Application Case Analysis Of MES System In Weaving Industry Of Textile Industry

1. Brief introduction of enterprise profile

Jiangsu Lian FA textile Limited by Share Ltd is a large high-tech enterprise integrating cotton yarn, dyed weaving, printing and dyeing, garment making, thermoelectricity and trade, Jiangsu innovative enterprise and Nantong Haian first listed company (Stock Code: 002394).

The company's main products are yarn, dyed fabric, printing and dyeing cloth, shirt four series.

It has the annual production capacity of 72 million tons of yarn, 80 million meters of dyed cloth, 50 million meters of printing and dyeing, and 6 million of shirts.

The products are sold to more than 20 provinces and cities nationwide and exported to 36 countries and regions, such as Japan and the United States.

In 2009, the company achieved sales of 1 billion 529 million yuan, earning 168 million yuan in foreign exchange, 276 million yuan in profits and taxes, and 1 billion 292 million yuan in total assets.

For the 12 consecutive year, the company has reclaimed the main economic indicators of the "ten top Chinese dyed fabrics industry", and has become the 20 strongest Chinese textile and dyed weaving industry in the whole country. It has won the 500 strong textile and garment industry in China for 5 consecutive years. It has been ranked the top 100 textile and garment industry in China for 6 consecutive years, ranking first in the Jiangsu color textile industry.

In 2007 and 2008, the private tax payers of Jiangsu province have been reelected for two years.

As a family

In the course of development, the company has been committed to scientific and technological innovation. It always aims at "using the most advanced equipment, the most advanced technology, cultivating the best employees, producing the best products and achieving the greatest economic and social benefits". It adheres to the idea of "leading the technology progress with high and new technology, promoting industrialization with information technology", and based on the combination of technological innovation and industry university research, to accelerate the upgrading of the core competitiveness of enterprises.

2, the problems faced by enterprises before the implementation of informatization projects.

In the second half of 09, the ERP system has been fully implemented, covering human resource management system, customer relationship management system, plan management system, quality management system, process management system, production management system, cost management system, equipment management system and so on.

However, due to the defects of traditional ERP for workshop management, the existing system basically serves the company managers.

It is basically impossible to monitor the logistics management, operation process execution and execution of plan tasks.

The management of the workshop can only be analyzed by the record of the post and the record of the job, which is short of timeliness.

It is difficult to extend the information system to the production equipment of the workshop, and it is difficult to integrate the ERP system with the workshop production equipment.

In the past, the company mainly introduced the production equipment of single station, and monitored the single station and closed loop control. However, most of the production equipment still stayed in the stage of local simple instrument control and manual site adjustment. In the ERP system, a lot of process information and equipment information could not be introduced into production equipment, and the actual process data and planning data in production could not be immediately fed back to the ERP system.

For production problems, quality hazards can not be found in time and effective control measures should be taken.

3, how to choose information products to solve these problems.

The company leaders clearly recognized the above problems and asked the IT department to build a MES system suitable for the company's weaving workshop.

The MES system is required to monitor the process, plan and quality information data of weaving machines in real time.

And through the MES system, the equipment and process parameters can be adjusted in real time for the equipment with problems.

The company's leaders require IT department and weaving division to collaborate and complete the joint application in one to two years.

System design, selection and implementation of the system on-line.

4. Brief introduction of Informatization Plan

The IT Department has introduced the system introduction and demo by contacting many equipment integrators at home and abroad, and visited the application of MES system in other enterprises of the same industry. The company finally decided to build a joint textile MES system based on the 2 subsystems of TOYOTA TMS (TOYOTA MONITORING SYSTEM) system and Xiamen soft loom monitoring system.

The company has invested a lot of manpower and material resources to make up all looms and cloth inspection machines in the LAN and connect them to the main network of the company.

And for each plan, quality, production management personnel, each grey cloth inspection machine has excellent personal computers and printers, and enough data and application servers are installed for each subsystem.

1) TOYOTA TMS (TOYOTA MONITORING SYSTEM) system

The TOYOTA TMS (TOYOTA MONITORING SYSTEM) system is an on-line monitoring system applied to TOYOTA series looms.

The company's weaving branch has applied more than 500 TOYOTA series air-jet looms. The TOYOTA TMS system is adopted. The system has good integration, no compatibility problems, simple placement of hardware and network equipment, convenient installation and installation of software system, and fast application.

The company selected TOYOTA TMS system as an on-line real-time monitoring system for TOYOTA series looms used by weaving factories.

The TOYOTA TMS system adopts the B/S architecture. The system is constituted as follows: all the TOYOTA looms of the company are made up of LAN and switch, which are connected to the main network of the company. The private data and application servers installed with TOYOTA TMS system are placed in the computer room, directly connected to the main network of the company, and connected directly to the loom LAN through the internal network of the company, which is responsible for real-time monitoring the operation and production of the looms; each client is connected to the data and application server, and realizes the monitoring function through visiting the main menu of the TOYOTA TMS system.

{page_break}

The TOYOTA TMS system mainly includes the following functions:

Data collection function

It is possible to collect monitoring data from each loom (data in the past week) and store them in the server host.

