For the informationization of the machine tool industry, management informationization, design informationization, and underlying equipment informationization can not be less. In all these aspects, the problems and challenges faced by Chinese machine tool enterprises are very big. Recognizing the gap, finding the gap, having the courage, the passion to face the challenge, and catching up is the attitude that Chinese machine tool enterprises must first possess.
The machine tool industry is one of the earliest industries in China to contact enterprise information. As the source of design and management information systems for modern manufacturing enterprises, information systems such as CAD, CAM, CAPP, CAE, MRPII and ERP are all conducive to the manufacture of machinery (machine tools). At the same time, mechanical (machine tool) companies are also the earliest and most typical applications of these systems.
However, after several months of interviews and surveys, we can't help but conclude that although companies such as Dalian Machine Tool, Shenyang Machine Tool, Beiyi Machine Tool, and Jinan Machine Tool have a large scale and a good information base, they are facing Significantly good machine tool companies such as relocation, reorganization, and accelerating the construction of CNC machine tool industry bases have established or are in the process of establishing a relatively complete information system architecture, and have been increasing investment in information technology. Most of the smaller machine tool enterprises are subject to capital conditions and The limitations of management's understanding and other reasons, the information base is still very weak, and information investment is still very limited. In March 2006, our publications also had a special issue of mechanical (machine tool) informationization. After two years, we found that although the informationization enthusiasm and enthusiasm of the machine tool industry companies have made great progress compared with two years ago. However, it is very regrettable that our survey conclusions are still strikingly similar to those of two years ago: compared with the steel and automobile industries in which information technology is in full swing, as the pioneer of manufacturing information technology, today's machine tools Manufacturing enterprises are obviously lagging behind in terms of the scale and degree of informatization applications and the level of overall information application.
Informatization specificity
It is precisely because the machine tool industry has many of the above characteristics, it also determines that the machine tool industry information has many special difficulties:
Niu Mengyu, an information consultant for Shenyang Machine Tool Group, believes that the implementation of basic data preparation and manufacturing systems is the most difficult point for machine tool companies with complex product types and specifications. This type of machine tool enterprise has many levels of components, and the basic data, including product structure data, object code, process information, and period data are collected and prepared. It requires a lot of solid, orderly, hard and meticulous work.
Niu Mengyu also believes that both PDM and ERP are implicated in workflow management and business process management. Only by combining process change and informatization construction can we achieve the intended purpose of informationization, and are subject to traditional customary forces and certain errors. The influence of opinions and the lack of some software functions make the process change and improvement become the difficulty of informationization in the machine tool industry. Due to the characteristics of the machine tool industry, the changes in the planning process, manufacturing process and material distribution process are more difficult.
Ren Changyi, director of Hanchuan Machine Tool Information Department, believes that in terms of technology, only a data source integrating data, process data and product data can be established to realize the unique sharing of data in the true sense and eliminate information islands in order to provide a digital image for enterprises. A basic platform for the unified management of operations and all resources. Only by solving the process data and product data with manufacturing cost data, making it the only shared data in design and production operations, and becoming the sole data source and the only standard in design, production, sales, management and other activities, can we When enterprises conduct production and management activities, they play an important role in informatization. Conversely, if the description of the capital cannot be added to the static manufacturing data (product data, process data), especially in the manufacturing data, the process with cost data cannot be fully integrated, and it is impossible for PDM, ERP, SCM, CRM, etc. Providing a unique shared data that supports the operation of digital enterprises. In other words, it is impossible to effectively manage enterprise resources and achieve effective integration of PDM, ERP, CRM and other systems and unique sharing of data.
Therefore, solving the integration of product and process data with cost data and the unique sharing problem in the entire enterprise data is the core issue of enterprise informationization.
Ren Changyi believes that enterprise informatization is a long-term system engineering. The application level of management personnel information technology and the standardization management level of enterprises are important factors that directly affect the success or failure of informationization. Only by managing data and using data well, the data is guaranteed to be unique. Sex, integrity, accuracy, and timeliness can make the system really play its due role.
Meng Baogang, deputy director of Jinan No. 2 Machine Tool Group Information Management Center, believes that the difficulty in enterprise information construction in the machine tool industry is the application implementation of ERP system. Different enterprise management priorities are different. Some enterprises have very complicated sales, but the production is simple; some purchases And manufacturing is very complicated, but there are not many contracts for one year, and sales management is not important. Because China's machinery manufacturing industry is still a large, full, small and complete production organization mode compared with developed countries, the specialized division of labor is not as fine as that of foreign countries. The "three-oriented" work foundation of most enterprise products is weak, resulting in the composition of components. There are many kinds of this, especially in the state-owned large and medium-sized enterprises. In addition, the parts are basically produced by themselves, and the huge amount of data runs in a system, which is obviously very difficult.
