CN102646220A - Multi-network-based manufacturing data real-time process management system and management method in ship manufacturing industry - Google Patents
Multi-network-based manufacturing data real-time process management system and management method in ship manufacturing industry Download PDFInfo
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Abstract
The invention discloses a multi-network-based manufacturing data real-time process management system and management method in a ship manufacturing industry. The manufacturing data real-time process management system is divided into a client access terminal, a manufacturing data real-time process management system platform, server terminals and a data center. The data center is respectively connected with the server terminals through a field operation plan management system, a real object tray tracing management system, a subsection transfer tracing management system, a construction data collecting system, a key equipment operation and maintenance management system, a field security examination management system, a field quality examination management system and a data management system. After the server terminals are optimized, the data center is linked with a PDA (Personal Digital Assistant) handheld terminal or a PC (Personnel Computer) client terminal through a multi-network module or a USB (Universal Serial Bus) port. According to the multi-network-based manufacturing data real-time process management system provided by the invention, the production executing efficiency is further improved, so as to bring about transformational influences on manufacturing management for ship manufacturing enterprises. With the development of the ship manufacturing industry in China, the project has the advantages of strong market demands and very wide industrialization prospect.
Description
Technical field
The present invention relates generally to the manufacturing data in real time course management system of a kind of shipping industry based on many networks; Specifically be that a kind of manufacturing data in real time course management system is to be core with the process mathematical model; Production run is carried out real time monitoring, diagnosis and control, accomplish the optimization shipping industry of the integration of whole production link and system manufacturing data in real time course management system based on many networks.
Background technology
In recent years, the China's Shipbuilding Industry speed of development is obviously accelerated, and from 2003, the Shipbuilding of China newly amount of receiving orders and hand-held order volume surpassed Europe comprehensively, and major customer crowd is changed the big shipowner in the world into by medium and small shipowner.China's shipbuilding in 2005 the newly amount of receiving orders has surpassed Japan, is only second to Korea S, ranks the second in the world.Yet, contrast developed country, the production efficiency of Chinese shipyard is also very low.Japan shipbuilding workman's annual value of production per capita reaches 550,000 dollars, and the Korea S workman is 480,000 dollars, and China then has only trivial 9000 dollars.The expert points out that the manufacturing equipment of China shipbuilding enterprise, factory condition and international most advanced level gap are little, and main gap is embodied in management level and informationalized application facet.
In the shipbuilding management, the Shipbuilding Mode of Japan and Korea S. advanced shipbuilding enterprise is developed rapidly to quick manufacturing mode by integrated manufacturing mode, and the key shipyard production model of China still is in shunting manufacturing mode (third level level in the Pyatyi); Because shipbuilding technology is out of trim, often cause a large amount of doing over again and serious quality problems; Because it is unreasonable that resource is equipped with, the human, financial and material resources waste is serious, cost of human resources, logistics cost height; Because technology is backward relatively, management level are low, and the material that concentrated expression goes out enterprise expends, expend man-hour, energy consumption and managerial cost expend number and are much higher than Japan and Korea S. advanced shipbuilding enterprise.Change everything; Must pay much attention to promote ship-lifting industry to intensivization development with informationization; Active use network and computer technology; In conjunction with management philosophy, management method, technical system and the advanced automated arm of integrated manufacturing, take measures to accelerate to promote to implement the information project of boats and ships enterprise.
The informatization of the most of boats and ships of China enterprise at present is in IT application in management and technical informationization integrated period, and minority leading enterprise has tentatively realized the application of CIMS, but also remains blank towards the manufacturing data management and control of plant working layer.According to retrieval; The corporate boss such as enterprise such as UFSOFT, tide, Jin Zhou who is engaged in ship informationization will provide the information-based product of business administration; And major customer's object of being engaged in the enterprise of MES research and development of software covers industries such as chemical industry, oil, electronics, communication; The domestic manufacturing data in real time course management system software that does not still have towards shipbuilding enterprise; Internationally recognizable shipbuilding management software MARS major side is reseted the production management in meter management, logistics management and workshop, does not also relate to manufacturing on-the-spot data acquisition and feedback management.
Summary of the invention
Main task of the present invention is to provide the manufacturing data in real time course management system of a kind of shipping industry based on many networks, specifically is the manufacturing data in real time course management system of the stronger shipping industry of a kind of integration, flexibility, opening, self-organization, self-adaptation and restructural ability based on many networks.
