MES Manufacturing Execution System
MES (manufacturing execution system, manufacturing execution system) is the United States AMR (Advanced Manufacturing Research, Inc.) proposed in the early 1990s, aimed at strengthening the implementation of MRP plans, the MRP plan with the shop floor to implement the function, the MRP plan with the shop floor to implement the function, the MRP plan with the shop floor to implement the function, the MRP plan with the shop floor to implement the function. The emergence of MES fills the gap of shop floor management, which takes job scheduling as the core, reduces production cost and improves production efficiency as the goal, collects real-time information in the production process and handles real-time events in a timely manner, and at the same time maintains bi-directional communication with the planning layer and control layer to receive relevant information and provide feedback from both the upper and lower levels. The upper and lower layers receive relevant information and feedback processing results and production instructions, thus realizing the optimization of the entire production process.
1. Flexible response to changing production orders
Order scheduling, flexible manufacturing lean production mode is the pursuit of automotive production of a more ideal mode of production organization, although the current personnel, cost, productivity, market and other factors, this is only a goal, but as the information system must be towards this aspect of the design and layout. As the automobile manufacturing enterprises encountered the above production-related issues, in the industry after the universality of ERP, although the sale of all aspects of the inventory has been a great improvement, but there are still issues similar to the above need to break through and improve, but often in the actual operation of the time to perfunctory and submerged in these issues only.
At present, the automotive industry has formed an almost unified understanding of the MES system, that is, the establishment of production control in the workshop and the upper level of ERP between the management system, whether it is the overall construction of the enterprise information technology in the three-layer arrangement of the intermediate layer, or four-layer theoretical layout of the second layer, are illustrating the same truth, MES is the production activities and management activities of the bridge of information communication, planning and production between the top and bottom of the bridge, and the production of the bridge between the bridge and the management activities of the bridge, planning and production of the bridge between the bridge and the bridge. MES, through real-time information collection in logistics management and production management, can not only assist planners in arranging operations, production and material preparation, suggest feasible solutions to planners, narrow down the scope of choices for planners, improve the efficiency of planning and reduce the burden of planners, but also can quickly transfer the results of production arrangements to the production center. Can also be the results of production arrangements quickly passed to the operating site, site management personnel can make timely adjustments to the work center of the work arrangements.
2. Managing complex products and processes
By defining products within the MES system, automotive product engineers can not only easily define new products, but also establish a link between the customer's products and the enterprise's products, reducing the workload of merging materials. The centralized and standardized process definition environment ensures that all processes, technology, engineering, manufacturing, and QC work in a unified and standardized environment, so as to facilitate the timely **** enjoyment of information, reduce the repetition of definition errors, and complete version management to guarantee the historical information of the process is retraced. By establishing the correlation between product and process, as long as the product is determined, the process flow can be determined automatically, and the work order can be generated and printed automatically. This greatly reduces the workload of automotive product engineers and improves operational efficiency.
3. Real-time monitoring of the production site
The automobile manufacturing industry is a pillar industry of the national economy, due to the complexity of the product itself, and its typical order production mode, determines its production is different from the general product, characterized as follows:
(1) Order-oriented production. Because of the order specifications, quantity, delivery date changes, each product has its own particularity, from the product ordering decision-making to the whole process of manufacturing, each product has a certain degree of independence, the enterprise must be organized according to the order of production.
(2) the production schedule is difficult to control. As a result of the wide variety of products, affecting the production process of uncertainty factors, often emergency orders, equipment failure, parts rework rework, etc., so that the plan is variable, and even plan to keep up with the changes, and the production of the actual phenomenon of disconnect. Therefore, it is often impossible to grasp the changes in production progress in time, and it is difficult to control the whole production process.
(3) production management difficulties. Automotive products manufacturing process is complex, high quality requirements, and the production process of uncertainty, with experience scheduling can not guarantee the coordination of the entire production process, process control difficulties, management difficulties.
