42 Institutes of China Aerospace Science and Technology Corporation Realize Barcode Management and Lean Manufacturing Based on Sincere MES System
chrispeng [ad_1]
I. Overview
Recently, Beijing Jingcheng MES barcode quality traceability system successfully signed a contract with China Aerospace Science and Technology Corporation Aerospace 42 Chemical Power Corporation to produce a barcode traceability system project. With years of professional R&D and successful experience in the MES field, Jingcheng stands out from many competitors. , creating a new application of MES system in the fields of national defense and aerospace.
Xiangfan Aerospace Chemical Power Corporation, a subsidiary of China Aerospace Industry Science and Technology Corporation, is a national key high-tech enterprise integrating scientific research, production and operation, founded by Hubei Institute of Aerospace Chemical Technology. The main products are gas generators for automobile airbags, chemical oxygen generators, shock absorption rubber for automobiles, polyurethane tape adhesives, mold release agents, polyurethane adhesives for dry compounding, epoxy potting compounds and other products.
With the expansion of the automotive industry market and the intensification of international competition, the market demand for safety components such as automotive airbags and gas generators has also gradually expanded. The quality traceability requirements of products have also reached an unprecedented height, and Aerospace Chemical Power still uses manual methods to complete the DAB/PAB assembly line, which can no longer meet the requirements of automated production and just-in-time production in the information age.
Based on the basic needs of the production line in terms of bar code 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 reporting, Jingcheng MES provides detailed The system solutions and implementation plans have been highly praised and recognized by the leaders.
Jingcheng MES system is precisely through the effective management of resources, real-time collection of information, dynamic monitoring and early warning of production and experimental processes, quality management, statistical analysis and product traceability, automatic generation of various reports and reports, etc., through the data interface. ERP, OA and MES are integrated into a large work platform to help enterprises achieve resource coordination and information sharing, greatly improve productivity, reduce quality management costs, and enhance core competitiveness.
2. Demand analysis
The actual requirements of Xiangfan Aerospace Chemical Power Corporation of Aerospace 42 in terms of MES production execution software are as follows:
1. According to the actual stations (34) and key data collection points (10) of the DAB-1 line and PAB-2 line in the workshop, it is urgent to realize the feeding, batch changing, feeding and production process of various raw material parts. (Process) control, production data collection, quality management and barcode traceability and other basic functions, to realize the process 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 productivity and efficiency of employees, equipment and production lines, and analyze the process in the product assembly process. Defects, easy to adjust in time.
3. Record weighing data, error alarms, generator height, pressure ring depth resistance measurement data collection through the electronic weighing data interface and special workstations, and at the same time can reflect the workshop’s work progress and work progress through the workshop’s large LED screen. Product quality status, production status, etc., and timely supervise workshop progress and product quality.
4. Through packaging barcode scanning, establish the relationship between packaging and products, complete outbound scanning and after-sales service traceability, and associate all raw materials, parts, suppliers, customers, production through any barcode information on the packaging or the product itself Process, 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 barcode traceability.
6. Establish a data interface with Inspur ERP system, realize unified maintenance and operation of various basic data (material information, personnel information, process data, etc.), reduce enterprise information islands, and realize the collaboration between MES production execution system and Inspur ERP system Work.
3. System structure
As the execution layer between the ERP enterprise resource management system and the 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 barcode equipment, equipment interface or manual input to collect the live information of the station 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 means such as comprehensive query and statistical analysis are also provided.
The system adopts C/S (Client/Server) structure design, Microsoft SQL Server 2000 database, and the network topology is as follows:
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 premise 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 above
2. Wireless mobile collector: (CASIO DT300/DT900) used for logistics inbound and outbound links
3. Wired scanner gun in workshop: (SYMBOL-LS2208) for production line data collection
4. Barcode printing equipment: (TSC-TTP243/Toshiba B-SX4T)
5. LED workshop kanban: (LED monochrome workshop display)
6. Station display screen: (9821SP LED industrial production line Chinese character liquid crystal display terminal)
7. Inspection and testing equipment: (altimeter, depth sounder, electronic balance, resistance tester, etc.)
8. Barcode label paper and related consumables, etc.
4. MES function design
Jingcheng EAS-MES manufacturing execution system complies with ISA-SP95 international standard and is designed in combination with China’s localized application requirements, providing resource management, production scheduling, data acquisition, process control, dynamic analysis, operation guidance, product traceability, dynamic inventory management, Quality management, quality early warning, automatic reporting and other functions can reflect production progress, man-machine efficiency, inspection results, and delivery status in real time, ensuring order receipt, orderly production, quality control, and strong traceability.
1. Production scheduling: Generate detailed production tasks according to monthly or daily production plans, and use large scheduling, weekly scheduling, and daily scheduling to assign tasks to production units (such as: workshop, assembly line, laboratory, team) , and control the daily capacity load status.