In order to solve above technical matters, a kind of shipping industry of the present invention is manufactured the data in real time course management system and is divided into client access end, server end and data center based on the manufacturing data in real time course management system of many networks; Data in the said data center by server-side processes after, through network or USB interface, input client access end; It is characterized in that: said data center is mainly linked with server end respectively by site work PCS, pallet management system for tracking in kind, segmentation transhipment tracing management, construction data acquisition system (DAS), key equipment operation management system, site safety inspection management system, on-the-spot quality inspection management system, data management; After the optimization process of server end, link with PDA handheld terminal or PC client terminal through many mixed-media network modules mixed-medias or USB interface.
The present invention also provides the management method of a kind of shipping industry based on the manufacturing data in real time course management system of many networks; It is characterized in that: said field operation planning management step is following: MRP gets into the production schedules step, after planning; Get into each workshop section's production schedules and assign step, after plan is assigned, get into each workshop section's production operation real-time process data validation step; Result through confirming is confirming to generate data in the reporting step as a result; And get into whether postpone step, if data are correct, do not postpone this field operation planning management and accomplish; Incorrect as if data, the delay back gets into and proposes the countermeasure step, upgrades the production plan step then, after after the completion renewal production plan, returns again, gets into the production schedules system and restarts;
Said pallet tracing management step in kind is following: assigned pallet running instruction before this, and behind the instruction issuing, got into pallet running step, and carried out pallet running real-time confirmation then; After confirming, carry out pallet and send to, and confirm whether pallet sends to undelivered; Return the step after pallet turns round, Delivered, the affirmation step that gets into pallet content correctness is confirmed incorrect; Turn back to the step after the pallet running, confirm correctly, get into the pallet step of accepting confirmation, finish this running.
Said segmentation transhipment tracing management step is following: at first carry out the segment information typing; Carry out the segmentation shift order then, after instruction is sent, carry out the segmentation transhipment; And entering segmentation transhipment real-time confirmation step; The step of above-mentioned affirmation is transported the judgement of success or not: transhipment is success not, is back to segmentation shift order step, carries out the segmentation transhipment again; Transport successfully, then get into transhipment and accomplish the affirmation step, finish this operation;
The step of said key equipment operation management is following: carry out assigning of key equipment information acquisition plan earlier; Then the key equipment operation information is gathered in real time; Confirm whether equipment is normal: normal state returns the step of assigning of key equipment information acquisition plan again, begins other security implementation inspections; Up-set condition promptly gets into key equipment and safeguards step, realizes the key equipment operation management;
Said site safety inspection management process is following: after the safety inspection plan generates, get into site safety inspection step, the inspection back judges whether inspection is qualified: under the eligible state, accomplish inspection; Under the defective state, the record check object information proposes rectification scheme, final updating inspection program then;
The step of said on-the-spot quality inspection management is following: Quality Test Plan gets into on-the-spot quality inspection after generating, and provides passed examination whether judgement then: under the eligible state, accomplish quality inspection, generate next Quality Test Plan; Under the defective state, the records tests object information proposes rectification scheme then, and the final updating inspection plan is accomplished this operation.
Advantage of the present invention: this project is based on for many years to bases such as the research of boats and ships business administration and embedded system development technology; Cooperation and support in conjunction with key pilot business; The crucial common technology of research shipbuilding site work information management and control; Exploitation is based on the MES product of the suitable shipbuilding process of many networks; This product orientation is in ERP and digitizer middle layer, and the on-the-spot bridge tie effect of making the data management and control of performance is that following digitizing ship is looked forward to indispensable main information-based product ingredient.
Manufacture the application of data in real time course management system, with the real-time collection and the feedback that realize on-the-spot multidate information, further refinement the granularity of operation management and control, improve science, enforceability and the controllability of the production schedule.Simultaneously; The application of manufacturing the data in real time course management system helps the standardization and the standardization of site work; Can fundamentally solve the production data recording hysteresis in process of production of traditional shipping industry, monitor and statistical difficulty problems such as data reliability difference in real time; This will improve the production efficiency of shipbuilding enterprise, flexible quick productive capacity and build guality, thereby strengthen the shipbuilding core competence of enterprises greatly.
