数字化系统的应用能为企业生产和管理带来怎样的便利？在工业和信息化部公布的2022年新一代信息技术与制造业融合发展试点示范项目中，临工重机股份有限公司（以下简称“临工重机”）打造的“研产供销财一体化管控能力”项目入选。通过该项目的实施，临工重机可快速响应客户个性化需求，使大规模定制成为可能。数字化转型网www.szhzxw.cn
一、快速响应客户个性化需求，选配效率显著提高
临工重机为何要进行数字化转型？采访中，新黄河记者获悉，临工重机原有的信息化系统已使用多年，难以满足客户个性化定制的需求，成为制约公司高速发展的瓶颈。“原来的系统之间没有集成，不能实现销售、设计、制造一体化，无法进行个性化选配，仅是改变生产订单备料，手段多较为原始，效率低下。”临工重机相关负责人说。
为了解决这样的难题，从2017年至今，临工重机就开始着手改造升级信息化系统。
在“研产供销财一体化管控能力”建设过程中，临工重机根据实际业务需求，对业务链相关业务模块业务管理方法进行了优化，IT流程部、采购部、财务部、研究院、高机生产事业部、矿机生产事业部等部门召开会议，对技术实现方式进行讨论，梳理出业务总体流程图，制定了实施的主体计划。通过对研发管理、生产管理、采购管理、销售管理、仓储管理、财务管理等关键过程及流程进行规范性管理，提升全面管理效率，实现订单从销售端到客户端，端到端全供应链的一体化管控。数字化转型网www.szhzxw.cn
在此基础上，集成多系统功能及模块，消除了系统间各自为政、信息孤岛的现象，从而实现了从研发至生产端全链条数字化管控，真正实现资金流、物流、信息流三流合一，并通过数据驾驶舱及OA系统的自动报表分析实现动态实时数据资源及目标管控。
信息化系统升级后，生产及管理的便利很快显现，临工重机实现了营销、服务、生产、财务的无缝对接和实时协同，可准确快速响应客户个性化需求，按客户定制需求进行选配，快速、简单、高效，效率显著提高。
“大规模定制的极端情况是每种产品的批量为一，临工重机把大规模定制做到了极致，实现了单台管理。根据销售订单参数化选配结果，通过MRP运算，生成生产线日计划，拆分成单台，可有效进行过程跟踪，通过齐套分析及时掌握缺件情况，确保准时满足装配的需要，提高了订单履约率。”临工重机相关负责人说，通过单台管理、单台配送，实现了单车成本核算，并通过阿米巴考核进行了经营体的精细化管控，为客户提供低成本、高质量的定制产品和服务打下了坚实的基础，也使临工重机进行大规模定制成为可能。
二、数字化车间油漆利用率达99%以上，成本降低约35%
信息化系统的建设是全面的，尤其是生产环节的数字化至关重要。数字化转型网www.szhzxw.cn
从2019年9月起，临工重机耗资6500余万元，开始建设高空作业平台结构件数字化涂装车间。该车间规划、设计、竣工历时15个月，于2020年3月建成并投产，涂装综合产能规划4万台。首创抛丸+阴极电泳+喷粉工艺的智能化涂装，是行业内最先进的综合涂装线，能满足10年防锈需求。
该车间采用模块化设计，标准化生产的方式建成，具有工艺路线最短化，生产作业高度自动化、轻劳化、柔性化、智能化的特点，整个车间实行数字化智能管理，中央监控管理系统负责涂装车间的实时监控、数据采集处理及人机对话功能，具有良好的人机互交、参数采集、动画显示、语音报警等功能。维护工程师可在系统网络任何一处点，根据授权登录接入网络可现场监控设备的运行状况、修改运行参数，提高了设备维护的快捷性。
临工重机相关负责人表示，作为国内第一个高空作业机械结构件前处理、电泳、喷粉车间，底涂采用水性电泳漆，油漆利用率可达99%以上，面涂采用喷粉工艺，粉末利用率可达95%以上，两种工艺在环保方面均为行业成熟涂装技术最为环保的工艺，大幅降低涂装过程VOCS、危废等处理成本。项目综合运行成本较原喷漆工艺降低约35%左右，在安全、环保、成本、控制、生产、信息化六个方面均领先行业。
三、打造智能工厂，关键工序设备可远程监测和诊断
信息化的建设是持续升级的。据了解，临工重机已制定智能工厂总体建设方案，利用济南高新区生产基地的二期用地 217.3 亩，建设配件车间、关键零部件车间、调试维修车间、臂车装配结构件联合车间、中试车间等，新增各类生产设备352台（套）。数字化转型网www.szhzxw.cn
该工厂采用其自主开发的领先技术，建设国内领先的智能化生产线，实现高端高空作业机械产品的国产化、智能化和进口替代。实现自动采集和可视化管理，实现整机各环节在制品流转监控；车架号扫描采集、打印；关键力矩监控；关键质量控制点拍照采集、存档，实现可追溯；采用牵引及嵌入式 AGV 进行两箱法物料自动配送等。数字化转型网www.szhzxw.cn
临工重机相关负责人表示，该智能工厂可实现新增产能3万台。生产设备数控化率较高，关键工序设备具有远程监测和远程诊断功能。未来，临工重机将持续推动数字化转型。
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翻译：
What convenience can the application of digital system bring to enterprise production and management? In the 2022 pilot demonstration project of the integrated development of the new generation of information technology and manufacturing announced by the Ministry of Industry and Information Technology, the project of “research, production, supply, marketing and finance integrated control capacity” created by JuKI Co., LTD. (hereinafter referred to as “JUKI”) was selected. Through the implementation of the project, the heavy machine can quickly respond to the personalized needs of customers, making mass customization possible.数字化转型网www.szhzxw.cn
First, rapid response to customer personalized needs, the selection efficiency is significantly improved
Why the Digital Transformation of Cranes? In the interview, the new Yellow River reporter learned that the heavy industry of the original information system has been used for many years, it is difficult to meet the needs of customers personalized customization, has become a bottleneck restricting the rapid development of the company. “There is no integration between the original system, unable to realize the integration of sales, design and manufacturing, unable to carry out personalized matching, only to change the production order to prepare materials, more primitive means, low efficiency.” Related person in charge of heavy machinery said.
