Application of MES in the hottest household applia

2022-08-12
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Application of MES in home appliance industry

the full name of MES is manufacturing execution system. The definition of MES by MESA (International Federation of MES) can make the whole experimental process more smooth as follows: "MES is a collection of hardware and software that can complete the management and optimization of workshop production activities. These production activities cover the whole process from order issuance to the production of finished products. It guides, imparts, responds to and reports various activities generated in the workshop by maintaining and using real-time and accurate manufacturing information, and provides task evaluation information about production activities to the enterprise decision support process."

throughout the application status of China's manufacturing information system, the focus of construction is generally on ERP management system and shop floor control system (SFC). However, the current mode of enterprises has rapidly evolved from production orientation to market orientation and competition orientation, which also poses a challenge to the management and organization of the production site of manufacturing enterprises. Relying on ERP and field automation systems alone is often unable to cope with this new situation. Manufacturing Execution System MES can just fill this gap. Manufacturing execution system (MES) is a workshop level production management technology and real-time information system that has developed rapidly in the world in recent 10 years. MES can provide users with a quick response, flexible and refined manufacturing environment, help enterprises reduce costs, deliver goods on time, improve product quality and improve service quality

in China, MES has been widely used in different industries (automobile, semiconductor, communication, it, medicine), which can provide good enterprise information management for single mass production and hybrid manufacturing enterprises with multiple varieties of small batch production and mass production. However, for the household appliance industry, there are few examples of MES application, and the scope of application is also very limited, Even in foreign home appliance enterprises, MES is not widely used. This paper will combine the opportunity of a domestic home appliance enterprise to realize MES system, introduce the application of MES system in home appliance industry and the benefits it brings to enterprises, and hope to bring some help to other home appliance enterprises to implement MES system in the future.

first, positioning

the establishment of any information system must have clear goals, needs and positioning in the enterprise, It is possible to succeed and bring benefits to the enterprise; For example, medical equipment, national defense and aerospace are typical discrete industries, and their MES requirements come from FDA and other departments, requiring enterprises to provide very detailed production process reports. For the automotive industry, another special reason is to control warranty and recall costs. For example, a component is provided by multiple manufacturers, but sometimes the problem is only the product of one manufacturer. Should we call back the components of the same number or just the components of one manufacturer that cause the problem? The latter means more cost savings. For the household appliance industry, the manufacturing cycle is short, the number of orders is large, and it only takes more than ten minutes from the time when the materials go online to the time when the products go offline. Its positioning of the MES system is different from that of other industries. We should not only pay attention to the error proofing control requirements in the workshop production process, but also require the MES system to be extended to the front-end logistics control and the back-end sales and quality traceability; The following describes the general goal of implementing MES in the household appliance industry through the implementation goal of MES in a household appliance industry:

1. At present, the recycling rate of waste plastics in China is not high

· through the construction of manufacturing execution system MES, a control mode of production management, quality management and logistics management with real-time enterprise characteristics is established in the enterprise, so as to improve production performance and quality level more pertinently

· through the manufacturing execution system MES, the flow of bar coded materials in warehouses, workshops and lines and the desire of merchants to enhance data collection, realize the refinement, transparency and automation of production logistics, and the real-time, data-based and integration of quality control. Finally, the finished products and key parts will be barcode managed in the whole process from supplier delivery, inspection, warehousing, production picking, production process control, inspection, product warehousing, shipping and after-sales service. The automatic data collection of the manufacturing site through the bar code can not only achieve forward and real-time production tracking, logistics tracking and quality control, but also achieve the reverse tracking of the forward link through the information feedback of the subsequent links such as after-sales service, so as to realize the multi-directional monitoring, analysis and improvement of the production line, station, personnel, quality, supply, product development, customer service and so on

· through the manufacturing execution system MES system, it realizes the integration with the upper transaction processing of ERP and the lower SFC real-time control system

