How to combine lean management with intelligence

The integration of informatization and lean application refers to the implementation of MES under the multi-variety and small-batch production mode, combined with the actual situation of enterprise manufacturing site, to realize the scientificity and effectiveness of the plan, to ensure the stability and efficiency of the operation process, to realize the streamline of manufacturing and improve the efficiency of operation through the effective use of resources, so as to enhance the comprehensive manufacturing capacity, management level and competitiveness of the factory and reflect the leading position of the factory. This paper mainly discusses from the following three aspects: 1 analysis of production management status 1. 1 The development of MES system and lean production in China started late, and the research direction at this stage mainly focuses on the development and application of MES. In the theoretical research, advanced concepts such as agility, networking, parallelism and reconfiguration are introduced. In the system design, many technologies such as object-oriented, agent and component are adopted, and many beneficial results have been achieved. From the perspective of production practice, domestic contact with lean production can be traced back to the end of 1970s, when Changchun No.1 Automobile Factory organized engineers to visit Toyota for the first time, even many years earlier than Western Professor J.WOMACK and others visited Toyota.

In recent years, with the continuous maturity and perfection of on-site improvement methods and theories, many domestic enterprises have regarded lean production as an effective tool to improve their competitiveness, but the research and summary of lean production in domestic academic and business circles lags far behind that in the United States and other western countries. 1.2 present situation of enterprise management and information application The main sources of enterprise production tasks can be summarized as follows: push component production plan issued by ERP; Part pull demand kanban issued by assembly link; Single-process cooperation plan between manufacturing units within an enterprise. Planners make quarterly, monthly, weekly and daily shift production plans according to production plans and production preparations, and issue production plans through MES system or manually.

After the planner prepares the daily shift production plan, it is necessary to dispatch workers to deal with the plan and dispatch production tasks to production workers according to the plan. Production workers carry out production after receiving operation instructions, and production is completed after completion. At present, all functional modules of enterprise MES system can be used normally, but there are still the following problems in the application of MES system: (1) The process data is inaccurate and missing, and the process is irrelevant to information such as equipment, tooling and tools. (2) On-site collection is not timely, and there are cases where planners start and complete operations instead of workers, and the production completion of shifts in the system is not good.

(3) The working hours data is inaccurate, so it is impossible to calculate working hours according to MES system. (4) Equipment information cannot be reflected in time. Information such as working procedures, personnel and equipment is irrelevant. When the planner dispatches the workers and the workers start and end the operation, the system can't read the information of the equipment, and the "equipment monitoring" function doesn't work. 2. Specific methods for enterprises to promote lean production by combining MES system. 2. 1 Upgrading MES system Considering the present situation of enterprise production management and the integration of MES system with ERP, PDM, DNC and other systems, the original MES system must be upgraded. The upgraded MES system includes nine subsystems: basic data management, planning management, workflow management, quality operation management, fixture management, equipment maintenance management, machine tool monitoring, visual control and system management. Important interfaces include product and process data interface with PDM, current work order data interface with ERP, inventory data interface with DNC and basic data acquisition interface. 2.2 Rely on MES system to limit overproduction. Use MES system to decompose quarterly plan, generate monthly input-output plan of parts and demand plan of blank and raw materials, control production quantity and time, and realize the lean concept of "supporting input, minimum input and latest input" on the premise of ensuring supporting delivery. In the process of production management, a workshop order SO level is added.

The transfer of parts between workshops is controlled by workshop order SO, thus strengthening the lateral coordination of parts entering and leaving the workshop. According to the assessment plan, the blank supply situation and the availability of equipment and tooling, the plan is adjusted, and the shift production is issued, so as to improve the feasibility and stability of the operation plan and reduce the disadvantages of field change and frequent batch production. 2.3 Improve the process operation plan management process. Production line management process operation plan, including inputting support information into the system after receiving the blank; Management of operation plan and workshop order for construction and completion, closing process; Adjust the process operation plan according to urgent tasks. In the process of dispatching operation-level equipment and personnel, the sequencing method is optimized based on project management theory and constraint theory, focusing on ensuring the efficient and full-load operation of bottleneck equipment. Improve the current network planning mechanism to improve the utilization rate of the whole value stream production line and the stability of production planning. 2.4 Expand the application scope of the system and improve the basic data management. In order to ensure the accuracy of MES system data, comprehensively sort out the process route data of MES system, focus on correcting the process route that is inconsistent with the actual situation, improve the basic data, and complete the information of equipment, tooling and tools in the process information of MES system.

As the archives of personnel, equipment, technology and tooling tools in the factory, the basic database of MES system organically associates operators, equipment and processes, and further realizes the economic batch processing of fixed products, curing process parameters and equipment by personnel and key equipment. 2.5 The visualization of progress information and the control of work in process rely on MES system to collect the progress of all levels of the plan in real time, including the overall parts plan-work order, the plan of going in and out according to workshop-workshop list and the operation plan of each process to realize visualization. Clear graphics are convenient for planners to supervise and adjust according to the changes of enterprise plans at any time. Through the visual monitoring of WIP, the congestion phenomenon in the process of WIP circulation can be reversed. 2.6 Realize global visual management of equipment status, establish equipment management account based on MES system, manage equipment status, define two-pack and three-pack cycle, the system will automatically generate two-pack maintenance plan, dispatch two-pack workers through the system, and record maintenance results and status. For the temporary fault maintenance of equipment, establish an alarm and response mechanism, speed up the information transmission and record the response time, and strengthen the assessment of machine maintenance personnel. Visual management of equipment is carried out on MES system platform, and information such as equipment running status, processed parts and operators are marked with different colors, which makes field equipment production more efficient, convenient and intuitive. Before the production plan is issued, automatically check the availability of equipment and find out the problems of equipment failure and shortage in time. Pay attention to the availability and utilization of equipment, reduce the non-value-added time of operators and ensure the effective labor of operators. 2.7 Establishment of lean production management performance evaluation mechanism based on information platform Through systematic demonstration and scientific analysis, it is clear that the performance evaluation mechanism of production management is established under the guidance of lean thinking, and a set of multi-level and multi-angle management evaluation mechanism is established on the basis of efficient and accurate information source guarantee. Provide a strong guarantee for lean production management in the information platform, and provide an incentive mechanism for the implementation of management.

On the basis of continuous improvement and optimization of systems and processes, the accusations of leaders and departments, enterprise work processes, enterprise rules and regulations, and job descriptions of various positions in the enterprise are summarized and arranged into the Collection of Enterprise Processes and Systems, which is bound into a book and distributed to all departments and electronic versions to every employee. Through the integration of field operation informatization and lean, the project effect evaluation has taken the lead in implementing the field operation informatization management under the guidance of lean thinking in the industry, quickly cultivated a high-quality manufacturing team, established an efficient product operation management system, and formed a unique lean production management mode of machining discrete manufacturing informatization, which provided practical experience for the information integration development strategy of ERP, PDM and MES.

Relying on the informatization of field operation, the lean production management of enterprises is realized, which makes the lean production management of enterprises achieve fruitful results, significantly improves the basic management level, and establishes the leading and exemplary position of field operation informatization in the industry.