Thoughts on the informatization construction of transformer industry (2010-1-1311:35: 03) Reprinted label: Random talk.
1 preface
Informatization is the development trend of manufacturing industry in the world today. Adopting information technology in time and making full use of information resources have become the key choice to improve the overall quality and comprehensive competitiveness of enterprises. In view of this, the government of China proposed: "Promoting industrialization by informationization". The informationization of the national economy has been promoted to an unprecedented height, depth and breadth. Transformer manufacturing industry is an important part of China electric power industry. Power transformers and special transformers provide reliable and uninterrupted energy for the development of national economy. It can be said that all walks of life in the national economy and people's lives are inseparable from Transformers. According to statistics, there are more than 0/000 large and small transformer manufacturers in China. However, the informatization level of transformer manufacturing industry is still low. Due to the characteristics of transformer industry, enterprise resource planning (ERP) strategy is rarely implemented, which limits the development of the whole industry. Although some enterprises have a high understanding of enterprise informatization and have begun to implement ERP, the overall effect is not ideal. Therefore, some enterprises are skeptical, and some simply hold a negative attitude. Then, how to carry out information construction in China's transformer industry? This paper will make a concrete analysis of this.
2 the necessity of information construction in transformer industry
With the rapid development of information technology represented by computer technology, communication technology and network technology, human society has moved from industrial age to information age, and people pay more and more attention to the transformation of traditional industries and the development and utilization of information resources by information technology. "Informatization" has become a key link in a country's economic and social development, and the level of informatization has become an important symbol to measure the modernization level and comprehensive national strength of a country or region. Enterprise is the foundation of national economy, and the most important thing of national informatization construction is enterprise informatization, which has become a global development trend. Enterprise informatization refers to the process that enterprises continuously improve the efficiency and level of enterprise production, operation, management and decision-making through the in-depth development and extensive use of information resources, thus improving the economic benefits and market competitiveness of enterprises. Generally speaking, enterprise informatization is a process of transforming enterprise business activities with information technology to make it more effective. At present, the general situation of informatization in developed countries is as follows: in the field of design and manufacturing, more than 90% enterprises adopt computer aided design (CAD) and product database technology (PDM); In the field of management and operation, business process reengineering and enterprise resource planning (ERP) strategies are generally implemented around the Internet. Therefore, in today's era of global market competition, the comprehensive application of information technology has become an important factor to improve the viability and core competitiveness of enterprises. Because the main users of transformer manufacturing enterprises are the power sector, many leaders of transformer enterprises believe that as long as they establish good relations with them, enterprises can develop without information construction. This view of weak information consciousness has seriously affected the informatization construction of transformer manufacturing industry, resulting in low level of enterprise information basic management, insufficient investment in informatization construction and less application of e-commerce. In fact, most transformer manufacturers have the following problems: (1) The market response is slow, and customers often complain about loopholes in marketing. In the information age, the response speed to the rapidly changing market has become the key to determine the competitive advantage of enterprises. Transformer manufacturers have many varieties and specifications. If the sales information system is not established, it will be difficult to deal with a large amount of product and customer information, so as to meet the customer's pre-sale, sale and after-sale services. It is also difficult to timely and effectively manage sales staff and customers, improve the enthusiasm of sales staff, and reduce the loopholes of business personnel misappropriating public funds and individual customers with low reputation defaulting. (2) The phenomenon of untimely delivery is common, and the contract performance rate is not high. In recent years, due to power shortage, the demand for transformers has increased, and the orders of transformer manufacturers have generally increased. However, a problem that comes with it is that many enterprises do not deliver goods in time and the timely performance rate of contracts is low. There are reasons for insufficient production capacity, insufficient liquidity and tight supply of silicon steel sheets in recent two years. Generally speaking, the delivery delay is most affected by the production capacity. In fact, in many cases, it is not the real shortage of production capacity, but the uneven production capacity. (3) Low level of digital design and manufacturing. In the design, there are many computer-aided drawings and electromagnetic schemes calculated by Excel, and there are few real computer-aided design (CAD). Even fewer are designed with three-dimensional CAD. Only real CAD can effectively reduce the design cost, improve the design efficiency and ensure the design quality. (4) Quality problems are widespread, and the first pass rate of products is low. Due to the imperfect quality system, the IS0900 1 quality assurance system has not been really implemented. Except for a few enterprises such as Jinan Siemens, most enterprises have not implemented the Six Sigma quality management method, so the first pass rate of transformer finished product inspection is low, mostly lower than the quality level of Sanxi Sigma, so there are many rework