Future smart printing factories, building from these four aspects
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Industry 4.0 has swept the world like a storm, which has aroused strong repercussions from all walks of life. The concept of efficient, environmentally friendly and green development has become the consensus of all. How to improve the current production mode and improve the efficiency of the factory is the focus of the whole society's thinking and discussion. Then how can the printing and packaging coating industry, which is relatively low in informationization and automation, change to cope with the challenges of the new era development, the answer is to change to the smart factory!
The intelligent printing factory is based on digital factories, using information technology and monitoring technology to strengthen information management services, improve controllability of production processes, reduce manual intervention in production lines, and rationally plan scheduling. At the same time, it integrates emerging technologies such as intelligent means and intelligent systems to build a humanized chemical plant with high efficiency, energy saving, green, environmental protection and comfort. Personally think that the construction of smart printing factory needs to start from the following aspects:
1. Reasonable production layout
For the printing factory, the reasonable production layout is to carry out the “U” layout of equipment, materials and logistics according to the flow of production process, which can reduce the unnecessary logistics crossover and achieve the best material circulation effect, and make the production process smoother. . However, the production layout of smart factories should consider more elements:
At the equipment level, under the requirements of national policies, environmental protection equipment is indispensable, so discharge equipment (printing composites, etc.) should be arranged as concentrated as possible, and the reasonable position of environmental protection equipment should be considered comprehensively according to the arrangement of the exhaust ducts;
The warehousing system, the storage of the smart factory must introduce a three-dimensional library, the large amount of space utilization and high degree of automation, and can be automatically docked with the logistics system. When planning the three-dimensional library form and location, it is necessary to fully consider the requirements of the production process. For example, the soft package and the coating workshop have clean and non-clean points, so it is necessary to design the three-dimensional library in two areas, and the three-dimensional library of the workshop is only used for Material temporary turnover buffer, the value can be small, but the position should be very particular, convenient for most sections to take the material; aluminum foil and matured coil material can not touch the tray, you need to hang up, so that the smallest unit size becomes larger, you need more Arrange the roadway (stacking machine); and so on.
Logistics system, the logistics system of the intelligent factory is to realize the automatic pulling of all materials in the workshop, mainly including AGV, hoist, conveying platform, etc. The channel of AGV operation is wider than the channel of manual logistics, and the different forms of AGV operation channel are not close. The same, so in the logistics planning, according to the actual situation (existing workshop size, logistics specifications, etc.) to select the appropriate model to determine the size of the logistics channel, such as the northwestern Shaanxi people developed backhoe AGV channel requirements are smaller, and forklift AGV requirements The space is relatively large. If the workshop is a cross-floor, you need to consider arranging the hoist; the automated packaging line will introduce a conveyor platform, palletizing robots, and so on.
Intelligent supporting systems, intelligent supporting systems involved in smart factories, such as automatic loading and unloading devices, intelligent visual flipping robots, intelligent curing systems, automatic weighing devices, intelligent packaging production lines, etc. all need to be considered within the layout. The weighing device needs to be properly designed in the logistics route, and the curing system should be added before the compounding section before the cutting and forming section.
Therefore, the production layout of the smart factory is a new consideration of the entire workshop and space, and finally the rational allocation of comprehensive production elements, which is the infrastructure of the smart factory, which plays an important role in the smooth operation of the latter.
2. Digital network
Digitalization of the workshop is the basic condition of the smart factory. Only by digitizing the production information of the workshop can the automatic collection by the acquisition system and the accumulation of big data gradually lay a solid foundation for production analysis. The digitization of the workshop is to give personnel, materials, and order work order code information, and can automatically collect information such as equipment status and process parameters, workshop environment, energy consumption, etc., and store the data through the network system.
New devices are generally equipped with intelligent genes, and all data of the device can be quickly collected. For relatively old equipment, it must be upgraded and upgraded, add network module to PLC, add mechanical sensor to convert electrical signal into mechanical signal, install temperature and humidity control system in workshop, install smart meter in workshop or equipment, install smart matching equipment Module: online detection, viscosity control instrument, ink color controller, etc. In short, digitalization is to convert all important production information flowing in the workshop into computer-recognizable data.
3. Informationization
Informatization is the use of software to achieve management ideas. At present, the printing plant has a low level of informatization, and most of them only go online with the ERP of simple function modules, which is difficult to play a greater role in production. The intelligent plant's informatization construction includes the following modules: ERP system, MES system, WMS system, WCS system, AGV system and other ERP systems as enterprise resource planning systems, which need to cover business, finance, orders, plans, processes, materials, energy and other modules. The MES system is the connection between the ERP system and the underlying equipment, receives the planning layer order and monitors the order execution and automatically collects the production information, ensures the production data is timely and accurate, and provides support for production analysis and high-level decision-making; the WMS system is the ERP material management module. The addition of the material process and refined management to ensure real-time accurate material information; AGV system is the extension and implementation of the WMS system, responsible for timely and accurate delivery of the required materials to the designated production equipment.
Therefore, informatization construction is ultimately an intelligent production system with multiple systems, equipment, personnel and materials interconnected, through special equipment (PDA, production board, bar code collector, PLC, smart sensor, remote I/O, arranged at the production site). Real-time data acquisition, control and monitoring of the production process from raw material procurement to finished product delivery by electronic means such as RFID and PC.
4. Lean production
Lean production and intelligent production are two concepts in the field. The focus is not the same. Lean production mainly emphasizes the management concept and implementation method in the production process. Intelligent production focuses on technology realization, but the two are complementary.
Many concepts in lean production guide the construction of intelligent production systems, such as standard operations. We first define the standard operating procedures in the MES system, standardize the production process of the products, and the informationization method is easier but more strict to control the production. The process ensures product quality; the intelligent production process adds the incoming material scanning confirmation link, which is also the embodiment of reducing unnecessary waste; the post-process pulling is also the idea of order operation in the intelligent production system. In addition, the concepts of fast switching, waste reduction, and visual production in lean production are also the process objectives for intelligent production. Similarly, methods and means such as equipment interconnection, advanced scheduling, process coordination, quality process control, big data analysis, visualization, and predictive maintenance in intelligent production all contribute to the promotion and improvement of lean production.
Therefore, the layout and informationization of smart factories is not simply a reproduction of a production mode, but under the guidance of lean production concepts and methods, in-depth analysis of production layout and product technology, and make effective improvements, for example, All kinds of waste in the process are sorted and improved. The inventory quantity should be optimized repeatedly to determine the size of the stereo library. The material storage method should be changed to reduce unnecessary duplication of work. The material storage and circulation methods must be determined clearly before determining the AGV and the library. Docking, avoid unnecessary or even wrong input, and so on.
Only profound analysis and change, but also make full use of the technological advantages of intelligent production, and ultimately achieve efficient, environmentally friendly, green, interconnected production and service models.
to sum up
Under the enthusiasm of smart factories, enterprises should not blindly follow the trend and build smart factories. They should plan the smart factory construction blueprints based on the medium- and long-term development strategies of enterprises and the characteristics of their products, processes, equipment and orders. On the basis of promoting standardization and standardization, we will gradually promote the construction of smart factories from the contradictions that the enterprises themselves are most urgently needed to solve.