The history of automobile manufacturing spans over a century, and the development of the automotive industry has played a crucial role in driving the development of the entire industrial sector. In the early days of the automotive industry, the market was a seller's market, characterized by mass production with a single product type. As it developed, it transitioned to a buyer's market, where automobile production shifted towards modified mass production methods and a desire for product diversification. Now, in a mature and competitive market, automobile production is characterized by flexible mass production, lean manufacturing, market segmentation, and a demand for diverse product types. It is precisely this demand that has provided the development opportunities and growth environment for the productization of Manufacturing Execution Systems (MES).
Compared to the history of automobile manufacturing, the history of MES (Manufacturing Execution System) is only 20 years old, but its impact and impetus on the automotive industry and other sectors are indelible. With the deepening of the era of globalized economy, automobile manufacturers have realized that a well-designed and operational MES system can help them gain and maintain a competitive advantage. Therefore, the commercialization of MES systems has significant strategic and practical implications for both automobile manufacturers and parts suppliers.
Traditional MES systems are defined as shop floor-oriented management information systems situated between upper-level planning and management systems and lower-level industrial control systems. However, MES productization goes beyond a fixed management scope, aiming for simultaneous expansion in both vertical and horizontal directions. It can fulfill some of the functions of upper-level planning and lower-level management systems when they are incomplete or missing, while also enabling the implementation of functions from parallel systems such as SRM/BOM.
I. Introduction to MES Product Functions
The MES product includes the following modules, which are interconnected but can also be used independently.
- Order Management
- Production Control
- Quality Management
- Materials Management
1. Order Management Module
Orders in the upper-level system are generally sales orders, formulated by the sales department based on customer orders and market forecasts. However, the MES system cannot directly schedule production after receiving these orders. It needs to scientifically break down and reorder the sales orders based on production constraints such as equipment capacity and production costs, forming a production sequence ready for immediate production. The basic function of the order management module is to automatically convert sales orders into production orders in the optimal way, track the execution process of production orders, and ultimately complete the assigned sales order tasks on time and in the required quantity.
Basic functions :
1) Receiving orders
2) Production scheduling
Based on actual conditions, production scheduling rules can be freely set. After the production scheduling module is set, the corresponding production sequence is automatically generated to guide workshop production. Multi-factory and multi-workshop modes are supported.
3) Order changes
It supports operations such as deleting, modifying, canceling, and freezing orders.
4) Emergency order insertion
Urgent sales orders can be processed through drop-off and production can be prioritized.
Scalable features :
For prototype vehicles required for new product development, MES can independently create orders and arrange production.
2. Production Control Module
MES products help companies implement complete closed-loop production by emphasizing the overall optimization of the manufacturing process, while providing process monitoring and management for production managers to ensure normal production operation. They include the following functions:
Basic functions :
1) Process path setting
The process path can be set for different vehicle models, and the process path will be automatically matched according to the vehicle attributes when scheduling or launching production.
2) Assembly sheet printing and reprinting
3) Printing of dispensing line instruction sheet
4) Production control of a single vehicle
Control individual vehicles during the production process, such as hold, setout/in, scrapping, requisition, repurpose, and return.
5) AVI Interaction
It receives AVI over-point information and distributes various vehicle control operations to AVI to achieve information exchange.
6) Reports
Various production control reports, such as daily production reports and reports on stranded vehicles.
Scalable features :
MES products can perform point-to-point scanning without needing to transmit information to AVI.
3. Quality Management Module
In today's world, with highly developed productivity and increasingly fierce competition in manufacturing, quality is a crucial factor in determining success or failure. Quality management is one of the core modules of a Manufacturing Execution System (MES) product, enabling enterprise quality personnel to improve their quality management level. It includes the following functions:
Basic functions :
1) Key component binding (precise traceability and batch traceability)
When mixing and assembling products on the same production line, automatic verification and operational prompts can prevent problems such as component assembly errors, production process errors, and mixed product assembly. It can also perform reverse traceability through components.
2) Quality gate inspection
3) Printing and reprinting of certificates of conformity
For vehicles that have already completed production, perform certificate of conformity inquiry, printing (reprinting), and information uploading. After the certificate of conformity is printed, no further operations such as binding key components are required.
4) Vehicle review
Record the results of the overall vehicle review, compile statistics, and generate different reports as required.
5) Defect Management
To manage the addition and removal of defects in manufactured vehicles.
6) Quality card scanning and storage
4. Materials Management Module
As customers demand higher product quality and faster production speeds, coupled with the conflict between cost reduction and production flexibility, traditional automotive logistics operations are clearly no longer adequate and require upgrading. MES products focus on logistics pull mechanisms, integrating the strengths of various pull methods, including the following functions:
Basic functions :
1) Kanban pull
2) Press the light and pull.
3) Pulling the empty box
4) Sorting and Pulling
5) Plan-driven
6) Pull along
7) Inventory point pull
8) Pick-up service
Scalable features :
1) Basic Warehouse Management
2) Supplier posting platform
3) Basic Supplier Management
II. The Inevitability of MES Productization
Currently, MES has been successfully implemented in industries such as automotive and steel, and its application benefits have been recognized by enterprises. With the development of technology, MES has become the mainstay of enterprise informatization.
Traditional MES systems suffer from increased development and application costs due to the lack of standardized design, development, implementation, and maintenance by different companies. Furthermore, the lack of uniformity in factory data modules results in insufficient integration between MES functional subsystems and between MES and other relevant enterprise information systems, reducing real-time performance and hindering the full realization of MES functionality. Under these circumstances, MES productization becomes inevitable.
III. Prospects for MES Productization
This year's goal is to version the MES product, deploying different versions to meet the different needs of different enterprises. All MES functions will be set as the flagship version, while basic versions for individual functions will be set, such as the MM version for material management and the PC version for production control. These can be deployed as individual modules or multiple basic versions can be deployed together. A trial version with basic functions can also be set up for customers to experience.
Based on the functionality of MES products, we will keep pace with the times, continuously innovate and optimize, and develop towards stronger integration, stronger real-time performance and stronger modularity, to build an MES brand for the automotive industry, while also expanding into automotive parts and discrete manufacturing.
