Based on Jingcheng MES quality traceability system, Shanghai Weiouai Weaving Belt Co., Ltd. realizes the lean production of safety belts
chrispeng [ad_1]
I. Overview
Dongfang Jiule (Group) Co., Ltd. is composed of Shanghai Dongfang Jiule Automobile Safety Airbag Co., Ltd. and Shijiazhuang Jiule Automobile Safety Equipment Co., Ltd. It is the earliest pioneer in the field of automobile safety airbags in China. It has all independent intellectual property rights and integrates scientific research, production and sales. , Service as a whole group company. It has assets of nearly RMB 800 million and 680 employees. The products mainly include automobile airbags and various related accessories. At the same time, we continue to develop passive safety related products to meet customer needs. After 10 years of development, the group has successfully matched airbag devices for nearly 20 models of more than a dozen domestic auto factories, with an annual production capacity of 500,000 sets.
In early 2003, Dongfang Jiule Group signed a contract with UFIDA, a well-known domestic software company, to jointly implement UFIDA’s U8 ERP management system. A complete set of information management platform from workshop production, storage of finished products to financial accounting, achieves effective control of the company in terms of planning, tasks and timely delivery, accounting accounting, etc., and establishes a complete set of management models that are in line with Dongfang Jiule Company’s actual management model. Information management platform.
However, after several years of practical application of the ERP system, it has been discovered that although the ERP system has improved a lot of efficiency in planning and calculation, it still has no effect in production task execution, work-in-progress management, product quality tracking, and after-sales maintenance services. To achieve good supervision and control, especially the large amount of data entry in the production line, it takes time and is prone to errors. The data cannot be updated in time, which brings a lot of inconvenience to production management.
Therefore, based on the collection of production line data and product quality traceability, Dongfang Jiule Company finally chose the Jingcheng EAS-MES production execution system to control the entire production process, so that the company can develop in the direction of flexible manufacturing and refined management, and improve market response Real-time and flexibility, reduce the rate of defective products, improve the operating efficiency of the production line, strengthen the production site data collection and in-process management, product quality and after-sales service capabilities, and reduce production costs.
With years of experience in the development and implementation of MES barcode systems, professional consulting and software implementation service teams, Beijing Jingcheng Software Co., Ltd. has reached a strategic partnership with Dongfang Jiule Airbag Company. This is another typical case of Jingcheng MES software in the automotive electronics industry. Based on the principle of mutual benefit, the two parties are going hand in hand to jointly promote the development of the national industry.
2. Demand analysis
The actual requirements of Dongfang Jiule Group Company in MES production execution software are as follows:
1. According to the actual needs of the assembly workshop and the plug-in workshop, there is an urgent need to realize the basic functions of parts loading, production process (process flow) control, production data collection, quality management and bar code traceability, so as to realize the process control and process control of the product production process. Data collection and quality traceability throughout the life cycle.
2. Through the MES barcode system, collect the production process data of key procedures and workstations, record qualified or unqualified phenomena, count the productivity and efficiency of employees, equipment and production lines, and analyze process defects in the product assembly process to facilitate timely Adjustment and early warning.
3. Through the workshop kanban, it can always reflect the work progress of the workshop, the quality of the products in progress, the status of production, etc., and timely monitor the progress of the workshop and the quality of the products, and generate the pass rate and defect rate within a certain period of time, and can export deviation graphs, platonics, etc. .
4. Establish the association relationship between the package and the product by scanning the package barcode, complete the outbound scanning and after-sales service traceability, and associate all raw materials, components, suppliers, customers, and production processes through any barcode information of the package or the product itself , Quality inspection and other key information.
5. Establish a product after-sales service tracking system, recall and repair products with quality problems, record maintenance information, generate various after-sales service reports, and automatically query products with quality defects through bar codes.
6. Reserve the data interface of UFIDA’s U8 ERP system in order to realize seamless data connection in the future and realize the collaborative work of MES production execution system and U8 ERP system.
3. Implementation plan
In line with the overall progress of the informatization construction and ERP project of Dongfang Jiule Group Company, the implementation of the MES system must follow the principles of overall planning and step-by-step implementation. After discussion, we believe that this MES system can be divided into two phases to complete, one phase The project is defined as a pilot project in the final assembly workshop, focusing on the completion of the assembly management of semi-finished products, components, and finished products, which can achieve basic data collection and quality traceability. The second phase of the project can optimize the barcode management system on the basis of the first phase. Promote in a production workshop, and finally realize the company’s entire barcode tracking management. The first phase of the project must consider reserving the ERP system interface, and at the same time, reserve the interface for the second phase of barcode management, laying a solid foundation for the company’s overall information construction.
