In the whole project process, after combing the strategic positioning and value orientation of the factory, it is clear that the smart factory construction project is mainly divided into three steps, including physical planning, management and operation reform, and information integration and interconnection.
Step 1: Physical planning. At this stage, based on the industry benchmark and the characteristics of multimedia logistics management, with the goal of realizing the "effective operation" and "integration and interconnection" of the future factory, management elements and requirements are embedded in the planning, and the logistics space, physical processes, facilities and equipment of the new factory are rationally planned.
Step 2: Manage operational changes. On the basis of physical planning, change management and operation, optimize logistics management process, and realize effective coordination of strategy-strategy-plan-implementation.
Step 3: Information integration. The focus of this stage is information integration and interconnection, so as to achieve effective coordination among plans, information, objects and operations. The information flow is consistent with the real material flow, so that the difference is kept within the standard range. The system has the characteristics of self-organization, self-decision, self-adjustment and intelligence.
In terms of physical planning, the overall layout runs through the whole planning process with logistics as the main line, emphasizing that flow is the last word, building the logistics center of the manufacturing factory, taking the automated three-dimensional library as the logistics center of the factory, radiating all production areas, and embedding management elements into the planning. Based on the factors such as products, materials, process characteristics, flow of each link, inventory demand, etc., the intelligent logistics system is configured in a differentiated manner, and under the premise of rationality, effectiveness and economy, the incoming logistics, production logistics and finished product logistics are fully integrated to meet the operational requirements of flexible production and complex scenes. Highlights of this project planning are as follows:
Highlight 1: Flexible storage, sorting and distribution mode planning, adapting to the compatible operation of personalized customization and mass production.
(1) Flexible mixed storage and transportation of pallet bulk materials. Intelligent display terminals mainly include TV, display screen, advertising screen and other terminal display products. The size of TV products covers a wide range, from more than 20 inches to more than 80 inches, and most of the corresponding large pallets have a strong correlation with the size of TV products. How to design a flexible intelligent logistics system to adapt to the storage of large pallets on various dimensional chains is the difficulty and focus of this project. Finally, after the discussion of the project team and the detailed analysis of the dimension chain, two kinds of pallet storage units, L 1400mm*W 1000mm and L21000 mm, are designed, and two units are placed in one cargo hold at the same time.
(2) Collaborative design of goods arrival and goods selection. Through the analysis of material picking characteristics, the flexible design of picking mode meets the demand of production for materials. For the materials sorted by pieces, smooth shelf picking is adopted, and rapid picking is realized through four-way shuttle+smooth shelf, which effectively reduces the frequent delivery of such materials and reduces the pressure on the system. At the same time, the personnel complete the picking operation according to the instructions of the electronic label on the smooth shelf. For the material distribution of the whole container, the manual location of the goods is planned in the required area of each production line by the way of goods-to-person delivery, which is convenient for the material supply after delivery. The whole picking and storage system is integrated to reduce the complexity of the system.
(3) The continuous and discrete material distribution mode. According to different production line models, combined with the actual situation and demand, flexible configuration of distribution technology. Individualized customized production line, the material demand of production line is characterized by multi-frequency and small batch, and the distribution frequency of each station is high. Based on this, the continuous transportation mode is adopted, and the materials are directly delivered to each station through the docking of the material box elevator and the high-speed car ferry, so as to realize the rapid and flexible delivery of materials.
For batch production lines, the characteristics of material demand are low frequency and large batch. Based on this, batch distribution mode and discrete AGV system are adopted. AGV is equipped with a revolving material rack, which automatically connects with the material rack at the edge station, and skillfully integrates low-cost automation with AGV, which not only reduces manual handling, but also reduces costs.
Highlight 2: Differentiated logistics system design to meet the complex multi-scene and multi-mode operating environment.
(1) Differentiated configuration of raw material warehousing and distribution mode. In the process of warehousing and distribution, different logistics systems are designed according to the material characteristics and flow requirements for different use scenarios. For example, in the storage link, relatively standardized materials are stored in the automated warehouse, while special-shaped parts are stored in a flat way. In the distribution link, AGV is used to cooperate with the turnover car for materials with large flow, and manual distribution is used for materials with small flow.
(2) Differentiated configuration of finished product handling and storage methods. In the finished product logistics, the offline transportation and storage of finished products are configured differently through PQ (product quantity) analysis. Among them, 80% products are palletized by continuous transportation, and then automatically stored in the 24-meter-high all-automatic pallet warehouse. The remaining 20% products are transported by discrete AGV and stored on the plane. The whole realization process is not for the sake of automation, but for the sake of economy and rationality, so as to realize effective operation.
