Intelligent factory is an important carrier to realize intelligent manufacturing. The intelligent production process is realized mainly through the construction of intelligent production system and network distributed production facilities. Smart factories have autonomous capabilities, which can be collected, analyzed, judged and planned; Inference and prediction are made through holistic visual technology, and simulation and multimedia technology are used to amplify the design and manufacturing process in real life. Each component of the system can form the best system structure by itself, with the characteristics of coordination, reorganization and expansion. The system has been equipped with self-learning, self-maintenance ability. Therefore, intelligent factory realizes the mutual coordination and cooperation between man and machine, and its essence is human-machine interaction.
In recent years, major economies around the world have been pushing ahead with a manufacturing Renaissance. Under the upsurge of Industry 4.0, Industrial Internet, Internet of Things and cloud computing, many Youxiu manufacturing enterprises around the world have carried out the construction of intelligent factories.
At present, China's manufacturing enterprises are facing huge pressure of transformation. On the one hand, the rapid rise of labor costs, overcapacity, fierce competition, customer personalized demand is growing and other factors, forcing manufacturing enterprises from low-cost competition strategy to build a differentiated competitive advantage. At the factory level, manufacturing enterprises are faced with recruitment difficulties, as well as the lack of professional technicians of great pressure, must achieve reduction of staff and efficiency, the urgent need to promote the construction of intelligent factories. On the other hand, the rapid rise of emerging technologies such as the Internet of Things, collaborative robotics, additive manufacturing, predictive maintenance, and machine vision has provided good technical support for manufacturing enterprises to promote the construction of intelligent factories. In addition, the strong support of the national and local governments has enabled more and more large and medium-sized enterprises in various industries to start the construction of intelligent factories.
Our country automobile, household appliances, rail transportation, food and beverage, pharmaceutical, equipment manufacturing, industries such as household enterprise for production and assembly line automation, intelligent control, and establish a new intelligent factory very strong demand, spring from haier, midea, dongguan jin sheng, shang pin home delivery, such as intelligent model of the construction of the factory.
However, there are still many problems and misunderstandings in promoting the construction of intelligent factories in China's manufacturing enterprises:
(1) blindly buy automation equipment and automation production line. Many manufacturing enterprises still believe that the promotion of intelligent factory is automation and robotization, blindly pursue the "black light factory", promote the robot transformation of single position, promote machine replacement, and mount the rigid automatic production line that can only process or assemble a single product. They only pay attention to buying high-end CNC equipment, but they don't have the corresponding software system.
② The automatic collection of equipment data and workshop networking have not been realized yet. When enterprises purchase equipment, they do not require open data interface, most of the equipment can not automatically collect data, and the workshop networking is not realized. At present, major automation manufacturers have their own industrial bus and communication protocol, OPC UA standard is not widely used.
③ The factory operation layer is still black box. In terms of factory operation, there is still a lack of information system support. The workshop is still a black box, and the whole production process is difficult to be traced. The manufacturing BOM data and man-hour data closely related to production management are also inaccurate.
④ The equipment performance is not high. Production equipment is not fully utilized, the health status of equipment is not effectively managed, often due to equipment failure to cause unplanned shutdown, affecting production.
⑤ There are still a large number of informatization and automation islands. Intelligent factory construction involves intelligent equipment, automation control, sensors, industrial software and other fields of suppliers, integration is very difficult. Many enterprises not only have a lot of information islands, but also a lot of automation islands. There is no unified planning for automated production lines, and transfer warehouses are needed between production lines.
The reason is that intelligent manufacturing and intelligent factory cover a lot of fields, the system is extremely complex, enterprises still lack of deep understanding. In this situation, manufacturing enterprises can not promote rashly, engage in the "Great Leap Forward", so as not to cause the investment of enterprises. It should rely on the consulting service organization with actual combat experience, combined with the internal IT, automation and lean team of the enterprise, the active participation of the senior management, according to the product and production process of the enterprise, do a good job of demand analysis and overall planning, and proceed on this basis to achieve practical results.
