In recent years, the automobile industry has continuously promoted the development of intelligent manufacturing, and more and more automated logistics systems have been introduced into the construction of intelligent factories to optimize the operation process of factories, improve quality, increase efficiency and reduce logistics costs.
SAGW is a famous transmission manufacturer in China. The company has set up five specialized and large-scale production bases in Shanghai, Yantai, Shandong, Liuzhou, Jiangsu, Kunshan, Chongqing and other places, mainly producing all kinds of supporting passenger cars, commercial vehicles, new energy vehicle transmissions and key parts, becoming one of the most influential manufacturing enterprises of D. The company is headquartered in Jiading Automobile City, Shanghai, covering an area of 965,438+00,000 square meters. In 20 19, the company's annual sales revenue was/kloc-0.08 billion yuan, and the total number of employees exceeded 7,000.
With the proposal of "Made in China 2025", SAIC Transmission has become a pilot unit of SAIC intelligent manufacturing. Qian Xiangyang, the general manager of the company, asked to speed up the standardization, automation and informatization construction of the company, set up a project team quickly, and gradually complete the transformation from traditional manufacturing to intelligent manufacturing. Gao, deputy general manager of the company, headed by Huawei, is responsible for the overall intelligent manufacturing project planning of the company; Shengdong Liu, executive director of the company's logistics department, is the deputy team leader, responsible for the overall planning and management of intelligent logistics; Li Zheng, executive director of the company's management development department, is the deputy head, responsible for the overall planning of the intelligent manufacturing information system; Chen Weifeng, senior manager of logistics department, is the project manager of intelligent logistics, responsible for the planning and implementation of intelligent logistics projects. After repeated discussions by all members of the project team, it was finally decided to implement the inbound logistics automation project in Yantai Base of SAIC Transmission, and realize the intelligent factory construction goal of automation and informationization of the whole inbound logistics process, such as material handling automation, transportation automation, warehousing automation, picking and loading automation, assembly off-line loading and unloading automation, and empty container return automation.
Project implementation process
The Yantai base of Shanghai Automobile Transmission Co., Ltd. (referred to as "Shandong SAIC Transmission" for short) settled in Yantai in 2004. 20 18, 10 In June, Shandong SAIC transmission TS 1 1 officially went offline. The newly planned CVT (continuously variable transmission) production base has built an industry green intelligent manufacturing demonstration factory from four directions: intelligent production, intelligent maintenance, intelligent logistics and intelligent quality. Therefore, the company and the leaders of the Planning and Logistics Department decided to take the TS 1 1 project as the pilot platform and choose Engel (Beijing) Intelligent Technology Co., Ltd. (hereinafter referred to as "Engel Intelligent") as the design implementation unit of the project, so as to integrate the logistics resources of Shandong SAIC Transmission, optimize the logistics operation mode, improve the automation rate, reduce logistics workers, improve the operation efficiency and meet the high-quality requirements of products.
Since the project started in June, 20 18, 1 1, it has gone through many stages, such as project preparation, blueprint design, hardware development, monotonous equipment, joint debugging, stress testing and online preparation. Finally, the project was successfully launched in June 20 19.
The whole project implementation process mainly includes six stages:
1. Preliminary research stage
On-the-spot investigation and current situation are sorted out for 5 times, and 29 kinds of 182 grading tasks are involved according to project modules and implementation stages; Layout of on-site logistics management points: 1 13 The on-site management points are arranged from five aspects of man-machine chart and environment to ensure the implementation of subsequent automation projects. See figure 1.
Figure 1 SAIC gearbox logistics technology development path
2. Project preparation stage
Organize field research, sort out the current situation and pain points of business operation, and sort out the current situation of field operation from the aspects of feeding mode, business process, pulling mode and supplier information specification. , determine the overall business needs and scope, organize discussions to determine the business optimization to be promoted before implementation, and finally output the business demand report and set the three-level business plan.
3. Blueprint design stage
Determine the implementation strategy, finally determine the system coverage and business coverage, organize business departments to participate in the blueprint process design, and output the main business processes through single scenario, cross-system and key issues.
4. Function check stage
According to the determined blueprint, the system supplier decomposes it into development instructions, checks functions, sorts out and outputs on-site hardware requirements, and tracks them in place according to the determined operation.
5. Scene testing stage
After the system function development is completed, the function test and verification are carried out for each business scenario. Debugging and debugging stage: after the system and hardware are ready, the software and hardware jointly debug the joint scene, estimate the business scene time according to the actual production rhythm, formulate the debugging and debugging scheme, and verify the stress testing function, so that more than 20% JPH can meet the demand. In this process, the problem handling and review: the mechanism of organizing a one-day problem review meeting, followed by the improvement of joint debugging.
6. Online preparation stage
Check online matters: follow up according to the three-level business plan and check online preparation in multiple dimensions. At the same time, in order to ensure online response and operation and maintenance, three types of operation and maintenance processes are output and training is organized.
