[cloud resident co creation] industrial wisdom "brain", a new acceleration script for old factories

1. brief introduction

2022 In, the Internet of intelligent manufacturing industry developed rapidly , Enterprises need to maintain efficient productivity at a lower cost . However, for the control of the production process , But it is the blind spot of many enterprises , The black box problem of production site management is quite serious , for instance ： The enterprise cannot monitor the equipment to prevent sudden equipment failure , The productivity of workshop workers cannot be counted , The labor cost cannot be accurately grasped and so on . also The workshop production process is opaque , Make it difficult for managers to master and trace , The problems and bottlenecks in the production process also restrict the improvement of the comprehensive efficiency of enterprise equipment 、 Cost reduction .

With the rapid development of new generation digital factory and intelligent manufacturing technology , How to improve the innovation ability of enterprises 、 throughput 、 Ability to manage 、 organization skills . Promote the digital transformation of enterprises ？

Let's take a look at Huawei cloud's high-quality ecological partners —— How does Shandong wanteng Electronic Technology Co., Ltd. solve the problems and challenges existing in the production and operation of the enterprise , To achieve efficient management and information transparency of enterprise production and operation .

2. We understand the characteristics of such enterprises

There are two types of manufacturing , The first type is process type , The second type is discrete , Today, the main content is discrete manufacturing , More specifically, the discrete manufacturing industry is aimed at the industry or field of mechanical equipment , Here's the picture ：

 

More and more enterprises are taking the equipment based on lean or product based production mode to gradually change For a new machining unit . stay above Again Add some machinery equipment 、 Transmission equipment Or inspection equipment , Form this whole into a small unit .

 

Assembly workshop or production line , Generally, there are several production modes ：

（1） Design to order （ETO） Generally, it is manufactured according to the project , Only after receiving the order will the design begin , It is often designed and produced at the same time , Long cycle .

（2） Make to order （MTO） The main production mode of mechanical processing enterprises , The production plan comes from the customer demand , Produce only when there is demand , No production without demand .

（3） Assemble to order （ATO） Assembly is the main production mode of the enterprise , The production plan comes from the customer demand , Generally, the assembly is configured according to customer requirements .

There are also, for example, production modes based on inventory , Now many enterprises in order to adapt to the changes of the market or the various needs of the market , There will be many modes , Especially some large and medium-sized enterprises 、 Enterprises with high degree of customization of products perhaps Supply demand or enterprises that respond quickly , They all have multiple modes coexisting .

 

Characteristics of industrial enterprises （ Integration of processing and assembly businesses ）：

• Many varieties 、 Mainly small batch or complex single piece production , The product supporting relationship is complex , There are many parts ;
• The manufacturing process involves a variety of manufacturing and molding technologies 、 A variety of manufacturing equipment 、 Multiple business units , Even multiple manufacturing industries across regions cooperate with each other ;
• The production process is complex , There are many processing procedures 、 The production cycle is long , Between processes / Between workshops / Factories need close coordination and cooperation ;
• Based on the development stage of the enterprise itself 、 Workshop space 、 New product development and other constraints , The layout of production equipment may not be based on products or processes , The same process may be performed on multiple devices , In the process of production , Materials are frequently transferred ;
• The factors to be considered in production planning are complex , Including staffing 、 Material inventory and distribution 、 Equipment resources 、 Fixture 、 Completeness 、 Order in process, etc , It is difficult to formulate ;
• There are many changes in the production process , Such as : External factors : The quantity and delivery date required by the customer for the order change , Insert new orders , And the shortage of raw materials ; Internal factors ; Design changes during manufacturing 、 Process changes 、 Rework and repair of parts ;
• It is difficult to control line materials and WIP . Such as : There are many parts of the product , And the manufacturing cycle varies 、 The complexity of processing technology varies , The production process needs to ensure the timely distribution of materials , Also try to reduce the backlog of products in process and raw materials . meanwhile , The position and state of WIP are constantly changing in the production process , Wide storage and distribution , It makes it difficult to control WIP ;
• The quality control in the production process is strict , There are many quality approval processes ; One machine, one book , Establish accurate product quality files for each individual ;
• There are many documents on the production site : The production process involves many documents and documents , Such as : Drawings 、 Work instructions 、 Technical notice, etc , The production process also needs to fill in the production progress information, quality information, etc , Most enterprises record and transmit through paper documents , The production information record and feedback are not timely , Data statistical analysis is difficult .