The production planning link is the focus of the management informationization of discrete machinery manufacturing enterprises, and it is also the most cumbersome and difficult to manage the whole enterprise management. The main point is to rationally establish a bill of materials (BOM) and various basic data for production, and timely handle various changes that occur at any time during the execution of the plan, such as the increase, decrease or quantity change of parts in different situations during the design process. Meet design changes and planned changes to improve the resilience of production systems and rapid response times.
Informatization problem
Speaking of the problems in the informationization process of the machine tool industry, Niu Mengyu, a consultant of Shenyang Machine Tool Information, believes that the management information application of the machine tool industry is generally lagging behind the application of digital design systems. Except for a few enterprises, most enterprises have not yet fully implemented the ERP system. Because of the lack of suitable software, there is still much work to be done in the depth of planning management, integration with organizational structure adjustment and process reorganization, and implementation of advanced production models (such as mass customization, project manufacturing, etc.). The integration of various aspects of informatization is still difficult, such as the integration between CAD, CAPP, PDM, and the integration between digital design system and management information system. The application of supply chain management is just getting started.
Meng Baogang, deputy director of the Information Management Center of Jinan Second Machine Tool Group, believes that the overall application of information technology in the domestic machine tool industry is higher in the success rate of single applications such as assistive technology, logistics and financial management and office automation. In the management informationization focusing on planning management, since the ERP software is different from the technical software such as CAD/CAM, involving various factors such as technology, system, concept, management foundation, etc., the shadow of low success rate has been plagued by enterprises. The combination of information system application and business optimization and reorganization is not close enough. Most enterprises have “information islands†to varying degrees, and the level of system integration and resource sharing needs to be improved.
At the same time, the CIOs of some machine tool companies pointed out that in recent years, with the continuous popularization of the ERP concept in China, and the growing awareness of the domestic and international management software vendors in the marketing process, ERP seems to become enterprise information. To some extent, proper nouns ignore the role of CAD/CAM/CAPP/PDM. In fact, this tendency is very one-sided. The product data source of manufacturing is CAD and CAPP, so CAD/CAPP must be able to automatically provide accurate, complete and standardized data for ERP, especially for multi-variety manufacturers. Apply PDM system to solve CAD/CAPP and ERP. The integration, on the basis of the implementation of ERP will be guaranteed. Without emphasizing this point, the single mention of ERP will re-enact the unsatisfactory situation in which more than 80% of enterprises in China have applied MRPII/ERP in the past 20 years.
In addition, relevant experts pointed out that in the aspect of enterprise management informationization, the exaggeration of enterprise informationization from the financial computerization (with financial software as the core) is also an important crux of the long-term informatization of the machine tool industry, we must know that enterprise informationization is To solve the T, Q, C, and S problems under the market economy conditions, the T, Q, C, and S problems are solved, and the financial problems of the enterprises are naturally solved, especially the machine tool manufacturing industry, which does not solve the cost problem and only solves the financial problem. Computerization has little effect on solving T, Q, C, and S problems.
To solve the cost problem, we must start from product development, because product development determines the cost of the product by 80% to 90%. To reduce costs and improve efficiency, we must first apply CAD, CAE, CAPP, PDM, and calculate the cost. There is no product data. Process data is not acceptable. It is obviously not the correct direction to solve the informationization problem of machine tool enterprises from the financial computerization. As a result of this guidance, many enterprises first went to financial software, replaced and booked with computers, reduced several financial personnel, and reduced financial affairs. The tedious manual labor of the personnel, but there are no conditions for reducing costs and improving efficiency, nor what conditions are created for the interest of other departments.
In addition, after the cancellation of most of the central industrial management ministries, the research and development of common projects characterized by the industry (product categories) has not been questioned. After the industrial research institutes are changed into scientific and technological enterprises, they are characterized by the industry (product categories). The failure to solve common problems is also a major problem in the informationization of the machine tool industry.
Informatization future direction
Based on the above difficulties and problems, what kind of informationization should the machine tool industry make? The CIOs of some machine tool companies gave their own answers.
