MPDV MES成功案例-上海鷹峰
【概要描述】
關(guān)于鷹峰 / About EAGTOP
上海鷹峰電子科技股份有限公司是以專業(yè)研發(fā)、生產(chǎn)電力電子無源器件為發(fā)展方向的高新技術(shù)企業(yè)，是國內(nèi)領(lǐng)先的無源器件解決方案供應(yīng)商。主要產(chǎn)品有薄膜電容器，電抗器，疊層母排，水冷散熱器，相變熱管散熱器，電阻器等。電容器的生產(chǎn)工藝包括卷繞、噴金、熱處理、賦能、焊接裝配、真空灌注、老化測試、成品檢測和包裝。
Shanghai EAGTOP Electronic Technology Co., Ltd. specializes in researching, developing and manufactures passive power electronic devices as a leading solution provider in China. The product portfolio ranges from film capacitors, reactors, laminated busbars, liquid-cooling radiators, 3D phase change heat sinks and resistors. The typical capacitor manufacturing processes consist of winding, metal spraying, heat-treatment, charging, wielding, vacuum dosing, aging, final inspection and packaging.
引入HYDRA MES的背景 / MES Hydra introduction background
為了滿足客戶質(zhì)量控制要求，鷹峰管理層決定在2014年底引入MES系統(tǒng)。同時也希望通過應(yīng)用MES來打開生產(chǎn)現(xiàn)場的黑盒子，以提高生產(chǎn)效率。與許多傳統(tǒng)的中小型民營企業(yè)一樣，鷹峰選擇相對來說初期投入比較低的國產(chǎn)定制化MES軟件，以滿足最基本的生產(chǎn)數(shù)據(jù)采集和追溯需要。然而，定制化軟件的不利之處在實施過程中已經(jīng)暴露出來，即實施周期比較長，廠商總是要問用戶應(yīng)該怎么做，而用戶只能提出概要的需求。故而，在實施過程中，不斷有需求變更。最終在雙方妥協(xié)下，系統(tǒng)在一年后終于上線。
To meet the growing compliance- and quality control requirements from customers and in order to improve the overall production effectiveness, EAGTOP Management decided to introduce an MES by the end of 2014. Like many small- to medium-sized private enterprises in China, EAGTOP instinctively preferred to invest less in software. In first consequence, EGTOP chose a local vendor proving with an entirely customized MES solution, given the seemingly low initial cost. The disadvantages of the customized MES solution soon emerged on repeated basis throughout the entire implementation period. Besides a prolonged implementation time due to time-consuming customizations, each new requirement or change request resulted in new additional delays and conflicts, due to miscommunications. Ultimately, the heavily compromised local MES solution started to go live after over one year.
2016年，隨著新產(chǎn)品的導(dǎo)入，鷹峰引入一些新設(shè)備替代原先一些手工工位，并對工藝路線和物料流進(jìn)行了優(yōu)化。另外，管理層對生產(chǎn)控制與數(shù)據(jù)呈現(xiàn)也有了新的需求。這時，他們發(fā)現(xiàn)現(xiàn)有的MES系統(tǒng)無法靈活更改，必須要投入與首次導(dǎo)入系統(tǒng)時相同的時間和成本來重新滿足新的管理需求。相當(dāng)于現(xiàn)有的系統(tǒng)等于被廢棄后重新建一套。鷹峰的管理層這時才意識到這種定制化的MES系統(tǒng)存在巨大的擁有風(fēng)險，因為他們無法預(yù)測未來管理需求的變化。他們試圖尋找一套能夠在4個月內(nèi)完成上線、靈活配置和擴展的系統(tǒng)，已滿足鷹峰不斷發(fā)展的生產(chǎn)管理要求。
In the course of 2016, EAGTOP commissioned new automated machines to replace older manual work stations. Production processes and material flows were optimized and adjusted for new products, too. EAGTOP Management expected the necessary flexibility within the existing local MES solution. Instead, the existing customized MES architecture needed to be broken up re-customized again, with a projected timeline of yet another one year. Now being aware of the inherent risk for any future changes, EAGTOP Management decided to look out for a new flexible solution that could be deployed in a lean approach in a short time frame of less than 4 months, with high configuration flexibility and expandability, to fit into the continuous growth strategy of EAGTOP.
