In recent years, European and American countries for the process industry first proposed the concept of “smart factory”. Process Industry intelligent factory of business intelligence, operational intelligence, operational intelligence three levels, due to the higher their level of automation, and therefore relatively easy to implement intelligent plant. Compared with the process industries, discrete manufacturing first in the bottom of the manufacturing sector due to the complexity of the production process, such as turning, milling, planing, grinding, casting, forging, riveting, welding highly intelligent production equipment requirements, a large investment . Particularly equipment manufacturing, household appliances, automobiles, machinery, tooling, aerospace, consumer electronics and other products mostly requires intelligent products, intelligent design.
Thus, in 2025 and supports the Chinese manufacturing industry 4.0 Information Fusion System CPS under physical, discrete manufacturing production equipment needed to achieve network, production data visualization, paperless document production, the production process transparency, and other advanced unmanned production site technology, so that the longitudinal, lateral and end to end integration, to achieve high-quality, high efficiency, low consumption, clean, flexible production, so as to establish based on industrial data and the “Internet” smart factory.
1. network equipment, to achieve workshop “Internet of Things”
Things industry proposed to “Made in China 2025”, Industry 4.0 provides a new breakthrough. Things refers to a variety of information sensing device, any need to monitor real-time collection, connection, information needs to interact with objects or processes, etc., whose aim is to achieve things and things, things and people, all the items from the network access and easy to identify, manage and control. Traditional industrial production using M2M (Machineto Machine) communication mode to achieve the communications equipment and devices, and the Internet of Things to Things of communication intelligent people, equipment and systems among by Things, non-interactive seamless connection.
Five characteristics tell you what is really intelligent plant
In discrete manufacturing workshop, CNC turning, milling, planing, grinding, casting, forging, riveting, welding, machining centers, is the main production resources. In the production process, all the equipment and stations unified network management, between the device and the device, capable of networking between the device and computer communications, equipment and station staff closely related.
Such as: CNC programming can be on your own computer programming, machining program will be uploaded to the DNC server, the equipment operator can program the device controller through the production site to download required, after the completion of the task to be processed, and then through the DNC network NC program back to the server, the process by the program administrator or personnel or archive comparison, the entire production process to achieve network, traceability management.
2.Â production data visualization, data analysis using a large production decisions
“Made in China 2025” after the proposed information technology and industrialization, rapid integration, information technology permeates all aspects of the discrete manufacturing industry chain, bar codes, two-dimensional code, RFID, industrial sensors, industrial automation systems, industrial networking, ERP, CAD / CAM / CAE / CAI technology is widely used in discrete manufacturing enterprises, especially the Internet, mobile Internet, networking and other new generation of information technology in industrial applications, discrete manufacturing enterprises have also entered into a new development of the Internet industry stage, have also increasingly rich data. Discrete manufacturing production line at high speed, resulting from the production equipment, gathering and processing of data is much larger than the amount of enterprise computers and artificially generated data, real-time data requirements also higher.
At the production site, once every few seconds to collect data, use of these data can achieve a lot in the form of analysis, including equipment operation rate, the operating rate of the spindle, spindle load rate, operation rate, failure rate, productivity, comprehensive utilization rate of equipment (OEE ), with a pass rate of parts, quality and percentage. First, improvements in the production process used in the production process of these large data, you can analyze the entire production process, understand how each link is executed.
Once a process deviates from the standard process, it will generate an alarm signal can more quickly find errors or bottlenecks, but also makes it easier to solve the problem. The use of Big Data technologies can also establish a virtual model of the production process, simulation and optimization of production processes, when all processes and performance data can be rebuilt in the system, this transparency will help manufacturers improve their production processes. Again, in terms of energy consumption analysis, the use of equipment in the production process sensors centralized monitoring of all production processes, it is possible abnormal situations or peak energy consumption, thus can optimize energy consumption in the production process of all processes analysis will greatly reduce energy consumption.
