Because with the continuous improvement of manufacturing automation, the production capacity is increasingly surplus, and the competition among enterprises has shifted from the original product increment to the value increment, which not only focuses on the benefits of traditional economic concepts such as efficiency and cost, but also needs to broaden and lengthen the value of products, such as increasing the value of a single product by providing follow-up value-added services for sold products, changing the product form through customization, and serving the specific needs of more customers.
Therefore, evaluating the value of intelligent manufacturing to manufacturing industry can no longer be based on traditional efficiency. The essence of intelligent manufacturing is to integrate the achievements of today's scientific and technological development, such as software, embedded systems, sensor networks, Internet of Things, intelligent algorithms and so on. Integrate into manufacturing industry, and realize the integration of physical entities in the objective world and virtual/logical entities in the digital world.
For the manufacturing industry, the virtual-real mapping system shown in the following figure is finally realized:
Of course, intelligent manufacturing also includes the automatic logistics distribution system within the enterprise, which is manifested as CPS on a broader level. In fact, as can be seen from the above figure, intelligent manufacturing and lean production are closely related.
Lean production is the concrete application of lean management in the production process, including JIT, TOC, ANDON, Kanban and other tools. In the traditional production process, lean production theory and tools are an independent system, but in the intelligent manufacturing environment, lean production will be integrated into the intelligent manufacturing system, and even lean production will become a part of the theoretical basis of intelligent manufacturing. Therefore, many people think that it is a fool not to introduce lean production into intelligent manufacturing.
First of all, from the essence of lean production and intelligent production, the essence of lean production is to eliminate non-value-added activities in the production process, while intelligent manufacturing makes value-added activities flexible and intelligent, so the relationship between lean production and intelligent manufacturing is integrated first;
Secondly, intelligent manufacturing provides unprecedented convenience for lean production; Traditional lean production tools, such as Anton, Kanban, PTL, etc., can be perfectly realized on the basis of intelligent manufacturing IT, and even some lean production tools are part of intelligent manufacturing. For example, PTL (Light Indicating Picking System, Pick to light or Electronic Label Picking System) system can be replaced by three-dimensional warehouse, and ANDON system can be realized by AGV (Automatic Guided Transport Vehicle).
Finally, in the integration system of lean production and intelligent manufacturing, in addition to the technical application of ICT, the realization of intelligent manufacturing is an important basis for determining the quality of intelligent manufacturing. Therefore, lean production and intelligent manufacturing are also the relationship between superstructure and material base;
So how does intelligent manufacturing carry the concept of lean?
As mentioned above, the core of intelligent manufacturing is CPS (cyber-physical systems), and the intelligent manufacturing system must be a fully digital manufacturing system. With digitalization and software manufacturing system, what theoretical support does software intelligence (or software design idea) need? The theoretical basis of intelligent manufacturing can not be said to be complete, but a large part of it is lean thinking. At the same time, lean thinking will become easier to popularize and land on the physical basis of intelligent manufacturing, because intelligent manufacturing gives the basis of materialization of lean thinking, and we can materialize lean thinking into strategies in intelligent manufacturing software.
The theoretical basis of the scheduling strategy in the above figure is lean production, including JIT and TOC (bottleneck theory).
Through the physical platform of intelligent manufacturing, lean production is more easily popularized and accepted by enterprises, so it can be said that intelligent manufacturing without talking about lean production is basically in the stage of no entry!
We usually advise customers to rebuild their production systems in three steps, as follows:
The goal of visualization is to realize the integration of man, machine, material, material, method and environment in the manufacturing process; By using RFID (radio frequency identification is a non-contact automatic identification technology) and other identification systems to identify various production factors, the production process can be digitized and moved with the product. The effect is as follows (3D shows the whole production process information), which is also the technology and material of lean production management.
The goal of lean implementation is to realize micro-scheduling and micro-scheduling. Through the analysis of visual data, different scheduling strategies and algorithms are implemented to achieve production balance and production synchronization, so as to meet the needs of all products that focus on creating value. Comprehensive, efficient and high-quality manufacturing control.
The goal of intelligent realization is to integrate the production factors related to manufacturing, such as AGV (automatic guided vehicle) and three-dimensional warehouse, and automatically schedule all the factors involved in production. At the same time, intelligent software algorithms such as risk prediction in manufacturing process and regression analysis of customer quality feedback are used to analyze and mine the whole product. I hope everyone will pay special attention to the concepts of micro-scheduling and micro-scheduling in lean implementation. Lean management based on intelligent manufacturing is more detailed and flexible.