Changhong Group's first smart factory is located in Hebian Town, Mianyang, Sichuan Province. The entire park covers an area of 460 acres and focuses on the production of smart display terminals, with a planned annual capacity of 6 million units. For this smart factory, Skyray Consulting and the Changhong team collaborated sincerely. Skyray Consulting conducted planning, collaboration and counseling from the current situation research, conceptual design, preliminary planning, detailed planning, management enhancement, implementation and debugging, to help the smart factory land and operate effectively.
In the whole project process, by sorting out the strategic positioning of the factory and value orientation, it is clear that the smart factory construction project is mainly divided into three steps, including physical planning, management and operation changes and information integration and interconnection.
The first step: physical planning. This stage is based on industry benchmarking and multimedia logistics management characteristics, to realize the future of the factory "effective operation" and "integrated interconnection" oriented planning embedded in the management elements and requirements of the new factory logistics space, physical processes, facilities and equipment, etc. to carry out a reasonable The new factory's logistics space, physical processes, facilities and equipment will be rationally planned.
Step 2: Management and operational changes. On the basis of physical planning, management and operation changes are carried out to optimize the logistics management process and achieve effective synergy of strategy - strategy - planning - execution.
The third step: information integration. This stage focuses on information integration and interconnection to achieve effective synergy of planning - information - physical - operations. Information flow and physical flow is consistent, so that the differences remain within the standard range. System self-organization, self-decision-making, self-regulation, to achieve intelligence.
In terms of physical planning, the overall layout of the logistics main line through the entire planning process, emphasizing the flow is the hard way, to create a manufacturing plant logistics centrality to automated three-dimensional warehouse as a factory logistics center, radiation of various production areas, while embedding management elements into the planning. Combined with the product, material, process characteristics, the flow of each link and stock demand and other elements, differentiated configuration of intelligent logistics systems, reasonable, effective and economical as the premise, from inbound logistics - production logistics - finished goods logistics for a comprehensive pull-through, to meet the flexible production, the complex scene of the operational needs. The highlights of this project are as follows:
Highlight one, flexible storage, picking, distribution mode planning, to adapt to personalized customization and mass production compatible operation.
(1) flexible mixed storage and transportation of palletized bulky materials. Intelligent display terminal focus including TV, display screen, advertising screen and other terminal display products. TV product size covers a wide range, from more than 20 inches to more than 80 inches, corresponding to most of the pallet large pieces and TV product size is strongly correlated, how to design a set of flexible intelligent logistics system to adapt to the various sizes of the chain of the pallet large pieces of storage, is the project's difficulty and focus. In the end, after discussion by the project team, after a detailed analysis of the size chain, taking into account the utilization rate, compatibility, economy and other dimensions, two kinds of pallet storage units were designed, respectively L1400mm*W1000mm and L2100mm*W1400mm, with one cargo compartment placing two small pallets or one large pallet at the same time, and adopting the mature stacker cranes pallet three-dimensional storage system, to flexibly Solve the problem of large pallet storage.
(2) People to goods and goods to people picking synergistic design. Through the analysis of material picking characteristics, flexible design picking mode, to meet the production demand for materials. For zero picking materials, the use of fluent shelves picking picking, through the four-way shuttle + fluent shelves form to achieve rapid picking, effectively reduce the frequency of such materials out of the warehouse, reduce the pressure on the system, and at the same time, the personnel in accordance with the instructions of the electronic label on the fluent shelves to complete the picking operation. For the whole box distribution materials, goods-to-person picking is adopted, and the goods-to-person position is planned in the area required by each production line, which is convenient for the supply of materials after picking is completed. The entire picking and storage system is designed to be integrated to reduce system complexity.
(3) continuous and discrete combination of material distribution mode. For different production line mode, combined with the actual situation and demand, flexible configuration of distribution technology. For personalized custom production line, the production line box pieces of material demand is characterized by multi-frequency, small batch, each station distribution frequency is high, according to the use of continuous conveyor mode, through the box elevator with high-speed shuttle, and through the conveyor line docking direct distribution to each station, to achieve rapid and flexible distribution of materials.
For the batch production line, its material demand is characterized by less frequent, large quantities, according to which the use of batch distribution mode, the use of discrete AGV system, through the AGV back turnover shelves, and with the line side of the workstation shelves for automatic docking, clever low-cost automation and the integration of the use of AGV, not only to reduce the manual handling and reduce the cost.
Highlight two, differentiated logistics system design, to meet the complexity of the multi-scene, multi-mode operating environment.
(1) Differentiated configuration of raw material storage and distribution modes. In the storage and distribution links, according to the characteristics of the material as well as the flow demand, for different use scenarios, the differentiated design of the logistics system. For example, in storage, relatively standardized materials are stored in automated three-dimensional warehouses, while shaped parts are stored in flat surfaces. In the distribution link, for the relatively large flow of materials, the use of AGV with the turnover car distribution mode, the flow of small materials, the use of manual distribution.