3. the production of documents paperless, efficient, green manufacturing
Construction of green manufacturing system, construction of green plant, production of clean technology, waste of resources, low-carbon energy is the realization of China 2025 “manufacturing” an important strategy to “manufacturing power”. Currently, resulting in discrete manufacturing enterprises variety of paper documents, such as process cards, replacement parts and blueprints, the number of three-dimensional mold, tool lists, quality documents, CNC programs, etc., these paper documents are mostly decentralized management, not easy to quickly find, centralized sharing and real-time tracking, and easy to produce large amounts of paper waste, loss and the like.
After the production of paperless document management, staff can quickly check at the production site, browse, download the required production information, production data generated in the process can immediately be archived, significantly reducing manual paper-based documents and deliver circulation, so as to prevent the files, data loss, and further improve the efficiency of production preparation and production operations efficiency, green, paperless production.
4. the production process transparent, smart factory “nervous” system
“China 2025,” clearly to promote the manufacturing process intelligence, through the construction of intelligent plant, promote emulation manufacturing process optimization, digital control, status information, real-time monitoring and adaptive control, thus achieving intelligent control of the whole process. In the machinery, automotive, aerospace, shipbuilding, light industry, household appliances and electronic information and other discrete manufacturing industries, the development of intelligent manufacturing enterprise core purpose is to expand the product value space, focusing on automation from a single piece of equipment and products of intelligent start, based on productivity improve product performance and achieve value growth. Therefore, its smart mode of propulsion plant construction equipment (production line) intelligence, through the introduction of various kinds with the equipment needed for the production of intelligence, based on the establishment of a manufacturing execution system MES workshop production level intelligence unit and improve precision manufacturing, agile manufacturing, manufacturing transparent Ability.
Discrete Manufacturing production site, MES plays a huge role in the realization of the production process automation, intelligent, digital and other aspects. First, MES to achieve by means of the transmission of information from product orders to complete the entire production process to optimize the management and reduce non-value added activities within the enterprise, effectively guide the operation of the process plant, and improving timely delivery. Secondly, MES between the enterprise and the supply chain in the form of two-way interaction on the basis of information production activities, make plans, production, resource three closely cooperate in order to ensure that decision makers and managers at all levels can master the production site in the shortest possible time changes, to make accurate judgments and to develop rapid response measures to ensure that the production plan is reasonable and rapid correction, smooth production processes, resources fully and effectively utilized, thereby maximizing productivity.
5, unmanned production site, truly “no” factory
“Made in China 2025” to promote the widespread application of industrial robots, mechanical arm and other smart devices, the plant unmanned manufacturing possible. In discrete manufacturing production site, CNC machining centers, coordinate measuring instrument and intelligent robots and all other flexible manufacturing cell for automated scheduling scheduling, parts, materials, tools for automated handling scheduling, you can achieve unattended fully automated production mode (LightsOutMFG). In the case of continuous automated production unit, management priorities and suspend production tasks, remotely view production status of the case management unit, if the production problems encountered, once solved, the immediate resumption of automated production, the entire production process without human intervention, true achieve “no” intelligent production.
Implement manufacturing power to a manufacturing power from the “upgrade”, “Made in China 2025” has become the most powerful strategy-driven. Gallup is “Made in China 2025,” the first explorers and practitioners. The actual depth of the current status of discrete manufacturing, based on 25 years of the world’s leading technology and Chinese 15 years of localization experience, Gallup put forward five discrete manufacturing intelligent direction of the factory, the factory intends to take advantage of global advanced intelligent overall solution (MES-SFC) the productivity engine, breaking the organizational boundaries, the whole enterprise production site management are integrated into the network, we are profoundly changing the manufacturing model structure and the whole manufacturing process, this innovative future competitiveness the outcome will push forward the transformation and upgrading of the manufacturing sector, but also to discrete manufacturing enterprises have a unique experience of new technologies, and set a successful example for the industry.