The mold factory is a highly technically intensive place, from CAD, CAM to various processing technologies, CNC, EDM, wire cutting also includes measurement technology, but also contains all the molding technology. How to establish a platform for centralized sharing of production information? How to manage the entire production process? How to control quality?
What is Industry 4.0?
With regard to Industry 4.0, there are many uses and methods. It is nothing more than a network approach, connecting everything together and connecting the entire manufacturing part.
So, what is the help of Industry 4.0 for the mold factory?
He has worked for a company that is well known in the mold and manufacturing industry for 16 years. At the beginning, we mainly designed, and later in 2002, we received a big order. At that time, we required each model to have a delivery time of 7 days and an accuracy of mm, which can be exchanged globally. In 2002, this task was a big challenge, and the number was very large. There were 200 sets of molds per month. The requirements of each set of molds were also a challenge in the past, and the personnel experience was insufficient. At that time, I thought, if we can't reach the boss's thinking according to the usual practice, since then, we have started planning the digital factory to better reduce manpower and improve efficiency.
From 2003 to 2006, we became the company's number one mold supplier in the world. Regardless of speed, quality, and delivery, we have achieved a significant lead and become the standard for our global suppliers. This is a very difficult thing, but we did it.
Mold development process and technology blind spots
The mold factory is a highly technically intensive place, from CAD, CAM to various processing technologies, CNC, EDM, wire cutting also includes measurement technology, but also contains all the molding technology. How to establish a platform for centralized sharing of production information? How to manage the entire production process? How to control quality? This is a complex industry with a lot of technology and content.
How to manage the process well, how to realize the automation of software integration, how to combine with professional knowledge, and integrate all the IO and monitoring parts to manage all the machines, so as to form intelligent manufacturing.
Mold intelligent manufacturing system
1. Device networking communication and data information management system
The equipment networking communication and data information management system is to network the entire production site to form an information base platform to support the functions of program transmission, online high-speed processing, and breakpoint transmission.
The device communicates to solve the transmission of the NC program, replacing the inefficiency of the transfer of the paper CNC program and the manual transmission process;
The equipment is networked to realize the management of data information, centralized control, and the machine-program-parts are matched to ensure the accuracy and uniqueness of the program.
The transfer of the mold program is an important part of the process before processing. Especially for mold processing, the mold processing program is generally relatively large, the program is simple, convenient, fast and stable transmission, which is the basic requirement for this link; especially for the control system with small CNC storage space, It is necessary and necessary to stabilize online processing for a long time.
2. Production planning work order management and tracking system.
Production Planning Work Order Management and Tracking System is an application that uses computers to create, organize, distribute, and document detailed production data, processes, and job guidance. Information from CAPP or MRPII / ERP / MES / PLM system as data can be effectively classified and managed by the system according to the actual situation on site, and managers and engineers can interactively create or configure effective and reasonable electronic work orders through LAN. Quickly dispatched to all aspects of the production site, allowing production personnel to fully understand the production plan and its production preparation information, providing a quick and easy viewing platform and scientific basis for timely and effective production preparation; at the same time, our managers can also The entire process of “electronic work order†is monitored in real time.
In the production process, our production personnel use the on-site touch screen to view the electronic work orders issued to the site and know what the work content of the day is. For example, the CNC machine operator knows what to do on the day and how to do it. The mold assembly personnel knows whether the assembly parts of the day are in place and how to assemble them according to the requirements. The refinement of the process, the clearing of the route, and the transparency of management reduce the risks in all aspects of the process. For a workshop, a team, a company, it is a requirement and a goal.
3. Tooling tool resource management system.
We have established a knife tool and a gage management system that can manage the tools and gauges in production. From the development of the tool and the gage order, the order is checked, the order is sent and received, and then the tool tool tool library is available. Borrowed out and tested regularly. The tool and measuring tool in the tool magazine can be seamlessly integrated with the equipment networking communication and data information management system to better track and manage all the tool tools and measuring tools on the production site, saving resources and other factors. The resulting funds are wasted.
4. Production data real-time collection and equipment monitoring system.
The real-time production data collection and equipment monitoring system realizes the real-time collection of production site data. There are a lot of data about the production information or process of the mold production site in the company database. In other words, there are a lot of content, items and steps. , status; data collected or collected, digitized, content, items, steps, status, such as how much time a machining center is in use, in circulation, in preparation, in shutdown, or in idle, when does it start? Or the end; the information of a certain mold, from the blank to the finished product, the time spent on each link, etc., will be reflected through this system. The collected data is stored in the database, and in a few seconds, it can be queried in real time, or continuously check the status of a certain stage. In the past, the management's judgment on the mold production site was very limited. For example, the production cycle, production index, qualification rate, and attendance rate of the mold were all collected and counted by hand, which was not perfect. Production data real-time collection and equipment monitoring systems can make up for these shortcomings.
By monitoring the condition of the equipment, our engineers and managers can quickly check the actual production status of the production site without leaving the office. Ability to analyze the device status time distribution and its utilization, to help them really understand how resources are being used, and more importantly, it can be seen at which link can reduce preparation time, downtime and idle time. Increase productivity. For example, analyze the time distribution of equipment status for the entire department or a specified machine for day, week, month, quarter, and year.
In general, the mold making system plays a role in our factory floor, which enables the right information to be delivered to the right people at the right time, and then to make the best decisions, so that we can have the most Good quality, best customer service, lowest manufacturing cost, fast response and flexibility are the “most valuable†status in today's fiercely competitive market environment.
MAIN NEW ENERGY CO.,LTD , https://www.greensaver-battery.com