phenomena and the quality cost remains high. The defect rate required by the Three Sigma quality level is 0.27%, that is, the qualified rate is 99.73%, not to mention the Six Sigma quality level, and the required defect rate is 3.4 parts per million, which is almost zero. (5) Accounts receivable and inventory occupy a large proportion of funds, and liquidity is tight. Due to the impact of rising raw material prices, transformer prices have risen in the past two years, and with the increase in orders, many enterprises are short of liquidity. From the inside of the enterprise, many reasons for the tight liquidity of the enterprise are the large proportion of accounts receivable and inventory, which leads to insufficient cash flow. (6) Low level of supply management Many transformer manufacturers have not established a good supply relationship, have no win-win thinking, and even the basic business processes are not perfect, such as the lack of contracts, which makes the supply work full of loopholes and easy to cause losses to the company. Few people adopt supply chain management. With the help of enterprise informatization, we can make full use of enterprise resources and information, reorganize business processes, change enterprise organization mode and management mode, and introduce modern management concepts to make decision-making rational and scientific, thus effectively solving the above problems, which are embodied in the following aspects: ① Improve decision-making level and work efficiency. Promote business process reengineering through information construction and change the unreasonable process of enterprises. Make the organizational structure of the enterprise flat, reduce the management level, strengthen the direct communication between the decision-making level and the executive level, and make the information communication smooth and timely. Informatization can provide enterprises with suitable management and operation mode, accelerate the implementation of enterprise decision-making and improve work efficiency. Through enterprise informatization, the intelligence of decision makers is extended, the uncertainty, randomness and subjectivity in the decision-making process are minimized, and the rationality, scientificity and rapidity of decision-making are enhanced. ② Effectively reduce the product cost and shorten the production cycle. Informatization can not only effectively reduce the design cost of products, but also rationally optimize production resources, reduce the inventory of raw materials, in-process products and finished products, and reduce the operating costs of enterprises. If the enterprise adopts ERP, it can also effectively shorten the production cycle of products and ensure the on-time delivery rate. For example, the capacity balance mentioned above can be done well with ERP. The production planning system of ERP is guaranteed by rough capacity planning (capacity demand planning generated by calculating the capacity of key work centers, such as capacity planning generated by calculating the capacity of silicon steel sheet transverse shearing line, body drying equipment, pouring pot for producing dry-type transformer, etc.). ) and capacity demand planning (accurately calculate all kinds of resources needed by each production stage and work center or process, obtain resource loads such as manpower load and equipment load, and balance production capacity and production load). ③ Improve the design level and accelerate product and technology innovation. With the help of enterprise informatization, transformer manufacturing enterprises can improve the level of digital design and manufacturing. Digital design and manufacturing refers to the technology that uses computer software and hardware and network environment to realize the whole process of product development. For transformer manufacturers, the key to digital design and manufacturing is to adopt CAD, CAPP (Computer Aided Manufacturing), CAM (Computer Aided Manufacturing) and PDM (Product Data Management). In particular, PDM organizes all kinds of information in the whole process of enterprise product design and manufacturing, data and documents in different design stages of products in a unified environment, which is very important for the technical department of transformer manufacturing. Because there are many specifications and varieties of transformer products and the drawings have their own industry characteristics, there are many common parts and borrowed drawings in the drawings. It will be very convenient to manage drawings with PDM. In a word, the application of digital design and manufacturing technology can improve the innovative design ability of enterprises and shorten the design and development cycle of new products. ④ Improve product quality. With the help of enterprise informatization, ISO900 1 quality assurance system can be implemented, which can effectively improve the quality of work and ensure the quality of products. If ERP can be implemented by Six Sigma quality management method, quality can be controlled more effectively, especially the quality of key processes will be greatly improved, and the overall quality of products will be fundamentally changed. Because the meaning of six sigma quality is: the product quality characteristics meet the needs of customers; On this basis, avoid any defects or mistakes. ⑤ Speed up the market reaction. Enhance market flexibility. In today's increasingly fierce market competition, without enterprise informatization, it is impossible to process a large amount of customer information in time and make timely decisions. Profit-centered view, ignoring the value of customers, is easy to cause customer dissatisfaction and can only achieve short-term benefits. In the long run, we must take customers as the center and improve customer satisfaction, so as to bring about sustained business growth. Informatization can establish a customer-centered business management process, timely understand customer needs, speed up market response, enhance market resilience, and improve the overall management level of enterprises. Promoting enterprise informatization, especially implementing ERP, and introducing advanced management concepts and methods into enterprises is a transformation of backward traditional management ideas or methods and a revolution of enterprises. Through enterprise informatization, we can change the traditional management concept and improve the comprehensive quality of all employees. Establish good management norms and processes to improve the overall management level of enterprises.
