Application of smart logistics solutions based on lean production in practice
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With the comprehensive implementation of lean production in the railway equipment manufacturing industry, especially in the context of the global innovation industry reform and China’s intelligent manufacturing 2025, the industry will accelerate its transformation and upgrading to meet the needs of railway equipment manufacturing enterprises for small-batch, multi-variety customized production, and to ensure product quality At the same time, reducing waste and improving production efficiency have become a new subject and task for railway equipment manufacturing enterprises.
In 2014, in order to meet the needs of lean production and intelligent manufacturing, the logistics company of Nanjing CRRC Puzhen Co., Ltd. independently developed an intelligent logistics solution (L2M), through the recycling platform, lean logistics MES, lean manufacturing MES, SLP production line, and supply The chain collaboration platform uses digitization, informatization, and Internet + means to fully integrate lean production and the business characteristics of the railway equipment manufacturing industry to form a “fixed-point catering” logistics supply mode for work stations, greatly improve the efficiency of production organization, and enhance the corporate economy Benefits provide a guarantee and lay a foundation for improving the core competitiveness of the enterprise and future intelligent manufacturing.
1. The main features of a comprehensive smart logistics solution based on lean production
CRRC Nanjing Puzhen Vehicle Co., Ltd. has been implementing lean production since 2008. Lean production has placed very high requirements on logistics and supporting facilities. The production situation of small batches, multiple varieties and multiple projects requires that logistics and supporting facilities must be punctual and packaged. According to this requirement, Puzhen Industrial Logistics came into being. Through several years of hard work, an intelligent logistics supply system based on the station system and rhythmic production was gradually established, namely the CRRC Puzhen Industrial Digital Platform (L2M).
1. The intelligent logistics solution is the integration of lean, informatization and business. It focuses not only on internal process reengineering, but also on logistics itself. At the front end, it can promote the further optimization of lean process management. Through abnormal pull, it can find the source of improvement and promote the improvement of lean process. In the upper reaches of the supply chain, the solution seamlessly connects with suppliers, and realizes unattended full-process management of external logistics, internal “micro-warehouse”, warehousing and “packages” through ERP. In the production process, the program realizes the linkage with the production organization, material procurement and rhythmic manufacturing process. Through the information platform, it is integrated with the enterprise’s production organization system, which is a strong guarantee for the enterprise to achieve “one flow” of production.
2. Subversion and transformation of traditional logistics management concepts, models and methods. For a long time, because many manufacturing enterprises in our country tend to “emphasize product production and neglect logistics management”, they have insufficient understanding of the importance of comprehensive optimization of internal logistics links, and have not fully exerted the leverage adjustment role of logistics management in resource circulation, resulting in internal enterprises. Logistics has serious problems such as slow response to changes in market demand, untimely delivery of orders, untimely arrival of materials, confusion in the transfer of materials in the workshop, poor matching of parts, high inventory and production costs, low production efficiency and material waste. According to statistical data, in the entire production process of the product, materials spend only 5% of the time in the processing and inspection links, while the remaining 95% of the time is in storage, loading, unloading, conveying and waiting for processing. 20% to 40% of the manufacturing cost is directly related to the circulation time of the logistics link. The current management status of focusing on “materials” and lighter on “flows” keeps corporate organizational efficiency, production efficiency and operating efficiency at a low level for a long time.
3. Realize the intensive management of the whole process of internal and external logistics. With the MES system as the main feature, through the docking with ERP, an informatization and intelligent management mode that runs through the entire logistics process of the manufacturing process is formed. An enterprise-level information management platform with the work station system as the core has been established as a daily business operation and management platform for product manufacturing and related departments. Including business process management; information collection management; information resource management; knowledge accumulation and management. Realize an integrated, electronic, networked, and intelligent lean production model to improve on-site execution and management. The existing business processes have been optimized and upgraded, and a new business model under the information system has been formed, achieving clearer responsibilities: quantification of the assessment system: real-time management personnel information and clear decision-making.
