2019, the automotive industry is undergoing tremendous change.
Market competition has become more intense. Since last year a number of major national policies and policies automotive industry, the automotive market had a significant impact. How to deal with such a complex situation, car prices and related industrial chain are seeking restructuring, upgrading to meet the ever-changing, highly competitive automotive market, but digitization is to become a major breakthrough in the automotive industry in transition.
Today to share with Shanghai Automotive Brake Systems Co., Ltd. (SABS) , manufactured in the context of intelligent information technology help manufacturing transformation and upgrading , operation and management of digital projects cockpit landing process.
Company Profile
Shanghai Automotive Brake Systems Co., Ltd. (SABS), Shanghai Automotive Industry Corporation (SAIC) and Continental AG (Continental AG) joint venture, established in July 1995, is the earliest introduction of international advanced technology to produce brake pliers, anti-lock braking system, booster and master cylinder rear wheel cylinder products.
Produced anti-lock braking system (ABS) has been included in the national key projects during the "fifteen", is currently the only domestic systems supporting the development of professional enterprise. In 2004 with the completion of the merger Haikang Di Automotive Brake Co., Ltd., to further expand its product range to become a supplier of automotive brake systems.
Background of the project
Information technology Shanghai Automotive Brake Systems Co., Ltd., is in the process of continuous improvement. Mainly in the replacement of hardware, software steadily. Construction of information technology, the various functional departments within the enterprise, businesses upstream and downstream together, get through its various aspects, in order to optimize various aspects, the reaction of the fastest, lowest cost, more targeted service, reach and quality and increase effective results.
Hardware:
With the development of business and product systems, SAIC braking walking down the transition period from the old to the new equipment upgrades of equipment modification, especially in the context of intelligent manufacturing current information technology help manufacturing transformation and upgrading of the old equipment can not the competitive environment for greater competitive advantage.
Information technology:
Currently information technology at SAIC braking force, rising phase in the continuous improvement process. Now on-line using the system office automation system (OA), SAP (ERP), PLC (the old plant production data acquisition), the central computer database (new plant production data acquisition); under construction have QDAS (coordinate system: quality management system), intelligent storage (AGV car); there are plans to implement device management systems.
Data Monitor Status:
With the development of information technology, data acquisition becomes more convenient, allowing real-time data monitoring becomes possible, before the introduction of soft sail products for data large screen monitor, SAIC brake has been applied Echarts realized production data automation , visual monitoring.
However, the production cycle pages long, difficult for the achievement and maintenance of complex needs, not related to a business theme, only part of the data to achieve the real-time monitoring of the production module, real-time data can only be ensured by Kafka.
Expectations for new products and teams:
Existing data analysis methods and reporting methods can not meet the needs of management decisions, we hope to introduce a mature product and team, through a sound management system to standardize the statistical data, and the ability to generate business divisions data theme classification, some fixed index data generated by the data on these topics, the final decision management have rendered valuable insights for management use.
The company on new products and expectations of the team goal is to SABS splicing screen can be upgraded to display the contents of SABS operations management cockpit, display content covering all sectors of production, quality assurance, industrial engineering, logistics, security and environment, business data, and through some interaction data to achieve multi-level drill display. Based on the above objectives, the company ultimately chose to sail soft cooperation to achieve:
- A full-screen display of business topics
- Online and offline data integration
- The automatic data acquisition line
- Real-time updates of front-end data
- Multi-level data drill
01. project requirements
First, the company needs
1. The company's business scope
production area
First to introduce the production process and SAIC brake indicator system, the main production activity and key nodes as follows:
According to the needs of SAIC braking system we developed a set of indicators:
The index system involves a number of key business topics concern manufacturers, have commonality in the manufacturing industry.
2. Data Collection
First, since only part of the business sector to digitize construction, and more business segments have not been information technology;
第二，数据维护单位和个人，在日常办公中习惯和善于使用Excel进行数据的记录、统计、分析，所以在建设的初期各部门业务数据均会以Excel的形式上传至指定Windows系统共享目录，使用kettle批量、固定周期自动采集入库。后期，根据信息化建设的推进，逐渐切换为线上数据。
由于数据分析的多级钻取，必须构建Excel维度数据的主数据，保证数据的一致性。
3.前端展示
页面需要有中、英文两版，考虑到篇幅，直接通过按钮进行切换。主要展示生产制造、物流绩效、质量绩效、工业工程、安全与环境5大主题的关键指标，每个主题包含多个指标，每个指标均有1~3级的数据钻取。此外，还包含智能制造词云图、厂区地图。整体效果主要体现“科技感”、“动态”、“实时”。
二、时间范围
项目整体时间规划分如下几个阶段：需求调研、蓝图方案、底层构建、中文版开发、英文版开发、上线运行、交付验收7个阶段。
时间规划如下表：
三、功能要求
实时数据监控、数据自动采集、多指标（23个指标）展示、多层级钻取（每个指标钻取1~3级）、底层数仓建设、中英文切换。
四、UI要求
UI要求高，主色调为SABS标志蓝（C:100 M:40 Y:0 K:30），辅助颜色为Conti标志黄色（C:0 M:35 Y:100 K:0）。整体效果主要体现“科技感”、“动态”、“实时”。
02. 技术&业务方案
系统整体技术架构如下图，以数据流向为基础。源数据来自Excel文件，文件存在共享盘，ETL与文件盘不在同一台服务器中，需要将远程文件盘本地化，如此，在ETL中才能实现远程文件的读取入库。在ETL中对抽取的数据进行转换、清洗后存入数据库。作为前段页面的数据源。远程文件的获取为本项目的关键点。
系统架构如下图：
业务方案如下：
根据展示层级需求，将所有指标根据钻取的层级划分为生产区域层、车间层、产品/设备层。
在分级的基础上，根据前端展示要求，形成如下整体布局：
03. 落地效果
Whole is divided into two regions machining and assembly of data analysis, and dividing the production line at each shop area. Maps and other sections of the presence of data linkage, when the click on the "mounting area" button, the display data area of the assembly; clicks "machining" button, the display data processing machine, while the map is switched to the machining map.
Map division workshop, click on the workshop, display data corresponding workshop. Map of the next level of the production line, the data linkage exists between the production line and the other sections. The linkage module production status, production planning and execution, Manning index, equipment failure rate.
By clicking the "Chinese", "English" button to switch Chinese version and English version. Click on the word cloud of keywords, switch to the corresponding keyword data analysis page, for example, keyword "AGV", click on this keyword when the jump to the AGV monitoring page.
Live performance:
Leadership during his inspection:
The following will be output and real-time device status for example, describes the role of the next page in terms of data monitoring.
1. Real-time output
Real-time output portion of the plan for the day program includes two shifts, the first shift start time of 7:00, but the front page shows the current time is 7:00 to planned and actual output, every two hours updated, that is to say from 7:00 shows the plan 7-9 point, but the actual real-time, to plan the time of 9:00 for the 7-11 point plan, while the actual output for real-time, and so on, With this chart to monitor the output of each case and each workshop production line, an exception occurs, find the corresponding person in charge of the production, a problem tracking.
2. Device Status
LV1:
Then the total number of assembly devices and the machining area and the number of good devices.
LV2：
If a faulty device, FIG click ring, view the current production zone, the number of failures of the workshop apparatus, particularly hover display device faults.