3 the choice of informatization in transformer industry
The content of enterprise informatization construction is very wide, which can roughly include: (1) extensive use of computers; (2) The establishment of intranet and its interconnection with the outside world; (3) It is convenient to obtain and utilize abundant (own or external) information resources; (4) Application of information technology in production process control; (5) Computer aided design is used to design new products; (6) The production, supply and marketing information system of the enterprise operates effectively, and conducts business with the outside world through the information network; (7) Enterprise integrated management information system; (8) enterprise informatization talent team; (9) enterprise informatization standards, norms and rules and regulations; (io) others. As far as the specific transformer manufacturing enterprises are concerned, it is impossible to cover all the information construction contents, and they can be selected and focused according to their nature, category, scale, foundation and other actual conditions. The establishment of the system should not only adapt to the existing actual scale of the enterprise, but also face the future development goals of the enterprise. However, it should be noted that even if enterprise informatization is realized, internal computer networks and websites are not established. Real informatization must be able to respond quickly to the market, production and management, so that information can be transmitted timely, accurately, quickly, fully and effectively within the enterprise, and the loss caused by time delay in the information transmission process can be avoided to the maximum extent. We should establish the concept that an enterprise information system is a management system first, and then a computer network system. The following introduces some optional information systems for informatization construction of transformer manufacturing industry. 3. 1 office automation system (OA system) China's office automation software (OA) system originated from the government's official documents and archives management. Traditional procedures for running documents include document drafting, review, countersigning, publishing and distribution, filing and borrowing. The complicated process and long circulation time lead to low office efficiency and slow decision-making. Because it is difficult to make great changes in organization and process, the solution is to adopt advanced computer and network technology, not only to digitize the contents of the document, but also to realize the electronization of the whole process, which can fundamentally change the traditional working mode. OA is defined as: realizing information transmission, information resource sharing, e-mail, file circulation, teamwork and workflow automation. The core of office automation is the processing of office documents. After adopting OA, enterprises can integrate enterprise resources, speed up information circulation, standardize office processes and improve work efficiency. In fact, the adoption of OA system by enterprises is not a real enterprise informatization, because all the work OA does is just to move manual work to the computer network, using some advanced characteristics of computer technology, without adding any advanced management concepts and methods. So we say OA is only a part of enterprise informatization. 3.2 Management Information System (MIS system) The management information system (tem) was gradually developed from the 1980s. There is no clear definition of management information system so far. From the enterprise's point of view, management information system is a system composed of people and computers, which can collect, transmit, store, process, maintain and use management information. In fact, it can measure all kinds of business conditions of enterprises, use past data to predict the future, help enterprises make decisions from the overall situation, use information to control the behavior of enterprises, and help enterprises implement planning objectives. Generalized enterprise MIS also includes ERP. What we usually call enterprise MIS is narrow, and there is no concept of lead time in ERP. It is mainly to realize the automation and informatization of basic management business processing activities, such as plan management, project management, financial management and human resource management, which mainly focus on enterprise strategic management and business management. 