Case of production management system in an assembly industry


Case of production management system in an assembly industry

1. Project Overview

In this project, there are 37 kinds of products produced, which are completed through 4 production lines and 1 assembly line, and a total of 68 processes are completed. How to control product quality, control production costs, and ensure delivery time under the premise of meeting the individual needs of users is the key requirement of this project. Including 4 modules of production progress tracking, process quality, material pulling and equipment management.

2. Workshop production characteristics

  • There are as many as 25 product categories, and the personalized production model is obvious
  • From raw material supply to shipment inspection, it is a continuous production process, and each production branch is interrelated and restricts each other
  • A wide variety of production reports, manual entry records, paper archives
  • The goal of production management and control is to reduce costs, ensure quality, and improve efficiency while meeting market demand.
  • There are many types of machine equipment, strong dispersion, mostly relying on serial communication, poor scalability and interactivity

3. Function highlights

  • Based on a model-based approach to change as needed
  • Online synchronization of screens, data, calculation models, and objects
  • The model meets both common and individual needs
  • Real-time tracking of progress based on production plan
  • Error-proofing of the process route to prevent the production of unqualified products during the production process
  • Real-time statistics of line balance, straight-through rate, and station time-consuming to quickly locate bottleneck processes
  • Material distribution and inventory dynamic inventory drive productions
  • Rely on complete bottom-level data collection to realize the forward/reverse traceability of the whole production process
  • Multi-dimensional traceability based on equipment integration
  • Equipment OEE and production capacity analysis to provide a basis for formulating production plans and improving production efficiency

4. system architecture

5.System function modules

(1) Production progress

Production progress tracking can view the current work order or product production progress in real time, which is convenient for managers or operators to visually refer to the production plan. The production progress module is divided into parts such as real-time tracking of production progress, production traceability, line balance and process beats, and alarms for the number of products in the buffer between processes.

(2) Process quality

Process quality is one of the basic content of production control, and it is also a reflection of the quality and effectiveness of production technology preparation. Through the functions of process operation guidance, process route error prevention, process parameter error prevention, product straight-through rate, parameter optimization, quality abnormal alarm and product traceability, the process quality is controlled to prevent the occurrence of defective products.

(3) Material pulling

Material pulling is part of lean production. Through the functions of material distribution, dynamic inventory, material error prevention and alarm, real-time deduction and statistics of materials in the production process, and timely material distribution reminders to the warehouse. Reduce material information transmission delays and delays in production.

(4) Equipment management

The main purpose of equipment management is to ensure that the enterprise obtains the best economic benefits by taking effective measures to ensure that the equipment operates in a high-efficiency, long-term, safe and economical manner. Divided into the following four modules: equipment OEE, equipment maintenance, equipment maintenance, equipment alarm.

6. Project summary or typical application

Through this system, the following effects can be achieved:

  • Workshop production grasps the production dynamics in real time and improves the response speed of handling production events.
  • Realize the quality control of the production process and improve product quality;
  • Realize comprehensive production tracking, including material tracking;
  • System information integration, effectively solving data interaction problems with ERP systems and production automation systems;
  • Real-time management and analysis of production to improve production flexibility, planning accuracy, and production capacity;
  • Through flexible factory modeling capabilities to adapt to business and process changes and adjustments, the entire production process is refined management.