(2) finished product handling, storage mode differentiated configuration. In the finished goods logistics link, through the PQ (product quantity) analysis, the finished product offline transportation and storage link to differentiate the configuration. Among them, 80% of the products off the line through the continuous conveyor mode to achieve mixed line palletizing, and then automatically enter the 24-meter-high automatic pallet three-dimensional warehouse for storage. The remaining 20% of the products are handled by discrete AGVs and stored on flat surfaces. The whole process is not automated for the sake of automation, but is fully economical and rationalized to achieve effective operation.
Highlight #3, the clever design of the aerial tour channel, to create a personalized tour of the attractions.
Take the material flow as the guide, design the air visit channel towards. Through the air visit channel, you can see the raw material automated three-dimensional warehouse - material distribution - workshop production - finished product automatic conveying, palletizing - finished product automated warehouse and so on all links. Overlooking the whole production workshop from the air visit channel, the vision is wide, through the panoramic display to give visitors a visual impact. At the same time, in the visitors passing through the route, consciously create a personalized visit attractions, the enterprise's manufacturing level, logistics management level, corporate culture to show visitors, enhance the overall image of the enterprise.
Factory planning is for operation, "all the money can buy the ability is not the core ability", the factory's operational capacity is also the same. Under the premise of the new system planning in logistics, we need to focus on the soft power of the factory (organizational capacity, planning synergy, material control, inventory turnover, team and talent training, etc.) to build. A new factory needs a new look and a new configuration of the ability system.
Based on this, the second phase of the management and operation of the change as the main theme, aims to comprehensively through the planning, procurement, logistics, production and other links, to create a set of new factory based on the new planning and adapt to the future development of the logistics operation system, the specific practices are as follows:
Plan management: the focus is to rationalize the plan - logistics - the synergistic logic of the management between the physical, to the fine management and adapt to the small batch production mode oriented. To adapt to the small batch production mode as the guide, the establishment of hourly operation plan as the traction, pulling the factory material distribution and JIT material to the goods of the refined management mode.
Supplier arrival and material management: based on the existing level, the establishment of step-by-step objectives, the end for the beginning, step by step, and steadily promote the procurement and inbound logistics to the small batch, multi-frequency transformation of the refined management model. At the same time, to clarify the rules of the arrival plan, for different materials to establish a differentiated logistics management model and standards, to create an orderly, controllable, visible material arrival management mechanism.
In-plant logistics operation management: with the goal of rapid response and service production, establish the material set management mechanism to ensure that the material set on line. At the same time, for different materials, different production line characteristics, the establishment of differentiated sorting and distribution mode, to support the new factory multi-species, small batch flexible production mode.
On the basis of the clear management needs of each link, the establishment of a matching logistics organizational structure. The logistics organization structure follows the principle of integrated logistics management, sorting out and defining the functions of the logistics management organization structure, designing the logistics organization structure, and establishing the key KPI indicators of the logistics organization, so as to provide organizational protection for the effective operation of the new plant.
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 needs of the implementation of the landing "not out of shape". Through the establishment of a structured, standardized five-level logistics process operation system, to create a set of standardized five-level process language. Through the new factory logistics related business five-level process sorting, the development of a unified process in line with the Changhong multimedia standard language, so that the business personnel on the business process to understand, say, do understand, in order to facilitate the process of deeper promotion.
Finally, on the basis of management needs, organizational safeguards, and process clarity, we put forward the main points of logistics informatization needs for each link, and solidify them with core information systems such as ERP, PCP, SRM, MES, WMS, QMS, WCS, etc., to ultimately achieve the integration of the entire process from planning, procurement, logistics to production with the underlying logistics equipment control system.
1. Output per unit area is greatly improved.
In this smart factory, more three-dimensional automatic storage system, the vertical space has been effectively utilized, so that the utilization rate of the plant area has been greatly improved, and the output per unit of area has increased.
2. Efficiency is greatly improved.
The introduction of automated logistics systems, management process optimization, the factory logistics personnel significantly reduced. At the same time, through the introduction of intelligent logistics systems, forcing enterprises to improve the level of management, planning management, procurement management, inventory control, quality management have put forward higher requirements, but also for the enterprise change injected a new impetus.
3. Realize the horizontal and vertical effective integration. Horizontally, it connects assembly plants, front-end supporting plants and external suppliers, and vertically, it connects the key links of research, supply, production, marketing and finance in the management of the enterprise, which truly achieves independent scheduling, independent management and independent decision-making in the whole process of production and manufacturing, and realizes the interconnectivity of the plant.
Smart factory from planning to landing is not a one-step process, the need for a clear strategic positioning and value orientation, on this basis, the process demand, production mode, logistics data, logistics scenarios for detailed analysis, differentiated configuration of the logistics system. At the same time based on the new logistics system, but also planning, procurement, logistics, production of all aspects of the management of operational changes, and through information technology integration to link them, and ultimately realize the goal of smart factory construction.