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Brief introduction of the case
Based on the actual situation and business requirements of the DAB/PAB assembly line of the 42nd Institute of Aerospace, Jingcheng MES barcode quality traceability system must have a high degree of flexibility and configurability. The core of the MES system is detailed production scheduling, maintenance management, process optimization and Production tracking, they provide very convenient technical support for optimizing production management through the coordination of different applications in the production process.
user name
China Aerospace Science and Technology Corporation Aerospace 42 Chemical Power Corporation
user type
Government Energy Manufacturing Logistics Small and Medium Enterprises
User Profile
Xiangfan Aerospace Chemical Power Corporation, a subsidiary of China Aerospace Industry Science and Technology Corporation, is a national key high-tech enterprise founded by Hubei Aerospace Chemical Technology Research Institute, integrating scientific research, production and operation. The main products include gas generators for automobile airbags, chemical oxygen generators, shock-absorbing rubbers for automobiles, polyurethane tape adhesives, release agents, polyurethane adhesives for dry composites, epoxy potting adhesives and other products.
With the expansion of the automotive industry market and the increasing international competition, the market demand for safety components such as automotive airbags and gas generators has gradually expanded. At the same time, in order to comply with the requirements of the automotive industry’s just-in-time production The quality traceability requirements of parts and components have also reached unprecedented heights. However, the DAB/PAB assembly line of Aerospace Chemical Power Company still uses manual methods to complete it, which can no longer meet the requirements of automated production and just-in-time production in the information age.
Based on the basic requirements of bar coded material management, production task execution, personnel performance management, equipment monitoring, production data collection, work-in-progress management, product quality monitoring, after-sales quality traceability, and production system reports, Jingcheng MES provides details The system solutions and implementation plans of the company have been highly praised and recognized by the leaders.
demand analysis
The actual requirements of Xiangfan Aerospace Chemical Power Corporation of Aerospace 42 Institute in MES production execution software are as follows:
1. According to the actual workstations (34) and key data collection points (10) of the DAB-1 and PAB-2 lines in the workshop, there is an urgent need to realize the loading, changing, replenishing and production processes of various raw materials and parts. (Process) Control, production data collection, quality management and bar code traceability and other basic functions, realize the process flow control of the product production process and the data collection and quality traceability of the entire life cycle.
2. Through the MES barcode system, collect the production process data of key processes and stations (34), record qualified or unqualified phenomena, count the capacity and efficiency of employees, equipment and production lines, and analyze the process of product assembly. Defects, easy to adjust in time.
3. Through the electronic weighing data interface and the special station to record the weighing data, error alarms and the collection of the measurement data of the height of the generator, the depth of the clamp ring, and at the same time, it can reflect the work progress and the work progress of the workshop through the large LED screen of the workshop. Product quality status, in-production status, etc., timely supervise the progress of the workshop and product quality.
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, parts, suppliers, customers, and production through any barcode information of the package or the product itself Key information such as process and quality inspection.
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. Establish a data interface with the Inspur ERP system, realize the unified maintenance and operation of various basic data (material information, personnel information, process data, etc.), reduce enterprise information islands, and realize the collaboration between the MES production execution system and the Inspur ERP system Work.
Technical route
MES function design
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. The reports show the first-hand process data of the production site in real time, and provide real-time output, process yield, etc. of the production line. A summary analysis of the operation status of equipment and personnel provides an effective evaluation basis for the production execution status and product quality improvement and promotion.
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.
system structure
As the executive layer between the ERP enterprise resource management system and management information systems such as CRM/MRP/DRP, Jingcheng MES production execution system is mainly responsible for production management and scheduling execution.
Jingcheng MES system uses bar code equipment, equipment interface or manual entry to collect live information of the workstations in the production process. After processing, the system automatically checks the correctness of the process, and displays the records and process information in the form of documents, reports, pictures, etc. Where necessary, comprehensive utilization methods such as comprehensive query and statistical analysis are provided at the same time.
The system adopts C/S (Client/Server) structure design, Microsoft SQL Server 2000 database, and the network topology is as follows:
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. Workshop billboard: (LED monochrome workshop display screen) LED
6. Station display: (9821SP LED industrial production line Chinese character LCD display terminal)
7. Inspection and testing equipment: (altimeter, depth sounder, electronic balance, resistance tester, etc.)
8. Bar code label paper and related consumables, etc.
Fruit
Implementation benefits
Based on the actual situation and business requirements of the DAB/PAB assembly line of the 42nd Institute of Aerospace, Jingcheng MES barcode quality traceability system must have a high degree of flexibility and configurability. The core of the MES system is detailed production scheduling, maintenance management, process optimization and Production tracking, they provide very convenient technical support for optimizing production management through the coordination of different applications in the production process.
After the implementation of the system, the visualization of the production process has been improved, and the actual operation information from the control system can be used for daily analysis and production reports. At the same time, due to the successful integration with the ERP system, the original manual data entry method was replaced by the MES online method with the production site, and the operating cost was effectively reduced. The system provides a reliable and friendly user interface for the operator, and all batches of data can be automatically collected, which greatly reduces the error rate of the operator, and also reduces the loss caused by misoperation to history lowest point.
The successful implementation of the system has injected new vitality into the informatization of the Institute of Aerospace Engineering. At the same time, the effective integration with the ERP system will greatly improve the company’s effective coordination from procurement, inventory, production, sales to financial management, and make the Institute’s informatization. The construction has moved to a higher level, which is another example of the application of Jingcheng MES system in aerospace and defense, automotive, petrochemical, telecommunications, electronics and other industries.
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