3.3 Enterprise resource planning (ERP system) Enterprise resource planning (ERP) embodies the most advanced management theory in the world today and provides the best solution for enterprise information integration. It unifies the logistics, capital flow and information flow of an enterprise for management, comprehensively balances and fully considers resources such as manpower, capital, materials, equipment, methods, information and time, makes maximum use of the existing resources of the enterprise, obtains greater economic benefits, and scientifically and effectively manages the specific business work of the enterprise such as personnel, finance, materials, production, supply and sales. Studying and popularizing ERP is a concrete method and way to effectively promote the development of enterprise management in China in a more scientific, reasonable and standardized direction. The management idea and technology of ERP have experienced more than 30 years of development, from MRP (material requirements) to closed-loop MRP, to MRP II (manufacturing resource planning), and finally to ERP. ERP technology has gone through the following stages: (1) in 1960s, Dr. Joseph A.Or- licky of the United States put forward the concepts of layered product structure, independent demand, related demand and lead time of materials, which formed the initial prototype of MRP method. At that time, the idea of MRP was to obtain the required materials at the right time and place according to the specified quantity around the products to be produced, so as to avoid inventory backlog. This is the basic MRP. (2) In 1970s, MRP developed into a closed-loop MRP production planning and control system. Compared with the basic MRP principle, it increases the verification and execution control of enterprise capabilities. Because it is often not feasible to make production plans and procurement plans using basic MRP principles, this is mainly because the information is one-way and inconsistent with PDCA. Closed-loop MRP thinks that master production plan and material demand plan should be feasible, that is, considering the constraints of production capacity, or putting forward demand plan for production capacity, on the premise of meeting production capacity demand. Only in this way can we ensure the implementation and realization of MRP. (3) In the late 1970s and early 1980s, the closed-loop MRP developed and expanded, and gradually formed the manufacturing resource planning MRP Ⅱ. It is an effective system for unified planning and control of various resources around the basic business objectives of enterprises and with production planning as the main line. It is also a dynamic feedback system, which makes the logistics, information flow and capital flow of enterprises smooth. Manufacturing resource planning MRP 1i overcomes the defect that closed-loop MRP only considers production planning, and only logistics has no capital flow. The main links of MRP 1i involve: business plan, sales and operation plan, master production plan, bill of materials and material demand plan, capacity demand plan, workshop operation management, material management (inventory management and procurement management), product cost management and financial management. (4) Since 1990s, MRP has been further developed and perfected, and an enterprise resource planning ERP system has been formed. In the early 1990s, Gartner Group Inc put forward the concept of enterprise resource planning (ERP) in view of the trend of economic globalization and the gradually formed global supply chain environment. In a short period of less than 10 years. It has been widely recognized and accepted, and has been continuously developed and improved. ERP overcomes the defects of MRPⅱⅱ, such as low integration, inability to integrate the overall resources of enterprises, inadaptability to large groups and global development, especially supply chain management. Compared with MRP ⅱ, ERP not only contains and strengthens various functions of MRP ⅱ, but also faces the global market. It has more powerful functions, manages more enterprise resources, supports mixed production mode and has wider management coverage. It also involves enterprise supply chain management, carries out operation and production planning from the overall perspective of the enterprise, and is a comprehensive integrated management system of manufacturing enterprises. The computer technology adopted by ERP is also more advanced, forming an integrated enterprise management software system. With the continuous development of information technology and advanced manufacturing technology, the demand of enterprises for ERP is increasing, which further promotes the development of ERP technology to a new generation of ERP or post-ERP. Customer relationship management, Six Sigma management and product data management can all be integrated into ERP, and the functions of ERP will become more and more powerful. 3.4 Customer Relationship Management (CRM) The main idea of modern marketing is to take the customer as the center, identify the specific requirements of customers, use various resources to provide customers with needs, achieve the greatest customer satisfaction, and finally get customer feedback. Customer relationship management (CRM) provides a direct and indirect way to identify customers' needs. There is no uniform definition of CRM at present. LOl believes that customer relationship management means that enterprises understand and influence customer behavior through meaningful communication, and ultimately achieve the purpose of improving customer acquisition, customer retention, customer loyalty and customer profitability. The core idea of CRM is to regard customer groups as valuable