As Luculent Discrete MES system is a production information control system oriented to the workshop implementation layer of the manufacturing companies, MES can provide the management modules for manufacturing data, scheduling, production deployment, inventory, quality, resources, work center/ equipment, tooling, cost, production process, bottom-layer data integration and analyzing, top-layer data integration and decomposition etc. to shape a solid, reliable, overall and feasible coordinated manufacturing management platform for these companies. At present, the Discrete MES System is widely utilized in the industries of domestic appliances, vehicles, semiconductors and telecommunication etc.
The manufacturing execution system (MES) takes SOA as its technical structure and ISA 95 standard as MES Business framework and effectively integrates information across various heterogeneous systems to encapsulate the interfaces between the MES and ERP systems as well as all automatic control systems in the mode of service component, so MES boasts better expandability, assembling capability and transportability. Meanwhile, Luculent MES integrates functions, information and control at the management layer by use of the latest modern management theory and technical measures; at the technical layer, it realizes the processor platform modularization so that the business process can be assembled as required by the user. In addition, the Discrete MES contains the following modules: management modules of plan, production, process, materials, equipment, performance, anti-error and quality, as well as that of supervision and pre-warning.
1.Diversified information acquisition modes
Our MES designs various modes to acquire the manufacturing data during production, including data acquisition car, equipment wiring, tablet computer, wireless PDA, fixed sensor, PC etc. so that it can conveniently and accurately obtain more production data.
2.Lot data acquisition
The general small products in size takes lot as the acquisition unit and such products are placed in one container, but the number of containers may vary with the products. Paste the traveler card onto the container to identify its uniqueness. Lot information acquisition mainly highlights acquiring the container barcode information. And cut the data acquisition operation into four time points, that is, operation station move-in, equipment move-in, equipment move-out and operation station move-out, and produce many efficiency indicators concerned by the customers through mathematical operation of these four time points and these equipment parameters.
3.Perfect process error prevention
The production process can be properly protected with the system to reduce the possibility of quality occurrences; the perfect process error prevention function of our system can ensure that the products are manufactured by the qualified personnel with correct methods to the correct process so as to reduce the possibility of product defects to the most extent, better the product quality and reduce the costs for product maintenance or scrap.
4.Visualize the process route
During the production, provide the visual enquiry for the production process route and visually show the defined procedures to be taken and the completed procedures as well as the production details.
5.Randomly combine the process routes
The process routes may vary with the product or the customer’s demands, so our software enables random combination as required by the customers.
6.Instantaneous and transparent production process
The production management can enquire statements and electronic billboards to get the production status in time, discover problems in time and adjust the production plans and the relevant resources for production efficiency maximization.
7.Flexible and diversified pre-warning
With the system pre-warning function, the relevant personnel can timely discover problems in the modes of mail, text message and alarm light etc. and eliminate such problems ahead of its expansion so as to reduce the consequential loss. If the system discovers any failure in the instantaneous production data acquired at the site, it will notify the relevant personnel and stop the production line to prevent problem expansion and the production goes on if the personnel takes proper actions, or the production line will stop for rectification.
8.Constant quality improvement
In the MES system, we design IQC incoming goods inspection, IPQC in-process spot check, QC unpacking inspection and SPC trend analysis on production test data so that the quality control staff can track and control the product quality level with various quality statements and better the corporate quality control strength and efficiency.
9.Full-process traceability system
MES can record the actual information such as raw material supplier, production batch no., production staff and equipment data, production test record, maintenance record, post-shipment customer name and quantity to establish the complete traceability archive. So in the case of an event, the system can provide accurate data and supports for the analyzers to identify the event and its affected scope.
1. Production management
Control the work flows between the production units in the modes of orders, worksheets, batches etc. and adjust the site work items in the specified order according to the schedule information when there is an occurrence in the workshop.
The software provides the whole order printing function to list and print all parts of a component on a worksheet (the worksheet of components) as well as the barcodes and resolve the problems such as loss of several parts, the large workload dispatched and a big printing amount.
The workshop IPC (industrial personal computer) can automatically print the transfer work tickets [with certain barcodes] and deliver the goods to the next procedure so that the staff of the next procedure can use PDA mobile reception, but use RFID induction receiver based on the material conditions sometimes, while the system can record the whole transfer process and provide the time spent for each section.
2. Resource management
Manage machine tools, instrument, staff, materials, other devices and other production entities (for example, the process documents, NC processing procedure and other documents must be prepared for processing) are used for normal production.
Provide the historic records of the resource utilization, ensure proper equipment installation and operation, and provide the real-time material status information at the same time. The management over these resources also includes reservation and deployment of such resources in compliance with the production plan requirements.