Highlight 3: Ingeniously design the air tour passage to create personalized tourist attractions.
Guided by logistics, design the direction of air tour passage. Through the air tour channel, you can see all the links of automatic three-dimensional warehouse of raw materials-material distribution-workshop production-automatic transportation of finished products, palletizing-automatic warehouse of finished products. Overlooking the whole production workshop from the air visit channel, the vision is wide and the visual impact is shown to the visitors through panoramic view. At the same time, tourists will consciously create personalized tourist attractions when passing through the route, show tourists the manufacturing level, logistics management level and corporate culture of the enterprise, and enhance the overall image of the enterprise.
Factory planning is for operation. "The ability that money can buy is not the core ability", and so is the operation ability of the factory. Under the premise of the new logistics system planning, we need to focus on building the soft power of the factory (organizational ability, planning and coordination, material control, inventory turnover, team and talent training, etc.). ). A brand-new factory needs a brand-new look and a brand-new capability system configuration.
Based on this, the main theme of the second stage is management and operation reform, which aims to build a set of logistics operation system based on the new planning of the new factory and adapting to the future development by comprehensively opening up all links such as planning, procurement, logistics and production. The specific method is as follows:
Planning management: the key point is to straighten out the collaborative management logic among planning, logistics and physical objects, establish a refined management model driven by hourly operation plan, promote the distribution of materials in the factory, and adapt to the small batch production model with the arrival of JIT materials as the guide.
Supplier arrival and material management: based on the current level, establish a step-by-step goal, start from the end, step by step, and steadily promote the transformation of procurement and incoming logistics to a small batch and multi-frequency refined management model. At the same time, define the arrival planning rules, establish differentiated logistics management models and standards for different materials, and create an orderly, controllable and visual material arrival management mechanism.
In-plant logistics operation management: aiming at rapid response and service production, establish a management mechanism for material alignment to ensure online material alignment. At the same time, according to the characteristics of different materials and production lines, a differentiated sorting and distribution model is established to support the flexible production mode of multi-variety and small batch in the new factory.
On the basis of defining the management requirements of each link, a matching logistics organization structure is established. The logistics organization structure follows the principle of integrated logistics management, sorts out and defines the functions of the logistics management organization structure, designs the logistics organization structure, establishes the key KPI indicators of the logistics organization, and provides organizational guarantee for the effective operation of the new factory.
At the same time, in order to meet the logistics operation objectives of the new factory, it is necessary to design a matching logistics process to ensure that the demand is implemented. By establishing a structured and standardized five-level logistics process operation system, a set of standardized five-level process language is created. By combing the five-level process of logistics-related business in the new factory, a unified process standard language in line with Changhong Multimedia is formulated, so that all business personnel can understand, speak and do business processes, thus further promoting the process.
Finally, on the basis of management requirements, organizational guarantee and clear process, the key requirements of logistics informatization in each link are put forward. Through the solidification of core information systems such as ERP, PCP, SRM, MES, WMS, QMS and WCS, the whole process from planning, procurement, logistics to production is finally integrated with the bottom logistics equipment control system.
1. The output per unit area has been greatly improved. In this intelligent factory, more stereoscopic automatic storage systems are adopted, which effectively utilizes the vertical space, greatly improves the utilization rate of the factory and increases the output per unit area.
2. The efficiency has been greatly improved. Through the introduction of automated logistics system and the optimization of management process, the number of logistics personnel in the factory has been greatly reduced. At the same time, the introduction of intelligent logistics system has forced the improvement of enterprise management level, put forward higher requirements for planning management, procurement management, inventory control and quality management, and injected new impetus into enterprise reform.
3. Effective horizontal and vertical integration has been achieved. Connect the assembly plant, front-end supporting plant and external suppliers horizontally, and vertically connect the key links of enterprise management, such as R&D, supply, production and sales, so as to truly realize independent scheduling, independent management and independent decision-making in the whole manufacturing process and realize the interconnection of factories.
Smart factories need clear strategic positioning and value orientation from planning to landing. On this basis, the process requirements, production mode, logistics data and logistics scenarios are analyzed in detail, and the logistics system is configured differently. At the same time, based on the new logistics system, it is necessary to carry out management and operational changes in planning, procurement, logistics, production and other links, and link them through information integration, so as to finally achieve the goal of building a smart factory.