The hottest digital factory moves from MES to inte

2022-07-27
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Digital factory: from MES to "intelligent" manufacturing

when we talk about intelligent manufacturing, what are we talking about? Is it smart equipment or smart factory? Or cloud, big data or service-oriented manufacturing? Or is it industrial interconnection? More microcosmic, is it a machine replacement or an AI

some people may say that this is the category of intelligent manufacturing. However, R & D and production are the core of the factory, and intelligent factory has also become the core of intelligent manufacturing. For enterprises of different development stages and forms, the roads of digitalization, networking and intellectualization are different. However, in the process of building intelligent factories and leading to intelligent manufacturing, an indispensable common link is the manufacturing execution system (MES)

MES, which is positioned in the manufacturing process management of the whole workshop, schedules jobs according to orders and plans. It builds a bridge between the planning management layer and the underlying control layer, which not only enables ERP to be implemented, but also optimizes the production process. Thus, MES has become the core of intelligent factory (Digital Factory) and the key link of lean production

Taiji intelligent factory architecture

the flowers are becoming more and more attractive. At present, industrial interconnection continues to ferment, and the popularity of big data and AI continues to rise. However, the road of factory intelligence still needs to vary from enterprise to enterprise. In this regard, Dr. zhaojinyuan, general manager of the intelligent manufacturing division of the enterprise business group of Taiji Computer Co., Ltd., believes that achieving accurate control, transparent management and scientific decision-making through intelligent algorithms and advanced management methods should be the focus of most enterprises' intelligence

I

let's first look at a case of intelligent production in the process industry

established in april2009, Qinghai Salt Lake Haina Chemical Co., Ltd., with a total investment of 7billion yuan, is a wholly-owned subsidiary of Qinghai Salt Lake Industrial Company, with caustic soda, PVC, calcium carbide and cement as its main products. It is a typical intermittent process manufacturing enterprise. In 2013, Haina chemical was put into operation, but the product quality fluctuated greatly, safety problems occurred frequently, and normal production could not be carried out. At the same time, the personnel turnover rate is high, and there are some problems in the inheritance of knowledge; Cost accounting is not accurate enough to realize quantitative assessment

in order to solve these problems, Haina has set its sights on the construction of digital chemical plants. In july2017, Haina MES project entered the substantive stage. After nearly two years of project implementation, the partner Taiji Co., Ltd. has built a production and operation management command system (generalized MES, covering the whole plant) for Haina chemical. Based on the industrial information physical system application solution of Taiji Co., Ltd., the system has built functional modules such as intelligent Kanban, production plan management, production scheduling management, quality management, energy management, operation management, safety and environment management, equipment management, production statistics and cost management, realizing the integration of production management and control of Haina

the company level intelligent Kanban

usually uses phenol based main antioxidant and phosphite based auxiliary antioxidant

at present, the overall Haina MES project has only completed the first phase and solved the problem of digitalization, but the effect is completely different. Through the system, the horizontal management has been opened up, the departmental barriers have been eliminated, and the closed loop from the company's business objectives to employee performance has been truly realized; The cost accounting from the company level to the team level has been realized. In the past, the cost accounting took at least one week, and the public's worries have not been eliminated, but now it is real-time statistics; All production control is completed in the dispatching hall, and abnormal conditions are reflected in the intelligent Kanban in real time. The dispatching instructions are directly issued in the dispatching management system, and the operation control is directly completed in the control operation station, which greatly improves the efficiency of production control

in particular, through the use of platform data support and analysis tools, the quality volatility of products, especially high-end products, has been reduced, and the stability of product quality has been significantly improved; At the same time, safety accidents can be warned in advance, reducing the frequency of safety accidents. Zhaojinyuan said

cost real-time analysis Kanban

II

someone once said: no AI, no intelligence. If this is not a kind of marketing, it is a prejudice or misleading. Intellectualization without attributives, even if it does not promote fashionable intelligent projects, will also cause confusion in cognition

there is no doubt that the MES project has laid a solid foundation for the digitalization of Haina chemical. On this basis, the next step is to do vertical precise control, which is the core of the intelligent chemical plant. But why Tai Chi

perhaps it is because of its industrial gene. When Taiji began to make control systems and expert systems in the copper smelting industry in 1993, the concept of informatization has not yet emerged

