Melting and casting is a metal hot working process, which is one of the basic processes in modern mechanical manufacturing industry and an essential processing link in the manufacturing of electromechanical integrated equipment. As a typical branch of the hybrid manufacturing industry, mechatronics integrated manufacturing has process manufacturing attributes in the first half of the melting and casting process, while the second half of the machining process has discrete manufacturing attributes, resulting in a complex workshop environment.
Pain points and challenges in the smelting and casting industry
Starting from the actual needs of the industry, starting with mature industry solutions, sorting out business problems and confirming optimization directions.
Industrial transformation and upgrading pressure
The industry generally suffers from outdated equipment and processes, low production efficiency, uneven technological levels, imbalanced scale development, significant waste of resources and energy, and serious environmental pollution. In recent years, "green", "low-carbon", and "compliant" have prompted enterprises to make changes, upgrade industries, and build core competitiveness.
Insufficient independent innovation capability
The overall technical level of the industry still needs to be improved, with low product profits, serious insufficient research and development investment, and weak innovation ability, which seriously affects the development of the casting industry. Although key castings in most fields in China have achieved independent manufacturing, in some high-precision and cutting-edge fields, castings cannot meet the requirements of the main engine and major technical equipment.
Difficulty in workshop control
Melting and casting belong to the field of hybrid manufacturing, which generally includes two major manufacturing models: discrete and process. The workshop environment is complex, and the control of formulas, processes, and molds can be a major challenge. The traditional extensive management model also makes it difficult to know the production progress and execution status. Intelligent manufacturing and green casting have become industry development goals.
Inaccurate cost accounting
Due to lengthy processes and processes, difficulty in cost allocation, and the inability of traditional methods to gather key data effectively, data often leads to inaccuracies or delays, seriously affecting managers' strategic decisions. It is urgent to build a visual analysis platform for enterprises, provide real-time data value, and comprehensively improve the efficiency of enterprise financial processing.
How does TransInfo solve management challenges for customers?
Analyze industry characteristics and use mature experience to help enterprises achieve comprehensive digital transformation and enhance profitability.
Overall architecture
Smelting formula management
Flexible Modeling of Foundry Workshop
Comprehensive quality control and traceability
Manufacturing execution MES system
Fine cost accounting
Intelligent warehouse management
轻智能制造场景
Overall architecture
Hybrid production method, also known as hybrid process, semi process, or discrete continuous process, is a complex production method with both continuous and discrete production processes. It achieves good management of the internal supply chain of hybrid production enterprises, helps enterprises reduce costs, improve product quality and delivery time, and tests the functionality and flexibility of ERP software.
TransInfo's smelting and casting industry solution leverages the flexibility of SAP ERP software, starting from the process formula management and casting process of casting enterprises, to help them standardize business processes, ensure product quality, improve production capacity, and achieve refined cost accounting management.
Efficient
Rapid collaboration of business processes
Real time
Provide real-time business value
Visual
Visualization of enterprise management data
Smelting formula management
The ERP solution of TransInfo smelting and casting is aimed at the foundry enterprises to realize the similarities and differences of casting process and products.
• Support a multi-input and multi-output production model:
Can support 5 types of input: material type, equipment type, labor type, miscellaneous type, operation specification instruction type.
Three types of output can be defined: finished products, co-products and by-products.
Support for extended formulations to combine multiple formulations to form a new process that defines inventory data and simplifies all processes between production, inventory and cost activities.
In order to collect quality inspection information more comprehensively, specify a pre-set quality inspection plan in each type of input and output link, with the support of a comprehensive data model, the software can comprehensively collect and produce the cost and quality inspection results related to the whole process.
Flexible Modeling of Foundry Workshop
The workshop job management components tailored for the production workshop of foundry enterprises can model the production site flexibly according to the different actual production modes. flexibly configured into three typical production models: automatic production line, discrete production mode, hybrid production mode.
Because the underlying data model of most ERP software is designed for discrete manufacturing enterprises, it is not suitable for the complex production site management of smelting and casting enterprises.
The SAP smelting casting solution can realize:
For the smelting and casting process: manage the production process according to the formula.
Machining link: rigorous discrete manufacturing business process, joined the batch demand planning subsystem, in order to better work out the production plan and material purchase plan of products and semi-finished products in each stage according to order, reasonably schedule production according to product capacity or equipment capacity, and improve the enforceability of production plan.
It can be better applied to planned production and order-to-order production mode, which greatly improves the efficiency and accuracy of the work.
Comprehensive quality control and traceability
The program provides complete quality control and management functions, covering all aspects of the supply chain, including purchasing and receiving, warehouse inventory, WIP, finished product delivery and return, etc.
The "centralized quality control and inspection" function of the SAP smelting casting solution provides centralized quality control for all application modules.
According to the material and transaction type, the enterprise can specify the standard quality inspection scheme and collect the quality inspection results of the whole supply chain when the actual business occurs.
Provide batch number and serial number management for all incoming and outgoing materials, when there is a product problem, you can record the maintenance status and track the original production status and raw materials of the product, and in turn find the same batch of products of the product, as well as the sales or inventory status of these products.
