How To Make Full Use Of Big Data To Enhance The Sanyang Textile MES Production Management System To The Answer?

Recently,

As a textile enterprise with high-end and extroverted strategic position, Sanyang Textile Co., Ltd. owns 500 thousand spindles.

After the production scale of 600 air-jet looms, 400 Sura twisters and 10000 air streams, the focus of the work was shifted to maximizing resource utilization.

Sanyang Textile Co., Ltd. introduced the MES production management system of Belgium BMS company to collect and monitor the more than 1000 devices in real time.

In particular, since the beginning of 2017, in combination with the new cost accounting mechanism and the integration and upgrading of the existing software and hardware resources with advanced information technology, the Sanyang textile has excavated a great deal of potential productivity resources, improved labor productivity, made the product quality more stable, and the unit cost has been further reduced.

Li Dasong, deputy general manager of Sanyang Textile Co., Ltd.

"MES production management system can help enterprises find their own short board, find the direction of upgrading, so as to further enhance the level of development and enhance their competitiveness."

Li Dasong, deputy general manager of Sanyang Textile Co., Ltd. commented in an interview with reporters.

Information technology helps to break through the bottleneck

Founded in 2003.

In the 15 years of rapid development, the company has always adhered to the development concept of "strengthening internal and external integration, focusing on both high-end and advanced development", and always adhered to the industrial development path of "combed spinning, high-end service and leading trend".

At present, the company has developed into a high quality cotton bleached yarn base.

Production base and professional line production base are professional solutions for yarn dyed and mercerized cotton yarn schemes.

The company has passed ISO9000 quality management system, ISO14000 environmental management system, OHSAS18000 occupational health and safety management system three management system certification, the company has won the "China brand", "China cotton textile industry influence brand", "Shandong brand" and other honorary titles.

According to the introduction, in terms of raw materials, Sanyang textile has obtained the authorization of SUPIMA cotton use in the US. The hardware configuration has the EFS cotton distribution system of the Cotton Corp of the United States, equipped with the technical equipment of Switzerland, Italy, Germany, Japan and other countries, and has the provincial technology center and the international standard of the Ulster laboratory. It has invested five sets of Swiss test equipment to ensure the internationalization, advanced and high quality of the production technology and equipment.

"Sanyang textile has always insisted on the selection of advanced international equipment.

The company invested 320 million yuan to introduce the 200 thousand line spinning production line of orrican full process at that time, locating in the production of over 80 high count yarn products.

Since then, the company has carried out the compact spinning pformation, and now the 500 thousand spindle ring spinning is all produced.

。

There are 400 double twisters in the double twisting project of the company, and all of them adopt Sura's double twisting equipment.

And become the first class professional twister manufacturer in China.

The efficiency of our equipment has been maintained at a relatively high level. The energy consumption of the equipment is 20% lower than that of the ordinary equipment. "

Zhang Sheng, Minister of production technology department of Sanyang textile company, said that under the condition of better equipment and management foundation, enterprises need new means and tools to further improve efficiency and reduce energy consumption.

At present, textile enterprises should deal with adverse factors such as rising costs, shortage of labor force and fast market changes. In order to maintain healthy and rapid development in fierce competition, we must rely on technological progress and rely on the continuous integration of information technology and business.

Informatization can enhance the enterprise's quick response ability, improve labor productivity, promote energy saving and consumption reduction, realize fine production, and make enterprises make decisions more quickly and accurately.

In this direction, Sanyang textile decided to introduce the MES production management system of Belgian BMS company.

BMS company is

The subsidiary company, relying on the long term accumulation of textile machinery production base and textile data intelligent acquisition, analysis, processing and other technical advantages, BMS has built a perfect MES system for the whole textile industry chain.

The MES system collects the data of production equipment in real time in wireless mode, integrates the data of machine running, quality information, personnel information and equipment energy consumption into the big data platform, and realizes real-time monitoring and management.

"In 2014, we began some preliminary experiments.

Construction of MES system began in June 2015 and was basically completed by the end of this year.

In the process of construction, it is necessary to open up the equipment port and connect more than 1000 kinds of production equipment in series, which requires a lot of detailed basic work.

Zhang Cuicui, Vice Minister of production technology department of Sanyang Textile Co., Ltd.

Although there are many difficulties in connection with equipment providers' opening of information ports in the early stage, the construction of production online management system is a solid step for enterprises to guide workflow with data flow and achieve production management upgrading.

Improving efficiency and reducing consumption by data flow guidance

"After using the MES production management system, the most important achievement is to improve efficiency, reduce consumption and reduce labor."

