Mengniu Dairy Group was established in 1999, and its headquarters is located in Lesheng Economic Park, Helinger County, Hohhot City, Inner Mongolia, with total assets of 7.6 billion yuan and an annual production capacity of 5 million tons of dairy products. With the continuous expansion of production scale, since 2002, Mengniu Dairy Group began to adopt automatic three-dimensional warehouse to improve storage capacity and logistics management level. It has more than 20 three-dimensional warehouses all over the country. Among them, the six-phase factory logistics system project, which was put into use in 2007, has attracted wide attention from the industry because of its large scale and high degree of automation.
In 2006, Mengniu Dairy Group made a decision to invest in the construction of the sixth production project at its headquarters, and put forward? Eight transformations? That is, internationalization, intelligence, scale, three-dimensional, exhibition-oriented, personalized, differentiated and systematic. We are prepared to adopt advanced design concepts and technical equipment to build a large-scale modern liquid milk production plant with the largest scale and the highest scientific and technological content in China, which integrates production, scientific research and training. The main project of this project has an investment of 654.38 billion yuan, a main workshop of 47,700 square meters, 22 production lines and a daily output of 2,000 tons of fresh milk. The central control system instructs all kinds of equipment to automatically complete the whole process from milk collection to product delivery. The completion of the sixth phase of Mengniu indicates that the technical level of dairy processing industry in China is ahead in the world, narrowing the gap between china dairy and the world dairy industry.
The supporting logistics system of Mengniu Phase VI project integrates automatic three-dimensional warehouse system, aerial suspension conveyor system, palletizing robot, circular shuttle car, linear shuttle car, automatic guided transport vehicle AGV, automatic forming machine, automatic film winder, hydraulic lifting platform, shelf shuttle board, continuous hoist and various types of conveyors. It is by far the most advanced logistics system in domestic dairy industry.
system requirements
Mengniu Phase VI Logistics System Project was planned and implemented by Taiyuan corundum Logistics Engineering Co., Ltd. Due to the long-term good cooperation between the two parties, the project took only half a year from bidding to completion, with amazing speed and efficiency. Taiyuan corundum logistics engineering co., ltd., the general contractor of this project, has withstood the severe test of big scheme, big integration and good service, showing its strong comprehensive strength.
Mengniu Phase VI logistics system mainly serves the production, storage and distribution of liquid milk at room temperature. According to the functional design, it is divided into production area, storage area, storage area and storage area, and the whole logistics process is automatically managed by computer. The sixth project * * * has 22 production lines, including 10 Tetra Pak 22 machines (3 ultra-thin and 7 standard models) and 12 Kangmei machines (5 ultra-thin and 7 standard models), with a production capacity of 1800 tons /20 hours and a delivery capacity of 5,000 tons/20 hours. According to the regulations, the daily storage capacity of products in the filling workshop is about 1 10 pallet/hour; The quantity taken out of the warehouse is 30 pallets/hour.
In the process of logistics system planning, Mengniu Group not only puts forward high requirements for handling capacity, but more importantly, it requires unmanned operation in the whole process from milk production to final product delivery, including all logistics operations such as the delivery of finished products, raw materials and packaging materials. At the same time, the whole system should meet the requirements of economy, flexibility, security and maintainability.
system composition
In order to realize unmanned operation from production to distribution, the logistics system of Mengniu Phase VI consists of a fully automatic three-dimensional warehouse and conveying system for finished products, an automatic three-dimensional warehouse and conveying system for inner packaging materials, an automatic conveying system for auxiliary materials and a computer management system running through these three subsystems.
1. Composition and characteristics of automated three-dimensional warehouse and finished product conveying system
The system can realize the storage and delivery of finished products of roller conveyor and empty pallets from the storage of products in the production workshop to after the shuttle bus leaves the storage area (before loading). The main equipment includes:
1, hoist
Twenty-two hoists are connected with a corresponding number of box sealers, with a lifting height of 2m, and are responsible for sending the finished milk boxes to the palletizing robot.
2. Robot automatic coding system
In order to improve the automation of the whole system, pallet palletizing is operated by robots. The palletizing robot can palletize the goods on two production lines at the same time. The manipulator has six axes and can work continuously for more than 20 hours every day.
3. Circular shuttle bus
The round shuttle car is used to automatically transport the fully loaded pallets stacked by the robot from the conveying line to all stations at the storage end of the finished product warehouse, and complete the automatic transportation of the empty pallets at the storage end to the decomposed empty pallets.
4. Conveying system
(1) The palletized goods arrive at the entrance of the warehousing circular shuttle car through the conveyor line and wait for the truck to be warehousing.
(2) There are 24 transport lines at the storage end, corresponding to 24 tunnels of the three-dimensional warehouse.
(3) There are 20 roller conveyors (with gradient) at the loading place, corresponding to 20 vehicles.
(4) After loading, the remaining empty pallets are sent back to the warehouse stacking place, splitting place or three-dimensional warehouse for storage through the conveying line.
(5) The remaining products after segmentation are also sent back to the three-dimensional warehouse through the conveying line.
