On February 18, Lei Jun issued a document saying that Xiaomi's Beijing Changping Smart Factory was officially completed and put into operation today, with a flagship mobile phone manufacturing capacity of more than 10 million units, which is the first large-scale factory in Xiaomi's history and another key milestone in Xiaomi's intelligent manufacturing.
Let's find out. This "smart factory".
The second phase of Xiaomi Smart Factory is located in Xiaomi Future Industrial Park, Changping District, with a total construction area of 81,000 square meters and an annual production capacity of 10 million smartphones.
This is an important production base of Xiaomi, and most of the work will be completed by intelligent robots after it is put into production, achieving 24-hour non-stop operation, with an average daily output of up to 30,000 smartphones. Xiaomi Smart Factory adopts the world's most advanced automation, digital production lines and intelligent manufacturing technologies, and infiltrates core capabilities such as "data-driven, flexible and agile, global collaboration, and green and low-carbon" into all aspects of intelligent manufacturing, making it one of the mobile phone factories with the highest degree of intelligence and digitalization in China.
At present, the Xiaomi smart factory has completed the installation and commissioning of the first production lineIt is planned that all production lines will be put into operation by the end of 2024, and the annual production capacity is expected to reach 10 million smartphones and the annual output value will reach about 20 billion yuan.
Figure 1 Real view of the second phase of Xiaomi Smart Factory
1. Digital intelligence transformation is at the forefront of intelligent manufacturing highlights
Highly automated mobile phone smart production line
The second phase of Xiaomi's smart factory has a second-generation mobile phone high-automation intelligent production line with a high automation rate, including the whole process section of patching, board testing, assembly, machine testing, and finished product packaging. With the increase in automation rate, production efficiency has been greatly improved. The intelligent equipment developed based on the concept of "platform + module" can quickly reconstruct the production line and increase the overall flexibility of the production line.
Figure 2 The second phase of the automated production line of Xiaomi Smart Factory
Intelligent logistics with high flexibility and flexibility
The second phase of Xiaomi's smart factory has a highly flexible and flexible logistics system, which increases the efficiency of logistics in the factory. At the hardware level, the flexible combination of different a** is adopted to adapt to different production logistics needs; At the software level, it is connected with the self-developed industrial digital intelligence platform to realize the functions of automatic calling of equipment, automatic allocation of handling tasks, automatic early warning of inventory, etc., so as to achieve point-to-point intelligent pull production from warehousing to equipment, and achieve the effect of less manpower logistics.
Figure 3 Logistics equipment of Xiaomi's smart factory
5G industrial big data with all elements and links
The second phase of Xiaomi's smart factory has built a 5G F5G network covering the whole plant, supporting 5G scheduling of logistics and F5G communication of intelligent equipment, to achieve more real-time and stable scheduling. Relying on the self-developed industrial digital intelligence platform, the real-time collection of intelligent equipment and logistics equipment data at the production site is realized, and the relevant indicators affecting quality, cost and delivery are accurately analyzed with the help of data mining related technologies, so as to improve the overall production management efficiency of the factory.
Figure 4 Industrial big data of Xiaomi smart factory
A full-scenario digital and intelligent management system from order to delivery
Xiaomi's self-developed SaaS smart applications have successfully landed in smart factories, opening up the complete manufacturing process from "order delivery" to "finished product delivery". Through advanced scheduling APS, the upstream orders are connected with the downstream line scheduling plan to achieve efficient optimization of production planning. With the help of process management PMS application, the digital management of the complete process is realized, and the product research and development is better connected to the digital realization of the process; Through the equipment management TPM, the introduction and verification of the production line body are completed according to the process and plan information; Through MES application and QMS application, the information traceability and foolproof management of the whole production process are realized to ensure the high quality of each production link; Through warehousing and logistics management WMS, the warehousing and outbound management of finished products is realized, helping the core business links to open up the link from "order-planning-line preparation-production execution-quality control-warehouse logistics-finished product delivery", and also through unified data services to connect all business activities, realizing the transparency of the management and operation of the second phase of the Xiaomi smart factory.
