In the current boom of smart manufacturing, many companies are planning to build smart factories. As we all know, the planning and construction of smart factories is a very complicated system project. In order to avoid detours, this paper sorts out the ten core elements to be considered in the construction and the key dimensions that need attention.
01
Data collection and management
Data is the blood of smart factory construction and flows between application systems. During the operation of the smart factory, business data such as design, process, manufacturing, warehousing, logistics, quality, and personnel will be generated. These data may come from application systems such as ERP, MES, APS, WMS, and QIS. In the production process, data such as output, quality, energy consumption, processing accuracy, and equipment status need to be collected in a timely manner, and associated with orders, processes, and personnel in order to achieve full traceability of the production process.
In addition, in the process of building a smart factory, data management specifications need to be established to ensure data consistency and accuracy. Also consider the interface specifications for data acquisition and the application of the SCADA (Supervision and Data Acquisition) system. Enterprises need to determine the collection method according to the frequency requirements for collection. For data that requires high-frequency acquisition, it should be automatically collected from the equipment control system.
In addition, when necessary, special data management departments should also be established to clarify the principles and methods of data management, establish data management processes and systems, coordinate problems in implementation, and regularly review the technical standards and procedures for implementing optimized data management. Implementation.
â–²Data Management
02
Equipment networking
The most important basis for realizing smart factories and even industrial 4.0, advancing the construction of industrial Internet, and realizing MES applications is to realize M2M, which is the interconnection between equipment and equipment, and to establish a factory network.
Enterprises should establish a unified standard on how to interconnect devices and devices, and what communication methods, communication protocols, and interfaces are used. On this basis, the enterprise can realize remote monitoring of the equipment. After the machine tool is connected to the network, the DNC (Distributed Numerical Control) application can be realized. Equipment networking and data collection are the foundation for companies to build industrial Internet.
03
Factory Smart Logistics
To promote the construction of smart factories, smart logistics at the production site is very important, especially for discrete manufacturing companies. When planning a smart factory, inefficient material handling should be minimized. Many manufacturing companies have set up a Kitting Area in the assembly shop, centralized distribution according to each customer order, and quick picking by means of DPS (Digital Picking System), distribution to the assembly line, eliminating the line side warehouse.
Discrete manufacturing companies can transfer materials using industrial robots with gantry rails, truss-type robots, etc. between two mechanical processes. They can also use AGV, RGV (railed shuttle) or suspended conveyor chains to transfer materials. The application of three-dimensional warehouses and roller path systems is also a problem that companies need to perform system analysis when planning smart factories.
04
Production Quality Management and Equipment Management
Improving quality is the eternal theme of an enterprise. When planning a smart factory, production quality management and equipment management are the core business processes. Implementing quality is the idea of ​​designing, producing, not testing.
Quality control needs to be embedded in the production process in the information system. For example, inspections and tests are handled as processes or steps in production orders; quality control processes, forms, data and production orders are related and penetrated; and quality management is basically established. Work route: Quality Control Settings → Detection → Record → Judgment → Analysis → Continuous Improvement.
Equipment is a factor of production, and the effectiveness of equipment (OEE-equipment overall efficiency) is the basic requirement for smart factory production management. The upgrade of OEE marks the increase of production capacity and cost reduction. The production management information system needs to set up equipment management modules so that the equipment can release the highest production capacity. Through reasonable production arrangements, equipment, especially key and bottleneck equipment, can reduce waiting time.
In the equipment management module, it is necessary to establish various types of equipment databases, set coding, maintain the equipment in time, collect equipment status data in real time, provide equipment capacity data for production scheduling, and establish equipment health management files according to the accumulated The equipment operation data establishes the fault prediction model, performs predictive maintenance, minimizes the unplanned shutdown of the equipment, and performs spare parts management of the equipment.
05
Intelligent plant design
In addition to the design of pipelines for water, electricity, gas, network and communications, the intelligent factory also plans intelligent video monitoring systems, intelligent lighting and lighting systems, ventilation and air conditioning systems, intelligent security alarm systems, smart access control card systems, and intelligent fire alarms. System and so on. With the intelligent video surveillance system, it is possible to determine the abnormal conditions in the monitoring screen and issue alarms or trigger other actions in the fastest and best way possible.
