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1. Social background
As a part of automatic identification technology, barcode technology is a kind of automatic identification technology that is widely used in commerce, postal service, book management, warehousing, industrial production process control, transportation, etc., which is produced and developed in computer application and practice. It has input The advantages of fast speed, high accuracy, low cost, and strong reliability occupy an important position in today’s automatic identification technology.
At present, Chinese enterprises have a certain understanding of the application of automatic identification technology. In addition to the extensive use of barcodes in the retail industry, manufacturing companies such as Haier, Founder, Nanqi, Jincheng and other manufacturing companies also use barcodes based on production, storage and transportation. Technical logistics tracking technology. In fact, for companies, the goal is to provide customers with satisfactory products and services by improving their core competitiveness. The use of technology is just a means. Therefore, we believe that the important thing for companies is not whether the barcode technology is adopted, but whether the technology is conducive to improving management.
The development of social economy and the intensification of market competition have presented a series of challenges to industrial production. The goals of efficiency, quality, and cost pursued by industrial production in the age of industrialization have been given new content. The number of products produced per unit of time has no longer become the main symbol of corporate competitiveness. The time from product development to product launch is The key for enterprises to win the market and customers, information has become the decisive factor for the survival and development of enterprises, and the production technology and organization management of enterprises are undergoing profound changes.
The product bar code application combines bar code technology and computer information management to prepare for the comprehensive informatization of enterprises and the entry of the electronic age. Based on the application of product barcodes, companies can efficiently manage product material preparation, production process, sales and circulation, and after-sales service.
PBA? (Product Barcode Application)-MES (Manufacturing Executive System) is a product bar code application-manufacturing executive system is a set of information system that combines bar code technology for manufacturing production process management. It provides operators/managers with the execution and tracking of plans and the current status of resources (people, equipment, materials, customer needs, etc.).
2. System design goals
1. Improve the controllability of the production process
Refine the job plan in the ERP/MRP-II system to realize job scheduling on the production site
Perform process statistics for production process management, provide quality management for quality statistics and quality control
Archive the production process management, provide product file query and product list query for product data management
Through the collection of parts and components in the production process and corresponding to the products, the parts can be traced back to the supplier and batch
2. Improve the efficiency of production operations
Optimize the production process to make the production process more suitable for the requirements of agile production
Through real-time data collection in the production process, electronic documentary of on-site operations is realized, and management and control of the production process are completed
3. System design features
Combined with automatic identification technology. The PB?A-MES system mainly uses barcode technology, and each product is pasted with a SN (Serial Number) barcode label. The SN number is used as the unique identification of the product to track the product from on-line, production, off-line, storage to product sales The whole process to the customer
Using intermediary technology, PBA?-MES has realized the interface with SAP, ORACLE, SSA BPCS, CA MMX, QAD MFG/PRO and other ERP systems
Diverse and comprehensive data collection.Support a variety of dedicated data collection terminals (ATOP, CIPHER, CASIO), and you can choose computer data collection terminals to meet the complex site conditions and process requirements of the workshop
Provides an integrated interface with industrial control systems.Collect product production process parameters generated by various industrial control systems
Four, application cases
Implementation case of a domestic air conditioner company:
(1) Project background
The company’s products are basically exported abroad, and they hope to introduce a set of production management system that combines barcode applications to solve the problems of tracing the main components of outsourcing, management of the production process, and real-time tracking and query of products. They plan to achieve the following goals:
Hierarchical management of corporate leaders
Real-time dynamic monitoring of production
Entry, maintenance, tracking and query of documentary information
Workshop quality information feedback
Dynamic query of workshop output
Statistics and query of key documents
Workshop on-site personnel management
Peripheral equipment integration (product data test equipment)
(2) Project application
The figure below is the information system architecture of the manufacturing enterprise described by the International MES Association. MES plays the role of connecting ERP/MRP-II and the workshop automation system.
System composition: PBA?-MES adopts a system structure that combines three-tier and two-tier applications. The third-tier is mainly used for remote information query and remote workshop control management.
1. Application of automatic identification technology-barcode label
Work in progress SN (Serial Number) serial number barcode label
The symbology of the bar code is CODE128, and there are two formats.
Format 1 style:
Format 2 style:
2. Product data manager
Product structure management.The operator maintains (add, delete, modify) the model of the product; the operator maintains (add, delete, modify) the product material code; the operator maintains the material configuration of the product material code
Fault code management.Operator maintenance (add, delete, modify) fault code category; operator maintain (add, delete, modify) fault code code
Workshop operation process route management.The administrator sets the product processing route and procedures according to the factory process; the administrator sets the processing center of the processing route; the administrator maintains (add, delete, modify) the processing center; the administrator sets the work team
3. Order executor
Receiving production orders-no ERP production order management. The administrator formulates a three-day rolling production plan for the factory based on the sales order and warehouse inventory; the administrator enters the factory production instructions (production instruction number, planned date, delivery date, product material code, quantity, preparation number, etc.) into the system
Receive the rework notice. The administrator receives the rework notice from the quality inspection department and formulates the factory rework notice; the administrator enters the factory rework notice into the system (rework notice number, original product material code, current material code, quantity, etc.)
