This article will explain to you: 1. The current situation and problems of equipment management; 2. The functions of equipment management systems; 3. How do manufacturing companies manage production equipment and analyze production data? 4. The value of manufacturing equipment management.
If you want to manage equipment well, issues such as equipment file management, inspections, repair reports, maintenance, analysis and early warning must be considered. Our company uses the equipment management and inspection system to solve the problem of equipment life cycle management with a QR code.
At the same time, we cannot ignore the processing and analysis of data. In fact, there are many and very detailed data in the traditional manufacturing industry. Due to space reasons, we can only briefly talk about it. Today, we will take the production data in the traditional manufacturing industry as an example to explain how to process data in the manufacturing industry. analyze. You can learn more through the template:
The system built by our company is here, you can pick it up yourself.
Device Management Solution>>>>https://www.jiandaoyun.com (Ready-to-use, Can be built by yourself)
Can device management be managed with just one QR code? What are the manufacturing production data? How to analyze?
If you are interested, you may wish to read this article. This article takes the equipment management and inspection system built by our company as an example to give you a good introduction to equipment management:
- Advantages of equipment management and inspection system solutions
- Device management coverage scenarios
- Current status and issues of equipment management
- The role and value of equipment management
1. Current status and problems of equipment management
1. Leaders do not pay attention to management
"Production volume is the most important", "Sales is the most important",< /span>Management concepts such as "emphasis on ERP and light on on-site management" are the norm in enterprises.
The profit-centered thinking of enterprises is correct, but equipment, as an important asset that creates corporate economic value and ensures safe production, is tied to corporate profits. Only with high equipment utilization, short downtime, and few repairs can we be able to stably produce high-quality products.
2. The management model is very outdated
Equipment is an important asset of production-oriented enterprises. In order to enhance market competitiveness, most enterprises spend large sums of money to purchase world-class equipment. However, the company's own management level and management model are not up to the world-class level, and equipment management still uses The backward methods,the "international first-class" equipment and the "backward" management model form a contrast, which affects the improvement of the enterprise's productivity, and then affects the enterprise's longterm development.
3. Equipment overload operation becomes normal
In order to meet the deadline, the production lines and production equipment of most companies operate 24 hours a day, the equipment is overloaded and even run sick. However, if the usual equipment inspection and maintenance are not in place, firstly, the equipment failure rate will remain high; secondly, due to the lack of equipment history, the historical repair and maintenance records of the equipment cannot be viewed in a timely manner, and the cause of equipment failure cannot be accurately analyzed.
4. Maintenance records have no sedimentation
Most equipment maintenance stillrelies on experience, with a certain degree of arbitrariness and blindness, but technical analysis of the causes of equipment failure is rarely carried out. Conclusion, it is impossible to establish an effective equipment maintenance manual and maintenance system.
5. Equipment operation and maintenance are out of touch
The most important thing in equipment management is the daily maintenance of operators. However, the division of labor between equipment operators and equipment maintenance personnel is too clear, and the concept of full management is lacking, which makes the management and maintenance of equipment still in the passive management and after-the-fact management stage:
- In order to rush the work, the operators overload the equipment, resulting in overload processing and fatigue use of the equipment;
- At the same time, operators believe that they only have the obligation to operate the equipment, but have no responsibility for daily management and maintenance;
- The maintenance personnel's daily maintenance of the equipment is a mere formality, and the management of the equipment only remains in post-event management and post-maintenance.
2. Why choose a zero-code platform?
If you want to develop a professional equipment management system for your company, you often have the following three options: independent development (self-research), outsourcing development, and using a development platform.
1. Traditional development model
Development time is calculated in "months", and a large number of demands cannot be solved in time.
- Phase 1Needs Assessment: Large Stack of Requirements
Medium and large organizations have many positions, complex businesses, many edge demands, and rapid changes. However, most demands lack efficient solutions, and demands are delayed again and again.
- Phase 2Requirement matching: barriers to demand communication
It requires multi-party communication between external/internal consultants, development, and business personnel. The ability to understand the requirements depends entirely on the consultant's ability, and the communication barriers are large.
- Phase 3Code development: high development/maintenance costs
Code development means high labor and time costs, and it must be maintained by people who know the code professionally.
