CN112070450A

CN112070450A - TCM system

Info

Publication number: CN112070450A
Application number: CN202010160978.XA
Authority: CN
Inventors: 张国良; 吴秀琴
Original assignee: Tongchui Intelligent Technology Suzhou Co ltd
Current assignee: Suzhou Deshenghui New Energy Technology Co ltd
Priority date: 2020-03-10
Filing date: 2020-03-10
Publication date: 2020-12-11

Abstract

The invention discloses a TCM system, which comprises a plan management unit, a process management unit, an equipment management unit, a production reporting unit, an exception management unit, a quality management unit, a billboard management unit, a statistical reporting unit, a system safety management unit and a system interface unit. The invention can achieve highly intelligent and visual management.

Description

TCM system

Technical Field

The invention relates to the application field of a functional module system, in particular to a TCM system.

Background

The TCM system is mainly developed by technicians in solar cell and module production based on field requirements, mainly realizes field management including human, machine, material, method and ring monitoring and management, and is mainly characterized by realizing information sharing and cooperative work of departments of technical preparation, production planning and scheduling, product processing, resource guarantee and the like in the whole process of production organization, ensuring the utilization rate of equipment, reasonably configuring and scheduling resources, improving the production capacity, realizing visualization of business processes and promoting continuous optimization of business processes.

The TCM system is in butt joint with ERP/SAP and OA systems, functional modules such as a planning functional block, a cost system, warehouse management, order management and the like are integrated based on a plurality of systems, planning, resources and production are organically connected in series, and real-time, intelligent and integrated updating is achieved.

Disclosure of Invention

In order to solve the above problems in the background art, the present invention provides a TCM system to achieve the purpose of highly intelligent and visual management.

In order to achieve the purpose, the technical scheme of the invention is as follows:

a TCM system comprises a plan management unit, a process management unit, an equipment management unit, a production reporting unit, an exception management unit, a quality management unit, a billboard management unit, a statistical reporting unit, a system safety management unit and a system interface unit;

the plan management unit makes a detailed schedule and a workshop production operation plan according to the order and the production plan;

the process management unit is integrated according to functions in the existing system, and reads out information required in the system, so that repeated work is avoided;

the equipment management unit carries out comprehensive management on production equipment, operation rules, management systems, operation monitoring, fault diagnosis, maintenance and operation statistics;

the production reporting unit reports the production progress in real time through a workshop;

the exception management unit carries out exception reporting, exception tracking processing, exception emergency plan processing setting and exception short message notification according to the exception condition, and generates an exception processing report and a report regularly;

the quality management unit sets inspection guide contents, quality inspection items and parameters for quality inspection personnel to compare and confirm aiming at key procedures;

data required by related personnel of the billboard management unit are displayed visually, and personnel needing to know the information can see the information clearly and help operators and managers to manage and control production;

the statistical report unit processes the collected statistics for multiple times, carries out systematic and deep analysis, and converts the statistics into various reports;

the system safety management unit divides functions according to system authorities, and each menu, each operation and each login person need to carry out detailed authority division;

the system interface unit comprises OA, PDM, MRP, WMS, SAP, ERP and PLC expansion interfaces.

Preferably, the plan management unit converts the production plan and the user order into a specific production operation plan, and arranges an efficient operation sequence of day, shift, line, table, and the like, and minimizes adjustment of equipment, taking into consideration conditions such as order priority, delivery date, stock, processing route, product characteristics, processing procedure, equipment load, and resource restrictions.

Preferably, the process management unit needs to cooperate with a developer of an existing system to provide an interface and related fields for reading corresponding information, which includes process document and graphic management, process flow management, process version management and approval management.

Preferably, the production work reporting unit comprises an operation terminal, production task check and production progress submission, wherein the operation terminal places a station terminal for each line key station or each plurality of devices for task check, production progress submission, abnormal calling and image-text check; the production task checking is to place an operation terminal at a designated position in a workshop site, an employee wears an RFID bracelet or an entrance guard card on the site, the terminal swipes the card or recognizes the face to know the production task of the employee, and the card checks the relevant station files and operation instructions; the production progress submission is to directly submit the production quantity through data acquisition of a field workstation or equipment.

