Manufacturing execution system
MES (Manufacturing Execution System) was put forward by American AMR Company (Advanced Manufacturing Research, Inc.) in the early 1990s, aiming at strengthening the execution function of MRP plan, and linking MRP plan with job site control through the execution system. The appearance of MES fills the blank of workshop management. It takes job scheduling as the core and aims at reducing production cost and improving production efficiency, collecting real-time information in the production process and handling real-time events in time. At the same time, it maintains the ability of two-way communication with the planning layer and the control layer, receives the relevant information of the upper and lower layers and feeds back the processing results and production instructions, thus realizing the optimization of the whole production process.
1. Flexible response to changes in production orders
The lean production mode of arranging production according to order and flexible manufacturing is an ideal production organization mode pursued by automobile product production at present. Although it is only a goal considering personnel, cost, production efficiency, market and other factors, as an information system, it must be designed and laid out in this respect. Just like the production-related problems encountered by the above-mentioned automobile manufacturing enterprises, although all aspects of procurement, sales and warehousing have been greatly improved after ERP, there are still problems similar to the above that need to be broken through and improved, but these problems are often perfunctory and submerged in actual operation.
At present, the automobile industry has formed an almost unified understanding of MES system, that is, a management system established between workshop production control and upper ERP. Whether it is the middle layer in the overall three-layer layout of enterprise informatization construction or the second layer in the four-layer theoretical layout, MES is the bridge of information communication between production activities and management activities, and the "information hub" between planning and production. MES can not only help planners to arrange jobs, put into production and prepare materials through real-time information collection in logistics management and production management, but also remind planners of feasible schemes, narrow the range of planners' choices, improve planners' efficiency and reduce their burden. It can also quickly transmit the results of production arrangement to the job site so that on-site managers can make timely adjustments to the work arrangement of the work center.
2. Managing complex products and processes
By defining products in MES system, automotive product engineers can not only define new products conveniently, but also establish the relationship between customer products and enterprise products, thus reducing the workload of combined feeding. Centralized and standardized process flow definition environment ensures that all processes, technologies, engineering, manufacturing and QC work in a unified and standardized environment, which facilitates the timely sharing of information, reduces repeated definition errors, completes version management, and ensures the traceability of process flow historical information. By establishing the relationship between product and process, as long as the product is determined, the process flow can be automatically determined, and the dispatch list can also be automatically generated and printed. The workload of automotive product engineers is greatly reduced and the work efficiency is improved.
3. Monitor the production site in real time
Automobile manufacturing is a pillar industry of national economy. Due to the complexity of the product itself and its typical order production mode, its production is different from general products and has the following characteristics:
(1) Order-oriented production. Because the order specification, quantity and delivery date vary greatly, each product has its own particularity. From product ordering decision to manufacturing process, each product has certain independence, and enterprises must organize production according to orders.
(2) The production schedule is difficult to control. Due to the wide variety of products and many uncertain factors affecting the production process, urgent orders, equipment failures, rework and repair of parts often occur, which makes the plan changeable, even unable to keep up with the changes and divorced from the actual production. Therefore, it is often difficult to grasp the change of production schedule in time and control the whole production process.
(3) Difficulties in production management. The manufacturing process of automobile products is complex and requires high quality, and there are many uncertain factors in the production process. The coordination of the whole production process can not be guaranteed by empirical scheduling, and the process control and management are difficult.
In MES system, automobile manufacturing enterprises only need to determine products when organizing production, and the system can automatically determine relevant material information and production routes. All the operation information in the production process is also recorded by the system in real time, which greatly reduces the number of work orders and ensures the accuracy of information transmission. The system provides workshop management personnel to arrange materials or semi-finished products to designated equipment for operation, and provides operation guidance during the operation to remind employees of the operation steps. The data acquisition function of the system can collect the quality and material information of the site in real time, and automatically record the operation information such as operators and operation time. Abnormal situations in production operations are also recorded in the system in real time to ensure future statistical analysis.
4. Improve the effect of quality management
In order to realize the "product identification and traceability" stipulated in ISO9000, many automobile manufacturing enterprises often adopt the method of process card, that is, a small card is hung on each product to record the production results of each process. When products flow to a certain process, workers need to record them on cards with pens. These process cards are very simple to use in the production process. Although they can play a positive role, they also have many disadvantages: too many (1) are difficult to manage. (2) The cost of the process card is not small. (3) It is not easy to get timely production data from the process card. (4) Manual filling of process cards is often irregular and not recognized.
MES system combines the latest barcode automatic identification technology, serial number management and barcode equipment (barcode printer, barcode reader, data collector, etc.). Effectively collect the relevant information and data of products in production and logistics operation, and track the whole process of production and circulation movement of products in the life cycle, so that enterprises can achieve the goals of tracking and monitoring materials in collection, sales and production, traceability of product quality, tracking of sales and goods, automatic warehouse management, production site management and quality management. If there are abnormal products that do not meet the target in production operation, MES system can immediately suspend all potential batch operations on site through WIP management to reduce losses. According to the exception handling constraints, the system will prohibit operations that exceed the constraints. On-site exception handling information can be quickly transmitted to other relevant departments for adjustment and preparation. It can also provide field data to SPC system to help quality engineers adjust existing products and processes in time to avoid and prevent quality accidents.
5. Provide complete and accurate production data.
In order to meet the dynamic customer demand and deliver on time, the business layer of automobile manufacturing enterprises must be synchronized with the production process. This means effectively organizing and coordinating the management of all manufacturing resources, such as materials, equipment and personnel. In addition, it provides real-time data about production events, equipment performance and downtime, and KPI calculation is very important for making correct decisions. Related reports can be generated manually, but to create a report that can truly reflect the production situation, it is necessary to continuously collect, store and submit production data.
MES establishes the relationship among materials, equipment, personnel, tools, semi-finished products and finished products through field data collection to ensure the inheritance and traceability of information. The real-time data provided by the system can not only provide the actual situation of workshop operations and equipment for production managers, but also provide the production situation of customer orders for business departments, and can also calculate the direct material consumption cost according to the actual production situation. The report and query function based on field data can support the decision-making of senior managers. It reduces a lot of statistical work, increases the comprehensiveness and reliability of statistics, and realizes the traceability of manufacturing data.
6. Localization application of global leading technology
Gallup MES (Manufacturing Execution System) is an advanced workshop digital production management solution based on more than 20 years of global technology precipitation and nearly 65,438+04 years of domestic localization experience. Manufacturing enterprises focusing on discrete production mode have rich successful cases in the automobile industry, national defense, weapons and equipment, aerospace, mold manufacturing, medical equipment, machinery manufacturing, shipbuilding industry, electrical appliance manufacturing and other fields. At present, more than 80% of Gallup MES users are Fortune 500 companies and have become the absolute leader in MES field.
With the gradual innovation of management methods, lean manufacturing is the future trend of automobile industry. To realize the lean production of automobiles, one of the core problems at the workshop level is how to comprehensively utilize various information flows in the production process of products, and further refine these information through the processing of information systems, so that it can be extended to all external links of the factory, such as automation equipment, quality management, delivery management, supply chain procurement, cost control, logistics management and so on. To put it simply, it is to enlarge and enjoy the production form of products in the workshop, and realize the optimization of management efficiency and resource allocation in this way. The carrier that can realize all the above lean production is MES manufacturing execution system.