A paperless factory
What is a paperless plant
Paper production is a new production mode in the manufacturing industry. The realization of paperless production in continuous production mainly relies on automated assembly lines, while the realization of paperless production in discrete production mainly relies on workers, which requires workers to be able to work in a paperless environment. It is much more difficult. Paperless production not only eliminates "paper", but more importantly, forms a new production model (change in roles and working methods). Foreign paperless workers say "let workers twist more wrenches and record less data", which vividly expresses the changes brought about by paperless production.
nullPaperlessMES/MOMFunctional framework of the system
Proposed paperless;MES/MOMSystem function framework, paperlessMES/MOMThe system software is divided into9Part: Workshop planning management, production preparation management, worker site operation management, equipment operation management, quality operation management, visual Kanban management, working hours management, production history management and exception management. From the design point of view, the paperlessMES/MOMThe functional framework of the system software has made the following considerations:
null1, Highlighting the status of workers' gateways
Worker Portal can not only display the visualized process, but more importantly, it enables workers to get all the information they need on the portal, avoiding workers logging into different systems to find information. Worker Portal enables information to be automatically pushed to workers, allowing workers to work and record quickly, thus bringing a new production model in a paperless production environment.
null2, proposedPDMWithCAPPRequirements for integration
Electronic work instructions used by workers on the worker portal under paperless production mode(EWI)It is a data package that integrates job instructions, process regulations, drawings and models(EWIThe concept ofISA95Offer), This demand has greatly promotedPDMWithCAPPIntegration. InPDMWithCAPPWhen integration is not yet mature, MES/MOMSystem andCAPPIntegration has also become an option in transitional situations, such asVisipriseIn Lockheed;·Implemented by Martin CorporationMES/MOMThe system includesCAPPOf modules.
null3Improve the efficiency of on-site collection
The information quantity of field data acquisition is expanded.MES/MOMThe system not only plays the role of reporting the start and completion of the project on site, but also needs to follow theEWIRecord all kinds of relevant information about the manufacturing process according to the requirements of: Manufacturing environment and related parameters, operating status of tools, tooling and equipment used, source and quality information of raw material blanks, batch and quality information of loaded parts, inspection and testing result data, And the processing information of non-conforming products, so as to obtain a complete production process history.
null4On-site exception management
In particular, the on-site exception management in terms of technology is particularly prominent. In order to improve production efficiency, process surpassing and temporary processes are often completed directly by technicians at the production site. After paperless, this information needs to beMES/MOMOn-site editing, modification and version management in the system, and can cooperate withPDM/CAPPCorresponding to the process data of. In engineering implementation, for some use of unstructuredCAPPThe discrete workshop can even follow the exampleSAP/VisipriseThe traditionalCAPPThe process preparation function in theMES/MOMIn system software.
5, Highlight the status of production preparation
Production preparation is divided into two levels: enterprise-level distribution and field-level distribution.MES/MOMThe system is responsible for the latter. Field-level distribution emphasizes the production preparation of short and medium cycles, and is committed to achievingJITThe distribution effect of style, so that workers can fully adapt to the role of "surgeon" under paperless production, Put more energy directly into the production process.
null6More emphasis on the integration of various factors of production and business activities
The paperless production environment makes the work of people more closely, and all the information needed for on-site production needs and can only be managed in the computer, which greatly improves the requirements of information integration.
nullPaperlessMES/MOMSpecific functions of each part of the system
null1Workshop planning management
ReceiveERPThe workshop order issued is decomposed into a process operation plan, and the operation tasks are dispatched to the site. This is the traditionMES/MOMSystem Software Functions that should be available.
null2Production preparation management
Manage tooling, workshop secondary inventory and work-in-process, and distribute these production resources to the site according to the process plan and dispatch requirements.
null3Workers' on-site operation management
Carry out on-site operations around the worker portal, workers receive work instructions on the worker portal, report the completion of the process, and fill in the processing and testing records. From the application of paperless production in foreign countries, worker portal and electronic work instruction book are the key to realize paperless production in discrete workshopsMES/MOMThe most critical element of system software.
null4Equipment operation management
Manage the equipment repair and maintenance process, record the equipment operation status, master the availability of equipment to support production scheduling.