Data preservation and presentation function.

The data collected in the server host can be saved as CSV (Comma Separated Value) file, and the data can be automatically converted into the format suitable for Microsoft EXCEL file. The data can be easily analyzed for production volume, productivity, parking reason analysis, alternate class report, production status list and forecast.

Loom monitoring and control functions

It can monitor the current production status of each loom and the setting of each production parameter in real time, and control the production of each loom, and control the adjustment of the production parameters of each loom.

　　·

Production data analysis

It can analyze the times and times of weft stop, stop and wait, and the speed and efficiency of looms.

Make an analysis of the quality of production and the implementation of the plan, and trace back afterwards.

The TOYOTA TMS system is developed directly by Toyota Corporation, which is complementary to the TOYOTA loom used by the company.

And the direct use of Toyota Corporation's monitoring system also eliminates the implementation of other companies' monitoring schemes, data validation and so on.

2) soft loom monitoring system

The soft loom monitoring system of Xiamen soft Tong Technology Co., Ltd. is the most widely used loom monitoring system in China. It has been installed on more than 20 thousand looms in more than 10 textile enterprises across the country.

Loom data monitored by the system is timely, accurate and reliable, and provides a large number of convenient and accurate data reports for planning, process and quality.

The company selected the Xiamen loom loom monitoring system as the non TOYOTA series loom of the weaving branch of the company, including the Begano series air-jet loom, the multi line rapier loom and the Somit series rapier loom online real-time monitoring system.

The soft loom monitoring system installed monitors on each loom to monitor the production and operation parameters of looms in real time.

The soft pass monitoring system takes advantage of the network that was originally assigned to each machine platform, and forms the monitor on all looms. It connects the main network of the company through special data converters and converters. The dedicated data and application servers installed on the server side of the soft loom monitoring system are placed in the computer room, directly connected to the main network of the company, and directly connected to the soft pit monitoring system data converters and converters through the internal network of the company, which is responsible for real-time monitoring the production of each loom; and each client is logged on to the client of the monitoring system to realize the monitoring function.

The system mainly includes the following functions:

Real time monitoring of loom production data

The loom monitoring system can collect the current production and operation status of looms in real time, such as normal operation, stop, weft stop, other shutdown or shutdown; collect current production and operation parameters, including current vehicle speed and efficiency; the output, average speed and average efficiency of this class; the total number and total time of various problems such as stopping and weft stopping in the production process of this class; and so on; {page_break}

Loom production data storage

The loom monitoring system can store the real-time production data to the server database, and facilitate the subsequent data analysis or other purposes.

Analysis of loom production

The loom monitoring system can analyze the collected production data, analyze the planning, operation and quality of the workshop in real time or in time, and understand the actual situation in the production process.

The soft loom monitoring system is a mature system, and its technology is in the leading position in China.

The system saves time and saves manpower and material resources.

5, application effect

1) real-time understanding and intervention in the production of weaving workshop.

Weaving MES system will organically combine all looms through two monitoring systems. Through the corresponding functions of the two monitoring systems, the production and operation of each loom can be obtained in real time and displayed in the MES system. It is convenient for weaving managers, equipment personnel and planners to get a timely understanding of the current operation status of each machine in the workshop.

And whether there is any need for necessary management intervention to deal with abnormal situations in production.

2) real-time feedback for weaving workshop planning

Companies and weaving planners can understand the planning status of all orders in weaving by weaving MES system.

Whether the order is normally produced, whether it can be completed according to the scheduled delivery time, at present, each machine is able to finish the weaving shaft when it is being woven; when there are several looms per day, how many weaving machines will finish weaving, and how many looms need to be prepared again; and so on.

Through the application of the MES system, the planners can make plans for the weaving situation, reduce the time to visit the production schedule on the spot, and facilitate the arrangement of the plan, so that the planners can spare more time and arrange more optimized plans.

3) real-time analysis of quality situation and time tracking.

Through the MES system, technicians and quality workers can understand the quality status of each order in time, and analyze the frequency and frequency of each type of quality problems, check out the root cause of the problem and give timely treatment advice and methods to reduce the frequency and frequency of similar quality problems.

For the quality problems that have occurred and exist, by consulting the quality of production and analyzing the quality problems, the specific causes of the problems can be traced back and the production of subsequent processes can be guided.

4) analysis of production cost

The production and operation parameters recorded in the MES system can be conveniently utilized in the calculation and analysis of the cost, making the actual cost data more accurate, and providing accurate data for analyzing the occurrence and saving of various costs.

6, experience

Through the implementation of the weaving MES system, we feel that the application of MES system will bring great changes to the workshop process, plan, quality and cost management, and overcome many blind spots of the company's ERP system.

Next, we plan to introduce the MES system to other production plants with conditional production facilities, such as the reverse machine, warping machine, sizing machine, dyeing machine, warping machine, dyeing pot and dryer. After finishing the singeing machine, desizing machine, mercerizing machine, setting machine, pre shrinking machine and other machines, we can realize the MES system of the whole company and realize the digital workshop management.