Luculent Chemical Industry MES System is a standard, lean and intelligent production and manufacturing implementation system based on the production and management models of the chemical companies and it is a control platform fully integrating all production and product business items of the production workshop and a integrated control platform fully utilizing all production-related resources. It can assist the chemical production companies in constructing and bettering 4 core competitive capabilities, that is, quality traceability, real-time monitoring, resource deployment and production decision-making capabilities.
Luculent Chemical Industrial MES is designed on the basis of analyzing the existing information system software at home and abroad and compatible with the relevant industrial standards; meanwhile, it also takes the current information level development status and business features of Chinese chemical enterprises and the specific demands of the corporate information system into consideration, so it develops the corporate application supporting platform with its independent copyright to construct a efficient, safe and reliable basic framework integrating corporate applications and support development, deployment, integration and control of the corporate applications.
1. With real-time control, boost transparent production process and strength production-related communication and coordination as well as lean management.
Summarize, statistically handle, analyze and represent the real-time production data for digital, real-time and transparent management over the production process and reflect the actual operation conditions and trend of production and equipment in an overall, visual and convenient way so as to strengthen production communication and collaboration as well as lean production management.
Establish a uniform, efficient and applicable centralized deployment and multistage applied operation supervision platform and the production & operation data center;
Intercommunicate the production indicators and real-time monitor the production process in addition to the historical event traceability;
Establish the plant operation equipment model platform and conduct dynamic digital management over production and equipment;
Realize mobile interconnection and real-time view production data at any place;
2. Based on the real-time interaction and feedback of orders or production resources, establish the flexible production mechanism.
Through interaction between MES and ERP systems, dynamically analyze and feedback information, establish the operation-production linkage mechanism for perfect transformation from sales orders to production plans; uniformly deploy and execute the production resources; flexibly arrange production and effectively conduct communication and coordination to validly better the production efficiency.
Get dynamic and flexible arrangements in the production plan, better the production plan accuracy and the change adjustment capability;
Predict the production trend and effectively eliminate the production bottlenecks and restriction factors;
Efficiently coordinate production and better the production efficiency through linkage and intercommunication of production information;
Optimize and better the supply chain management, improve the rapid market response capability and reduce the corporate inventory and the fund accumulation;
3. With overall energy monitoring, analyzing and improvement system, constantly optimize the energy utilization efficiency.
Taking scientific energy management system as the core, the system constructs the overall energy control framework and takes the closed-loop optimization and management process of the corporate energy. By use of the automation and information technology, it takes centralized flat dynamic monitoring and digital management at each section of the corporate energy system, improves and optimizes the energy use effects and further carry out the corporate management for energy saving and consumption reduction.
Carry out the real-time, visual and perspective energy management;
Real-time analyze and represent the energy utilization efficiency of each section and statistically analyze the actual energy use conditions;
Construct the energy data model and the expert library, real-time send the failure pre-warning, timely discover the energy use problem and constantly optimize the energy utilization efficiency;
Establish the energy efficiency improvement and management system at the five levels of “company – department – procedure – team - post” and constantly optimize and better energy utilization;
4. Perfect cost management system for cost control and analyzing in addition to constant optimization and promotion.
Establish the process-oriented cost management accounting system with settlement in batch, acquire and statistically analyze data from the production process, real-time control and pre-warn the change to production cost and constantly optimize and improve the cost with the cost control system.
Enhance the overall budget management and improve the planning and management capability of the corporate expenses;
Establish the four-level cost amortization model, construct the overall indicator system and statistically compare and analyze the cost;
Set up the cost prediction model optimized constantly, understand the cost management defects and reasonably control costs;
Manage the linkage between abnormal changes and cost results in the process and shape the quantitative, dynamic and real-time cost change analyses.
5. Improve the product quality reliability through multi-cause analyses and control of the production process.
Improve the full-process and closed-loop quality control system, construct the management system of quality records, control, traceability, analyzing, constant optimization and perfection, provide the all-dimension quality control capability and meet the quality demands rapidly emerging of the production and manufacturing companies.
Fully cover the corporate quality management network and keep the full-process production quality controllable, controlled or under control;
Predict and pre-warn the quality management and convert quality management from post-event to pre-event prevention;
Establish the rapid response system of quality events and avoid occurrence and expansion of such events;
With complete quality data management and accumulation, trace and replay the full process of quality analyses;
Establish the big-data model of quality management, statistically analyze data and resolve the quality control bottlenecks for constant improvement;
6. With the life-cycle equipment management, keep the production units safe, stable and long-term running.
Taking the equipment ledger as its basis, the worksheet submission, appraisal and execution as its main line and improving the maintenance efficiency and reducing overall maintenance cost as its goals, provide the maintenance and servicing modes such as fault repair, planned maintenance and status maintenance, integrate collaborative applications such as management of materials, budget, project and finance, provide life-cycle equipment management and support constant optimization of equipment management.
Provide reliable, stable and long-term equipment operation and equipment value preservation and appreciation;
Carry out lean and all-dimension equipment control in addition to leading cost strategies;
Establish the systematic maintenance strategies and realize safe and economic maintenance to keep equipment and assets controllable, under control;
Integrate PDCA closed-loop management conception, constantly improve and optimize the corporate equipment management.
7. With the full-process material management, provide full-process traceability, efficient coordination and timely supplies.
From the viewpoint of the supply chain, establish the perfect material management system, organically combine material control with many procedures such as planning, procurement and inventory and ensure timely supply of production materials, and track and statistically analyze material use or consumption in the whole process to pre-warn the abnormal use of such production materials.