null5Quality operation management
Manage on-site inspection process, inspection data collection, and non-conforming product processing process.
null6Visual Kanban management
It is used for all kinds of large-screen Kanban on the production site, and provides visual query functions for management.
null7Working hour management
Manage quota working hours and actual working hours of workers, as well as automatic generation of working hours reports. Among them, the collection of man-hour data is completed by the field operation module, and the confirmation of man-hour data is completed by the quality operation module.
null8Production history management
With the support of the above modules, a complete resume of the "man-machine-material-method ring" in the processing process is formed.
null9Exception management
Handle all kinds of exceptional events and their impact on production planning, and improve the system's ability to adapt to and deal with exceptional events in production.
PaperlessMES/MOMThe implementation of the system is not only the implementation of a software system, but also needs to include the improvement of the process and hardware level as the basis. Sometimes a new product model represents a new design and manufacturing model. Therefore, building paperlessMES/MOMThe system needs to consider the problems of different product models and different application stages.
nullGenerally, there are many types of mixed production lines in the workshop, using the same setMES/MOMIt has become an inevitable choice for the system to adapt to data of different maturities. In particular, the work portal used in the field needs to receive work instructions for different products. Therefore, in paperlessMES/MOMIn the design of the system, special emphasis needs to be placed on the standardization of worker portals and work instructions, Improve the functional flexibility and configurability of the Worker Portal.
nullPaperlessMES/MOMAnalysis of the key technology of the system
nullPaperlessMES/MOMThe implementation of the system requires not only the change of the management mode, but also the support of many software and hardware technologies:
1Production site terminal technology
The production site terminal is used to display work instructions and work instructions, and the operator can check the work tasks, report the start and finish the work on the terminal;If conditions permit, you can also view drawings, process regulations and digital models on the terminal.
nullRelevant applications abroad have shown that the use of portable wireless terminals or offline terminals is becoming aMES/MOMAn important direction of system application. Especially those that meet the confidentiality and security requirements of aviation and military production, Terminal technology with wireless encryption transmission function will become an aviationMES/MOMKey technologies of the system.
nullThe number of on-site terminal configurations in paperless workshops should be able to meet the needs of paperless production. In principle, one equipment or one operator should be equipped with one terminal.
null2 Logistics identification technology
MES/MOMThe system emphasizes the control of logistics, and accurate and fast logistics management often requires the use of identification technology, including: bar code,RFIDEtc. The application of logistics marking technology is more urgent in the case of paperless.
At present, miniaturized laser-engraved two-dimensional codes, pasted-type anti-metal interference and corrosionRFIDThey are all identification technologies that can meet the needs of discrete manufacturing, and related national military standards are also under pre-research.
null3Automatic data acquisition technology
nullContinuous manufacturing enterpriseMES/MOMSystems generally emphasize the application effect of management and control integration, and discrete manufacturing enterprisesMES/MOMDue to the lack of sufficient automation and integration means in the system, It is often difficult to achieve the degree of integration of management and control, but the integration of management and control is always a discrete manufacturing enterpriseMES/MOMThe development direction of the system is also paperlessMES/MOMThe inevitable direction of system development. In order to realize the integration of management and control for discrete manufacturing enterprises, the most important thing is to have the support of automated data acquisition technology.
At present, the more feasible automatic data acquisition technologies include: automatic data acquisition technology of CNC equipment operation, automatic data acquisition technology of furnace temperature control system, automatic data acquisition technology of measurement system, etc.
null4Human-computer interaction technology
nullMES/MOMSystems manage the execution of manufacturing, which is fraught with changes and exceptions, and this problem is particularly prominent in the case of the loss of paper as a record carrier. This is also the impact of human-computer interaction technology on paperlessMES/MOMThe reason why system software is so important.
nullHuman-computer interaction technology generally requires logistics identification technology and automatic data acquisition technology(Especially automatic acquisition of test data)As a support, it can realize the prompt for the components that select the wrong batch serial number, RightBOMAnd the technical status of the process supplementary documents for verification and alarm, and the measurement results are automatically packaged and analyzed. Electronic Assembly AbroadMES/MOMThere are already engineering applications of human-computer interaction in the system.