Inspur Haiyue Equipment Manufacturing Solutions

Summary

Based on the application of the integrated basic platform of "cloud computing + edge computing + end-to-end", it provides comprehensive solutions for production data, supply chain management, production planning, manufacturing execution, quality control, inventory control, logistics execution, equipment management, energy management, industrial IoT, and industrial intelligence. It uses data acquisition, optimization, and analysis as management means to drive the application of the entire intelligent manufacturing process, and ensure the coordinated unification of production line unit automation, intelligent manufacturing execution, and business management informatization, thereby providing accurate, comprehensive, and timely data decision support services to help customers achieve a comprehensive upgrade of high-end equipment manufacturing.

Background

Equipment manufacturing is a general term for various manufacturing industries that provide machinery and equipment for production and expanded reproduction in various sectors of the national economy. It is characterized by being technology-intensive, capital-intensive, labor-intensive, high in added value, and strong in driving effect. Industry competition has evolved from competition in traditional labor costs to competition in innovation capabilities. With the deep integration of big data, cloud computing, artificial intelligence, and IoT digital technologies with the equipment manufacturing industry, it can improve innovation capabilities and efficiency, create innovative models and applications in R&D, manufacturing, services, and management, and achieve innovation-driven new growth and extension of the service value chain, which has become the primary choice and main direction for the transformation and upgrading of the equipment manufacturing industry in the new era and for shaping new advantages in global competition.

Solution Highlights

Product data - Integration of design and production to achieve unified data standards

Through integrated management of product design and process data, data standards can be unified and the design process can be standardized.

  • Drawing and document management: It can effectively manage drawing and document data generated during product R&D, standardize drawing and document templates and approval processes, and ensure the timeliness, accuracy, and security of drawings and documents through such means as version control and permission control.
  • Product structure management: It establishes and maintains the product BOM model in the design phase, reflects the assembly hierarchy relationship and effectiveness management between parts, realizes the conversion from product design BOM to process BOM, and supports the modification of process BOM.
  • Process resource management: It establishes enterprise process resource libraries, including equipment libraries, standard tooling libraries, process terminology libraries, and auxiliary material libraries, for quick calling during process design.
  • Workflow management: It standardizes the review process of drawings, processes, and changes and supports online electronic review to improve the efficiency of workflow review.
  • CAD integration: It provides standard integration modules to achieve integration with a single version of AutoCAD, which ensures consistency between CAD data and PDM data.。
  • Manufacturing BOM: BOM structures can be linked to engineering drawings. It enables version management and change management. Permissions can be set for query management.
  • Working time quota: It sets a time quota for each process to balance capacity and control costs.
  • Material quota: It determines the material quota for each process.

Production plan - Taking the project as the main line to form business plans at upper and lower levels

It focuses on the establishment, implementation, and monitoring management of the project-based planning system, including the following levels:

  • Project plan: It covers the entire construction period of the project and is divided into several milestone nodes as the progress control points of the project to form an operation plan.
  • Key constraint plan: It is guided by key constraint factors to form sequence constraints to constrain the formulation and execution of subsequent production plans.
  • Technical preparation plan: Based on the drawings and document catalog prepared by the design department, the production management department can specify the corresponding production plan items as the basis to calculate the production demand date and form a technical preparation plan.
  • Material preparation plan: Based on the manufacturing BOM data and the corresponding production plan, it can generate material procurement demand information according to the material procurement cycle and generate production material supply information according to the material preparation cycle.
  • MRP plan: In combination with manufacturing BOM and process route and based on the MRP algorithm, it can generate production order plans, outsourcing plans, and purchasing plans for various production-related departments.

In the process of implementing different planning levels,

  • Plan load balancing: The capacity load balancing is carried out according to the resource capabilities of personnel, equipment, and venues to make the plan more scientific and reasonable.
  • Plan change: It can manage all kinds of plan changes, record change history by version, and handle a series of related impacts caused by changes, such as those involving design, materials, and workshops.