II. Main functions and benefits

when the goal of implementing the MES system is clear, the implementation of the manufacturing execution system will bring obvious benefits to the enterprise in the whole manufacturing process. The following describes the benefits brought by the MES system to the enterprise by taking the main business improvement points after the MES system of a household appliance enterprise:

1. Overall aspects

a) establish a perfect traceability mechanism

i. provide information on people, machines, materials, methods Bidirectional traceability of rings

ii Provide material traceability at two levels of single product and operation, and balance the requirements of quality and efficiency

iii. integrate quality information with logistics and production information

iv. track the station, equipment and personnel that each product monomer passes through

v. track the monomer barcode of special key materials used (such as compressors)

vi. track the batch of key materials used in operation or product monomer (such as motors)

vii It can automatically collect the execution information or detection information of the equipment (such as vacuum pumping, cold charging, media and performance detection when the sensor is under the effect of tension P)

b) realize error proofing in the logistics and production process

I. picking error proofing, sub assembly error proofing, first inspection and patrol error proofing, production line assembly error proofing

C) integrate ERP and MES two business systems

I. establish a clear plan hierarchy relationship, master plan - workshop plan

ii. Be able to grasp the first-hand data of the production site accurately and in real time, and feed these data back to the ERP system to ensure the enforceability of the daily production plan

2. Logistics

a) logistics can realize container and batch management

i. the material label can be used as a unique barcode identification for each container

ii Material labels can record suppliers and arrival batches or production batches

iii. batch information can be transferred to the production line through material labels or ingredient labels

b) pull of key materials

i. for key materials in key processes, the line side quantity can be displayed in real time

c) logistics improvement provides the basis for production and quality improvement

i. automatic arrival inspection, reducing the delay caused by document delivery

ii Create conditions for the complete set of physical products

iii. realize error proofing in the process of ingredient label printing and picking and partial loading

iv. realize operation level material batch traceability through the picking process

3, production aspects

a) transparency of production site progress and quality information

i. you can dynamically master the production status and efficiency status of each production line

ii Real time update of operation online and offline information

iii. production capacity, efficiency and quality status of each production line

iv. it can reflect the quantity change of key materials at the line

v. it can truly reflect the situation of product repair

vi. error proofing, timely discovery and timely correction

b) improvement of operation set

i. improve the reliability and timeliness of physical set. Considering the physical arrival and IQC inspection conclusion, the full set function is applicable to general assembly operations and assembly operations in the general assembly workshop (such as internal machine plastic parts)

ii. Improve the integrity of the complete set of information. Consider the commitments of self-made parts and reserved materials, and realize the systematic management of material commitments

c) improvement of daily production scheduling

i. build a daily production scheduling information sharing platform, and Kanban and assembly workshops can view the latest daily production scheduling in real time

4. Quality

a) collection and analysis of quality data

i. establish a mechanism for centralized management and analysis of quality data

ii Collect the conclusion of quality inspection in time

iii. you can enter the specific items and inspection values of quality inspection

iv. you can record all kinds of quality defects,

v. you can record all kinds of rework information to make the quality information more complete

b) improve the efficiency of quality information feedback

C automatic inspection upon arrival

c real-time record the inspection conclusion with PDA on the inspection site

c on-site inspection of operation materials with PDA, Find problems immediately

c) determine the repair scope by using the traceability information to prevent quality accidents

d) improve the straight through rate by using error proofing to prevent quality accidents

III. the end

Manufacturing Execution System MES is the executive level between the planning level and the field automation system in ERP, which is mainly responsible for the production management and scheduling implementation of the workshop. Through the implementation of MES system in enterprises, management functions such as production scheduling, product tracking, quality control, equipment fault analysis, reports and so on can be integrated on a unified platform. Using a unified database and through network connection, workshop management information services can be provided for production departments, quality inspection departments, process departments, logistics departments and so on at the same time. The system helps enterprises implement complete closed-loop production by emphasizing the overall optimization of manufacturing process, and helps enterprises establish an integrated and real-time erp/mes/sfc information system. (end)

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