Composition and main operation links of logistics system
Figure 2 TS 1 1 Plan of Project Logistics System
TS 1 1 Logistics Automation Project is the first factory-wide logistics automation integration project of SAIC Drive, as shown in Figure 2. The construction area of this project is 108 10 square meter, which involves laying 3 10 meters of automatic transportation lines and 750 meters of AGV running routes. There are 160 SKUs for stored materials, and the average daily turnover of materials is about 1650 boxes. The average daily turnover of finished products is 1 10 Torr. The robot rapid sorting system is 3 100, and the automatic three-dimensional warehouse is 448. The TS 1 1 project finally realized the intelligent production goal of intelligent factory with fully automatic production operation, material transportation and storage.
Transmission materials are divided into parts and finished products. In terms of spare parts, large pieces are packed in tray boxes and small pieces are packed in Sichuan trays. Small pieces are put in the turnover box first and stacked on the Sichuan plate in a unified way. There are four specifications of turnover boxes, the maximum mass is 15kg. See table 1 and table 2 for details.
Automation technology covers all the operation links of in-plant logistics, mainly including: outsourcing parts receiving link, outsourcing parts warehousing link, parts sorting and online link, offline automatic assembly and automatic delivery link. The whole set of automatic logistics system equipment includes: automatic chain loading and unloading system, AS/RS intelligent three-dimensional warehouse, robot rapid storage system, AGV automatic distribution system and automatic assembly palletizing and loading system. See table 3 for details.
1. Receipt of purchased parts
According to the requirements of the system, the purchased parts truck stops at the automatic loading and unloading lane, and the driver completes the power signal docking between the automatic loading and unloading lane and the vehicle; The automatic loading and unloading system automatically transports the materials in the car to the cache line in the warehouse; After the packaging label is scanned by the conveying mechanism, the materials are sent to the designated storage areas respectively. Pallet boxes are transported to the storage area of the three-dimensional warehouse, and the goods are stored in the designated cargo space by the stacker according to the instructions of WMS. At the same time, the system completes posting. The pallet of the turnover box is conveyed to the robot unstacking station by the conveying system. After the robot unpacks, the turnover box is transported to the robot rapid storage system and stored in the corresponding position according to the instructions of WMS. The system completes posting. Outsourcing warehousing process completed.
2. Outbound link of purchased parts
According to the requirements of MES and WMS, the pallet stacker system and the robot rapid storage system automatically take out the designated pallets or turnover boxes and put them on the conveying line; Pallet box-type conveying system, which distributes products to designated conveying ports according to the superior dispatching system; The small turnover box is manually transported to the designated station blanking point; The large materials in the pallet box are automatically transported to the blanking point of the demand station by AGV through automatic docking to complete the blanking task. At the same time, they are taken back to empty boxes and automatically returned to empty boxes at the collection point. The system completes the outbound process.
The material distribution in the workshop is realized by AGV, which has 8 material off-line points, 1 feeding point and 1 empty container recovery point. A total of 8 AGVs were put into operation, including 5 parts (large parts) and 3 assemblies.
3. Recovery carrier of purchased parts
AGV will recycle the used empty purchased parts carrier from the production line to the designated place; The returned empty small turnover boxes are manually placed on the conveying line, and then manually coded after being conveyed to the corresponding ports; The returned empty pallet boxes are automatically brought back by AGV, automatically docked with the conveying line at the empty box recovery point and conveyed to the empty box return line; The empty pallet box of the manual pallet small turnover box is directly transported to the empty container buffer line of the automatic loading and unloading vehicle through the conveying line, waiting for loading; After the fully loaded vehicle is unloaded, the system will automatically load the empty vehicle of the cache line. No-load recovery process completed.
4. Finished product loading link
The lower assembly line is sent to the drum conveyor line through AGV, and the drum conveyor line completes the three-layer stacking of the assembly frame through the stacker, and is automatically docked with the truck through the conveyor chain. After the AGV unloaded the full load of electrical appliances, it moved to the interface of the roller table of empty electrical appliances and waited to receive the empty electrical appliances; The folding buffer roller line automatically transports empty appliances to the pallet truck towed by AGV; After AGV transports pallet trucks and empty appliances back to the finished product off-line station, AGV returns to the standby area; The purchased parts are delivered from the raw material warehouse to the logistics cache warehouse, which realizes the automatic loading and unloading of trucks, scanning and posting, and automatic distribution and warehousing of cargo spaces.
The truck loaded with empty appliances arrives at the loading and unloading crossing, completes docking with the automatic docking positioning device, and then starts the automatic loading and unloading system; The automatic loading and unloading system translates the empty instruments to the empty instrument conveying line one by one through the rice transplanter at the crossing; The empty appliance conveying line is directly connected with the roller alignment line (centering station) to convey the empty appliances to the roller alignment line one by one. The empty instruments entering the wheelset need to be centered in this station, and then transported to the buffer roller line (stacking station) of the stacker through the wheelset, so as to stack the empty instruments.
