提到索菲亚，人们立即会想到“定制家居”。自2003年成立以来，索菲亚专注于经营定制衣柜及其配套定制家具的研发、生产和销售，并充分利用自身制造和信息化优势，不断提高服务质量，更及时地满足消费者对设计、安装等专业服务的要求，使公司在与其他品牌的竞争中脱颖而出，市场占有率逐年提升。
近年来，索菲亚致力于促进家居制品产业向数字化、网络化、智能化方向发展，并于2014年成立信息化公司——广州极点三维信息科技有限公司，2015年成立智能制造系统公司——广州宁基智能系统有限公司(以下简称“宁基智能”)，着手对定制家居产品智能制造规划和布局，构建了智能制造管理系统MES、智能仓储系统WMS，以及拥有自主知识产权的智能制造控制系统LCS、智能控制通讯与规则系统Darwin等，通过多年不断投入和探索实践，已实现了全线智能制造，在索菲亚黄冈生产基地、成都生产基地已经建成智能制造示范工厂，并于2018年开始正式投产。
目前索菲亚正在总部广州增城建设智能制造工厂，该项目建设以“解放双手”、“降耗减排”、“创新驱动”、“智慧协同”作为目标，整线集成智能仓储、智能装备、智能物流设备及智能质量检测设备等于一体，实现全智能化生产。
总体而言，由宁基智能规划的4.0智能数字化板式家具生产车间，不仅为索菲亚提供了先进生产力，为其数智化升级赋能，而且也可以推广应用到更多家居企业，为整个家居行业的高质量发展提供坚实基础。
一、项目简介
宁基智能规划的4.0智能数字化板式家具生产车间，是集数字化、网络化、智能化为一体的工业4.0智能车间。
（一）整体布局与作业流程
工业4.0智能数字化板式家具生产车间由自动材料库、智能上料开料、实时在线检测、智能钻孔、智能封边、智能分拣、自动包装，以及车间缓存、车间物流输送、车间协同控制、设备封装/感知/决策/执行、自动数据采集与实时看板、光伏绿色能源等部分组成。
在智能车间内，实现了从板材自动上料、智能开料、实时检测、智能封边、智能钻孔、智能分拣、自动包装、自动入库等全部制造环节的集成与贯通，实现了所有设备（包括欧美设备）的互联互通，实现全生产流程的自动化、数字化、智能化，单位量产处行业领先水平（参见图1）。
生产流程为：生产领料→开料→封边→打孔→分拣→包装→入库，以及为了提高生产质量和加工效率等目标而在主流程之间设置的其他为了提高产品质量的工序，如开料后的板材清洁工序、质量检测工序等。
（二）主要通讯网络与通讯流程
定制家具自动化生产线的各生产设备和硬件单元与控制系统的主要通讯网络（参见图2）。
主要通讯流程为：生产过程执行系统（MES）准备所有工段生产数据，并下发给车间每个工段的每台设备。立体仓储接收到MES系统备料数据后，开始按照生产顺序依次进行备料、拣选。在生产过程中，各个工段通过感应器扫码触发开始生产，结束生产后，可编程逻辑控制器（PLC）请求线控系统获取加工数据。线控系统通过WinCC／OPC实时监控PLC请求，当检测到PLC请求后，线控系统自动从设备数据库中获取生产数据进行计算分析，计算分析完成后通过WinCC／OPC反馈给PLC，PLC再根据线控反馈结果，控制产品加工。标准设备生产实时数据、设备实时状态通过网络、数据库方式实施采集。
（三）智能制造系统组成
总体来看，定制家居智能制造系统由四个层级组成（参见图3）：
●前端数据提供层，把客户的订单转换数字化数据。
●车间执行层，根据客户的出货计划进行排产，对整个生产过程进行管控。
●工业控制边缘层，是上层系统和设备层之间的桥梁，起着信息化通道的作用。
●设备层，是执行机构，由各自的CNC加工设备、配套的物流输送设备、各种信息采集设备、现场看板组成。
定制家具4.0智能生产线的系统构成（参见图4）。
定制家具4.0智能生产线是软、硬件有机的融合，形成一套智能化的生产体系。
生产执行系统MES、生产线控制系统LC的数据，通过工业互联网形成数据流把各智能装备连接起来，通过传感技术、扫描技术、视觉技术、数据库、企业云等把数据形成制造闭环，订单数据流根据实时制造动态流向各加工设备上，加工设备把实时加工信息通过线控返回到MES系统中。
现场人员通过HMI人机交互界面、实时监控系统看板等实时掌控生产线的动态运行状态。
（四）绿色节能部署
为了适应绿色制造的发展理念，智能制造车间的房顶全部采用太阳能板覆盖，既能进行太阳能发电，又能在夏天降低车间的温度；太阳能发电联网，既可以用于生产线的用电，又可以在充足的条件向外输出；通过对生产线的实时监控，自动按需启停设备，节约电力及降低设备的损耗。
二、项目特点
（一）车间的物流转运、分拣及存储实现全自动化
车间的物流转运、分拣及存储实现全自动化，具备先进的生产制造系统MES、板材仓库存储系统WMS，生产线设计产能超过2万件/天。从智能立体原料仓出发，每一块板件经历开料、封边、打孔、分拣、打包，全程不落地、不经人手。
（二）车间可与传统生产车间的制造孤岛联接为一条智能化生产线
车间可与传统生产车间的制造孤岛联接为一条智能化生产线，最大程度缩短每批次板件的生产周期，加快物流转运，减少工序之间的等待时间。智能制造系统涵盖信息系统、生产技术装备、自动化设备、仓储物流技术装备，物流发运效率达到500订单/天、260托盘/小时。
（三）智能制造系统集成ERP系统