The work area (processing, assembly, inspection, purchase, delivery, storage, etc.) of the entire plant should be analyzed according to the principles of industrial engineering. Simulations of equipment layout, production line layout, and workshop logistics can be simulated using digital manufacturing simulation software. In the design of the plant, it is also necessary to think about how to reduce noise, how to easily adjust the layout of the equipment, and how to transport logistics in multi-storey buildings.
06
Application of smart equipment
When manufacturing companies plan smart factories, they must pay close attention to the latest developments in smart devices. Machine tools are moving from numerical control to intelligence. Many companies use industrial robots when loading and unloading equipment. In the future, the metal additive manufacturing equipment will be combined with equipment such as cutting (substituting) and forming (equal materials) to greatly increase the material utilization rate.
In addition to the six-axis industrial robots, the application of SCARA robots and parallel robots should also be considered, and the collaborative robots will appear on the production line to enable workers to improve work efficiency.
07
Smart Line Planning
Intelligent production line is the core link of intelligent factory planning. Enterprises need to use reasonable methods such as value stream mapping to plan intelligent production lines according to the product family, production capacity and production cycle that the production line will produce.
The characteristics of the smart line are:
â–³In the process of production and assembly, data acquisition such as production, quality, energy consumption, and equipment performance (OEE) can be performed automatically through sensors, numerical control systems or RFID, and real-time production status can be displayed through electronic signage. ;
â–³The cooperation between processes is realized through the lamp system;
â–³ The production line can realize rapid die change and realize flexible automation; it can support mixed production and assembly of multiple similar products, flexibly adjust the process, and adapt to the production modes of small batches and multiple varieties;
â–³ has a certain redundancy, if there is equipment failure, can adjust to other equipment production;
â–³ For intelligent workstations, intelligent tips can be given and human-machine collaboration can be fully utilized.
Designing intelligent production lines needs to consider how to save space, how to reduce the movement of people, and how to carry out automatic detection, so as to improve production efficiency and production quality.
08
Manufacturing Execution System MES
MES is the focus of smart factory planning and landing. It is connected to the ERP system and is connected to the site's PLC program controllers, data collectors, barcodes, and inspection instruments. MES aims to strengthen the execution function of the MRP program, implement production planning, execute production scheduling, and feedback production progress in real time:
â–³ Facing production front-line workers: What do the directives do, how do it, meet what standards, when to start, when to finish, what tools to use, etc.; record production data such as “man, machine, material, method, ring, testâ€, etc. The data link for product traceability; feedback progress, feedback issues, application support, and pulling and cooperation;
â–³ facing the team: to play the management effectiveness of the grass-roots team leader, task management and assignment of the team;
â–³ Facing first-line production support personnel: Ensure the requirements of the production site, such as the distribution of materials, tooling and measuring tools, workpiece turnover and so on.
In order to improve the on-time delivery rate of products, improve equipment efficiency, and reduce waiting time, MES system needs to import production scheduling functions to provide auxiliary tools for production planning and production scheduling, and improve the accuracy of the plan.
09
Paperless production
With the improvement of information technology and the reduction of the cost of smart terminals, it is possible to universalize information-based terminals to each workstation in smart factory planning. Operators will be able to accept work orders at the terminal and accept production data such as drawings, processes, and orders, and can flexibly adapt to changes in production plans, drawings, and processes.
10
Production monitoring and command system
The production line of the process industry company is equipped with a DCS system or a PLC control system. Through the configuration software, the status of various devices and instruments on the production line can be viewed. However, most discrete manufacturing companies have not yet established a production monitoring and command system.
In fact, discrete manufacturing companies also need to build a centralized production monitoring and command system, present critical equipment status, production status, quality data, and various real-time analysis charts. Through kanban visual display. Provide multiple types of content presentation and assist decision-making.
In short, planning smart factories requires a comprehensive application of these core elements and comprehensive considerations from various perspectives. Comprehensive balances should be made from various aspects such as investment budget, technological advancement, investment recovery period, system complexity, and production flexibility. Unified planning and establishment of a smart factory that is forward-looking and effective.
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