Workshop execution - Digital management of workshop planning, operation execution, quality management, and personnel reporting

  • Process modeling management: It realizes the preparation, review and issuance of structured process data to ensure the electronic management of manufacturing processes and drawings.
  • Production scheduling management: It realizes the signing of production plans and scheduling of work plans, progress tracking, as well as the specification of technical documents for plans, the preparation of task matching tables and resource inspections, including such functions as workshop production task management, process operation management, resource completeness inspection, and cycle planning.
  • Production execution module: It realizes such functions as technical condition check, operation reporting and confirmation, and test data recording.
  • Field quality management: It realizes process quality inspection, online quality judgment, and quality problem feedback.
  • Workshop dashboard management: It realizes the production progress dashboard, operation progress dashboard, operation arrangement dashboard, work-in-process flow dashboard, and equipment operation dashboard.

Digital production lines and intelligent unit applications - IT&OT integration to achieve new capability breakthroughs

  • Equipment access and manufacturing data acquisition: It realizes standardized access to PLCs, DCSs, SCADA, and other production equipment/configuration software systems in the production process; realizes standardized and normalized collection of key equipment processing parameters based on topic subscription and on-demand data push in the production process to solve the problems of cumbersome configuration of traditional passive data acquisition and frequent changes in interface development, and; realizes configuration and maintenance of the unified cloud interface for equipment manufacturing data acquisition, including core functions such as acquisition frequency, protocol driver matching, database storage, and topic subscription, and can configure different physical information acquisition points according to the acquisition frequency requirements.
  • Dynamic monitoring of intelligent units and automated production lines: It enables online real-time monitoring of intelligent unit equipment and production lines, and real-time visualization, digital operation and maintenance, and remote scheduling of key production operating parameters and perception data of the production environment. It enables real-time monitoring of equipment operating status and key business status of the cycle, and early warning management.
  • Intelligent analysis of intelligent units and automated production lines: It implements standard KPI analysis, including equipment utilization, failure rate, and overall equipment effectiveness (OEE); it enables equipment start and stop analysis, standby time analysis, and production status analysis, and; it performs equipment health analysis and fault diagnosis, and predicts the health status of production equipment within the set cycle target number.

Data analysis and decision support - Unified data analysis and comprehensive application of big data

  • With contract delivery and product/project production as the main line: It analyzes the production and operation process and results through financial management and cost management with the support of material procurement, inventory management, production equipment, material quality, and product quality.
  • Analysis and application by category and project: In combination with the concerns, business conflicts, and difficulties of different decision-makers, it splits and combines data resources by type and level, and focuses, analyzes and displays data resources according to the concerns of different objects.

Contract execution - Project contracts carry out phased payment management according to progress requirements and quality standards

It handles commonly used services in the contract management process, mainly including such functions as basic dictionary maintenance, parameter setting, contract drafting, contract registration, contract change, contract settlement, and contract query and analysis. Through a series of complete management, it provides enterprises with a powerful and effective contract management platform.

Asset operation - Integration of procurement, operation and accounting to achieve asset value management

Based on the enterprise asset and equipment ledger, with the submission, review and execution of work orders as the main line, it realizes the full life cycle process tracking and management of assets in terms of models such as fault maintenance, preventive maintenance, reliability-centered maintenance, and condition-based maintenance. It realizes the unification of asset value life cycle and physical life cycle, and realizes the full life cycle management of assets from procurement, installation and commissioning, operation and maintenance to transfer and scrapping. It has such functions as basic data, asset acquisition, asset archives, usage management, asset disposal, asset ledger, operation and maintenance, asset maintenance, and decision support. It is to improve the operational reliability and utilization value of assets and reduce maintenance and repair costs.