智能制造系统集成ERP系统（参见图5）、MES系统、仓储管理系统WMS、仓储控制系统WCS、智能物流系统TMS等各个系统无缝衔接，覆盖了从销售前端的设计画图、报价、下单，再到后端生产的计料、排单、开料、包装、库存等完整覆盖整个销售生产流程（参见图6）。
（四）车间的所有的物料及产品进行了数据代码管控
车间的所有的物料及产品进行了数据代码管控。从原材料开始记录信息，方便对板材进行管理；对每一件板材编码后，机器能够快速调取；实现了板件产品全流程跟踪、监控与追溯。甚至是定制方面出现的错误和问题，都可以及时“追根究底”。以下以板材追溯为例，说明数据采集的流程。
通过扫码仪扫描原材料板材的二维码，获取的信息通过基本树莓派的采集程序发送到采集服务器上。同步进行采集电子开料锯的加工信息并发送数据到采集服务器上。把采集的数据和MDB文件里的板材信息进行匹配，把所有的电子锯上的信息汇集到总部的采集中心数据库，并同步进到ERP/MES中（参见图7）。
在电子锯上料端根据上料台动作信息自动启用扫码仪，为了防止二维码出现损坏丢失信息，每张板件的侧面喷三个二维码。
采集的数据通过网络实时传输到采集数据中，并以报表的形式显示出来（参见图8）。
把采集的数据通过数据处理生成监控看板，根据显示的状态判断系统是否正常（参见图9）。
三、项目六大创新点
创新点一：基于RAMI4.0技术构造定制家居智能制造的框架模式
基于RAMI4.0组件封装技术、知识框架技术，研发了一种定制板式家居智能制造的柔性生产线。以客户订单为中心贯穿定制家居的制造流程，通过解析定制家居的功能，转换为信息层，建立标准的全平台通讯层，到集成设备层，实现定制家居制造框架模式的搭建。通过机器视觉、分布式自适应智能控制原理，采用智能拆单+智能拼单+智能排料技术，提高了板材利用率；采用负荷平衡+多工位多工序协同控制技术+多机器人协同分拣和包装技术，提高了产能；生产车间屋顶全部安装光伏板，实现部分清洁能源供电；通过具有自我感知与自主执行的智能板式家具生产设备，实现了生产设备数据驱动下的互联互通、面向智慧工厂纵向集成的柔性动态配置网络化制造。
创新点二：基于自主知识产权达尔文全平台通讯及监控构建定制家居多类型设备协同模式
研发了一种基于达尔文平台的设备数据采集与监控技术，通过面向对象OO技术和OPC UA技术，采用C#语言开发了面向家居智能制造设备和智能仓储及物流设备的通信协议、通信规则，打通了企业资源计划系统ERP、制造执行系统MES与智能设备PLC/控制系统接口之间的连通，实现了跨平台多种设备的实时接入、通信、监控（参见图10）。
创新点三：基于机器视觉与光学检测创制的在线检测系统
采用领先视觉检测技术实现高速的在线检测，集成上下表面质量检测，封边检测， 尺寸（外观尺寸、孔尺寸、槽尺寸）等，检测结果实时同步到MES（生产管理系统中）， 进行质量数据分析，实现加工质量的预警（参见图11、图12）。
创新点四：基本订单流程构建的柔性化智能生产线动态均衡模式
订单转换为数字化，在制造的过程中呈现不同的形态，保证效率的前提下实现高效、均衡。设备数据驱动下的互联互通、面向智慧工厂纵向集成的柔性动态配置网络化，信息的实时反馈及优化处理，实时调节，达到生产线动态均衡。
创新点五：基于机器人协同的货架式定制家居板件分拣模式
按包出库的分拣模式创新，3条分拣通道，配合多台发那科分拣机器人，及多条包装通道，采用西门子PLC，OPC接口通讯方式，实现板件全自动分拣。同时开发了单件包直通功能，实现单件包板件不上书本架，直接流通至包装工段，提升了书本架利用率，并提升了分拣效率约10%。分拣出包逻辑可实现按单分拣及按包分拣2种逻辑，更大程度实现柔性化生产。机器人运行程序由宁基智能开发，其中离线编程、实物模拟仿真等技术在分拣工段中发挥巨大作用（参见图13、图14）。
创新点六：创新智慧清洁能源技术及应用
混批生产模式的创新，本智能制造系统采用多台电子锯同时对一个批次进行开料的方式，批次间切换紧密连接，同时，线上采用多个链式缓存，可实现线上存在不同批次板件同时生产，更大程度实现柔性化生产。
四、应用的核心技术
1.智能制造的全线协同控制技术；
2.设备信息采集、传输及分析；
3.多设备协同控制及指令系统；
4.设备运行状态在线监控与故障处理；
5.排产、揉单生产，生产节拍优化控制；
6.生产线产能均衡技术；
7.批次加工板材动态分配技术；
8.缓存技术；
9.智能分拣混批技术；
10.高速滚筒/皮带输送线；
11.高速车间输送及缓存技术；
12.高速顶升移载技术；
13.输送设备的分合技术；
14.链式缓存；
15.高效分拣技术；
16.机器人柔性化协同作业技术；
17.码垛机器人的协同工作；
18.分拣机器人的协同工作抱垛机器人的协同工作。
五、效能提升
（一）人均产能的提升带来人工成本的大幅降低。
人均产能的提升带来人工成本的大幅降低。一条智能生产线日产量约为2万件，需要生产人员（含管理人员）76人，而传统的生产线，相同的产量需要161人，节约与传统车间相比，生产人效提高2.12倍，按照人工成本9.5万元/年计算，一条生产线节约人工成本约为807.5万元。
（二）产品质量的提升、智能算法板材利用率的提升带来的效益