3. Process management
Run through the whole process of planning, design, manufacturing and management and conduct the coordinated and uniform management over the process information during production. Production process, linkage drawings, pictures, process cards, assembly drawings etc. can be prepared in MES and automatically downloaded from the external ERP and PLM. Upon the process preparation, production can be carried out to the process flow and called out at the site.
For the process tracking engine in the discrete industry, automatically disassemble bracket assembly and other complicated components and automatically decompose the component sheet into the part sheets for further implementation to greatly reduce the quantity of such sheets and track the part production progress.
4. Production plan
Based on the limited capability deployment, the production plan takes production-related staggered, overlapped and concurrent operation into consideration to exactly calculate the equipment charging and discharging and adjust the time required.
The scheduling plan is the assembly plan prepared by the workshop and the workshop decomposes the monthly production task into the weekly assembly plans which are taken as the calculation basis for the parts required, while the pre-production time is designated as the part delivery time to ensure the workshop production and improve the production efficiency.
5. Document control
Control, manage and transmit the information documents related to production units, including work commands, formula, engineering drawing, standard process practice, part NC machining procedure, batch machining record, engineering change notification and communication record between various transformation and operation rooms, and provide the information editing function.
6. Data acquisition
With various measures such as barcode scanning, RFID and equipment sensor, real-time collect the production workshop data, automatically generate statements and exhibit the gap between the production schedule and the goal by use of production control billboard for real-time follow-up to reach the original production goals planned.
The workshop production site data contain production schedule, quality data, equipment load, staff work status, in-process product machining status etc. to provide the site data supports for other modules of the system.
MES system divides the workshop production data acquired into two types wherein one type is the data acquisition based on the automatic recognition technology, mainly used for assembly data collection in the discrete industry, while the other type refers to the equipment-based instrumentation data acquisition mainly used for material information collection in the automatic controller and the fluid type production.
7. Process management
Monitor the production process, automatically correct the errors during the production and provide the decision supports for the users to better the production efficiency. These activities may aim at some operations at the bottom layer, mainly emphasizing the machines monitored and controlled, so they requires constantly tracking the production and operation process.
Depending on the pre-warning and alarming functions, the workshop staff can discover the machining process beyond the allowable tolerance in time and take proper measures timely to avoid defective products or prevent loss increase.
8. Quality management
MES system can automatically, real-time collect various data at the production site, generate the quality statements and the quality data analysis report and analyze the data at the key points of the key procedures through intelligent monitoring to discover the potential quality problems during the workshop production, pinpoint the problems as early as possible and better the production efficiency. In addition, it real-time analyzes the process data collected so as to find the problem points and provide the theoretical basis for site control and improvement.
9. Material control
The material control module can support reception and shipment of workshop materials in single unit or in batch and control various materials in the workshop (blank, in-process and finished goods).
MES system can track all materials and all finished goods made of such materials used and support the reverse tracking from the finished goods to the raw materials to satisfy the recall-related business demands of some industries to assist the manufacturers in minimizing the loss and providing better services for customers.
10. Equipment management
Real-time collect the operation status information of the primary production equipment in the company, establish the running information database of the production equipment and analyze the status information collected and calculate the corresponding KPI indicators so that the management staff can real-time master the overall equipment operation conditions and the running efficiency.
Based on the equipment running information database established by the data acquisition system, give the current status of the production equipment (busy, idle and failed) and the equipment utilization information to provide comprehensive data enquiry service for the production deployment and planning system.
For the main production devices, customize the spares management module, the equipment maintenance and servicing record module and the visualized management module of equipment status etc. to facilitate management and maintenance of the primary equipment by the management staff.
Shenzhen K&D Technology Co., Ltd. incorporated in Shenzhen of 2006 is a national hi-tech enterprise engaged in R&D, production and sales of LCD modulus, capacitance, electromagnetic/resistance touch screens. And its products are widely used in the fields of tablet computer, laptop, two-in-one machine, smart phone, learning machine, vehicle-mounted device, smart wearable device, smart domestic appliances, industrial control and medical treatment etc. and the company provides integrated solution and products of “touch display + fingerprint recognition”. Depending on the outstanding touch display and the overall solution capability, the company assists its customers in identifying unique competitive advantages with its key partners in the industrial chain to represent a colorful touch display world in front of the final users!
MES project is implemented to support and coordinate business operation of such business divisions as procurement, production, quality and warehouse logistics and gets transparent production, traceable quality and detailed logistics etc. by use of the barcode application.
Reduce the production cycle by 25%
Reduce/elimiante the data entry time by 50-100%
Reduce the inventory by 15%
Reduce the document operation in the foregoing processes by 80%
Reduce the adaptation time by 10%
Provide accurate and real-time data for ERP