pesmel flow how - new approach for shortening lead times in aluminum production

pesmel flow how－鋁產(chǎn)品生產(chǎn)中縮短半成品滯留時間的新途徑

pesmel oy is the pioneer in industrial factory logistics. in aluminum mill complex the production includes different processes built by various suppliers. however, the total efficiency is very much dependant on how well these processes are connected to each other and how we manage the daily manufacturing operations.

pesmel是工廠物流解決方案的供應(yīng)商。復(fù)雜的鋁產(chǎn)品生產(chǎn)工藝需要許多來自不同供應(yīng)商的設(shè)備，如何將這些不同的設(shè)備有效地協(xié)同工作，往往會決定整個工廠的總體效率。

the key for this is the coordinated material and information flow throughout the entire production cycle. and this is obtained by connecting internal logistics devices seamlessly with process equipment for faster production cycle.

提高工廠總體效率的關(guān)鍵是在貫穿整個生產(chǎn)鏈中協(xié)調(diào)物流和信息流，通過將物流設(shè)備和生產(chǎn)線無縫連接，這種協(xié)調(diào)即可實(shí)現(xiàn)。

example of a flow chart in an aluminum mill

鋁板帶生產(chǎn)物流范例

building an efficient production structure starts from simulation. in simulation study the milllay-out with production processes, automated warehouse, packing and internal logistics is simulated with different demand scenarios to optimize and verify production efficiency and delivery capability. simulation study specifies the needed equipment and gives guidelines for control system.

建立一個有效的生產(chǎn)架構(gòu)從仿真試驗開始。在仿真試驗階段，我們根據(jù)不同生產(chǎn)需求，讓生產(chǎn)線、自動倉庫、包裝和物流設(shè)備進(jìn)行仿真運(yùn)行，以確認(rèn)系統(tǒng)配置的效率和產(chǎn)能。通過仿真試驗，我們可以決定對設(shè)備的需求，并指出控制系統(tǒng)的設(shè)計方向。

the equipment implementation is executed according to the simulation study either to an existing mill or to a new mill. simulation study for existent mill ensures the usage of existing equipment as far as possible.

系統(tǒng)中配置的設(shè)備可以上新上設(shè)備，也可用已經(jīng)存在的設(shè)備，仿真試驗可以確認(rèn)現(xiàn)有設(shè)備的可利用程度。

control mom (manufacturing operations management software) supports the information flows in manufacturing operations optimizing the use and control of different processes. control mom includes all the needed control levels:

control mom(制造運(yùn)行管理軟件)支持制造運(yùn)行管理過程中的信息流，優(yōu)化控制不同生產(chǎn)線的工作，它涵蓋所有必要的控制層級。

level 3 manufacturing operations management

l3 制造運(yùn)行管理

level 2 monitoring and supervisory/automated control

l2 監(jiān)控自動控制

level 1 automation

l1 自動控制

total efficiency can be obtained only with fully integrated control system including all the control levels.

將這些控制層級完全集成起來，可以成就很好的工廠運(yùn)行效率。

the control mom includes the following functions:

control mom(制造運(yùn)行管理軟件)具有以下功能：

production planning:optimize cost savings and sustainability by scheduling the most resource consuming production phases by weather conditions or electricity spot prices from the internet.

生產(chǎn)計劃功能：根據(jù)不同的條件優(yōu)化排產(chǎn)，例如依據(jù)消耗最大的生產(chǎn)環(huán)節(jié)，或天氣或用電低峰時段。

production execution and tracking: the customers can see in real time the status of their orderin your production line. the plant director can see the latest production yield reports on his sofa, on an ipad for example.

生產(chǎn)執(zhí)行和跟蹤：客戶可實(shí)時看到他們的訂單的執(zhí)行情況。生產(chǎn)廠長坐在家里也可查看最新的生產(chǎn)報告。

production control: yard and warehouse operations are remotely controlledfrom far distance. warehouse or yard stock status can be seen in real time.

生產(chǎn)控制：平面庫和高架庫的運(yùn)行可實(shí)現(xiàn)遠(yuǎn)程控制，并實(shí)時監(jiān)控。

maintenance: the equipment can order spare parts and maintenance services for themselves when they need to, before anything breaks.

設(shè)備維護(hù)：計劃維修前，設(shè)備可自動發(fā)送備件和服務(wù)需求。

qualitycontrol: automated quality data collection and reporting based on your quality plan. readily accessible to the customers when tracing needs occur.

質(zhì)量控制：自動收集質(zhì)量數(shù)據(jù)，并根據(jù)質(zhì)量計劃自動生成報告，當(dāng)有追溯需求時，可立即查看。

safety: the operations can be driven determinedly towards a zero accident principle (employees, machines, products) and the progress can be followed. sick leave amounts, unplanned production downtimes and product defects are minimized.

安全：工廠運(yùn)行在“0”事故狀態(tài)下運(yùn)行（人員、設(shè)備、產(chǎn)品安全），安全狀態(tài)全程跟蹤。病假率、意外停機(jī)和產(chǎn)品缺陷都可降到最低。

environment: the actuators can be optimized to work energy efficiently （e.g. feed the dynamic brake energy of regenerative drives back to the power grid）. calculate and reduce the carbon footprint.

環(huán)境：執(zhí)行器都會被優(yōu)化到最佳節(jié)能狀態(tài)(例如：將大功率電機(jī)的剎車電流回饋到電網(wǎng))，減少碳排放。

in summary, the coordinated material and information flow throughout the entire production cycle is implemented by the following steps:

總而言之，物流和信息流在生產(chǎn)鏈中的貫穿分三步實(shí)現(xiàn)：

simulation study

仿真試驗

equipment implementation

配置設(shè)備

control mom (manufacturing operations management software)

配置control mom(制造運(yùn)行管理軟件)

with proper control the lead times are shortened and efficiency increased.

如此以來，半成品的滯留時間縮短，生產(chǎn)效率提高。

for further information, please contact:

欲知更多信息，請聯(lián)系：

劉謙/ jeany liu qian

tel/fax： +86-27-87807431, mobile: +86-13006161741

email:jeany.liu@pesmel.com

pesmel oy is an international expert in material handlingand packing. company’s highly automated handling, packing and storaging systems improve the internal logistics of the mills as well as the product quality. pesmel’s two main customer groups are metal and paper industry.

pesmel是一家致力于物流和包裝的跨國公司，高度自動化的物流、包裝和倉儲系統(tǒng)提升工廠的物流和產(chǎn)品質(zhì)量，主要經(jīng)營領(lǐng)域在金屬和造紙工業(yè)。

during nearly four decades pesmel has delivered over 400 handling and packing projects and approximately 120 storage systems.

在將近40年的發(fā)展歷史中，pesmel交付了超過400套物流和包裝項目，近120座倉庫。

read morehttp://www.pesmel.com

欲知更多信息，請參見http://www.pesmel.com