The hottest manufacturing execution system is the

2022-08-24
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Manufacturing execution system, the only way for manufacturing power

since entering the 21st century, the scale of China's manufacturing industry has developed rapidly. In recent years, the output value of manufacturing industry accounts for about 40% of the gross national economy, ranking fourth in the world and becoming a manufacturing power attracting worldwide attention. However, the level and scale of the manufacturing industry I have worked in are quite different from those of the United States and Japan in terms of product technology, processing technology and manufacturing management. China is far from being a world manufacturing power. The reality of China's manufacturing industry is mainly to rely on labor and resources and comparative advantages to maintain scale expansion at the low end, but it has not yet achieved to rely on knowledge and technology and competitive advantage to compete with foreign advanced manufacturing enterprises

modern manufacturing process requires comprehensive information technology to provide enterprises with fast information channels, so that enterprises can obtain agile response ability in production. With the gradual promotion and deepening of MRP, ERP and other tools and management concepts in China, as well as the introduction of advanced digital production equipment, the number of power lithium battery enterprises in China alone has been reduced from 84 to 40, and the informatization awareness of national manufacturing enterprises has been gradually strengthened. However, because ERP mainly provides planning effect, it cannot effectively control and manage the operation site, and the plan cannot be effectively implemented There is a fault between the equipment control. As a result, the demand for MES is gradually highlighted

the concept of manufacturing execution systems (MES) has appeared since the 1980s. In the early 1990s, AMR organization proposed a complete MES model. For more than 20 years, MES system has been widely used in enterprises in North America, Western Europe and Japan. Combined with lean production, Toyota Management Mode and other ideas, MES system has played a great role in improving the manufacturing level and production efficiency of enterprises

brief introduction to the development of MES abroad

MES, which appeared in the early 1980s, came into being in the competition with Japanese manufacturing enterprises. In the middle of last century, "made in Japan" was synonymous with "cheap" and "imitation". However, TQM, just in time and flexible manufacturing technologies implemented by Toyota, Sony and Honda have achieved remarkable results in reducing inventory, shortening cycle time and reducing costs, making their product quality and goods delivery almost perfect

the western manufacturing industry is forced to adapt to this change quickly in order to obtain the survival opportunities of enterprises. But unionization and labor policies forced western manufacturers to put the promotion of factory automation in the first place. In the past 20 years, it has doubled the speed of manufacturing industry and achieved great benefits

while improving the speed of the manufacturing industry through automation, it reduces the number of employees needed to supervise and inspect the production process, but this forms an "information gap" between the enterprise level management system and the workshop level equipment control layer, which cannot be effectively communicated. The traditional MES system is used to eliminate this "gap" that affects the benefits of automation. The MES system connects the PLC and logistics operation equipment of the factory and warehouse, so that the supervisor can obtain instant visibility to manage and control "events"; At the same time, the MES system receives work orders from the enterprise management system, and feeds back detailed transaction processing after the task is executed. In order to improve the speed and accuracy of decision-making, improve management productivity, and maintain continuous and smooth operation, MES system provides a tool for detailed scheduling, management of labor, resource allocation, task assignment, job scheduling, process management, quality control, maintenance, record keeping, and performance management, forming a link between macro management and micro affairs

the necessity of developing MES application in China

the advantages of China's manufacturing industry in the period of scale expansion have gradually lost

At the beginning of reform and opening up, China's manufacturing industry seemed to have inexhaustible resources of cheap labor, land and raw materials. This makes the products produced in China have a low cost and a strong competitive advantage in the world. However, with the expansion of manufacturing scale and the development of national economy, the following problems are in front of us:

rising labor costs. Due to various reasons, the labor market in cities and manufacturing intensive areas has begun to be tense. In the mainland and coastal areas of China, new factories continue to emerge, exceeding the growth rate of workers. In recent years, there has been a phenomenon of "labor shortage" in even all parts of the country. Due to the increasingly serious shortage of personnel, the enhancement of workers' awareness of self-protection of rights, and the reduction of seasonal workers flowing from rural to urban areas caused by the improvement of rural living conditions, the wages of industrial workers in China are on the rise. Although they are still very low according to Western standards, the rise in wages directly increases production costs. The improvement of people's living standards is inevitable for social development. Therefore, the increase of labor costs is irreversible for manufacturing enterprises

