板式定制家具企业制造执行系统的构建与应用
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摘要
为了探究板式定制家具企业计划层与车间层的信息断层问题,提出了制造执行系统(MES)的解决方案。通过分析板式定制家具企业生产流程中存在的订单排产难度大、重要生产信息传递方式落后、生产计划与调度不足、生产状态反馈性较差等问题,提出了板式定制家具企业MES系统功能模块,包含基础数据管理、生产数据采集、生产计划管理、物料管理和生产过程管理,并从系统结构、功能层次模型以及硬件架构3个方面探讨了板式定制家具企业MES系统功能的实现方式。基于ERP(企业资源计划)/MES/PCS(过程控制系统) 3层结构,设计了板式定制家具企业MES系统结构,并阐述了3层之间的信息传递特征,进一步提出了板式定制家具企业MES系统功能层次模型,将系统功能分为数据采集层、基础数据层、数据访问层、业务功能层和表示层5个层次;同时,依据车间各工序与系统的数据交换方式,构建了板式定制家具企业MES系统的硬件架构,实现生产全过程的数据采集与传递。通过MES系统实施,提高了板式定制家具企业的生产效率和核心竞争力。
With the increasing demand from the home furnishing market for rapid response to customer requirements,improvement of product quality and shortening delivery time,the panel customized furniture enterprises took the lead in introducing the advanced enterprise management system,while bringing about the problem of information fault between the management and the manufacturing workshop. In order to explore this advanced enterprise management system of the panel customized furniture enterprises,the solution of manufacturing execution system(MES) was put forward. Based on the unique feature of the panel customized furniture enterprises,the system architecture of the MES was proposed distinguishing from the other industries. Through the analysis of the production problems,including difficulty of order scheduling,transferring important production information in traditional way,lack of production planning and scheduling,and poor feedback of production status,and the characteristics of the MES for panel customized furniture enterprises which included the differentiation of products and components,production drived by digitalization and production information integration,the functional modules of the MES for panel customized furniture enterprises were suggested. Its detailed diagram was drawn,from which,it can be found five functions of the MES for panel customized furniture enterprises including the basic data management,production data collection,production planning management,material management and production process management. The implementation of the MES for panel customized furniture enterprises was discussed from three aspects of system structure,functional hierarchy model and hardware architecture. Based on the three-layer structure of ERP/MES/PCS,the system structure of the MES for panel customized furniture enterprises was designed and the characteristics of information transmission between three layers were expounded according to the MES structure drawing for panel customized furniture enterprises.Furthermore,the functional hierarchy model of the MES for panel customized furniture enterprises was presented,which was divided into data acquisition layer,basic data layer,data access layer,business function layer,and presentation layer. In the functional hierarchy model diagram of the MES,the relationship and characteristics of information transfer between the five layers were analyzed. Meanwhile,on the basis of data exchange methods between each working procedure and system,the hardware architecture of the MES for panel customized furniture enterprises was structured in order to realize data acquisition and transmission of the whole production process,resulting in hardware devices connection through workshop bus,personal digital assistant(PDA) transmitting data through wireless network,local users viewing data through Client/Server,and remote users completing the corresponding operation through the Browser/Server in the hardware architecture diagram. With the help of the timely feedback of the production data by the MES,the transparent management of the workshop was realized,and the gap between the management and the manufacturing workshop was filled up. Through the implementation of the MES,the production efficiency and competitiveness of panel customized furniture enterprises would be improved.
With the increasing demand from the home furnishing market for rapid response to customer requirements,improvement of product quality and shortening delivery time,the panel customized furniture enterprises took the lead in introducing the advanced enterprise management system,while bringing about the problem of information fault between the management and the manufacturing workshop. In order to explore this advanced enterprise management system of the panel customized furniture enterprises,the solution of manufacturing execution system(MES) was put forward. Based on the unique feature of the panel customized furniture enterprises,the system architecture of the MES was proposed distinguishing from the other industries. Through the analysis of the production problems,including difficulty of order scheduling,transferring important production information in traditional way,lack of production planning and scheduling,and poor feedback of production status,and the characteristics of the MES for panel customized furniture enterprises which included the differentiation of products and components,production drived by digitalization and production information integration,the functional modules of the MES for panel customized furniture enterprises were suggested. Its detailed diagram was drawn,from which,it can be found five functions of the MES for panel customized furniture enterprises including the basic data management,production data collection,production planning management,material management and production process management. The implementation of the MES for panel customized furniture enterprises was discussed from three aspects of system structure,functional hierarchy model and hardware architecture. Based on the three-layer structure of ERP/MES/PCS,the system structure of the MES for panel customized furniture enterprises was designed and the characteristics of information transmission between three layers were expounded according to the MES structure drawing for panel customized furniture enterprises.Furthermore,the functional hierarchy model of the MES for panel customized furniture enterprises was presented,which was divided into data acquisition layer,basic data layer,data access layer,business function layer,and presentation layer. In the functional hierarchy model diagram of the MES,the relationship and characteristics of information transfer between the five layers were analyzed. Meanwhile,on the basis of data exchange methods between each working procedure and system,the hardware architecture of the MES for panel customized furniture enterprises was structured in order to realize data acquisition and transmission of the whole production process,resulting in hardware devices connection through workshop bus,personal digital assistant(PDA) transmitting data through wireless network,local users viewing data through Client/Server,and remote users completing the corresponding operation through the Browser/Server in the hardware architecture diagram. With the help of the timely feedback of the production data by the MES,the transparent management of the workshop was realized,and the gap between the management and the manufacturing workshop was filled up. Through the implementation of the MES,the production efficiency and competitiveness of panel customized furniture enterprises would be improved.