We have seen above and summarized some characteristics of this industry or field based on our experience . Based on these characteristics, what, er, puzzles or pains do these enterprises have in the field of operation or in the business process . Let's look at the next section .

 

3. The puzzles and pains encountered by discrete manufacturing industry in the field of manufacturing operation

3.1 Difficulties and adjustments faced by discrete manufacturing industry

First of all, from a macro point of view, the current position of these discrete manufacturing enterprises is still under great pressure for industrial upgrading , And they are more and more restricted by various factors , Cause their own lack of competitiveness ;

 

The labor cost is getting higher and higher , Many enterprises are facing the problem of difficult recruitment . When we go to enterprises, we often find , For example, there will be a revelation about the recruitment at the gate , The above requirements become simpler and simpler , For example, he only needs you to arrive 10 The number of , Then I can read the English letter . So this is also a very practical problem .

 

In addition, the price of raw materials is gradually rising, which is also a great challenge for enterprises ;

 

The demand for global coordination of supply chain is becoming higher and higher , If the internal collaboration or resource data cannot be fed back in time and effectively , It is also difficult to manage the supply chain ;

 

In addition, the degree of customization of products is getting higher and higher , The minimum lot size is in addition to the equipment manufacturing complex single pieces just mentioned , Perhaps the smallest batch has reached the single digit level . More and more enterprises are facing personalization 、 Customized and green requirements .

3.2 The impact of the epidemic on discrete manufacturing

Another point is the epidemic 3 Over the years, it has had a great impact on many manufacturing enterprises , However, the epidemic itself has also led to some new changes in enterprises ：

(1) The ability of automation and intelligence has been improved ;

(2) Can only be favored by remote services ;

(3) The upstream and downstream of the supply chain are closer ;

(4) Remote online operation has become the new normal ;

(5) Security 、 The importance of health prevention ;

(6) Accelerate socialized Finance 、 Global industrial cloud application ;

 

3.3 Problems faced by different roles in the factory

The following figure shows a factory as an example , Different roles and positions have different problems ：

 

sales ： Customer A Can the goods be shipped on time ?

Factory manager ： How about today's output and quality ?

PMC： Why is the output so low today ?

Material management ： When can the next order be placed ? When to replenish ? What material ?

purchase ： Supplier B What is the quality of the materials delivered this time ？

Quality control ： What is the quality level today ?

engineering ： This problem can only be analyzed with long-term production data ?

QA ： Customer A What is the yield of that shipment ?

Equipment maintenance ： mechanical D How high is the failure rate of ?

Process management ： mechanical D production E What are the product parameters ?

Standard working hours / Efficiency improvement ： Whether the efficiency can be improved ?

Cost planning and control ： product E How many man hours have been invested ? How about the yield ?

After-sales service ： Customer A What was the production status of the goods complained about at that time ?

These are the difficulties and pain points faced by the enterprise from a micro perspective , Of course, there may be feedback of this information in the enterprise now , But is the information and data valid ？ Is it true ？ Just in time ？ Is there any relevant tool ？ Is there any way to ensure that the points concerned by each role can effectively support his work ？

For enterprises, from a micro perspective , There are many varieties , Multi batch , Small batch , Medium volume , Large quantities of demand may exist , Then you need high quality 、 Low cost 、 flexible manufacturing 、 Rapid response, energy conservation, emission reduction and environmental friendliness can also adapt to , These problems need to be solved both within the enterprise and from the micro perspective .

4. Application scenarios of pain point solution matching with industry characteristics 、 Service cases

4.1 Ideas for solving users' pain points

Solution scenarios build enterprise intelligence “ The brain ”

Driven by the business scenario, realize the integration of data and objects , Zhijie provides cross organizational services for business innovation , End to end data flow across departments , stay “ data + Calculate the force + Algorithm ” To resolve the uncertainty of complex systems , Realize the optimal allocation of resources 、 Business innovation .

 

Key needs and construction direction

Different industries have specific needs , This also sorts out some key needs and solutions for different industries or fields .