The first phase of the project focuses on completing the following basic functions:
System management, basic data definition, procedures and process routes, production tasks and dispatch, picking and returning, warehousing, storage, production execution (SMT patch, assembly, inspection, maintenance, debugging, aging, packaging, etc.), progress and follow-up Work inquiries, quality management, after-sales maintenance, barcode traceability, comprehensive reports, U8 ERP interface, etc.
The second phase of the project completes the barcode management of the entire factory. Combining the basis of the first phase of the project, it can realize a complete set of enterprise resource management systems such as procurement, sales, production, picking and returning, barcode traceability, supplier evaluation, and customer analysis.
The implementation of the EAS-MES barcode traceability system will form an integrated barcode for the company from raw material procurement to inspection and storage, production control from production picking to assembly, commissioning, maintenance and packaging, and from finished product storage to sales out of storage. Tracking, realize product life cycle control and management, and seamlessly connect with the existing ERP system, and finally realize comprehensive integration and collaborative production.
Fourth, the system structure
EAS-MES production execution system, as the execution layer between the ERP enterprise resource management system and management information systems such as CRM/MRP/DRP, is mainly responsible for production management and scheduling execution.
EAS-MES improves manufacturing competitiveness by controlling all factory resources including materials, equipment, personnel, process instructions and facilities, and provides a systematic integration of functions such as quality control, document management, and production scheduling on a unified platform. In this way, the integration of real-time EPR/MES/process control system is realized, which forms a bridge of information exchange, enabling enterprise managers to grasp production information in real time and make production decisions.
The system adopts C/S (Client/Server) structure design, Microsoft SQL Server 2000 database, and the network topology is as follows:
After adopting the production line code technology, the order number, part type, and product quantity number are first formed into a bar code, and the bar code is printed and pasted on the production line of product parts and assembly. In this way, the production process and required materials and parts of a product order on a certain production line can be easily obtained.
After the product is completed on the production line, the product bar code and production line code number are scanned by the production line quality inspector after passing the inspection, and the worker’s bar code is scanned in the order of the process (it can be confirmed once and unchanged). For unqualified products to be sent for repair, the cause of the failure (process location) is determined by the repair.
After the final packaging process is completed, it enters the finished product warehousing link, and then completes the sale, forming an overall process association.
The Jingcheng EAS-MES manufacturing execution system is based on a large number of network hardware equipment and barcode scanning equipment. The normal operation of these equipment ensures the stability of the system and is the prerequisite for the safe, efficient and stable operation of the production workshop management system, including:
1. Server: HP/IBM server: Zhiqiang 2.4×2/1G/72G×2/Gigabit network card or more
2. Wireless mobile collector: (CASIO DT300/DT900) for logistics in and out links
3. Workshop wired scanner: (SYMBOL-LS2208) for data collection on the production line
4. Barcode printing equipment: (TSC-TTP243/Toshiba B-SX4T)
5. LED workshop board: (LED monochrome workshop display screen)
6. Station display: (9821SP LED industrial production line Chinese character LCD display terminal)
7. Bar code label paper and related consumables, etc.
Five, system function
The Jingcheng EAS-MES manufacturing execution system complies with the ISA-SP95 international standard, combined with the design of Chinese localized application requirements, and provides resource management, production scheduling, data collection, process control, dynamic analysis, operation guidance, product traceability, dynamic inventory management, Quality management, quality early warning, automatic reporting and other functions, real-time response to production progress, man-machine efficiency, inspection results, delivery status, to ensure that the receipt of orders is documented, production is orderly, quality control is effective, and traceability is strong.
1. Production scheduling: generate detailed production tasks based on monthly or daily production plans, and use large scheduling, weekly scheduling, and daily scheduling to assign tasks to production units (such as workshops, assembly lines, laboratories, teams) , And control the daily capacity load conditions.
2. Assignment of tasks: According to the production scheduling plan, implement task assignment and monitoring of equipment, work types, workstations, procedures, and procedures. Production instructions can be assigned by the hour, and the execution of tasks can be collected and monitored according to the production process data.
3. Plan execution: According to the allocation result of the production instruction unit, the authority is controlled, and the system automatically prompts its operation instructions, cooperation personnel, quality inspection personnel, equipment, tools, materials, auxiliary materials and other operation guidance information.
4. Process management: Define product BOM structure and operating procedures, process flow, key control points, quality standards and related process requirements to form a complete product process database, which is convenient for version control, process optimization and process improvement.
5. Resource management: unified management of all information related to production resources, such as personnel information, material information, equipment information, auxiliary materials and tools in the production process, to achieve personnel performance appraisal, material procurement, warehousing, picking, return, and uploading. The management of basic resource information such as materials, dynamic inventory, cost analysis, etc., facilitates the effective tracking of various resources in the later stage.
