Introduction (text/e-works Huang Pei, Xu Zhiying, Zhang Hefang)
Jiangsu Hengshun Vinegar Co., Ltd. was founded in 1841, and it is a "Chinese time-honored enterprise" with a history of 181 years. The company conforms to the requirements of the times and leads the development of enterprises with the latest technology.
this article is selected from "practical guide to intelligent manufacturing" (author: Huang Pei, Xu Zhiying, Zhang Hefang), which is being edited and will be published soon.
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Step by step
Building a benchmark for industry transformation
On the basis of a comprehensive survey of the development status at home and abroad and the development needs of the enterprise itself, Hengshun Vinegar Industry actively explored the development trend of the industry, followed the development trend of the world, and comprehensively launched the vinegar brewing intelligent factory project based on the industrial Internet. Using intelligent manufacturing to break through the data barriers of all links, realize real-time and accurate control of the whole process, drive production and operation management with big data, and provide "whole process" data traceability service for product safety production, which provides strong support for improving the "intelligent brewing" level and food quality and safety guarantee ability of enterprises and the same industry, and realizes the breakthrough and upgrade of the traditional production enterprise's two-in-one integration application mode.
Make great efforts to build a first-class intelligent demonstration factory in domestic brewing industry, explore a feasible way for traditional brewing enterprises to implement intelligent manufacturing, and form a set of mature brewing intelligent factory construction scheme, which will provide reference and demonstration for the practice of the integration of two industries in China traditional condiment industry.
the vinegar brewing intelligent factory project based on industrial internet is mainly divided into three stages, namely, the application of intelligent equipment, the establishment of intelligent and information intelligent management platform and the promotion of industry standards, which will promote the development of the industry through the improvement of its own intelligent manufacturing level.
the first stage: the intelligent control system of brewing production line is composed of information system and advanced production equipment.
The intelligent management and control system of brewing production line is established by using information system and advanced production equipment to ensure the stable operation of key technological links. Through the production management MES system, the process parameters and energy consumption parameters of the production line are monitored, recorded and analyzed, and the functions of production process monitoring, quality analysis and equipment performance analysis are realized.
the second stage: integrate BOM, MES, ERP, TMS and other systems to build a Hengshun intelligent integrated information intelligent management platform.
We will integrate various systems such as BOM, MES, ERP, TMS, etc., and build a Hengshun integrated information intelligent management platform to realize data sharing-the production management can know the current raw material source, inventory status and order status; The management of the company can master the data of new product development, material supply, production, inventory, logistics and sales. Open up the data barriers in all links and realize real-time and accurate control of the whole process.
the third stage: compiling the intelligent standard of brewing industry and promoting it to the whole industry.
through cooperation with government authorities, relevant professional institutions and scientific research institutes, the project experience of "Intelligent Factory for Food Brewing and Brewing" is sorted out and summarized, and the standard system related to intelligent manufacturing in brewing industry is accelerated and promoted to the whole industry in combination with the integrated management system of the Ministry of Industry and Information Technology.
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Fully deploy
Promote the upgrading of traditional manufacturing intelligence
Hengshun Vinegar Industry has established an intelligent factory management and control system based on industrial Internet through the construction of vinegar brewing intelligent factory based on industrial Internet.
1) The internal digital middle platform of the enterprise
realizes cross-domain data integration and knowledge precipitation through data modeling of business intelligence (BI) system, realizes data encapsulation and opening through standardized data exchange platform, quickly and flexibly meets the requirements of upper-level applications such as ERP, WMS and TMS, meets the needs of internet personalized data and applications through mobile display of SFA system, and strengthens the digital processing of internal technology undertaking, business guidance, normative definition construction and global connectable extraction.
Figure 1 Hengshun Vinegar Sales Cockpit
Figure 2 Hengshun Vinegar Logistics Debugging Center
2) Industrial Internet data platform
Through the data collection of key production control points by the marginalized intelligent computing gateway of the Internet of Things, historical and real-time data are fully utilized to realize centralized management of production data and deeply explore data value, so as to finally effectively manage and utilize enterprise data assets and realize intelligent production.
Figure 3 Real-time Monitoring of Hengshun Soy Sauce Workshop
Figure 4 Real-time Monitoring of Hengshun Cooked Vinegar Workshop
3) Logistics Information Management System
After obtaining the order data, the logistics information system will automatically optimize the transportation route and stowage mode according to the carrier's capacity, and the system will automatically settle the freight after the customer confirms the receipt. In this whole process, from placing an order for sales to the delivery of goods to customers, unattended operation has been realized. Since the operation of the system, the order processing time has been reduced from 5 days to 2 days, and the checkout cycle has been reduced from 15 days to 7 days, and the logistics carrying capacity has been doubled.
4) Intelligent mobile marketing system
SFA system is applied in the marketing terminal. Through the deployment of SaaS-based cloud computing platform, the supervision of market display information, promotion activities, competing products information and salesmen is realized, and communication with customers is also strengthened. At present, the system has covered 25 offices of the company, more than 611 salesmen and more than 1 million terminals.