Preferably, the exception management unit is used for realizing rapid information transmission, call application, real-time display, statistical analysis and report generation, carrying out real-time information transmission and management on processes such as working procedure operation, equipment state, quality problem, material supply condition and the like, and supporting the whole production process; when the quality, the process, the equipment and the equipment parameters are abnormal, the system can remind step by step according to the preset personnel, processing time and reminding mode if the responsible person does not process the alarm within the time.

Preferably, the quality management unit submits data of product self-inspection, scrapping, repair and the like in the production process through a field terminal; the inspection personnel are provided with a mobile terminal, select a production task through the mobile terminal for inspection, and submit inspection data; checking the inspection record and the statistical result of the current production task in real time by a worker through the system; and through equipment data acquisition, automatically acquiring the inspection data of the inspection equipment and submitting the inspection data to the system.

Preferably, the billboard management unit can place corresponding billboards on each production line, key station and key department, and the types of the billboard boards include liquid crystal billboard boards or LED billboard boards.

Preferably, the report in the statistical report unit includes an equipment fault statistical report and an equipment operation statistical report, and supports freely selecting a time span and counting objects.

Preferably, the system security management unit adopts a hierarchical system authority division function in authority division, and defines the authority level, the operation range and the information knowing range, so that the system information and operation safety are ensured, and the privacy and independence of accurate control information are achieved.

Preferably, the system interface unit comprises an interface with an ERP system, that is, contents which are required and exist in the ERP are read into the TCM system through integration, such as part or all information of an equipment management module and a BOM management module; the interface with the PDM system realizes seamless connection of a production field processing task, a part process drawing and a process route; the interface with the PLC system, because the PLC system can exist as an independent system, the direct data interaction of the PLC and the TCM needs to be realized by a system integration mode.

Through the technical scheme, the TCM system provided by the invention realizes a production management target of agile manufacturing by utilizing various modern technologies such as a sensing technology, a wireless communication technology, a network technology, an intelligent digital technology and the like through product in process management and equipment networking, accurately grasps resource load conditions of various productions through data support provided by information visualization, realizes visualized holographic workshop management through an informatization means, and improves production benefits.

Drawings

In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the embodiments or the prior art will be briefly described below.

FIG. 1 is a schematic structural view of the present invention;

FIG. 2 is a block diagram of the present invention;

FIG. 3 is a schematic diagram of the system integration of the present invention;

FIG. 4 is a schematic diagram of a production reporter unit of the present invention;

FIG. 5 is a schematic view of a process of the present invention;

FIG. 6 is a schematic diagram of a production execution unit of the present invention;

FIG. 7 is a schematic view of an MES layer of the present invention;

FIG. 8 is a schematic of the operational statistical analysis of the present invention;

FIG. 9 is a schematic diagram of a kanban management unit of the present invention;

FIG. 10 is a schematic view of a production planning billboard of the invention;

FIG. 11 is a schematic view of a production progress signboard of the present invention;

FIG. 12 is a schematic view of a quality and process control billboard of the invention;

FIG. 13 is a schematic illustration of the production daily of the present invention;

FIG. 14 is a schematic illustration of a monthly report produced in accordance with the present invention;

FIG. 15 is a schematic illustration of personnel performance statistics of the present invention;

FIG. 16 is a schematic of a quality statistics analysis of the present invention;

FIG. 17 is a schematic of a cost analysis of the present invention;

FIG. 18 is a schematic diagram of a business architecture of the present invention;

FIG. 19 is a schematic illustration of the design concept of the present invention;

FIG. 20 is a schematic diagram of the system architecture of the present invention;

FIG. 21 is a schematic diagram of the underlying communication mechanism of the present invention;

Detailed Description

The technical solution in the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings in the embodiments of the present invention.