- Phase 4Project Delivery: Extremely Slow
By the time it is delivered, it has often been several months or even half a year, and it is easy to have the problem of "just developed, but the requirements have changed again".
2. Zero-code development model
Development time is calculated in "hours", and it can be easily completed no matter how many demands you have.
- Phase 1Needs Assessment: Covering a Large Range of Needs
A general development platform that covers scenarios ranging from production, personnel, finance, and sales management to statistics, reservations, food ordering, daily reports, progress inquiries, etc.
- Phase 2Requirement matching: barrier-free internal communication
Through simple learning, business personnel can clearly understand what the platform can do, or build it independently to avoid lengthy demand communication.
- Phase 3Application construction: low development/maintenance costs
Simple applications can be built with zero code and in a few hours. System stability is guaranteed by the platform, and business personnel can maintain it themselves.
- Phase 4Project delivery: extremely fast delivery
Provides rich templates for reference, simple development process, and extremely fast delivery.
3. What is a zero-code platform?
The zero-code platform is a kind of software development tool for rapid application development, which can effectively reduce the technical threshold of application development. Reduce coding and simplify technology so non-technical people can create applications by providing visual tools and pre-built components.
——In the past, if enterprises wanted to realize various information functions, they needed to develop software based on code development platform.
——Now, based on the zero-code development platform our company is using, the enterprise team does not need code Just like building blocks, you can build a personalized management application that meets the needs of the enterprise.
3. Equipment management system functions
1. A QR code opens the way to device management
- One thing to one code: Each device corresponds to an exclusive QR code, and you can view the corresponding information by scanning the code;
- Scan the QR code if you need anything: Whether you want to inspect, repair, or view information or analyze, just scan the QR code to get it all done.
2. Manage device information in an all-round way from static to dynamic
- Equipment files: Whether it is dynamic records such as equipment inspections, repairs, maintenance, spare parts replacement, etc., or static data such as instructions and basic information, you can view it by scanning the QR code;
- Real-time update: After the device information is recorded online, it will be updated in real time.
3. Paperless inspection, clear display of inspections and pending inspections
- Customized inspection cycle: mobile phones automatically receive inspection message reminders to prevent employees from forgetting;
- Avoid fake inspections: GPS positioning + photo watermark
- Inspected and awaiting inspection: Displays inspected equipment information and uninspected equipment information in real time to prevent omissions.
4.Report for repair in three seconds, effectively reducing downtime
- Scan the QR code to report for repair: When a fault is found on-site, scan the QR code to submit a maintenance work order;
- Rich information: supports pictures, texts, and videos to describe fault information to facilitate maintenance personnel's troubleshooting;
- Real-time reminder: Maintenance work orders will be reminded to maintenance personnel in real time to reduce the duration of the fault.
5. Calendar management, maintenance plan is simple and orderly
- Maintenance plan: Check the maintenance plan through the calendar, and the pending maintenance plan is clear at a glance;
- Real-time reminder: According to the maintenance calendar, the message will be reminded to the individual at the specified time.
6. Proper entry and exit, and keep track of spare parts receipt records
- Inventory view: display the inventory status of spare parts in real time;
- Collection tracking: who received what and when is recorded;
- Inventory warning: When the inventory is insufficient, the corresponding responsible person will be automatically reminded.
7. Multi-dimensional analysis to view equipment status in real time
- One thing to one code: mobile viewing: supports computer/mobile phone viewing of device analysis reports;
- Multi-dimensional reports: Provide multiple types of reports to improve equipment management accuracy;
- Filter query: You can customize filter conditions to view device status of different categories.
4. How to analyze production data in the manufacturing industry
It is very important for the manufacturing industry to analyze and process production data. These data can provide key insights to help companies optimize production processes, improve efficiency and enhance competitiveness. Next, let’s talk about how to analyze production data. Production data in the manufacturing industry can be divided into the following categories:
- Production task data
- Production equipment data
- Production material data
- Process quality data
- Workshop personnel data
- Production safety and environmental data
1. Production task data
Production task data is one of the core and largest amounts of data in the manufacturing production process.
It includes: production plan and execution data, production work orders for each station, production start time of the work order, intermediate pause time, production end time, man-hour consumption information of each processing step, completion amount of the production plan, etc. .
