The equipment manufacturing industry undertakes the important task of providing production tools for various sectors of the national economy and driving the development of related industries, and is also considered to be the "heart of industry" and "the backbone of the manufacturing industry". The equipment manufacturing industry is the "machine manufacturing industry that produces machines", and for enterprises, the products they produce are a piece of equipment, such as machine tools, testing equipment, etc.; Or a production line, such as an automated production line for automobiles, automated production lines for home appliances, etc.
In the context of increasingly fierce competition, enterprises in the equipment manufacturing industry need to provide products with shorter delivery time, higher quality, and more powerful functions, and at the same time, with the wave of global digitalization, intelligence and the development of the Internet of Things, the requirements for personalized and intelligent products are getting higher and higher, which has brought huge challenges to the R&D and manufacturing of equipment manufacturing industry enterprises, and digital transformation is imperative.
Most of the products of equipment manufacturing enterprises are varied, non-standard, small batch, personalized customized production, and the manufacturing technology and process are complex. Due to the industry characteristics of the equipment manufacturing industry, most enterprises are faced with challenges such as more design, complex production control, difficult project management, and difficult cost management. As a result, the benefits of a successful digital transformation are even more significant.
First, the development dilemma of the equipment manufacturing industry
1. Marketing and sales management
Project-based manufacturing is the majority, production is made to order, and the market demand is difficult; Factors such as the dispersion of industry production capacity, the relationship between supply and demand, and the skew of buyers make it difficult for enterprises to open source.
2. R&D and design process
According to the order modification or design, design and production, the demand is uncertain, the change is frequent, and the product structure is complex, there are many BOM levels, many parts, and the development cycle is uncontrollable, the conflict between design standardization and demand personalization is complicated, and the cost of sample development and testing is high.
3. Plan the coordination link
The bullwhip effect, seasonal changes in demand and other reasons lead to the instability of the ** chain; Poor coordination between upstream and downstream plans leads to slow inventory turnover and high capital occupation.
4. Procurement management
The opacity of the purchase order fulfillment process makes it difficult to guarantee the delivery of production plans; High risk of quality of purchased products; outsourced management out of control, etc.
5. Warehouse management
There are many types of materials, semi-finished products and purchased parts are frequently in and out of the warehouse, and the inventory accuracy is required. The change of project-based materials leads to a lot of sluggish materials.
6. Quality management
The coupling of the influence of multiple factors on the quality of the process, such as personnel, raw materials, equipment, technology, and environment, is difficult to analyze, and there is no effective quality control means.
7. Production management
The product structure is complex, there are many parts, many and long processes, the OTD cycle is long, the control points are numerous and complex, and the manufacturing process is not transparent, resulting in very difficult operation and execution; Cycle time and process cycle instability caused by human-machine mixing and the difference in the degree of automation.
8. After-sales service
Chaos in on-site construction management; Factors such as the shortage of spare parts lead to a long equipment troubleshooting cycle; High cost of equipment operation and maintenance, harsh environment, etc.
The digital transformation and upgrading solution for equipment manufacturing enterprises provides "end-to-end" from enterprise management and control to business sites, from digital planning to implementation, opens up the three-layer architecture of planning, operation and system, helps enterprises carry out digital transformation diagnosis, analysis, governance and construction, enables enterprises to form a complete management closed loop of production and manufacturing, and provides enterprises with integrated management of design and manufacturing, production collaboration, process control and equipment integration, and takes digitalization and intelligence as the goal of information construction and transformation. Help enterprises improve the efficiency of production control in an all-round way, and help enterprises steadily move towards a new era of intelligent manufacturing.
2. Digital transformation solutions for the equipment manufacturing industry
1. Integration of design and manufacturing
The core pain points of product design in the equipment manufacturing industry are many non-standard designs, low product standardization rate, rebirth of design quality problems, and high requirements for engineers' skills. The core of solving this kind of problem should focus on design quality and design efficiency, how to greatly compress the design cycle, improve the design quality, is the starting point of our value landing.
Through the PLM system, the digital control of product technical documents and processing technology is realized, and the unified management of equipment production process, processing process parameters and quality standards is realized. Through the integration with the ERP system, the front-end technical data is transmitted to the downstream to realize the integrated management of technology and production.
Taking an enterprise as an example, its business is a turnkey project of robot systems, and there are dozens of R&D and design personnel corresponding to various non-standard mechanism equipment design. At the end of the project, the design standards and specifications were formulated for the customer, the enterprise design library was established, and finally a parametric rapid system was formed, which reduced the average design man-hours of the project from 667 hours to 405 hours, reduced the design man-hours by 40%, and shortened the drawing delivery time by two weeks.
