ERP, SRM and OA systems to achieve R&D and design collaboration, supply chain collaboration, production and manufacturing integration and workshop management collaboration.
MES is integrated with ERP. The production plan, product delivery information and full production control in ERP must be transmitted to MES in a timely manner. MES establishes the production plan of the workshop based on the ERP master production plan. Various information about the production process of the product in the workshop must be fed back to ERP. in the system.
MES is integrated with PLM. R&D personnel transfer product-related information (including parts information, configuration, documents, drawing files, structural information, etc.) and all product-related processes (including process definition and management) to MES through the PLM system to achieve full-process tracking and control of the project. Realize design standardization, coding standardization, drawing digitization, process digitization, approval process and electronic signature .
MES is integrated with SRM. The purchasing department connects with the workshop MES through the SRM system to realize collaborative management of the supply chain. Through systematic evaluation of supplier performance, standardized and transparent management of performance and supply quotas is achieved, and traditional business processes are transformed. Through electronic reconciliation, manual reconciliation error rates are reduced and work efficiency is improved. Through barcode management and delivery notifications, Quickly move in and out of the warehouse to improve inventory turnover.
MES is integrated with OA systems. The OA system is an important means of enterprise office management. Enterprise decision-making and specific management generally go through the OA system, and some important data for workshop management must also be transmitted to the enterprise's decision-making department through the OA system in a timely manner. Performance appraisal, personnel management and other data in MES must be able to be transmitted to and from the OA system.
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Things to note during the MES design process
5.1 Intelligent workshop design should be fully considered and carried out step by step as needed
The design of a smart workshop must be comprehensively considered from the beginning, and cannot be ignored just because many conditions are not currently met. The correct approach is to comprehensively evaluate the enterprise's confidence in implementing MES. It is recommended that enterprises start with those that are easy to implement first, and reserve interface space for those that are currently difficult or do not meet the conditions. They cannot appear together, and none of them can be used properly. Case.
5.2 Selection of MES software modules
Currently, there are not many suppliers that can fully provide system-wide MES software, and the designs of each sub-module of MES also vary widely. Due to the inconsistent understanding of workshop management needs between software designers and workshop management personnel, many MES cannot adapt well to the needs of workshop management.
5.3 Emergency channels should be reserved during the implementation process
As a management tool, MES is not a panacea, especially in the early stages of implementation. The purpose of enterprises implementing MES is to improve efficiency and reduce labor costs and management costs. If there are problems with the system due to some unexpected factors, manual processing processes must be reserved and cannot be trapped by the system.
5.4 It is necessary to strengthen the skill level training of on-site operators and improve the reliability of the system
Data collection and processing are the key to the operation of MES, and the data processing principles are formulated by the enterprise. Reasonable and scientific processing methods will greatly improve the efficiency of the system. Therefore, on-site operation managers must be able to continuously modify some processes according to the actual situation of workshop management, optimize the data processing environment, and ensure the efficiency and reliability of MES.
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Conclusion
According to the relevant requirements of the "Guidelines for the Construction of National Intelligent Manufacturing Standard System (2021 Edition)", the digital transformation of enterprises has been put on the agenda. To truly realize the digital transformation of enterprises, on the one hand, the majority of software design companies must be able to design corresponding information management software according to the characteristics of the enterprise, and the society must be able to provide a large number of high-quality information operation talents, and at the same time, there must be corresponding network support. . The development of 5G comes at the right time, and its advantages of efficiency, security, and high transmission rate can provide great convenience for the implementation of MES.
The advantages of 5G network objectively lay the foundation for workshop intelligence, and the mature application of MES modules opens the door for enterprises to implement management improvements. It is believed that with the further promotion of MES, a large number of "black light" manufacturing factories will become a reality.
[The above information is compiled and released by Aibo Testing. If there is any discrepancy, please correct it in time. If there is any reference, please indicate the source. Welcome to discuss together. We have been paying attention to its development! Focus: CCC/SRRC/CTA/operator warehousing]