基于MES的集成质量管理系统的研究与应用
摘要
质量是企业在激烈的市场竞争中取得胜利的重要条件之一。尤其对于离散制造企业来说,由于工艺过程不连续,制造过程和质量活动相互独立,降低了质量管理活动的执行效率。如何通过将制造过程物流信息与质量信息有效地集成来提高制造过程的质量控制能力是传统制造企业面临的共性课题。制造执行系统(Manufacturing Execution System,MES)能够提供企业制造过程中所有物料的实时状态。因此,对基于MES的集成质量管理系统进行研究具有一定的现实意义和理论意义。
本文以某风电增速器生产企业为研究背景,在对国内外集成质量管理系统的研究现状、当今先进质量管理技术和主流质量管理理论进行研究的基础上,基于ERP/MES/PCS的三层企业集成模型,建立了基于MES的集成质量管理系统的体系结构。根据企业产品特征、生产特点、组织结构和业务流程的调研分析,确定了质量管理系统的集成需求和功能需求,建立了系统的功能模型。通过对现有业务流程、信息流程进行分析和优化,建立了基于MES的集成质量管理系统的业务流程和信息模型；针对企业在生产过程和质量过程的信息交互方面的需求,提出了一种松耦合的集成方案,并将其应用于基于MES的集成质量管理系统中；通过对统计过程控制(Statistical Process Control, SPC)技术原理的研究,建立了质量管理系统中SPC的流程,从而完成了系统功能模块的详细设计。在此基础上,基于C/S模式,利用面向对象设计的方法,选用SQL Server 2000作为数据库系统,采用Visual Basic.NET作为开发工具实现了基于MES的集成质量管理系统程序的开发。
目前,通过系统在企业半年的正式运行,提高了企业制造活动与质量活动的交互效率,提高了质量管理的执行效率。对离散制造企业的信息化技术应用具有一定的示范作用。
Quality is one of the most important conditions for a company to success in the fierce market competition. Especially for the discrete manufacturing enterprise, whose quality management efficiency is reduced by the mutual independence of the manufacturing process and quality activities because of the discontinuous process. How to improve the quality control ability by integrating the logistics information with the quality information in the manufacturing process is a common issue for the traditional manufacturing enterprises. MES can provide enterprises with the real-time status of materials in the manufacturing process. So the research of the integrated quality management system based on MES has practical and theoretical significance.
With an certain enterprise producing wind accelerators as the background, based on the research situation of the integrated quality management system at home and abroad and today's advanced quality management technology and mainstream quality management theories, according to the ERP/MES/PCS structure which is a three-tier model for enterprise integration, the architecture of the integrated management system based on MES is established in this paper. By the investigation and analysis of products and production features, organizational structure and business process of the enterprise, the integration and functional requirements are confirmed, and the functional model of the system is established. According to the analysis and optimization of the current business processes and information flows, the business processes and information models of the quality management system based on MES are established; In view of the requirements of information exchange between production process and quality process, a loosely coupled integration method is proposed and used in the integrated quality management system based on MES; by researching the technology principle of SPC, the SPC flow in the quality management system is established and the detailed design of the functional models of the system are completed. Finally, based on C/S mode, using object-oriented design methods, choosing SQL Server 2000 as the database system, and adopting Visual Basic.NET as the development tool, the integration quality management system is developed and implemented.
At present, through the implementation of the system in the enterprise for half a year, the quality management efficiency is improved with improving the interaction efficiency between the manufacturing process and the quality activities. The research in this paper is exemplary for other discrete manufacturing enterprises to apply IT.
本文以某风电增速器生产企业为研究背景,在对国内外集成质量管理系统的研究现状、当今先进质量管理技术和主流质量管理理论进行研究的基础上,基于ERP/MES/PCS的三层企业集成模型,建立了基于MES的集成质量管理系统的体系结构。根据企业产品特征、生产特点、组织结构和业务流程的调研分析,确定了质量管理系统的集成需求和功能需求,建立了系统的功能模型。通过对现有业务流程、信息流程进行分析和优化,建立了基于MES的集成质量管理系统的业务流程和信息模型；针对企业在生产过程和质量过程的信息交互方面的需求,提出了一种松耦合的集成方案,并将其应用于基于MES的集成质量管理系统中；通过对统计过程控制(Statistical Process Control, SPC)技术原理的研究,建立了质量管理系统中SPC的流程,从而完成了系统功能模块的详细设计。在此基础上,基于C/S模式,利用面向对象设计的方法,选用SQL Server 2000作为数据库系统,采用Visual Basic.NET作为开发工具实现了基于MES的集成质量管理系统程序的开发。
目前,通过系统在企业半年的正式运行,提高了企业制造活动与质量活动的交互效率,提高了质量管理的执行效率。对离散制造企业的信息化技术应用具有一定的示范作用。
Quality is one of the most important conditions for a company to success in the fierce market competition. Especially for the discrete manufacturing enterprise, whose quality management efficiency is reduced by the mutual independence of the manufacturing process and quality activities because of the discontinuous process. How to improve the quality control ability by integrating the logistics information with the quality information in the manufacturing process is a common issue for the traditional manufacturing enterprises. MES can provide enterprises with the real-time status of materials in the manufacturing process. So the research of the integrated quality management system based on MES has practical and theoretical significance.
