1. Production scheduling
When formulating production schedules, it is necessary to consider factors such as material shelf life, semi-finished product inventory, merged production of products with the same mold, priority production capacity constraints, delivery time constraints, and day and night shift priorities.
2. Material feeding management
Feeding management can scan codes to identify logistics and batches, achieving error prevention and foolproof handling. In specific applications where material packaging is sizable and handling proves challenging, all incoming raw materials are affixed with barcodes containing pertinent information such as material codes, batch numbers, quantities, and more.
The MES system utilizes a wireless serial port scanning device to scan material barcodes, automatically identifying material specifications based on the barcode and feeding requirements. It appraises the correctness of feeding operations by considering material batches and adhering to the first in, first out rules, thus meeting the requirements for anti-deception measures.
3. Production monitoring
Through the application of scientific scheduling and real-time monitoring, the MES system effectively manages various aspects of workshop sites, including shift handover, waste collection, allocation of production machines, and the receiving and returning of equipment. This leads to the achievement of management objectives that go beyond what can be accomplished through experience-based scheduling alone.
The system offers real-time feedback on production status, facilitating on-site process control and monitoring of material information, process information, equipment information, defective rates during production, as well as presenting real-time displays of production site status through visual interfaces for production visualization and electronic Kanban management. This enhances equipment energy efficiency and ensures the smooth progress of production as planned.
4. Equipment monitoring
The MES system acquires operational status information from equipment, automatically documents equipment start and stop times, calculates equipment utilization rates, and provides a comprehensive and detailed breakdown of the location and causes of equipment shutdown events. Real-time calculations generate equipment production efficiency and mechanical efficiency, enabling predictive maintenance, spot checks, and maintenance and repair procedures throughout the entire process.
Furthermore, the system reports equipment maintenance status, triggering automatic prompts for maintenance and performance evaluation. It offers equipment maintenance and scheduling, controls equipment health, and serves as a basis for production scheduling, thereby markedly elevating the overall utilization rate of equipment and fostering continual progress in production efficiency.
5. Quality inspection
Upon implementation of the MES system, relevant material and semi-finished product batches are inputted during the inspection process. The system automatically captures inspection data and supports mobile quality inspections. Results can be recorded and uploaded at any given time, with quality inspection reports scanned and linked to specific production batches. Through remote monitoring of production quality, the system enables swift traceability of the source of any quality issues and provides real-time alerts for defects and deficiencies. It rigorously enforces quality control and ensures comprehensive oversight during the quality inspection process, ultimately leading to the generation of more accurate data.
6. Traceability management
Throughout the entirety of component production, the MES system collects, tallies, tracks, alerts, and analyzes diverse data. It records initial and random inspection data for each production cycle within the system. In the event of a component quality issue, detailed parameters can be traced back, facilitating timely consultation, analysis, and resolution by staff members. Each component product is equipped with a unique barcode or number, thereby effectively establishing a system for product quality traceability.
7. Mold management
Online mold resumes are generated, facilitating visibility into mold status, including idle, offline, visible for scrapping, and inventory management. The system enables visual oversight of mold lifespan, complete with automatic warnings and timely reminders for scrapping and maintenance. Real-time tracking of mold status is conducted, and integration with intelligent positioning hardware can be employed to achieve seamless control over the mold production process.
8. Inventory management
Warehouse management encompasses the control of raw materials, semi-finished products, and finished products. Through the implementation of the MES system, warehouse goods are organized and managed by boxes, and inbound and outbound operations are facilitated via PDA scanning. Simultaneously, ERP documents are automatically generated to streamline accounting tasks.
To further enhance efficiency, the deployment of an Automatic Identification System utilizing RFID technology and an LED lighting system can replace PDA operations, enabling contactless entry and exit and automated generation of ERP documents.
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