时间：2019-10-26 点击：925次
科勒 SKE 动画配音解说(第 6 稿)
SKE 是科勒电子产品的全球研发及制造基地, 产品覆盖一体化智能座便器、智能座便盖板、
感应器及感应龙头以及带有物联网功能的其他卫浴电子产品。
SKE is a global R&D and manufacturing base of Kohlers Electronic Products, which covers
intelligent toilet, Bidet Seat, Sensor and Sensor Faucet as well as other sanitary electronic
products with the function of Internet of Things.
主要功能区域包含办公区、研发区、生产区 1(1 楼生产一体化智能座便器, 2 楼生产智能座便
盖板和感应器)、生产区 2(生产 2 区 1 楼主要为 NPI 和小批量产品生产线)、立库区、AGV 平
库(1 楼成品、2 楼包材)。
The main functional areas include office area, R&D area, production area 1 (1st floor for
Intelligent toilet production, and 2nd floor for Bidet seat & Sensor production), production area 2
(the 1st floor of this area mainly for NPI and small batch production), three-dimensional
warehouse area, and AGV plane warehouse (1st floor for finish goods and 2nd floor for
packaging materials).
在智能家居需求增加背景下, SKE 构建了工业 4.0 四大目标:
With the increasing demands for smart homes, SKE has put forward the four major goals for
Industry 4.0:
1、实现客户端—科勒电子—供应商端业务实时信息的横向集成。
2、贯穿整个产品全生命周期的端到端的设计工程数字化集成。
3、建立灵活可变的柔性化制造系统的纵向集成 。
4、建立智能数据驱动响应的快速的智慧运营体系。
1. Horizontal integration of the real-time information of customer/SKE/supplier.
2. Digital integration of end-to-end design engineering throughout the whole life cycle of
products.
3. Build vertical integration of highly flexible manufacturing system.
4. Build fast reacting management system with intelligent data driven.
接下来, 让我们来到 SKE 开始我们的数字化的企业之旅，通过搜集客户产品需求, 在这里我
们将完成产品的设计、规划和工程工作, 客户的定制需求通过 PLM 软件实现模块化、虚拟化
并与供应商协同优化。在 PLM 里, 产品工艺路径被定义出来, 并通过工艺仿真虚拟运行, 保
证装配工艺的执行效率, 而后通过虚拟的调试技术, 自动化编程的设备调试工作可以大幅提
前, 生产时自动从 PLM 获取参数, 将虚拟设计与现实制造实现完美结合。
Next, lets come to SKE to start our digital journey. By collecting customer product demand, we
will complete the product design, planning and engineering work in SKE. The modular and
virtualized design for the customization demands, collaboratively designed with suppliers, of the
customer will be realized through PLM software, and the product will be collaboratively
optimized with suppliers. In PLM, the product process path is defined and virtually performed
through process simulation to ensure the efficiency of the assembly process, then through virtual
debugging technology, the debugging of automatic programming equipment can be greatly
advanced through virtual debugging technology, and the parameters can be automatically
obtained from the PLM during the production to perfectly combine the virtual design with real
manufacturing.
完成产品的设计、规划和工程工作之后, PLM 触发 SAP 和 APS 排产, 并与 SRM 集成, 实现 JIT
物料拉动, MES 在接到 APS 排产信息后将订单释放, 将通过 WMS 将物料配送至产线, 实现
供应链的透明化、数字化和精益化, 通过工业以太网的传输, 该订单信息由产线的读写器写
入托盘上二维标签, 这个标签中的信息, 让托盘、产线 、设备及 MES 确保实现沟通, 实现
柔性制造。上层系统指令能够上传, 保证了生产效率和过程透明, 在装配工站, 根据零部件
ID, 自动从 PLM 读取信息进行装配, 与虚拟世界的计算机辅助制造设计构成了数字化双胞
胎, 同时, 自动生产线的运行参数通过网络上传到工业云平台, 通过大数据分析, 实现设备
的预防维护提高整体装配和检测性能, 每个工站产品的相关数据、质量和节拍时间都会被记
录并上传到 MES, 及时作出判定, 触发干预行动, 产品 ID 将以二维码形式呈现, 作为未来数
据追溯的依据。所有数据通过网络上传工业云平台, 通过大数据分析, 提前预警与处理。长春配音
After the completion of the product design, planning and engineering work, PLM activates SAP
and APS production scheduling, and integrates with SRM to realize JIT material pulling. MES
releases orders after receiving APS production scheduling information, and will deliver the
materials to production line through WMS to realize the transparency, digitization and leanness
of the supply chain. Through the transmission of industrial Ethernet, the order information will
be written by the reader on the production line into the 2D tag on the pallet, which connects
the communication among the pallet, production line, equipment and MES to realize flexible
manufacturing. The instructions from upper level system can be uploaded to ensure the
production efficiency and process transparency. The information can be automatically read from
the PLM for assembly according to the component ID, and the digital twin will be constructed
with the Computer Aided Manufacturing of the virtual world. Meanwhile, the operation
parameters of the automatic production line will be uploaded to the industrial cloud platform
through the network, and with the big data analysis, the equipment can be preventively
maintained to improve the overall assembly and inspection performance. The relevant data,
quality and takt time of each workstations products will be recorded and uploaded to the MES
for timely determination and triggering the intervention action, then the product ID will be
presented as a two-dimensional code as the basis for future data tracking. All the data is
uploaded to the industrial cloud platform through the network for early warning and handling
through big data analysis.