land and tax costs increased. We all remember that in the early days of opening up, many local governments provided a lot of support and preferential policies for enterprises in land resources, taxation and other aspects in order to attract investment and rapidly develop the economy. However, land is the land of the state, and it is impossible to use it for long-term preferential treatment or even free of charge; Taxation is the guarantee of the normal operation of society, and it will gradually return to the normal level. Therefore, the cost increase of this part is irreversible

price competition is escalating and resources are gradually lacking. Foreign capital and private capital investment quickly set up new factories, intensifying the price competition of domestic enterprises' products and raw materials. Manufacturers cannot increase prices at the rate of rising raw material and labor costs

the role of MES in manufacturing 4. The testing accuracy of copper rod tensile testing machine is level 1 manufacturing enterprises

modern MES integrates management ideas such as lean production, JIT, TQM, 6 σ, and its ultimate purpose is to reduce manufacturing costs, improve product quality, and enhance enterprise competitiveness

mes provides the executive power of the production plan to ensure that the production plan is completed on schedule. Like other business activities, the manufacturing process of enterprises also has two levels of planning and implementation. A correct and scientific plan is the basis to ensure the completion of the task, but only the plan is far from enough. If the plan cannot be implemented, it is empty talk. MES undertakes the function of implementing the plan from the perspective of implementation, and ensures the implementation of the plan from the aspects of detailed production scheduling, resource scheduling, quality management, process control and so on

in many enterprises, master production plan (MPS) is a rough plan, especially in enterprises with large production batches. Sometimes the cycle of a master production plan can be as long as several days or even weeks. For example, some general-purpose parts manufacturing enterprises often make production plans in the form of mass planned stock. In this way, how to decompose the production plan according to the specific use of production resources such as equipment, personnel, materials, molds, etc. has become the first task of the main production plan. The planning and scheduling function of MES plays this role

at present, the production mode of manufacturing enterprises is increasingly turning to MTO (production to order) mode. Under this production mode, small batches and multiple varieties of products are produced continuously on the same line, and the process of each order is different. Under the condition of frequent product switching, workers are prone to process errors, resulting in more rework, high defect rate and low production efficiency. MES arranges production according to the process requirements of each order and the principle of continuous production with reference to the same process. Through the collection and analysis of detailed production data, MES judges the correctness of each processing operation, avoids the occurrence of process errors to the greatest extent, and can improve the production efficiency of the enterprise by more than 30%

the recall system of defective products is being extended to more and more industries. How to accurately locate defective products, gradually restrict and stop the use of such flame retardants, and reduce the recall cost has become an important problem that these enterprises need to solve. MES records the specific production data in detail during the production process, forming a traceable product manufacturing process database, which provides strong data support for the accurate positioning of defective products

the production process improvement of enterprises is a long-term and continuous process. MES records detailed information in the production process, finds out the key problems affecting production efficiency through scientific analysis, and guides managers to solve and improve gradually. Before the implementation of MES in a large state-owned enterprise, no one can count the number of products in process. The number of products in process has always been a fuzzy number. Relying on the estimation of workers alone, it brings inaccurate factors to planning, scheduling and other work. At the same time, it often causes the loss and accidental damage of products in process

mes is necessary for the development of manufacturing enterprises.

mes, as the link between the top-level plan management system and the bottom-level control system, is an indispensable management tool for manufacturing enterprises. The collaborative work of MES with ERP, SCM, SCADA, DCS and other systems constitutes a comprehensive information application of manufacturing enterprises, and realizes the real enterprise information exchange, data sharing and enterprise operation automation

As a plan implementation tool, MES can integrate advanced production management methods and concepts such as lean production and total quality management, combined with advanced methodology, modern information technology and the actual production of enterprises, to create an efficient manufacturing express line for enterprises. The scientific use of MES, combined with other management tools and means, to continuously reduce costs and improve quality is the only way for modern manufacturing enterprises to achieve steady and rapid growth and establish an efficient manufacturing mode based on the distribution of various steels produced by local Angang, Shagang, Xinpu, Fengbao and other enterprises

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