Only with production task data can we statistically analyze key production management indicators such as rhythm, production output, completion accuracy of planned delivery, and order delivery cycle.
Through the "Production Statistics Kanban", we can draw the following conclusions:
Conclusion 1:The production plan completion rate this month was 102.86%, exceeding the scheduled plan, indicating that the production department can efficiently execute the production plan.
Conclusion 2:Between July 15, 2023 and July 19, 2023, the process volume increased significantly.
Measures:Companies should pay close attention to the adaptability of resources and processes to cope with sudden increases in production demand:
- Ensure sufficient resources: Evaluate the supply of equipment, manpower and raw materials on the production line to ensure that increased process demands can be met;
- Optimize process flow: evaluate the process flow and find possible bottlenecks or unnecessary delays to improve process efficiency;
- Effective team collaboration: Coordinate cooperation between relevant departments and teams to ensure the smooth operation of the production line to cope with the challenges caused by the surge in process volume.
2. Production equipment data
If equipment management is not done well, the hidden cost of production will be higher. At worst, if a piece of equipment is damaged and not repaired in time, the progress of the entire workshop production will be affected.
This type of data includes equipment status and tooling data, equipment power-on and off status, alarm data, equipment operating pressure, speed, temperature and other real-time data, as well as time data corresponding to these equipment status data, tooling mold models, life span and other usage information .
Only with equipment status data can we count the downtime of equipment, calculate equipment utilization efficiency, analyze and solve problems based on alarm data, and analyze and optimize equipment parameter settings.
Through the "Equipment Statistics Dashboard", we can draw the following conclusions:
- Equipment utilization
Conclusion:The equipment utilization rates of SB001 and SB003 are low. Although they are operating normally within the acceptable range, there is still potential for improvement.
Measures:Enterprises need to analyze the reasons for low equipment utilization (such as unreasonable production plans, process defects, insufficient equipment operation technical training, etc.) and take improvement measures. To improve equipment utilization and further optimize production efficiency.
- Equipment utilization rate
Conclusion:The utilization rate of SB004 shows a downward trend, and the utilization rates of SB003 and SB005 show an upward trend.
Measures:Enterprises should conduct careful fault diagnosis and maintenance of SB004 to ensure that it can operate normally to improve its availability. At the same time, SB003 and SB005 can be further studied to understand what factors lead to their increased availability, and these experiences can be applied to other equipment.
3. Production material data
Including: the name, quantity, batch of the material, and the time when the material was accepted and used by the work station
Only with material data can we accurately control material demand and material inventory levels, and can we keep quality tracking records and ensure accurate traceability of quality materials.
Through the "Inventory Turnover Analysis Dashboard", we can draw the following conclusions:
Conclusion:The overall product inventory turnover rate decreased from March to April and remained stable thereafter.
- Dusun Pi4 has a high inventory turnover rate
- MTQ8200-HS2F has low inventory turnover
Measures:Enterprises should analyze the reasons for changes in inventory turnover (such as seasonal demand changes, supply chain issues, etc.) and closely monitor subsequent changes.
For products with high inventory turnover rates (Dusun Pi4), procurement plans can be optimized, supply chain cycles can be shortened, and cooperative relationships with suppliers can be strengthened.
For products with low inventory turnover rates (MTQ8200-HS2F), it is necessary to conduct an in-depth analysis of market competition and demand, re-evaluate product positioning and marketing strategies, optimize inventory management, and avoid excessive purchasing and backlog of inventory.
4. Process quality data
This is the most important indicator data in the manufacturing production process.
Quality monitoring data includes data generated by comprehensive quality management and control from incoming material inspection, process inspection, product inspection, delivery inspection, return inspection, inventory inspection to sample management, quality accidents, customer complaint handling, etc.
The quality management system uses the data captured in these links to achieve a closed loop of quality management through strict step-by-step review, real-time reminders, intelligent data statistics, and automatic formation of weekly management reports.
Through the "Quality Statistics Dashboard", we can draw the following conclusions:
Conclusion 1:On July 10, 2023, the defective rate of the product rose sharply to 2.54%, and the subsequent defective rate continued to rise, rising from 0.07% to 1.84 %. Among them, in the pickling process, the defective rate remains high.
