The plastics industry is transforming to smart manufacturing
Faced with a sharp decline in performance, in addition to the previous government's plastic reduction laws, the gross profit margin is declining due to fierce competition and the overall operating environment In response to changes in the market environment and laws and regulations, in addition to developing new products or new applications close to the market, companies mainly expand factories overseas or invest in new technologies and equipment, strengthen quality and R&D capabilities, and seek opportunities for cross-domain transformation. High-margin market opportunities. In response to the rapid changes in the market, the company's flexible manufacturing capabilities and accelerated manufacturing speed are necessary competitive strategies for the plastics industry.
The need for digital transformation in the plastics industry
Plastics belong to the equipment-based industry. The main equipment is equipment and molds. How to make the equipment continuously produce, and deliver to customers with high-speed and qualified quality within the delivery period. In the era of mass production, it is enough to pursue efficient output as much as possible. However, in today’s small, diverse and highly customized market, molds and equipment are becoming more sophisticated and complex, and customers have higher and higher quality requirements. In addition to pursuing speed and improving on-site production efficiency, factories also need to meet customer delivery commitments. So how Establishing a set of on-site real-time monitoring, integrating data to generate a complete production history, combining quality systems, and building a smart production knowledge base through big data analysis is a difficult problem facing the improvement of the plastics industry’s operation. This production knowledge base can be to improve production data and methods, and establish the company's long-term management wisdom database, form a management knowledge base, which can be used to automatically track and audit the entire operation and production activities, and move towards the digital transformation of smart manufacturing.
Plastic Field Activities and Lean Production
Starting from the on-site inspection of the plastics industry, to increase the delivery rate, customers will unconsciously increase the raw material inventory level to solve the problem of production flexibility and insufficient speed. The prediction of semi-products also raises the water level, so often Seeing that on-site inventory is piled up like a mountain, on-site management is often full of waste, including overproduction, idle equipment, quality defects, even low utilization rate and uneven production line capacity. Waste exists in every corner of the factory in various forms. The scene makes it difficult for the plastics industry to break through the current dilemma under the conditions of low gross profit, small order quantity and short delivery time. Lean production is "non-waste production." Eliminating any waste thoroughly, by improving the process to the simplest and making the waste visible, is one of the most important ways to make problems surface. The plastic site is an efficient and continuous production activity. When a defect occurs, if it is not dealt with immediately, the defect will be quickly copied. So how to monitor any defect in the site immediately, and how to quickly shut down and notify when a defect occurs It is very important that the handlers come to deal with it. By designing a system, a quality control mechanism is built into the process. When the quality is about to be abnormal, a line stop warning will be issued in advance to prevent defective products from being produced, and the warning message will be exposed on the electronic billboard at the same time. The purpose of the system It is to quickly post on-site issues and raise warning messages, and finally react immediately to eliminate on-site waste.
Build a digital framework for a smart factory in the plastics industry
Under the influence of the plastic restriction policies of various countries, to improve the friendly environment, the plastic industry is thinking about how to use recyclable plastic materials and bio-plastic materials, how to save energy and reduce waste, and improve production efficiency and material utilization rate, and start from the source. To the terminal, it can provide a complete production history and environment-friendly manufacturing technology to ensure the sustainable development of the industry, which is also the focus of the plastic industry's active thinking. Therefore, the introduction of a set of smart factory production technology for the plastics industry has become a top priority.
In traditional plastic factories, most of the production types are mass production, the machines are old and most production parameters are not connected to the Internet. Therefore, when a customer complains about returning a product after shipment, most of the current production data of the product cannot be found completely. The information is often pieced together, so that it is impossible to quickly and correctly analyze the cause and reason of the defect. To improve the countermeasures, the final result still has to rely on the memory of the teacher and the rules of experience to solve the problems, and therefore most of them still cannot solve the problems according to the data rules formed by the accumulation of knowledge.
Therefore, to solve this problem, the first step is to establish a digital knowledge accumulation system. The traditional factory management will be transformed from digital to data analysis, knowledge accumulation, and the formation of an early warning mechanism. Plant development. Only in this way can the plastics industry quickly implement strategic choices, because whether it is a high-value strategy or a factory expansion strategy, the factory needs to have the ability to quickly replicate data laws and implement the consistency and stability of factory production quality.
Plastic factory production data, in addition to basic data such as basic materials, production quantities, and personnel activities, mainly records environmental temperature and humidity, mold temperature, injection machine shooting speed, injection pressure and other production parameters, forming a complete production history for retrospective use, and Responding to the customer’s production history tracking needs, and the collected production data is used to build a knowledge base and analyze and improve production quality. It is also simultaneously presented in the electronic kanban situation system in real time, so that the entire production plant is in real-time monitoring status, allowing on-site management personnel to jump Move around the traditional scene visual management.
When the on-site equipment is abnormal, the management personnel can take immediate actions. When the entire production quality model is established, the quality mechanism (SPC) is imported into the production execution system (MES). If the on-site production quality trend is poor, the early warning mechanism is It can instantly react to the situation of the war system, avoiding that in the traditional production mode, when you see the red light of the equipment, a bunch of bad products have been produced, causing production waste. Therefore, after continuous interactive verification and optimization of production data and quality data, and the establishment of a solution knowledge base, the production decision-making system and mechanism of human-computer interaction, and the wisdom of the plastics industry with flexible manufacturing, speed, efficiency, and quality can be developed. The chemical plant moves forward.