First, the emergency of masks, forehead temperature gun, mask machine, melt spray cloth, respirator and other epidemic prevention materials, the Bank's enterprises to expedite the production of other leading automation degree of enterprises across the border to support, BYD, SAIC-GM-Wuling, GAC Group, and many other enterprises are involved in the manufacture of masks.
On the other hand, the whole network cloud with goods is emerging. Netroots e-commerce companies have changed the shopping habits of consumers, but also changed the way the supply chain, the degree of small single fast reaction further deepened. Increasingly fierce market competition, forcing enterprises in various industries to break the routine, and actively looking for a way out.
One side is cross-border, one side is transformation.
A **** nature is that the impact of the epidemic can quickly complete the production line switch, or quickly adjust the strategy of the enterprise, most of the advanced automation, digitalization, intelligence level, behind which lies a can be called "flexible production" ability.
For example, BYD, on February 8, officially announced the deployment of resources to aid the production of masks. By upgrading the purification level of the ready-made cell phone assembly production workshop, we can easily have a clean room for the production of masks; through the various types of high-precision equipment in use and professional technician reserves, we can complete the research and development and manufacturing of the mask machine within seven days. BYD's speed, is in less than half a month to realize the mass production of masks and climbing, and now the daily output reached 50 million, jumped to become the world's first production capacity.
For example, Huichuan technology, when the understanding of the N95 mask machine debugging operation has become a major problem for equipment manufacturers (some manufacturers hard to buy back the mask machine, debugging half a month or not normal production, the most nervous outside the debugging engineers offer has soared to 100,000 yuan for 1 day), and then quickly launched a full servo based on the Intel hardware and software platform of the N95 mask machine electromechanical solutions The solution is based on Intel's hardware and software platform, which reduces the debugging workload of the equipment by about 1/3 and helps the customer save tens of thousands of dollars in debugging costs. The important thing is that the mask machine less running day, less production day mask, time is the most valuable.
The tide fades to know who is swimming naked. Perhaps the sudden epidemic mercilessly scrubbed a number of lack of crisis response ability of manufacturing enterprises, survived the players to see more clearly "flexible" to bring the charm of empowerment.
The full text is long, mainly from four points to develop:
1, to soften the hard.
2, flexible production charm geometry?
3, flexible production needs?
4, flexible production changes what?
1, to soften the rigid
There are soft and rigid, rigid production appeared earlier, refers to the product in a large-scale way of mass production, mainly used to meet the needs of society on a large number of industrial products.
In a rigid production environment, the market as a whole is in short supply, and as long as a product can be produced, it will definitely be sold. Just like the 1950s to the 1980s, the domestic popularity of "food stamps, cloth stamps", the lack of supplies, but also what the bicycle?
The most typical case of rigid production comes from Ford Motor Company.
In 1908, Henry Ford made a strategic decision to build an affordable automobile that would meet the needs of the masses.
In 1913, the world's first automobile assembly line appeared in Ford's factory. This batch assembly process allowed the time, cost, and resources required to produce automobiles to be dramatically reduced, while production efficiency was dramatically increased.
By 1927, Ford had produced 15 million Model T's in one ****, propelling the automobile from a luxury item to affordable transportation for the general public.
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Ford Model T
To put it in a more intuitive example, in the past, a clothing factory only needed to make a few models a year to easily support a large family, even if they walked down the road with a high rate of collision, the consumer is still willing to pay.
But along with the upgrading of the consumer structure, the downstream demand is weak, the seller's market has gradually become a buyer's market, rigid production lack of personality, cost waste, slow response time and other shortcomings gradually exposed.
Especially in some areas of manufacturing enterprises in the face of consumer personalization, customization, timeliness and other requirements of the step by step, found to meet the "diversified, small-scale, controlled cycle" of the flexible production model, will be the key to future survival and victory.
As in the garment industry, behind the live fire, is the textile supply chain is under pressure, they must adapt to the definition of flexible production of small orders under the rhythm of fast reaction, in order to have the opportunity to accept more orders and customers.
"A sample garment to take over, if this factory half a day to do not come out, do not use them, anyway, the Yangtze River Delta garment factory is much." A person who once helped the anchor docked the factory said so.