With an certain enterprise producing wind accelerators as the background, based on the research situation of the integrated quality management system at home and abroad and today's advanced quality management technology and mainstream quality management theories, according to the ERP/MES/PCS structure which is a three-tier model for enterprise integration, the architecture of the integrated management system based on MES is established in this paper. By the investigation and analysis of products and production features, organizational structure and business process of the enterprise, the integration and functional requirements are confirmed, and the functional model of the system is established. According to the analysis and optimization of the current business processes and information flows, the business processes and information models of the quality management system based on MES are established; In view of the requirements of information exchange between production process and quality process, a loosely coupled integration method is proposed and used in the integrated quality management system based on MES; by researching the technology principle of SPC, the SPC flow in the quality management system is established and the detailed design of the functional models of the system are completed. Finally, based on C/S mode, using object-oriented design methods, choosing SQL Server 2000 as the database system, and adopting Visual Basic.NET as the development tool, the integration quality management system is developed and implemented.
At present, through the implementation of the system in the enterprise for half a year, the quality management efficiency is improved with improving the interaction efficiency between the manufacturing process and the quality activities. The research in this paper is exemplary for other discrete manufacturing enterprises to apply IT.
引文
[1]陈邦柱.迎接21世纪的质量竞争与挑战[J].城市技术监督,2001,(2)：11.
[2]夏建中.制造业质量管理信息化现代及趋势[J].中国质量,2005,10：68-70.
[3]苏秦.现代质量管理学[M].北京：清华大学出版社2005.
[4]段桂江,孙飞.集成质量系统的过程化趋势[J].中国质量,2005,8：20-22.
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[15]范玉顺,吴澄.工作流管理技术研究与产品现状及发展趋势[J].计算机集成制造系统,2000,6(1)：1-7.
[16]李成,高建民.基于过程控制的集成质量系统体系结构研究[J].计算机集成制造系统,2007,13(10)：2041-2046.
[17]吴军,邓超,邵新宇,等.面向PLM的协同质量管理系统[J].华中科技大学学报(自然科学版),2006,34(6)：74-76.
[18]高文俊,王海龙,王冰冰,等.航天产品制造过程质量管理系统的研究[J].航天制造技术,2007,10(5)：43-47.
[19]刘晓冰,刘彩燕,马跃,等.基于制造执行系统的动态质量控制系统研究[J].计算机集成制造系统,2005,11(1)：133-137.
[20]MESA International. MES functionalities & MRP to MES data flow possibilities [R]. 1997
[21]黄学文.制造执行系统(MES)的研究和应用[D].大连：大连理工大学,2003.
[22]李春杰.浅议PDCA循环方法和统计分析方法在质量控制中的应用[J].制造业自动化,2009,6：69-71.
[23]龚仁伟,尹超,鄢萍.基于MES的车间制造过程动态质量管理系统研究[J].现代制造工程,2008,30(6)：26-30.
[24]刘忠明,段守敏,王长路.风力发电齿轮箱设计制造技术的发展与展望[J].机械传动,2006,30(6)：1-6.
[25]杨静萍.钢铁制造业集成化生产质量管理方法的研究[D].大连：大连理工大学,2009.
[26]王娴,刘辉,倪远平.B/S与C/S体系结构的应用研究[J].信息技术,2006,6：53-55.
[27]吴大刚,肖荣荣.C/S结构与B/S结构的信息系统比较分析[J].情报科学,2003,21(3)：313-315.
[28]华太企业管理咨询有限公司,聂微.SPC实施指南——SPC软件应用技术手册[M].广州：广东省出版集团,2006.
[30]张海藩.软件工程.北京：人民邮电出版社,2007.
