Application case of Lingfrog Manufacturing Execution System in Shanghai Schneider
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Shanghai Schneider Electric Power Distribution Co., Ltd. was established as a joint venture between an international electrical appliance group company and the Shanghai local government in 1996, with an investment of 18 million U.S. dollars and more than 200 employees. Its main product has international leading advantages, and it is the only manufacturer of this product in China.
The enterprise adopts a make-to-order (MTO) model. Orders are small in batches and change a lot. Sometimes an order has only one finished product. The production process and product specifications do not have continuity. In addition to the wide variety of parts, employees face changing orders at any time. Mis-installation, over-installation and omission of parts often occur, resulting in high defective product rate and low production efficiency.
Since the products of this company are industrial electrical appliances, once quality problems occur, they will have a great impact on customers, and at the same time, they will definitely affect the competitiveness of the company’s products. The quality of parts is an important factor that causes problems in the use of products. However, when a company discovers that a certain important part of a finished product has a hidden quality problem, it cannot accurately locate the product using the same batch of parts, so it cannot be timely Repair defects and reduce losses.
Another major problem with Schneider is that the production line is divided into three sections: two sub-component production sections and one final assembly section. The semi-finished products of the two sub-sections require high synchronization. Due to the small batch and multiple changes in orders, the ERP system cannot effectively schedule production accurately to the production section, which often results in inconsistent production between the two production sub-sections, and the final assembly section is often in a waiting state.
Beginning in 2002, after many times of communication and analysis between our company’s consulting and implementation personnel and Schneider’s production management personnel, we have grasped the above major issues, and around these major issues, we have built the most suitable manufacturing for the company. Execution system.
First of all, for the production scheduling problem, we use our previous experience in successfully integrating with mainstream ERP products to connect the company’s existing ERP (SAP) system and MES system into an organic whole, and design and optimize production scheduling algorithms based on the actual production of the company. The production process of the ERP production plan is decomposed into each section and process of the production line. On the basis of giving full play to the production capacity of each section, it ensures the synchronization of the final assembly of the product and the on-time delivery of the product to the customer.
The designers of our company use bar code automatic identification technology to build a complete automatic identification and traceability system for materials and finished products for the enterprise. Unify the raw material code and finished product identification code. During the production process of employees, the system automatically records which materials are used for each finished product. Because materials and finished products already have an “ID card”, once a quality problem occurs, the company can quickly find other related products that may have problems, and by replacing parts for customers in a timely and accurate manner, the company’s losses are minimized, and the customer’s approval is also obtained. Recognized.
With the automatic identification system for materials, we have implemented a production process control module for the company, and through a flexible production process customization mechanism, we formulate a standard production route for each finished product. In the actual manufacturing process, if an employee fails to install after installation, the system automatically reminds and strictly controls the continuation of the manufacturing process to ensure the correctness of the production process, and every unqualified operation is timely control. In addition, data interaction with large-scale test equipment is realized, and the results of quality inspection are directly applied to the process control of the system.
The system is developed using the Lingfrog management platform independently developed by our company. Both the server and client operating systems use the WINDOWS series, which is easy to operate and maintain. Since the design of the workshop did not consider the wiring problem when the factory was built, we designed a network architecture that combines LAN, RS845 and 802.11b wireless networks for the enterprise, which enhances the convenience of enterprise use.
The design of system architecture and data structure has reserved interfaces for the vision of comprehensive enterprise informatization, and can be integrated with other top-level or bottom-level information systems (such as CRM, SCM) at any time. The application of advanced management platform and development technology also ensures the easy upgrade and secondary development of the system.
The entire system has set up 24 data collection points, and the implementation period is 4 months. The entire implementation process has received strong support from the high-level leaders of the enterprise and foreigners.
After the implementation of the system, due to the strict process control mechanism adopted within the system, the defective rate of finished products in the Schneider production process has been reduced by more than 50%, and the phenomenon of incorrect, over-installed or missing parts has been basically eliminated, and the production efficiency has also increased by 20%. % Improvement. A detailed file relationship is established between the product and the raw material, and the loss caused by the raw material defect is reduced to the lowest point in the quality management. Accurate production scheduling enables products to be produced on time, improve factory efficiency, and deliver to customers in a timely manner. Through the collection and analysis of production data for a period of time, detailed basic data and analysis results helped Schneider find some unreasonable configuration of the production line, and through gradual adjustment, the production capacity was greatly improved. At present, the system has gradually been promoted and used within the Schneider Group.
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