The hottest MES improves GAC passenger car product

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MES improves GAC passenger car production management

I. enterprise profile

Guangzhou Automobile Group Passenger Car Co., Ltd. is a wholly-owned subsidiary of Guangzhou Automobile Group Co., Ltd. as the implementation carrier of GAC's own brand passenger car project, it is committed to the production and sales of complete vehicles, engines, parts and auto supplies with international advanced level, as well as the research and development of automotive engineering technology. GAC passenger cars was founded on July 21, 2008 with a registered capital of 1.2 billion yuan. The company covers an area of nearly 1.2 million square meters, and the initial investment budget is 3.8 billion yuan. The annual production capacity of GAC passenger cars is planned to be 100000 vehicles and 100000 engines, and the follow-up will be phased to an annual output of 400000 vehicles and 450000 engines

adhering to the principle of "people-oriented, safe and economical, compact and reasonable", the factory process and layout fully integrate the advanced technology of the domestic and foreign automotive industry to achieve lean design and lean production. The whole vehicle includes four processes of stamping, welding, coating and final assembly, as well as a 1300m long test track. The engine includes three processing lines of cylinder block, cylinder head and crankshaft, and the assembly line of the whole machine. The first phase of the plant was started in 2008, completed at the end of 2009 and put into operation in 2010

looking at the world and the future, the selection of GAC Rockwell hardness scale is shown in table 2-2. Passenger cars will be market-oriented, guided by science and technology, adhering to the enterprise philosophy of people-oriented, faith-based and innovation first, create an environment-friendly, safe, efficient and harmonious enterprise, serve the society with high-quality products, achieve healthy, stable and sustainable development, and strive to become a world-class automobile enterprise

II. Overall status and development plan of informatization application

1 Current situation of informatization application

in response to the national requirements for the integration of industrialization and industrialization, the IT Department of GAC passenger cars once planned erpmesdmsscmpdm systems within one year. At present, these systems have been fully launched, quickly helping GAC passenger cars put into production and market smoothly, and providing comprehensive informatization support in the recent process of increasing production

2. Informatization development plan

Figure 2 GAC passenger car informatization overall blueprint

the above system modules have been launched in GAC passenger cars, which has fully realized the core informatization module of the automobile factory. In this process, it is a plan and the overall implementation is launched, so the business flow between the systems is coherent, there is no fault, and the interfaces between the systems are clear, simple and stable; For example, complete the design and finalization of vehicles in PDM; DMS completes the order release of the dealer's vehicles, DMS sends the order to ERP for resource planning, ERP then sends the scheduled daily production plan to MES for production and manufacturing, and sends the purchase plan to SCM supply chain to guide the supplier to prepare goods; MES will feed back the production progress to ERP and DMS; Submit the completion plan to ERP after manufacturing; Finally, DMS is put into storage and responsible for the sales and maintenance process of the 4S station; CRM system provides after-sales care to customers according to DMS sales and maintenance records; Finally, the closed-loop information flow of a vehicle from design to delivery to customers is completed

at present, one of the biggest problems encountered by enterprise informatization is the integration between systems. If the integration is not done well, the system cannot operate stably. GAC passenger car has completed the basic construction of the whole system and realized the application of core modules. The focus of informatization in the future is to deeply explore and use the functions of each module

Figure 3 the relationship between MES and quality inspection of various information systems

III. detailed introduction to information technology projects participating in the evaluation

1 Introduction to the project background

the automobile industry is a large-scale industry. If an automobile manufacturing enterprise wants to achieve economic benefits and stabilize the market in the current fierce automobile competition environment in China, in addition to having a good brand and excellent sales skills, it also needs to produce hard and low-cost products. This requires enterprises to carry out refined management of the manufacturing process. Under the rapid production pace of the assembly line, they can also coordinate the operation relationship of equipment, materials and personnel in an orderly manner, control the quality defects in the production process, and reduce the inventory in the production process. The traditional ERP system solves the problems of finance, personnel, warehouse, process and product data, while ERP cannot effectively solve the management in manufacturing for the workshop manufacturing process that is very different from each industry and enterprise. Therefore, when the informatization of GAC passenger car was launched in 2009, in addition to ERP and DMS (dealer management), it also synchronously imported Rockwell Automation MES platform

as GAC passenger cars are subordinate to GAC group, and GAC Toyota and GAC Honda are two famous automobile factories under GAC group, GAC leaders require that the production and manufacturing of GAC passenger cars must absorb the excellent management experience of Toyota and Honda, and on this basis, make further transformation and improvement in combination with the production characteristics of its own brand. The current MES system of GAC passenger cars combines the large-scale efficiency of Honda's mass production and the logistics mode of Toyota's flexible lean production to form a set of advanced MES system originally created by domestic independent brands

Figure 4 MES architecture

2 Project objectives and principles

the main objective is to achieve 1- digital and transparent production management of the whole plant; 2-lean production management; 3 - quality management of the manufacturing process of the whole plant. In order to achieve these three goals, specific requirements:

1) according to the ERP plan, MES generates the sequence production plan of the welding, coating and final assembly workshop, and guides the workshop production

2) mes can monitor the progress of vehicles in the manufacturing process of the welding, coating and final assembly workshop, as well as abnormal conditions such as vehicle repair and scrapping