The invention provides a TCM system, which takes informatization transformation such as flexible manufacturing system and agile manufacturing as a construction target, and utilizes a plurality of modernization technologies such as sensing technology, wireless communication technology, computer network technology, intelligent digitization technology, RFID Internet of things application service platform technology, AI image recognition, cloud computing platform and the like to build a comprehensive demonstration platform based on the industrial Internet of things, and the comprehensive demonstration platform comprises a plan management unit, a process management unit, an equipment management unit, a production and reporting unit, an exception management unit, a quality management unit, a billboard management unit, a statistical reporting unit, a system safety management unit and a system interface unit;

the plan management unit makes a detailed schedule and a workshop production operation plan according to the order and the production plan; the plan management unit needs to take into account the conditions of order priority, delivery date, inventory, processing path, product characteristics, processing procedures, equipment load, resource limitations, etc., convert the production plan and the user order into a specific production operation plan, discharge the operation sequence of high efficiency day, shift, line, station, etc., and reduce the adjustment of equipment to the minimum, and the following requirements are mainly required in the system design process:

1) order planning (system integration): in the system design process, the planned import and delivery date of processing production lines of various orders are controlled and managed by considering the whole factory, and the detailed production scheduling work of a workshop site is carried out in a TCM system;

2) manual labor scheduling: the functional module is mainly decomposed according to a main plan read from a main plant, and enterprise workers carry out manual scheduling, dispatching and other operations in the system according to the conditions of field equipment load, delivery date and the like, and can specifically arrive at personnel, equipment, stations and the like;

3) tracking the production progress: the actual progress of each order on the workshop production line site can be known in real time.

The process management unit is integrated according to functions in the existing system, and reads out information required in the system, so that repeated work is avoided; the process management unit needs to be matched with a developer of an existing system to provide an interface and related fields so as to read corresponding information, and the process management unit comprises process file and image-text management, process flow management, process version management and approval management, wherein the process file and image-text management can carry out unified management on production process images-texts and related files in the system, the process flow management can define process routes and the like in the system, the process version management can manage the process routes and the like through versions, the process flow or the process versions in the system need to be approved when changed, and the approval process can be defined by users.

The equipment management unit carries out comprehensive management on production equipment, operation rules, management systems, operation monitoring, fault diagnosis, maintenance and operation statistics; the main requirements are as follows: managing the equipment machine account; real-time operation monitoring (equipment networking PLC system); equipment failure alarm (equipment networking PLC system); statistical analysis of equipment operation (equipment networking PLC system); point patrol informatization management (realized in TCM); service maintenance management (implemented in TCM); spare part management (TCM implementation); parts procurement (TCM implementation).

The production reporting unit reports the production progress in real time through a workshop; the production work reporting unit comprises an operation terminal, production task checking and production progress submitting, wherein the operation terminal is used for placing a station terminal for each line key station or each plurality of devices and performing task checking, production progress submitting, abnormal calling and image-text checking; the production task checking is to place an operation terminal at a designated position in a workshop site, an employee wears an RFID bracelet or an entrance guard card on the site, the terminal swipes the card or recognizes the face to know the production task of the employee, and the card checks the relevant station files and operation instructions; the production progress submission is to directly submit the production quantity through data acquisition of a field workstation or equipment.

The exception management unit carries out exception reporting, exception tracking processing, exception emergency plan processing setting and exception short message notification according to the exception condition, and generates an exception processing report and a report regularly; the abnormity management unit realizes rapid information transmission, application calling, real-time display, statistical analysis and report generation, carries out real-time information transmission and management on processes such as working procedure operation, equipment state, quality problem, material supply condition and the like, and supports the whole production process; when the quality, the process, the equipment and the equipment parameters are abnormal, the system can remind step by step according to the preset personnel, processing time and reminding mode if the responsible person does not process the alarm within the time. The main requirements are as follows: the exception type can be set in a system in a user-defined way; related personnel can be notified in the modes of short messages, mails and signboards, and different processing personnel are set according to different fault types; when the abnormity occurs, the processing overtime of the processing personnel can be reported step by step; abnormal calling can be carried out through the field operation terminal, and the employee card is required to be swiped to record information of calling personnel, calling time, calling stations, processing personnel, processing time and the like during calling.

The quality management unit sets inspection guide contents, quality inspection items and parameters for quality inspection personnel to compare and confirm aiming at key procedures; the quality management unit submits data of product self-inspection, scrapping, repair and the like in the production process through the field terminal; the inspection personnel are provided with a mobile terminal, select a production task through the mobile terminal for inspection, and submit inspection data; checking the inspection record and the statistical result of the current production task in real time by a worker through the system; and through equipment data acquisition, automatically acquiring the inspection data of the inspection equipment and submitting the inspection data to the system.