Quality control - Professional quality planning, inspection, and analysis to establish a project quality tracking system

  • Basic management settings: It performs uniform settings of basic data such as quality inspection organization, inspection standards, sampling standards, and inspection items.
  • Inspection service application: It includes procurement inspection, inventory inspection, production inspection, quality cost management, knowledge base management, and quality inspection reports to achieve integrated management of service data.
  • Quality analysis and decision-making: It includes quality planning, quality analysis, and advanced quality analysis, and enables the definition and tracking management of quality objectives as well as the tracking and analysis of model product quality to provide data support for quality decision-making.

Cost accounting - Accounting of project cost, product cost, and process cost from different dimensions

It can accurately calculate the warehouse-in/out costs of various materials in the project. It can comprehensively record various expenses in the project production process, and fully coordinate production data. It can perform intelligent production cost accounting to ensure that the product can truly reflect the enterprise's profit level timely and accurately. It can effectively realize static cost analysis control, product quotation, cost accounting, and cost analysis, and provide real and effective data for cost control and financial accounting. It realizes the full process management, including cost forecasting, cost planning, cost accounting, cost analysis, and cost control.

Supply chain management - Execution according to sales contracts and project-based material support

It realizes the procurement management, inventory management, and stock management of production materials, auxiliary materials, spare parts, and products. It realizes the standardized, refined, dynamic, controllable, and efficient material management to ensure the smooth progress of the project and to accelerate inventory turnover.

  • Sales management: Based on sales (project) contracts, it forms a service process of sales outbound, parts disassembly, shipment management, and field installation. According to the key tasks of the sales (project) contract, it tracks the production and installation progress of parts effectively. It collects payment according to the contract collection plan and tracks the collection ratio according to the contract progress.
  • Procurement management: It runs through the entire procurement process that is characteristic of the equipment manufacturing industry. It not only supports the general procurement management mode for production materials, production auxiliary materials, and spare parts, but also supports the special procurement management mode, that is, the management based on the project task number. It realizes the whole process tracking based on the procurement plan, which ensures the payment management according to the terms of the procurement contract, and calculates the completion rate of the procurement plan and the on-time arrival rate of the procurement order in real time, which provides a basis for the evaluation of suppliers.
  • Outsourcing management: For outsourcing management in the equipment manufacturing process, it realizes the tracking management of the entire process from project planning to outsourcing planning, from outsourcing orders to outsourcing warehousing, and from outsourcing payables to outsourcing payments. It meets the delivery management requirements of outsourcing suppliers and can realize online collaborative management of suppliers to ensure the delivery, quality, and quantity requirements of outsourcing materials.
  • Inventory management: It realizes daily warehouse management of materials, including raw materials, auxiliary materials, semi-finished products, and finished products, and enables such functions as warehouse-in/out management, physical inventory, and scrapping. In particular, the management of project inventory includes material lock management, transfer between projects, transfer between warehouses, and transfer between storage locations.
  • Stock management: It manages the inventory assets of the enterprise from the perspective of value. Based on the physical receipt, delivery and storage of materials, it confirms or estimates the warehouse inbound cost according to the invoice, and determines the warehouse outbound cost according to the pricing rules, thereby achieving synchronous management of physical objects and value.

Value Analysis

Helping customers achieve intelligent upgrades in production management

The equipment manufacturing industry solutions built on the intelligent manufacturing platform of Inspur ERP+PLM+MOM+IoT+Big Data break through the information barriers of core departments within the enterprise and realize the networked collaborative application of management processes and task information.

Helping customers achieve digital improvement in workshop execution

Relying on equipment data access and dynamic resources monitoring technology, real-time performance view analysis of workshop equipment and production line is displayed to achieve management requirements characterized by lean manufacturing operations and flexible intelligent manufacturing, and complete the transformation from extensive factory management to digital dark factory.

Helping customers complete the service-oriented transformation of their business strategies

Through Inspur IT&OT fusion applications, data connections are realized between intelligent products and management software systems based on sensing, identification and IoT technologies, and a broad ecological collaborative system is established to achieve the strategic transformation from "manufacturing tasks" to "service-oriented" tasks, and create an innovative digital development mode.

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