Assembly information management of the hottest lig

Light truck engine assembly information management

1, abstract

based on my years of practical experience in the field of engine assembly, and according to the characteristics of engine assembly production, this paper expounds how to realize assembly production informatization from three levels: engine assembly planning and implementation; Assembly parts distribution plan and implementation; Part quality control and data acquisition in the process of engine assembly. And how to expand ERP from the planning level to the logical implementation level in combination with MES after the completion of ERP project implementation

2. The production characteristics of light truck engines and the demand for informatization

China's light truck market sells more than 1 million vehicles every year, and the engine production mode is basically a flow production mode. There are many individualized engines, small batches and varieties, and short assembly cycle. The engine production takes a short time from receiving the order to delivering the main engine to the customer, and it needs to be supplied within a week. Fast and low-cost production reflects the viability of an engine manufacturer. Production planning mode orders and forecasts coexist, and forecasts play a leading role, with safe storage and order point production. The whole process of engine production, from planning to parts organization and supply, whole machine assembly, calibration, painting, sorting and warehousing, must be organized and coordinated. The quality of informatization directly affects the efficiency, cost and quality of enterprises

engine manufacturers attach great importance to informatization, which is reflected in the following aspects: first, product data management, PDM or PLM management of product life cycle, and the application of computer design such as computer-aided process design; The second is the application of ERP, SCM and CRM; The third is the application of MES system, computer-aided manufacturing and other executive manufacturing; The fourth is the application of auxiliary management software such as OA and encryption system. In terms of engine assembly, this paper focuses on the three aspects mentioned in the summary, which belong to the second and third applications

3. Engine assembly plan and execution

engine assembly plan are the source of engine assembly tasks. The plan is based on the comprehensive consideration of market customer demand, product inventory status, parts inventory, parts supply, parts quality and products in production. Generally, the production plan of an enterprise has three levels: monthly plan, weekly plan and daily assembly plan. The daily production depends on the daily assembly plan. The enterprise can selectively carry out the monthly plan and weekly plan according to the market changes and the quality of the enterprise itself, strengthen the controllability of the plan, strictly implement the daily assembly plan, and ensure the stability of the production organization to meet the needs of customers to the greatest extent

due to the particularity of China's light truck market, the time from order receipt to delivery of engine production is very short, usually in 3-5 days. The engine manufacturer adopts the conventional product safety order point method for the planned production scheduling of the engine; The production of cold varieties is arranged in an order, and the inventory is properly stored for emergency. This situation leads to the uncertainty of the monthly production plan, and the weekly plan also fluctuates by about 30%. In order to survive, enterprises must strengthen communication with vehicle manufacturers, strengthen order management through ERP system, improve the accuracy of plan sources, and realize system harmony and stability through the comprehensive planning and scheduling of products, parts inventory, supplier orders, and workshop execution through MRP subsystem. At the same time, strengthen supplier management to ensure the quality of purchased parts and the timeliness of supply

erp system plan execution system:

as shown in the above structural block diagram, the ERP system gives strong support to the organization level of the engine product assembly production plan, and comprehensively manages the daily assembly instructions issued by the assembly production line, the material distribution plan, the post supplementary distribution material Kanban management, and the station progress report and control. However, ERP does not solve the problem of data acquisition. It is necessary to set up several reports and control points (station reports) in the assembly line according to the management requirements with the help of MES system to clarify the assembly position and status of each engine in the production line

schematic diagram of the information collection points of the assembly production line (because the engine production line is complex, the schematic diagram is a schematic diagram. The whole engine production line is not drawn, but some information collection points are selected according to the needs of the article):

Figure 2

the engine identity carrier adopts RF chips, which are automatically scanned by the RF controller, and automatically transmitted to the MES system and ERP system when the engine passes through each station. The identity carrier of subpackaged parts uses barcode to establish association with the engine through barcode scanning

the form of station reporting:

A) station reporting using PLC data

the PLC control system automatically reads out the data in the engine RF chip and stores it in the data area through the RF controller. Read PLC data storage area data through MES system and transmit it to ERP system

b) use the measurement data to report the work position

the measurement equipment automatically reads the data in the engine RF chip through the RF controller, executes the relevant functions of the measurement equipment, and stores the measurement data and engine identity data into PLC or database. The data stored in the database or PLC of the measuring equipment is transmitted to the ERP system through the MES system

c) adopt the barcode scanning method to report the work position

manually scan the barcode data, and transmit the part sub assembly work position information to the ERP system through the MES system

functions that the assembly plan execution system must realize:

a) query of orders and predicted demand sources

b) generation and release of assembly plan

c) monitoring of assembly process and query of daily, weekly and monthly plan implementation

d) scheduling of assembly process

4. After the delivery of the assembly parts distribution plan and the implementation of the

daily assembly plan, the first is the material distribution plan required for the assembly of the engine. According to the distribution plan, the parts required for the assembly of the engine are timely and accurately distributed to the corresponding assembly stations to ensure the correct installation of parts

the following prerequisites must be met for the logistics distribution of engine assembly:

