How to combine the data for intelligent scheduling of flexible packaging printing
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At present, most of China's flexible packaging enterprises still rely on traditional extensive production management, and the level of informationization of enterprises is relatively low. According to incomplete statistics, less than 40% of flexible packaging enterprises adopt ERP and other information management, and adopt "Internet +" Soft packaging companies such as big data and other advanced ideas and methods are rare. This easily leads to the large amount of funds occupied by the flexible packaging enterprises, resulting in waste, and the efficiency of the staff is not high, and it is impossible to reasonably coordinate the "capacity" and "delivery", which is easy to reduce the customer's satisfaction with the delivery rate. This will seriously affect the long-term development of flexible packaging enterprises.
The company where the author is located is a leading enterprise in the domestic flexible packaging industry, and has the courage to try advanced ideas and methods in the management of flexible packaging production. In this paper, the author will combine the current situation of the production of flexible packaging industry and the idea of information system design to introduce how flexible packaging enterprises can use data to conduct rational and intelligent scheduling, in order to improve production efficiency and meet customer delivery.
At present, there are problems in the way of scheduling of flexible packaging enterprises in China.
Most of the domestic flexible packaging enterprises have adopted the scheduling process, which is the first-order printing process. After the printing is completed, the compounding process is repeated. After the composite curing is completed, the cutting process is followed by the cutting process. After that, the bag making process is finally repeated.
Under normal circumstances, the adoption of this type of rolling scheduling, the focus of flexible packaging companies will be placed in the production of the source printing process. In order to meet the delivery requirements, the printing process is bound to become the key, and due to the limitation of delivery time, each process after printing will become a bottleneck process that restricts the delivery of production.
Moreover, another problem brought about by this sort of process scheduling is that, no matter how reasonably arranged, there will always be products that affect the delivery deadline. For example, although the printing is completed within the expected quality and the quality is up to standard, if the subsequent compounding process, or the production speed of the slitting and bag making process, is not kept up in time, the product is still not delivered in time, and the product is still in the printing process. Taking up a certain amount of production capacity will inevitably affect the normal production of more urgently delivered products, and a vicious circle will be formed over time.
In this series of cases, the specific problems that are easy to occur in flexible packaging companies are as follows.
1. Can't reply the order delivery accurately
After receiving the customer's order, what criteria should the flexible packaging company use to answer the customer an accurate delivery date?
If there are problems such as order insertion, delivery change, quantity change, order cancellation, machine failure, etc. during the production process, can the flexible packaging company predict which orders will be affected?
If the order is affected, can the flexible packaging company predict whether it will be completed in advance or delayed? And how long will it be delayed or delayed?
Under the traditional sub-process scheduling method, the above mentioned problems are basically not known accurately.
2. It is impossible to accurately predict the future machine capacity and cannot allocate production capacity evenly.
In normal production, can soft packaging companies predict which processes and machines will be busy in the future, and which ones will be idle?
If you want to transfer orders or change production plans, which machines will have a capacity load that exceeds the standard? These are basically not known in time.
3. Manual Excel method for rough scheduling
So far, most of the flexible packaging companies still use the manual Excel method for rough scheduling. This method can only estimate and arrange the flexible packaging production plan based on the experience and the order delivery time given by the customer. However, it is often impossible to combine the order delivery date, the order quantity, the difficulty of the process, the length of time required for the process, the importance of the customer, the priority of the order, the spare time of the machine, etc., to consider the priority of the production arrangement. Production time and production quantity.
4. What is the pre-process, what does the post-process do?
There is a common phenomenon in many flexible packaging enterprises in China. The right to schedule production in the post-processing machine lies in the directors of various workshops. When multiple orders are available, the workshop directors estimate the order of these orders based on experience and feeling. order. In addition, there are some soft-package enterprises that still have the phenomenon of ordering the order of people by the relationship of the salesperson. This situation can easily affect the progress of the company's overall orders, often resulting in orders that are not urgently scheduled to be scheduled first, and urgent orders will arrive later, but the inorganic stations are available, thus delaying delivery.
Rationalized scheduling recommendations
In view of the above problems, the author suggests to adopt “process linkage scheduling”, arrange specific machines for each process, and calculate the start time and completion time of each previous process from the subsequent process according to the specific equipment capacity (speed). .
