Five Trends of "Made in China 2025" Smart Factory
In recent years, Europe and the United States first proposed the concept of "smart factory" for the process industry. The process industry smart factory consists of three levels: business intelligence, operational intelligence, and operational intelligence. Because of its high level of automation, implementing a smart factory is relatively easy. Compared with the process industry, the discrete manufacturing industry first has a high investment in the bottom manufacturing process due to the complexity of the production process, such as vehicles, milling, planing, grinding, casting, forging, riveting, and welding. . In particular, equipment manufacturing, home appliances, automobiles, machinery, molds, aerospace, consumer electronics and other products require smart products and intelligent design. Therefore, under the support of the “China Made 2025†and “Industry 4.0†information physical fusion system CPS, discrete manufacturing needs to realize the networking of production equipment, the visualization of production data, the non-paper production documents, the transparency of the production process, and the absence of production sites. Humanization and other advanced technology applications enable vertical, horizontal, and end-to-end integration to achieve high-quality, high-efficiency, low-consumption, clean, and flexible production, thereby establishing a smart factory based on industrial big data and “Internet+â€.Networking of production facilities and realization of workshop "Internet of Things"
The Industrial Internet of Things proposed a new breakthrough for "Made in China 2025" and Industry 4.0. The Internet of Things refers to all kinds of information needed to monitor, connect, and interact with objects or processes in real time through various information sensing devices. The purpose of the Internet of Things is to realize objects and things, objects and people, and all objects and networks. Connection for easy identification, management and control. Traditional industrial production adopts M2M (MachinetoMachine) communication mode to realize communication between devices and devices, while the Internet of Things realizes intelligent and interactive seamless connection among people, devices and systems through the way of ThingstoThings communication.
In the workshop of discrete manufacturing companies, CNC cars, milling, planing, grinding, casting, forging, riveting, welding, and machining centers are the main production resources. In the production process, all equipment and workstations are networked and managed in a unified manner so that the equipment and equipment and the equipment and the computer can be networked and communicated with each other. The equipment is closely associated with the staff. Such as: CNC programmers can be programmed on their own computer, upload the processing program to the DNC server, equipment operators can download the required program through the device controller at the production site, after the completion of the processing task, and then through the DNC network The NC program is transmitted back to the server, and is compared or archived by a program administrator or a technician. The entire production process is networked and retrospectively managed.
Production data visualization, using big data analysis to make production decisions
After the “Made in China 2025†was proposed, information technology and industrialization quickly merged, and information technology penetrated into every link of the discrete manufacturing enterprise's industrial chain. Barcodes, two-dimensional codes, RFID, industrial sensors, industrial automation systems, industrial Internet of things, ERP, Technologies such as CAD/CAM/CAE/CAI have been widely used in discrete manufacturing companies, especially the application of new generation information technologies such as the Internet, mobile Internet, and Internet of Things in industrial fields. Discrete manufacturing companies have also entered new developments in the Internet industry. At the stage, the data it possesses is also growing. The manufacturing line of discrete manufacturing companies is operating at a high speed. The amount of data generated, collected, and processed by production equipment is much larger than that generated by computers and labor in the enterprise, and the real-time requirements for data are higher.
At the production site, data is collected every few seconds. Using this data, many types of analysis can be performed, including equipment operating rate, spindle operating rate, spindle load rate, operating rate, failure rate, productivity, and equipment utilization (OEE). ), parts qualification rate, quality percentage, etc. First of all, in terms of improving the production process, using this big data in the production process, you can analyze the entire production process and understand how each link is implemented. Once a certain process has deviated from the standard process, an alarm signal will be generated, the error or bottleneck can be found more quickly, and the problem can be solved more easily. Using big data technology, you can also create a virtual model of the product's production process and simulate and optimize the production process. When all process and performance data can be reconstructed in the system, this transparency will help manufacturing companies improve their production processes. For another example, in terms of energy consumption analysis, sensors are used to centrally monitor all production processes in the production process of the equipment, and it is possible to find abnormal or peak energy consumption, thereby optimizing the energy consumption in the production process and performing all processes. Analysis will greatly reduce energy consumption.
Five Trends of "Made in China 2025" Smart Factory
Transparent production process, "nervous" system of smart factory
"Made in China 2025" clearly proposes to promote the intelligentization of the manufacturing process, through the construction of a smart factory, to promote the optimization of the manufacturing process simulation, digital control, real-time monitoring of state information and adaptive control, and then realize the intelligent management of the entire process. In discrete manufacturing industries such as machinery, automobiles, aviation, shipbuilding, light industry, household appliances, and electronic information, the core purpose of the development of smart manufacturing in enterprises is to expand the product value space, focusing on the automation of single equipment and product intelligence, based on production efficiency. Increase the value of product performance and achieve value growth. Therefore, the smart factory construction model promotes the intelligentization of production equipment (production lines). Through the introduction of various types of smart equipment required for production, a workshop-level intelligent production unit based on the manufacturing execution system MES is established to improve precision manufacturing, agile manufacturing, and transparent manufacturing. Ability.
At the production site of discrete manufacturing companies, MES plays an important role in realizing automation, intelligence, and digitalization of the production process. First of all, MES uses information transfer to optimize management of the entire production process from completion of the order to the finished product, to reduce the company's internal value-added activities, effectively guide the factory production and operation process, and improve the company's timely delivery capacity. Secondly, MES provides basic information of production activities in the form of two-way interactions between enterprises and supply chains. It enables planning, production, and resources to work closely together to ensure that decision-makers and managers at all levels can master production sites in the shortest possible time. Changes, make accurate judgments and formulate rapid countermeasures to ensure that production plans are reasonably and quickly corrected, production processes are smooth, resources are fully and effectively used, and production efficiency is maximized.
Unmanned production site, truly "unmanned" factory
"Made in China 2025" has promoted the widespread application of smart devices such as industrial robots and robotic arms, making it possible for unmanned factory manufacturing. In the production field of discrete manufacturing companies, CNC machining centers, intelligent robots and coordinate measuring machines and all other flexible manufacturing units perform automatic scheduling scheduling, and automatic loading and unloading of workpieces, materials, and tools enables unattended, fully automated production. Mode (LightsOutMFG). In the case of automated production of non-stop units, priority is given to the management of production tasks, and the status of production within the management unit is reviewed remotely. If problems are encountered in production, once it is resolved, automatic production is resumed immediately. The entire production process does not require manual intervention. To achieve "no one" smart production.
The realization of "upgrading" from a manufacturing giant to a manufacturing powerhouse and "Made in China 2025" has become the most powerful strategic driver. Gallup is a pioneer and practitioner of "Made in China 2025." Combining the actual status quo of the current discrete manufacturing industry, based on 25 years of global leading technology and 15 years of localized experience in China, Gallup proposes five directions for discrete manufacturing smart factories, aiming to use the global advanced intelligent factory overall solution This productivity engine (MES-SFC) breaks the boundaries of the organization and integrates the company's entire production site into the management network. It is profoundly changing the structure of the manufacturing model, the process, and the entire manufacturing industry. This innovation is competitive in the future. The results will effectively promote the transformation and upgrading of the entire manufacturing industry. It will also allow discrete manufacturing companies to gain a unique new technology experience and set a successful example for the industry. (Source: OFweek Industrial Control Network)
Five Trends of "Made in China 2025" Smart Factory