6. Material management: Material management of the entire process of purchasing, preparing, picking, loading, refilling, returning, replenishing materials, and finished product warehousing and selling out of the warehouse of the raw material workshop, and replaces raw materials or spare parts. Check and record the products and scrap products, provide real-time location and status of specific materials, and record the actual consumption and loss rate in real time.
7. Production assembly: Complete the corresponding parts assembly and key data collection according to each operating station. Based on the BOM list, the system automatically completes the correspondence between the finished product bar code and the material batch, the key part bar code and the collected data, and automatically checks the actual operators, The correctness of quality inspectors, procedures, materials, equipment, and tools can realize the traceability of assembly process data.
8. Quality inspection: Through the real-time collection of on-site information, the identification, cause, and scope of quality problems can be quickly and accurately located and the traceability and analysis of hidden product hazards can be achieved. The stability of the process, the product yield, and the distribution of defective defects Real-time monitoring and early warning of fluctuations in the production line provide effective prevention of problems on the production line.
9. Data collection: Generate or read bar codes at the source according to bar code rules, and can use wired, wireless, RFID, magnetic cards and other methods to complete the collection to quickly obtain information on personnel, materials, production processes, products, processes, inspections, etc. Manual keyboard and hardware interface can be used to realize automatic data collection of automatic scanning equipment and sensors.
10. Early warning reminder: According to statistical principles and special quality assurance principles, advance warning is implemented, and automatic warning is carried out for equipment, procedures, personnel, materials, quality standards and other data that may have potential quality problems, through sounds, graphics, and warning lights/bells. Effectively prevent the wrong installation, missing installation and multiple installation of spare parts.
11. Kanban management: At the processing, assembly, and inspection sites, according to the actual production process and progress, display current process information and completion information, including process regulations, work-in-progress information, material information, completion information, and quality information, prompting operation and collaboration , Inspection and handover information, and can provide the current product’s entire process completion status.
12. Packing and warehousing: provide automatic generation of package barcodes according to a certain package quantity, automatically correspond to products and packaging, prevent leakage and wrong packaging, and automatically print packaging labels and packing lists.
13. Maintenance management: Products with quality problems in the production process and after-sales can automatically record the maintenance details, quantity, reasons for non-conformity, replacement barcode replacement, maintenance accounting and maintenance historical data statistics through maintenance management, so as to realize the production and after-sales service process Tracing the root cause of the quality problems in the middle, the quality management runs through the entire life cycle of the product.
14. Traceability management: According to the quality defects of the batch of materials, it can track all the finished products that use the batch of materials. It also supports the reverse tracking from the finished product to the raw material to adapt to the recall system of certain industries and assist the manufacturer in the loss Minimize and better serve customers.
15. Statistical analysis: Through a series of post-production work such as mathematical statistics, mathematical analysis, and data mining, the analysis data needed by the enterprise is derived and various quality reports, charts and reports such as Plato, histogram, and Xbar chart are automatically generated, and feedback to Online system for performance analysis and improvement.
16. Decision support: A large number of reasonably designed and optimized reports provide managers with quick statistical analysis and decision support, and grasp every link in production in real time. The comprehensive report shows the first-hand process data of the production site in real time, and summarizes and analyzes the real-time output of the production line, the process yield, the operation status of equipment and personnel, and provides an effective way for the improvement and promotion of production execution status and product quality. Basis for evaluation.
17. Data interface: This system can be seamlessly integrated with mainstream ERP systems such as SAP, ORACLE, Yonyou, Jindie, etc. It can also provide secondary development according to user needs to meet the needs of personalized management for growing enterprises.
18. System authority: system user management, authority management, log management, system settings, announcements and notifications, online short messages, data backup and recovery, password modification, ERP interface, LED interface and other functional modules.
6. Implementation benefits
The MES execution system developed by Jingcheng Technology Company, combined with the application of barcode technology in the management process, solves the company’s management of inventory products, semi-finished products, and original attached materials. On the one hand, product barcodes will run through the entire logistics link. Search and trace in the system at any time. On the other hand, the system can strengthen the on-site management system, standardize business processes, improve everyone’s overall collaboration ability, improve efficiency and accuracy, and provide a basis for later data query analysis and headquarters data docking Data source;
The MES system is integrated with the ERP system to complete the delivery of workshop tasks, and at the same time manages and controls the production and operation level of the workshop, which makes up for the weakness of the ERP system in the on-site manufacturing process that cannot manage scheduling. It meets the company’s requirements for product timeliness, quality reliability and traceability, more detailed cost control, and more complete material control.
The successful implementation of the system has injected new vitality into the informatization of Dongfang Jiule Company. At the same time, the effective integration with the ERP system will greatly improve the effective collaboration of Jiule Company from procurement, inventory, production, sales to financial management. It is truly built in the enterprise. The establishment of a unified and integrated manufacturing management platform has brought the information construction of Dongfang Jiule Group to a higher level.
[ad_2]