[31]苏啸.数据库原理与SQL Server2000教程[M].北京：北京工业大学出版社,2002.
[32]李春葆,曾慧.SQL Server2000应用系统开发教程.北京：清华大学出版社,2005.
[33]龙马工作室.新编VB. NET 2005程序设计[M].北京：人民邮电出版社,2008.
[2]夏建中.制造业质量管理信息化现代及趋势[J].中国质量,2005,10：68-70.
[3]苏秦.现代质量管理学[M].北京：清华大学出版社2005.
[4]段桂江,孙飞.集成质量系统的过程化趋势[J].中国质量,2005,8：20-22.
[5]秦观生.质量管理学[M].北京：科学出版社,2005.
[6]Dessouky. M.I., Kappor. S. G, DeVor. R. E.. Methodology for integrated quality systems [J]. Journal of engineering for industry,1987,109(3):241-247.
[7]J. D. T. Tannock, R.S.Maull. The integrated quality system in CIM [J]. Computer Integrated Manufacturing Systems,1988,1(4):228-234.
[8]Jose A. Heredia, Ip-Shing Fan, Fernando Romero, et al. A Framework for an Integrated Quality System [J]. Journal of Materials Processing Technology 1996,61:195-200.
[9]M Shindo, T Narusawa, H Sawamura. A Study for designning QC information system [J]. Electronic Manufacturing Technology Symposium,1989,28:356-359.
[10]Alireza Lari. An integrated information system for quality management [J]. Business Process Management,2002,8 (2):169-182.
[11]A.S. Nookabadi, J. E. Middle. An integrated qualtiy assurance information system for the design-to-order manufacturing enviorment [J].The TQM Magazine, 2005,27(12):174-189.
[12]唐晓青.计算机辅助质量管理系统[M].中国质量,2001.
[13]段桂江,唐晓青.基于过程方法的集成质量系统建模与实施技术研究[J].制造业自动化,2001,16(26)：1-3.
[14]唐晓青,段桂江,王雪聪,等.集成化质量信息管理技术在中国企业的实践[J].中国质量,2003,9：277-282.
[15]范玉顺,吴澄.工作流管理技术研究与产品现状及发展趋势[J].计算机集成制造系统,2000,6(1)：1-7.
[16]李成,高建民.基于过程控制的集成质量系统体系结构研究[J].计算机集成制造系统,2007,13(10)：2041-2046.
[17]吴军,邓超,邵新宇,等.面向PLM的协同质量管理系统[J].华中科技大学学报(自然科学版),2006,34(6)：74-76.
[18]高文俊,王海龙,王冰冰,等.航天产品制造过程质量管理系统的研究[J].航天制造技术,2007,10(5)：43-47.
[19]刘晓冰,刘彩燕,马跃,等.基于制造执行系统的动态质量控制系统研究[J].计算机集成制造系统,2005,11(1)：133-137.
[20]MESA International. MES functionalities & MRP to MES data flow possibilities [R]. 1997
[21]黄学文.制造执行系统(MES)的研究和应用[D].大连：大连理工大学,2003.
[22]李春杰.浅议PDCA循环方法和统计分析方法在质量控制中的应用[J].制造业自动化,2009,6：69-71.
[23]龚仁伟,尹超,鄢萍.基于MES的车间制造过程动态质量管理系统研究[J].现代制造工程,2008,30(6)：26-30.
[24]刘忠明,段守敏,王长路.风力发电齿轮箱设计制造技术的发展与展望[J].机械传动,2006,30(6)：1-6.
[25]杨静萍.钢铁制造业集成化生产质量管理方法的研究[D].大连：大连理工大学,2009.
[26]王娴,刘辉,倪远平.B/S与C/S体系结构的应用研究[J].信息技术,2006,6：53-55.
[27]吴大刚,肖荣荣.C/S结构与B/S结构的信息系统比较分析[J].情报科学,2003,21(3)：313-315.
[28]华太企业管理咨询有限公司,聂微.SPC实施指南——SPC软件应用技术手册[M].广州：广东省出版集团,2006.
[30]张海藩.软件工程.北京：人民邮电出版社,2007.
[31]苏啸.数据库原理与SQL Server2000教程[M].北京：北京工业大学出版社,2002.
[32]李春葆,曾慧.SQL Server2000应用系统开发教程.北京：清华大学出版社,2005.
[33]龙马工作室.新编VB. NET 2005程序设计[M].北京：人民邮电出版社,2008.