4. Provide a guarantee and lay a foundation for the intelligent manufacturing of enterprises. In the process of digitization, informatization, automation, and intelligence, smart logistics solutions have surpassed and successfully cracked the “dead knot” of logistics supply and achieved success. In terms of development concept and development speed, the solution is at a pace comparable to the world’s advanced level, providing a strong guarantee for the acceleration of the pace of intelligent manufacturing of Chinese enterprises.
2. Ten core modules of smart logistics solutions
1. Lean logistics MES. Committed to helping companies realize automation based on the actual situation of the company and using the most advanced management concepts. The system is reflected in plan decomposition and arrangement, execution and feedback, business, process analysis, real-time monitoring, abnormal control, electronic billboard display, and information transmission; production scheduling and progress, on-site equipment, material inventory and tracking, and process , Quality control, data collection and analysis functions will be controlled in real time.
2. Lean manufacturing MES. This system adopts a new control concept, takes the key technological actions of the operator as the control handle, controls the product manufacturing process, and at the same time realizes the control required for the production of materials and resources used in the manufacturing process, and sets the actions, materials, The relationship between the three resources and the time is to achieve the purpose of mutual verification and ensure the accuracy of the process design. The system can realize human-computer interaction, intelligent judgment and identification, intelligent error prevention, monitoring and detection, data traceability, abnormal management, production task release, execution process control, change management, abnormal feedback and other functions. At the same time, the system integrates and connects the underlying key equipment , To realize the writing and reading of key data.
3. Micro library, SLP intelligent logistics assembly line, AGV trolley. The micro library is mainly based on automatic three-dimensional containers, combined with a self-developed software control system, realizes the intelligent control of the system for the entire process of material storage, storage, and sorting, and realizes “materials find people, and the system gives people instructions” to avoid human intervention Picking errors, suitable for warehousing and matching of multiple types of standard parts; SLP intelligent logistics line, applying ERP, lean logistics MES, establishing an intelligent logistics platform, data collection and analysis, intelligent monitoring of the whole process, equipment can automatically identify and extract data, through independent research and development Solve the comprehensive scheduling problem of multi-task and multi-execution. At the same time, the system and AGV’s task is issued, information feedback, and automated logistics pipeline distribution is completed.
4. Smart material box. The specifications of smart bins are tailor-made according to the types of storage materials, and strive to store the most materials in the smallest space. It is suitable for: backup storage of materials on the job site, and storage of occasional replacement parts at the inspection and repair site.
5. Smart toolbox. Using RFID radio frequency technology, each tool is embedded with an electronic tag, and the system records all use time, user, frequency of use, whether the tools are all set, inspection cycle, information and can be connected with the MES system, which has strong applicability.
6. Intelligent warehouse management. In accordance with the requirements of the workstation system, implement the logistics model of warehousing by workstation in the warehouse area. After the materials are put into the warehouse, the shelves are divided and arranged according to the production stations to establish simulated stations, and the material storage of each project is placed according to the corresponding material stations of the workshop, which improves the efficiency of picking and reduces errors. At the same time, the same person is responsible for material loading and picking, with clear responsibilities.
7. Circulating reclaiming platform. The MILKRUN method is adopted to cycle to suppliers for pick-up and empty-box delivery, which effectively utilizes transportation resources and realizes joint delivery. The transportation vehicles are used efficiently. The high-frequency method of cyclic pick-up greatly reduces the emergency of low loading rate. Logistics vehicles to reduce costs.
8. Smart garage. Using the Internet, smart sensors, information transmission systems, automated equipment (AGV), automatic charging equipment, combined with the actual situation of the garage, to achieve the smallest space occupation and the lowest cost to achieve unmanned management of vehicle access and automatic charging of modern new energy vehicles solution.
9. Industrial network security. Realize the isolation of information network and control network; isolation of critical systems from non-critical systems; isolation of control systems of different suppliers; separate isolation of engineer stations and APCServer, which are more likely to be infected by viruses, to ensure safety and reliability.
10. Supply chain collaboration platform. Create a set of efficient supply chain information management platform through informatization, networking, coordination and other means. All customer demand information and all supplier action information are uniformly reflected on the platform.