Automatic loading of electrical appliances at full load: the finished gear box is assembled and stacked by the manipulator at the off-line station, and the manipulator directly stacks the finished products on the finished electrical appliances; The MES system sends the vehicle demand information, and the AGV docks the full instrument, transports it to the finished product automatic loading parking space along the path, docks with the automatic loading and unloading system, and transports the full instrument to the docking roller line; Fully loaded instruments enter the roller line to complete the alignment of instruments, and the fully loaded instruments are stacked by conveying the roller line to the buffer roller line (stacking station) of folding instruments, thus completing the stacking of three sets of fully loaded instruments; Directly conveying the stacked appliances to the fully loaded appliance conveying sliding chain line of the automatic loading and unloading system, and moving the stacked fully loaded appliances to the vehicle loading and unloading interface buffer through the sliding chain line; When the number of buffers meets the loading requirements, the automatic loading and unloading system is started, and the finished products are automatically loaded to complete the loading task of finished products.
In terms of logistics system, WMS system directs WCS system to automatically complete system operations such as warehousing, warehouse operation and warehouse delivery. WMS system is highly integrated with SNC, MES, ERP and WCS systems. TS 1 1 project is a multi-system integration, and its architecture is designed as three layers: system management ERP, execution system (order coordination SNC, warehouse management system WMS, manufacturing execution system MES) and control system (warehouse control system WCS, automatic car AGV), and SAP system is responsible for all accounting management; In the execution system, SNC is responsible for delivery coordination with suppliers, WMS is responsible for warehouse account management, and MES is responsible for material pulling and delivery management of production line. The control system is responsible for the scheduling and operation of automation equipment. So as to realize the automation of supplier order warehousing, warehousing, submission and other information, as well as the automation of physical loading and unloading, shelving, distribution and delivery, that is, the supplier SNC generates a delivery note and transmits it to ERP and WMS；; ; ; When the materials are put into storage, WMS will transfer them to WCS for automatic storage; When materials are consumed, MES generates pull information according to consumption, and transmits it to WMS to generate waves, which automatically controls WCS to take delivery from the warehouse and schedules AGV to deliver goods automatically. See figure 3.
Fig. 3 Architecture diagram of logistics information system
Project Difficulties and Technological Innovation
1. Implementation of unmanned scene
The main innovation and design difficulty of this project lies in that all warehousing and logistics links (from raw materials entering and leaving the warehouse to warehousing, materials off-line, finished products off-line and finished products automatically put on shelves) are unmanned, and the warehousing and production links are seamlessly connected. It is the first project in the auto parts industry to realize full automation of warehousing and logistics.
A collection of some live photos.
2. Wrong materials and goods damage caused by human intervention are greatly reduced.
From the delivery of materials to the delivery of online materials, it is automated. All materials are tracked intelligently by the intelligent WCS system, and there is no need for personnel to participate, which reduces the error probability of employee identification and greatly reduces the risk of congestion or lack of materials at the side station caused by unbalanced cargo pulling (over delivery, less delivery, early delivery and late delivery).
Fig. 4 Flow chart of line edge system
3. Logistics operation efficiency has been greatly improved.
In particular, the application of automatic loading and unloading vehicle system can complete unloading from full container to empty container loading within 5 minutes. In the whole loading and unloading process, the driver only needs to press the button, which completely replaces forklift operation, saves forklift and loader, reduces manpower and optimizes personnel cost by more than 70%. There is no damage to the goods during loading and unloading, and the safety risk is low; The loading and unloading efficiency is greatly improved, which is more than 10 times higher than that of forklift operation. In addition, the automatic loading and unloading system can also save a lot of transportation capacity and storage area, saving more than 3 cars every day. The loading and unloading of finished products and the recycling of empty household appliances only need to occupy two crossings.
Fig. 5 Flow chart of automatic receiving system
Through the implementation of the logistics automation project, Shandong Transmission Company has basically realized unmanned warehousing and on-site logistics operations, at the same time, it has effectively improved the safety and operation efficiency, and achieved the system design effect, which has been highly affirmed and appreciated by relevant departments and company leaders.
Fig. 6 Flow chart of finished product automatic off-line and delivery system
At present, the auto parts manufacturing industry needs to increase the investment in automation technology in repetitive work. The warehousing and online logistics of automobile parts can greatly improve the automation level, thus improving the logistics efficiency and reducing the logistics cost. The successful start-up and application of automation projects can effectively improve and optimize these links, and at the same time significantly enhance the intelligence of factory logistics, lay the foundation for the promotion of intelligent logistics, and make SAIC drive at the leading level in the field of logistics intelligence.
Million car purchase subsidy