In 1987, the former 15th Research Institute of the Ministry of electronic industry (now the 15th Research Institute of China Electronics Technology Corporation) established Taiji Computer Company. The company was reformed in 2002 and listed in 2010. At the end of 2018, Taiji made strategic adjustments. Taiji's new strategic vision is to be the best digital service provider in China, a leader in intelligent applications, a national team in data operation, an autonomous and controllable main force, and an achiever of employee value. Supported by the three strategies of data-driven, leading the future by cloud and securing the world, and with the three core technical capabilities of security and reliability, data service and business process, the company focuses on the four areas of government affairs, public security, national defense and enterprises

it is reported that in 2002, with the rise of enterprise informatization, Taiji gradually developed into a comprehensive IT service provider. In this process, Taiji began to build a factory database platform for the bottom layers of factory instruments, PLC, industrial control system, etc., and integrate all the bottom equipment, process, quality and other data into the platform. On this basis, the company has gradually developed production management, quality management, logistics management, energy management and other systems on the data platform. In 2010, the company officially formed an integrated production and operation management and control platform (generalized MES). At present, customers are distributed in the steel, nonferrous metals, fine chemicals and discrete manufacturing sectors of the process industry

III

mes is oriented to production and operation control, but how is it realized? And how to become the core of intelligent manufacturing? Zhaojinyuan said that the integrated production and operation management and control platform is not simply a stack of software, but a combination of many management concepts. It solves the practical problems faced by enterprises from two main lines

one is the main line of management. Many on-site operation workers in enterprise workshops have high skills, but it is undeniable that if the enterprise management mode does not form a closed loop and the assessment is not quantified, there will be problems in the enthusiasm of employees. The production and operation management and control system decomposes from the enterprise's business objectives, generates production plans, from production plans to operation plans, and finally quantifies them to operation posts. Therefore, KPI indicators are formed. This tensile testing machine can be equipped with different fixtures, accessories, two-point extenders and load elements to carry out various test samples. Every day, each team can see the quantitative results, that is, the KPI index, which is linked to the performance bonus

this will greatly improve the enthusiasm of employees. This forms a closed-loop control from the perspective of management. Without this system in the past, it was difficult to achieve this. Zhaojinyuan said

another main line is around control. The essence of production control in process industry is how to process incoming raw materials into final products efficiently, safely and at low cost. The core of control is the equilibrium change of material flow. This requires that the management and control system should be built to realize the effective coordination between various equipment and the accurate execution of control instructions, so as to finally achieve the safe, efficient and green production of the whole production

therefore, as a production oriented management and control system, its internal management ideas, management methods and data processing technology are the key factors to measure the level of different systems. Zhaojinyuan thinks

four

data is the core factor for MES to produce efficiency, including xBOM data management, production process data information collection and management, and many other aspects. This is the root of intelligent control and lean production

in recent years, Taiji has continuously strengthened the research and development of the correlation between the original data of the plant database platform and the batch, feeding, process and working conditions. At present, it can not only achieve the above matching, but also match every meter in the steel plant. For example, steelmaking can be matched to each furnace, including oxygen blowing, nitrogen flow, pressure, tapping carbon content, phosphorus, sulfur and other components. At the time of casting, it can be matched to each meter. On the slab, it can be matched to 0.1M

what does this precise matching mean to the enterprise

on the one hand, when the whole process and all parameters are under the control of Six Sigma, the quality must be qualified. On the other hand, if there is a problem, no inspection or sampling is required. The system can tell the enterprise what kind of quality event there is in the meter and which part needs to be inspected. This greatly reduces the loss of inspection. More precisely, when the steel mill can be accurate to 100mm, the system can tell the enterprise which roll is high-end steel, or which part of this roll is high-end, so that differentiated marketing can be implemented. This technology has been successfully applied to the chemical industry

in fact, the future digital factory and intelligent factory will bring benefits to the enterprise from two dimensions, one is management and the other is production control. But now most people pay attention to the latter. They want robots and AI. I think these control methods can be applied at a single point, but from the perspective of system, it is still very difficult. Zhaojinyuan said. He called on the future intelligent factory, if it can give full play to the subjective initiative of front-line workers, it will be far greater than the value brought by robots and artificial intelligence

over the past decades, lean management has been continuously extended to all aspects of enterprise management, greatly improving the overall efficiency of the manufacturing industry. At present, China's economy is changing from a high-speed growth stage to a high-quality development stage. Improving the high-quality development of the manufacturing industry through digitalization, networking and intelligence has become a practical action of the manufacturing industry. However, no matter how the new generation of information technology is integrated with the manufacturing industry, the production end at the core level is not only the foundation of the manufacturing industry, but also the key path of high quality

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