Application of barcode technology in a domestic air conditioner company
chrispeng [ad_1]
1. Social Background
As a part of automatic identification technology, barcode technology is a kind of automatic identification technology that is widely used in commerce, postal service, library management, warehousing, industrial production process control, transportation and other fields generated and developed in computer application and practice. The advantages of high speed, high accuracy, low cost and strong reliability occupy an important position in today’s automatic identification technology.
At present, Chinese enterprises have a certain understanding of the application of automatic identification technology. In addition to the widespread use of barcodes in the retail industry, manufacturers such as Haier, Founder, Nanjing Automobile, Jincheng and other manufacturing companies also use barcodes in the production, storage and transportation links. The technology of logistics tracking technology. In fact, for enterprises, the purpose is to provide customers with satisfactory products and services by improving their core competitiveness. Adopting technology is just a means, so we believe that for enterprises, the important thing is not whether the barcode technology is adopted, but whether the technology is conducive to improving management.
The development of social economy and the intensification of market competition have brought a series of challenges to industrial production. The goals of efficiency, quality, cost, etc. pursued by industrial production in the industrialization era have been given new content. The number of products produced per unit time is no longer the main indicator of enterprise competitiveness. The time from product development to product launch is The key to winning the market and customers for an enterprise, information has become a decisive factor for the survival and development of the enterprise, and the production technology and organizational management of the enterprise are undergoing profound changes.
The product barcode application combines barcode technology and computer information management, which is prepared for the comprehensive informatization of enterprises and the entry into the electronic age. Based on the application of product barcodes, enterprises can efficiently manage product material preparation, production process, sales circulation, and after-sales service.
PBA® (Product Barcode Application)-MES (Manufacturing Executive System) is a product bar code application-manufacturing execution system is a set of information systems combined with bar code technology for manufacturing production process management. It provides the operator/manager with the execution and tracking of plans and the current status of resources (people, equipment, materials, customer needs, etc.).
2. System design goals
1. Improve the controllability of the production process
Refine the job plan in the ERP/MRP-II system to realize job scheduling on the production site
Carry out process statistics for production process management, and provide quality management for quality statistics and quality control
Archive the production process management, and provide product file query and product list query for product data management
Through the collection of parts in the production process and corresponding to the product, the parts can be traced back to suppliers and batches
2. Improve the efficiency of production operations
Optimize the production process flow and make the production process more adaptable to the requirements of agile production
Through the real-time data collection in the production process, the electronic document of the field operation can be realized, and the management and control of the production process can be completed.
3. System design features
Combined with automatic identification technology. The PB®A-MES system mainly uses barcode technology. Each product is pasted with a SN (Serial Number) barcode label. The SN number is used as the unique identifier of the product to track the product from online, production, offline, storage until product sales. the whole process to the customer
Using intermediary technology, PBA®-MES has realized the interface with SAP, ORACLE, SSA BPCS, CA MMX, QAD MFG/PRO and other ERP systems
Diverse and comprehensive data collection.Support a variety of dedicated data acquisition terminals (ATOP, CIPHER, CASIO), and computer data acquisition terminals can be selected to meet the complex site conditions and process requirements of the workshop
Provides an integrated interface with industrial control systems.Collect product production process parameters generated by various industrial control systems
4. Application Cases
Implementation case of a domestic air conditioner company:
(1) Project background
The company’s products are basically exported abroad. They hope to introduce a set of production management system combined with barcode application to solve the problems of traceability of outsourced key components, management of production process and real-time tracking and query of products. The following goals are planned to be achieved:
Enterprise Leadership Hierarchical Management
Real-time dynamic monitoring of production
Entry, maintenance and tracking query of documentary information
Workshop quality information feedback
Dynamic query of workshop output
Statistics and inquiries of main items
Workshop on-site personnel management
Peripheral Device Integration (Product Data Test Equipment)
(2) Project application
The figure below is the information system architecture of manufacturing enterprises described by the International MES Association. MES plays the role of linking the ERP/MRP-II and the workshop automation system.
System composition: PBA®-MES adopts a system structure combining 3-layer and 2-layer applications, and the 3-layer is mainly used in information remote query and remote workshop control management.
1. Application of automatic identification technology – barcode label
Work in process SN (Serial Number) serial number barcode label
The code system of the barcode is CODE128, and there are two formats.
Format 1 style:
Format 2 style:
2. Product data administrator
Product structure management.The operator maintains (adds, deletes, and modifies) the model of the product; the operator maintains (adds, deletes, and modifies) the product material code; the operator maintains the material configuration of the product material code
Fault code management.Operator maintenance (add, delete, modify) fault code category; operator maintenance (add, delete, modify) fault code code
Workshop routing management.The administrator sets the product processing route and procedure according to the factory process; the administrator sets the machining center of the processing route; the administrator maintains (adds, deletes, and modifies) the machining center; the administrator sets the work team
3. Order Executor
Receive production orders – no ERP production order management. The administrator formulates a three-day rolling production plan for the factory based on the sales order and warehouse inventory; the administrator inputs the factory production order (production order number, planning date, delivery date, product material code, quantity, spare order number, etc.) into the system
Receive rework notices. The administrator receives the rework notice from the quality inspection department and formulates the factory rework notice; the administrator enters the factory rework notice into the system (rework notice number, original product material code, current material code, quantity, etc.)
