Paperless factories
What's a paperless factory?
Paper production is manufacturing. Industries A new production model whereby paperless production through continuous production is largely dependent on automated water lines, while paperless production through discrete production is mainly dependent on workers, who are required to work successfully in paperless environments, which is much more difficult. Paperless production not only eliminates “paper”, but also, more importantly, creates a new production model (a shift in roles and working methods). The very image of paperless production is expressed by what paperless workers say: “Let workers screw up a few wrenchs and make little data available”.
Paperless MES/MOM System functionality framework
Paperless proposal MES/MOM System functionality framework, paperless MES/MOM The system is divided into nine components: workshop planning management, production preparation management, worker on-site operations management, equipment operation management, quality operations management, visual panels management, time management, production history management and exceptional management. From a design point of view, paperless. MES/MOM The system software functionality framework provides the following considerations:
Highlight the workers' portal
The workers ' portal not only displays visualization, but also, and more importantly, enables workers to obtain all the information they need on the portal and avoids workers accessing different systems for information. The workers ' portal enables information to be automatically delivered to workers, allowing them to work and record quickly, thus introducing new production patterns in paperless production environments.
2. Request for integration of PDM and CAPP
Under paperless production patterns, the electronic work guide (EWI), used by workers on the workers ' portal, is a data package that combines operational instructions, process protocols, drawings and models (the concept of EWI is proposed by ISA95). This demand has greatly facilitated the integration of PDM and CAPP. In the case of PDM and CAPP, where the integration is not yet mature, there is a need for a better understanding of the problem. MES/MOM The integration of the system with CAPP has also become an option in transition situations, such as Visiprise in Lockheed Martin. MES/MOM The system includes CAPP modules.
3. Increased efficiency of field collection
The amount of information collected on-site data has been expanded. MES/MOM The system not only plays the role of completion on the ground, but also requires the recording of various types of relevant information about the manufacturing process as required by EWI: The environment and its associated parameters, the state of operation of the tools and equipment used, the origin and quality information of the gross amount of raw materials, the batch and quality information of the loads, and the data of the test results, And processing information on the non-conforming products to obtain the full curriculum vitae of the production process.
4. Field exception management
In particular, on-site exception management is particularly prominent. In order to increase production efficiency, process over and temporary processes are often done directly by processors at the production site, and this information is required after paperless MES/MOM The system is managed with on-site editing, modifications and versions and can be matched with PDM/CAP data. In the course of the project, some discrete workshops using unstructured CAPPs could even include the process development function in traditional CAPPs, following the example of SAP/Visiprise MES/MOM System software.
5. Highlighting the position of production readiness
Production preparation is divided into two levels of distribution at the enterprise level and on-site, where MES/MOM The system is responsible for the latter. Field-level distributions emphasize short- and medium-term production readiness and aim to achieve JIT-type distributions that enable workers to fully adapt to the role of “surgeon” in paperless production. More energy is directed to the production chain.
Increased emphasis on the integration of factors of production and operations
In paperless production environments, people work more closely, and all information needed for on-site production needs to be managed in computers only, greatly increasing the requirement for information integration.
Paperless MES/MOM Specific features of system components
1. Workshop plan management
Received ERP Workshop orders were issued, which were broken down into a schedule of work, and work was assigned to the site. It's tradition. MES/MOM System software should be functional.
Production readiness management
The assembly tools, workshop level II stocks and products in production are managed and the production resources are distributed to the site in accordance with the schedule of work and assignment requirements.
3. Worker ' s on-site operations management
On-site work was carried out around the workers ' portal, where workers received work instructions, the process was completed, and processing and testing records were completed. From the application of paperless production abroad, the workers portal and e-work guide are paperless in discrete workshops MES/MOM The most critical element of system software.
4. Operation management of equipment
Management of the equipment repair and maintenance process, complete recording of the equipment ' s operational status and availability of the equipment to support disposal.
5. Quality Operations Management
Manage on-site testing processes, test data collection, and the processing of substandard products.
6. Visualized board management
For the production of large screen panels for the site and for visual querying for management.
7. Hour management
Management of fixed working hours and actual processing hours of workers, as well as automatic generation of time statements. Of these, the collection of working time data was completed by the field operation module and the validation of working time data by the quality operation module.
8. Production curriculum vitae management
Supported by the above-mentioned modules, a complete curriculum vitae of the processing process, the Human Material Law Ring, was developed.
9. Exceptions Management
Address all types of exceptions and their impact on production plans and improve the system ' s resilience to production exceptions.
Paperless MES/MOM The implementation of the system is not simply a software system implementation, but also needs to include process and hardware upgrading as a basis, and sometimes a new product model represents an entirely new design and manufacturing model. Therefore, building paperless MES/MOM The system needs to consider different product types and different stages of application.
The workshop usually has multiple-model product hybrids, using the same set MES/MOM The system adapts to data of varying degrees of maturity as a necessary choice. In particular, the work portals used on the ground need to receive work guides for different products. So, paperless. MES/MOM In the design of the system, particular emphasis needs to be placed on the standardization of the workers ' portal and the work guide, Improve the functionality and configuration of the workers ' portal.
Paperless MES/MOM System critical technical analysis
Paperless MES/MOM The realization of the system requires not only a change in the management model but also a lot of hardware and software technology to support:
1. Production site terminal technology
Production site terminals are used to display work instructions and work instructions, and operators can view work assignments, report start-ups and completions at the terminals, and drawings, process protocols and digitized models at the terminals if conditions are available.
Applications abroad have shown that the use of portable wireless or offline terminals is becoming MES/MOM Important directions for system applications. Especially those who meet the security requirements of confidentiality in the production of aviation military engineers, Terminal technology with wireless encrypted transmission will become aviation MES/MOM Key technology of the system.
The number of site terminals in paperless workshops should meet paperless production needs and, in principle, one equipment or operator should be equipped with one terminal.
2. Logistics marking techniques
MES/MOM Systems emphasize control of logistics, accurate and rapid logistics management often requires the use of labelling techniques, including bar codes, RFID, etc. The application of logistics tagging technologies becomes even more urgent when paperless.
At present, miniaturized laser type 2D, adhesive RFIDs resistant to metal interference and corrosion are all marking techniques that can be adapted to discrete manufacturing needs, and related national military markings are being pre-developed.
3. Automated data acquisition techniques
It's a continuous manufacturing business. MES/MOM The system generally emphasizes the application effect of integrated controls, of discrete manufacturing enterprises MES/MOM The system is not sufficiently automated to integrate. It is often difficult to achieve regulatory integration, but it is always discrete manufacturing enterprises. MES/MOM The direction of the system is paperless. MES/MOM The inevitable direction of system development. The most important thing for discrete manufacturing enterprises to achieve regulatory integration is supported by automated data acquisition techniques.
The current more feasible automated data acquisition techniques include: automated data capture technology for running equipment, automated data acquisition technology for furnace temperature control systems and automated data acquisition technology for measurement systems.
4. Human interactive technology
MES/MOM The implementation process of systematic management of manufacturing, which is fraught with changes and exceptions, is particularly acute when paper is lost as a record carrier. It's also an interactive human technology for paperless. MES/MOM The reasons why system software is very important.
Human interactivity technology generally needs to be supported by logistics marking techniques and automated data acquisition techniques (especially testing automatic data acquisition) to enable the prompting of zero components that select the wrong batch number, The technical status of BOM and process supplement documents is verified and alerted, and measurements are automatically packaged and analysed. Electronic assembly abroad MES/MOM There is an interactive engineering application in the system.