In order to solve this problem, from 2017 to now, the heavy machine began to upgrade the information system.数字化转型网www.szhzxw.cn
In the construction process of “research, production, supply, marketing and finance integrated control ability”, JuKI optimizes the business management method of business chain related business modules according to the actual business needs. IT process Department, Purchasing department, finance department, research institute, high machinery production Department, mining machinery production Department and other departments hold meetings to discuss the technology implementation mode and sort out the overall business flow chart. A main plan for its implementation has been formulated. Through normative management of key processes and processes such as R&D management, production management, procurement management, sales management, warehousing management and financial management, the overall management efficiency is improved, and the integrated management and control of orders from the sales end to the client end and the whole supply chain from end to end is realized.
On this basis, multi-system functions and modules are integrated to eliminate the phenomenon of separate administration and information island between systems, thus realizing the digital control of the whole chain from research and development to production end, truly realizing the integration of capital flow, logistics and information flow, and realizing dynamic real-time data resources and target control through data cockpit and automatic report analysis of OA system.
After upgrading the information system, the convenience of production and management soon appeared.
The heavy machine realized the seamless docking and real-time coordination of marketing, service, production and finance. It can accurately and quickly respond to the personalized needs of customers, and choose according to the customized needs of customers.数字化转型网www.szhzxw.cn
“The extreme case of mass customization is the batch of each product for one. The heavy machine to do the extreme mass customization, to achieve a single machine management. According to the parametrized matching results of sales orders. The daily production line plan is generated through MRP calculation. And the production line is divided into a single unit, which can effectively track the process.
The missing parts are timely mastered through the complete analysis, to ensure that the assembly needs are met on time, and the order performance rate is improved.” Related person in charge of heavy machine said, through single machine management, single machine distribution, the cost accounting of a single machine is realized, and through amoeba assessment of the fine management and control of the business body, for customers to provide low-cost, high-quality customized products and services to lay a solid foundation, but also make heavy machine mass customization is possible.
The paint utilization rate of the digital workshop is more than 99%, and the cost is reduced by about 35%
The construction of information system is comprehensive, especially the digitization of production link is very important.
Since September 2019, with an investment of more than 65 million yuan, the construction of digital painting workshop for structural parts of high-altitude working platform began. It took 15 months for planning, design and completion of the workshop, which was completed and put into production in March 2020, with a comprehensive capacity of 40,000 painting units planned. It is the first intelligent coating with shot blasting + cathode electrophoresis + powder spraying process, and it is the most advanced comprehensive coating line in the industry, which can meet the needs of rust prevention for 10 years.
The workshop is built by modular design and standardized production.
It has the characteristics of shortest process route, high automation, light labor, flexibility and intelligence of production. The whole workshop implements digital intelligent management. And the central monitoring management system is responsible for real-time monitoring. Data acquisition and processing of painting workshop and man-machine dialogue. With good man-machine interaction, parameter collection, animation display, voice alarm and other functions. Maintenance engineers can log in to the network as authorized from any point on the system network to monitor device running status and modify operating parameters, improving device maintenance speed.
Heavy machinery related person in charge said, as the first domestic high-altitude mechanical structural parts pretreatment, electrophoresis, powder workshop, the base coating using water-based electrophoretic paint, paint utilization rate can reach more than 99%, surface coating using powder spraying process, powder utilization rate can reach more than 95%, two kinds of process in environmental protection are mature painting technology industry the most environmentally friendly process, The cost of VOCS and dangerous waste treatment in coating process is greatly reduced. The overall operation cost of the project is about 35% lower than that of the original painting process. And it is leading the industry in six aspects: safety, environmental protection, cost, control, production and informatization.
Build smart factories where key process equipment can be monitored and diagnosed remotely数字化转型网www.szhzxw.cn
The construction of information technology is continuously upgraded. It is understood that heavy industrial machinery has developed the overall construction plan of intelligent factory. The use of Jinan high-tech Zone production base of 217.3 mu of land, construction parts workshop. Key parts workshop, debugging and maintenance workshop, arm car assembly structural parts joint workshop, pilot workshop, 352 new types of production equipment (sets).
The factory adopts its self-developed leading technology to build the leading intelligent production line in China and realize the localization, intellectualization and import substitution of high-end high-altitude working machinery products. Realize automatic collection and visual management, realize the whole machine each link of the product in process flow monitoring. Frame number scanning collection and printing; Key moment monitoring. Key quality control points photograph collection, archive, traceability. Traction and embedded AGV are used for automatic distribution of materials in two boxes.
A person in charge of the machine said that the smart factory can achieve an additional capacity of 30,000 units. The production equipment has high numerical control rate, and the key process equipment has remote monitoring and remote diagnosis functions. In the future, JuKI will continue to promote digital transformation.
本文由数字化转型网（www.szhzxw.cn）转载而成，来源：新黄河；编辑/翻译：数字化转型网宁檬树。
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