A case of production informatization in the custom furniture industry


A case of production informatization in the custom furniture industry

1. Project Overview

A custom furniture company in Guangdong is a leading brand enterprise in China's solid wood customization industry. It has established four large modern production bases in Dongguan, Guangzhou, Beijing and Tianjin. In 2018, a high-end customized furniture smart factory was built in Yichun City, Jiangxi Province. The products produced include wardrobes, cabinets, wooden doors, etc., involving solid wood and panel furniture customization. This project mainly focuses on the production information construction of the entire Jiangxi factory, and includes the production planning and scheduling functions of the entire group company.

The customer's product production model is large-scale and multi-variety personalized, the product production cycle contained in the order varies greatly, product outsourcing and other complex factors make the manufacturing department unable to answer to the business department when to deliver on time, and the manufacturing department is difficult to deliver on time; Each production subsystem is isolated, and data is not shared and interacted, resulting in low production efficiency. How can the production information system integrate comprehensive information with related systems to effectively solve the problem with the ERP system, the order splitting system, the layout optimization system, the WMS system, Data exchange issues between production line automation systems.

2. Project goals

Specific functions to be realized by the system:

(1) Maintenance of basic data

a. Order data management

b. Production line equipment capacity maintenance

c. Material data management

Including plate inventory, edge banding inventory, hardware inventory data maintenance, etc.

d. Factory production calendar management

e. Product BOM data management, etc.

(2) Scheduling

a. Sales order inquiry period

b. Main production plan

The master production plan includes the development of a group order production plan and a factory-level kneading batch plan.

The function of the group order production plan is to allocate orders and order production sequence to specific factories according to the order area and factory capacity.

The kneading batch plan is a kneading order generation operation plan for the orders dispatched to a specific factory. The subdivision functions include order filtering, order batch optimization, kneading batch generation, batch re-kneading, material inventory warning, and machine materials Distribution plan, product packaging plan, etc.

c, rescheduling function, etc.

Subdivision functions include order insertion, work order re-kneading, plan rearrangement, plan adjustment, etc.

(3) Production schedule management

a, production progress tracking

Subdivision functions include order progress tracking, work order progress tracking, workstation progress tracking, work in progress tracking, etc.

b. Production statistics

Subdivision functions include order statistics, station/process shift, daily and monthly production statistics, etc.

c. Product traceability/p>

(4) Material management

a. Material pulling

The subdivision functions include material shortage ordering, distribution, verification, and return

b. Feeding management

c, the management of the remaining material

d. Finished product warehousing management, etc.

(5) Equipment management

a. Equipment ledger

b. Equipment maintenance management

c. Equipment maintenance management

d, equipment OEE

e, tool management, etc.

(6) Quality management

a, product maintenance management

b. Product scrap management

c. Production line through rate, etc.

(7) Personnel management

a. Staff dismissal management

b. Production shift, daily and monthly working hours, piece rate statistics, etc.

Three, the solution

(1) System architecture

In the new five-level architecture, KingFusion3.5 products realize the functions of SCADA, MES, ALS, and APS. The APS system realizes the group order scheduling and branch factory kneading single batch scheduling functions, the ALS system realizes the production line operation sequence, and the MES system realizes Schedule, material, quality, equipment, personnel, production execution management, SCADA system is responsible for production line monitoring and execution, and the systems that need to be connected include ERP system, order splitting system, layout optimization system, WMS system, etc.

(2) System software and hardware deployment

The system hardware is mainly composed of two hosts, multiple monitors and a switch, which are connected in a local area network. System software deployment: KingFusion3.5 engineering services and library services are deployed on one host; KingFusion3.5 data calculation engine, collection engine and WEB service are deployed on the second host; there are several production line boards, and KingSCADA is responsible for production line production Monitoring; KingIOServer is responsible for collecting factory production line data.

(3) Program highlights
  • Accurately reply to the order delivery date.
  • Develop an effective production plan. The system can respond to abnormal conditions such as inserting orders, order cancellations, and equipment failures in the production process in a timely manner, and realize dynamic adjustment of production plans.
  • The production line operation sequence ensures the balance of equipment capacity and load, collaborative production, shortens the waiting time for complete sets of orders, and realizes simultaneous shipment of ordered products.
  • Develop a reasonable material demand plan and machine material distribution plan, timely warning of material inventory, and realize efficient material supply.
  • According to product packaging rules, a reasonable pre-packing plan is formulated in the system to increase the utilization rate of the packaging box and realize efficient packaging of the product.
  • Real-time control of production dynamics to improve the response speed of handling production events. The production scheduling personnel understand the details of the production in time, monitor the production activities, deal with the problems in the production as soon as possible, and improve the efficiency of production management.
(4) The software platform has the following characteristics

Reliability: to ensure the data integrity and consistency of the distributed system and the security of information interaction with related systems.

1. Quality analysis: statistical analysis of defect rankings, the number of different levels of defects, and more comprehensive quality management

2. Security: The system provides security configuration content such as security zones, operations, levels, units, and users. All models, data objects, visual graphics objects, etc. need to be configured with security attributes, and only authorized users can access related content.

3. Integrability: to realize the integration of systems with different manufacturers and the protection of the existing systems of the enterprise.

4. Scalability: It can not only expand its functions in a factory, but also expand to other manufacturing plants and other stages of the product manufacturing life cycle to meet various complex manufacturing needs.