3) mes can realize lean logistics distribution, and according to the production progress, Pull the materials to be assembled to the production line in real time, so as to reduce the workshop inventory

4) mes carries out defect management on the quality in the manufacturing process, and can collect the batch number of key parts, and finally form a quality file for each vehicle, which can be used as the basis of national vehicle recall data

5) mes integrates the data of workshop equipment, summarizes the data of torque machines and other main equipment to the MES system, and provides query and analysis functions; Integrated with some automatic equipment in the workshop, it can transmit vehicle data to robots and machine transportation lines, so as to guide the operation of automatic equipment

6) integrated with ERP, PDM, DMS, SCM and other systems, it can not only obtain orders, BOM and other data from relevant systems, but also send vehicle manufacturing information to other systems, forming a closed loop of information flow in the enterprise

principles to be followed in the process of project implementation

1) ERP, PDM, DMS and MES systems should be planned at the same time and implemented in stages. The functional division of each system is clear and clear, so as to ensure the integrity of a business operation

2) the basic data among ERP, PDM, DMS and MES systems must be consistent. Whoever generates the data, stores the data, while other systems can only obtain the data through the interface. Through this method, Keep data differences between several major systems

3) mes relies on relevant networks, equipment (torque machine, engraving machine, filling machine, robot, machine transport line, PLC, etc.) in the workshop, output terminals (scanning gun, printer, RFID, industrial computer, touch screen), etc., so these equipment also need to be planned at the same time, and when MES does demand analysis, it is necessary to discuss the interface data specification with the equipment manufacturer in advance, And make certain tests to verify

4) MES is a manufacturing execution system. In order to ensure production, it even requires 7*24 hours of operation, so MES needs higher stability and security than ERP. Therefore, when planning MES system, we should consider network security, hardware security and data security of digital display system with key speed regulation and experimental force displacement, and have a complete disaster recovery mechanism

3 Detailed introduction of project implementation and application

the MES system of GAC passenger car was launched in November 2009, the first phase function was realized in February 2010, and the second phase function was realized in July 2010, and the integration with ERP, DMS and PDM was completed. During the implementation of the project, Rockwell assigned a professional MES project team to implement the whole process on site. The project managers of both parties are responsible for the full-time implementation in strict accordance with the software implementation process: (demand analysis, system design, system development, system testing, system integration, data preparation, system online). At each stage, strictly control the process quality and risks in the process according to the project implementation methodology, Avoid taking the problem to the next stage

in the implementation process, difficulties are encountered in each stage. For example, in the demand analysis stage, the biggest problem is how to determine the functional boundary between MES and ERP. For example, to what extent does the daily plan of ERP achieve? Does it need to do preliminary sequencing before giving it to MES? In addition, if the plan of ERP changes, what impact will it have on MES? For example, if material pulling is done in MES, how to transfer the pulled material data to ERP, What document does ERP use to correspond to the material pull of MES; To solve these problems, MES consultants, ERP consultants and key users need to discuss together. During the discussion, the focus is that all parties should not only analyze the problem from their own standpoint, but should think about where this function should be implemented, which is the most beneficial to the whole system. After repeated discussions between the consultants and key users of GAC passenger cars, especially the consultants of Rockwell have done a large number of MES cases in car factories, and have rich experience in this field. The project team quickly completed the functional division of erpmes

at this stage of the system, we also encounter great difficulties. Because GAC passenger cars is a new factory, the output is small in the initial stage, and the production plan is unstable. Sometimes when producing trial production vehicles, the production line stops, so the workshop planning module and material pulling module of MES system can't be used. Even because of temporary changes in production or data errors, it needs to manually modify the data in MES. Although the MES function is available, this function is to deal with the production mode after mass production. During the trial production period, some functions of MES cannot be blindly launched. Those that need to maintain manual operation should continue to be used gradually after mass production

MES function planning of GAC passenger cars:

1) production control module

mes generates workshop production plans to guide production

the system can realize vehicle in-process tracking. Through bar code scanning or RFID, it can monitor the process management of vehicles in the assembly line in real time, which makes it convenient for production managers to count the production reports of various models

in the coating workshop, the complete adoption of RFID brings confidence automatic tracking system to the extruder enterprise. No matter where the body in white is coated, it can be queried quickly. Through RFID identification and interaction with the equipment PLC signal, it can control the transmission chain to automatically select the exit and entry ways, so as to realize the flow of the body controlled by the system; The coating system will also transmit the vehicle type and color information to the spraying robot to guide the robot to spray automatically

the system can automatically drive the printer to print the assembly instructions of the main line and sub assembly line of a single vehicle in the assembly workshop according to the order of the vehicle, and guide the workers to operate according to the vehicle order and the configuration table of the assembly order, so as to avoid the wrong installation

2) material management module

the products of some foreign manufacturers

generate various distribution bills by means of synchronous material pulling, batch material pulling and SPS material pulling, and guide the batching personnel to distribute the materials to the production line in time and section according to the production demand from the warehouse and unloading temporary storage area, so as to realize lean production and effectively reduce the line inventory

3) quality management module

mainly in the production process, the key parts (heavy

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