Founded in 1923, an electrical group is a world market leader in electrical connectivity, electronic interfaces, lightning and surge protection, Industrial Ethernet, fieldbus and industrial automation.

Since 1993, the Group's subsidiaries in China have taken root in Nanjing, and after more than 20 years of rapid growth, it has now developed into a national-level regional headquarters of multinational companies with 6 wholly-owned companies and 1 joint venture company in China, becoming the Group's largest overseas production and R&D base, and one of the Group's three global competitiveness centers.

The company now covers an area of more than 94,000 square meters, with a registered capital of more than 100 million US dollars, and its market share has ranked first in domestic counterparts since 1996, with more than 1,800 employees and annual sales of nearly 2 billion yuan.

As a leading enterprise in intelligent manufacturing and Industry 4.0, the company officially released its own intelligent strategy at the 2014 Industry Fair. At the same time, we also put forward that the core of Chinese enterprises to achieve Industry 4.0 is to realize the concept of "intelligent manufacturing + integration of industrialization and industrialization". Among them, the application of automation technology is a necessary condition, and digital technology is a sufficient condition.

    1. Introduction to the background of the project

With the continuous optimization and promotion of Lean Production in the company's manufacturing center, how to further improve the production and manufacturing level of the manufacturing workshop and ensure the real implementation of the intelligent strategy is a practical problem we are facing.

The object of this project is the injection molding workshop of our company's manufacturing center, which is mainly based on the production mode of multiple varieties and small batches. With the increasing demand for customized production of customers, product production switching is becoming more and more frequent, and its efficient operation of scheduling, equipment, molds, personnel, materials, production processes and other aspects puts forward higher requirements.

    2. Project objectives and implementation principles

In order to improve the flexibility of production and improve the transparency of the production process, the company hopes to achieve the following goals through the intelligent transformation of the injection molding workshop:

    In terms of planning and scheduling:

Simplify the difficulty of scheduling and improve the efficiency of scheduling: the system automatically executes it by setting rules;

Improve the accuracy of scheduling: the data of materials, molds, machine tools, and orders are all collected and integrated in real time, and the scheduling plan is more accurate and reasonable;

    Equipment operation monitoring:

Real-time and automatic collection of production status and other related parameters of injection molding equipment;

When the equipment fails, it can be found in time to help the equipment maintenance department respond in time;

    Transparency in the production process:

When the production process is inconsistent with the plan, it can get timely feedback and adjust and deal with it;

    Improve OEE:

Through the implementation of the MES system, it can help the injection molding workshop to schedule production reasonably, reduce the waiting time of molds, equipment or materials, find equipment failures in time, reduce the downtime caused by equipment failures, and can respond quickly to temporary orders or product switching according to the current state, collect production data in real time, and automatically conduct statistics and analysis, so as to ensure that unreasonable links in production are found and eliminated in time, eliminate waste, and effectively improve the comprehensive utilization rate of equipment OEE, thereby improving production capacity and saving equipment investment costs.

Automated Logistics:

The dispatching system is integrated with the roller line, automated small warehouse, MES and WMS systems, and then the AGV trolley is called to complete the entire logistics and transportation closed-loop without any manual participation.

3. Benefit analysis

•Improved the efficiency of planning and scheduling:

• Simplified scheduling steps: Through the system, it is very easy to obtain real-time status information, the current execution of orders, and improve efficiency.

•Improve the accuracy of scheduling: through the acquisition of real-time status on site, the quality of scheduling is higher, and through the system setting, the scheduling rules and related calculation indicators are automatically realized, which effectively reduces the difficulty of scheduling, improves the speed and accuracy of scheduling, and makes the adjustment and change of the plan simpler and more effective.

•Improved the stability and convenience of scheduling: The accuracy of scheduling has been greatly improved, and the stability of scheduling can be easily improved, and the scheduling plan can be more than 1 week.

•Improved planning accuracy of ERP and other systems, providing room for improvement in the efficient scheduling of the entire enterprise resource planning and further supply chain optimization.

•Improve the operation efficiency of equipment and tools:

•The utilization rate of equipment and tools has been improved under the condition of effective planning and scheduling. At the same time, after the problem of equipment and tools, the management departments at all levels can see the problem status at the first time and deal with it in time, which improves the efficiency of the use of equipment and tools. Since the launch of the system, the OEE indicator has risen steadily.

•Improve the stability of equipment and tool operation:

•The maintenance and repair of equipment and tools are pushed by the system, which improves the visualization and assessability of the tasks of the management team of equipment and tools, effectively implements many prevention tasks through the system, and reduces the risk of equipment and tool failure.

• Improved personnel performance:

•Through the use of the system, planners can complete the planning and scheduling tasks faster than before, and can use more time to consider how to improve the work; mold needle change and maintenance personnel can carry out task scheduling, so that the whole team can have a clearer understanding of the workload and work arrangement, effectively arrange the work of personnel, and the system issues relevant work reports; workshop operators and material preparation personnel can see the real-time scheduling information in the field terminal, and the personnel can obtain the production preparation information more conveniently and orderly; quality inspection personnel, directly in MES The terminal sees the drawings, and the quality inspection information can be obtained through the MES system, and the quality inspection evaluation report is more objective and effective.

• Improved OEE metrics and credibility:

• The system uses a unified metric standard to automatically calculate, which improves the accuracy. Since the use of the system, the OEE index has risen steadily, and the factors that affect OEE can also be analyzed by taking out data to facilitate timely processing.

After the system runs for a period of time, according to the feedback of relevant data on the site, the whole production efficiency is increased by more than 9%, and the time of on-site material flow is reduced from an average of 30 hours to an average of 12-16 hours, so as to speed up the flow of cash; at the same time, according to the production line and process scheduling, reduce the number of orders to make up for the problem of insufficient team tasks, and reduce the number of production line changes by more than 40%; after the system is operational, it is 100% for 2 and 100% for on-site abnormal information 100% of the actual production cost of each order is recorded, including labor hours, material costs, finished product scrapping and other data, so as to further improve the market competitiveness of products.