Four, typical functions

(1) Production visualization

The production visualization display content includes daily planned batch progress, daily planned order progress, batch planned production latest TOP10 progress, order delivery date latest TOP10 progress, the first pass rate of production line products, and the implementation of material distribution plans.

"Batch progress details" displays the batch information in progress on the production line and the line balance rate.

"Order progress details" displays the completed order information, uncompleted order information, and the specific location information of the uncompleted order product on the production line.

(2) Planning and scheduling module

The plant's requirements for planning and scheduling include assessing the delivery date of sales orders, formulating a single batch plan, formulating a material demand plan, formulating a machine material distribution plan, and formulating a product packaging plan.

a, order inquiry period calculation

The order is broken down according to the sheet specifications of the inquiry order to obtain the number of sheets that need to be produced on the main line and auxiliary lines of the factory, and then according to the main line, auxiliary line production capacity and factory calendar, without affecting the delivery date of the received order , Insert the inquiry order into the time period when the main line and auxiliary line capacity are not saturated, and get the earliest time that the inquiry order can complete production.

b, kneading

Including order selection, order group batching, batch generation. After the batch is generated, the layout optimization software optimizes the batch to obtain the optimization rate of each batch, manually reviews the optimization rate, performs batch recalculation for the batches that fail the optimization rate, and updates the batches. Calculate and review the optimization rate until the optimization rate of all opening batches is approved, and all opening batches that meet the optimization rate are obtained.

c, packaging algorithm calculation

According to the production tasks in the planning period, a specific packaging plan is given. The generation of the packaging plan needs to consider that the sheets of the same product and the same specification according to the order number are placed in a package first, with package weight and package height restrictions, and plate stacking constraints , Including the big board on the bottom, the small board on the top, and the same level of boards except the top layer. The packaging algorithm needs to increase the board packaging loading rate under the conditions of meeting the above constraints, and finally get the specific loading order for each package number No., sheet size and specific space coordinates of each sheet.

d. Insert single calculation

When there is an urgent order that requires priority production, all processing operations cannot be suspended. The time point for inserting urgent orders can only be arranged after the tasks that have been produced and before the tasks waiting for production, so that the insertion of the order will cause other orders It may not be carried out according to the scheduled time node, so it will also affect the delivery date. Therefore, before executing the insert order, the impact of the insert order must be evaluated first, and the dispatcher will then determine whether to execute the insert order based on the order evaluation result.

(3) Production schedule module

The requirement of the factory in terms of schedule control is to realize real-time tracking of production, production statistics and product traceability. The functions realized by the production schedule include order schedule, work order/batch schedule, work-in-process tracking, station/sequence statistics, order set statistics, material opening statistics, packaging statistics, product traceability, etc.

a. Production Kanban

The production kanban is used to guide the workshop production. The blanking kanban is used to monitor the real-time progress of the blanking production and the auxiliary operations required for the blanking production, including material ordering, material return, work order planning and distribution plan query.

b. Order progress

Perform statistical analysis on the progress of each level of the order structure, and track the unfinished part of the order.

c. Production line work order

Production line work order tracking is to track the completion of work orders on the production line.

d. Cutting progress

Real-time display of the cutting plan and actual completion in the form of a Gantt chart to achieve an intuitive visual experience of plan tracking.

e. Work station statistics

It is used to make statistics on the completion of production in shifts, days and months.

(4) Material management module

Material pulling, including stacking material inventory tracking and production ordering, material distribution and verification tracking, material return tracking and production replenishment tracking, etc.; real-time tracking of factory products, including tracking of semi-finished products in the factory, tracking of unfinished materials, and packaging Number generation tracking, finished product stacking completion tracking, etc.; material statistical analysis and tracing, including raw material material return records, product packaging completion records, finished product storage records, etc.

a. Feeding information

The replenishment information is used to guide the production line to replenish scrap products.

(5) Quality management module

Product maintenance records, product scrap records, and production line product through rate statistics.

a. Product through rate

The straight-through rate of the product counts the probability that the product of the production line will pass the first process to the last process (without being repaired).

(6) Equipment management module

Some functions of equipment management include equipment maintenance, equipment maintenance, equipment OEE, tool management, etc.

a, equipment OEE

b. Tool management

Five, project summary

  • Evaluate the delivery date of the order and accurately answer the delivery date of the customer's order. Develop effective group-level and branch-level production scheduling plans, so that customer orders can be delivered on time.
  • Carry out a reasonable sequence of production line operations, coordinate production, shorten the waiting time for complete sets of orders, and realize simultaneous shipment of ordered products.
  • Develop a reasonable material demand plan and machine material distribution plan to achieve efficient supply of materials. According to the product packaging rules, formulate a reasonable pre-packaging plan in the system to achieve efficient product packaging.
  • Realize the visualization, digitization and intelligent improvement of management processes such as orders, batches, material status, production progress, production efficiency, quality information, logistics information, equipment operation, etc., to improve production efficiency and product quality, and reduce production costs.
  • Open up the data communication of the underlying equipment, realize the interconnection and intercommunication of production data with various equipment in the industries such as Halma, Biesse, Schelling, and Nanxing.
  • Production-related systems carry out comprehensive information integration. The data interaction between MES system and ERP system, order splitting system, layout optimization system, WMS system, production line automation and other systems is accurate and efficient.