A) the daily assembly plan is stable

b) the assembly process of the production line is stable and the production pace is relatively stable

c) the quality of parts assembled on the production line is relatively stable

d) the delivered parts must be marked without missing parts. The process appliance rack and standard container are used for storing materials

e) the product BOM is relatively accurate and the station BOM data is complete

logistics distribution generally adopts the following methods:

a) ERP generates sequential distribution plan

erp system automatically generates the distribution list of production line parts according to the daily assembly plan of the engine, the beat of the production line, and the station BOM of the product. Logistics distribution personnel sort the parts required for assembly in the warehouse and then distribute them to the corresponding assembly station according to the parts distribution list of each period. This processing method is often to know the engine assembly time and sequence in advance

data processing method:

manual bookkeeping processing method: the material issuing personnel carry out station distribution through the ERP distribution list. After the feeding is completed, the distribution list is passed to the bookkeeping personnel, and the distribution plan is automatically generated into an issue document through ERP for bookkeeping processing. The disadvantage is the poor timeliness of processing

real time scanning and accounting method of distribution list: the material issuing personnel wirelessly scan the parts to be distributed on site through the MES system according to the ERP distribution list, and conduct real-time outbound accounting processing

b) according to the sequence of the engine on-line, the MES system automatically collects, and automatically generates the distribution industry statistical delivery list according to the position BOM of the ERP system for distribution and bookkeeping

in this method, when there are sequential changes in the production process of the engine and there is no certain rule, the engine identity is used for real-time collection, and the BOM of the product station is generated according to the time period summary method. These will make the test results produce an error distribution list for distribution and accounting processing

c) adopt post complementary distribution for the attributes of parts (standard parts, general parts)

if the parts to be assembled are general-purpose parts and standard parts, the post supplementary material distribution method can be adopted. Electronic Kanban is defined by ERP system. According to the actual consumption of the production line, Kanban pulling is implemented, and the scanned parts are distributed and accounted according to electronic kanban

functions that the material distribution system must realize:

a) production progress query

b) distribution plan and release

c) inquiry of station material in production and station distribution material delivery

d) warehouse material query and statistics

5. Part measurement data collection and quality control during engine assembly

China will implement the automobile recall system on October 1st, 2009, which shows that China is paying more and more attention to automobile quality. The implementation of t16949 quality standard in the automobile industry itself is strict, quality is life, and the informatization of the quality system is particularly important. Its assembly quality and control can be strengthened through the following three aspects

5. the rule error should not be exceeded. 1. Engine assembly data measurement and SPC control

the measurement of key parts and components is achieved by using measuring equipment. The data is stored in the local database or file, and the local data is read out by the MES system and transmitted to the SPC system for analysis, so as to timely find the changes of parts and components, effectively control the engine assembly quality, and control the quality problems to the minimum, Minimize the loss. The way of data acquisition is to transmit the measurement data and engine identity information to SPC system through MES system interface, and the quality management personnel will monitor SPC on site, analyze and deal with quality problems

5.2. Part batch quality tracking

for the manufacturer and production batch tracking of key parts or important parts, as well as the production batch tracking of self-made parts, the code and production batch of the part supplier can be read through the bar code to realize quality tracking. When parts and components have problems, it can help to find the engine or parts assembled in the same batch in time to avoid greater losses

5.3. After sales service quality tracking and supplier's secondary claims

collecting the data of parts suppliers and production batches during the production process of assembled engines can also help us trace parts and components when quality problems occur during product sales and user use, so that the tracing of suppliers can be based on evidence, reduce the economic losses of host manufacturers, and also provide a basis for supplier management and optimization

functions that the data acquisition and quality control system must realize:

a) inquiry of station assembly process

b) production progress query

c) engine tracking query

d) SPC query

6. Conclusion

the engine assembly information management system involves many basic data and various systems, including the engine assembly hardware equipment management system. This paper can not see one by one from the lower part of the force measuring cylinder, and its purpose is to emphasize the main line. Grasp the main line, expand others, and adhere to the constant, which is a necessary condition to achieve perfection. While we do informatization, we must pay attention to the optimization of organizational processes and the improvement of management, so as to make the enterprise a higher level. (end)