實施 / Implementation
2017年4月，鷹峰的董事長開始和MPDV接觸，并親自主導(dǎo)了需求分析，且至始至終參與方案評審，包括系統(tǒng)建設(shè)目標(biāo)、一期功能劃分、物理實施范圍以及項目實施計劃。最終，項目在2017年5月正式啟動，7月正式上線，8月完成最終驗收。
By April 2017, EAGTOP Management engaged in relevant pre-sales activities of proposal generation, target definitions, functional & physical scope definitions, together with MPDV Shanghai, ultimately leading to a project kickoff in May 2017. Within a short time frame of 3 months, MES Hydra started to go live in July 2017, with a final acceptance and signed-off by August 2017.
主要應(yīng)用 / Main application
復(fù)雜的制造流程對生產(chǎn)管控要求非常嚴(yán)格，對于每道工序每件產(chǎn)品必須確保其工藝參數(shù)的穩(wěn)定和精確，并能實現(xiàn)完整的追溯。這是鷹峰對本次MES系統(tǒng)建設(shè)提出的基本要求。
The complexity of the production requires very strict production control. The essential requirements are stability of process values within strict tolerance limits and traceability of every single product.
系統(tǒng)集成 / System integration
HYDRA系統(tǒng)的功能完整性使得鷹峰的IT系統(tǒng)非常簡單：應(yīng)用于商業(yè)管理的Kingdee ERP和應(yīng)用于制造管理的HYDRA。而且兩個系統(tǒng)之間的集成也非?？煽?。
The broad & configurable Hydra standard function scope resulted in a very simple IT layer architecture at EGATOP: The ERP system Kingdee caters for the entire business management, whereas Hydra caters for all aspects of production. The logical interfacing model and physical interfacing process between Kingdee and Hydra turned out very reliable and robust.
Hydra采集車間現(xiàn)場的生產(chǎn)、物料批次、工藝參數(shù)、質(zhì)量和人員數(shù)據(jù)，并加以整理和分析。本期項目引入ERP系統(tǒng)集成（EIS-ERP）、生產(chǎn)訂單數(shù)據(jù)管理（BDE）、和物料追溯（MPL&TRT），過程檢驗管理（FEP）。Hydra辦公室客戶端MOC提供標(biāo)準(zhǔn)的、豐富的各類統(tǒng)計分析報表，無需任何報表方面的定制開發(fā)。
The Hydra modules BDE, MDE, MPL/TRT and CAQ capture and process the entire spectrum of shop-floor data. The Hydra standard reports in the Hydra “MOC” office client are being used without any necessary report customization.
為能夠在生產(chǎn)中以及產(chǎn)品回召時清楚知道產(chǎn)成品的追溯記錄，工人除了在車間終端AIP上登錄工序信息，在生產(chǎn)中采集原材料批次信息和生產(chǎn)工位。對于每個半成品都分配一個新的批次或單件系列號，形成批次追溯樹。如此，不僅可以反向追溯原材料批次，還可以知道相同缺陷材料的供應(yīng)商信息。Hydra提供批次樹圖和數(shù)據(jù)表兩種方式查詢追溯記錄。
Operations are logged on by the operator at the “AIP” shop floor client. All relevant information objects of order, work place/machine, operator ID, input material batch ID’s are recorded. During execution, process values and various quality characteristics are being captured. New output batches are generated along with their relevant unique batch ID’s as well as serial numbers, through real-time reporting through user-friendly transaction points on the shop floor.
Hydra的產(chǎn)品追溯已經(jīng)幫助鷹峰通過德爾福等主要客戶的審核。
The entire Hydra traceability has helped EAGTOP successfully pass the audit by their key customers like Delphi Automotive.
工藝參數(shù)管理確保工藝穩(wěn)定 / Process data control – to ensure process stability
穩(wěn)定的工藝參數(shù)確保生產(chǎn)可靠性。通過與賦能設(shè)備的集成，采集賦能參數(shù)值，并與每個元件號關(guān)聯(lián)，充分了解每個電容的過程質(zhì)量。
Stable process values ensure reliable production. Hydra captures all charging data by integrating the charging machines, amongst others, and correlates the data with captured serial IDs. Users can efficiently obtain a clear and detailed view of their production process quality.