Production order scheduling.The administrator determines the schedule date and selects the production instruction; the administrator enters the current scheduling quantity, and issues the production instruction scheduling; the system modifies the production instruction scheduling number and adds it to the detailed operation plan of the factory
Detailed operation plan (operation scheduling).The administrator determines the job scheduling time and specifies the sub-workshop; the system calculates the detailed job plan according to the workshop production capacity, and completes the automatic scheduling (the administrator can also select the detailed job plan for job scheduling); the administrator specifies the job scheduling process route , Work team, issue job scheduling; the administrator revises the job schedule and confirms to the system
Terminate job scheduling.The administrator selects the unfinished job scheduling; the system displays the status of the job scheduling work in progress; the administrator confirms, the system ends the job scheduling
Review the production order; the system checks the execution status of the production order and prompts the administrator to review the production order if it is completed; the administrator reviews the production order and deletes the operation plan without production; the system closes the production order and creates a completion report
Production plan statistical report.The administrator enters the date range, and the system outputs the time range production order scheduling table; the production line output statistics report according to the time period; the production order execution report according to the time period query; the production order timeout alarm
4. Operation manager
Job scheduling.According to the job scheduling table, the administrator issues the job scheduling of the work team; the system assigns the SN of the work-in-progress for the job scheduling, prints the SN barcode label and the product nameplate label; the dispatcher issues the SN barcode label and product nameplate, and assigns the job scheduling order to Production line, start production
Job scheduling completion report.The dispatcher conducts the job scheduling completion report; the system outputs the job scheduling that completed the production on the same day; the dispatcher chooses to enter the work team; the system conducts the job scheduling completion report
Job scheduling statistics.The dispatcher produces a statistical report according to the time and work team; the dispatcher selects the production date, and the system displays the production daily report
Production process control.The system displays the number of job scheduling online and completed; the dispatcher selects the production line, and the system displays the online work-in-process list of the production line; the dispatcher selects the job scheduling, and the system displays the work-in-process list of the job scheduling; real-time monitoring and control of the production line, graphical display of the line models of the production line And offline models and real-time quantity
5. Production process operator
Online collection (general process).The operator collects the work-in-process SN; the system saves the collected work-in-process SN, the operator, and the collection time, and identifies the work-in-process online
Assembly collection-assembly collection of master parts (assembly process). The operator judges whether the supplier of the master part of the work-in-progress has changed; if a change occurs-the operator enters the supplier of the used material into the system, and the author enters the completed assembly to confirm the work-in-progress SN, The system receives the work in process, completes the process production, and marks it as the first sample; no change-the operation enters the system to complete the assembly to confirm the work in process SN, and the system receives the work in process and completes the process production
Packing and warehousing collection. The operator starts the packaging operation.Enter the SN of the WIP; the system checks whether the WIP process route is legal; the system records the process collection (operator, time), and modifies the process status of the WIP
Then invest in collection.The operator inputs the SN of the work-in-progress into the system; the system checks whether the work-in-progress is faulty, and the registered work-in-progress starts maintenance; the operator enters the work-in-process maintenance method, responsibility judgment, and maintenance personnel into the system after the maintenance is completed; the system saves the work-in-progress maintenance Record and modify the status of work in progress
6. Quality Manager
Product data traceability query-follow the product SN traceability. The operator enters the SN of the product to query the product file.The system organizes the production data of the product, and outputs: basic product information (production instructions, preparation number, production date, work team), product material traceability information (material code and description, supplier, operator, time), and detection process collection ( Operator, time, test results), sampling process collection (operator, time, test results)//Sampling products; the operator traces the product out of the warehouse; the system displays the packing list of the product out of the warehouse tracking
Product data list query. The operator enters the time range, model, production instruction, preparation number, product code, fault code category, fault code code, line body, operator, main supplier or any of the above single conditions or any combination of conditions ; The system outputs a list of products that meet the conditions (product SN, product model, product code, product name, production instruction, job scheduling, production time, status)
Statistics of job sampling.The administrator enters the date range; the system randomly checks the product list according to each process
Work quality statistical report. The administrator enters the date, the system counts the process quality daily report; the system calculates the straight-through rate of production instructions and the process quality status; the system calculates the product straight-through rate; the system calculates the report that the fault code appears in the top N digits of the product during the time period (administrator enters the date Range and N value, the system performs statistics)
quality analysis. The administrator inquires the production failure palato according to the time range; the administrator counts the fault code category defect product list according to the time range; the administrator counts a statistical report of the offline pass rate (based on the index value and the actual value, calculate the cash value, the formula: cash =(Actual compliance value-indicator value)*assessment value); PPM value report and line chart for the administrator to calculate the straight-through rate of the production line (calculating PPM calculation formula = (1-qualified rate) * 1000000)
7. Quality operator
Detection collection. //Leak detection 1, operation, leak detection 3, final inspection.The operator starts the work-in-process inspection and inputs the inspection results (test data/qualified or fault code) into the system; the operator inputs the SN for inspecting the work-in-process into the system; the system checks whether the work-in-process route is legal; the system receives the process inspection collection and judges whether it is Whether the product is qualified or not, the system records the inspector, time and inspection results, and revises the work-in-process process
Sampling inspection collection (sub-sampling inspection process).The operator starts the work-in-process inspection and inputs the inspection result (test data/qualified or fault code) into the system; the operator inputs the SN for inspecting the work-in-process into the system; the system checks whether the work-in-process route is legal; the system receives the process inspection collection and judges Whether the product is qualified or not, the system records the inspector, time and inspection results, and revises the work-in-process process
(3) Project implementation effect
In response to the company’s requirements, our company gave a detailed project proposal. In the end, our company carried out the secondary development of the software on the basis of the self-developed PBA?-MES software product combined with the company’s special case. The software requirements analysis, design, coding, testing and engineering implementation were completed in less than half a year. Now the PBA?-MES software has been operating normally in the company for more than a year, and the software has received unanimous praise from the company.
The survey showed that after the company implemented PBA?-MES software, the company’s benefits increased significantly:
Reduce manufacturing cycle time by 30% on average
Reduce data input time by 75% on average
Reduce work in progress by 20% on average
Reduce the paperwork of assignment conversion by 60% on average
Reduce production lead time by 20% on average
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