(6) The replenishment of empty pallets in the storage and palletizing area is automatically completed by the system, which can ensure that empty pallets can always be used for backup when the robot palletizes. After the empty pallets needed for palletizing are taken out of the three-dimensional warehouse (8 pallets are a stack), they are sent to the empty pallet conveying line by the circular shuttle car for disassembly, and then distributed to the robot palletizing area.
5. High shelves
The total construction area of the finished product warehouse is 102? 106m. The highest point of the warehouse is 24 meters and the lowest point is 20 meters. Shelves are distributed in 24 rows and 76 columns 12 floor and 24 rows and 76 columns 13 floor, with * * * 45,600 cargo spaces.
6. Single extension stacker
(1) 24 single linear track roadway stackers, with maximum lifting capacity 1200kg.
(2) Frequency conversion speed regulation is adopted to complete the delivery of workshop goods from warehousing operation or abroad.
(3) The stacker and computer management monitoring system adopt infrared communication mode.
(4) Stacker operation mode: online operation, single machine operation and manual operation.
Second, the composition and characteristics of inner packaging materials and conveying system
The system starts when the inner packaging materials are manually palletized and the pallets are transported to the storage conveyor line by forklift, and ends when all the inner packaging materials are sent to the production workshop (including empty pallets returning to the warehouse). The inner packaging materials are stored in direct contact with milk (including paper rolls and cartons), so there are certain requirements for the cleanliness of the warehouse, so the automatic three-dimensional warehouse is used for storage. In addition, the inner packaging material warehouse also has the functions of external adjustment of packaging materials and empty pallets going out. Mainly consists of the following equipment:
1, drive-in shelf system
(1) The total construction area of the packaging material warehouse is 102? 30 meters, warehouse clear height 9 meters, the total number of goods 2400. Because the pallet sizes of the two packaging materials are different, the shelf is divided into two areas, each accounting for 50%. The tray size for placing tetra pak materials is 1200? 1200mm, and the weight of tray and packaging material is1200mg/tray. The tray size for placing Kangmei packaging materials is 1240? 1000 mm, and the pallet and packaging materials weigh 780 kg/pallet.
(2) The rack adopts shuttle cargo hold, which is bolted and adjustable in height.
2. Single extension stacker
(1) Two rotary stackers are adopted, and the maximum lifting capacity of each stacker is 1300kg, which can meet the requirements of purchasing foreign packaging materials, loading of packaging materials sent to the workshop and different shelf sizes.
(2) There are no overload and rope loosening protection devices, broken rope protection devices, fork action interlocking protection devices, fork moment limiters, cargo position detection devices and cargo detection devices.
(3) The stacker and computer management monitoring system adopt infrared communication mode.
(4) There is no loading device on the stacker, which is convenient for personnel to maintain and manage the highest shelf.
(5) Operation mode of stacker: online operation, single machine operation and manual operation.
3. Automatic handling system of outbound robot (AGV system)
At the end of communication with the production workshop, the packaging materials are automatically sent directly to the designated position of the aseptic filling machine by AGV, and the empty trays are sent back to the packaging material warehouse by AGV. AGV is guided by laser and consists of AGV trolley with conveying and loading mechanism, ground navigation system, online automatic charging system, peripheral conveying system, AGV console and communication system.
Iii. Composition and characteristics of automatic conveying system for auxiliary materials
The system starts from manually putting the auxiliary materials into the automatic loading and unloading suspension car until the auxiliary materials are accurately delivered to the auxiliary materials position in the workshop. The auxiliary material warehouse is located outside the production workshop and across the road. This is a drive-in warehouse for storing cartons and straws. The elevation of the air duct bottom of the auxiliary material warehouse is 5m, and the length of the air duct is 30m.
The carton demand of each production line is 834 pieces/hour for Tetra Pak and 500 pieces/hour for Combibloc. The transportation of cartons and straws to the cartoning machine and pasting machine in the production workshop is completed by unmanned automatic transportation crane in the air. Unmanned aerial vehicle (UAV) adopts monorail suspension mechanism and runs on the annular main track.
Four. Computer monitoring and management system
The whole computer monitoring and management system can realize the unified management of finished product automation library, inner packaging material automation library and auxiliary material library. Automatic warehouse of finished products and packaging materials require online automatic control, monitoring and management, which mainly includes three parts: warehouse logistics information management system, automatic warehouse control and monitoring system and automatic warehouse control execution system. Among them, the warehouse logistics information management system has functional modules such as warehouse management, warehouse management, inventory management, data collection, quality inspection management, batch management, query and statistics, system management, warehouse management, human resource management, early warning, rectification, humanized operation interface and so on. System characteristics
1, under the unified command of the computer, complete the operation of the three-dimensional warehouse, realize the automatic management of the information of goods in and out of the warehouse, and automatically complete the operations of data maintenance, query, modification, report cleaning, inventory analysis, report printing and so on. , and dynamically display the equipment status, location, work completion, fault tips, alarm information and inventory distribution.
2. When receiving the goods, the system can distribute the goods freely. According to the bottom-up principle, it can also specify any commodity. When leaving the warehouse, in principle, the order of warehousing (warehousing date and batch number), that is, the principle of first in first out.
