A case study of the informatization system in the auto parts industry


A case study of the informatization system in the auto parts industry

1. Project background

Liuzhou Wuling Automobile Industry Co., Ltd. (hereinafter referred to as "Wuling" or "Wuling Industry") is a large-scale Sino-foreign joint venture integrating development, manufacturing and sales, and a comprehensive automobile industry group with certain international competitiveness. Wuling is market-oriented and promotes the coordinated development of the three main businesses of parts, engines, and vehicles through technological innovation, product innovation, and management innovation. Wuling has grown into a large-scale automobile industry group based in Guangxi and operating across provinces, covering automobile manufacturing and automobile aftermarket business. Four automobile manufacturing bases in Liuzhou, Guilin, Qingdao and Chongqing and two automobile business centers in Tianjin and Hunan have been formed. With an annual production capacity of 1.4 million sets of auto parts, 800,000 auto engines and 100,000 complete vehicles, it is China's largest manufacturer of mini-car parts and a leader in domestic micro-light commercial modified vehicles.

2. Analysis of corporate pain points

Before the informatization construction, the current production status of the enterprise is as follows:

  • The section chief of each workshop receives the production tasks from the planner by email, and the section leader verbally assigns production tasks to the production lines of the workshop;
  • The counts of production completion of each production line are counted by manual labor, and the monitor will summarize and manually enter into the ERP system after get off work;
  • When the production line is stopped or other problems that affect the production, manually record the length of the stoppage and the reason for the stoppage;
  • The equipment of the production line is isolated and not connected to the Internet. The equipment and production-related personnel cannot monitor the operating status of the equipment at any time.
  • Manual extraction of customer demand plans, extraction from multiple files is prone to errors

3. Implementation plan

3.1 System Architecture

The overall system is divided into two parts, namely the intelligent production line terminal system and the central MES system (including APS function modules). The intelligent production line terminal system is positioned at the production execution level of the workshop production line, responsible for receiving production tasks, workshop data collection, production process recording, etc.; the central MES system is positioned at the production management level, responsible for planning and scheduling, issuing production tasks, and collecting production Data, various information traceability, team performance appraisal, etc.

3.2 Main functions
3.2.1 Basic data
(1) Product bill of materials

Used to display manufacturing BOM information, that is, the types of product materials in each workshop section.

(2) Basic data of production line
Realize the association between products and determine the types of products that can be produced by the production line, as well as the standard tempo and standard labor for producing a certain product.
(3) Factory calendar management

Maintain the production calendar of each section of the production line, with operations such as adding, editing, deleting, and querying.

3.2.2 Planning and Scheduling
(1) Monthly capacity assessment

This interface implements monthly capacity assessment and query functions based on demand.

(2) Daily production capacity assessment
(3) Operation plan

This interface implements operations such as formulating and issuing production plans for each production line, and has functions such as manual order placement and batch import of production plans.

(1) Production Daily

This interface is used to display the production completion status of each section every day.

(2) Production line OEE

This interface is used to display the monthly OEE of each production line and the daily OEE indicators of a certain month.

(3) Work order traceability

This interface is used to query the execution status of historical work orders, including the completed number, the number of warehousing, etc.

4. Project summary

Through the introduction of the APS system, the multi-customer and multi-source requirement documents are standardized, so that the system can automatically read and translate customer requirements, and through the BOM structure, the assembly product requirements are sequentially decomposed into the requirements of each semi-finished product, which greatly reduces the plan The staff extracts the workload of the factory’s required supply requirements from multiple demand documents, and conducts monthly, weekly, and daily capacity assessments based on production resources. From 2-3 hours of manual scheduling by planners to ten minutes.

In terms of production execution, it replaces manual statistics and records completion data. The intelligent production line terminal automatically performs completion statistics according to equipment piece-rate signals or scan code information, realizes the digitization of the production process, and improves the efficiency of production information transmission. The management can be in the MES system in real time Check the production progress of the monitoring production line, and realize the transparency of production.

In terms of production data tracking, the system collects production data every day and generates a daily report, which allows you to visually check the completion of the entire plant the day before. It is also possible to query and trace the production completion status for each line and each shift through more detailed function points such as production efficiency and planned completion rate.

In terms of system integration, the MES system integrates data with the WOMS system and the ERP system, and transmits the production plan, production completion and other data to the ERP and WOMS systems to realize the reduction of materials and the settlement of costs, instead of manual orders in the ERP system , As a key link in the data chain, close the loop of production data from source to end.