Manufacturing execution MES system
The scheme constructs the MES manufacturing execution function on SAP to solve the problems encountered by foundry enterprises in the process of production execution, such as untimely order execution, scattered process, rough production capacity and low production efficiency, so as to improve production efficiency.
• Strengthen the workshop operation plan.
Reasonable allocation of personnel and working hours, timely and accurate production feedback, ensure the transparency of production data and progress, and improve the completion rate of production planning and product delivery.
• Real-time collection of workshop data.
Through bar code technology to track the whole production process from material production to finished product storage, real-time collection of all events occurred in the production process, making the whole workshop completely transparent.
• Transparency of production process.
Make the products clear and transparent in the whole production process, efficiently trace the causes of problems, formulate measures to solve quality bottlenecks, achieve product quality traceability, and reduce costs.
• Progress and resource tracking.
Record and monitor the completion of production processes and processing tasks in real time, analyze personnel work efficiency, labor productivity, equipment utilization rate, product qualified rate, scrap rate, etc., find the problems in the implementation process and improve them in time.
Fine cost accounting
The scheme can help foundry enterprises to correctly calculate the product cost, flexibly configure the cost accounting methods of foundry workshop and machining workshop, and adapt to the complex mixed manufacturing business.
The solution subdivides the cost into: material cost, labor cost, manufacturing cost and processing cost.
At the same time, it aims at the links of the foundry workshop, including the cost sharing of various types of products: finished products, co-products, by-products, intermediate products, etc.
The cost calculation method adopts the batch and step-by-step method, and provides flexible settings for the allocation of labor and expenses to adapt to a variety of complex situations.
It really frees the financial staff from the complicated manual operations such as data collection and cost sharing, provides cost information for managers faster and more accurately, and improves the management decision-making level of the enterprise.
Financial affairs
Fine financial management
Cost
Actual cost accounting
Report form
Flexible data report
Intelligent warehouse management
The scheme constructs an intelligent warehousing system, through docking with PDA, bar code gun, inventory machine, various transport equipment and other equipment, to achieve fine inventory management, so as to optimize the procurement process and improve inventory accuracy.
• Innovative Integration of Bar Code label and RFID Technology.
Intelligent equipment runs through the whole logistics link, realizing digital and intelligent management and control of products.
• Establish the application scene of automatic equipment such as three-dimensional shelf / three-dimensional container.
Through the sub-bus system, four-way shuttle vehicle technology, multi-layer shuttle vehicle technology, ground four-way light 2 heavy AGV technology, cargo picker system, WMS (warehouse management system) system, WCS (warehouse control system) system and other information technology: "shelf + robot = automatic storage system solution".
轻智能制造场景
Combined with the related research and business practice of SAP for intelligent manufacturing and intelligent workshop, the TransInfo R & D center is based on SAP system and oriented to small and medium-sized manufacturing enterprises, helping small and medium-sized manufacturing enterprises to build light intelligent manufacturing application scenarios at affordable costs, and bridging multiple automation equipment and data centers with the help of SAP Leonardo innovative solutions.
• SAP's solution for Industrial Internet.
Omni-channel solution (Hybris) / Core Operations Management (Sramp 4 HANA ERP) / Agile R & D Management (PLM) / Intelligent Manufacturing solution (ME/MII).
• SAP's solutions for the external Internet of things:
SAP HANA Cloud platform / big data Predictive Analysis / SAP Leonardo Internet of things solution.
The combination of SAP Leonardo and related intelligent manufacturing hardware equipment: Siemens / Panasonic / Foxconn / Honeywell, etc.
Targeted
Designed for smelting and casting industry research and development, mature industry solutions can accelerate the digital transformation of enterprises.
Integration
Fully integrate the business process of smelting and casting enterprises, break down information barriers and achieve efficient coordination.
Complianc
Improve the compliance level of enterprises, lay a good foundation for further development, and realize the sustainable development of enterprises.
How does Translnfo focus on serving customers in the smelting and casting industry of different scal
For over 10 years, TransInfo has provided digital transformation services to over 600 enterprises
LeJoneschina is a valve seat ring production enterprise jointly established by L.E. Jones of the United States and Chengdu Haolong Automotive Parts Co., Ltd. (specializing in the production of valve seat rings). We have passed ISO/TS16949 quality system certification and the early quality development audit process for host customer products, and have become a designated supplier for host supporting equipment. We are partners with manufacturers such as Dongfeng Cummins, Honda Cummins, Carter, and VOLVO.
Taixiang Industry, founded in 1997, is located in Shiyan Economic Development Zone of Hubei Province. It is mainly engaged in the production, R & D and sales of automobile engine main bearing covers. It is a state-level high-tech enterprise and an invisible champion in Hubei Province. It is a global supplier and A-class supplier to Volkswagen. Products are mainly used in Volkswagen Audi, Volkswagen, Skoda and other brands, customers at home and abroad.
Hongtuo casting is a mechanical casting company specializing in the production of stainless steel accessories for various pumps and valves. The company covers an area of more than 8000 square meters and has advanced equipment production lines in China. Its products are exported to home and abroad. Based in Guangzhou, Yangcheng, Hongtuo casting has been growing and developing. In order to better serve customers, Hongtuo casting has successively absorbed advanced technologies at home and abroad to improve its service and product supply capacity.
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