3. The computer monitoring system adopts full Chinese graphical interface, which has good openness, and the system functions are easy to modify and re-develop.
operating procedure
According to the classification of finished products, inner packaging materials and auxiliary materials, the logistics operation process is as follows:
First, the finished product logistics
Mengniu Phase VI Logistics Center has a production area, a storage area, a storage area and a storage area from front to back. The specific operation process is as follows:
(1) production area
Twenty-two sealing machines are connected with the palletizing robot through a conveyor chain. When the cartons filled with Qianjiang products are palletized, the conveyor chain is lifted to a position 2 meters above the ground. Cartons are neatly stacked on pallets on the downstream conveyor belt by palletizing robots according to the size requirements of shelf spacing.
(2) storage area
1. Pallets filled with coded products are transported by a circular shuttle to a conveyor connected to a roadway stacker outside the automated warehouse. Pallets for storing slender products need to be wrapped in plastic film before storage.
2. There is a double-station high-speed circulating shuttle bus in the storage area to deliver the storage goods to the storage port. Pallet goods must pass through the shape qualified detection device before passing through the carriage, and the unqualified goods are sent to the shaping device by the carriage and put into storage after shaping.
3. Pallets that have passed the inspection and palletizing are automatically put into the storage space designated by the computer system by the palletizer.
(3) Leave the reservoir area
1. There are 20 parking spaces in the outbound operation area, which can meet the task of loading and unloading 20 transport vehicles at the same time. The stacker takes out the trays with products from the shelves and sends them to the circular shuttle bus outside the warehouse. According to the sales list, the product pallet is sent from the drum conveyor to the truck.
2. Set a product disassembly area somewhere on the circular threading car, and the tray to be disassembled will leave the threading lane and return to the threading lane after manual sorting.
Second, the logistics of inner packaging materials
1, storage
When the inner packaging materials are purchased from outside, they are manually unloaded and stacked on the pallet, then placed on the conveyor by forklift and transported to the storage platform (entrance). After receiving the instruction, the stacker puts the goods on the shuttle plate nearby or at the preset position, and puts the goods on the shelves (two sizes of shelves) through the reciprocating motion of the plate.
2. Outbound
According to the production needs, the stacker will automatically take out the required paper rolls and cartons and put them at the end communicating with the production workshop. The material handling from the warehouse to the production filling machine adopts laser-guided automatic handling robot (AGV). AGV sends the whole paper roll or carton to the designated station of aseptic filling machine, and manually loads the paper roll or carton. AGV sends the empty pallet back to the packaging material warehouse. The system fully considers the problem of returning the remaining packaging materials after production, and gives priority to using the remaining packaging materials in the next shipment.
Third, the logistics of auxiliary materials
Carton: at the designated station of the auxiliary materials warehouse, the box is manually unpacked and put into the loading mold of the truck according to the quantity and direction required by production.
Suction pipes: at the designated station of the auxiliary materials warehouse, after manual unpacking, put all the suction pipes in the box into the turnover box on the truck.
The transportation of cartons and straws to the packaging and pasting machine in the production workshop is completed by unmanned automatic handling suspension vehicles in the air. Trucks can automatically send these accessories to the cartoning machine to be loaded, and automatically put them into the carton buffer station on the cartoning machine. After the production is finished or the variety is changed, the truck can send the remaining cartons or straws back to the auxiliary material warehouse.
Technical highlights
Mengniu Phase VI automatic logistics system is a high integration of high-tech equipment and control technology, which has attracted much attention from the industry because of its large scale, many innovations, high degree of automation and high operation efficiency. The project has many innovative technologies from information management control system to logistics equipment application.
In the control system, the unified scheduling management of production logistics and multi-warehouse storage logistics is realized. The high degree of automation of logistics center requires unified scheduling and management of finished product automatic warehouse, inner packaging material automatic warehouse and auxiliary material warehouse, that is, the establishment of information control system including warehouse logistics information management system, automatic warehouse control and monitoring system and automatic warehouse control execution system; Realize automatic control of production logistics and packaging, unified management and scheduling of production logistics and warehousing logistics, and overall management of multi-warehouse warehousing and production logistics.
In the application of high-tech equipment, the project covers a variety of advanced and efficient automation equipment, among which AGV and air suspension transportation system are the biggest highlights of Mengniu Phase VI. In particular, the introduction of AGV into the outbound link of inner packaging materials has fundamentally realized the real automatic handling, which has become a major breakthrough in similar projects of Mengniu Group. It is understood that in the three-dimensional warehouses of other projects, the inner packaging materials are mostly transported by computer-controlled stackers, so that the goods are taken off the shelves and out of the warehouse through the track. In contrast, the application of AGV makes the transportation system of Mengniu Phase VI completely intelligent, which greatly improves the work efficiency and reduces the labor cost.
Judging from the operation in the past year, the logistics system of Mengniu Phase VI has basically reached the original planning and design objectives and achieved satisfactory results. On this basis, Mengniu Dairy Group is confident to build its headquarters in Hohhot and Lindel County into the largest modern factory with the highest scientific and technological content in China and a model of dairy industry at home and abroad.
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