First, traditional factories: manual statistics, low efficiency and inaccurate


In many traditional small and medium-sized factories in China, the collection of equipment production data is almost completely completed by manual work. The flow of people, scattered data, resulting in the preservation of data has become a huge problem. At the same time, the efficiency of manual statistics is also very low, often after work every day or weekly statistics, completely unable to carry out real-time production data update.


In addition, the reference data for equipment with timeliness and historical data, the key role of data records from the underlying operators - data analysis - data feedback - the manager's decision, in the middle of the link to the efficiency of the data is greatly reduced, at the same time, artificial record statistics can also cause problems such as inaccurate data, and the huge data calculation and analysis, It is a very big drain on manpower.


Secondly, historical data is of reference significance for the maintenance of equipment, but the data of traditional factories, relying on sheets of record paper or a large number of Excel sheets, will undoubtedly add difficulty to the future work, and the factory can not control the flow of personnel, and every handover may lead to the loss of data.

II. Digital factory: equipment is connected to the Internet, and data is automatically uploaded and fed back


In the digital factory, the concept of the Internet of Things is applied to every device. Between devices, it is not an island of information, but a close connection between people and devices through data. A factory manager can observe the real-time data of each device from a mobile phone or PC terminal, and can receive the status reminder of the device at any time.


For example, if you set the temperature of the bearing above 80 degrees on the device treasure, the temperature is too high. When the equipment is above 80 degrees Celsius, it will be reminded immediately, which enables the synchronous process of collection, analysis and feedback, greatly shortening the time and improving the efficiency of decision-making. In addition to "de-worker" functions such as collection, calculation and feedback, one of the major benefits of connecting devices to the Internet is the storage of data. A large number of historical data, including equipment loss data, also provide reference significance for many operations of the plant equipment in the later period. Later, in the case of staff turnover in the factory, these data can still be called at any time and saved perfectly.


Three, traditional factories: frequent unexpected equipment shutdown, causing a lot of losses


In addition to data management, traditional factories suffer from frequent unplanned outages. Unexpected shutdown not only resulted in production stagnation, but also caused immeasurable hidden damage to the equipment. A semiconductor plant can lose $1 million from a two-hour shutdown, the most frightening consequence of an unplanned shutdown. In order to prevent the unexpected shutdown of equipment, factories usually arrange 24-hour shift workers to inspect the factory, causing serious manpower consumption. Hour-by-hour inspections also do not fully detect the various factors that could lead to an unexpected shutdown of equipment. Traditional factory through hand touch, listening and other primitive ways, such inspection method makes a lot of equipment small faults are easy to be ignored, it happens that those small faults caused losses of more than one million losses.

Secondly, due to the fear of serious losses caused by unexpected shutdown, many factories will also buy a large number of spare parts to prevent the maintenance needs of unexpected shutdown. However, the reality is that some equipment unexpected shutdown failure cycle is very long, resulting in a large number of spare parts are not used, resulting in a waste of cost.


Four, digital factory: equipment unexpected shutdown warning notice, so that the equipment at all times to maintain the best operating state


During the operation of the digital factory, everything of the equipment is monitored and fed back at any time. Before the unexpected shutdown occurs, some parameters of the equipment will change. At this time, the equipment Bao can give early warning notice in time when the parameters change, so that the equipment fault can be found and operated before the occurrence. In other words, mobile phones can be alerted before a failure occurs and decisions can be made immediately to ensure that plant equipment is operating at its best at all times.


Even if a fault has already occurred, the correct solution can be found immediately in the past equipment failure statistics to minimize the loss. This is an important step towards the realization of the digital factory, which makes predicting the future part of the intelligent factory.