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Application Of ERP And MES Integration Technology In Garment Industry

2011/12/9 13:09:00 15

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Integrated Technology Application In Garment Industry

1 difficulties facing the apparel industry

China is one of the largest textile and garment producers in the world. Customs data show that in 2007, the total volume of textile and clothing exports totaled 171 billion 200 million US dollars.

An increase of 18.9% over the same period.

From the data point of view, textile exports still maintain a sustained growth trend.

The rapid growth of orders has also brought many difficulties to garment enterprises in production management. Due to the lack of scientific management and over reliance on experience to co-ordinate the work, the efficiency and capacity planning of workers are inconsistent, which is likely to cause partial underemployment and affect the production efficiency of enterprises.

At the same time, the production data collection is also facing many difficulties, including failing to know in time how many workstations are waiting for work or waiting, failing to know the actual production situation in progress, and failing to know in time what each worker is doing and unable to know when a product is not qualified for quality inspection.

Therefore, how to solve the informatization of garment industry has become an urgent problem for every garment manufacturer.

2 ERP and MES

ERP (Enterprise Resource Planning) - ERP was developed by Caftner Group company in 1990 and developed by MRP II.

ERP mainly includes three functional modules: finance, production, purchase and sale.

With the continuous development of ERP, the functional modules of ERP are becoming more and more extensive. In the garment manufacturing industry, ERP will integrate with the manufacturing execution system MES, and form a real-time system to control the workshop floor of the manufacturing industry in real time.

MES (Manufacturing Execution System) a manufacturing execution system is made by the American advanced manufacturing Research Institute (Advaneed Manukluring Research, AMR).

propose

It is defined as "management information system oriented to the workshop level" between the upper level planning management system and the underlying industrial control. MES mainly consists of 11 functional management modules: operation planning module, resource allocation and state management module, production scheduling module, product tracking, human resource management, equipment maintenance, process standard management, performance analysis management, process management, quality management, data acquisition, etc.

AMR also proposes a three level Pyramid management model composed of plan level, execution layer and control level, which clearly describes the position of MES in the enterprise management system.

The planning layer emphasizes the planning of the enterprise, takes the customer orders and market demand as the source of the plan, and makes full use of all kinds of resources in the enterprise to reduce inventory.

Improve enterprise

benefit

。

ERP is the planning layer of the enterprise. The execution layer (MES) is the middle layer connecting the planning layer and the control layer of the enterprise. It can integrate the planning layer and the production site well through MES, and the control level (Contron) emphasizes the control of the workshop.

From the enterprise integration model, we can see that the manufacturing execution system has built a bridge between the plan management level and the bottom control, and has filled the gap between them.

Because garment manufacturing industry belongs to labor-intensive enterprises, the demand and emphasis of enterprise informatization mainly focus on MES's data collection and performance analysis module.

This paper mainly analyzes the new integration mode of ERP and MES based on the electronic ticket system of Wuhan Shang Yan Institute of Electronics: integrating MES into ERP, making ERP more detailed and accurate in production planning module, and on-line management of production process, making ERP more powerful and more in line with the needs of enterprises.

3 Wuhan Shang Ji electronic ticket system

The Wuhan Institute of electronics has revolutionized the introduction of RFID (Radio Frequency Identification RFID) into the production management of garments, and used RFID to identify and collect technology to replace the workshop.

tradition

It has the advantages of large information capacity, high real-time performance, versatile functions, quick and convenient operation, reusable use and low cost of long-term use.

With the help of computer software, RFID card reader and network, it can monitor and manage the whole production process in real time by identifying the operation of the electronic tags carried on each garment in each production process, including the execution and completion of orders, the tracking and control of garment production progress.

It is found that pipeline bottleneck, garment production quality control and workers' wage accounting can also be used for intelligent production scheduling of orders according to the accumulation of past production information.

Process improvement to maximize production efficiency and enhance customer productivity and competitiveness.

The background database used by this system middleware is SQL Server.

After collecting data from the RFID device, the system communicates with the computer by means of wireless communication base on the wireless base station connected to the computer.

The wireless base station pmits data through middleware and data on the computer through serial port communication, so that the data of the production workshop can be sent to the time successfully.

In the enterprise ERP system.

