一、前言
2020年，横店东磁太阳能电池片六厂被评为全省首批12家“未来工厂”之一；2021年，建成“未来工厂”升级版——电池片七厂，是浙江全省智能工厂的代表；2022年，电池片七厂的照片也出现在北京“奋进新时代”主题成就展的醒目位置。
作为全球最大的永磁铁氧体生产企业和全球最大的软磁材料制造企业，位于“中国磁都”东阳市的横店东磁无疑是行业巨头。横店东磁拥有磁性材料、新能源和器件三大产业，获得过太阳能制造的领跑者证书，下属70多家工厂，是全国磁性行业的龙头企业。即便是行业龙头，东磁当初也面临着数字化建设落后的困境，如今能取得今天的数字化成就实属不易。
二、背景
磁性材料作为一种重要的功能材料，被广泛应用于家电、汽车、计算机、通讯、医疗、航天和军事等领域。磁性材料更是在节能环保、新能源电动汽车、智慧城市、智慧地球等新兴领域中得到越来越广泛的应用，随着5G通信、物联网、人工智能、新能源汽车等新兴应用市场的不断开拓发展，中国磁性材料产业也随之蓬勃。但在产业蓬勃发展的背后，却是全产业在数字化建设方面的落后。
即便是横店东磁，数字化建设也远远落后于世界其他巨头。横店东磁集团认为，公司只有进行数字化建设，才能和日本、欧美等世界企业真正站在同一水平线。2016年前后，横店东磁决定开始系统性进行数字化转型建设，并于2017年申请了国家工信部智能制造新模式应用的科技项目。
东磁对数字化转型的需求非常明确：希望实现生产系统的无纸化管理，为集团70多家工厂提供标准的、一致的系统，并且能够打通产业链上下游，使用统一的平台进行数据汇总与业务协同。
三、传统管理模式弊端
（一）生产管理粗放
生产管理粗放，无法满足高性能产品对制造过程的精确控制需求。如：以前东磁几乎没有通用的生产管理系统，生产计划和生产线调度都只能依靠人工巡逻完成。
（二）准确性不高
生产计划执行准确性不高，生产工单准时完工率过低。
（三）生产成本高
能源消耗、原材料成本、人工费用等不断增高导致生产成本增高。
（四）设备无法实时监控
设备无法实时监控，无法提高其生产效率。如：以前东磁每家工厂有数百台设备，每台设备的数据都不透明，很难了解每一台的生产状态。
（五）数据不准确
生产过程数据收集难，车间现场的原始数据无法准确反馈，无法了解详细生产制程数据。如：以前东磁生产车间的管理多靠纸质流程进行，管理流程不标准，且数据获取也不准确，产品溯源成问题。
（六）供应链不稳定
上游议价能力不断提升，导致原材料成本增加，同时下游客户不断要求降价，并要求更高性能的产品、更优质的服务质量，磁性材料企业竞争加剧。
（七）生产协同效果差
集团下工厂之间没有系统进行连接，各工厂不能快速实现生产协同，工厂间的产品流动同样需要依靠纸质单据。
四、具体成效
在整个生产过程中，本着“提质、增效、降成本”的目的，为磁性材料企业设计了上百道管控手段，为企业带来经济效益的明显提升。
√ 通过MES系统实现无纸化办公作业，用系统替代了原始纸质单据；
√ 拼接屏多屏和单屏数据展示；
√ 物料流转全过程条码扫描防错、防呆；
√ 用料批次信息与用料防错管控；
√ 生产过程透明化、订单进度、产品生产过程信息详细追溯，实现产品质量追溯；
√ 电子秤数据采集；
√ 现实信息化、数据可视化管理，能时时展现各报表数据，例如生产进度，质量报表，替代人工做报表。
√ 实现主要检测仪器数据直接上传系统，SPC数据分析
√ 建立设备监控中心，对设备状态进行实时监控以及设备利用率、稼动率、OEE等数据分析
√ 经营指标的管理支撑：利用信息技术对各部门及制造单元计划执行率，设备利用率OEE、良品率、一次合格率等绩效指标量化评比，实现生产数据实时呈现，提供单线、单工单、单产品、物料使用、生产数据分析与趋势；通过设备利用率实时管理，使资源回报最大化。
翻译：
Preface
In 2020, Hengdian Donghe Solar Cell Plant No. 6 was rated as one of the first 12 “future Factories” in the province; In 2021, the upgraded version of “Future Factory” — battery Plant 7 will be built, which is the representative of Zhejiang Province’s smart factory. In 2022, the photos of the seventh battery Factory also appeared in the prominent position of the “Striving for a New Era” theme achievement exhibition in Beijing.