Data required by related personnel of the billboard management unit are displayed visually, and personnel needing to know the information can see the information clearly and help operators and managers to manage and control production; the billboard management unit can place corresponding signboards on each production line, key stations and key departments, and the types of the signboards comprise liquid crystal signboards or LED signboards.

The statistical report unit processes the collected statistics for multiple times, carries out systematic and deep analysis, and converts the statistics into various reports; the report in the statistical report unit comprises an equipment fault statistical report and an equipment operation statistical report, and supports freely selecting time span and counting objects.

The system safety management unit divides functions according to system authorities, and each menu, each operation and each login person need to carry out detailed authority division; the system safety management unit adopts a level system authority division function in authority division, and defines the authority height, the operation range and the information knowing range, thereby ensuring the system information and operation safety and achieving the privacy and independence of accurate control information.

The system interface unit comprises OA, PDM, MRP, WMS, SAP, ERP and PLC expansion interfaces, and comprises an interface with an ERP system, namely, the required content existing in the ERP is read into the TCM system through integration, such as part or all information of equipment management and BOM management modules; the interface with the PDM system realizes seamless connection of a production field processing task, a part process drawing and a process route; the interface with the PLC system, because the PLC system can exist as an independent system, the direct data interaction of the PLC and the TCM needs to be realized by a system integration mode.

The production management target of agile manufacturing is realized through WIP (product management) + SCADA (equipment networking) in this system to the visual data support that provides of information, the resource load situation of accurate grasp all kinds of productions improves bottleneck resource utilization, promotes raw materials frock clamp delivery precision, promotes production strain capacity. Problem prediction and problem prevention are achieved through information visualization, and production problems are reduced. The production operation state information in operation is transmitted in time, and the implementation of problem solving processes and the perfection of a field management group system are promoted. And the visual holographic workshop management is realized by an informatization means. And various statistical analyses are provided, sufficient data bases are provided for decision makers, and a modern production system with advancement, scientificity and foresight is created.

Through visual workshop management, promote the benefit, transparent, the real-time of raw materials preparation, production plan information, course of working promotes the delivery precision, and the production facility operational aspect is monitored, ensures in time to produce the delivery. The equipment information is visualized, the equipment informatization level is improved, the rejection rate is reduced, and the user satisfaction is improved. The product life cycle is visualized, the flow bottleneck is analyzed, the production coordination is effectively promoted, the production execution error rate is reduced, and the department cooperation efficiency is improved. The process content is visualized, the autonomy of the staff is enhanced, the data sharing efficiency is improved, and the strain capacity of a production line is increased. The abnormal information is visualized, the response is fast, the solution is effectively realized, the line stop is avoided, and the risk is reduced. Through the transparentization and the real-time of the inventory information, the material in and out warehouse mistakes caused by the information transmission delay are avoided, the warehousing cost is reduced, and a transparent, real-time and modern intelligent workshop is formed.

The visualization specifically comprises:

visualization of production progress: the production progress is tracked in real time, the production bottleneck is excavated, and the delivery period control is improved;

visualization of production quality: analyzing the problems in the production process, summarizing and summarizing the reasons of the defects, sorting the solution and improving the production quality;

and (3) visualizing abnormal information: the response speed of abnormal conditions is improved, the smoothness of the production process is ensured, and the production efficiency is improved.

The information process flow is created, the production scheduling and the production process are highly automated, and the production process is standardized and accurate; through informatization and intellectualization, the labor cost is reduced, and the high cooperation capability of the equipment is improved. Automatic acquisition of equipment data, online operator data acquisition and automatic reporting of the equipment data and production data are realized through the RFID internet of things technology. And various statistical analyses are provided, so that a decision maker is provided with sufficient data basis.

The system is implemented as follows:

as shown in fig. 1 to 6, taking international PLCs such as siemens and ohm dragon as an example of field processing equipment of a production line, communication interaction is performed with the field PLC in a daserver (opc server) manner, and equipment information such as process parameters, alarm information, yield and the like in the field processing equipment is acquired into a system history database, corresponds to a current production work order, a current processing procedure, a current processed product and a current processing time, and is displayed in a report form.