Middleware through storage

process

The database can be queried, inserted and recorded.

Through this system, the following functions can be realized: 1, improve the pricing system of labor prices.

According to the production situation, we can collect samples in time, analyze the reasonableness of process work hours intelligently, and provide real-time data for improving the process pricing system.

2, production real-time monitoring.

Monitor the production schedule of each order at any time.

We can understand the completion of different orders in detail according to the color size, pparently produce production schedule, and provide strong support for planning and scheduling.

3, efficiency is fully controlled and efficiency improved.

We can conduct multi-directional query analysis according to different factories, teams, sections, machines, personnel and so on, so that operators can understand the actual production information of factories and unify target standards, so as to improve efficiency.

4, establish an effective performance appraisal system and continuous improvement.

To help managers of enterprises to establish effective evaluation mechanism, so that managers can keep abreast of differences between staff and enterprise standards, establish staff, team and workshop comparison evaluation mechanism, improve production and management enthusiasm, and continuous improvement.

5, improve planning and scheduling support to solve the backlog problem of semi-finished products.

It can provide online quantities and online time of different workstations at any time, and help the managers of enterprises to discover the impact of production schedule in advance, and provide help for balancing production.

In terms of network routing, the reader in the system communicates with the base station through wireless communication.

The corresponding settings can be used to determine which card reader communicates with which base station.

Such a network

deploy

The structure reduces the trouble of arranging network lines.

Make networking wiring faster and more convenient.

System network deployment is shown in Figure 3.2:

4 system function analysis

This system is mainly based on RFID and middleware integration of ERP and MES information management system.

Through the analysis of the function of the system, it can provide reference for information management in similar labor intensive industries like garment and textile.

4.1 system architecture

Through integration of middleware, MES's functional modules can be integrated into the new ERP system. It can query the workshop's production situation anytime and anywhere. Using RFID RFID technology can reduce the cost of manual recording and improve the efficiency of data acquisition. Managers and workers can query the production scene through middleware, and at the same time, set up different access rights for different personnel through middleware.

4.2 data collection

The traditional barcode method relies on

Computer

In the process of production, according to their own production status, scissors are used to cut off their own process bar code as production vouchers, and then unite together to gather the workers' barcode (Philippine tickets) to the computer system.

This method is too dependent on scanning equipment, and the error rate of different scanning equipment is different, resulting in low accuracy of the pieces, but also brings the waste of paper and the high cost of data collection.

Using RFID radio frequency identification technology, with the help of RFID terminal collection technology, every ticket information is stored in the RFID tag. The workers send their information to the computer directly through the acquisition terminal according to their own processes, and finish the work.

This approach has the following advantages:

1) high real-time.

After adopting the RFID technology, the decision maker can know the production schedule of the workshop in time by means of the middleware system, which is favorable for the decision level to make accurate prediction and improvement for the production plan.

2) safety and stability

Compared with barcode, the safety and stability of the system are greatly enhanced. Workers can place data cards on the parking card reader before completing a process.

3) sharing information and sharing information

Production information is completely pparent, and workers can query through RFID.

query

To the day's production situation, managers can also know the production schedule in time.

4) analysis the flow of water to solve the block

The system automatically records each worker's work hours and how long it takes. After analysis, the decision maker can arrange the workers' production reasonably and solve the production bottleneck scientifically and timely.

5) cost saving

A RFID reading head can carry out tens of thousands of credit card records, while the cost of a RFID card is around twenty yuan.

Compared to barcode, if a workshop of 3000 people is used to calculate, the cost of labor and ticket materials can be saved by 360 thousand in one year.

6) improve management

Improve productivity and production line pparency, save salaries, responsibility to individuals, reduce defective products, optimize production management process, and reduce WIP's accumulation on production line.

5 concluding remarks

Integration of ERP system and MES for manufacturing industry

information

The development of chemistry is an indispensable stage, which can greatly improve the level of management automation of enterprises.

The new ERP and MES integrated information system, which combines RFID and middleware technology, not only solves the fault between the bottom control system and ERP system well, but also brings revolutionary changes to the enterprise in terms of information technology.

The production efficiency of garment manufacturers has been greatly improved.

For ERP system, how to integrate MES's other functional modules into ERP system well.

It will become a problem to be solved by software developers.