As the world’s largest manufacturer of permanent magnet ferrite and the world’s largest manufacturer of soft magnetic materials, Hengdian East Magnetic Co., LTD., located in Dongyang City, the “magnetic capital of China”, is undoubtedly an industry giant. Hengdian Dongmagnetic owns three industries of magnetic materials, new energy and devices, and has obtained the leader certificate of solar energy manufacturing. With more than 70 subordinate factories, it is a leading enterprise in the magnetic industry in China. Even as the industry leader, Dongmagneto was faced with the dilemma of backward digital construction at the beginning, and it is not easy for it to achieve today’s digital achievements.
Background
As an important functional material, magnetic materials are widely used in household appliances, automobiles, computers, communications, medical, aerospace and military fields. Magnetic materials are more and more widely used in the emerging fields of energy conservation and environmental protection, new energy electric vehicles, smart cities, smart Earth and so on. With the continuous development of emerging application markets such as 5G communication, Internet of things, artificial intelligence and new energy vehicles, China’s magnetic materials industry is also booming. However, behind the vigorous development of the industry is the backwardness of the whole industry in digital construction.
Even for Hengdian Dongmagnetic, digital construction lags far behind other giants in the world.
Even for Hengdian Dongmagnetic, digital construction lags far behind other giants in the world. Hengdian Dongmagnetic Group believes that only through digital construction can the company truly stand on the same level with Japanese, European and other world enterprises. Around 2016, Hengdian Dongmagnetic decided to start the systematic construction of digital transformation, and in 2017 applied for the National Ministry of Industry and Information Technology, the application of new mode of intelligent manufacturing technology project.
Dongmagneto has a very clear demand for digital transformation: it hopes to realize paperless management of production system, provide standard and consistent system for more than 70 factories of the group, connect the upstream and downstream of the industrial chain, and use a unified platform for data summary and business collaboration.
Disadvantages of traditional management mode
01 Extensive production management
Extensive production management can not meet the requirements of high performance products for precise control of manufacturing process. For example: in the past, there was almost no general production management system, and production planning and production line scheduling could only be completed by manual patrol.
02 Low accuracy
Production plan execution accuracy is not high, production work order completion rate is too low.
03 High production cost
Energy consumption, raw material costs, labor costs and so on continue to increase the cost of production.
04 The device cannot be monitored in real time
The device cannot be monitored in real time to improve its productivity. For example: in the past, there were hundreds of equipment in each factory of Dongmagneto, and the data of each equipment was not transparent, so it was difficult to know the production status of each one.
05 The data is inaccurate
Production process data collection is difficult, the original data of the workshop site can not be accurately feedback, unable to understand the detailed production process data. For example: in the past, the management of production workshop of Dongmagneto was mostly carried out by paper process, which was not standard, and the data acquisition was not accurate, and product traceability became a problem.
06 The supply chain is unstable
The upstream bargaining power continues to improve. Leading to an increase in raw material costs. While downstream customers continue to demand lower prices, and demand higher performance products, better service quality, the competition of magnetic material enterprises intensified.
07 Poor production synergy effect
There is no systematic connection between the factories of the group. So the factories cannot quickly realize production collaboration, and the product flow between the factories also needs to rely on paper documents.
Concrete results
In the whole production process, in line with the purpose of “improving quality, improving efficiency and reducing cost”, we have designed hundreds of control measures for magnetic material enterprises, which has significantly improved economic benefits for enterprises.
√ Realize paperless office work through MES system, replacing original paper documents with system;
√ Spliced screen multi-screen and single-screen data display;
√ Bar code scanning in the whole process of material transfer;
√ Materials batch information and materials error prevention control;
√ Production process transparency, order schedule, product production process information traceability, to achieve product quality traceability;
√ electronic scale data acquisition;
√ Real information, data visualization management, can always show the report data, such as production progress, quality report, instead of manual report.
√ Realize the main test instrument data directly upload system, SPC data analysis
Establish a equipment monitoring center to monitor equipment status in real time and analyze data such as equipment utilization rate, operation rate and OEE
√ Management support of business indicators: Use information technology to quantitatively evaluate performance indicators such as plan implementation rate, equipment utilization rate OEE, quality rate and primary qualified rate of each department and manufacturing unit, realize real-time presentation of production data, and provide analysis and trend of single line, single order, single product, material use and production data; Maximize resource returns through real-time equipment utilization management;
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