通过自动采集系统, 产线的一举一动在在系统掌控下, 定制化产品经过无缝价值链集成后,
快速交付到客户手中, 售后质量数据通过云平台同步到工厂端 QMS 系统进行分析和处理,
Through the automatic acquisition system, every operation of the production line is under the
control. After the seamless value chain integration, the customized products can be quickly
delivered to the customer, and after-sales quality data will be synchronized to the factorys QMS
system through the cloud platform for analysis and processing as well as integrating the
experiences into the knowledge base.
系统的透明化, 可以追溯到产品任何一个数据, 从设计到过程质量, 从物料到节拍时间, 这
些数据离不开工艺网络和自动化技术, 各个系统数据交互, 真正实现了端到端的数字集成,
实现了企业整个价值链整合。
All product data can be traced back through the transparency of the system. The data from the
design to process quality, from the material to takt time, cannot be separated from the process
network and automation technology, the data exchange of each system can truly achieve the
end-to-end digital integration and the entire value chain integration of the enterprise.
SKE 将实现工厂全过程的物流自动化, 原料入库包含托盘入库、料箱入库、混合分拣入库、
包材入库。原料出库包含托盘分拣后经空中输送线运至产线; 料箱分拣后经 AGV 输送至产线;
包材开箱后经空中输送线运至产线。成品经空中输送线自动运至码头。
SKE will realize the logistics automation of the factorys entire process. The storage of raw
materials includes pallet receiving, material box receiving, mixed sorting receiving, and packaging
material receiving. The output of raw materials includes pallets sorting and delivering to the
production line via an air conveyor line; material box sorting and delivering by the AGV to the
production line; packaging materials unpacking and delivering to the production line via the air
conveyor line. The finish goods will be automatically transported to the dock via the air conveyor
line.
一体化智能座便器自动生产线主要工艺是经过陶瓷投入、整机组装、本体组装、本体测试、
上盖安装、综合测试。节拍为 130s, 年产能约 50 万套, 工位自动化率 62%。
The main processes of the intelligent toilet automatic production line include ceramic input, the
whole product assembly, body assembly, body test, cover installation and integrated test. The
beat time is 130s, annual production capacity is about 500,000 pieces and workstations
automation rate is 62%.
组装完成后, 视觉识别机器人进行间隙检测, 检测结果自动判别与处理。综合测试采用机器
人搬运到工位自动化检测。
After the completion of the assembly, the visual recognition robot performs gap detection, and
the detection results are automatically determined and processed. The integrated test is
conducted by automatic detection after using robots to the workstations.
智能座便盖板主要工艺为: 本体装配、本体测试、安规测试、综合测试。节拍为 35s, 年产
能约 100 万套, 工位自动化率 79%。
The main processes of the Bidet Seat include body assembly, body test, safety test, and
integrated test. The takt time is 35s, annual production capacity is about 1,000,000 pieces and
the workstations automation rate is 79%.
生产线模块化装配设计单元可以支持即插即用, 机器人滑轨移动实现工艺和资源的灵活调
配, 使产线做到最大柔性化。
The modular assembly design unit of the production line can support plug-and-play, and the
robots slide movement realizes the flexible deployment of the processes and resources, all of
which can finally realize maximum flexibility of the production lines.
感应器/感应龙头, 分布 3 条自动生产线, 工位自动化率 80%。
Sensors/Sensor Faucets are distributed among 3 automatic production lines, workstations
automation rate reaches 80%.
商务智能通过设备数据采集、检验参数采集、生产过程监控、质量数据的统计等, 集成了
底层设备和业务系统数据, 商务智能通过数据管理模块进行分析, 基于可视化和挖掘分析的
成果形成数据应用。
Business Intelligent integrates the underlying equipment and business system data through
equipment data acquisition, inspection parameter acquisition, production process monitoring,
quality data statistics, etc. BI analyzes through the data management module and forms data
applications based on the results of visualization and excavation analysis.
商务智能展示关键的 KPI 与绩效有: 运营、营销、研发、生产 KPI 与行动计划。
The key KPIs and performances shown by Business Intelligent include: operations, marketing,
R&D, production KPIs and action plans.
商务智能是智能制造大脑, 对销售&订单的大数据分析、预测管理, 对供应商质量和绩效的
大数据分析和预测, 对制造全过程的大数据记录、分析、预警、决策与追踪。通过 IOT 智能
决策等技术, 实现运营信息纵向贯通和横向整合。
Business Intelligent is a smart manufacturing brain used for big data analysis and prediction
management of sales & orders and supplier quality& performance, and big data recording,
analysis, early warning, decision making and tracking of the entire manufacturing process.
Through the IOT intelligent decision-making and other technologies, the operation information
can be vertically and horizontally integrated.
为了让客户了解 SKE, 设立参观通道和智能展示区.
In order to help customers understand SKE, a visit passage and smart display area will be set up
for customers to better know about SKE.
SKE 智能工厂 将实现如下目标:
SKE Smart Factory will realize the following goals:
LOTIF 达到 98%; CCU 达到 0.36%; inventory turn 达到 11.8; Headcount 下降 48.6%;OLE 达到
81.13%; OEE 达到 89.23%;CAPACITY 达到 2, 637, 805 套; 制造周期达到 1.9 小时; Switch Time
达到 2.1 分钟;
LOTIF reaches 98%; CCU reaches 0.36%; inventory turn reaches 11.8; Headcount decreases by
48.6%; OLE reaches 81.13%; OEE reaches 89.23%; CAPACITY reaches 2, 637, 805 pieces;
manufacturing cycle time reaches 1.9 hours; Switch Time reaches 2.1 minutes.