Figure 5 Full-intelligent checking
Figure 6 Commodity counting
5) Automated three-dimensional altar warehouse
In May 2119, nearly 51 million yuan (including infrastructure) was invested to build a new 2,111-square-meter automated three-dimensional altar warehouse. Tanku consists of three-dimensional shelves, master-slave car system, conveyor system and WCS control system. The warehouse * * * has 11,659 pallets, the maximum storage capacity is nearly 5,511 tons of high-end vintage vinegar, and the maximum storage capacity is 211 jars per day, which is nearly 11 times higher than the existing manual storage efficiency.
fig. 7 automatic three-dimensional altar warehouse
6) intelligent tumbling machine
The intelligent tumbling machine adopts the automatic temperature measurement function, adopts the multi-point temperature measurement strategy for the cross section of the material pile, and sends the measured parameter information to the intelligent tumbling machine console by wireless communication. The console adjusts the tumbling process parameters according to the temperature distribution model, and automatically starts the tumbling.
fig. 8 intelligent fermenter
7) intelligent vinegar brewing machine
The whole process of vinegar brewing is intelligently improved, and the materials are automatically fed and discharged, and the fermentation tank rotates instead of fermenting, so as to monitor the physical and chemical indexes of vinegar fermented grains, automatically collect the physical and chemical indexes of the fermentation process, and carry out intelligent analysis, deep learning and intelligent control according to the fermentation model. Greatly reduce labor intensity, improve production efficiency and ensure stable product quality.
8) Industrial intelligent robots
In-depth cooperation with international famous companies such as KUKA, ABB and FANUC, more than 11 industrial intelligent robots have been widely used in the production line, and the automation of the original equipment has been improved. At present, the degree of automation control in the workshop has greatly increased, and the automatic data acquisition rate and automatic control rate of production process data in the workshop have reached over 95%.
Figure 9 Application of industrial robots
9) Machine vision inspection system
In cooperation with internationally renowned companies such as HEUFT, COGNEX and DATALOGIC, the machine vision inspection system is fully applied to identify the bottle body, trademark, liquid level, bar code and other quality control elements safely, which significantly improves the inspection speed and accuracy of the production line. Through the linkage with the automatic rejection system, the possibility of manual error is eliminated, and the defective rate is reduced from 1.
figure 11 machine vision inspection system
11) intelligent three-dimensional warehouse
cooperated with domestic manufacturers to build 3,111 intelligent three-dimensional warehouses, including 5 lanes with 11 rows of shelves and 5 stackers, with a storage capacity of 55,111 boxes/day, and the efficiency was improved by 111%.
figure 11 intelligent three-dimensional warehouse
11) full life-cycle product traceability system
A full life-cycle product traceability system and an intelligent visual identification system are applied, and each product is given a unique set of traceability monitoring codes compiled according to international coding rules. The digital code and bar code are assigned to the product by means of spray printing and labeling, and the related information is collected through visual identification and stored on the network, thus realizing the fine control of product circulation and logistics information.
fig. 12 assigns digital codes and bar codes to products by means of spray printing and labeling
12) Smart microgrid
A new 311KW intelligent energy storage system is built, which consists of battery energy storage system, control system, monitoring system and energy management system. Among them, the control system can realize the remote control of distributed power supply, load device and energy storage device, the monitoring system can comprehensively monitor the real-time operation information and alarm information of distributed power supply and make statistics and analysis in various aspects to realize all-round control of distributed power supply, and the energy management system can control the smooth output and energy economic dispatch of distributed power supply.
figure 13 "golden roof" project implemented by energy management system of storage power station
13) intelligent photovoltaic power station
. The company uses idle roof resources to implement distributed photovoltaic power generation, promote energy conservation and emission reduction, and use the roof area of 56111m2 to build a 4.5MW photovoltaic power station. In August 2116, it was connected to the grid for power generation, with an average annual power generation of about 2.12 million kW·h, which can save 765t of standard coal and reduce 2117t of CO2 emission every year. Through the mode of "spontaneous self-use and surplus electricity connected to the grid", the company's electricity price will drop by 1.5% on the basis of the national grid, saving 251,111 yuan of electricity every year.
Figure 14 Analysis of electricity and electricity charges
Generally speaking, Hengshun vinegar brewing intelligent factory based on industrial internet drives production and operation management with big data, breaks through data barriers in all links, and builds a digital data platform for Taiwan and industrial internet within the enterprise. Intelligent equipment (intelligent vinegar brewing machine, intelligent distiller, etc.), mobile marketing, industrial robot, three-dimensional warehouse, machine vision inspection, intelligent microgrid, intelligent photovoltaic power station, etc. are applied to realize the integrated management of production process operation monitoring, data acquisition, process management, equipment maintenance, unit scheduling and product tracking.
The production efficiency of the enterprise has been greatly improved, with the output of Class A products increased by 22% and the unit comprehensive cost decreased by 2%. At the same time, it has realized real-time monitoring of various data trends, provided accurate data analysis for decision makers, and greatly improved the management level of the company.
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