General situation of production planning and scheduling management of cigarette enterprises in China

In recent years, the informatization construction of cigarette enterprises has developed rapidly, but due to the lack of "integration" between subsystems, the enterprise informatization system cannot undertake the heavy responsibility of enterprise reorganization and integration. This demand is mainly manifested in the following aspects:

(1) The production process information at the enterprise production planning level is an important resource, but in the enterprise management system, the production process information is always "offline" and cannot be continuously, automatically and completely reflected in the enterprise management system.

(2) It is necessary to effectively solve the contradiction between the production planning layer and the production process automation, make the traditional production management transparent, make full use of the current real-time production data, and make the production commanders and dispatchers get enough production site data support in the process of making the production plan, so as to optimize the production plan while considering the production balance and improve the real-time and flexibility of the production plan.

(3) Effective integration of enterprise application systems should be realized, so that production managers can grasp production information such as quality technology and material consumption in time, find problems that affect product quality and cost, strengthen online control of production, and minimize the number of waste products and defective products.

(4) The improvement of enterprise competitiveness is reflected in whether the OEE (overall equipment efficiency) and KPI (key performance indicators) of the production line can be continuously improved. The data source on which the production management decision is based is not only the operation of a single production device, but the whole production process.

(5) Equipment maintenance management stays in the traditional emergency maintenance stage. Due to the lack of management means, it is difficult to accumulate maintenance experience, mainly relying on personal skills and experience, lacking the support of standardized and professional maintenance experience, and the work efficiency is low. In the tenth five-year plan project of Lanzhou Cigarette Factory, in order to realize the organic integration from enterprise management, production command to production automation control system, make relevant production departments work together, ensure the coordinated operation of the whole production process, improve the production management level of the enterprise and realize the rapid response of the production process, the production execution system is put forward and implemented.

1 Manufacturing Execution System Architecture

Using advanced and mature software technology, combined with the advanced management concept of MES, the technical solution of agile manufacturing in cigarette enterprises is designed and realized. See figure 1 for the technical architecture of the system.

Figure 1 MES system technical architecture

(1) The real-time and historical information integration platform of the factory ensures the real-time performance of the system. Advanced real-time database technology is adopted to solve the problems of large-scale acquisition (10000 points), long-term storage (1 ~ 3 years), field data filtering, alarm and event triggering.

(2) The production model platform ensures the adaptability of the system. MES system is a management system oriented to production process, and its adaptability is mainly reflected in the degree of fit with the process. When the process changes, MES system must have the ability to adapt to this change. With the support of the platform, the system established the model of cigarette equipment, process flow, materials and management activities, and realized the unification of logistics, information flow and instruction flow.

(3) Application of system development platform to solve the problems of system reconfiguration and maintainability. This system adopts. . NET development platform.

(4)MES integration platform to solve the integration, openness, reconfiguration and interoperability of MES. With the development of information technology, large-scale software generally adopts modular component structure system, and application programs adopt integration technology to realize specific business intelligence. MES system involves business modules such as production, quality, technology, equipment and personnel, and the platform provides an integrated supporting environment for all business functional modules.

(5) Enterprise data exchange platform to solve the information integration problem of cigarette enterprises. There are many schemes to establish enterprise data exchange platform, such as adopting middleware, establishing EAI environment and establishing intermediate tables. According to the EAI integration environment of enterprises, the system adopts Tuxdeo middleware with excellent performance and predefined information exchange standards conforming to XML specifications to establish an enterprise data exchange platform.

(6) Support the open data acquisition interface of MES system. The system adopts OPC technology to support the interface of monitoring application.

Function of 2 MES

The production execution system of Lanzhou Cigarette Factory is model-driven, which integrates different business functions such as production scheduling, command scheduling, quality inspection, production standard management, equipment operation and maintenance management, and material tracking, as shown in Figure 2.

Figure 2 MES system function

(1) Production scheduling and command scheduling functions. The system accepts the production plan issued by ERP system, generates daily package plan according to the equipment capacity and process characteristics of cigarette enterprises, and decomposes it into machine work orders on this basis. According to the production arrangement of wrapped silk, combined with the storage situation of cut tobacco and the characteristics of silk-making process, the work orders of each silk-making production process unit are automatically discharged, and the above work orders are downloaded to the production automation unit according to the scheduling control mode of "lean manufacturing", that is, the central control system for the implementation of wrapped silk production. In the process of production execution, the system collects the production data uploaded by the package control center and the silk-making control center in real time, classifies the data according to the planned work order, and feeds it back to the business manager in the form of reports, thus realizing the closed-loop management of production scheduling.

(2) Quality inspection function. According to enterprise quality inspection standards, the system automatically generates quality inspection requests according to the movement of materials through model-driven technology. By filling in the test data manually, the system automatically collects the data of quality instruments and testing equipment on the production site, obtains the original data of quality inspection, and automatically analyzes and evaluates the quality according to SPC and quality assessment standards, forming a closed-loop management of quality control.

(3) Production standard management function. Systematically manage the production standards of enterprises, and realize the central control of silk making, central control of wrapping and power energy system under the production standards. Real-time production process data are collected during equipment production and operation, and compared with production standards, which provides a basis for formulating new production standards and improving production technology, and realizes closed-loop management of production process.

(4) Equipment operation and maintenance management function. In the system, enterprise ERP receives the equipment ledger in asset management, formulates the equipment maintenance plan, and carries out equipment maintenance according to the equipment maintenance requirements. By analyzing the work records of maintenance personnel, the equipment maintenance process is effectively managed. At the same time, according to the running state of the automation equipment, the start-stop and fault information of the equipment are collected in real time, and the equipment fault maintenance request is generated. According to the fault causes and downtime, the maintenance experience library is generated to guide equipment maintenance and realize closed-loop management of equipment.

(5) Material tracking function. The system collects production data in batches, and by establishing different tracking routes, the data scattered in different modules such as production and quality inspection are effectively organized according to the process route, so as to realize the tracking of the whole production process from raw material feeding to finished product warehousing.