01 Preface

With the changes in the international and domestic macroeconomic situation, the domestic printing and dyeing industry is currently facing multiple pressures such as the appreciation of the renminbi, export restrictions, domestic raw material prices, and rising labor costs. The transformation and upgrading of the printing and dyeing industry cluster is imminent.

02 Enterprise needs and dilemmas

Before the construction of the information workshop, the current production status and main management pain points of printing and dyeing enterprises are summarized as follows:

03 MES system architecture

The overall system architecture is divided into three parts, namely, the production plan APS, the production process control MES and the field equipment monitoring SCADA. The central MES system is positioned at the production management level, responsible for issuing production tasks, summarizing production data, tracking production progress, worker production planning, production history statistics, etc. The SACDA system is positioned at the production execution level of the workshop production line, responsible for receiving production tasks, workshop data collection, production process recording, etc.

04Main functions

1. Production scheduling

2. Process and quality control

(1) Equipment data collection and control

It mainly includes data collection and control of key equipment such as cloth spreading, dyeing vat, shaping, rolling, etc., to achieve accurate control of the production process and reduce the adverse effects caused by manual intervention.

Dyeing vat monitoring: mainly the operation status of the dyeing vat, products being processed, process execution status, real-time process parameters, historical curves, etc.

Select a dye vat to view detailed dye vat production steps, current temperature, flow, water level and other process parameters, and also view the production history of the first few vats of the dye vat

(2) Production process selection

This interface is to realize the binding and modification of each process card and the corresponding dyeing and setting process before production. During the production process, the corresponding process is automatically selected according to the number of spread meters.

(3) Dyeing proofing management

This interface implements operations such as formulating and issuing production plans for each production line, and has functions such as manual order placement and batch import of production plans.

Dyeing proofing management

(4) Material control

After the feeding formula is issued, the worker clicks on the production link to select the content of feeding aids and dyes. The system can directly obtain the formula and work order information, control the PLC pipeline to directly feed, and record the history of materials.

3. Production progress tracking

(1) Production plan issuance and progress statistics

This interface is used to display the production tasks and completion status of each process every day.

Overview of production progress

(2) Job reporting interface

This interface is used for workers to report work and deal with feedback that some plans cannot be executed normally.

4. Semi-finished products running

05. Application effect

Through the construction of automation, digitization, and information system projects, Yakong Technology helps companies achieve upgrading and transformation in terms of production planning, process control, logistics transfer, quality management, and equipment monitoring.

Through the realization of the intelligent optimization of production scheduling in the printing and dyeing workshop, the production process data collection and control, the production process control and distribution, and the establishment of big data models for accurate statistical analysis of production costs, the realization of pre-production preparation, process optimization, and post-production analysis to achieve full production Process control mode. From planning management to on-site implementation of personnel, equipment, and material data, realize closed-loop management and control of production data from source to end.

After Yakong's MES system was launched, the quantifiable effect of the workshop customer's production workshop in optimizing the existing business:

The plan can be implemented quickly, while reducing enterprise investment, ensuring that small and medium-sized enterprises can also quickly transform, and build a batch of new printing and dyeing enterprises with "mass customization, flexible customization, rapid response, and green environmental protection" characteristics.