Digital transformation case analysis. Gain insight into industry challenges and explore the path to digital transformation. Case: Construction of intelligent production workshop for rubber and plastic products (Aerospace Cloud Network) [Project background] A company is a high-tec

digital transformation case analysis.

has insight into industry challenges and explores the path to digital transformation.

Case: Construction of intelligent production workshop for rubber and plastic products

(Aerospace Cloud Network)

[Project background]

A company is a high-tech enterprise specializing in the production of automotive rubber accessories. Its products are well-known and sell well at home and abroad. The company's annual production capacity reaches 100 million pieces. However, under the current trend of deep integration of intelligent manufacturing and big data, traditional rubber and plastic product manufacturing companies have exposed key common problems in the industry: for the rubber mixing equipment in the workshop, they need to rely on manual inspection of temperature, pressure, and time. and other parameters, it is impossible to conduct real-time monitoring and analysis of manufacturing process parameters such as the number of internal mixing and changes in temperature and pressure, resulting in low efficiency in the manufacturing process and low overall product quality. There are many types of rubber and plastic products and large sales volumes. As a result, the company has a huge amount of operational data, and relying solely on the experience and judgment of managers cannot make the company operate efficiently and reasonably.

Through specific demand analysis, the project will digitalize and intelligently transform the production process of the company's workshop through the construction of MES, PDM, DNC/MDC and other enterprise information systems to create a smart factory, thereby improving production efficiency and product quality. Ultimately, Realize process collaboration and online control.

[Project construction content]

smart workshop construction content mainly includes the following parts: intelligent upgrading and transformation of existing equipment, workshop interconnection network architecture, on-site data collection and visualization of the manufacturing process, and information integration of on-site data and production management software. The overall program architecture is shown in the figure below.

(1) Intelligent upgrading and transformation of existing equipment

In view of the technical requirements of key processes (refining, formula) of the intelligent automatic production line of rubber and plastic products, the existing automated manufacturing equipment is upgraded and transformed to create a safe and controllable core. Intelligent manufacturing equipment forms a new, intelligent rubber and plastic product production line; in response to the requirements of rubber and plastic product production technology and quality testing, a new model that combines independent innovation and integrated innovation is adopted to build a safe and controllable DCS distributed control system.

1. Fully automatic internal mixer

This equipment is used to refine the rubber raw materials required for the company's production according to the company's formula. Add intelligent terminals at workstations to receive production tasks and report the progress of existing production tasks to production managers; add data acquisition devices to transmit the production status of the internal mixer to the equipment monitoring and management system in real time. At the same time, equipment managers are regularly reminded to perform maintenance or fault analysis; barcode scanning equipment is added to bind production parameters to production raw materials according to different material batches to support product traceability.

2. Weighing scale system

This equipment is used to control the quality of raw materials entering the internal mixer and complete the implementation of formula standards. Add intelligent terminals at workstations to receive production formulas and report the progress of existing production tasks to production managers; add data collection devices to transmit production data from formula scales to the equipment monitoring and management system in real time. At the same time, equipment managers are regularly reminded to do maintenance or fault analysis; barcode scanning equipment is added to bind production parameters to production raw materials according to different material batches to support product traceability; the recipe management system is integrated into MES to collaborate with the production management system manufacture.

3. Upper auxiliary machine system

This equipment is used to supply raw materials for internal mixing. Add intelligent terminals at workstations to receive production formulas and report the progress of existing production tasks to production managers; add data acquisition devices to transmit production data from formula scales to the equipment monitoring and management system in real time. At the same time, equipment managers are regularly reminded to perform maintenance or fault analysis; barcode scanning equipment is added to bind production parameters to production raw materials according to different material batches to support product traceability.

4. DCS distributed control system

builds a distributed control system (DCS) to carry out decentralized control and centralized monitoring of rubber and plastic product production line equipment and complete the construction of a digital workshop. The DCS system network architecture is shown in the figure below.At the process control level,

performs stand-alone control of field equipment. On this basis, industrial Ethernet is used to connect various production lines and monitor them through the upper industrial computer to form a production monitoring level, thereby forming a field bus and industrial Ethernet DCS system. The entire control system runs through the field equipment layer, workshop monitoring layer and factory management layer.

(2) Workshop interconnection network architecture and information model

1. Workshop interconnection network architecture and information model

is based on the MES system, comprehensively considering the common needs of the enterprise's digital workshop construction foundation and the equipment manufacturing industry construction, and carries out integrated development. Existing management information systems and systems to be implemented (ERP, PDM, CAPP, etc.) and automation equipment (internal mixers, auxiliary machines, formula scales, etc.) are integrated to realize the integrated application of equipment, production, and logistics. Build a workshop interconnection network architecture and information model, and establish a digital workshop integration platform.

2. Develop modular information model according to the needs of Jingzhong Rubber and Plastics

(3) On-site data collection and visualization of the manufacturing process

1. On-site data collection and visualization of the manufacturing process

The company builds a manufacturing process collection and analysis system, and comprehensively analyzes the on-site data of the manufacturing process. Information collection and visualization, efficient and unified implementation of product quality consistency management, and automated means to achieve online, real-time quality detection, analysis, display and early warning.

2. System functions, architecture and data integration

achieves dynamic management of the entire process of product production and quality control through the construction of a manufacturing process collection and analysis system and seamless integration with the MES system. Through quality planning, real-time collection, dynamic analysis, online detection and early warning functions for each product, we can accurately grasp product quality information during the manufacturing process, strengthen real-time on-site management and control capabilities, reduce errors, improve efficiency, and stabilize the manufacturing process. The

system is composed of four parts as a whole, which are data collector, integrated production line data collection system, collection and control application server and monitoring client. As shown in the figure below, the area on the right side of the figure is the MES system. The manufacturing process acquisition and analysis system and the MES system realize business interoperability through the database.

3. Data collection and visualization

monitors the equipment, collects on-site data of the manufacturing process, and closely correlates the production plan with real-time temperature information, pressure and other information during the equipment processing, thereby discovering bottlenecks in the existing processing process. Further support the lean improvement of enterprises.

(4) On-site data and production management software realize information integration

is integrated with ERP and CAPP systems. The MES system regularly reads the task data in the ERP system and CAPP system and synchronizes it to the MES system database.

[Implementation effect]

Through the implementation of the intelligent transformation project,

has achieved an increase in corporate workshop production efficiency by more than 20%, a reduction in operating costs by more than 20%, a shortening of product development cycles by more than 30%, and a reduction in product defective rates by more than 20%. Energy The utilization rate will increase by more than 10%, and the project is expected to create comprehensive income of more than 1 billion yuan during the execution period. At the same time, the optimization of enterprise business processes and management models achieved through transformation has had a more profound impact on its goal of intelligent transformation.

demonstrates the operation process of data information flow such as industrial data collection, transmission, analysis and processing, and judgment by establishing a workshop interconnection network architecture and information model; it uses design and process simulation software to realize digital three-dimensional design and high-speed product processing. Simulation analysis; realize product data management by establishing a product data management system (PDM); realize on-site data collection and visualization of the manufacturing process by using DCS system; realize seamless integration of on-site data and information system by implementing data exchange system, which is beneficial to Implementation of production decisions and advanced scheduling of production plans.

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