随着信息化技术的发展，尤其是汽车行业“电动化、智能化、网联化、共享化”的新四化提出，基于数据采集与分析技术的应用发展起来的 MES 系统（生产制造执行系统）被越来越多的汽车企业所广泛使用。
工业工程（Industrial Engineering，简称 IE）是对人、物料、设备、能源和信息等所组成的集成系统，进行设计、改善和实施的一门学科，它综合运用数学、物理和社会科学的专门知识和技术，结合工程分析和设计的原理与方法，对该系统所取得的成果进行确认、预测和评价。
IE 作为企业效率化管理的有效工具，关注过程效率，追求在有限条件下的效益最大化。如果只是单纯追求 MES 系统的信息化集成，而忽略了对公司数据使用需求的识别，则容易因为缺乏必要的基础数据支撑而导致 MES 系统束之高阁而无法发挥应有的作用。同时,不同企业间的特性各有差异，唯有与企业运营体系深度结合才能有效发挥 MES 系统的效率化特性。为此，需要将 MES 系统与 IE 应用结合，提升企业的管理效率。
一、MES 系统的应用现状
1992 年，美国的 MESA 国际协会（Manufacturing Execution System Association，MESA International）成立，MESA 是以宣传 MES 思想和产品为宗旨的组织。MESA 认为，能通过信息的传递，MES 对从下发订单到产品制造完成的整个生产过程进行管理，并在管理过程中及时反馈过程信息进而优化管理效率，并应用从现场准确收集的数据对生产过程进行指导和异常情况处理。当前国内的 MES 系统集成商大多遵循该理念进行 MES 系统构建。 数字化转型网www.szhzxw.cn
1. MES 系统的功能
MES 的主要功能体现为 3 个方面：
（1）它基于企业的运营计划，自主排程生产什么以及什么时候生产———保证按照订单规定日期交付准确的产品。
（2）它基于设定的产线型谱，决定哪个产线通过什么方式进行生产———通过优化全域资源配给，提供最高效的资源应用。
（3）它基于硬件的数据收集与分析，输出生产时间、产品质量等信息———帮助管理者实施系统过程/产出分析。
为了实现 MES 系统的功能构架，MES 系统集成商通常采用的模式，都注重与应用企业间进行业务需求调研，通过向应用企业讲解自身系统功能、收集并解读应用企业的功能要求来进行 MES 系统设计。
2. MES 应用企业的系统需求
MES 系统的应用企业以制造型企业居多。制造型企业的关键业务主要围绕“人机料法环测”六个方面开展，而以对象实体来说，可以定义人员、物料、设备、能源、信息为管理对象，而这，既是 MES 系统功能构架的基础服务对象也是管理对象，其基础期望是通过 MES 系统的应用，提升对受管理信息收集的准确性、及时性，以此提升管理响应速度与准确性。 数字化转型网www.szhzxw.cn
而为契合当下信息化、智能化的时代特征，越来越多的制造企业在搭建 MES 系统的功能构架时，会需求搭建一些带有基于数据收集的系统自动化操作，如，高度集成的数字报表目视化呈现、能够基于现场采集到的数据进行自动比对并拦截不合格产品继续往下游流动、针对刀具/工具/工装使用频次的预警等。集成的数字化企业的发展目标是通过全面采用先进的信息技术，实现产品研发数字化、制造过程数字化、生产过程数字化、管理数字化，并通过集成实现企业数字化。
二、IE 在MES 系统功能构架建设中的应用优势和方式
在工作研究、人因工程、质量管理、设施规划与物流分析、生产计划与控制中，作为工业工程的组成模块，完全契合企业对其自身的业务体系提质增效的需求。
1. 搭建 MES 系统的过程也是对企业实施业务流程效率化验证与改善的过程
在 MES 系统功能构架过程中，对业务流进行程序逻辑分析，并实施模拟验证，我们可以找到业务流程中的短板或阻滞点。因为工业工程涉及企业整个生产经营全过程，且独立于研发、采购、质量、生产等主业务模块之外，为工业工程开展业务流改善提供了其他技术模块所不具备的全局改善视角。
立足于“消除浪费”的工业工程思维，在 MES 系统的功能构架方案规划上，我们不是寻求性价比最极致或单一模块性价比最大化的方案，而应该在评估各方实际的有限投入基础上，制定综合性价比最适宜的方案，并持续探寻该综合性价比不断提升的方案。正是基于这个工业工程的全局视角，可最大化避免了其他专业模块因业务知识面的范围不足而导致局部效益大于综合效益的情况发生。为此，借助于 5W1H 与 ECRS 等工业工程改善手法的应用，对业务流程短板进行改善，是提升 MES 系统功能构架运行效率的有效路径，而这，也是对系统工程师的核心技能需求。 数字化转型网www.szhzxw.cn
2. IE 在 MES 功能构架建设过程中的应用方式
IE 工程师可以应用 5G，在工厂、车间中实施网络互联，在生产线设计、实施和持续优化过程中推动工业制造的智能化，提高生产率和效率，更好地达到工业工程目标，而 MES 系统则是最佳载体之一。首先，在实施 MES 系统功能构架的前期需求调研时，需要建立起企业的通用业务模型，以“人机料法环测”为对象，界定系统功能的服务边界。其次，在 MES 功能构架蓝图设计时，基于霍尔三维模型，对各功能子项的关联关系进行筛分，识别并定义类别与管理方式，对构建的各功能子项建立业务流矩阵网。而后，基于全局视角，评估/测试各子项功能运作逻辑的闭环有效性，并结合 ECRS 手法（即，取消 Eliminate、合并 Combine、重排 Rearrange、简化Simplify）实施及时的流程业务优化与功能设计更新。
三、MES 系统的功能构架应用实例
本人所在团队在建设新的智能工厂 MES 系统时，组建了一个 MES 系统功能构架策划小组，该小组涵盖工业工程、工艺、质量、生产、物流、设备、IT 等业务人员，负责实施 MES 系统的顶层功能策划。