At present, MES (manufacturing execution system) has become quick strategy and the basic fundamental means that realize the Workshop Production agilityization made of enterprise implement, and along with the expansion of range of application and the intensification of degree, the development of MES is closely bound up with industrial expansion.Computer World Information (CCW Research) investigation result shows that the market scale of Chinese MES in 2008 reaches 7.2 hundred million yuan, increases by 15.6% on a year-on-year basis.Family surplus the shipbuilding enterprise 600 of the existing medium-scale of China, the nearly million people of the direct practitioner of the whole industry, 2008, shipping industry was accomplished gross industrial output value and is reached 4,143 hundred million yuan.The second half year in 2008, the Chinese government has released the development planning of boats and ships enterprise, revitalizes planning and has created condition for the development of China's Shipbuilding Industry, and enterprise will produce more urgent demand for the level of how enhancing productivity and strengthen management under adverse circumstance.
In sum, the research and extension of this project is used and will be made shipbuilding enterprise make the relation of production management layer and work layer in order, further improves to produce and carries out efficient, will bring the influence of the property changed for the manufacturing management of shipbuilding enterprise.Be accompanied by the development of China's shipping industry, this project has the very strong market demand, and its industrialization prospect is with boundless.
Description of drawings
Fig. 1 is the manufacturing data in real time course management system synoptic diagram of the many networks of shipping industry;
Fig. 2 manufactures data in real time course management system block diagram;
Fig. 3 builds the data acquisition system (DAS) process flow diagram;
Fig. 4 site work planning management process flow diagram;
Fig. 5 is a pallet management system for tracking process flow diagram in kind;
Fig. 6 segmentation transhipment tracing management process flow diagram;
Fig. 7 key equipment operation management system process flow diagram;
Fig. 8 site safety inspection management system process block diagram;
The on-the-spot quality inspection management system of Fig. 9 process flow diagram.
Embodiment
As shown in Figure 1, manufacturing data in real time course management system of the present invention is divided into client access end 1, server end 2, manufactures data in real time course management system platform 12 and data center 3; Data in the said data center 3 are optimized through server end 2 by after manufacturing 12 processing of data in real time course management system platform, at last through network or USB interface, and input client access end 1.
Above-mentioned client access end 1 adopts PDA and PC, can through common PC through LAN conduct interviews, handheld terminal can control visit through WIFI, 3G, 4G network.Even under the situation that network interrupts, also can data be derived through USB interface.
Above-mentioned manufacturing data in real time course management system platform 12 is the background processing module of total system.For playing the effect of a bridge between PDA handheld terminal and the data center 3.Simultaneously also avoided data center 3 directly is exposed to the terminal user, strengthened safety of data.Adopt the WebService method of service, adopt the JAVA language, application server uses Weblogic.Modules such as the real-time management that main contents are planned for the manufacturing, quality management, safety management, system management use the JBPM workflow engine to realize manufacturing the automatic configuration management of flow process.
Above-mentioned data center 3 is data warehouses of total system.Use the database Oracle 11g of the international esbablished corporation inscriptions on bones or tortoise shells.
In the present invention; Other are conventional for its data center 3; Main bright spot contains the manufacturing data in real time course management system 13 of independent research for it; This system mainly is made up of site work PCS 4, pallet management system for tracking in kind 5, segmentation transhipment tracing management 6, construction data acquisition system (DAS) 7, key equipment operation management system 8, site safety inspection management system 9, on-the-spot quality inspection management system 10, data management 11, and is as shown in Figure 2; And manufacturing data in real time course management system 13 links with manufacturing data in real time course management system platform 12 through data center 3; And, link with PDA handheld terminal or PC client terminal through many mixed-media network modules mixed-medias or USB interface through after server end 2 optimization processes.
The manufacturing data in real time course management system management process of the many networks of boats and ships of the present invention is following:
As shown in Figure 5, the field operation planning management, its step is following: MRP (step 1) gets into production schedules (step 2), after planning; Get into each workshop section's production schedules assign (step 3), the plan assign after, get into each workshop section's production operation real-time process data validation (step 4); Result through confirming is confirming that result's report (generates data in the step 5); And whether entering postpones, and (step 6) if data are correct, postpones to finish this program; If data are incorrect, the delay back gets into the proposition countermeasure, and (step 7), (step 8) is returned after accomplishing the renewal production plan again, gets into the production schedules system and restarts to upgrade production plan then.
