德语
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The mold factory is a very technically intensive place, from CAD, CAM to various processing technologies, CNC, EDM, wire cutting also includes measurement technology, and all molding technologies are also included. How to establish a platform for centralized sharing of production information? How to manage the entire production process? How to perform quality control?
What is Industry 4.0?
Regarding Industry 4.0, there are many uses and explanations, which are nothing more than using the Internet to connect everything and connect the entire manufacturing part.
So, what is the help of Industry 4.0 to mold factories?
I have worked in a very well-known company in the field of molds and manufacturing for 16 years. At the beginning, we mainly did design, and then in 2002, we received a large order. At that time, the delivery time of each set of molds was required to be 7 days, with an accuracy of mm and being interchangeable worldwide. In 2002, this task was a great challenge, and the number was very large. There was a number of 200 molds per month. The requirements for each set of molds were also a challenge in the past year, and there was insufficient personnel experience. At that time, I thought that if we follow the conventional practices, we could not achieve the boss's ideas. Since then, we have begun planning for digital factories to better reduce manpower and improve efficiency.
From 2003 to 2006, we have become the company's number one mold supplier in the world. Regardless of speed, quality, and delivery time, we have achieved a significant lead and become the standard for its global suppliers. This is a very difficult thing, but we did it.
Mold development process and technical blind spots
The mold factory is a very technically intensive place, from CAD, CAM to various processing technologies, CNC, EDM, wire cutting also includes measurement technology, and all molding technologies are also included. How to establish a platform for centralized sharing of production information? How to manage the entire production process? How to perform quality control? This is a complex industry that contains a lot of technology and content.
How to manage the process well, how to combine software automation, how to combine it with professional knowledge, and also include integrating all IO and monitoring parts to manage all machines, so as to form intelligent manufacturing.
Intelligent mold manufacturing system
1. Device network communication and data information management system
The equipment network communication and data information management system networks the entire production site and forms a basic information platform to support the functions of program transmission, online high-speed processing, breakpoint continuous transmission and other functions.
The equipment communicates and solves the transmission of CNC programs, replacing the inefficiency of paper CNC programs and manual transmission of manual programs;
The equipment is connected to the network to realize the management of data information, centralized control, and correspond to the machine tool-program-parts, ensuring the accuracy and uniqueness of the program.
The transmission of mold programs is an important link before processing. Especially for mold processing, the mold processing program is generally relatively large, and the simple, convenient, fast and stable transmission is a basic requirement for this link; especially for control systems with small CNC storage space, stable and long-term online processing is even more necessary and necessary.
2. Production planning work order management and tracking system.
Production Planning Work Ticket Management and Tracking System is an application that uses a computer to create, organize, distribute and record detailed production data, processes and work instructions. As data, information from the CAPP or MRPII / ERP / MES / PLM system can be effectively classified and managed by the system according to the actual situation on site. Managers and engineers interact to create or configure effective and reasonable electronic work orders. Through the local area network, it can be quickly distributed to all links of the production site, allowing production personnel to fully understand the production plan and production preparation information, and provide a quick and easy viewing platform and scientific basis for making production preparations on time and effectively. At the same time, our managers can also monitor the entire process of "electronic work orders" in real time.
During the production process, our production staff check the electronic work orders issued to the site through the on-site touch screen to know what the work content was on that day. For example, the operator of CNC machine tool knows what to do and how to do that day, the mold assembly personnel knows whether the assembly parts on that day are in place, and how to assemble them according to requirements. The refinement of the process flow, clearness of the route, and transparent management reduce the risks in all aspects of the processing process. For a workshop, a team, or a company, it is a requirement and a goal.
3. Tooling tool resource management system.
The tool and gauge management system we have established can uniformly manage tools and gauge in production. Starting from formulating tool and gauge orders, reviewing orders, sending and receiving orders, and then entering the tool and gauge library, it can be borrowed and used at any time and inspected regularly. The tool tools and measuring tools in the tool magazine can be seamlessly integrated with the equipment network communication and data information management system, so as to better track and manage all tool tools and measuring tools at the production site efficiently and scientifically, saving money waste caused by factors such as resource loss.
4. Real-time production data collection and equipment monitoring system.
Real-time collection of production data and equipment monitoring systems realize real-time collection of production site data. The company's database has a lot of data about the production information or process of mold production site. In other words, there are a lot of content, entries, steps, and status; the data monitored or collected digitizes these content, entries, steps, and status. For example, when does a machining center have time to start or end when it starts or ends when a certain mold, from the blank to the finished product, and how much time is used in each link, etc., will be reflected through this system. The collected data is stored in the database. In a few seconds, you can query the status of a certain stage in real time or continuously query the status of a certain stage. In the past, the management's basis for judging the mold production site was very limited, such as the mold production cycle, production indicators, pass rate, attendance rate, etc., which were collected and counted manually, and were imperfect. Real-time production data acquisition and equipment monitoring systems can make up for these shortcomings.
By monitoring the status of the equipment, our engineers and managers can quickly check the actual production status of the production site without leaving the office. It can analyze the equipment status time distribution and its utilization, helping them to truly understand how resources are used. More importantly, it can see in which link preparation time, downtime and idle time can be reduced to improve production efficiency. For example, analyze the daily, weekly, monthly, quarterly, and annual equipment status time distribution of the entire department or a specified machine.
In general, the mold manufacturing system plays a connecting role in our factory workshop. It allows the right information to be transferred to the right people at the right time, and then the best decisions can be taken. In this way, we can have the best quality, the best customer service, the lowest manufacturing cost, quick response and flexibility, and ultimately occupy the "most valuable" position in today's fiercely competitive market environment.
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