在完成各业务的功能策划后，小组内部开展横向的功能关联性评估，与 MES 系统集成商、设备厂家结合需求调研进行 MES 系统功能构架的锁定。历时 6 个多月，该MES 系统各功能构架建成，该 MES 系统通过网联化布局实时收集整个工厂的质量、计划、效率、设备、人员、能耗等综合信息并实施实时统计测算，将分析数据反馈至产线实施智能化自动控制，扼制异常件流出到下工序；同时，通过信息化技术，可将整个生产信息分类推送至管理者电脑及手机等终端，并可与供应商和客户实现产业数据共享，以支持快速运营决策。 数字化转型网www.szhzxw.cn
1. 实施要点
（1）构建具有工业工程全局视角的 MES 系统功能构架策划小组。有不少企业在实施时是由 IT 或工艺牵头组建的实施团队，而我们由工业工程部门牵头组建，基于工业工程全局视角评估功能设计的必要性及实施效率，平衡各职能权限的设置。通过该模式，极大地避免了单一技术模块主导带来的短板效应，保持有限投入下获得较为优良的综合性价比。
在某 MES 系统建设中，各模块是独立完成本区域的业务流程，因缺乏系统性预评价导致在区域交叉业务中出现了低效的流程设计。在最初系统逻辑设计时，物料响应流程需要操作者进行手工发起的设置（图 3），因为对人的依赖过多，程序流程设置复杂，存在操作者无法保证及时发起指令而导致物料配送延误的高风险事项。 数字化转型网www.szhzxw.cn
而本次新产线搭建策划初期，通过工业工程的视角进行业务统筹，在各业务部门完成业务流程初稿编订后，基于动作经济原则与流程分析，识别业务流程中的关联区域及关键路径，识别并分析可能的风险点，并结合人机工程分析组织跨区域评审，使新的物料响应流程更清晰简洁且可自动执行并防错（图 4）。与此同时，因为取消了非必要的人工确认环节，员工的动作也得到简化。
（2）自主实施 MES 系统功能构架策划。相较于直接选用 MES 系统集成商提供的通用模型，自主策划固然会带来特性设计的成本影响，但通过借鉴通用模型开展自主策划能保证系统在可控成本下提升企业业务的适配性，与此同时，也为企业后续提升维保自主性与持续改善搭建基础团队。
（3）结合企业技术资源条件定义 MES 系统的功能构架目标。从工业工程的角度，追求有限条件下的性价比最优化，为此，并不是越先进越好。如果企业未具备某项功能的技术资源，则相应设计有可能是一种盈余设计，无法基于数据化应用带来效益。我们通过对企业的设备维保框架的调研发现：企业在 MTTR（Mean Time To Repair）做了基础统计，也开展了一些改善，但应用不充分；而在 MTBF（Mean Time Between Failure）方面基础统计与应用仍处于空白。基于此，在MES 系统功能设计阶段，我们对 MTTR 的设计进行了全功能策划，而 MTBF 则仅设计了基础数据收集与统计。这样做的好处在于，通过数字化手段提升MTTR 的统计与分析效率，减少了非必要的数据端口收集进而降低服务器的数据负荷，而通过基础端口预留为 MTBF 的探索保留了关键数据支持。 数字化转型网www.szhzxw.cn
2. 应用实例的经验与教训
（1）以工业工程的全局视角指导 MES 系统的功能构架建设，是提升建设速度与系统有效性达成的有效手段之一。工业工程关注全局综合效力，可有效平衡各业务模块之间的效力博弈，有助于达成有限条件下的综合效力最佳。
（2）对应小组成员的选择，要评估其是否具备主动改善特性与学习特性。MES 系统的建设不同于设备投入，需要更多地对企业自身业务的分析，并结合MES 系统效率性与其他企业的业务流程优点进行自我革新，为此，拥有学习与改善自主性的成员是关键因素之一，而这恰是工业工程的优势领域之一。
（3）MES 系统的功能构架建设是一个持续改善的过程。完成 MES 系统的建设只是业务优化的起点，为了持续提升流程效率，必须定期回顾评估流程效力，并结合企业业务的调整进行及时的更新———始终以提升企业业务流程效力为目标。 数字化转型网www.szhzxw.cn
四、结语
综上所述，基于工业工程的全局视角，从 MES 系统策划初期运用工业工程的流程分析等方法进行功能构架的效率化分析，可降低 MES 系统功能构架中的业务流设计不平衡，进而降低特性需求的系统适配难度，提升 MES 系统功能构架的有效性；与此同时，立足于工业工程的改善功能发挥，持续开展业务流程优化，可以减少过量的冗余功能设计，提升 MES 系统运行效率，进而保持企业的运营效率持续优化。
翻译：
Application practice of IE in MES function construction of Wuling willow machine
With the development of information technology, especially the new four modernizations of “electrification, intelligence, networking and sharing” in the automotive industry, the MES system (production and manufacturing execution system) developed based on the application of data acquisition and analysis technology is widely used by more and more automobile enterprises.
Industrial Engineering (IE) is the design, improvement and implementation of integrated systems composed of people, materials, equipment, energy and information. It integrates the expertise and technology of mathematics, physics and social sciences with the principles and methods of engineering analysis and design. The results achieved by the system are confirmed, predicted and evaluated.