2, flexible production charm geometry?
In contrast to rigid production, flexible production gives the most intuitive feeling of "fast, diverse".
In the industry, flexibility is defined as two aspects:
First, the production capacity of the flexible response capability, mostly refers to the production capacity of small quantities of machinery and equipment.
The second is the agility and precision of the supply chain to respond, from the traditional "production to sales" model to "sales to production", requiring manufacturers to respond in a timely manner.
For example, yesterday the factory had two production lines to produce the A series, two production lines to produce the B series; today the A series needs to be increased to three production lines to be able to deliver according to the volume, the B series needs to be reduced to open only one pull line.
A, B series of different processes, to use the equipment, jigs and fixtures, processing procedures and parameters, and even operators are different, at this time, if the flexible production can be achieved to the extreme, that is, regardless of the scheduling plan how to change, can quickly complete the production line to adjust the production line without having to stop production and change the line.
Another example of customization according to customer demand has been the trend, cell phone shells can be customized, Tsingtao beer can be customized, Haier refrigerators can be customized ......
I once contacted a well-known domestic industrial control enterprises, self-reported that they are often through a small batch of diverse ways to sell products. The company's more than 4,000 product models, any one of which can be ordered in accordance with the minimum batch size of 30 units, the production line can be changed at any time, and to ensure delivery time.
Overall, flexible production is able to respond to internal or external changes in a timely manner, with the ability to switch between production varieties quickly and cost-effectively, and to precisely adjust production capacity to align with market demand, avoiding undercapacity or overcapacity.
It is important to emphasize that flexible production has its own field of application, and is not a basket of slogans to achieve barbaric development.
Its model is generally applicable to the variety and quantity of changes in the enterprise, or although the variety and quantity of changes is not fast, but the product sales have a clear off-peak season of the enterprise.
Like the Netherlands ASML such a monopoly in the field of photolithography, the sale of only 26 units of extreme ultraviolet (EUV) photolithography equipment in the whole year of 2019 can also make a fortune, and there is no need to talk about flexible production. But in areas like automotive, 3C, and home appliance manufacturing, flexible production capacity is the biggest competitive weapon.
In addition, the promotion of flexible production does not mean that the abandonment of rigid production, rigid production standardization, process characteristics, in today's still have an important place.
3, flexible production needs?
Flexible production is not proposed today, talking about it, the industry will generally mention 2 important arguments:
1, flexible production of customization does not mean the elimination of standardization, flexible production is a building block production.
According to the consumer's individual needs to achieve customization is indeed the trend, but flexible production to do is definitely not unlimited customization.
In the words of Mr. Steve Jobs, "Consumers don't know what they need until we come up with our own products, and they find out that's what he wants."
Flexible production requires manufacturers to guide customers in sorting out their needs, rather than letting them run wild and free.
Although from the realization of the difficulty, unlimited customization is not impossible, but the biggest problem is that the cost does not allow ah, which is not in line with the nature of business.
Therefore, today's emphasis on flexible production, emphasizing the customization of manufacturers, should still have the ability to modularize product design, standardization, can be simplified as much as possible into a number of compatible and replaceable functional modules, what you need to spell out what, so that you can quickly create a diverse range of products.
2, flexible production with automation and unmanned as the key features.
Take the previous hottest N95 mask production as an example, because the degree of flexibility is not enough to encounter many pain points.
For example, the hard work to buy back the mask machine debugging high cost, low efficiency, affecting the production line start.
The reason for this is not only related to the advanced degree of the equipment itself, but also with the complexity of the mechanical structure of the equipment, the debugging process is cumbersome, and the technical requirements of the master workers are high.
In particular, the stamp and cutter phase synchronization and send the nose strip and push the nose strip of the mechanical action sequence, generally at the same time need more than one debugging masters to cooperate and repeated attempts to achieve the debugging requirements.
