时间：2020-04-15 点击：1236次
Voice Narration for Kohler SKE Animation (Seventh Version)
SKE is a global R&D and manufacturing base of Kohler's 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.
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).
With the increasing demands for smart homes, SKE has put forward the four major goals for Industry 4.0:
1. Whole value chain integration,including supplier/Kohler/customer .
2.Integrate product life cycle management system and big data for customization and services
3. Build Automated Manufacturing lines and Automated Warehouse with flexible system.
4. Build intelligent data driven fast reacting management system
Next, let's 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.
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 workstation's 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.
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 factory's QMS system through the cloud platform for analysis and processing as well as integrating the experiences into the knowledge base.
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 will realize the logistics automation of the factory's 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.
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 workstation's automation rate is 62%.
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.
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 workstation's automation rate is 79%.
The modular assembly design unit of the production line can support plug-and-play, and the robot's slide movement realizes the flexible deployment of the processes and resources, all of which can finally realize maximum flexibility of the production lines.
Sensor & Sensor Faucet production line will realize highly flexible & automatic manufacturing, that allows it to produce urinal sensor, toilet sensor & sensor faucet at the same time. The optimal TAKT is 35s; annual production capacity is about 1,110,000; workstations automatic rate reaches 80%.
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.
The key KPIs and performances shown by Business Intelligent include: operations, R&D,.
Business Intelligent is a smart manufacturing brain used for big data analysis and prediction management of demand & supply and quality performance, and big data recording, analysis, early warning, decision making and tracking of the entire manufacturing process. Through the intelligent decision-making system，the operation information can be vertically and horizontally integrated.
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 Smart Factory will realize the following goals:
LOTIF reaches 98%; CCU reaches 0.36%; inventory turn reaches 11.8; Headcount decreases by 48.6%; OLE reaches 81.13 81.1%; OEE reaches 89.23 89.2%; CAPACITY reaches 2, 637, 805 pieces; manufacturing cycle time Total throughout time reaches 1.9 hours; Switch Time Change-over time reaches 2.1 minutes.
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