School of Machinery and Automation, Wuhan University of Science and Technology, Xie Liangxi E-Works Li Xiang 2003-3-31
Keywords: information technology MES steel abstract: Information technology is vigorously promoting industrial automation and management of modern revolution. The steel industry has always attached importance to the automation control of the production process; in the management information, the management information system represented by ERP has also begun on the steel enterprises in the steel enterprises in recent years. However, there is a digital divide between process automation and management informationization, resulting in management of the management of the production of tightly combined, ERP and other management automation systems, even causing the ERP system failure. The production and manufacturing implementation system (MES) developed in the middle of the 1990s is an indispensable means of opening this bottleneck. With the flattening of operating management, MES is becoming an effective integration of enterprises to achieve production activities and operating activities, optimize operation, optimization control and optimization management bridges and links, is one of the important technologies that improve corporate competitiveness. The new feature of the steel industry is one of the pillar industries of my country's national economy. It has made a positive contribution to the sustainable development of the national economy. The current production and operation environment facing the steel industry has the following characteristics: according to orders, more Variety, small mass production is the development trend of the steel industry, the steel industry is originally used in large-scale mass production. In the past decade, the market competition environment facing steel enterprises has changed huge changes. The customers have more and more demand for steel varieties, specifications (such as the width, coating and mechanical performance indicators, etc.), and more customer demand Variety, small batch characteristics. Under this situation, the prediction of the steel enterprises to user needs is more difficult. In order to reduce stocks, cost savings, the most effective operational strategy is to change traditions to push systems that predict the spindle to with demand programs ( Demand Planning) is a pull system of the spindle. Enterprise production will reduce predictive production, which is mainly based on order production (MTO); production model has also been changed from a large number of production methods to multi-variety and small batches. In this production mode, the company's sales department should know very well about the production department, master the real-time data of the production line, avoid signing the unreasonable contract, avoiding the problem of contract prices below production costs, the delivery period is not guaranteed; The dispatched personnel must be able to grasp the historical situation and current data in time, which makes it easy to combine small orders according to actual capacity, and formulate scientific and reasonable production scheduling programs, scientific command and coordination of the production sector; and the production department also needs to master the current Order case, production planning command, can quickly and accurately arrange the production of teams according to the sales contract and dispatch plan. Strengthening cost management and comprehensive scheduling is an inevitable requirement of the survival and development of the steel industry. In the current market competition, the price factor has become an important factor in product competitiveness. Overall, steel products have been changed by the past supply to be converted into large than seeking, and product profits have been greatly diluted. Steel companies must enhance cost management while ensuring product quality and delivery, allowing products to get appropriate profits in the low price. To reduce product costs, effective methods are to strengthen comprehensive monitoring and scheduling on raw materials, coal water and electricity and personnel. First, we must strengthen accounting, fully collect real-time data related consumption, and create a reasonable assessment indicator for relevant data; the second is to strengthen comprehensive dispatch management, so that the existing resources are maximized; the third is to strengthen the production site Integrated management, reducing the subprinted waste and unnecessary loss, avoiding ineffective labor; in addition, try to produce, reduce product inventory, reduce the unreasonable occupancy of funds.