As an effective tool for enterprise efficiency management, IE pays attention to process efficiency and pursues maximum benefit under limited conditions. If we simply pursue the information integration of MES system, and ignore the identification of the company’s data use needs, it is easy to cause the MES system to be shelved and unable to play its due role because of the lack of necessary basic data support. At the same time, the characteristics of different enterprises are different, and only the deep combination with the enterprise operation system can effectively play the efficiency characteristics of MES system. Therefore, it is necessary to combine MES system with IE application to improve the management efficiency of enterprises. 数字化转型网www.szhzxw.cn
First, MES system application status
In 1992, MESA International (Manufacturing Execution System Association, MESA International) was established in the United States. MESA is an organization for the purpose of promoting MES ideas and products. MESA believes that through the transmission of information, MES can manage the entire production process from the issuance of orders to the completion of product manufacturing, and timely feedback process information in the management process to optimize management efficiency, and use accurate data collected from the field to guide the production process and handle abnormal situations. At present, most domestic MES system integrators follow this concept to build MES system.
1. Functions of MES system
The main functions of MES are reflected in three aspects:
(1) It independently schedules what to produce and when to produce it based on the company’s operational plan – ensuring that accurate products are delivered according to the date specified in the order. 数字化转型网www.szhzxw.cn
(2) Based on the set production line profile, it determines which production line is produced by what means – by optimizing global resource allocation, providing the most efficient resource application.
(3) It is based on hardware-based data collection and analysis, output production time, product quality and other information — to help managers implement system process/output analysis.
In order to realize the functional framework of MES system, the mode usually adopted by MES system integrators pays attention to conducting business demand research with application enterprises, and carries out MES system design by explaining its own system functions to application enterprises and collecting and interpreting the functional requirements of application enterprises.