In the MES system, the automobile manufacturing enterprises in the organization of production only need to determine the product, the system will be able to automatically determine the relevant material information and production routes. All the operational information in the production process is also recorded by the system in real time, greatly reducing the number of work orders, to ensure the accuracy of information transfer. The system provides workshop managers with the ability to arrange materials or semi-finished products to the designated equipment for operation, and provides operational guidance during the operation, prompting the staff to work step by step. The data collection function of the system can collect real-time quality and material information on site, and automatically record operating information such as operating personnel and operating 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
Many automobile manufacturing enterprises in the production process, in order to achieve ISO9000 in the provisions of the "product identification and traceability", often using the process card, that is, each product hangs above a small card, the card records the experience of each process of production results. When the product flow to a process, workers need to use a pen to record on the card. These process cards are simple to use in the production process, although they can play a certain positive role, but there are many shortcomings: (1) too many, not easy to manage. (2) Process cards have a not insignificant cost. (3) The process card is not easy to count the timely production data. (4) Process cards are often not standardized and identifiable when filled out manually.
The MES system combines the latest barcode automatic identification technology, serial number management, barcode equipment (barcode printers, barcode readers, data collectors, etc.) to effectively collect the product in the production and logistics operations related information and data, tracking the production of the product as well as the flow of the whole process of the movement of the lifecycle, so that the enterprise to achieve the procurement, sales, production, tracking of materials, monitoring, product quality traceability, sales tracking and tampering of goods. Traceability, tracking of sales tampering, warehouse automation management, production site management and quality management and other objectives. The MES system can immediately suspend the operation of all potential batches at the site through WIP management to reduce the loss of abnormal products that are inconsistent with the target in the production operation. Based on the exception handling constraints, the system will prohibit operations beyond the constraints. Abnormal handling information from the field can be quickly passed on to other relevant departments to facilitate adjustments and preparations. Field data can also be provided to the SPC system to help quality engineers make timely adjustments to existing products and processes to avoid and prevent quality incidents.
5. Provide complete and accurate manufacturing data
In order for automotive manufacturing companies to meet dynamically changing customer needs and deliver on time, the company's business layer 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, providing real-time data on production events, equipment performance and downtime, and KPI calculations is critical to making the right decisions. While reports can be generated manually, creating a true picture of the production situation requires continuous capture, storage, and presentation of production data.
Through on-site data collection, MES establishes the correlation between materials, equipment, personnel, tools, semi-finished products, and finished products to ensure the inheritance and traceability of information. The real-time data provided by the system can not only provide production managers with the actual status of workshop operations and equipment, but also provide business departments with the production status of customer orders, and also calculate the direct material consumption cost based on the actual production situation. Reporting and query functions based on field data can provide support for decision-making by senior management. It reduces a large amount of statistical work and increases the comprehensiveness and reliability of statistics, realizing the traceability of manufacturing data.
6. Localized application of global leading technology
Gallup MES (Manufacturing Execution System) is a set of advanced shop-floor digital production management solutions based on more than 20 years of global technology precipitation and nearly 14 years of localized implementation experience in China, which focuses on discrete production mode of manufacturing enterprises, in addition to the automotive industry has a wealth of successful cases in the defense industry, military equipment, weapons, equipment and other equipment. In addition to rich successful cases in the automotive industry, Gallup MES has also occupied a leading position in the industries of national defense industry, weapon equipment, aerospace, mold manufacturing, medical equipment, machinery manufacturing, shipbuilding, electrical manufacturing, electronic equipment and so on. Currently, more than 80% of Gallup MES users worldwide are Fortune 500 companies, and Gallup has become the absolute leader in the MES field.
With the gradual innovation of management methods, lean manufacturing is the future trend in the automotive industry. To realize the lean production of automobiles, placed in the workshop level of one of the most core issues is how the production process of the product of a variety of information flow to the comprehensive use of these information through the information system processing for further refinement, so that it extends to the factory's automated equipment, quality management, delivery management, supply chain procurement, cost control, logistics management and so on the various external links. Simply put, it is the unlimited amplification and **** enjoyment of the production form of the product in the workshop for the use of each external link, through which the optimization of management efficiency and resource allocation can be realized. And can realize all of the above lean production carrier, non-MES manufacturing execution system.