产品质量的提升、智能算法板材利用率的提升带来的效益，据统计黄冈生产基地2021年1月份至5月份，智能车间的板材利用率是85.77%，普通车间的利用率是76.75%，提升了9个百分点，年成本节约约为800万元。
（三）产品在智能生产线加工到包装完成的平均处理时间为1.7个小时
产品在智能生产线加工到包装完成的平均处理时间为1.7个小时，而在传统生产线则需要3～4个小时，智能车间大大缩短了产品的生产周期和交付周期，有效实现了降本增效及提升客户的消费体验，给企业带来良好的经济效益。
（四）采用绿色光伏能源的效益提升
采用绿色光伏能源的效益提升，据2019年的统计，节约的电费成本约为150万元。
（五）社会效益的提升
社会效益的提升。传统的生产线基本上都是人工操作，工作条件艰苦。智能生产线操作人的工作是保障生产线的稳定运行，劳动强度和工作环境得到极大的改善，符合社会发展的方向，为其它的企业带来良好带领示范作用，具有良好的社会效率。
性能方面的主要技术指标比对如表1所示，效率和能效方面的主要技术指标比对如表2所示。
六、发展成果和进一步的发展
项目成果已推广到索菲亚的各个生产基地，2018年建成并应用黄冈基地的4.0A、4.0B智能制造生产线，2020年建成并应用成都基地的4.0C智能制造生产线，目前正在建设总部广州基地的4.0D生产线以及浙江嘉善基地的生产线。
本智能制造系统具有智能化、柔性化的特点，可满足各种个性化加工需求，无需大量人工参与，适用于板式个性化定制家居产品的规模化制造。随着经济发展，人们生活水平提高，对定制家居产品个性化需求越来越高、订单量需求越来越大、一线劳动工人招聘越来越难，在这样的发展趋势背景下，未来本智能制造系统必将完全替代当前的传统生产线和柔性生产线。
When it comes to Sofia, people immediately think of “bespoke home”. Since its establishment in 2003, Sophia has been focusing on the research and development, production and sales of customized wardrobe and its supporting customized furniture, and has made full use of its manufacturing and information advantages, constantly improving the quality of service, more timely to meet consumers’ requirements for design, installation and other professional services, so that the company stands out in the competition with other brands, and its market share has increased year by year.
In recent years, Sofia has been committed to promoting the development of household products industry towards the direction of digitization, networking and intelligence. In 2014, IT established Guangzhou Pole 3D Information Technology Co., LTD., and in 2015, it established Guangzhou Ningji Intelligent System Co., LTD. (hereinafter referred to as “Ningji Intelligent”). We began to plan and layout the intelligent manufacturing of customized household products, and constructed intelligent manufacturing management system MES, intelligent storage system WMS, intelligent manufacturing control system LCS with independent intellectual property rights, intelligent control communication and rule system Darwin, etc. Through years of continuous investment and exploration and practice, we have realized the full line of intelligent manufacturing. Intelligent manufacturing demonstration factories have been built in Huanggang Production Base in Sofia and Chengdu production base, and officially put into operation in 2018.
