A smart production platform based on ERP system is built around the production process of denim products. Using information technology combined with automation technology to achieve intelligent detection and control of the entire production process, through the network, MES, indigo automatic feeding and ERP system seamlessly docked, to achieve real-time production process data collection, to achieve production process traceability function, and according to the collection Data to achieve intelligent maintenance of the device. Through the combination of information technology and industrial processes, industrial technology, and management models, the level of informationization and intelligence of denim production enterprises will be improved.
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Spinning - Pulping - Weaving - Post-ERP
Workflow approval:
Various types of purchases, orders, master plans, processes and notifications, test reports, invoices, and development approvals (PC and mobile).
Production on time and on schedule:
According to the order quantity and variety loss, the delivery date of the finished product is accurately set in advance of the purchase/cotton spinning/slurry dyeing/weaving/post-production delivery. According to this, the workshop is decomposed into a machine plan and delivered to the site for on-time operation.
Comprehensive process management:
Spinning, dyeing, weaving, finishing (silk / pre-shrink / stereotype) process, bulk / sample process.
Quality control throughout the process:
From the specification input of the order, the workshop, the laboratory to the inspection and inspection of the finished product, the whole process is online and controlled. All the quality problems clearly record the responsible person and the reason, and automatically generate the deduction and punishment.
Costing:
According to the raw materials and energy consumption of the order, combined with the fixed cost of dyeing materials, machine materials, and labor.
MES machine networking system
ERP machine planning and process parameters are sent to the site to guide workshop production. Provide real-time data for ERP, master on-site changes, quickly correct production plans, and provide traceability of production processes.
1 spun yarn single ingot detection system:
Debris detection, strong and weak boring, bad spindles, idle spindles, broken ends analysis with thousands of spindles, analysis of doffing breaks, and joint time analysis.
2 whole (ball) by the monitoring system:
Collect break rate, speed, tension, and time.
3 pulp dyeing machine monitoring system:
Collect temperature, length, speed, pH, concentration, moisture regain, energy consumption, exceed a certain range of deviation, and send out an alarm signal.
4 loom monitoring system:
Production and shutdown collection, monitoring of machine efficiency.
5 finishing machine monitoring system
Automated material and conveying system
Automation is the premise of the realization of Industry 4.0, and intelligence is the management and inheritance of knowledge. It is connected with the ERP formula management to make the production process control intelligent, reduce people and increase efficiency, and stabilize quality.
1 unattended automatic cooking pulp system
Reduce precision by reducing the efficiency of people, increasing gelatinization time, cooking temperature, etc., reducing waste.
2 automatic feeding of dyeing auxiliary
Solve the problem of inaccurate metering, different hand quality, waste of additives, and inability to track production problems. And cut labor, improve product consistency, while conducive to environmental protection, improve product competitiveness and so on.
3 indigo dye automated material delivery
Improve the automation level of the chemical process, eliminate the artificial ingredients error, improve the batching efficiency; reduce the consumption of additives, reduce the salt in the dye, improve the dye permeability and color fastness; improve the working environment and working conditions. The large screen monitors the flow pump to reduce quality accidents.
Blank inspection and inspection packaging system
1 The grey cloth inspection records the inspection result online; the result of the grey cloth inspection is fed back to the inspection inspection interface according to the finishing card number;
2 Realize the whole process tracking of the grey cloth cloth number to the finished cloth volume number, complete the blank cloth cloth number from the grey cloth falling cloth, the whole process of the gray cloth inspection and finishing finishing process, the finished product inspection and the opening, cutting and packaging, to facilitate the later stage. Tracking backtracking of each piece of finished product;
3 Realize the online inspection system of the inspection workshop, re-inspection, sampling inspection, online collection of information such as defects and cloth length of each piece of cloth;
4 Inspect the previous process to fabricate the point, and make a corresponding score according to the four-point scoring standard, and cut according to the condition of the cloth surface.