After the raw materials and the tool fixtures are scanned and confirmed to be correct, the raw materials and the tool fixtures are clicked at a station terminal (a touch screen) to start machining, real-time process data in the machining process are acquired in real time at the field industrial control level, uploaded to a system server and displayed at the station terminal for a machining worker to check, and the service flow is shown in fig. 5.

Production planning and scheduling

Because an enterprise has a plurality of management systems including ERP, PDM and the like, part of functions in the TCM system are overlapped with some functions in SAP/ERP, and in order to avoid repeated work of employees, the TCM system needs to be systematically integrated with the SAP/ERP system. In the aspect of production planning, the TCM system needs to read the production main plan and delivery period information of the SAP/ERP system, and then the TCM system carries out detailed task decomposition according to the main plan obtained from the SAP/ERP, as shown in FIG. 7, according to the process route or the process standard of the product, the task is decomposed to a workshop or a production line, and a production task dispatching module is used for further carrying out detailed decomposition on the task which is sent to the workshop or the production line by a workshop front-line manager according to the TCM system, and the task can be specifically sent to people, quantity, stations, equipment, time and the like. And then, the rework task dispatching module is used for dispatching tasks of unqualified products which need to be reworked in the production process or after inspection, and the products can be dispatched to original production personnel and can also designate other personnel, so that the production tasks can be managed, such as task suspension, task restart, task shutdown and the like, and when the tasks are in different states, different influences can be generated on the production process.

Secondly, equipment data acquisition management

Remote monitoring equipment state: one computer can monitor the real-time states of all the devices of the whole line at the same time, and the states (running, idle, fault, shutdown, maintenance and other states) of all the devices can be checked at any time in the form of an electronic billboard.

Collecting information of the PLC equipment:

for an automatic production line or equipment with a network interface, the TCM system directly exchanges data with a PLC of the equipment through a network, and can acquire the following production data: simultaneously can with upper production management to the realization makes the workshop transparence to the control of bottom equipment, includes:

the operating state of the production line or equipment (manual, automatic, running or stopped, etc.); operating parameters of the production line or equipment; fault and alarm information of the production line or equipment; other relevant production information, such as: production quantity, defective product quantity and alarm, production cycle/tempo, shutdown times and time, etc.

A visual and vivid graphical interface can be formed, and field real-time information is provided for managers; the method provides effective help for maintenance engineers to quickly position and analyze field faults and determine solutions, and can also display key process parameters of production lines or equipment in real time, realize digital monitoring of the processing process and provide managers for analyzing the production process parameters.

Third, program management and process control

The TCM system can run independently and can be integrated with MES and ERP, and has the following functions:

1) the system architecture includes:

based on ORACLE development, the method is suitable for managing a large number of data files, and users have no worry about overlarge data volume; by adopting the product structure tree form, a multi-level program directory can be established according to materials, the readability is good, the system security problems such as a shared folder are completely avoided, and the system has no potential risks such as network security, virus attack, artificial damage and the like; program documents can be managed according to tree structures of production lines, equipment and material classification, each management structure supports a downward multi-level tree structure, and the tree structures can be customized by users; a server/client architecture is adopted, a network floating version is completely supported, and a client can float freely on the network; the system supports the structure of a head office/workshop, only one management server needs to be arranged in the head office, personnel in each workshop automatically enter the workshop system when logging in, and data have the greatest safety.

2) The process control comprises the following steps:

the system is seamlessly integrated with a PLC (programmable logic controller) or line-edge material code scanning system, the PLC or line-edge material code scanning system directly reads materials and equipment information from a database, and the system is directly uploaded and stored in the database; the database management can be carried out on various information of the equipment and the materials, such as line numbers, equipment numbers, material information, user information and the like; automatically generating a flow card file which comprises an order number, a product model and a bill of materials, and automatically associating the flow card file with related equipment; the automatic extraction function of the information of the flow card, for example, the system automatically extracts the information such as order number, user information, equipment and the like; the intelligent program query function can carry out combination and fuzzy query according to products, order numbers, equipment, operators and the like; the powerful role management functions, such as operators, inspectors, technical masters and the like, carry out reliable authority management on the production process, and different personnel set different authorities.