Ren Changyi, director of the Hanchuan Machine Tool Information Department, believes that the main body of informationization is people, and the renewal of ideas is a prerequisite for ensuring the success of informationization. Enterprise informatization, like other jobs, relies on people to operate specifically, so the improvement of employee quality is very important. Therefore, companies must continuously train their employees to improve their information technology.
Ren Changyi believes that informatization is a unified collection of management and technology integration. It is a process of full participation and a process of universal education of information technology and management knowledge. Only pursuing technical exquisiteness, neglecting the strengthening of management; overemphasizing the advanced nature, neglecting applicability and practicality; emphasizing elitism and neglecting universalization, it is possible to introduce informationization into the "technical" trap.
In addition, if enterprises want to win the informatization construction, standardization work is indispensable. Standardization of management work, business standardization, unification of report documents, standardization of raw data, and standardization are the basis and guarantee for enterprise information construction.
Niu Mengyu, an information technology consultant of Shenyang Machine Tool Group, believes that since the machine tool industry is a typical “processing-assembly†discrete manufacturing industry, the key points of the machine tool industry informatization are: implementation and application of MRP-based production management, and cost management integrated.
Wu Junting of Wuhan Wuzhong Machine Tool believes that the focus of the future management of the machine tool industry is: First, adopt the idea of ​​group technology, strengthen standardization, modularization, and serialization work, so as to design as few components as possible. Second, the types and specifications of machine tools; Second, the idea of ​​parallel engineering, breaking the "wall" between the design, process, planning, procurement, production, sales and other departments, the establishment of multi-functional project teams, teamwork for new product development; Third, adopting the idea of ​​resource outsourcing, the technology/manufacturing part of the enterprise with core competence is strengthened, and the rest is tried to adopt the method of outsourcing or outsourcing to shorten the production process, reduce inventory and reduce risks. Fourth, adopting the idea of ​​MRP, all products are manufactured in a unified planning mode, so that the same parts in each product can be batch-produced or purchased as much as possible in order to reduce costs and shorten the production cycle.
The focus of the information system is: First, use 3D CAD/CAM software to solve the machining programming of user parts, 3D simulation of machine tool assembly and design problems of fixtures; use PDM software to establish enterprise product information and technology/management Knowledge base, establish product development parallel engineering environment, solve the problem of engineering change in production process, solve cumbersome table preparation and change control problems; use MRPII / ERP software to solve centralized, parts-based planning and accurate financial / Cost information issue.
Meng Baogang, deputy director of the information management center of Jinan Second Machine Tool Group, believes that the support and participation of leaders is the premise and basis for the smooth implementation of enterprise informationization. Leadership here includes all relevant middle-level and above-level leading cadres in the enterprise, especially senior leaders. This support is reflected in all aspects, including human, material and financial inputs.
Meng Baogang believes that enterprise information construction should be based on the actual situation of enterprises, fully reflecting the characteristics of production and management and corporate characteristics. It is necessary to have a clear and feasible goal, to clarify the goals that can not be solved in the current manual management of enterprises, improve efficiency, improve overall management level, and can be achieved in a certain period of time. The goal must be operative, and should be Long-term combination. To strengthen project management. The main point of project management is to establish a strong organization, develop detailed project implementation plans, formulate various rules and regulations, operational specifications, operational procedures and project schedules, conduct assessments and assessments at all stages of the project, and only strengthen project management and implementation. The rules and regulations can guarantee the success of the project implementation.
Dong Baoqing, director of the Information Center of Tianjin No. 1 Machine Tool Plant, believes that the managers of machine tool enterprises must truly understand that information construction is a project of continuous investment and continuous improvement and upgrading. It cannot be considered that all investment is good, and at the same time, information construction is by no means simple. It is a matter of computer professionals. It requires the active participation of senior management personnel who understand both IT technology and enterprise business and operation management. It is impossible to form two skin phenomena that are disconnected between actual operation and information management.
Chen Zongqi, expert committee of computer application technology in China's machine tool industry, believes that informatization of the machine tool industry, we must first do a good job of standardization and standardization of all work in the enterprise. Without standardized and standardized data, the biggest investment will be lost. This is the reason that "three-point technology, seven-point management, and twelve is data".