3. L2M system platform software support
1. Lean logistics MES. Lean logistics MES system refers to the use of RFID radio frequency identification, network communication, information system application and other information technology and advanced management methods on the basis of warehouse management business process reengineering to realize storage, storage, inventory, and unified management Automatic information capture, automatic identification, automatic warning and intelligent management functions to reduce storage costs, improve storage efficiency, and enhance storage intelligent management capabilities.
The handheld device used in this system is a PDA device with its own infrared scanning function. Carry out various business operations by scanning the barcodes of cargo locations, materials, and tooling.
2. Lean manufacturing MES. Lean manufacturing MES system is an intelligent manufacturing execution system independently developed by Nanjing CRRC Puzhen Industrial Logistics Co., Ltd. The system is designed based on the original and novel core idea of action coding, and at the same time, it uses the mature lean management method of the enterprise to deeply digitize, informatize and structure the manufacturing resources, and set the interaction between manufacturing actions, materials and resources. The three-dimensional and three-dimensional relationship makes the system fully flexible and intelligent, comprehensively control the enterprise product manufacturing process, promote the overall optimization of the enterprise manufacturing process, and help the enterprise realize the transformation and upgrading of intelligent manufacturing.
3. Intelligent quality (QMIS). From the perspective of quality data processing flow, this system has full-process quality data management functions, including quality data planning, collection, post-analysis and control. The system also covers the handling of unqualified products, quality analysis meetings, and inspections in quality management. The business process includes: inspection planning, task allocation, task execution (handheld terminal), exception handling, inspection query, and image retrieval.
4. Recycling reclaiming platform. Recycling is the core module of the system. According to the actual production needs of customers, supplier distribution, material demand information, etc., the optimal assembly plan and transportation route are calculated through the system. The transportation service team carries out loading and transportation according to the set plan and route. At the same time, the supplier performs packing and other tasks in advance according to the recycling reclaiming plan to ensure that the loading and unloading tasks can be carried out smoothly after the arrival of the transport vehicle.
5. Lean maintenance of MES. Based on the work station system and rhythm management concept, through the whole process control of disassembly, repair and assembly, the manufacturing execution of the whole production process management is realized, which effectively guarantees the station system and rhythm production of the lean maintenance production line. System modules include: system administrator module, exception management module, repair BOM control center, production command center, and message management module.
6. Supply chain collaboration platform. All customer demand information and all supplier action information are uniformly reflected on the platform, so that all problems can be accurately presented and resolved at the first time, and the extension of supply chain management has been realized through informatization, networking, and coordination. Create an efficient supply chain information management platform.
All data is interacted through cloud services, which can realize the multi-layer correspondence between OEMs, suppliers and secondary suppliers, and realize the overall system coordination from order to purchase, transportation, warehousing, and quality assurance.
7. L-NEURE system. The L-Neure system has designed an open and easy-to-expandable equipment monitoring system solution, which is a data acquisition and monitoring control system, which is similar to the SCADA system in response to the wide variety of industrial production field equipment, different communication protocols, and the lack of unified management and control. .
While the system establishes communication with a variety of industrial equipment and obtains equipment operating status information, it can also receive operating instructions from MES (Manufacturing Execution System) and WMS (Warehouse Management System), and send them to production equipment to perform operations on the equipment. Control operation. It is the bridge between the CPS system in the industrial production process to connect production equipment and MES and other information systems.
8. SLP intelligent logistics platform. Smart logistics platform (SLP, smart logistics platform) is a collection of smart logistics solutions: micro warehouse + conveyor line + AGV.
The micro library software part is the integration of the self-developed lean logistics MES system and the warehouse management WMS to achieve real-time acquisition of material information. Lean Logistics MES formulates a material sorting plan according to the production plan, and pushes the plan to the intelligent warehouse management system WMS. The system sorts the picking instructions using the optimal algorithm, and sends them to the corresponding automatic container operation terminal for picking operation, and the picking task starts After the electronic label lights up, only the position of the material box needs to be allocated. The operator places the material box with the bar code in that position and scans the bound material box. When starting to pick materials, the laser indicator indicates the sorting position, the printer automatically prints out the warehouse label, and the electronic label indicates the placement position. The operator can perform operations such as warehousing, outgoing, inventory, and warehouse adjustment according to the instructions.