 

Solution scenario ideas

The first is that all things interact with each other , In fact, the interconnection of all things may sound big . But it corresponds to a factory or a workshop , In fact, we are more concerned about these equipment on site 、 personnel 、 The production process of the product 、 working procedure 、 How can these collaborative elements in the warehouse enable it to achieve interconnection and data transparency .

 

second , On site is the digitalization of the operation process , The information of some key links can be collected digitally , Then we will make transparent decisions 、 Data analysis 、 Data decision making , Drive our business execution with data . meanwhile , In the process , We need to increase or use some mature technologies to solve these problems , Such as bar code 、RFID、 gateway 、 Kanban 、AI Algorithm etc. . At this time, we need to expand some business points in some specific scenarios according to the actual situation .

 

 

 

4.2 Solve the user's pain points 3 Dimensions

One 、 Connect ： By building an enterprise level or regional level Internet of things （IoT） operating system , Realize equipment operation control connection . from IoT Level to avoid the generation of information islands .

 

Focus on connecting assets , Ensure the stable and orderly operation of production , Shorten the return on investment cycle .

The effect of the connection ：

Improve equipment utilization ：2%-5%

Effectively promote lean production ： Continuous improvement

Reduce program transmission time ：78%+

Reduce equipment failure rate ：3%+

Save labor statistics cost ：4 People are naturally / month

 

Two 、 management ： Industrial equipment TPM service

At the equipment level , Many enterprises, especially small enterprises, are due to personnel or other reasons , Many times, people will go to the scene to fight the fire , It is the equipment that has frequent failures and needs to be repaired , For the maintenance process

In fact, they didn't do very well ; At the same time, for example, it is difficult to make some inspection plans , I feel it is very complicated to issue the task

Passively repair equipment failure , Then the maintenance process is not transparent .

We just want to say that this form can be implemented or opened in the form of a code , A real and effective management system for the whole equipment . This means that we need to control the whole life cycle of the equipment , One stop solution to the management requirements of the equipment itself .

 

 

From asset purchase and warehousing to scrap disposal , From mobile phone scanning inventory to all staff self-service , Open the new equipment management specification .

 

The effect of management ：

Improve the efficiency of spot inspection and patrol inspection ：12%-28%

Improve fault response speed ：15-30min/ The repair order

Improve maintenance efficiency ：16%-36%

Reduce equipment maintenance costs ：12-27%

Save labor statistics cost ：3 People are naturally / month

 

3、 ... and 、 operating ： plan 、 perform 、 logistics 、 quality 、 resources 、 energy consumption 、 Cost and performance data driven transparency .

The whole process of information tracing and operational Kanban really realize the closed-loop control in the whole operation process 、 Closed loop management , Make these data real-time and effective , Let these data ultimately drive our decisions .

 

be based on VT MOM Services build a cloud based digital factory

The virtual digital factory on the cloud of the enterprise can be established according to different application scenarios , We can make the entire operational business data transparent .

 

Effect of operation ：

Improve productivity ：6-21%

Reduce WIP fund occupation ：3-27%

Improve communication efficiency ：1-3 Hours

Save paper for production ：70-100%

Save labor statistics cost ：4 People are naturally / month

 

4.3 Typical cases

Here are some typical cases using the above solutions , Better understand the connection 、 management 、 Changes brought about by operation ：

Zhongtong bus , Through to 165 Equipment and AVI Vehicle monitoring , The connection of equipment in the whole plant area is realized , It can monitor the whole production process in real time .

 

In Qiangxin mechanical technology , Due to the precision of the customer's machine , More concerned NC Program and equipment alarms , Through to 40 Connection of multiple devices , Get information in real time , Ensure timely discovery and solution of production problems .

 

Liancheng precision casting factory , Because there are many casting links , There should be no mistake from sand mixing to warehousing , Through the connection and control of the equipment , Automate some links , Improved productivity .

 

Qingdao Hairong , adopt AI Algorithm and image recognition , Can quickly identify whether the product is qualified , Whether there is any position error 、 Parts forgotten, etc , Improved product quality , Reduced labor costs .

 

Nori forklift , With a complete process set 、SCADA Data acquisition and plant level MES To build a smart factory .