Above-mentioned steps realizes that production plan receives and the performance feedback, realizes management such as site work handing-over.Production management department can carry out production schedule arrangement to each operation, each workshop section, each personnel in advance through native system; Then by production supervision department; Pass through handheld terminal to the scene; Plan is confirmed, and used the PDA handheld terminal of band camera function will confirm that the result sends to server end through image and written form.Production management department can be in time plans the affirmation that whether postpones through management platform, is convenient to early work as dispatcher, and finds out simultaneously to postpone reason and countermeasure.Managerial personnel can carry out the production process data inquiry through landing the native system platform, promptly and accurately grasp field data, enhance productivity.
As shown in Figure 6, pallet tracing management in kind, its step is following: (step 11) is behind the instruction issuing to assign pallet running instruction before this; The running of entering pallet (step 12), (step 13) after confirming, is carried out pallet and is sent to carry out pallet running real-time confirmation then; And (step 15), undelivered return pallet running (step 12), Delivered to confirm whether pallet is sent to; Get into the affirmation (step 16) of pallet content correctness, confirms incorrectly, turn back to the pallet (step 12) that turns round; Confirm correctly, get into pallet and accept confirmation (step 17), finish this running.
Adopt RFID technology or PDA that sending and receiving information of pallet in kind followed the tracks of, and, make managerial personnel in time grasp the whereabouts of pallet in kind through real-time transmission.
As shown in Figure 7, segmentation transhipment tracing management step is following: at first carry out segment information typing (step 21), carry out segmentation shift order (step 22) then; After instruction is sent; Carry out segmentation transhipment (step 23), and get into segmentation transhipment real-time confirmation (step 24), the step of above-mentioned affirmation is transported the judgement (step 25) of success or not: transhipment is success not; Be back to segmentation shift order (step 22), carry out segmentation transhipment (step 23) again; Transport successfully, then get into transhipment and accomplish affirmation (step 26), finish this operation.
The segmentation preparation amount of large-scale shipyard generally has hundreds of individual; There is not timely record because of the segmentation displacement or after transporting in the manual management; Look for the phenomenon of segmentation through regular meeting; Be employed in and dispose PDA on the flat-bed trailer, gather the positional information of segmentation at any time, management system can be showed segmentation positional information accurately on full factory Background.
As shown in Figure 4, building course data acquisition step: after the steel pre-service (step 61), carry out steel pre-service work handover and judge (step 62): judge and defectively return steel pre-service (step 61) and handle again; Judge qualified after, carry out next step hull cutting process (step 63); After hull cutting finishes, carry out hull cutting process work handover and judge (step 64): judge and defectively return hull cutting process (step 63) and handle again; Judge qualified after; Carry out the segmentation manufacturing and handle (step 65), and segmentation manufacturing work of treatment handing-over is carried out in the operation after the segmentation manufacturing judged (step 66), defectively return a step; Qualified entering hull carries handles (step 67); After hull carries and disposes, get into hull lift-launch work of treatment handing-over and judge (step 68): judge the defective step (step 67) of returning, judge qualified this operation that then finishes.
For key operation links such as cutting, segmentation manufacturing, lift-launch configurations handheld terminal, the completion of record master operation joins information in operation, has promptly simplified the work handover program greatly, also realized to the tracking of building course information with review.
As shown in Figure 8; The step of said key equipment operation management is following: assign (step 31) of carrying out key equipment information acquisition plan earlier; Then the key equipment operation information is gathered (step 32) in real time; Confirm equipment (step 33) more whether normally: normal state returns assign (step 31) of key equipment information acquisition plan, begins other security implementation inspections; Up-set condition promptly gets into key equipment and safeguards (step 34), realizes the key equipment operation management.
Operation and maintenance information to key equipments such as dock, harbour, gantry cranes is carried out regular collection, reports the operation work information at any time, but the existing scope of operation load condition of managerial personnel's dynamic knowledge.
As shown in Figure 9, said site safety inspection management process is following: after the safety inspection plan generates (step 41), get into site safety inspection (step 42), inspection whether qualified (step 43) is judged in the inspection back: under the eligible state, accomplish inspection (step 44); Under the defective state, record check object information (step 45) proposes rectification scheme (step 46), final updating inspection program (step 47) then.