At present, Sofia is building an intelligent manufacturing plant in Zengcheng, Guangzhou, the headquarters of which aims at “freeing hands”, “reducing consumption and emission reduction”, “innovation-driven” and “intelligent collaboration”. The whole line integrates intelligent warehousing, intelligent equipment, intelligent logistics equipment and intelligent quality testing equipment, so as to realize fully intelligent production.
In general, the 4.0 intelligent digital panel furniture production workshop planned by Ningji Intelligent not only provides advanced productivity for Sofia and enables its digital intelligent upgrading, but also can be applied to more home furnishing enterprises, providing a solid foundation for the high-quality development of the entire home furnishing industry.
Project introduction
4.0 intelligent digital plate furniture production workshop of Ningji Intelligent planning is an industrial 4.0 intelligent workshop integrating digitalization, networking and intelligence.
Overall layout and operation process
Industry 4.0 intelligent digital plate furniture production workshop is composed of automatic material library, intelligent feeding and opening, real-time online detection, intelligent drilling, intelligent edge sealing, intelligent sorting, automatic packaging, as well as workshop cache, workshop logistics transportation, workshop collaborative control, equipment packaging/perception/decision/execution, automatic data acquisition and real-time Kanban, photovoltaic green energy and other parts.
In the intelligent workshop, it realizes the integration and penetration of all manufacturing links such as automatic plate feeding, intelligent opening, real-time detection, intelligent edge banding, intelligent drilling, intelligent sorting, automatic packaging and automatic storage, realizes the interconnection and interworking of all equipment (including European and American equipment), and realizes the automation, digitalization and intellectualization of the whole production process. Industry-leading level of unit mass production (see Figure 1).