引文
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[4]MESA International.The benefits of MES:a report from the field[R]. Pittsburgh,USA:MESA International White Paper Number1,1997.
[5]周国利.基于多品种小批量的MES在汽车装配企业中的应用[J].湖南工业大学学报,2009,27(6):83-88.ZHOU G L. Application of MES based on multi variety and small batch in automobile assembly enterprise[J]. Journal of Hunan University of Technology,2009,27(6):83-88.
[6]程志伦,范玉青.钢铁企业基于组件的柔性制造执行系统设计[J].计算机集成制造系统,2007(3):490-496.CHENG Z L,FAN Y Q.Design of flexible manufacturing execution system based on component in iron and steel enterprise[J]. Computer Integrated Manufacturing System,2007(3):490-496.
[7]刘刚,谌湘临,张少宁.石化生产执行制造系统智能化功能提升及应用[J].化工进展,2017,36(7):2714-2723.LIU G,CHEN X L,ZHANG S N.Improvement and application of the intelligent function of petrochemical production execution system[J]. Chemical Industry,2017,36(7):2714-2723.
[8]熊先青,吴智慧.大规模定制家具的发展现状及应用技术[J].南京林业大学学报(自然科学版),2013,37(4):156-162.XIONG X Q,WU Z H. Development and application technology of the mass customization furnitur[J]. Journal of Nanjing Forestry University(Natural Sciences Edition),2013,37(4):156-162.
[9]彭文湘.实现家具企业大规模定制途径的研究[D].长沙:中南林业科技大学,2007.PENG W X. Research on the way to realize large-scale customization of furniture enterprises[D]. Changsha:Central South University of Forestry and Technology,2007.
[10]ZNAMENAK J.A proposal for production data collection on a hybrid production line in cooperation with MES[J]. Research Papers Faculty of Materials Science and Technology Slovak University of Technology,2016,24(39):137-144.
[11]GJELDUM N.Performance analysis of the RFID system for optimal design of the intelligent assembly line in the learning factory[J].Procedia Manufacturing,2018,23(3):63-68.
[12]王杰,高昆仑,王万召.基于OPC通信技术的火电厂DCS后台控制[J].电力自动化设备,2013,33(4):142-147.WANG J,GAO K L,WANG W Z. DCS backstage control in thermal power plant based on OPC communication technology[J].Power Automation Equipment,2013,33(4):142-147.
[13]熊先青,吴智慧.大规模定制家具生产过程的信息采集与处理技术[J].木材工业,2016,25(6):17-30.XIONG X Q,WU Z H.Information collection and processing technology in the process of mass customization furniture[J]. Wood Industry,2016,25(6):17-30.
[14]夏刚.浅谈企业车间MES生产调度的设计分析[J].电子技术与软件工程,2017(2):201.XIA G. Discussion on design and analysis of MES production scheduling in enterprise workshop[J]. ElectronicTechnology and Software Engineering,2017(2):201.
[15]熊先青,吴智慧.大规模定制家具物料管理中的信息采集与处理技术[J].中南林业科技大学学报,2012,32(11):200-205.XIONG X Q,WU Z H. Information acquisition and processing technology of mass customization in material management of[J].Journal of Central South University of Forestry and Technology,2012,32(11):200-205.
[16]代绪强,孙亚振,许自力,等.基于MES系统的离散制造业质量信息管理研究[J].机械制造与自动化,2014(2)132-135.DAI X Q,SUN Y Z,XUN Z L,et al.Research on quality information management of discrete manufacturing industry based on MES system[J]. Mechanical Manufacture and Automation,2014(2):132-135.
[17]于雄,张株瑞,周应军.离散制造企业设备管理系统与MES集成研究[J].软件,2016,37(2):174-176.YU X,ZHANG Z R,ZHOU Y J. Research on the integration of equipment management system and MES in discrete manufacturing enterprises[J]. Software,2016,37(2):174-176.
[18]BYEONG J. Conceptual framework of smart manufacturing execution system based on systems engineering approach[J]. Incose International Symposium,2016,26(1):2118-2133.
[19]WEN L. Research on development method of MES based on component and driven by ontology[J]. Journal of Software,2010,5(11):1228-1235.
[20]彭刚,陈长林.MES在电缆行业生产过程监视系统中的应用[J].华中科技大学学报(自然科学版),2015,43(S1):497-500.PENG G,CHEN C L. Application of MES in production process monitoring system of cable industry[J]. Journal of Huazhong University of Science and Technology(Natural Science Edition),2015,43(S1):497-500.