Because the operation place of general shipbuilding enterprise is bigger, and is higher to safety requirements, and operating personnel's know-how is uneven, for ensureing production safety, enterprise all is provided with on-the-spot safety patrol inspection person and carries out safe supervise and examine.Patrol and examine the PDA handheld terminal of personnel through the band camera function, can be at any time, note security hidden trouble through the form of picture, animation, literal everywhere, be convenient in time propose measures to rectify and reform, remove a hidden danger.
Shown in figure 10; The step of said on-the-spot quality inspection management is following: after Quality Test Plan generates (step 51); Get into on-the-spot quality inspection (step 52); Provide passed examination whether judgement (step 53) then: under the eligible state, accomplish quality inspection (step 54), generate next Quality Test Plan (step 51); Under the defective state, records tests object information (step 55) proposes rectification scheme (step 56) then, and final updating inspection plan (step 57) is accomplished this operation.
The scene of shipbuilding enterprise has all that the place is bigger, operating environment is complicated.For can accurately and timely grasping on-the-spot quality situation, relatively more difficult.The present invention develops this system and can share fast to all related management personnel, helps correct decision-making and rectification in time fast.
Claims (2)
1. a shipping industry is manufactured the data in real time course management system and is divided into the client access end, manufactures data in real time course management system platform, server end and data center based on the manufacturing data in real time course management system of many networks; Data in the said data center through server-side optimization, at last through network or USB interface, are imported the client access end by after manufacturing data in real time course management system platform processes; It is characterized in that: said data center is mainly linked with server end respectively by site work PCS, pallet management system for tracking in kind, segmentation transhipment tracing management, construction data acquisition system (DAS), key equipment operation management system, site safety inspection management system, on-the-spot quality inspection management system, data management; After the optimization process of server end, link with PDA handheld terminal or PC client terminal through many mixed-media network modules mixed-medias or USB interface.
2. the described shipping industry of claim 1 is based on the management method of the manufacturing data in real time course management system of many networks; It is characterized in that: said site work planning management step is following: MRP gets into the production schedules step, after planning; Get into each workshop section's production schedules and assign step, after plan is assigned, get into each workshop section's production operation real-time process data validation step; Result through confirming is confirming to generate data in the reporting step as a result; And get into whether postpone step, if data are correct, do not postpone this site work planning management and accomplish; Incorrect as if data, the delay back gets into and proposes the countermeasure step, upgrades the production plan step then, after after the completion renewal production plan, returns again, gets into the production schedules system and restarts;
Said pallet tracing management step in kind is following: assigned pallet running instruction before this, and behind the instruction issuing, got into pallet running step, and carried out pallet running real-time confirmation then; After confirming, carry out pallet and send to, and confirm whether pallet sends to undelivered; Return the step after pallet turns round, Delivered, the affirmation step that gets into pallet content correctness is confirmed incorrect; Turn back to the step after the pallet running, confirm correctly, get into the pallet step of accepting confirmation, finish this running.
Said segmentation transhipment tracing management step is following: at first carry out the segment information typing; Carry out the segmentation shift order then, after instruction is sent, carry out the segmentation transhipment; And entering segmentation transhipment real-time confirmation step; The step of above-mentioned affirmation is transported the judgement of success or not: transhipment is success not, is back to segmentation shift order step, carries out the segmentation transhipment again; Transport successfully, then get into transhipment and accomplish the affirmation step, finish this operation;
The step of said key equipment operation management is following: carry out assigning of key equipment information acquisition plan earlier; Then the key equipment operation information is gathered in real time; Confirm whether equipment is normal: normal state returns the step of assigning of key equipment information acquisition plan again, begins other security implementation inspections; Up-set condition promptly gets into key equipment and safeguards step, realizes the key equipment operation management;
Said site safety inspection management process is following: after the safety inspection plan generates, get into site safety inspection step, the inspection back judges whether inspection is qualified: under the eligible state, accomplish inspection; Under the defective state, the record check object information proposes rectification scheme, final updating inspection program then;
The step of said on-the-spot quality inspection management is following: Quality Test Plan gets into on-the-spot quality inspection after generating, and provides passed examination whether judgement then: under the eligible state, accomplish quality inspection, generate next Quality Test Plan; Under the defective state, the records tests object information proposes rectification scheme then, and the final updating inspection plan is accomplished this operation.
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