Production order scheduling.The administrator determines the production scheduling date and selects the production order; the administrator enters the current production scheduling quantity and issues the production order scheduling; the system modifies the production order scheduling number and adds it to the factory detailed operation plan
Detailed job planning (job scheduling).The administrator determines the job scheduling time and specifies the sub-workshop; the system calculates the detailed job plan according to the workshop production capacity, and completes the automatic production scheduling (the administrator can also select the detailed job plan for job scheduling); the administrator specifies the job scheduling process route , work teams, issue job scheduling; the administrator modifies the job schedule and confirms to the system
Terminate job scheduling.The administrator selects the unfinished job scheduling; the system displays the status of the job scheduling work-in-progress; the administrator confirms, and the system ends the job scheduling
Review the production order; the system checks the execution status of the production order, and if completed, prompts the administrator to review the production order; the administrator reviews the production order and deletes the job plan without production; the system closes the production order and creates a completion report
Production planning statistics report.The administrator enters the date range, and the system outputs the production order scheduling table in the time range; the production line output statistical report is calculated by time period; the production order execution report is inquired by time period; the production order timeout alarm
4. Job administrator
Job scheduling.According to the job scheduling table, the administrator releases the job schedule of the work team; the system assigns the SN of the work-in-progress to which the job schedule is released, and prints the SN barcode label and product nameplate label; the dispatcher issues the SN barcode label and product nameplate, and assigns the job scheduling order to production line, start production
Job scheduling completion report.The dispatcher makes the job scheduling completion report; the system outputs the job scheduling completed on the day; the dispatcher selects the input work team; the system makes the job scheduling completion report
Job scheduling statistics.The dispatcher produces a statistical report according to time and work team; the dispatcher selects the production date, and the system displays the production daily report
Production process control.The system displays the online quantity and completed quantity of the job scheduling; the dispatcher selects the production line, and the system displays the online WIP list of the production line; the scheduler selects the job scheduling, and the system displays the job scheduling WIP list; the production line is monitored and controlled in real time, and the online model of the production line is displayed graphically. and offline models and real-time quantities
5. Production process operator
Online collection (general process).The operator collects the WIP SN; the system saves the WIP SN, operator, and collection time, and marks the WIP online
Assembly collection – main parts assembly collection (assembly process). The operator judges whether the supplier of the main parts of the work in process has changed; if there is a change – the operator enters the supplier of the material used to the system, and the author enters the completed assembly to confirm the work in process SN, The system receives the work in process, completes the process production, and marks it as the first sample; no change – the operation enters the completed assembly confirmation work in process SN into the system, the system receives the work in process, and completes the process production
Packaging and storage collection. The operator starts the wrapping operation.Enter the SN of the work in process; the system checks whether the process route of the work in process is legal; the system records the process collection (operator, time), and modifies the process status of the work in process
Re-enter the collection.The operator inputs the SN of the work in process into the system; the system checks whether the work in process is faulty, and the registered work in process starts maintenance; after the operator completes the maintenance, input the work in process maintenance method, responsibility judgment, and maintenance personnel into the system; the system saves the work in process maintenance Record, modify the status of work in process
6. Quality manager
Product data traceability query – traceability by product SN. The operator enters the SN of the product to inquire about the file of the product.The system organizes the production data of the product, and outputs: basic product information (production order, preparation order number, production date, work team), product material traceability information (material code and description, supplier, operator, time), inspection process collection ( Operator, time, test results), sampling process collection (operator, time, test results)//Sampling products; the operator traces the product out of the warehouse; the system displays the packing list for the product out-of-warehousing tracking
Product data list query. The operator enters the time range, model, production order, spare order number, product code, fault code type, fault code code, line body, operator, supplier of main components or a single condition or any combination of the above conditions. ;The system outputs a list of products that meet the conditions (product SN, product model, product code, product name, production order, job scheduling, production time, status)
Job inspection statistics.The administrator enters the date range; the system randomly checks the product list according to each process
Job quality statistics report. The administrator enters the date, and the system counts the daily report of process quality; the system calculates the pass-through rate of the production order and the process quality status; the system calculates the pass-through rate of the product; the system calculates the report that the fault code appears in the top N digits of the product within the time period (the administrator enters the date range and N value, the system performs statistics)
quality analysis. The administrator queries the production failure Paragraph according to the time range; the administrator counts the list of defective products of the fault code category according to the time range; the administrator counts the one-off pass rate statistical report (according to the index value and the actual value, calculate the redemption value, formula: cash =(Actual up-to-standard value – index value)*assessment value); the administrator’s statistics on the PPM value report and line graph of the straight-through rate of the production line (calculation formula for calculating PPM=(1 – pass rate)*1000000)
7. Quality operator
Detection collection. //Leak detection 1, operation, leak detection 3, final inspection.The operator starts the WIP inspection and inputs the inspection result (test data/qualified or fault code) to the system; the operator inputs the SN of the WIP inspection to the system; the system checks whether the WIP process route is legal; Whether the product inspection is qualified, the system records the inspector, time and inspection results, and the work-in-process process is modified
Sampling collection (sub-sampling process).The operator starts the WIP inspection and inputs the inspection result (test data/qualified or fault code) to the system; the operator inputs the SN of the WIP inspection to the system; the system checks whether the WIP process route is legal; Whether the product inspection is qualified, the system records the inspector, time and inspection results, and the work-in-process process is modified
(3) Project implementation effect
In response to the requirements put forward by the company, our company gave a detailed project proposal. Finally, on the basis of the self-developed PBA®-MES software products and combined with the company’s special cases, our company carried out the secondary development of the software. The software requirements analysis, design, coding, testing and engineering implementation were completed in less than half a year. Up to now, the PBA®-MES software has been running normally in the company for more than a year, and the software has been well received by the company.
The survey showed that after the company implemented PBA®-MES software, the increase in business benefits was significant:
Reduce manufacturing cycle time by 30% on average
Reduce data entry time by 75% on average
Average reduction of WIP by 20%
Reduced paperwork for job switching by an average of 60%
Reduce production lead time by 20% on average
[ad_2]