Another example, the traditional quality inspection process, such as detecting whether there are foreign objects on the surface, the flatness of the nose bridge and sponge strip, the width of the sealing edge and the spot welding status of the earwires, etc., the judgment standard is taught by the production line workers by word of mouth, although it works, but it is also rough, because people will always be wrong to check and omit the inspection of the case. In order to prevent errors, can only be more processing bits, a few more people to detect, but this is a waste of cost.
In contrast, Sany Heavy Industry's "Plant 18" is very famous in the industry for flexible production.
The biggest feature of the 18th plant is that "all links are automated, information technology, only in the key position to increase human intervention.
According to the information in 2017, a production line can produce 5 to 10 models, and the whole plant can realize the flexible production of 69 kinds of mixed products. Compared to the usual one traditional production line can only produce one or two models, it can be said to be a leap forward.
The benchmark is already there, how can we be like it?
Simply put, we believe that flexible production can be considered from 4 links, which will involve the understanding and application of emerging technologies such as the Internet of Things, big data, cloud computing, and artificial intelligence.
01, perception: through the deployment of sensors, cameras and other hardware, so that the production line has the ability to obtain data;
02, analysis: after the data is uploaded to the trusted cloud platform, it usually forms a real-time monitoring system screen with interactive capabilities, which is used to understand and analyze the data.
03, decision-making: through the modeling of data, enabling machines with the ability to reason and analyze, the simple decisions or instructions to the machine to do.
04, implementation: flexible manufacturing is based on the automation of equipment and production lines, the degree of automation will greatly affect the flexible production space, is the real realization of fast, efficient production requirements of the important guarantee.
4, flexible production has changed what?
A thousand good, bring considerable benefits is really good. Specifically, it must be cost savings, efficiency improvements.
Or use the above mentioned Huichuan Technology N95 mask electromechanical solutions as an example, see what changes flexible production actually brings?
01, the program adopts the full servo drive mechanism, electrical transmission instead of mechanical transmission, to solve the mask machine production line debugging difficult to deliver the slow problem, reducing the debugging workload of the equipment about 1 / 3.
02, the program adopts the industrial Internet of Things remote operation and maintenance, so that the equipment on the cloud, to achieve the production line level and factory level monitoring, to improve the efficiency of fault detection;
03, the program adopts the machine vision QC + corrective system, the introduction of a full range of deep learning technology, in the source section, the shipping section, etc. to achieve the defect detection of the machine-for-human style, to improve the efficiency of quality control.
Technical realization, this system is based on Intel X86 processor, combined with OpenVINO? graphics processing acceleration tools developed. The whole system deploys multiple industrial cameras in four different production stations of the mask production line, capturing the product status through images and transmitting them to Huichuan's Intel Core i5-based processor. Kinovision, a high-performance computing platform based on Intel Core i5 processor, conducts online training through the edge training server and performs real-time inference operations based on the trained model, thus ensuring the accurate effect of defect detection.
In terms of implementation effect, it can achieve the detection volume of 150 pieces of masks per minute (150pcs/m), and at the same time, it can realize 99.98% accuracy, and on average, while reducing 2-3 inspectors per production line, it can still ensure 24x7 non-stop production.
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Splendid Folding Stereo Mask Machine Vision Inspection System
It is worth mentioning that machine vision is becoming one of the necessary forms of industrial transformation and upgrading. OpenVINO is a toolkit launched by Intel for rapid development of high-performance computer vision and deep learning applications, hoping to give full play to its strengths in the fields of artificial intelligence and heterogeneous edge computing. Give full play to the advantages to help enterprises quickly deploy capacity, efficient and flexible production.
5, the road will be winding, but the direction is right
Early a few years ago, the industry talked about analyzing the flexible production of the article there are a lot, but recently it is slowly becoming less.
For no other reason, the positioning of flexible production has gone through the expectations of the actual peak period, is currently in the recovery of rationality, looking for a way out of the stage. On the one hand, the concept has to be said, the market has to be cultivated; on the other hand, customers are more eager to see mature and stable flexible production solutions.
Now the new infrastructure concept is on fire, the importance of the industrial Internet was mentioned again and again, the market demand is more and more unpredictable ...... but everything has to go forward, flexible production in front of the waiting to be more understanding and application, who first touched, there is a greater opportunity to ride the wind and rise.