In addition, Li Lin, the chairman of Beijing Jiejie Information Technology Co., Ltd. and former C1 of Beijing No.1 Machine Tool Plant, believes that market competition changes the business environment, and the business philosophy, management methods and manufacturing models of the company also change. The business philosophy is from the past. From product-centered to customer-centric; production organization changed from large-scale/single-piece small batch production to mass-customized production in the past; enterprise structure changed from a large enterprise in the past to a rational social division. Or dynamic alliance. If enterprises want to survive in the competition, they must adapt to the changes and gradually reconstruct the business management process of product development, manufacturing, and service. Li Lin believes that enterprise information construction is a process of continuously summing up experience, accumulating and innovating constantly, and he has learned from the sour, sweet, bitter and spicy to the following words: the change of concept is the driving force; the basic work is the cornerstone; The overall planning, step-by-step implementation, and gradual effectiveness are strategies; resource sharing, system integration, and business collaboration are the core; innovation plus efficiency is the goal.
Let the internet enter the workshop
Speaking of the impact of information technology on the machine tool industry, Li Lin told reporters that the impact of information technology on the machine tool industry is mainly reflected in two aspects: machine tool form and machine tool manufacturing mode. The machine tool will no longer be an isolated processing equipment, but a node directly connected to the CAD/CAPP engineering design system and the MRPII management information system in the network environment, which can dynamically reconstruct the processing route, remotely manage the machining process and troubleshoot. At the same time, the production and operation process of machine tool products will also realize the network life of the product life cycle. Advanced manufacturing technology represented by agile manufacturing will become the main means for enterprises to respond quickly to market needs, survive and develop. The innovation of the machine tool industry will be mainly reflected in the four aspects of management ideas and management concepts, organizational structure and management mechanism, management norms and work processes, management methods and manufacturing technologies, improving manufacturing capabilities as a whole, achieving flexible manufacturing and effective supply chain. .
As Li Lin said, with the increasing use of network technology, it is only a matter of time before the Internet enters the workshop, which will be the main symbol of digital manufacturing. In fact, if enterprise informationization is limited to the upper management departments of business management departments (people, finance, materials, production, supply, sales) or design and development, it is not enough. The lowest processing equipment in the workshop - CNC machine tools Being able to connect to the network and not providing the underlying data for design and management informationization will inevitably form an information bottleneck.
Therefore, for the modern manufacturing plant, in addition to improving the numerical control rate of the machine tool, it is necessary to have the two-way, high-speed network communication function of the CNC machine tool to ensure the flow of information between the bottom layer of the workshop and the bottom and upper layers. The flow is unimpeded.
At present, some of the developed countries of machine tool manufacturing are already leading the way. For example, the new generation of machining centers introduced by Mazak Japan not only automates the machining process and tool exchange, but also is equipped with an external device called an information tower. Including computers, mobile phones, off-board and in-camera cameras, it can realize the communication functions of voice, graphics, video and text. The machine is networked with the production schedule to reflect the machine's working status and processing progress in real time. The operator needs fingerprint confirmation permission to observe the processing on the screen. It is an independent, self-managed manufacturing unit.
The company's production planning and scheduling system arranges a week's processing tasks and sends them to the information tower. The tower gives instructions to the operator and displays the real-time working status of the machine on the screen. The operator follows the on-screen instructions. When you encounter a problem, you can always consult the operating manual in your computer. Under normal circumstances, the machine automatically works, and the operator and the machine are separated in time and space. Managers and operators can query production conditions, estimated processing completion time, and delay reports and fault alarms via mobile phones.
In the event of a machine failure, the screen will show you how to troubleshoot. Mazak's repair center can see the problem at the same time, providing assistance in a timely manner to minimize machine downtime.
The latest product from Andron, Germany, is a new generation of open CNC systems based on PC and Windows platforms. It uses two Intel processors to communicate with each other via a PCI-PCI bridge. One processor is responsible for numerical control operations (NC computers) and the other is used as a human interface computer. An NC machine card is inserted in the NC computer. The NC machine card is connected to the CNC drive and communicates with the HMI computer via two bus cards with PCI bridges. The internal bus card of the HMI computer is connected to the control panel of the CNC system and the external interface. The CPU card of the HMI computer controls the touch LCD display as well as computer peripherals and network communications.
For the informationization of the machine tool industry, management informationization, design informationization, and underlying equipment informationization can not be less. In all these aspects, the problems and challenges faced by Chinese machine tool enterprises are very big. Recognizing the gap, finding the gap, having the courage, the passion to face the challenge, and catching up is the attitude that Chinese machine tool enterprises must first possess.
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