Brief Analysis of the Functional Design of Jinan Iron and Steel's Quality Management System, MES, and ERP System
2026-04-06 05:58:35··#1
[Abstract] This paper mainly introduces how Jinan Iron and Steel Group (Jinan Steel) fully leverages its information automation capabilities in quality management, closely integrating quality management with MES and ERP to form an automated management system from planning to production organization and finally to data quality analysis and collection. Its functional structure, network architecture, and information interface design are described and explained. [Keywords] MES, ERP, Quality Management System 1. Current Situation Analysis With the further deepening of enterprise informatization, the MES application platform has become a crucial layer connecting enterprise management systems (ERP, CRM, SCM) and field control systems through direct two-way communication of key information about product behavior within the enterprise and the entire product supply chain. MES plays a very important role in enterprise production informatization, serving as a vital link between upper and lower levels. Many enterprises strengthen management by implementing ERP. However, upper-level production planning management is increasingly influenced by the market, and it is evident that plans cannot keep up with changes. Faced with customers' stringent delivery requirements, more product modifications, and continuous order adjustments, enterprise decision-makers realize that planning must rely on the market and actual operational status, rather than solely on material and inventory returns to control production. Meanwhile, ERP software primarily targets resource planning. These systems can typically handle events that occurred before yesterday (for historical analysis) and predict and process events that will occur tomorrow, but they often leave gaps in the standardization of events happening today. Traditional production site management is essentially a black box operation, which can no longer meet the needs of today's complex and ever-changing competition. Therefore, how to make this black box operation transparent, identify any problems affecting product quality and cost, improve the real-time nature and flexibility of planning, and simultaneously improve production line operating efficiency has become a concern for every enterprise. Manufacturing Execution System (MES) can precisely fill this gap. MES is the execution layer between the planning layer and the shop floor operation control system, primarily responsible for production management and scheduling execution. It improves manufacturing competitiveness by controlling all factory resources, including materials, equipment, personnel, process instructions, and facilities. It provides a systematic way to integrate functions such as quality control, document management, and production scheduling on a unified platform, thereby realizing a real-time ERP/MES/SFC system for the enterprise and bringing significant economic benefits. The effective integration of the quality system with the MES and ERP systems maximizes data sharing and automates data settlement. Jinan Iron and Steel Group (Jinan Steel) adopted the principle of "overall planning and distributed implementation" in the construction of its information system. First, they prioritized infrastructure development, taking various measures to strengthen the construction of their information infrastructure. This infrastructure includes networks, industrial control equipment, intelligent instruments, quality inspection equipment, metering equipment, information security equipment, and system hosts. Jinan Steel has achieved good results in this regard and has reached a certain scale. From the perspective of company informatization, MES is the foundation of informatization for manufacturing enterprises. Without timely, accurate, and effective production management information, the enterprise ERP system is merely a castle in the air. 2. System Design Objectives Jinan Steel's ERP can be adjusted based on continuously evolving business needs. Through close integration with the production management system and MES, it achieves the integration of quality standards with production. Simultaneously, through the integration of the ERP system with the inspection and testing system and the MES system, it can achieve automatic collection and management of quality data and process data. Through an integrated quality database, Jinan Steel's quality data can be managed centrally and uniformly, providing data sources for a data warehouse for future quality data mining. The quality management system is closely integrated with production, procurement, metrology, and MES systems to achieve quality specification management, timely collection of quality data, and information sharing. This enables the management of quality processes, quality data, quality standards, and statistical analysis of quality data. Since the Oracle quality system focuses on quality data management and cannot automatically read data from machines, it is recommended to establish a unified metrology quality system based on the Oracle quality system. This system would enable data measurement, quality sampling management, automatic data reading, quality assessment, and the printing and management of final quality assurance certificates. The Oracle Quality Module is an integrated quality management application used to manage quality information in manufacturing and distribution processes. It strengthens enterprise quality control through end-to-end logistics control within the ERP system to improve product quality. Its main function is to collect quality data by defining collection elements and collection plans, achieving information sharing of quality data. The integrated production management execution information system (MES system) achieves full-line production management automation (L3) (integrated production planning, integrated dynamic scheduling, and integrated execution tracking), ensuring stable and balanced production, rapid dynamic scheduling, improved production efficiency, reduced production costs, standardized production management methods, improved production decision-making environment, and modernization of production line management. 