MES analysis and design of medium and heavy plate

2022-09-21
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MES analysis and design of medium and heavy plate production line of Jigang

1 After entering the 21st century, with the rapid development of information technology and network technology, the demand of enterprise management for informatization is also expanding. In order to make any valuable breakthrough, we must use informatization to drive the development of new industrialization, establish an enterprise integrated automation system based on ERP (Enterprise Resource Planning), MES (Manufacturing Execution System) and PCs (process control system), and include the relevant businesses of the market, manufacturers, suppliers and partners in the scope of enterprise management, which is an inevitable way to achieve win-win for all stakeholders in the industrial chain

many iron and steel enterprises are building ERP systems. In practice, people find that the ERP system can not solve the complex production management problems of enterprises in a package as originally expected, and it can not timely gather or spread real-time production process information. The ERP system is like a castle in the air, which can neither work well nor achieve the goal of enterprise resource optimization. The upper management information system and the lower executive automation system lack an organic link unit. Demand drives progress, and MES production execution system to solve this problem came into being

the International Association of manufacturing execution systems mesa gives the definition of MES: MES is an information system that optimizes the production process from placing an order to producing the final product. In the process of implementing informatization in iron and steel enterprises, MES is an indispensable or insurmountable important bridge between production automation and management informatization. From the perspective of production practice, the most effective function of MES is data acquisition and transmission, which collects various random and real-time data information in the production site, such as the temperature of each control point of the heating furnace, the feeding quantity, the thickness of the steel plate being rolled, and so on

in 1962, the British RTB steel company established a production control level system, which linked production management and process control, and became the MES system of early iron and steel enterprises. In the 1960s and 1970s, a hot rolling production control level system was built in the mccraws steel plant in the United States. China's Taiwan Sinosteel Corporation has developed an overall production and marketing system containing MES. European steel enterprises, such as ThyssenKrupp and VAI, use the manufacturing execution system suite software developed by European professional companies. POSCO in South Korea, Nippon Steel in Japan and Baosteel in China have all developed manufacturing execution systems for the iron and steel industry. WISCO and Pangang have built MES for key production lines

with the development of computer technology applied to steel production management, in recent years, a production execution system (MES), also known as the production and marketing integration system, has appeared abroad, which is specially used for production execution, so that the production management of steel enterprises can achieve level 1 planning management, that is, the production department plans can be centralized to furnace times, pouring times, rolling times, and branch plants only need to operate and execute. At present, domestic Baosteel and WISCO are the first to introduce foreign MES, which has achieved first-class production planning management and achieved obvious economic benefits. Angang Steel is also developing a production and marketing system. Shagang and Jiuquan Iron and steel first carried out institutional reform, abolished branch plants, and set only operators on site, also in order to fully introduce the internationally advanced first-class production management mode. Whether it is to carry out institutional reform first or to launch the production and marketing system first, its development direction is determined, that is, to finally realize the primary production plan management mode

2. Overview of Jigang MES system

Jigang is one of the top ten steel mills in China and one of the top 500 enterprises in the country. Jigang ERP system is an integrated management information system integrating production, inventory, cost and sales based on MRPII (Manufacturing Resource Planning) as the core and combined with the actual management organization of Jigang. The functions of the system cover Market Analysis and prediction, engineering data management, production plan management, material demand plan management, procurement and supply management, production capacity analysis, man hour and process management of work in process, raw material and finished product inventory management, customer order management, quality management, after-sales service management, office automation, etc., and carry out dynamic coordination for the enterprise, so that the enterprise is in a comprehensive controlled state

however, due to the lack of effective links to the MES system, ERP information is like an island, which cannot be seamlessly linked and effectively combined with the l1/l2 information within each manufacturer, directly affecting the explicit efficiency and potential of information means. There are the following shortcomings in production implementation and management:

1. There is no good data interface with the ERP system of the head office, and the plan needs to be manually input and issued; Data collection is limited to L3, which is managed within the branch plant, and there is no company level sharing of resources

2. The system data is inaccurate, and there is often a serious mismatch between physical inventory and computer inventory, resulting in some confusion in the statistics of production data. Therefore, the relevant financial data cannot be used effectively, and can only be supplemented by manual entry

through the development of MES, it needs to be eliminated. It can provide workshop level scheduling management functions that cannot be achieved by basic automation system and process automation system; Provide the acquisition and analysis function of production data that cannot be achieved by ERP and other management information systems, become a bridge between workshop production and enterprise management, and can bring real or potential economic benefits to enterprises, including: accurately grasp the production status, improve the accuracy of delivery, and achieve production and marketing cooperation; Correctly grasp the production status and the tracking of defective products to reduce production costs; Manage the product production data. 3. The data transmission mode is USB transmission, which is convenient for quality tracking and improve the product service quality; Effectively avoid bad operation and improve production efficiency; Make effective use of production equipment and make full use of production capacity; Be able to make production decisions correctly and quickly, and enhance the competitiveness of enterprises. The relationship between Jigang ERP system and MES and the secondary PCs control system of each branch is shown in Figure 1:

Figure 1 the relationship between ERP system and MES and PCs of each branch

the implementation of MES system in order to support and improve the ERP production and manufacturing management function and realize the goal of production and marketing integration of Jigang information system, the implementation of MES system is synchronized with ERP system. In the design of the production and marketing integration scheme, the ERP system forms a comprehensive production and management plan according to the demand forecast and sales order, the MES system sorts and schedules the detailed production plan according to the main generation plan generated by the ERP system, and transmits the operation instructions to the secondary system to complete the whole production process. At the same time, the MES system collects, summarizes and feeds back the production performance and quality information from the secondary system to the ERP system, forming a complete production management system from sales, planning, process management, job scheduling and so on. In the design of the production and marketing integration scheme, the MES system is divided into two levels: the production and marketing integration system and the L3 level automation system of the branch. The production and marketing integration system mainly completes the post steel production scheduling, including APS, operation scheduling, furnace number, pouring number, rolling number and other process plan management, on-site operation management and related production control. The L3 level automation system mainly completes the L3 level computer network construction of the branch plant and the on-site operation execution and tracking system, so as to complete the collection of production scheduling tasks and operation performance

3. MES function design of medium and heavy plate production line of Jigang

the design goal of MES of medium and heavy plate production line of Jigang is to establish MES of medium and heavy plate production line, realize the automation of production management (production planning, dynamic scheduling, execution tracking) of the whole line, stabilize and balance production, quickly and dynamically make operation easier scheduling, improve production efficiency, reduce production costs, standardize production management mode, and improve production decision-making environment, Realize the modernization of production management of medium and heavy plate production line

the main functions of MES of medium and heavy plate plant are: receiving the production plan data of medium and heavy plate from the upper ERP system, monitoring the production status of the production line of medium and heavy plate plant, controlling the production process, and providing material demand information; Reflect the operation status of the equipment of the medium and heavy plate production line, connect the l1/l2 automation systems of the production line, implement the production plan, and issue manufacturing orders and manufacturing standards; Track the logistics of the whole line, and collect, judge and track the measurement and quality information; Form various production statistical statements, etc

the relationship between MES and secondary PCs systems of medium and heavy plate production line is shown in Figure 2:

Figure 2: the relationship between MES and PCs

the operation management of medium and heavy plate plant is divided into eight business function modules: steel rolling operation management, finishing operation management, steel plate warehouse management, roll management, operation performance management, slab warehouse management, operation instruction management and other management. Its function is described as follows:

⑴ rolling operation management: input of operation plan, slab information input, input and query of charging plan (specify the charging position, heating furnace number and pass number of slab); Record the actual performance of heating furnace (charging, discharging, missing number), rolling mill (roughing mill, finishing mill), ACC and straightening operation; Query the actual performance of each process in the steel rolling area

⑵ finishing operation management: 1~3# actual performance entry of cooling bed, shearing, flame cutting, spraying number, falling on the floor, offline and other operations; Input and query the actual performance of steel plate quality inspection (surface, finished product inspection, ust flaw detection, steel plate grinding, etc.); Query and modify the actual performance of finishing operation

⑶ steel plate warehouse management: input and query the actual performance of steel plates in the temporary stacking area; Input the actual performance of steel plate warehousing, movement in the warehouse, delivery and return to the warehouse; Steel plate warehouse inventory and warehouse drawing query

⑷ roll management: input and query the actual performance of roll, bearing and bearing seat warehousing and scrapping; Roll assembly, use, grinding, fault performance input and query; Inventory inquiry of rolls, bearings and bearing pedestals

(5) operation performance management: query the production status information of each process of the medium and heavy plate production line; Input and query the actual shutdown performance and energy performance of each process of the plate production line; Statistics and inquiry of all kinds of plate edges and rolled scrap steel plate information

⑥ slab warehouse management: Inquiry of stock and drawing of slab warehouse of No.3 steel smelting plant; Slab information input and query of medium and heavy plate

⑺ operation instruction management: rolling instruction, finishing instruction, process parameter query; Input and query of medium and heavy plate manufacturing standards

8 other management: input and query of standard management information of heating furnace; Statistics and query of raw material consumption and rolling volume per shift

the function package diagram of the plate operation management system is shown in Figure 3:

Figure 3: the function package diagram of the plate operation management system

4. MES software architecture

as an enterprise application software, MES system should have a distributed software architecture. With the development of network technology and the change of application requirements, the architecture of distributed application software is gradually transformed from the original two-tier c/s architecture to three-tier or multi-tier distributed architecture

in order to facilitate deployment, expansion and maintenance, combined with the successful experience of typical MES in the steel industry, the technical architecture of this system logically adopts a three-tier architecture, including presentation layer, business layer, and data access layer. The main responsibility of the presentation layer is to provide information for users, or translate the user's operation instructions into data packets and send them to the business layer. The business logic layer is mainly responsible for verifying and reprocessing the instructions and data provided by users and storing them in the storage layer. It is also responsible for extracting the data from the data storage layer and returning it to the presentation layer. Data storage layer refers to the database, including tables, views, stored procedures, triggers and other data objects. Its logic diagram 4 is as follows:

Figure 4: application architecture layered diagram

in the database storage layer, its basic function is to store data. But considering the convenience of data operation in the background

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