external resources of enterprises, and bring them into the control scope of enterprises as far as possible, with a view to increasing customer value, effectively meeting customers' personalized needs, improving customer relations and enhancing the market competitiveness of enterprises. CRM uses data warehouse technology to manage customer information, customer orders and product manufacturing in a unified way, uses data mining technology to find potential important customers and customer needs, uses network technology to quickly transmit query information and control information, and adjusts enterprise business behavior through the "one-to-one" marketing concept to meet customized personalized needs, thus improving the organizational structure of enterprises to quickly respond to customer needs and standardize workflow. In order to improve the service level to customers, form a sensitive response mechanism and meet the special requirements of customers for varieties, specifications and quality, so as to seize old customers, stick to new customers and find potential customers. The real meaning of customer relationship management is: management concept+information technology. The implementation of CRM will improve the efficiency of enterprise sales management, tap and identify market opportunities through various channels, improve customer satisfaction, maintain good relations with customers, reduce the operating costs of enterprises and create long-term sustainable profit sources for enterprises. 3.5 Supply Chain Management (SCM) Supply chain is a concept formed by people's observation of the mutual behavior of enterprises. Stenves of the United States believes: "Controlling the flow from suppliers to users through value-added processes and distribution channels is a supply chain, which starts from the source of supply and ends at the consumer end." Evenss thinks: "Supply chain management. SCM) is a model that connects suppliers, manufacturers, distributors and retailers through feedforward logistics and information flow until the end users are connected into a whole. " There is a core enterprise in every supply chain. To sum up, supply chain management is to plan, dispatch, allocate and control all kinds of materials, funds, information and other resources in each link with the core enterprise as the center, thus forming the overall function of the whole supply process of users, retailers, distributors, manufacturers and procurement suppliers. Supply chain management reflects enterprises' attention to the external environment, which is the inevitable result of fierce market competition and global economic integration. The resources of a single enterprise are difficult to adapt to the development of the market, and the competition for resources among enterprises has developed into the competition for all resources of the whole supply chain among enterprises. 3.6 E-commerce (EC or EB) E-commerce is recognized as an inevitable trend of economic globalization and information globalization. E-commerce originated from English ELECTRONIC COMMERCE, abbreviated as EC. E-commerce refers to the use of simple, fast and low-cost electronic communication methods to conduct various business activities without meeting buyers and sellers. The development of e-commerce has gone through two stages. The first stage mainly focuses on information release, and each enterprise establishes its own "home page" to introduce the company and its products; The second stage is the implementation of online transactions. The development trend of e-commerce is EB (Electronic Commerce) proposed by IBM. EB includes not only EC, but also all applications from front-end to back-end, and becomes the engine of modern enterprises. E-commerce not only simply deals with e-commerce, but also redefines the traditional business model. With the support of information technology, customer value and enterprise profit can be maximized. In the future, there will be more and more cases of using electronic means in commodity procurement, production, distribution, marketing and payment, which will greatly accelerate the efficiency of global economic operation. Under the mode of e-commerce, production and business activities have new characteristics due to virtualization of subjects, paperless processes, electronization of payment means, globalization of activities and digitalization of trading objects. Of course, to achieve a complete e-commerce will involve many aspects, in addition to buyers and sellers, banks or financial institutions, government agencies, certification bodies, distribution centers and other institutions need to join. In short, the informatization construction of transformer manufacturing enterprises should have long-term and strategic planning, consider the enterprise's own situation, improve the basic management work, and do not blindly pursue one step at a time, which makes it difficult for the completed information system to play its role. Transformer manufacturing industry can choose the appropriate information scheme according to its own scale, and can refer to the scheme table given by the author.