Four, application cases
The lean and intelligent logistics solution of Nanjing CRRC Puzhen Industrial Logistics Co., Ltd. was first fully verified in the new plant of CRRC Puzhen. Prior to the application of this program, enterprise logistics and supporting facilities have always been the main problems hindering lean and rhythmic operation. Because supporting systems cannot be punctualized and packaged, rhythms have become empty talk, and all the work in the early stage of lean production has been in vain.
Since 2014, Puzhen Industrial Logistics has concentrated on research and development, and formed a series of products under the L2M platform. The use of these products has broken through the obstruction of station system and rhythmic production, making it possible to organize production and improve efficiency.
Save a lot of logistics costs. The number of personnel engaged in warehousing and distribution has dropped from 190 to 106 at present, and the number of handovers has been reduced from 4 in the past to 0. Compared with the past, the workshop production station has reduced the material abnormality by more than 70%. The daily production station’s planned fulfillment rate has reached more than 99%, and the monthly planned fulfillment rate has reached 100%. With no increase in space and production stations, the production efficiency has been doubled through on-time delivery. Puzhen City’s urban rail vehicle production capacity has increased from 400 in the past to more than 1,000 now, but the logistics cost has been reduced by 27%.
Through lean intelligent logistics, the company’s logistics delivery time is controlled on time, and employees do not need to work overtime. While ensuring production efficiency and efficiency, it increases employee happiness. Lean and intelligent logistics solutions have not only become a new industry model, but also attracted widespread attention in the industry.
In 2016, the company received a total of more than 300 batches of more than 3,000 people from inside and outside the industry to observe and study. The well-known domestic consulting and training institutions Aibo Rui and Best Rui cooperated with Puzhen Company to conduct open class training with the logistics center as the benchmark. At present, the company’s external service network covers Jiangsu, Hebei, Liaoning, Guangzhou, Shandong, Shanxi, Shanghai, Tianjin and other cities, providing full services to more than 60 enterprises. Among them, XAC and Shanghai EMU are serving. The system has made significant contributions to solving problems in aviation and high-speed rail maintenance.
5. Development trend
Intelligent logistics based on station system and rhythmic production is not only an important breakthrough in lean production. With the acceleration of enterprise intelligent manufacturing, this system solution also creates conditions for intelligent manufacturing and lays a solid foundation.
As a part of the enterprise’s intelligent manufacturing platform, the intelligent logistics system will embody “one integration and three integration” in the future.
“One”: refers to the realization of human-machine integration. Relying on digitization and cloud platforms, intelligent logistics systems will emphasize intelligence in the future, through machines assisting people, and people assisting machines, ultimately realizing the integration of man and machine. The system itself has more complex system thinking, not only unattended, but also early warning, detecting and automatically solving problems. As the ultimate manager, people are more involved in machine empowerment and strategy implementation.
“Three Integrations”: One is to achieve better integration with the enterprise’s intelligent manufacturing platform. At this stage, smart logistics is only a regional and partial process smart system. In the future, when companies complete the process of building smart manufacturing systems and platforms, they must be related to market, research and development, design, technology, process, quality, operation and after-sales service. The integration and docking of processes helps companies to get through horizontal and vertical integration and build a bridge from automation to intelligent transformation of production processes. A smart factory that realizes digital, informatized, networked, green, efficient, and flexible production mode.
The second is to use a new generation of information technology to achieve integration with virtual technology. Enterprises and users can check the order execution status in the virtual factory at any time, including logistics and distribution, product quality, process quality and existing problems; related accessories and products can be customized according to their own needs, and the intelligent logistics system can meet the special needs of users and ensure that they are on schedule High quality delivery.
The fourth is to realize the integration of modern enterprise management. The ultimate goal of intelligent logistics is to establish a “one body, three wings” intelligent manufacturing management matrix, and build three wings of intelligent management, intelligent operation, and intelligent products on the industrial digital intelligent platform to improve production efficiency, reduce operating costs, and create core competition force.
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