2. The system requirements of MES application enterprises
The application enterprises of MES system are mostly manufacturing enterprises. The key business of manufacturing enterprises is mainly carried out in six aspects of “man-machine material method”, and in terms of object entities, personnel, materials, equipment, energy, and information can be defined as management objects, which are both the basic service objects and management objects of MES system functional architecture, and the basic expectation is through the application of MES system. Improve the accuracy and timeliness of the collection of managed information to improve the speed and accuracy of management response. 数字化转型网www.szhzxw.cn
In order to meet the characteristics of the current information and intelligent times, more and more manufacturing enterprises will need to build some system automation operations based on data collection when building the functional framework of MES system, such as, Visual presentation of highly integrated digital reports, automatic comparison based on data collected in the field and interception of unqualified products continuing downstream, early warning of tool/tool/tooling usage frequency, etc. The development goal of the integrated digital enterprise is to realize the digitization of product research and development, the digitization of manufacturing process, the digitization of production process, the digitization of management, and the digitalization of the enterprise through integration through the full adoption of advanced information technology.
Second, the application advantages and ways of IE in the construction of MES system functional architecture
In work research, human factor engineering, quality management, facility planning and logistics analysis, production planning and control, as a component of industrial engineering modules, fully meet the needs of enterprises to improve the quality and efficiency of their own business systems.
1. The process of building MES system is also the process of verifying and improving the efficiency of business process
In the process of MES system function architecture, the program logic analysis of business flow is carried out, and the simulation verification is carried out, we can find the short board or block point in the business process. Because industrial engineering involves the entire production and operation process of enterprises, and is independent of the main business modules such as R & D, procurement, quality and production, it provides a global improvement perspective for the improvement of industrial engineering business flow that other technical modules do not have. 数字化转型网www.szhzxw.cn
Based on the industrial engineering thinking of “eliminating waste”, in the planning of the functional framework of the MES system, we are not seeking the most cost-effective or the most cost-effective scheme of a single module, but should develop the most appropriate comprehensive cost-effective scheme on the basis of evaluating the actual limited investment of all parties, and continue to explore the comprehensive cost-effective scheme. It is based on this global perspective of industrial engineering that can maximize the occurrence of local benefits greater than comprehensive benefits caused by the insufficient scope of business knowledge of other professional modules. Therefore, with the application of industrial engineering improvement techniques such as 5W1H and ECRS, improving the short board of business process is an effective path to improve the operating efficiency of MES system functional architecture, which is also the core skill demand for system engineers.
2. The application of IE in the construction process of MES functional framework
IE engineers can apply 5G, implement network interconnection in factories and workshops, promote the intelligence of industrial manufacturing in the process of production line design, implementation and continuous optimization, improve productivity and efficiency, and better achieve industrial engineering goals, and MES system is one of the best carriers.
First of all, in the implementation of the preliminary demand survey of MES system functional architecture. It is necessary to establish a general business model of the enterprise, and define the service boundary of the system function with the object of “man-machine material method and loop measurement”. Secondly, in the design of MES functional architecture blueprint, based on the Hall three-dimensional mode. The correlation of each functional subitem is screened, the categories and management methods are identified and defined. And the service flow matrix network is established for each functional subitem constructed. Then, based on the global perspective, the closed-loop effectiveness of the functional operation logic of each sub-item is evaluated/tested. And timely process and business optimization and functional design update are implemented in combination with ECRS techniques (i.e., Eliminate, Combine, Rearrange, Simplify). 数字化转型网www.szhzxw.cn
FIG. 1 Hall 3D model
Application examples of functional architecture of MES system
When building a new smart factory MES system, my team set up an MES system functional architecture planning group, which covers industrial engineering, process, quality, production, logistics, equipment, IT and other business personnel, responsible for implementing the top-level functional planning of MES system.
After the functional planning of each business is completed, the team carries out horizontal functional relevance assessment. And locks the functional framework of MES system with MES system integrators and equipment manufacturers combined with demand research. After more than 6 months, the functional framework of the MES system was completed. The MES system collected the comprehensive information of quality, plan, efficiency, equipment, personnel and energy consumption of the whole factory in real time through the network layout and implemented real-time statistical calculation. The analysis data was fed back to the production line to implement intelligent automatic control and prevent abnormal parts from flowing out to the next process. At the same time, through information technology, the entire production information classification can be pushed to the manager’s computer, mobile phone and other terminals. And industrial data can be shared with suppliers and customers to support rapid operational decisions. 数字化转型网www.szhzxw.cn
Figure 2 Process of MES system development
1. Implementation points
(1) Construct an MES system functional architecture planning team with a global perspective of industrial engineering.