The decision-making efficiency of improving business management is the necessary means of enterprise. During the management process of business management, often face various difficult decisions; and the market fluctuates frequently, the opportunity is fleeting, if business managers can't make quick decisions, even if they can eventually It is also possible to sit in the right decision. Therefore, in a fierce market competition, business management decisions must not only ensure correctness, but also have certain timeliness. The example of business management personnel needs to make a difficult choice, for example, it is assumed that the economy of enterprise refining a furnace steel is 500 tons, apparently if only 300 tons of the company are smelted, due to the time of occupating equipment and human resources, there is no corresponding proportion Reduce, resulting in a significant increase in unit cost. At this time, if there is a user just just order 300 tons of products, the company's sales personnel face this option: Do you undertake this order? How should I quote if I get it? How to determine delivery date? Obviously, if the business decision maker wants to make decisions quickly and accurately, in addition to the need to master a large number of basic data, it is necessary to ensure the authenticity and timeliness of these basic data, on this basis, the analysis and judgment can make correct decision. In the above example, corporate salesperson needs timely grasping other relevant orders, production lines, and the current production plan, corporate production capacity status, etc., in the basis of comprehensive analysis, it can eventually make reasonable decisions. The status quo and characteristics of the steel industry and its characteristics "Promoting industrialization" is an inevitable choice for manufacturing to improve production and operation. my country's steel industry has gradually implemented basic automation and process automation in the long-term information application process; in terms of management informationization, it has achieved certain results from the initial simple MIS system to ERP / e-commerce. The informationization characteristics of the steel industry is that the basic automation and process automation bases are good for the growth of the steel industry, many links, complex process, and automation technology applications. Since the 1990s, the steel industrial automation applications have been expanded, and the application level is continuously improved, and the digitization is increasing. Specifically, the device control grade has a large number of DCS, PLC; in detecting driving level, various smart tables, digital sensors, and full-digital AC transmission devices have been generally applied; process control is widely used in small machine-based automatic control systems . The traditional "gauge, electricity, instrument" division of labor has no longer obvious, and the application of computer technology has been in depth. For example: in modern blast furnace control, electrical control system, instrument control system, communication system is being replaced by the integration system of the integrated loop adjustment, sequential control, transmission control, and multimedia. Some large PLC manufacturers, DCS manufacturers have extended their respective functions to each other, and even the robots, artificial intelligence controllers, etc. are also used as part of the system. On the human-machine interface, the console of various functional uses is also replaced by the same model hung in the same web integrated MMI. Intelligent control technology is widely used. Such as blast furnace smelting expert system, fuzzy-controlled electric arc electrode improvement system, using neuronal networks, co-casting steel forecasting system, hot furnace fuzzy control system, steel cooling intelligent control system, etc., is applied in practice It has achieved better application results. Although the specific automation of different steel companies is different, from the entire industry, the basic automation, process automation is widely used in steel enterprises, and gradually deepends with the development of automation technology. The company is increasingly paying attention to the construction of the construction of the steel industry in the long-term information practice. It has gradually recognized that the process automation of the unit equipment or production process is very important to enterprise production, but it is more important for enterprise development. Improve the level of management.
How to give full play to the company's production capacity, reduce the consumption of energy and raw materials, and rationally allocate human resources and production equipment to maximize the company's existing human resources and equipment to maximize its role, and steel companies need to focus. problem. Iron and steel companies have recognized the major role of management information, recognizing realizing corporate informationization, the most important thing is to achieve management information; management information is more than just ERP / CRM / SCM and other management software applications, but also promoting enterprises Important means of management. Guo Yucheng, the total control room of the Capital Iron and Steel Group, said: "Shougang regards informationization construction as a breakthrough in comprehensive promotion management progress." Dr. Wang Baiqing, Wang Baiqing, Baoqi Group, Baixin Software Co., Ltd., said: "Iron and steel industry should implement information Chemical, three-point technology, seven-point management. "Based on this understanding, a large number of steel companies represented by Baosteel, Shougang and Wugang, do not hesitate to invest in the management information system, and began to implement ERP / CRM / SCM and e-commerce Representative business management information system. There is a digital divide between the process automation and management information system. It should be seen that although the steel industry has basically realized basic automation and process automation, these automation systems are detected and controlled by unit production equipment, and the production equipment Form a lot of "automated and disadoles". This type of "automated and canal" model lacks the unified management of information resources and the unified management of production process, which is difficult to adapt to the requirements of modern steel production. The MIS / ERP and other management information systems itself is difficult to interface with the base automated system and cannot automate production data. And these management information systems are actually depends on the actual data generated during the production and operation of the company in conducting production management plans and decision-making. If there is no data generated in actual production, ERP is difficult to obtain convincing results through operation and analysis, and the application effect of ERP and other management information systems will be greatly reduced. In order to facilitate the ERP system operation, the actual operation has to be passed through the paper report, and then entered into the management information system by the relevant user. Thereby forming such embarrassing sites: On the one hand, a large number of control and detection data have occurred during the production process, which can be stored in electronic format; but cannot be automatically passed to the management information system. On the other hand, the management information system requires a large number of data, and there is only to transcribe, print, print, information transfer in paper media in the form of statements; after receiving paper reports, the relevant departments are manually entered. Similarly, data such as management information systems is urgently needed, and cannot be automatically transmitted to the production control system, but data transmission is performed by paper. The drawbacks of this approach are that a large number of data can be transmitted and re-entry, and it is possible to cause data inaccurate because the operator is unintentionally or intentional; due to data, the efficiency is relatively low, the data lags obtained In actual production, seriously affect the effectiveness of basic data, the consequence is that the management information system cannot be related to the production and operation of production and operation in time, which seriously affects the use of ERP, and even does not trust the applicant's ERP system. This situation shows that there is still a significant digital divide between the basic automation and management automation in the enterprise information system. MANUFACTURING EXECUTION SYSTEM, which is gradually developed in the 1990s, can achieve effective integration of enterprise production activities and business activities, becoming optimized operation, optimization control and optimization management bridges and links, is worth One of the close attention of steel companies. Mes' bridge effect MES is an abbreviation for Manufacturing Execution System.
