Customer requirements:    

MAGNA International group is the world's most diversified automotive parts supplier with annual sales of us $24.1 billion in 2010. Designs, develops and manufactures automotive systems, assemblies, modules and components, as well as the ability to design and assemble complete vehicles for sales in North America, Europe, Asia and other parts of the world. The MAGNA Group has nine product systems, including rearview mirror, metal forming, vehicle assembly, power systems, exterior and interior systems, electronics and rotating systems. For Mercedes, BMW, Audi, Volkswagen, GENERAL Motors, Ford, Dyke, Peugeot, Citroen and other world famous automotive brands to provide parts and after-sales service.

This round of customer demand mainly for automotive decorated interior and exterior information construction, based on the i3 Plus platform realizes automatic generation of order receiving and parsing, production process management, intelligent logistics management,  Andon system, data acquisition and data display, etc.Centralized information platform construction of supporting environment and an increasingly sophisticated products and processes, To realize the improvement of innovation ability, achieve efficient transfer of value chain and profit, and complete the digitalization and transparency of OEMS supply chain coordination, so as to improve the process and production process, reduce cost and increase efficiency, and take a step ahead to realize the transformation of intelligent manufacturing.

Solution:

· EDI information analysis of production order process

  JSP ratio: the ratio of a product in JSP (10-day rolling plan in EDI) ；

  Stock ratio: the stock ratio of a product can be calculated as follows: 10(stock quantity) /100 (maximum stock quantity -- advanced maintenance), the stock ratio of a product can be: (10/100) *100=10%;

  Production quantity: (Proportion of JSP * maximum stock) - Current stock = production quantity (20%*100) -10= 10 A negative result indicates that the quantity in stock is greater than the planned quantity and a positive result indicates the quantity that should be produced.

· Production order adjustment strategy

  Batch production order adjustment strategy: ① Priority production when below the minimum inventory. (2) Those below the standard value need to be supplemented. (3) After each assembly line consumes 1 complete package of semi-finished products, the next cycle calculation will be started and the production scheduling results will be sent to the corresponding production line；

  JIS Order production adjustment strategies: ① Advance/delay production; ②, temporary insert order; (3) Order deletion; ④ Queue sorting adjustment.

· Production data acquisition

  MES data collection in the production process (PLC of the equipment records the bar code of the door mold, whether the product is good or not, processing data of each process, etc.)

  Data collection: there are 4 nozzles at the current workstation, PLC will write the number of spraying of each nozzle in the corresponding PLC address, MES needs to read these information to achieve equipment maintenance. (The current station only needs the equipment to provide the number of injection, and does not need to interact with MES)

     1. PLC writes the spraying times of 4 nozzles;

     2. PLC data readiness signal (0: not ready, 1: ready);

     3. When the MES injection times reach the set value, a prompt message will be given. After replacing the nozzle, the equipment personnel need to clear the corresponding nozzle injection times on the equipment.

  Motor assembly data collection: communicate with torque gun equipment, collect torque information, record the relationship between torque and product, easy to use and report. (Torque gun PF6000);

  Grating induction data acquisition: PLC writes the bar code of the door mode automatically read by the equipment, and PLC collects grating data and verifies it.

· Intelligent logistics pulling

  According to the production plan, the corresponding material labels will be lit to remind employees to avoid wrong taking, missing taking and reduce the error probability；

  Different customer products are placed in the offline position of the material rack, the system lights up to remind the current product should be stored in the material rack position, guide the staff operation;

  For product delivery check, use PDA to scan single bar code of product material rack to check whether the bar code of material rack matches the delivery queue.

· Offline production mode 

  The production line can work normally without MES sending formula, such as MES failure or network abnormality；

  How long will it take to switch to offline production mode after MES fails to work? Relevant rules need to be formulated as to who, when and how to decide to switch.

· Equipment management

  Check the equipment status (start, stop, pause, failure, etc.);

  Computing equipment OEE;

  MTBF, MTTR statistics;

  Equipment maintenance and ledger list.