4 transformer enterprise information implementation
4. 1 Preliminary work in the implementation process (1) Doing a good job in basic management enterprise informatization is the basis of scientific management. Sound management system, reasonable management system, stable operation order, scientific management methods and perfect and accurate raw data are the premise and foundation of enterprise informatization. Only by standardizing management process and business, integrating and coding data and standardizing report format can enterprise informatization be possible. Therefore, in order to implement enterprise informatization, transformer production enterprises must first do a good job in basic management. Solutions; (2) Management supporting enterprise informatization is a complex system engineering, and its implementation needs the support of management from beginning to end, especially the support of the "number one". When the process reengineering is involved in the project implementation, it is difficult to carry out the project without the support and participation of senior leaders. Therefore, it is very important to strengthen the information awareness of leaders and get strong support from management. Most successful informatization enterprises have a similar experience: the main leaders of enterprises, especially the top leaders, must first have a deep understanding and sense of urgency about manufacturing informatization. (3) To set up a preparatory group to implement the project, we must first set up a project team. If an enterprise decides to go on an ERP project, it is even more necessary to set up a preparatory group. The composition of the preparatory group should be composed of people familiar with computer science, people familiar with management and leaders with prestige in the company. Through the feasibility study of enterprise informatization project, the preparatory group puts forward an analysis report, and makes arrangements for the budget and overall plan of the project for leadership decision-making; And analyze the needs of the project, do a good job in software and hardware planning, adhere to the combination of advanced technical performance and applicability, and prepare for your own development or choice (choose products suitable for your own software company). (4) Cultivating talents with engineering knowledge is the foundation of information construction of transformer manufacturing industry. The informatization construction of transformer manufacturing industry needs a large number of compound talents who know both technology and information technology and management. Therefore, we should attach great importance to the cultivation of information talents. Make a good training plan, you can send people to study in N~'i- plane, or invite experts to give lectures in the company. If conditions permit, it is best to invite consulting institutions in the field of information technology. Because institutions in China can learn more information. (5) Feasibility Analysis and Project Establishment Through necessary knowledge training, the preparatory group submits an analysis and project establishment report according to the present situation of the enterprise. (6) The preparatory group for demand analysis shall conduct demand analysis for the enterprise, preferably under the guidance of relevant experts. The main contents of demand analysis are as follows: ① business requirements that each department needs to deal with; (2) the business authority to process data; ③ Business statement requirements; ④ Openness of data interface. (7) If you choose a mature information software, you need to pay attention to the following aspects: ① Whether the function of the software is suitable for the needs of enterprises and future development; (2) Whether the software supplier or integrator has comprehensive management knowledge; (3) Maintenance and secondary development capabilities of software suppliers or integrators; (4) Normality and completeness of documents; ⑤ Quality and methods of implementing services; ⑥ The system price includes the charging method of after-sales service; ⑦ Software-permitted environment; (8) The sustainable development ability and service ability of software suppliers or implementation service providers. 4.2 Implementation Process of Project (1) The ERP implementation process of large and medium-sized enterprises is as follows. Of course, if other information schemes are adopted, we can also learn from them and reduce the steps according to the corresponding situation. The general implementation process is as follows: ① Establish a three-level project organization; (2) Make the project implementation plan; ③ Research and consultation; ④ System software installation; ⑤ Training and business process reengineering; ⑥ Prepare materials; ⑦ prototype testing; 8 customization; Pet-name ruby secondary development and simulation operation; Attending to establish a working point; @ Parallel; @ officially run. (2) Implementation Policy The informatization construction of transformer manufacturing enterprises should implement the implementation policy summarized by CIMS expert group of 863 Plan: overall planning, benefit-driven, key breakthrough and decentralized implementation. Enterprise information engineering is an extremely arduous project, and few enterprise information engineering can be completed in one step. Transformer manufacturing enterprises must combine the capital and personnel quality of their own enterprises and implement them step by step according to the long-term and short-term goals on the basis of overall planning. Take the implementation of ERP project as an example, whether it is self-developed or using mature software, you can sell the system first; Secondly, add inventory system, production planning system, workshop operation system and quality system, and establish an automation system with production control as the core; Then go to the financial system and establish a management system with finance as the core; Finally, go to the human resources system. After each step is successful, the next step will be implemented, and finally the system will be debugged to ensure the overall success of the system.
5 concluding remarks
Through the above introduction, we think it is necessary and urgent to strengthen the informatization construction of transformer manufacturing enterprises, and enterprises with certain scale and parts should seize the time to build them. The informatization construction of transformer manufacturing enterprises should have a long-term and strategic plan, and each transformer manufacturing enterprise can choose the appropriate informatization scheme and adopt the correct method to carry out informatization construction according to the specific situation of the enterprise. This paper introduces several schemes of enterprise informatization, puts forward the selection methods of informatization schemes of transformer manufacturing enterprises, and introduces some methods of informatization implementation, which has a good reference for the informatization construction of transformer manufacturing industry.