Figure 5 All-scenario digital and intelligent management
Green, low-carbon and intelligent energy management
Build an intelligent factory system, connect all electromechanical systems such as air conditioners and air compressors in the factory to the industrial digital intelligence platform, and realize energy consumption optimization and intelligent scheduling through analysis and mining of energy consumption data and environmental data.
Figure 6 Night view of the second phase of the Xiaomi Smart Factory
Second, innovative practices continue to break through innovative production technology leading
Process intelligent closed-loop tuning technology
In order to solve the problems of fine manufacturing process and complex mechanism, dependence on expert experience for process parameter debugging, and long time for manual parameter tuning, Xiaomi realizes intelligent closed-loop optimization of process parameters based on digital twin technology, and builds a model of detection results and process parameters through big data analysis and mining of process data before and after stations, so as to achieve intelligent optimization of process parameters. For example, in the placement section, through the joint mining and analysis of the data of the SPI station and the printing station, the algorithm is used to dynamically adjust the process parameters of the printing machine according to the SPI detection results, helping to further improve the production yield.
Equipped with the best maintenance technology
In view of the problems of large equipment maintenance workload and large loss of line stop in the scenario of high automation rate, Xiaomi has developed the best maintenance algorithm of intelligent equipment based on industrial big data, which can recommend the life of core valuable devices in the equipment and maintenance solutions. For example, in the test section of the mobile phone motherboard, through the algorithm of the service life of the RF probe, the abnormality of the probe can be identified 500 test cycles in advance and the remaining life of the probe can be dynamically identified, and the replacement will be automatically reminded when the life is critical, which is expected to save 10% of the equipment downtime loss and equipment maintenance costs.
Intelligent operation management technology
In terms of intelligent operation, Xiaomi's self-developed IAMS intelligent operation management system provides comprehensive early warning of factory abnormalities through the deep interconnection and dynamic perception and analysis of all elements in the factory, such as man, machine, material, method, and environment, so as to realize the digital control of key manufacturing elements and the efficient handling of abnormal problems. For example, when there is an equipment failure, Xiaomi's front-line engineers will receive the problem solving order issued by the system as soon as possible, realizing online management of business problem solving and improving the efficiency of problem solving.
Xiaomi Industrial Digital Intelligence Platform
In order to realize intelligent manufacturing based on full-scene digitalization, Xiaomi has developed a digital and intelligent platform-level solution - Xiaomi Industrial Digital Intelligence Platform. As an amplifier of manufacturing factors, the digital intelligence platform aims to realize the dataization of production factors, the modeling of manufacturing knowledge, and the automation of business execution, and provide technical foundation support for intelligent processes, intelligent equipment, and intelligent operations. At present, the industrial digital intelligence platform has been basically formed, and the next step will focus on improving the intelligence level of the entire platform, and through continuous iteration, realize a high degree of intelligence in process, equipment, and operation links, and truly achieve self-perception, self-decision-making, and self-execution.
3. Increase transformation, reduce costs and increase efficiency, and the results of intelligent manufacturing are highlighted
By building a smart factory and relying on advanced intelligent manufacturing capabilities, Xiaomi can improve the production efficiency and capacity utilization rate of products, realize the optimization and upgrading of product production processes, reduce product conversion costs, reduce downtime, and improve the flexibility and adaptability of production lines.
In the future, Xiaomi Group will continue to deepen the underlying core technology, continuously increase R&D investment, and build technologies such as intelligent technology, intelligent equipment, intelligent operation, and industrial digital intelligence platform with smart factories as the traction, so as to empower and drive the manufacturing efficiency of related industries in Beijing, Tianjin and Hebei, form a cluster effect of domestic 3C intelligent manufacturing, and enhance the comprehensive competitiveness of China's electronics manufacturing industry.
Figure 7 Exterior view of the second phase of the Xiaomi Smart Factory