The International Federation is defined for MES as follows: MES optimizes management throughout the production process to the product completion from the production command through the delivery of information. When there is a real-time event in the factory, MES can respond, report, and to constrain them with current accurate data. Specifically, MES is in real-time monitoring, diagnostics, and control, completing unit integration and system optimization, completion unit integration and system optimization, completion unit integration and system optimization, completion of the process layer (rather than management) in real-time database or non-real-time relational database. Live material balance, arrange production plan, implement dispatch, production, and optimization. Further, the material stream, energy stream, mass flow and capital flow, data streams are monitored, and the four major elements are fully monitored, analyzed, controlled, and optimized. As can be seen from the above definition: 1MES's optimization goal is the entire production process. 2MES needs to collect a large number of real-time data during the production process, and process the real-time events can be processed in time. 3MES requires both the planning layer and the control layer to maintain two-way communication capabilities, from the upper, lower two layers, receive corresponding data and feedback processing results and production instructions. MES as the core of the production management system is a bridge between the production enterprise process automation system and the management information system, and there is a close data exchange relationship between the relevant systems (Figure 1). ERP system requires actual production data provided by MES, manufacturing cycle, and estimated output time, etc .; SCM takes the actual state of production orders from MES, and the current actual production capacity of the company, and the mutual constraint relationship of production shifts in the enterprise; CRM; The successful quotation of the module and on-time delivery are determined at the actual situation of each time, so it must be closely related to MES; process control needs to optimize the process parameters of the product based on MES; and the basic control module must be from MES Take the control data or operation steps. On the other hand, MES also takes the data needed from other systems that ensure that MES is operating normally in the factory. For example, ERP's planned data is a basis for MES for production scheduling; SCM controls the development of production plans and certain parts in the factory in the factory; specific customer requirements in CRM purchasing orders; It is an important basis for guiding factory production; the real-time production status data from the control module is used by MES for judgment of actual production performance evaluation and operating conditions. MES is the management problem facing the steel industry informative construction, and promotes the application of the informationization of steel industry; while the Iron and Steel Enterprise Informationization, MES is an important bridge between production automation and management informationization. From the actual production of the steel industry, the most effective function of MES is data acquisition and delivery, in addition to this, usually have the following functions: field data acquisition and process handling the various necessary data information in the production site, For example, each control point temperature of the converter; the number of feeds; steel sheets that are rolling, and the like. Instant analysis processing, monitor production processes, and automatic correction of errors in production, monitoring the efficiency and quality of processing activities, or provides warning or correction measures to operators. The MES system will monitor the production status of the work, convenient for the order execution; record all normal data in the production process, including the data in the event of a fault, convenient for future quality traceability. Equipment maintenance management of real-time monitoring equipment operation and load, and generates the phased, periodic and preventive maintenance plan of the equipment, and responds to sudden failures, providing fault diagnosis support; record equipment historical files and spare parts management It is convenient for optimization management and maintenance to the equipment. Production plan management is based on the monthly production plan and order information of ERP, prepares detailed week, day offers.