質(zhì)量管理 – 一切盡在掌握 / Quality management – all under control
根據(jù)客戶要求采用全檢和抽檢，由產(chǎn)線作業(yè)員和質(zhì)檢實驗室分別執(zhí)行?？梢匀斯せ蛲ㄟ^接口自動匯報在線檢測結(jié)果或?qū)嶒炇覝y試值。根據(jù)質(zhì)檢結(jié)果確定該批次產(chǎn)品是否合格并流轉(zhuǎn)。由于與ERP的無縫集成，在開始生產(chǎn)工單時，檢驗計劃也隨之自動下達(dá)，使作業(yè)員及時知曉，以確保質(zhì)檢作業(yè)按時執(zhí)行。
Full inspection or sampling can be set upon customers’ request, and performed by operators online in the field (IPQC) or in separate QC labs. Inspection data is captured in Hydra both manually at shop-floor “AIP” as well as automatically via connectivity protocols. Whether a single WIP unit is allowed to pass forward into next operation is dictated by the inspection results at the predecessors. A pre-defined inspection plan contains all relevant quality characteristics to be checked, and the relevant inspection points are triggered automatically, based on the defined sampling schemes. Thus, operators never forget to conduct necessary QC-inspections.
用戶之聲 / Voice of users
董事長洪先生：集成式、模塊化的產(chǎn)品架構(gòu)有利于按需分步導(dǎo)入各種功能模塊，而無需考慮各功能模塊之間的系統(tǒng)集成。配置選項能夠幫助用戶靈活響應(yīng)生產(chǎn)管理變更。豐富的MES應(yīng)用功能讓我們無需擔(dān)心系統(tǒng)建設(shè)的滯后，和國際領(lǐng)先的MPDV合作能夠讓我們更好地把最佳生產(chǎn)實踐經(jīng)驗和先進(jìn)的數(shù)字化管理系統(tǒng)有效融合。
Mr. Hong, EAGTOP President: The integrated and modulized Hydra MES makes it possible to implement MES applications step by step by real needs, without consideration of the weary integration between individual applications. Configurability gives the right answer regarding flexibility of production changes. The very comprehensive functional scope of Hydra has eliminated our concerns whether it can meet our future demands. In our cooperation with MPDV as a leading global MES solution provider, we are now finally able to leverage on best practice approaches and experiences with digital manufacturing management systems.
生產(chǎn)總監(jiān)丁先生：引入HYDRA后，生產(chǎn)環(huán)節(jié)更加穩(wěn)定和可控，車間管理更為透明。原先的MES系統(tǒng)只是完成了數(shù)據(jù)采集功能。HYDRA系統(tǒng)不僅能夠更有效規(guī)范生產(chǎn)現(xiàn)場執(zhí)行，系統(tǒng)提供的統(tǒng)計分析信息能夠幫助我們迅速發(fā)現(xiàn)改進(jìn)之處并監(jiān)控改進(jìn)措施的落實效果。HYDRA幫助我們成為世界級制造工廠。標(biāo)準(zhǔn)的IT架構(gòu)最大程度降低了實施風(fēng)險。我們現(xiàn)在已經(jīng)準(zhǔn)備預(yù)算，將現(xiàn)在的應(yīng)用成果擴展到其他車間。此外，我們還打算在下一期同步引入設(shè)備績效管理和人員資質(zhì)管理。
Mr. Ding, EAGTOP Production Director: The production has become much more transparent so that it’s more controllable and stable with the help of Hydra MES. All shop-floor activities are standardized and manageable. Precise statistic information are timely presented to management so that the right decision can be made and proper actions can be taken. Hydra helps us to build up a world-class manufacturing environment. We are planning the rollout towards other EAGTOP shops as well as towards further Hydra function areas, namely Machine Performance Data (MDE) and Workforce Requirement Planning & Qualifications Management (PEP).
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