The production process is: production receiving → opening → edge sealing → punching → sorting → packaging → storage, and in order to improve the production quality and processing efficiency and other objectives set between the main process in order to improve the quality of products, such as the sheet cleaning process after opening, quality detection process.
Main communication network and communication process
The main communication network between the production equipment and hardware units of the customized furniture automation production line and the control system (see Figure 2).
The main communication flow is: Production Process Execution system (MES) prepares production data for all sections.
And sends it to each unit in each section of the workshop. After receiving MES system material preparation data, three-dimensional storage began to prepare and select materials in accordance with the production sequence. In the production process, each section is triggered by the sensor code scanning to start production. After the production is finished, the programmable logic controller (PLC) requests the wire control system to obtain the processing data. Wire control system through WinCC/OPC real-time monitoring PLC request, when the detection of PLC request, wire control system automatically from the equipment database to obtain production data for calculation and analysis, calculation and analysis is completed through WinCC/OPC feedback to PLC, and then according to the wire feedback results, control product processing. Real-time production data of standard equipment and real-time state of equipment are collected through network and database.
Intelligent manufacturing system composition
In general, the custom home intelligent manufacturing system consists of four levels (see Figure 3) :
● Front-end data provision layer, the customer’s order into digital data.
● Workshop execution layer, according to the customer’s shipment plan to schedule production, control the entire production process.
● Industrial control edge layer, is the bridge between the upper system and the equipment layer, plays the role of information channel.
● Equipment layer, is the executive mechanism, by their CNC processing equipment, supporting logistics conveying equipment, a variety of information acquisition equipment, site Kanban composition.
The system composition of customized furniture 4.0 intelligent production line (see Figure 4).
4.0 intelligent production line is the organic integration of hardware and software, forming a set of intelligent production system.
The data of production execution system MES and production line control system LC form a data stream through the industrial Internet to connect various intelligent equipment. The data form a manufacturing closed loop through sensing technology, scanning technology, vision technology, database, enterprise cloud, etc. The order data flow flows to each processing equipment according to real-time manufacturing dynamics. The processing equipment returns the real-time processing information to MES system by wire control.
Field personnel control the dynamic running state of the production line in real time through HMI man-machine interaction interface, real-time monitoring system Kanban, etc.
Green and energy-saving deployment
In order to adapt to the development concept of green manufacturing, the roof of the intelligent manufacturing workshop is covered by solar panels, which can not only generate solar power, but also reduce the temperature of the workshop in summer. The solar power generation network can not only be used for electricity production line, but also can be exported in sufficient conditions; Through real-time monitoring of the production line, automatic start-stop equipment on demand, saving power and reducing the loss of equipment.
Project characteristics
The logistics transfer, sorting and storage of the workshop are fully automated
The logistics transfer, sorting and storage of the workshop are fully automated, with advanced production and manufacturing system MES and board warehouse storage system WMS. The designed production line capacity exceeds 20,000 pieces per day. Starting from the intelligent three-dimensional raw material warehouse, each piece of board goes through material opening, edge sealing, punching, sorting and packing without landing or manual.
The workshop can be connected with the manufacturing island of the traditional production workshop as an intelligent production line
The workshop can be connected with the manufacturing island of the traditional production workshop into an intelligent production line, which can minimize the production cycle of each batch of sheet parts, speed up logistics transfer, and reduce the waiting time between processes. Intelligent manufacturing system covers information system, production technology and equipment, automation equipment, warehousing and logistics technology and equipment, logistics delivery efficiency reaches 500 orders per day, 260 pallets per hour.
Intelligent manufacturing system integrated ERP system
Intelligent manufacturing system integrates ERP system (see Figure 5), MES system, warehouse management system WMS, warehouse control system WCS, intelligent logistics system TMS and other systems seamlessly, covering from the front of the sales design drawing, quotation, order, Then, the material counting, scheduling, opening, packaging and inventory of back-end production completely cover the entire sales and production process (see Figure 6).