3. Business Model Introduction Based on the three-tier organizational structure of the head office's production management, the system's functions are set up in three layers: "Head Office – Branch Plant – Production Position." The upper layer is the head office's decision support system and business application system; the middle layer is the branch plant's business application system; and the bottom layer is the production position's business application system. It mainly consists of three functional architectures: ERP, MES, and the quality control system. The interface design is shown in Figure 1. (Figure 1 Functional Structure Diagram) 4. System Network Architecture Analysis The quality control system integrates with the head office's production department and ERP information system through the backbone network (L4 level), providing information service support for the entire plant's management and control. The MES (Manufacturing Execution System) is an L3-level system built upon the L1-level basic automation system and L2-level process automation system of the entire plant. This L3-level system receives production plans from the upper level (L4) and issues specific production control instructions to L1/L2; simultaneously, it forms full-line production management control based on L1/L2 level information and transmits information to the ERP level. The overall hardware structure of the system is shown in Figure 2. (Figure 2 Network Architecture Diagram)5. Functional Design of the Quality and Accounting System Based on the MES information infrastructure, a quality and accounting system centered on ERP and meeting professional management needs was constructed. The Jinan Iron and Steel Group's quality and accounting system comprehensively covers the company's inbound logistics, internal transfers, outbound logistics, energy monitoring, inbound material inspection, pre-iron material inspection, billet/plate/section inspection, material/power/energy management, billet/plate/section warehousing, quality certificates, premium pricing management, underlying data acquisition, data interfaces, and other business operations. The main functions of Jinan Iron and Steel's quality control system include: quality traceability and defective product root cause analysis, quality analysis, statistical process control, and a data expert system, laying a solid foundation for providing reliable data for scientific decision-making. The implementation of the quality control system project promoted management transformation and achieved the management goal of "unified data management." It completely changed the management model where raw material plants, pellet plants, sintering plants, coking plants, ironmaking plants, power plants, and gas plants each issued their own statistical settlement data. It fully covered the manual operations of 13 business processes in the ERP system of each branch plant, eliminating all pull-type material issuance operations in the ERP system, replacing them all with settlement data generated by the system. This replaced more than 1,400 manual operations per day in each branch plant. During the project implementation, the management processes of inbound logistics, internal logistics, and outbound logistics were streamlined, ensuring smooth and balanced logistics and the synchronization of logistics and information flows. RFID and IC cards were applied to inbound logistics, constructing Jinan Iron and Steel's unique quality control system, ensuring the efficient and accurate operation of the inbound logistics system, and gradually refining the material inbound plan to achieve the goal of balanced inbound delivery. The system monitors and manages all aspects of incoming material inspection, including fitting, measurement, quality inspection, and data uploading. It oversees the entire process, from issuing inspection orders to sampling, sample preparation, sample handover, testing, review, and data uploading, while also providing video monitoring of the quality process. By addressing the issue of train downtime for incoming materials, the system rigorously monitors each stage, effectively reducing downtime caused by quality inspection and historically lowering inspection time to within 6 hours. The quality assessment of billets/sections/plates is closely integrated with warehousing operations, automatically replacing manual operations such as completed warehousing, sub-warehouse transfers, and returns in the ERP system. This not only improves work efficiency but also enhances the timeliness and accuracy of warehousing data. It provides timely quality data throughout the entire process to the production module, enabling rational production planning and guidance. The system achieves full-process quality control and analysis, improving quality assurance capabilities. The quality information system automatically uploads all pre-shipment settlement data to the ERP system daily, laying a solid foundation for the ERP's daily cost calculations. Providing timely, accurate, and reliable quality data for the ERP system minimizes manual intervention and ensures the authenticity and reliability of raw material intake, product output, and production input-output data. The implementation of the quality information system lays a solid foundation for eliminating manual transmission of quality documents and achieving paperless office operations. It improves the collection of underlying data, strengthens production process control, and uses the quality system as a link to achieve information integration between the equipment and application layers. The most important effect is the automatic matching of incoming raw material quality data, timely uploading to the ERP system, and timely online settlement, providing the ERP system with detailed and accurate production data. Currently, Jinan Iron and Steel's quality data upload accuracy reaches over 96%, and the online settlement rate reaches 100%. 6. Conclusion: MES, with process mathematical models as its core, connects to real-time or non-real-time relational databases to monitor, diagnose, and control the production process in real time, completes unit integration and system optimization, performs material balancing at the production process level (rather than the management level), arranges production plans, and implements scheduling, production scheduling, and optimization. Furthermore, the unified monitoring of material flow, energy flow, quality flow, capital flow, and data flow in the production process, effectively integrated with the ERP system and quality control system, achieves information integration from raw steel plates to finished products, and automatic warehousing and statistics. The close integration of Jinan Iron and Steel's quality control system with its MES system platform is significant in that it creates a standardized first-level production management model (consistent with the first-level financial management/first-level inventory management of the ERP system). Our current production management will shift from manual, extensive management to refined, system-based management, which will help solve existing problems, allow production management to reach international advanced levels, further improve production efficiency, and further reduce production costs.