2. Collaborative integration of production
Enterprises need to build a digital platform to integrate production, chain, R&D, sales and other business links. The platform should have functions such as data collection, storage, processing, analysis, and visualization, and be able to share and collaborate on data. Optimize business processes, including production planning, material management, quality management, logistics management, etc., through digital means, you can realize the automation and intelligence of business processes, and improve production efficiency and product quality.
Through the organic combination of ERP, APS, WMS, and MES, the collaborative operation of order promise, accurate scheduling of orders, control of material requirements, production execution, intelligent scheduling, and completion and warehousing of production ingredients is realized. Strengthen production coordination, realize the integration of production collaboration, including the close link of man-machine-material-law ring and other elements, more scientific and accurate planning, production site, resource allocation arrangement and scheduling management, strengthen the coordination of all aspects of production, and improve the coordination and command ability between various departments and systems.
3. Integration of process management and control
* As one of the most risky management problems of enterprises, problems such as untimely incoming materials and poor quality of incoming materials will not only lead to the increase of labor costs such as procurement, quality inspection, warehouse management and production scheduling, but also lead to a series of problems such as rising production costs, customer complaints and loss.
Pull through the processes of all aspects of production and manufacturing, use industrial tablets and handheld devices to use code scanning operations, or through the combination of industrial bracelets and automation equipment to realize the collection, transmission and accurate analysis of production big data, real-time monitoring of the progress of each process and dynamic scheduling, rapid processing of early warning problems, and realization of lean production control and precise collaboration of business.
Taking a domestic robot listed company as an example, after the drawing design is completed, it needs to be put into production in a timely manner, and in the face of 1500+ drawings and 200+ merchants, procurement and merchants are facing a huge workload. Previously, in the traditional paper order + email mode, it was difficult to effectively control the production progress of the first chain, which brought a lot of confusion to the management work.
With the concept of standardization, we establish an information management system between users and businessmen. Through the whole process of data chain control, application, inquiry, document preparation, delivery, receipt, quality inspection and other links, reduce labor costs and improve management efficiency. On the premise of ensuring the workload, the overall procurement efficiency has increased by 90%, and the overall procurement budget achievement rate has increased to more than 95%.
4. Equipment integration and integration
Fault management of core equipment components involves many aspects, such as equipment interconnection, production monitoring, operation and maintenance, OEE improvement, etc. Integration with automation equipment or industrial robots, based on the actual production performance of equipment, detection of the best collection, abnormal monitoring, to achieve statistical analysis of production process control and equipment operation management, to achieve equipment preventive maintenance, spare parts, tooling and other management, NC program management.
Take a customer as an example, the customer needs to digitally transform the equipment of the workshop production. After conducting research and communication, it was decided to first carry out the first operation and maintenance implementation of the core components (equipment spindle, feed shaft, etc.) of the customer's 24 machine tools and 6 manipulators, as a pilot application scenario, there are potential hidden dangers in the bearing after the spindle is out 3 months in advance, and the production efficiency is increased by 15%, so that the customer can truly achieve accurate investment and rapid results.
Digital transformation is a change in the enterprise, involving multi-dimensional changes in organization, business processes, cultural concepts, etc., which is a systematic project and not achieved overnight.
We propose a "1+1+N" service model:
A consulting training to form a transformational resonance:For the middle and senior management of enterprises, we will conduct training and consultation on digital transformation methods to unify their understanding.
A diagnostic assessment to take the pulse of the enterprise's pain points:Accurately identify the main problems and weak links of the enterprise at the current stage, and provide overall planning and phased implementation suggestions.
N specific scenarios are implemented to achieve enterprise value landingSolve the most urgent and urgent 1-2 application scenarios of enterprises, and achieve quick results.
American scholars Joseph Pine and James Gilmore once pointed out in The Experience Economy: "Experience is in fact the good feeling that arises in consciousness when a person reaches a certain level of emotional, physical, intellectual, and even spiritual energy; And, when the work of the experiential presenter disappears, the value of the experience remains. When enterprises consciously take services as the stage and rely on commodities to integrate consumers into it, the experience economy is also born. "The next exciting content update "Comprehensive Upgrade, Dassault Systèmes Experience BIM Collaboration Platform 3DEXPERIENCE", so stay tuned.
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Written by: Chengdu Hengrui.
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