Many enterprises are led by IT or process during the implementation of the implementation team. And we are led by the industrial engineering department, based on the overall perspective of industrial engineering to evaluate the necessity of functional design and implementation efficiency, balance the setting of authority of various functions. Through this model, the short-board effect caused by the dominance of a single technology module is greatly avoided. And a better comprehensive cost performance is obtained with limited input. 数字化转型网www.szhzxw.cn
In the construction of an MES system, each module completes the business process of the region independently. And the lack of systematic pre-evaluation leads to inefficient process design in regional cross-business. In the initial logical design of the system, the material response process required the operator to manually initiate the setting (Figure 3). Due to excessive reliance on people, the process setting was complicated. And there was a high risk of material delivery delay due to the operator’s inability to guarantee timely initiation of instructions.
Figure 3 Original material response logic
At the initial stage of the construction and planning of the new production line, business planning was carried out from the perspective of industrial engineering. After each business department completed the draft of the business process, based on the principle of action economy and process analysis, associated areas and critical paths in the business process were identified, possible risk points were identified and analyzed, and cross-regional review was organized by combining ergonomics analysis. Make the new material response process clearer, simpler, automated and error-proof (Figure 4). At the same time, the actions of employees are simplified by eliminating unnecessary manual confirmation.
Figure 4. Case material response logic 数字化转型网www.szhzxw.cn
(2) Independently implement MES system functional architecture planning.
Compared with the general model provided by the MES system integrator directly, independent planning will certainly bring the cost impact of feature design, but by learning from the general model to carry out independent planning can ensure that the system can improve the adaptability of enterprise business under controllable costs, and at the same time, it also builds a basic team for the enterprise to improve the autonomy of maintenance and continuous improvement.
(3) Define the functional architecture objectives of MES system in combination with the technical resource conditions of the enterprise.
From the perspective of industrial engineering, the pursuit of cost-effective optimization under limited conditions, for this reason, is not the more advanced the better. If the enterprise does not have the technical resources for a certain function. The corresponding design may be a surplus design, which cannot bring benefits based on data application. Through the investigation of the equipment maintenance framework of enterprises, we found that:. Enterprises have done basic statistics in MTTR (Mean Time To Repair), and also carried out some improvement. But the application is not sufficient; However. The basic statistics and application of Mean Time Between Failure (MTBF) are still blank.
Based on this, in the functional design stage of MES system. We carried out a full-function planning of MTTR design, while MTBF only designed basic data collection and statistics. The advantage of this is that the statistical and analysis efficiency of MTTR is improved by digital means. And the data load of the server is reduced by reducing the collection of unnecessary data ports. While the key data support is retained for the exploration of MTBF through the reservation of basic ports.
2. Experience and lessons from application examples
(1) Guiding the construction of the functional framework of MES system from the global perspective of industrial engineering is one of the effective means to improve the construction speed and the effectiveness of the system. Industrial engineering pays attention to the overall comprehensive effectiveness. Which can effectively balance the effectiveness game among various business modules and help to achieve the best comprehensive effectiveness under limited conditions.
(2) Corresponding to the selection of group members. It is necessary to evaluate whether they have the characteristics of active improvement and learning. The construction of MES system is different from equipment investment, which requires more analysis of the enterprise’s own business. And self-innovation combined with the efficiency of MES system and the advantages of other enterprises’ business processes. For this reason, members with the autonomy to learn and improve are one of the key factors. Which is just one of the advantages of industrial engineering. 数字化转型网www.szhzxw.cn
(3) The construction of the functional framework of MES system is a process of continuous improvement. The completion of the construction of MES system is only the starting point of business optimization. In order to continue to improve the efficiency of the process. It is necessary to regularly review and evaluate the effectiveness of the proces. And in combination with the adjustment of the enterprise business for timely update – always to improve the effectiveness of the enterprise business process as the goal.
Conclusion
In summary, based on the global perspective of industrial engineering. The process analysis of industrial engineering and other methods are used to analyze the efficiency of the functional framework from the initial stage of MES system planning. Which can reduce the imbalance of business flow design in the functional framework of MES system. Thus reducing the difficulty of system adaptation of characteristic requirements and improving the effectiveness of the functional framework of MES system. At the same time, based on the improvement of the function of industrial engineering, continuous business process optimization can reduce the excessive redundant function design, improve the operating efficiency of MES system, and then maintain the continuous optimization of the operating efficiency of the enterprise.
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