3) The process management comprises the following steps:

the system has the advantages that the system is complete in process signing and checking management, completely supports processes such as compiling, proofreading, auditing and approving, and can be customized by a user according to actual conditions of an enterprise; the system has strict authority security measures, and relevant data of the system can be accessed only according to relevant authorization, and the authority precision is specific to each menu, each file and each device.

4) The version management includes:

the version management system has a perfect version management function, generates a new version every time of change, can automatically track and record all changes of a program file, and allows a user to compare/recover the old version; the method can realize the operation of providing prompt, modification and renaming when the files with the same name have different extension names in the same directory.

5) The paperless manufacturing comprises the following steps:

the method can carry out relevant management on related files such as a bill of material, a flow card, a production state picture and the like; can directly browse various data files such as NC, TXT, DOC, BMP, PDF, Autocad, Solidworks, CATIA, PRO/E, UG and the like; the large icon interface of the touch screen is provided, and the large icon interface is suitable for an operator to conveniently operate on the touch screen.

6) Process tracing

The program management records including the time and personnel of events such as creation, modification, trial cut, approval, deletion and the like are automatically generated, so that the program has traceability, completely conforms to the ISO9001 management standard, and the records can be classified and managed.

7) Device operation statistics

The device has a device load counting function, and automatically generates a load of an operator and each device and a historical device operation counting report. And is expressed in the forms of striking and intuitive column diagrams, pie charts and the like.

8) Backup and restore

The system has the functions of automatic data backup and manual data backup, and the server can automatically and periodically backup the data and can quickly recover the data when needed.

The TCM system provides abundant statistical report templates for customers to select, can conveniently and neatly display various data needed by the customers, and can accurately know what condition happens to your equipment and the condition of completing a production plan. Such as: the number of products produced per operator or per shift group; equipment startup time, equipment shutdown time, equipment failure time and equipment running time; operator efficiency, equipment utilization (OEE), etc. Various forms of daily, monthly, quarterly, annual newspapers. And each machine tool, one team and the whole workshop can be counted specifically. The data can be counted and analyzed in various ways such as pie charts, bar charts, line charts, statistical tables, and the like.

Fourth, management of production site

1) Checking the production task: the unit has the main functions of being used for workshop staff to check the production task of the day, making clear the work target of each staff, checking the material ratio, the flow card and the process content, arranging logistics staff to prepare materials and feed materials in time and improving the production efficiency.

The staff check their work tasks and submit the work progress through swiping the card, and everyone can only see their tasks.

2) Production progress submission

The module mainly realizes real-time submission of production progress, and an operator checks own work tasks and submits work progress through swiping a card in a site station terminal, and can submit the work tasks for multiple times or submit all the work tasks at one time.

3) Artwork viewing

The staff can check the process graphics and texts of the product according to the task product and compare the own graphics and text version to determine the product as the latest version at the station terminal, thereby reducing the product scrap caused by the problem of process description version.

4) Production progress tracking

The module has the main functions of: the manager or planner can know in real time the progress of the current production order in the office PC, the order being in that process, how much produced, the percent of pass, the rate of rejection, etc. And can see whether the current order is delayed or not, and provide data for the arrangement of subsequent production and product delivery judgment of managers.

Fifth, exception management

1) And (3) abnormal type maintenance: the abnormal conditions which may occur in the production process are maintained in advance, and different modes are adopted for processing according to different abnormalities.

2) Setting an abnormal call flow: when problems occur in the workshop, it is often encountered that the worker cannot find the treating person or does not know which person should be found in the department to treat the problems, thereby causing production delay.

The module sets the calling flow in advance according to different abnormal types, when the abnormal occurs, the system can automatically inform the related department or inform a person in a short message, mail or billboard mode, and when the abnormal occurs, the abnormal occurs is not processed or solved within the set time, the abnormal occurs is reported step by step, so that the response speed and the solving efficiency of solving the problem are improved.

3) Abnormal call processing: under the condition that the abnormal type and the abnormal flow are set, when the workshop site is abnormal, workshop personnel only need to select a corresponding abnormal type button to click through a production line terminal. The system will automatically notify the corresponding person or department.

Sixth, quality management

1) And (3) recording procedure quality inspection: after the production of the key process is finished, the process quality inspection is carried out according to the requirement, the quality inspection data is submitted according to the task, and the processing modes of unqualified products, such as repair, scrapping and the like, are submitted.