All materials and products in the workshop are controlled by data code
All materials and products in the workshop are controlled by data code. Record information from raw materials to facilitate the management of plates; After the code of each sheet, the machine can be quickly transferred; The whole process tracking, monitoring and tracing of board products are realized. Even errors and problems in customization can be “investigated” in a timely manner. The following sheet traceability as an example to illustrate the process of data acquisition.
The QR code of the raw material plate is scanned by the scanner, and the information obtained is sent to the collection server through the basic Raspberry PI collection program. Collect the processing information of electronic cutting saws synchronously and send the data to the collection server. Match the collected data with the board information in the MDB file, collect all the e-saw information into the acquisition center database at the headquarters, and synchronize it into ERP/MES (see Figure 7).
At the feeding end of the electronic saw, the scanning code instrument is automatically enabled according to the action information of the feeding table. In order to prevent damage and loss of the two-dimensional code, three two-dimensional code is sprayed on the side of each plate.
The collected data is transmitted to the collected data in real time through the network and displayed in the form of a report (see Figure 8).
Through data processing, the collected data is generated into a monitoring Kanban, which determines whether the system is normal according to the displayed state (see Figure 9).
The project six innovation points
Innovation point 1: Construct frame mode of customized home intelligent manufacturing based on RAMI4.0 technology
Based on RAMI4.0 component packaging technology and knowledge frame technology.
A customized flexible production line for intelligent manufacturing of plate household was developed.
Taking customer orders as the center, it runs through the manufacturing process of customized home. By analyzing the functions of customized home, it is transformed into the information layer, establishing the standard all-platform communication layer, and then to the integrated equipment layer, realizing the construction of the frame mode of customized home manufacturing. Through machine vision, distributed adaptive intelligent control principle, intelligent dismantling + intelligent ordering + intelligent discharging technology, improve the board utilization rate; Load balancing + multi-station and multi-process collaborative control technology + multi-robot collaborative sorting and packaging technology has been adopted to improve production capacity. The roof of the production workshop is all installed with photovoltaic panels to realize partial clean energy power supply; Through the intelligent panel furniture production equipment with self-perception and self-execution, the connectivity of production equipment driven by data and the flexible dynamic configuration network manufacturing oriented to the vertical integration of smart factories are realized.
Innovation point 2: Based on the independent intellectual property Darwin all-platform communication and monitoring, the construction of customized home multi-type equipment collaboration model
A kind of equipment data acquisition and monitoring technology based on Darwin platform is developed. Through OO technology and OPC UA technology, C# language is used to develop the communication protocol and communication rules for intelligent manufacturing equipment and intelligent warehousing and logistics equipment in home. The connection between ERP of enterprise resource planning system, MES of manufacturing execution system and PLC/ control system of intelligent equipment is achieved, realizing real-time access, communication and monitoring of various cross-platform devices (see Figure 10).
Innovation point 3: online detection system based on machine vision and optical detection
Advanced visual detection technology is adopted to realize high-speed online detection, integrating upper and lower surface quality detection, edge sealing detection, size (appearance size, hole size, slot size), etc. The detection results are synchronized to MES (production management system) in real time, quality data analysis is carried out, and the early warning of processing quality is realized (see Figure 11, Figure 12).
Innovation point 4: flexible intelligent production line dynamic balance model constructed by basic order process
The order is converted into digital, which presents different forms in the process of manufacturing, so as to achieve high efficiency and balance under the premise of ensuring efficiency. Equipment data-driven connectivity, flexible dynamic configuration networking for vertical integration of smart factories, real-time information feedback and optimization processing, real-time adjustment, to achieve dynamic balance of production lines.
Innovation point 5: Sorting mode of shelf-type customized household panels based on robot collaboration
According to the sorting mode innovation of package delivery, 3 sorting channels, with a number of Fanuc sorting robots, and a number of packaging channels, using Siemens PLC, OPC interface communication mode, to achieve automatic sorting of board parts. At the same time, the single package through function is developed to realize that the single package board is not on the book shelf, but directly circulated to the packaging section, which improves the utilization rate of the book shelf and improves the sorting efficiency by about 10%. The sorting and sorting logic can realize two kinds of logic: sorting by single and sorting by package, and realize flexible production to a greater extent. The robot operation program is developed by Ningji Intelligence, in which off-line programming, physical simulation and other technologies play a great role in the sorting section (see Figure 13, Figure 14).