Establish the perfect collaboration mode for efficient coordination of materials in many procedures to ensure timely supplies;
Through full-process material traceability and data linkage, exactly evaluate and effectively manage the suppliers or the materials supplied;
Effectively better the material information circulation efficiency, reduce the staff labor intensity and save the labor cost;
Optimize the inventory quantities of materials and reduce the corporate circulating fund accumulated;
Utilize the material failure alarming and the trend analyzing statistics, timely discover problems and alien changes during production;
8. Establish HSE-oriented risk control system and assist the companies in safe, stable and efficient production.
Assist the companies in establishing HSE-oriented risk control system and environmental protection management supervision system, fulfill the safety responsibilities, take the risk management as the core and safety technology as the measure, innovate HSE information management measures and promote overall HSE management level for safe, stable and efficient corporate production.
Fully cover the HSE management elements and keep the whole production and manufacturing process safe and stable;
Fully converge and effectively monitor various safety and environmental protection data on the platform by use of the software and hardware system integration;
With combination and integrated design of safety and environmental protection management as well as staff ledger, intercommunicate management data in the procedures such as staff resources, safety and environmental protection training, event responsibilities, performance evaluation and occupational health, and validly control safety and environmental protection and constantly better the orientation;
Through the statistical analyses of safety and environmental protection data, control and warn safety problems or environmental protection problems in advance and improve the corporate control capability of safety and environment protection risks;
With the mobile internet and other technology, realize mobile office and site management functions for safety and environmental protection.
1) Track quality and sources
With MES visualized modeling, establish the product process standard and quality norms in combination of the real-time production monitoring and compare the quality indicators, use the process prediction and pre-warning through SPC analyses to predict the process or quality event in advance and adjust the process operation for avoidance of quality accidents.
Establish the quality control system and embed the electronic batch record, carry out quality management by use of inspection application, inspection sheet, inferior quality improvement sheet, defective goods treatment sheet, scrap application and reworking application etc. for process control, and take the process relevancy by products to track the whole product quality process and better the product percent of pass.
Introduce the national or corporate quality inspection norms into the system so that the QC personnel can automatically promote the spot check mode, the chemical laboratory test mode and the analyses etc. during the work.
2) Implement monitoring and process management
The factory workshop establishes a real-time production monitoring system for the whole production workshop by use of the MES system to carry out intensive, real-time, lean and professional workshop management over each production procedure and constantly improve the production technology system in the standard, information and proper process direction.
Integrate each independent, discrete monitoring and supervision system of the workshop into the uniform data platform, establish a large real-time data warehouse based on equipment and processes, assemble the key equipment models, structure numerous discrete data, construct the key real-time dynamic model platform during the digital workshop production and publicize the dynamic equipment attributes to the business layer with the equipment codes so that other specialized technicians unrelated to operation are allowed to utilize the real-time platform and jointly participate in real-time data analyses, treatment and application for the equipment and the production process. Develop the application modules based on the real-time information to maintain the optimal efficiency of the production process through treatment, screening and excavation of real-time and historical data.
As real-time production monitoring can be used by the workshop to share the production indicators and information, meet the centralized process monitoring and the control and traceability of the major abnormal events, statistically analyze the current production and operation status in a visual way through real-time norm compliance management, improve the indicator deviations and help the production center construct the remote analyzing command center integrating “production data + specialized knowledge + production and operation experience” at the same time, and monitor the events in the production process (including historical data), control the operation during the production and automatically generate statistical statements, assist the production staff in providing instructions and supports for the workshop production optimization.
3) Plan production arrangements and coordinate resources
MES system provides the all-dimension production schedule plans and utilizes the advanced information technology and the planning technology, such as genetic algorithm, restriction theory, operations research, production simulation and restriction conformance technology etc., and specifies the feasible material demand plans and the production schedule plans under the corporate resource (mainly refers to materials and equipment productivity) restrictions and the production site control and assignment rules to meet the customer’s demands and deal with the market demands of fierce competition.
With the system, the production decision-making staff rapidly considers production information (such as order, manufacturing process, inventory, BOM and productivity restriction) to make the optimal planning and decisions balancing the corporate benefits and the customer interests and deploy various resources at the first time, including staff, materials and production equipment etc., and improve the collaboration capability of each business department as well as the production efficiency.
4) Aid decisions and plan the layout
Establish the big data center related to products and production, collect various monitoring and management data, such as production process, quality parameters, production plans, equipment operation parameter, preventive equipment maintenance data and warehoused quantity, extract the indicators concerned by the corporate production decision maker and automatically calculate such indicators in combination of SCM/ERP and other systems, dock them with the market information and timely adjust the production strategies.
A coalification company and a salinization company subordinate to Hangzhou Jinjiang Group Chemical Undertaking Division are Jinjiang Chemical Engineering Co., Ltd. and Jinsheng Chemical Engineering Co., Ltd. respectively situated in Xinjiang Kuitun and Guangxi.
The former company has the certain construction scale with the annual yields of 300,000 tons synthetic ammonia, 520,000 tons urea, 17.42 million tons sulfur and 60,000 tons melamine. And the latter has the equipment and the supporting units of chloronated polyethylene, active floridin, epoxy chloropropane etc. with the annual yiedl of 200,000 tons caustic soda.
As the project scope mainly contains the equipment and property management system with the spot check and fixed repair as its core and the worksheets as the main line, the system not only specifies the equipment management business of the production companies for docking to the financial and material systems to further reduce the management cost and the equipment maintenance cost, but also enables the equipment management status of the frontline companies remotely monitored by Hangzhou Jinjiang Chemical Division so that the equipment management business activities become more flexible with the mobile terminal application of the equipment management.