In recent years, with the needs of the transformation, upgrading and development of enterprises in the clothing industry, the development direction of intelligent manufacturing has been highly recognized and valued by industry enterprises.
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China is the largest clothing country in the world, the most complete variety, the most complete industrial configuration network, and the highest international market share. With the acceleration of economic globalization, the gradual weakening of demographic dividends and cost advantages While the competitive pressure of end-to-end manufacturing is gradually emerging, my country's garment industry is also facing more direct competition with developed countries in the high-end areas of the industrial value chain. The competition characteristics have changed from the competition of natural resources to the competition of "knowledge innovation". "Knowledge innovation" not only requires the product itself to have a high content of knowledge and technology, but also requires innovation in the technology, management methods, organization, mechanism and production mode involved in the product manufacturing process.
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In recent years, with the needs of the transformation, upgrading and development of enterprises in the apparel industry, the development direction of intelligent manufacturing has been highly recognized and valued by industry enterprises. Clothing enterprises have devoted themselves to intelligent transformation. The equipment level and informatization construction level of clothing enterprises have been significantly improved, and many concrete achievements have been made in technological innovation and manufacturing upgrading. Some well-known clothing enterprises have initially built intelligent production workshops. Intelligent production is the main line of intelligent manufacturing, and intelligent factory is the main carrier of intelligent production and the main goal of informatization construction in the clothing industry.
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The smart factory integrates preliminary intelligent means and intelligent systems and other technologies. It mainly realizes the intelligentization of the production process through the construction of intelligent production systems and networked distribution of production facilities. The smart factory integrates advanced production control theories and methods such as intelligent manufacturing, lean logistics, visual management, standardized management, and green manufacturing. , using simulation and multimedia technology to expand the real world clothing design and manufacturing process, can realize intelligent, flexible and agile product manufacturing, thereby shortening product development cycle, reducing inventory, improving product quality, and realizing product personalization custom made. For the apparel industry, there are three main points to build a smart factory:
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1. Complete data connection
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The connection of data is the basis for the flow of various tasks in the smart factory and the guarantee for the normal operation of the production system. To build a smart factory, we must first carry out an overall data design from a full business perspective to ensure that the data structures are interrelated and avoid information islands. During the operation of the smart factory, business data from various application systems will be generated, including design information, process parameters, manufacturing information, warehousing and logistics data, quality information, personnel information, etc. Therefore, in the construction process of the smart factory, it is necessary to A set of unified standard system to standardize the whole process of data management, establish a series of data management specifications such as data naming, data coding and data security, to ensure the consistency and accuracy of data. In addition, it is necessary to clarify the principles and construction methods of data management, establish data management processes and systems, coordinate problems in implementation, and regularly check and implement technical standards, processes and implementations for optimizing data management. The smart factory data architecture mainly has the following requirements:
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(1) Digitization: establish a shared database and knowledge base for product life cycle activities, and record data for each link;
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(2) Networking: establish a continuous and interconnected computer network, numerical control equipment network and production IoT/logistics network, so that all information can be interconnected based on the network;
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(3) Integration; internal integration of each application system to efficiently complete data checking, cleaning and mapping;
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(4) Information visualization: Through the factory-level communication and monitoring system, the transparency and visualization of the factory production process are realized, and useful information is formed through data processing and displayed on demand;
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(5) Intelligent coordination and decision-making: Coordinate the disturbances and fluctuations in the actual production process, use relevant data and information to simulate the actual production process, select the optimal production path, and form the best decision.
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Second, the application of intelligent equipment
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Intelligent equipment and intelligent manufacturing units are the basis for supporting the realization of intelligent clothing factories, and they are also the key conditions for the implementation of intelligent clothing manufacturing. Intelligent factories require manufacturing equipment to be digitized, networked, and intelligent, with functions of perception, analysis, reasoning, decision-making and control. Clothing intelligent manufacturing equipment mainly includes intelligent cutting bed, intelligent sewing system, intelligent hanging system, intelligent flexible ironing system, intelligent storage system, etc., and integrates sensors, intelligent control system, robot or manipulator, RFID technology, etc. Real-time monitoring of equipment, production systems and production status, and intelligent decision-making and adaptive control through human-computer interaction.
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In addition, clothing intelligent production equipment needs to realize the mutual perception and cooperation between "intelligent machine-robot-human". While completing grasping, conveying and other repetitive labor tasks through auxiliary manipulators or robots, Emphasis on human-machine collaboration, making full use of human judgment, decision-making ability and flexibility to complete complex and changeable tasks.
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The intelligent equipment used in the clothing industry should be adaptively designed and developed according to the actual needs and characteristics of enterprise production. Through the establishment of a highly flexible production system, the pull method is used for just-in-time production, from production planning, production line balance and rapid changeover. To achieve production balance, improve production quality, minimize inventory, and achieve efficient and lean manufacturing.
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3. Realize information management
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Intelligent management is the management of all activities in the entire clothing manufacturing process. It transforms raw materials into clothing commodities by coordinating and managing resources such as personnel, equipment, raw materials and energy in smart factories. The intelligent production management system mainly manages the actions performed by equipment, people and information systems, and manages activities related to scheduling, production capacity, product definition, historical information, production equipment information, and related resource status information.
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1. Resource information management
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Resource information management mainly refers to the factory's management of the collection of various information activity elements (information technology, equipment, information producers, etc.) accumulated in information activities and centered on information, and its main task is to effectively collect and obtain information. and processing information inside and outside the plant, maximizing the quality, availability and value of information resources, and enabling all parts of the plant to share these information resources. ERP system is the main means to realize resource information planning, and its main contents include production management, supply chain management, financial management, human resource management and data management.
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2. Production information management
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Production informatization runs through all aspects of smart factory operation, management, product development and production, mainly by improving production efficiency and product quality, reducing energy consumption, and driving the development of design methods, design tools, management models, manufacturing technologies and inter-factory collaboration. Innovate, realize product design and manufacturing and factory management information, production process control intelligence, manufacturing equipment numerical control and consulting service network.
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MES, as the core system for the production process of smart factories, is used to support centralized control and scheduling of assembly lines, and can provide manufacturing data management, production planning management, production scheduling management, inventory management, quality management, human resource management, and equipment management. , Tooling management, procurement management, cost management, project Kanban management, production process control, bottom-level data integration analysis, upper-level data integration and decomposition and other management modules. The MES system can be connected to ERP upwards, and can be connected to production PLC downwards, and can automatically import production orders, collect data on-site and analyze.
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3. Digital operation management
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Digital operation management refers to the use of digital means to plan, organize, implement and control the operation process. Digital market operation is based on clear database objects, through digital multimedia channels, with the help of the Internet, computer communication technology and digital interactive media. It uses advanced computer network technology as much as possible to carry out market development and consumer mining in the most efficient and economical way.
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Data, equipment and management are important elements to realize the intelligent factory of clothing. Intelligent manufacturing is carried out on the basis of data, and it is interconnected with each link of operation and management. It is the basis for the clothing industry to build a fully integrated and collaborative intelligent factory. With the in-depth advancement of intelligent manufacturing in the clothing industry, the completion of clothing intelligent factories will be just around the corner.