2. Task allocation: According to the production schedule, tasks are allocated and monitored for equipment, types of work, workstations, processes, and procedures. Production instructions can be allocated by the hour, and the implementation of monitoring tasks is collected and monitored according to 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, cooperating personnel, quality inspection personnel, equipment, tools, materials, accessories 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, and form a complete product process database for version control, process optimization and process improvement.
5. Resource management: unified management of personnel information, material information, equipment information, auxiliary material tools and other information related to production resources in the production process, to achieve personnel performance appraisal, material procurement, storage, picking, returning, uploading The management of basic resource information such as materials, dynamic inventory, cost analysis, etc., is convenient for the effective tracking of various resources in the later stage.
6. Material management: material management for the whole process of purchasing, stockpiling, preparing, picking, loading, changing, returning, replenishing, and finished product stocking, selling and stocking out of the raw material workshop. Check and record the products and scraps, provide the location and status of specific materials in real time, and record the actual consumption and loss rate in real time.
7. Production and assembly: The corresponding parts assembly and key data collection are completed according to each operating station. The system automatically completes the correspondence between finished product barcodes and material batches, key condition barcodes and collected data based on the BOM list, and automatically checks the actual operators. The correctness of quality inspectors, procedures, materials, equipment and tools to achieve the traceability of assembly process data.
8. Quality inspection: Through the real-time collection of on-site information, the determination of quality problems, the causes, and the scope of the impact can be quickly and accurately located, and the traceability and analysis of product hidden dangers can be realized. The stability of the process, product yield, and distribution of defective defects Real-time monitoring and early warning of the fluctuation of the production line, and effective prevention and provision of problems on the production line.
9. Data collection: generate or read barcodes at the source according to barcode rules, and can use wired, wireless, RFID, magnetic cards and other methods to complete the collection, and quickly obtain information such as personnel, materials, production processes, products, processes, inspections, etc. The manual keyboard and hardware interface can be used to realize the automatic collection of equipment data such as 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 given for equipment, processes, personnel, materials, quality standards and other data that may have potential quality problems. It can effectively prevent the wrong installation, missing installation and multi-installation of spare parts.
11. Kanban management: at the processing, assembly, and inspection site, according to the actual production process and progress, display the current process information and completion information, including process regulations, work-in-progress information, material information, completion information and quality information, etc., prompting operation and collaboration , inspection and handover information, and can provide the completion of the entire process of the current product.
12. Packaging and warehousing: Provide automatic generation of packaging barcodes according to a certain number of packaging, 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 maintenance details, quantities, reasons for failure, replacement of replacement barcodes, maintenance accounting and maintenance historical data statistics through maintenance management, so as to realize the production and after-sales service process. Trace back to the root cause of quality problems, and implement quality management throughout the entire life cycle of the product.
14. Traceability management: According to the quality defects of the material batch, all finished products using the batch of materials can be traced, and the reverse tracking from finished products to raw materials can also be supported to adapt to the recall system of certain industries and help manufacturers reduce losses. Minimize, better serve customers.
15. Statistical analysis: Through a series of later work such as mathematical statistics, mathematical analysis, and data mining, the analysis data required by the enterprise is derived, and various quality reports, charts and reports such as Plato, histogram, and Xbar graph are automatically generated, and fed back to the Online system performance analysis and improvement.
16. Decision support: Numerous 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 output rate of the process, the operation status of equipment and personnel, and provides an effective tool for the improvement and improvement of production execution status and product quality. Evaluation basis.
17. Data interface: This system can realize seamless integration with mainstream ERP systems such as SAP, ORACLE, UFIDA, Jindie, etc. It can also provide secondary development according to user needs to meet the needs of personalized management of growing enterprises.
18. System permissions: system user management, permission 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.
V. Implementation Benefit
Based on the actual situation and business needs of the DAB/PAB assembly line of Aerospace 42, the Jingcheng MES barcode quality traceability system must have a high degree of flexibility and configurability, and the core of the MES system is detailed production scheduling, maintenance management, process optimization and Production tracking, they provide a very convenient technical support for optimizing production management by coordinating different applications in the production process.
After the implementation of the system, the visualization degree of the production process has been improved, and daily analysis and production reports can be carried out using the actual operation information from the control system. At the same time, due to the successful integration with the ERP system, the original manual data entry method was replaced by the online method of MES and the production site, and the operating cost was effectively reduced. The system provides the operator with a reliable and friendly user interface, and the data of all batches can be collected automatically, which greatly reduces the operator’s error rate, and also reduces the losses caused by misoperation to historical levels. lowest point.
The successful implementation of the system has injected new vitality into the informatization of Aerospace 42. 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 informatization of Aerospace 42. The construction has moved to a higher level, and it is another example of the application of Jingcheng MES system in aerospace and defense, automobile, petrochemical, telecommunications, electronics and other industries.
[ad_2]