When it comes to the actual effect of the MES production management system, Zhang Cuicui concluded.

"Improving efficiency" is reflected in the stability of production equipment and the further improvement of production efficiency.

Through the MES system, the operation data of each device can be monitored in real time, and the abnormal situation can be alerts and early warning in order to avoid losses.

At the same time, through comparison and analysis, we can carry out targeted maintenance to the weak machine platform and improve its operational efficiency.

"Consumption reduction" is mainly reflected in the reduction of power consumption of production equipment.

After using the MES system, the power consumption per hour of each device can be real-time statistics and display.

When the machine is short of oil or parts wear out, its power consumption will increase abnormally, suggesting that corresponding measures should be taken.

Zhang Cuicui said: "when we first started using the MES system, we found that the power consumption of the same type of machine would be relatively large when producing the same varieties.

In view of this situation, we carried out detailed inspection and analysis, and strive to reduce the energy consumption of the machine with high power consumption.

In addition, in the past, we thought that the power consumption of mainframe equipment would be relatively high. In order to save energy, some hosts would be stopped according to the production condition.

After using the MES system, we found that in fact, the power consumption of mainframe equipment accounts for only 25% of the total electricity consumption.

To save energy, it is more effective to reasonably configure the number of hosts and auxiliaries.

Through the MES system, all kinds of production information data can be real-time statistical analysis, production order scheduling is more convenient and reasonable, greatly reducing the workload of managers.

"We used to have 3 statisticians in each workshop to produce production information, and now only 1 people are kept."

Zhang Cuicui said that after using the MES system, the statistics of artificial data were greatly reduced, while the accuracy of statistics was higher.

The characteristics of cotton textile production are multi process, multi machine and 24 hours continuous operation. The control of production process is very important.

The application of information technology not only changed the traditional way of data processing and recording, but also triggered the innovation of management mode, production mode and operation process.

Through the MES system, the operation data of the shop floor can be included in the information system in real time. It can reflect the operation of the production operators, reduce the repetitive work of the operators, improve the work efficiency of the operation personnel, and also standardize the operation of the operators with the help of the information system.

According to the monthly production data and cost data, the information system analyzes the material consumption and cost of each production process, accurately calculates the cost situation, and guides the finance and sales department to carry out data analysis for the loss orders and high profit orders.

Guided by accurate and comprehensive production data, the production efficiency, management level and reaction speed of enterprises can be improved in an all-round way.

Two integration needs further promotion

Like other cotton textile enterprises, Sanyang textile is also facing the pressure of rising production costs and recruitment difficulties.

Under the new industry situation, Sanyang company adheres to the marketing concept of "creating value for customers", and constantly promotes industrial upgrading and management upgrading.

According to Li Dasong, in order to aim at the international market and take an active part in the strategy of the country and the whole area, Sanyang textile has invested double twists in Vietnam.

The project invested 4 million 839 thousand US dollars, covering an area of 20000 square meters, making use of the advantages of Vietnam's local labor and electricity to carry out the deep processing of high count combed yarns.

The project is formally put into operation and will become a new economic growth point for the company.

Sanyang Textile Co., Ltd. also set up a wholly owned subsidiary, Liyang Textile Co., Ltd. in Dongying comprehensive insurance area, with a total investment of 80 million yuan, and plans to introduce advanced international air spinning equipment to build an annual output of 4800 tons of high-grade spinning production.

In addition, the technical pformation project of the 6 million m high grade wide fabric made by Sanyang textile company has also been completed and 200 new air-jet looms have been added.

In the field of equipment, the textile will continue to upgrade, introduce automatic falling yarn robot, automatic pipe machine and other equipment, to further reduce the use of work and improve the quality of the product.

Li Dasong said that in terms of production and marketing, Sanyang textile hopes to be closer to the needs of downstream enterprises and provide more comprehensive services.

To adapt to this pformation requirements, next, in the integration of two aspects, enterprises need to further promote.

"Taking into account the cost and other issues, our MES production management system has not yet achieved single spindle detection, and the integration with ERP system is not enough.

We hope that we can learn from and learn from the experience of advanced enterprises. Informatization will not only develop into the integration of internal information resources and business synergy, but also gradually extend to the downstream, so as to provide better services for customers.

In the face of ERP, SCM, CRM, EIP, PDM and so on, there are many kinds of information management software. In view of the lack of integrated integrated information management system in textile enterprises, the technical personnel of Sanyang Textile Co., Ltd. also expressed the hope that the textile manufacturing intelligent manufacturing overall solution provider can help to promote the integration of two technologies and realize intelligent manufacturing.