2) And (3) checking and inquiring the quality of the working procedures: and inquiring the quality inspection information in real time.

Seventhly, managing the kanban, as shown in figures 9-12,

1) production plan signboard: the production task of the current production line and the task completion condition of the production line are mainly displayed in the production process, so that production personnel can conveniently know the production task in real time, and then the operation time and the like are reasonably arranged.

2) Production progress billboard: the method mainly provides all current progress conditions of production tasks for planning group personnel, so that the planning group personnel can know the progress of each production task in real time without a workshop, and can regulate and control workshop production according to progress information.

3) Abnormal calling board: the method mainly provides the abnormal conditions of the phenomena for technical group personnel or material group personnel, and visually displays the abnormal conditions proposed by the people on the line and the station. And the technical personnel reasonably arrange the working personnel to process the abnormal conditions in time according to the abnormal information. Thereby improving the state that people cannot be found or not known when the abnormity occurs.

4) Quality and process control billboard: the method mainly provides real-time product bad and process bad conditions for a quality group or a process group, and quality personnel and process personnel improve the process flow or material batches in time according to the bad conditions.

Eight, statistical analysis, as shown in figures 13-17,

1) producing daily newspapers: the system can visually know the conditions of the manual work utilization rate, the equipment mobility rate, the plan achievement rate, overtime and the like of each production day, and is convenient to analyze.

2) And (5) producing a monthly report.

3) And (5) carrying out statistics on the performance of the personnel.

4) And (5) counting production abnormity.

5) And (3) quality statistical analysis: and automatically generating a quality daily report through warehousing scanning gun and mobile phone scanning judgment. The cell corresponding to the form is counted by mobile phone code scanning and automatic classification judgment, so that the manual counting and inputting procedures are reduced, and the accuracy is improved.

And inputting parameters after the code is scanned by the mobile phone, and automatically generating an X-R management drawing. The quality characteristic parameters to be collected are input after the codes are scanned by the mobile phone, the existing manual statistics is replaced, and the quality characteristic parameters are input into a form of a computer, so that the workload is reduced.

6) Daily, monthly, quarterly, annual cost analysis.

As shown in fig. 18, the overall business architecture of the system platform has the technical design concept that: the separation of system presentation logic (user interface) and service logic (specific service logic) is realized by adopting the latest distributed multilayer architecture, J2EE, XML, XSL technology and service logic component technology in the industry and the classical MVC (Model-View-Controller) design mode in the industry, so that the 'zero maintenance' of a client application system is realized, and various client access devices can be supported; by adopting JAVA technology, an application system in a website application server can be written once and Run everywhere (Write once, Run anywrite); by adopting network security technology; by adopting a hardware device (Web server, application server and the like) cluster technology, the expandability of the system is realized; we also implement user personalized login at the Web server side as shown in fig. 19.

The application system architecture adopts an advanced MVC (Model-View-Controller) Design paradigm (Design Pattern), as shown in fig. 20, and adopts a distributed multi-layer system, and uses a platform-independent technical framework and a service logic componentization technology.

The structure is divided into three layers from the system processing function in a horizontal classification way, namely: the system comprises a portal representation layer, an intermediate application layer and a data processing layer, wherein: the portal presentation layer is divided into a working layer, a management layer and a decision layer according to the application longitudinal direction;

viewing the image layer: the view control layer performs data interaction with the data link layer through a TCP/IP transmission protocol of the network transmission layer and persists data;

an intermediate application layer: the system consists of a group of software and a system framework, is beneficial to quickly constructing a customized application system, ensures the expandability, easy modification, interconnectivity and independence of a system platform, and comprises J2EE, a minimum business data unit component, a business model processing component, an integrated service engine, a content service engine, a rule service engine and a workflow engine;

a data processing layer: the data access, backup and processing layer taking the database technology as a core adopts a mysql/sqlserver database.