 

Donghong Management Co., Ltd , Realize the connection of workshop equipment ,MES System building , Use the simulated three-dimensional model to conduct real-time simulation and real-time monitoring on the factory site .

 

Suzhou Dahua , Connect the data between the factory and the enterprise management , Realize paperless control and digital management of production process .

 

 

4.4 Solution summary

summary ： Wanteng technology manufacturing operation management （MOM） With “ spot - Line - Noodles ” Different business scenarios promote enterprises to promote digital transformation , The process of intelligent upgrading .

 

On the one hand, it refines the granularity of enterprise manufacturing operation management , Improve the level of operation management ：

• Customer / The main engine plant plans to cooperate , Adapt to the requirements of the main engine plant
• Realize flexible production scheduling , Make the production organization more reasonable
• Realize the whole process tracking of manufacturing process
• Standardize the engineering change process of the enterprise , Design and production fast Street connection
• Realize the whole process quality traceability , Improve customer satisfaction
• Strengthen performance management , The manufacturing site shall realize daily clearing and daily settlement
• Supplier collaboration , Realize lean supply chain
• Continuous cost reduction , Calmly meet the cost reduction requirements of the OEMs

On the other hand, strengthen performance management , Improve the maintenance skills and operation and maintenance management level of production personnel ：

• Reduced Edition : Know the investment income of equipment everywhere . Reduce equipment waiting time and maintenance costs , Better manage the life cycle of equipment .
• Efficiency : Grasp the real equipment operation efficiency anytime and anywhere . Accurately master equipment status and team performance , Improve the comprehensive efficiency of enterprise equipment .
• Mention mass : Improve the production efficiency of bottleneck process . Reduce the scrap rate , Improve the quality level , Catch device exceptions in time , Accelerate processing to solve .

 

5. Solutions and product features

System cloud deployment 、 Cross enterprise collaborative control ：

Cloud deployment is possible , You can also realize this kind of collaborative management and control across enterprises . Now some enterprises, for example, have ERP、MES A supply chain system or a system with three-party logistics , The corresponding workshop or execution phase needs to interact with these applications . The deployment mode can be cloud or private .

 

standard API Interface to realize third-party docking ：

Provide standard API Interface to realize docking with third-party applications , Many enterprises already have relevant applications, or they need to add some applications at some time in the future , In this way, try not to add new islands , And there is a problem to be solved in this process , That is, the boundaries of all applications and the interfaces between applications are more clear .

 

VBP The platform architecture ： Microservice architecture 、 Platform development 、 Cross system platform applications 、Web API Expand applications

The platform architecture is a standard microservice architecture . Now there are various applications and solutions based on the platform itself , When we develop again

Must be based on platform development , Uniform standard , Cross system platform applications , External API, You can extend some components or customize some demands

It does not affect the original product itself .

 

6. Cooperation with Huawei cloud

Wanteng Technology The cooperation with Huawei cloud is 2、3 Started years ago , Step by step, from ordinary commodities to the later strictly selected commodities to the current strictly selected self-management . Become an application of Huawei cloud intelligent manufacturing solution .

Wanteng Technology Adapted to Kunpeng system , It has obtained the compatibility certification of Kunpeng system .

Wanteng Technology Adapted to Huawei cloud IMC、 Digital factory base , In depth service to manufacturing enterprise customers .

2021 year 5 month Wanteng Technology And Huawei cloud and others 7 Partners released 《 Intelligent manufacturing joint solutions 》.

At present, the manufacturing industry all over the world is transforming to intelligence , Whether it's industry 4.0, Or intelligent manufacturing 2025, All show that the traditional manufacturing industry has not adapted to the current social development , This paper introduces the advanced solutions of Huawei cloud partner wanteng technology in the field of intelligent manufacturing , Hope to give you some inspiration . Huawei cloud and many senior industrial partners including wanteng technology have been working hard , Help China's traditional manufacturing industry transform to intelligent manufacturing with the best solutions .

This article participates in Huawei cloud community 【 Content co creation 】 Activity number 17 period .

https://bbs.huaweicloud.com/blogs/358780

Mission 9： Industrial wisdom “ The brain ”, The old factory's new acceleration secret script