[2]熊先青,郭伟娟,黄琼涛,等.大规模定家具数字化制造质量管控技术研究[J].林业工程学报,2017,2(4):152-157.XIONG X Q,GUO W J,HUANG Q T,et al. Study on quality control technology for digital manufacturing of large scale furniture[J]. Journal of Forestry Engineering,2017,2(4):152-157.
[3]吴智慧.工业4.0时代家具产业的制造模式[J].林产工业,2016,43(3):6-10.WU Z H.The manufacturing model of furniture industry in the industrial 4 age[J]. Forest Products Industry,2016,43(3):6-10.
[4]MESA International.The benefits of MES:a report from the field[R]. Pittsburgh,USA:MESA International White Paper Number1,1997.
[5]周国利.基于多品种小批量的MES在汽车装配企业中的应用[J].湖南工业大学学报,2009,27(6):83-88.ZHOU G L. Application of MES based on multi variety and small batch in automobile assembly enterprise[J]. Journal of Hunan University of Technology,2009,27(6):83-88.
[6]程志伦,范玉青.钢铁企业基于组件的柔性制造执行系统设计[J].计算机集成制造系统,2007(3):490-496.CHENG Z L,FAN Y Q.Design of flexible manufacturing execution system based on component in iron and steel enterprise[J]. Computer Integrated Manufacturing System,2007(3):490-496.
[7]刘刚,谌湘临,张少宁.石化生产执行制造系统智能化功能提升及应用[J].化工进展,2017,36(7):2714-2723.LIU G,CHEN X L,ZHANG S N.Improvement and application of the intelligent function of petrochemical production execution system[J]. Chemical Industry,2017,36(7):2714-2723.
[8]熊先青,吴智慧.大规模定制家具的发展现状及应用技术[J].南京林业大学学报(自然科学版),2013,37(4):156-162.XIONG X Q,WU Z H. Development and application technology of the mass customization furnitur[J]. Journal of Nanjing Forestry University(Natural Sciences Edition),2013,37(4):156-162.
[9]彭文湘.实现家具企业大规模定制途径的研究[D].长沙:中南林业科技大学,2007.PENG W X. Research on the way to realize large-scale customization of furniture enterprises[D]. Changsha:Central South University of Forestry and Technology,2007.
[10]ZNAMENAK J.A proposal for production data collection on a hybrid production line in cooperation with MES[J]. Research Papers Faculty of Materials Science and Technology Slovak University of Technology,2016,24(39):137-144.
[11]GJELDUM N.Performance analysis of the RFID system for optimal design of the intelligent assembly line in the learning factory[J].Procedia Manufacturing,2018,23(3):63-68.
[12]王杰,高昆仑,王万召.基于OPC通信技术的火电厂DCS后台控制[J].电力自动化设备,2013,33(4):142-147.WANG J,GAO K L,WANG W Z. DCS backstage control in thermal power plant based on OPC communication technology[J].Power Automation Equipment,2013,33(4):142-147.
[13]熊先青,吴智慧.大规模定制家具生产过程的信息采集与处理技术[J].木材工业,2016,25(6):17-30.XIONG X Q,WU Z H.Information collection and processing technology in the process of mass customization furniture[J]. Wood Industry,2016,25(6):17-30.
[14]夏刚.浅谈企业车间MES生产调度的设计分析[J].电子技术与软件工程,2017(2):201.XIA G. Discussion on design and analysis of MES production scheduling in enterprise workshop[J]. ElectronicTechnology and Software Engineering,2017(2):201.
[15]熊先青,吴智慧.大规模定制家具物料管理中的信息采集与处理技术[J].中南林业科技大学学报,2012,32(11):200-205.XIONG X Q,WU Z H. Information acquisition and processing technology of mass customization in material management of[J].Journal of Central South University of Forestry and Technology,2012,32(11):200-205.
[16]代绪强,孙亚振,许自力,等.基于MES系统的离散制造业质量信息管理研究[J].机械制造与自动化,2014(2)132-135.DAI X Q,SUN Y Z,XUN Z L,et al.Research on quality information management of discrete manufacturing industry based on MES system[J]. Mechanical Manufacture and Automation,2014(2):132-135.
[17]于雄,张株瑞,周应军.离散制造企业设备管理系统与MES集成研究[J].软件,2016,37(2):174-176.YU X,ZHANG Z R,ZHOU Y J. Research on the integration of equipment management system and MES in discrete manufacturing enterprises[J]. Software,2016,37(2):174-176.
[18]BYEONG J. Conceptual framework of smart manufacturing execution system based on systems engineering approach[J]. Incose International Symposium,2016,26(1):2118-2133.
[19]WEN L. Research on development method of MES based on component and driven by ontology[J]. Journal of Software,2010,5(11):1228-1235.
[20]彭刚,陈长林.MES在电缆行业生产过程监视系统中的应用[J].华中科技大学学报(自然科学版),2015,43(S1):497-500.PENG G,CHEN C L. Application of MES in production process monitoring system of cable industry[J]. Journal of Huazhong University of Science and Technology(Natural Science Edition),2015,43(S1):497-500.