Innovation point six: Innovative smart clean energy technology and application
The innovation of mixed batch production mode, the intelligent manufacturing system uses multiple electronic saws to open a batch at the same time, the switch between batches is closely connected, at the same time, the online use of multiple chain cache, can realize the simultaneous production of different batches of plate online, to a greater extent to achieve flexible production.
The core technology of application
- Full-line collaborative control technology of intelligent manufacturing;
- Equipment information collection, transmission and analysis;
- Multi-device collaborative control and instruction system;
- Online monitoring and troubleshooting of equipment running status;
- Schedule production, knead sheet production, optimize and control production tempo;
- Production line capacity balancing technology;
- Batch processing plate dynamic distribution technology;
Caching technology; 8.
- Intelligent sorting and batch mixing technology;
- High-speed roller/belt conveyor line;
- High-speed workshop conveying and caching technology;
- High speed jacking and load shifting technology;
- Separation and closing technology of conveying equipment;
- Chain cache;
- Efficient sorting technology;
- Flexible collaborative work technology of robots;
- Collaborative work of palletizing robots;
- Cooperative work of sorting robots Cooperative work of stacking robots.
Efficiency improvement
The increase of per capita production capacity brings about a substantial reduction in labor costs.
The increase of per capita production capacity brings about a substantial reduction in labor costs. The daily output of an intelligent production line is about 20,000 pieces, requiring 76 production personnel (including management personnel), while the traditional production line, the same output needs 161 people, saving compared with the traditional workshop, production efficiency increased by 2.12 times, according to the labor cost of 95,000 yuan/year calculation, a production line saving labor cost is about 8.075 million yuan.
he benefits brought by the improvement of product quality and the improvement of the utilization rate of intelligent algorithm plate
According to statistics, from January to May 2021 in Huanggang production base, the board utilization rate of intelligent workshop is 85.77%, and that of ordinary workshop is 76.75%, an increase of 9 percentage points, and the annual cost saving is about RMB 8 million.
The average processing time from the intelligent production line to the completion of packaging is 1.7 hours
The average processing time of products from processing to packaging in the intelligent production line is 1.7 hours, while in the traditional production line it takes 3 ~ 4 hours. The intelligent workshop greatly reduces the production cycle and delivery cycle of products, effectively realizes cost reduction and efficiency improvement and improves customers’ consumption experience, bringing good economic benefits to the enterprise.
The efficiency of green photovoltaic energy is improved
The efficiency of adopting green photovoltaic energy is improved. According to the statistics in 2019, the electricity cost saved is about 1.5 million yuan.
Improvement of social benefits
The improvement of social benefits. The traditional production line is basically manual operation, working conditions are difficult. Intelligent production line operators work to ensure the stable operation of the production line, labor intensity and working environment has been greatly improved, in line with the direction of social development, for other enterprises to bring a good leading demonstration role, with good social efficiency.
The comparison of the main technical indicators of performance is shown in Table 1, and the comparison of the main technical indicators of efficiency and energy efficiency is shown in Table 2.
Development achievements and further development
The project results have been extended to various production bases in Sofia. In 2018, 4.0A and 4.0B intelligent manufacturing production lines in Huanggang base were completed and applied, and in 2020, 4.0C intelligent manufacturing production lines in Chengdu base were completed and applied. Currently, 4.0D production lines in Guangzhou Base and Jiashan base in Zhejiang are under construction.
The intelligent manufacturing system has the characteristics of intelligence and flexibility, can meet various personalized processing needs without a lot of manual participation, and is suitable for the large-scale manufacturing of plate personalized customized household products. With the development of economy and the improvement of people’s living standards, the personalized demand for customized household products is becoming higher and higher, the demand for order quantity is becoming larger and larger, and the recruitment of front-line workers is becoming more and more difficult. Under such a development trend background, the intelligent manufacturing system will completely replace the current traditional production line and flexible production line.
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