For example, if the delivery date of a product is July 20 and the transportation time is 2 days, it is easy to conclude that the delivery date should be July 18. Therefore, the slowest product completion date can only be July 18. Assume that the product is a 1-layer composite flexible packaging product, and the production cycle is calculated in 5 days. For the sake of simplicity, it is assumed here that each production process requires a production time of one day. In the actual calculation, the "starting time + processing time + waiting time for conversion" should also be considered. After calculation, the completion time of each production process should be as shown in Table 1.
According to the completion time of each production process, the preliminary simulated production is calculated. According to the results of the preliminary production, the material guarantee of each raw material is analyzed: whether there is inventory, whether the material is missing or the material is on the way. If you are on the way, can you arrive at the warehouse in time before the start of production; if there is no material, delay the production and arrange the procurement of raw materials. At the same time, the scheduling of flexible packaging production is also the basis for material procurement and supply arrival.
Based on the above ideas, in order to achieve intelligent production scheduling, the relevant data and constraints must be set in advance. First of all, it is necessary to digitize and serialize the time required for each order of the company and the production of the machine, as follows.
(1) The order priority setting of the order.
(2) The specific transportation time of each order.
(3) The time required for each production process per order.
(4) Equipment that can be ordered for each order in each production process, and the priority level of equipment scheduling.
(5) The start-up time for each order before each production process.
(6) The time for each order to be changed during each production process.
(7) Capacity per unit of production process and per unit of equipment (used to calculate the production and processing time of the order).
(8) Residence time of the composite membrane in the ripening chamber.
The above time is used to calculate the specific time of order production, so the accuracy of each time statistics must be high, otherwise it will affect the overall scheduling plan, and thus can not guide the normal operation of production.
Another premise is that for each order's production time and transportation time, the salesman must confirm with the customer in the contract when designing the product. For example, the production time of the calculated order takes 5 days, and the customer hardly requests. 3 days delivery, this is no way to achieve, must communicate with the customer a good scheduling plan, allowing customers to accept reasonable delivery time.
If the above data can be sorted out well, and the data accuracy is high, follow-up work can consider using the system software to achieve intelligent scheduling, that is, the intelligent APS scheduling system, its main advantages are: encountering customer urgent orders At any time, you can insert the order processing, and at the same time you can view the impact of the insert on other orders; optimize the scheduling of resources, try to eliminate waiting time, change production time, improve production efficiency, reduce non-production time in the workshop, and improve the timeliness of data. And accuracy; reduce inventory, pursue zero inventory, the finished product production completion time and delivery time are infinitely close; material demand and production schedule scheduling are automatically calculated by the system, which can greatly reduce the workload of planners and merchandisers, and operate Simple, no need for extensive production experience, the general operator is competent.
If the entire production schedule of the order is in order, the author suggests that a preliminary simulated scheduling can be performed at the time of ordering to provide the customer with a pre-answer for the delivery date. If there is no time to arrange, you can also coordinate with the customer when ordering, in order to improve the overall delivery timelines of the order.
Suggestions on the implementation of intelligent scheduling
Nowadays, flexible packaging companies can't simply define themselves as production and processing enterprises, but also should switch to service-oriented enterprises. Therefore, in order scheduling, flexible packaging enterprises should transform traditional management thinking methods and establish new rules in line with the times. The author summarized the following recommendations for implementation, for industry reference.
(1) For the orientation of production workshop assessment, flexible packaging companies consider not only the level of production and unit consumption, but also the timely rate of order completion delivery.
(2) As far as customer orders are concerned, ensuring on-time delivery is the primary consideration; for each production process, it is necessary to ensure the punctuality of the post-process operation, and the next production process must be immediately followed by the next process. Ensure the effective connection of the two production processes before and after.
(3) It is best to use an intelligent APS scheduling system to arrange production. It is necessary to pay attention to the orderly insertion order, which can clearly understand the impact and changes brought by other orders.
(4) Many people believe that the flexible packaging industry is complex and has many changing factors, so it is impossible to manage and arrange production with intelligent systems. In fact, as long as you think hard, have the determination and courage to change, and establish relevant technical research teams, it is impossible to do it. There are always ways, as long as there is a determination to find a way.
(5) It is recommended to set up a special team within the company to set up production scheduling personnel, first collect and organize the data of each positioning and equipment machine, and evaluate the accuracy of the data; then, the intelligent APS scheduling system and MES ( Production workshop implementation) The system conducts evaluation and investigation to judge the difficulty and feasibility of its implementation. If there is difficulty, it is necessary to study how to overcome the problem and continuously improve and improve.
Flexible packaging companies need to establish a healthy development model. Advanced production equipment can make flexible packaging companies “run” faster, and the fine management of information systems can ensure that flexible packaging companies go further.