The bottom layer communication mechanism of the system platform is shown in fig. 21, and has the technical characteristics that:

through a workflow operation tracking monitoring function and workflow operation analysis, business process optimization (BPI) and information recombination are supported, and a workflow cross-platform mechanism is supported;

taking a core workflow as a main line, combining various professional process flows, dividing various minimum management units, reflecting the independence of a business processing mechanism (or department), and directly reflecting the uniqueness of the workflow and actions, so that the system application is changed from passive to active, namely: information driving work;

the user-defined flow is supported by a convenient, flexible and visual workflow management mechanism, and complete safety and permission design is provided;

supporting the transfer of work tasks through a work entrusting function;

the system has a directory management function and realizes multi-type management of information;

and performing overall data modeling by taking the minimum unit of the equipment as an object, and dynamically and logically dividing a work unit object and an equipment containing unit (the object contains a plurality of sub-objects) according to the management characteristics of the enterprise.

The previous description of the disclosed embodiments is provided to enable any person skilled in the art to make or use the present invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other embodiments without departing from the spirit or scope of the invention. Thus, the present invention is not intended to be limited to the embodiments shown herein but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. A TCM system utilizes sensing technology, wireless communication technology, network technology, intelligent digitization technology, RFID Internet of things application service platform technology, AI image recognition and cloud computing platform, and is characterized by comprising a plan management unit, a process management unit, an equipment management unit, a production reporting unit, an abnormity management unit, a quality management unit, a billboard management unit, a statistical reporting unit, a system safety management unit and a system interface unit;

2. The TCM system of claim 1, wherein the schedule management unit is configured to convert the production schedule and the customer order into a specific production operation schedule, to exclude efficient operation sequences of days, shifts, lines, stations, etc. and to minimize equipment adjustments, taking into account order priorities, delivery dates, inventory, processing routes, product characteristics, processing procedures, equipment loads, resource constraints, etc.

3. A TCM system according to claim 1, wherein the process management unit is required to cooperate with the developers of the existing system to provide interfaces and related fields for reading the corresponding information, including process document and graphics management, process flow management, process version management and approval management.

4. The TCM system according to claim 1, wherein the production work reporting unit comprises an operation terminal, production task submission and production progress submission, wherein the operation terminal places a station terminal for each line key station or each plurality of devices for task submission, production progress submission, abnormal calling and image-text review; the production task checking is to place an operation terminal at a designated position in a workshop site, an employee wears an RFID bracelet or an entrance guard card on the site, the terminal swipes the card or recognizes the face to know the production task of the employee, and the card checks the relevant station files and operation instructions; the production progress submission is to directly submit the production quantity through data acquisition of a field workstation or equipment.

5. The TCM system of claim 1, wherein the anomaly management unit implements rapid information transfer, call application, real-time display, statistical analysis, report generation, and real-time information transfer and management for processes such as process operation, equipment status, quality problems, and supply material conditions, and supports the entire production process; when the quality, the process, the equipment and the equipment parameters are abnormal, the system can remind step by step according to the preset personnel, processing time and reminding mode if the responsible person does not process the alarm within the time.

6. The TCM system of claim 1, wherein the quality management unit submits data of product self-inspection, scrapping, repair, etc. in the production process through a field terminal; the inspection personnel are provided with a mobile terminal, select a production task through the mobile terminal for inspection, and submit inspection data; checking the inspection record and the statistical result of the current production task in real time by a worker through the system; and through equipment data acquisition, automatically acquiring the inspection data of the inspection equipment and submitting the inspection data to the system.

7. The TCM system of claim 1, wherein the billboard management unit can place a corresponding billboard in each production line, key station, and key department, and the types of the billboard include a liquid crystal billboard or a LED billboard.

8. The TCM system according to claim 1, wherein the reports in the statistics report unit include device failure statistics report and device operation statistics report, and support freely selected time span for object statistics.

9. The TCM system of claim 1, wherein the system security management unit adopts a hierarchical system authority division function in the authority division to define the authority level, the operation range and the information awareness range, so as to ensure the system information and operation security and achieve the privacy and independence of precise control information.

10. The TCM system according to claim 1, wherein the system interface unit includes an interface with an ERP system, that is, the required contents existing in the ERP are read into the TCM system through integration, and part or all of the information of the equipment management module and the BOM management module; the interface with the PDM system realizes seamless connection of a production field processing task, a part process drawing and a process route; the interface with the PLC system, because the PLC system can exist as an independent system, the direct data interaction of the PLC and the TCM needs to be realized by a system integration mode.