Conclusion 2:The order through rate is above 95%. Among them, the pass rate of products in the pickling process is low.
Measures:Enterprises need to focus on and improve the pickling process. First, we should immediately investigate and determine the specific reasons for the increase in the defective rate of the pickling process (such as equipment failure, improper process flow, operator skill issues, or raw material quality fluctuations, etc.), and take targeted measures (such as providing employee training, improving process flow, etc.) , strengthen equipment maintenance) to ensure the stability of the production process and the controllability of product quality.
5. Workshop personnel data
Workshop personnel data is actually a type of data that is easily overlooked but equally important.
For example: who produced what product model at which station, records of start time and completion time, workshop team layout and other data;
With personnel data, we can help us locate whether personnel changes have caused quality problems when quality problems occur; with personnel data, we can statistically analyze the work efficiency of personnel, etc.
6. Production safety and environmental data
The so-called "safety environment" refers to safety environment data
By grasping risk management, safety inspections, safety training, and health management in the enterprise's production process, we can reduce the occurrence of production accidents, occupational diseases, and environmental pollution.
For example, health management is achieved through the collection and regular monitoring of data such as [employee health files] and [labor protection supplies management].
Monitor the safety of the production environment in real time by collecting data on employee safety training, equipment safety inspections, and safety hazard inspections:
5. The value of manufacturing equipment management
1. Covers 20 categories + QR code device management scenarios
Here are some classic scenes -
(1) Production workshop equipment management: boilers, grinders, molding machines...
(2) Petrochemical electronic patrol: high-end distribution rooms, hot blast furnaces, alkali distribution workshops...
(3) Inspection of construction equipment: tower cranes, distribution boxes, technical briefings...
(4) Fire equipment safety inspection: fire extinguishers, fire safety inspection...
2. The role and value of equipment management
Inspection efficiency, fault response speed, maintenance work efficiency, maintenance cost... these are all real data——
The role and value of equipment management are mainly divided into the following three points:
1. Equipment is the guarantee for safe production of enterprises
Safety production is the prerequisite for enterprises to do a good job in production and operation. Without safety production, all work may be in vain. Therefore, governments and departments at all levels from the central to local governments all emphasize production safety and pay close attention to production safety.
Equipment management is the guarantee for safe production of enterprises. According to statistics on safety accidents, excluding individual human factors, more than 80% of safety accidents are caused by unsafe equipment. In particular, poor management of some pressure vessels, power operating equipment, electrical equipment, etc. is the hidden danger of accidents.
To ensure safe production, we must have well-operated equipment, and good equipment management will eliminate most accident hazards and prevent most safety accidents.
2. Good equipment management can improve production efficiency and profits.
The purpose of enterprises' production and operation is to obtain maximum economic benefits.
The main task of equipment management is to provide enterprises with excellent and economical technical equipment, so that the enterprise's production and operation activities are based on the best material and technology, so as to ensure that the enterprise improves product quality, improves production efficiency, and conducts safe and civilized production.
Good equipment management can, on the one hand, increase product output and improve production efficiency; on the other hand, reduce consumption and production costs. Among a series of management activities, equipment management is a method that can effectively improve the economic benefits of an enterprise in the long term.
3. Equipment management level symbolizes enterprise management level and delivery capabilities
Under the conditions of market economy, enterprises often organize production according to contracts and determine production based on sales. The agreement is protected by law and cannot be changed without special circumstances. Any breach of contract will be subject to severe economic sanctions.
Without the guarantee of a high level of equipment management and good equipment operating conditions, it is impossible to perform the contract stipulations well. Once a breach of contract occurs, it will bring not only economic losses to the enterprise, but also the loss of markets and customers, which will have a serious impact on the development of the enterprise.
Therefore, equipment management is the guarantee of an enterprise's output, quality, efficiency and delivery time. The level of equipment management is also one of the important indicators of an enterprise's management level, production development level and market competitiveness.
The above is about the current situation, problems and functions of equipment management, how manufacturing companies manage production equipment, analyze production data and the value of manufacturing equipment management< a i=2>, I hope it will be helpful to everyone.