MES solutions for the cable industry


MES solutions for the cable industry

1. Program overview

The special industry characteristics of the cable industry: customized, multi-variety, high cost, low profit, etc., can no longer be implemented in the form of traditional manual paper-based production, and must implement refined management. At the same time, the increasingly mature application of network technology in the field of industrial control makes the realization of MES in manufacturing enterprises easier and easier. That is, relying on network technology and intelligent manufacturing technology to dynamically monitor and manage the production process of the production workshop in real time.

  • Integrate available resources, connect the planning layer and operation layer of the enterprise, and integrate information islands;
  • Electronic production data to provide help for process improvement and performance statistics;
  • Improve management methods, fully integrate production planning, material flow, schedule, process control, process monitoring, quality management and other activities in the manufacturing process, and organically coordinate the execution of these activities, so that the manufacturing process develops in an efficient direction;
  • Improve production efficiency and personnel efficiency;
  • Improve factory operation and incident handling capabilities, and strengthen factory production adaptability;
  • Improve the level of enterprise production automation and enterprise production management, and strengthen the enterprise's adaptability and core competitiveness.
Management goals
  • Electronic production data, to provide help for process improvement and performance statistics;
  • Realize product quality traceability and improve the quality of cable products;
  • Realize the standardization of work process and improve the level of production management;
  • Improve production efficiency and personnel efficiency;
  • Realize factory production automation, continuity and equalization;
  • Realize the visible and controllable management of output, consumption, quality, technology and other aspects in the production process.

2. Project highlights

  • Work order energy + factory energy plan management, real-time monitoring, and history tracing to achieve controllable energy management.
  • The Gantt chart form realizes the intuitive visual experience of plan tracking.
  • Work orders are automatically associated with process quality parameter management, process parameters are monitored in real time, and the best process parameter practice is realized through historical data.
  • Class product qualification rate + class plan completion status + class output comparison to achieve performance evaluation of class personnel.
  • Data alarm + video linkage to quickly locate faulty equipment.

3. system architecture

Core data access solution

1. Data access plan

status quo:

At the current cable production line, the bottom electrical of each production line is composed of PLC plus TD400 text display, etc., displaying some alarm information, which can only achieve the automation of a single device. Each production line is independent of each other, forming a lot of island information and information about production. It is inconvenient to summarize.

In the production process, quality mainly includes optical cable appearance detection and OTDR optical cable reduction detection. At present, these two data are recorded by manual paper. The data record contains subjective factors of the recorder. When a problem occurs, the analysis problem is Certainty.

Data access plan:

Solution 1: The basic data of the underlying equipment is integrated into a single device through Kingview, and is aggregated into a single device control unit on site. After the data is collected by KingIOServer, the data is sent to the data server and the history server for data storage and data storage. Real-time display.

Solution 2: KingIOServer takes PLC data through TCP protocol, but collects serial devices such as TD400 or serial devices in the form of a network through the serial server, and then collects and transmits them to the PLC device.

2. Docking with other platforms

The back-end databases of other platforms are generally relational databases such as Oracle/SqlServer/Mysql/Pgsql.

The software platform has the following characteristics:
  • Integrability: to realize the integration of systems with different manufacturers and the protection of the existing systems of the enterprise.
  • Configurability: It can quickly configure the system structure for newly introduced products in the factory and unexpected changes in demand to meet the changing needs of users.
  • Adaptability: The system can automatically adapt to changing workloads and conditions or changes in business processes through the system's good reconfiguration capabilities.
  • Scalability: It can not only expand its functions within a unit, but also expand to other manufacturing units and other stages of the product manufacturing life cycle to meet various complex manufacturing requirements.
  • reliability. Ensure the data integrity and consistency of distributed systems and the security of virtual enterprise information interaction.

4. system function

Production management
  • The production management module includes: production order, progress tracking, real-time monitoring, capacity statistics, equipment analysis, and OEE analysis.
  • Production order: Convert sales orders into production work orders to achieve visualization of production tasks.
  • Progress tracking: real-time tracking of production progress.
  • Real-time monitoring: monitor the real-time data of equipment, reflect the real situation of the scene, and quickly locate the problem equipment with video linkage.
  • Capacity statistics, equipment analysis, OEE analysis: Analyze the use efficiency, capacity, equipment status, frequency of use, etc. of the equipment through histograms, horizontal charts, slub charts, etc.
Quality Control

Realize product quality traceability and improve the quality of optical fiber products. First, in the production process, quality mainly includes optical cable appearance detection and OTDR optical cable reduction detection. At present, these two data are recorded by artificial paper, and the data is recorded with subjective factors of the recorder. When a problem occurs, analyze the problem With uncertainty. Second, the special optical cable produced by the braiding machine may not be used until two years later. If the product has quality problems, the production process needs to be reshaped, and the basic data and video data from the production of this optical cable will be used. The MES system can monitor the entire production process in real time, and directly store the detection data in the dispatch center from the equipment. If quality problems occur, they will be alerted in time, and video linkage will be generated to record the problematic production environment in time. It can trace historical production problems and video playback through the analysis of recorded historical data, and more accurately discover and determine the cause of the problem.

Warehouse management

Detailed records are made on the inventory volume and the storage and exit conditions to achieve inventory transparency. Track the use of materials in production, clarify the number of remaining materials in the production line, and determine whether an application for ingredients needs to be issued.

Equipment management

Establish a complete equipment file, and conduct a comprehensive management of the entire process of equipment from purchase to scrap. Develop regular equipment maintenance plans, and record and track equipment maintenance.

Personnel management

The organizational structure is completed in the system to facilitate the assessment of personnel performance and real-time adjustment of personnel permissions online.

5. Program summary

  • 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 that occur in the production at the first time, and improve the efficiency of production management;
  • Achieve comprehensive production tracking, including material tracking.
  • Real-time management and analysis of production, improve production flexibility, planning accuracy, reduce downtime, increase production capacity, and optimize production performance;
  • Realize the quality control of the production process and improve product quality;
  • Collect real-time production consumption and output data through the MES system to achieve real-time statistics of production consumption. The control of production is not only controlled to the month, but also controlled to the fineness of the day, shift, and machine to improve the level of enterprise management. , To improve operational efficiency and reduce costs;
  • Through flexible factory modeling capabilities to adapt to the changes and adjustments of production business processes and production processes, enterprises can carry out refined management of the entire production process. In the production control process, the production standard information is quickly transferred to the production site. Through the real-time collection of a large number of process real-time data, problems and trends in the production process can be discovered in time, and the information of each link in the production process can be recorded.

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