This article is a case study for the "2015 China's Leading and Best Practice Award for the Application of the Integration of Two Systems". This activity selects the best practice projects that bring outstanding benefits in the field of integration in 2015, comprehensively introduces the steps, key points and difficulties, and benefits obtained by enterprises in the process of promoting integration, and shares the experience in the process of information construction for the majority of manufacturing industry enterprises to study and learn.
I. Enterprise Introduction
In the past 18 years, Suzhou Golden Dragon has built a modern bus manufacturing base of 950,000 square meters, and Hagrid buses have been sold in 94 countries and regions around the world, opening up a sustainable and rapid development path. The sales volume exceeded 11 billion RMB. Haige-Bus was awarded "China Well-known Trademark", "China Famous Brand", "National Export Exemption Product" and so on, and its brand value of 20.286 billion yuan was ranked among With a brand value of 20.286 billion yuan, the company was ranked among the "China's 500 Most Valuable Brands", and became the fastest growing enterprise in China's bus industry, the national automobile export base enterprise, and the top 100 Chinese enterprises in informationization.
The company now has total assets of 8.1 billion yuan, more than 6,000 employees, including more than 1,100 professional and technical personnel of various types, with an annual production capacity of 35,000 units of large and medium-sized buses and 10,000 units of light vehicles and other complete vehicles and chassis, under the jurisdiction of the postdoctoral research workstation, Jiangsu Provincial Enterprise Technology Center, Jiangsu Provincial New Bus Engineering Technology Research Center, the new high-speed bus R & D center, Suzhou Haig Suzhou Golden Dragon has been awarded TS16949, TS16949, TS16949, TS16949, TS16949, TS16949 and TS16949. Suzhou Golden Dragon has obtained TS16949 and 3C certifications, and has more than 50 categories and 300 varieties of Haige-E series, H series, A series, V series, W series, B series, Star series buses and light vehicles, covering high-end business, passenger, tourism, bus, school bus and group vehicle fields. Hague buses not only sell well in China, but also in Southeast Asia, the Middle East, Africa, Russia, Eastern Europe, America and other places.
Second, the overall situation of enterprise informationization application
Suzhou Golden Dragon Bus Company started its informatization early and set up a special process and IT department, and introduced PTC's WINDCHILL product to implement the whole life cycle management of product design data with the company's business process as the guide. And with independent development
Suzhou Golden Dragon Bus has exceeded the 10 billion mark in sales in 2014, and has achieved very good results in informationization work, and has successfully put on line ERP, PDM and other systems, but the degree of informationization in this piece of process management is relatively lagging behind, and the management work is still carried out manually, which lags behind the pace of the Group's development management to a certain extent.
The characteristics of the passenger car industry: design and organize production mainly according to orders, short product delivery, high quality requirements, process design and process preparation workload, process technology preparation time is relatively long.
At present, enterprises in process design and process management need to solve the following problems.
(1) How to further improve the efficiency and quality of process design
At present, the enterprise process design is done through Word or Excel and other non-professional CAPP software, and the process is prepared in an interactive card-filling way, which has a lot of repetitive work and a large workload and affects the speed of process response. And the process statistics summary work is basically done by hand, by looking up the information already in the process file, and then copy the information repeatedly by hand, which is inefficient and easy to cause inconsistency of data.
(2) How to promote the work of process standardization
At present, enterprises have established some specifications of process design and process management, and need professional CAPP software to further establish a standardized process terminology library, material library, process equipment library, equipment library, etc. The typical process of the enterprise has not built a shared resource base.
(3) Summary and application of process knowledge is not enough
After years of work, enterprises have accumulated a large amount of process knowledge of various models of products and parts, but there is a lack of professional CAPP software to summarize, share and accumulate these valuable wealth of enterprise knowledge.
(4) Enterprises urgently need to establish electronic means of product process management
The process of task assignment, process document approval and process change in the process of process design is mainly carried out manually, which is more arbitrary and loosely controlled. Due to manual management, it is difficult for the project leader to know what stage the process design is in, and it is difficult to grasp the task completion situation of the project team members immediately.
The use of three-dimensional visual assembly technology can better guide the workshop site.
To sum up, no matter from the perspective of information development trend or from the perspective of business construction of Suzhou Golden Dragon Bus itself, Suzhou Golden Dragon urgently needs to implement CAPP system to improve the efficiency of process design, shorten the process preparation cycle, promote the standardization of process design and process management, summarize and inherit the knowledge of bus process design, improve the level of process design and design quality, and assume the role of data link and bridge between design and production. Before the data link and bridge role, to achieve efficient data integration.
The process management project is guided by the unified planning of enterprise informatization, through the implementation of process management software system in the process room, standardization room and other business departments related to process, to standardize the process terminology and typical processes of Golden Dragon Bus, establish the enterprise's process resource database and standardize the process review and approval process of the enterprise. The process management system to be implemented mainly includes three main parts of CAPP process editing, process management and process integration.
The main objectives to be achieved by the project implementation are
(1) To improve the efficiency of enterprise process preparation, shorten the time of process technology preparation, ensure the standardization and advancement of process, and enhance the quality of process design. To realize the standardization, centralization and scientificization of process design data management.
(2) Improve the level of process management. Promote process standardization by establishing standardized process terms, typical processes, and process resource libraries Realize paperless process management through computerized management of process design process as well as process tasks
(3) Improve process technology innovation and process knowledge accumulation capability. Through establishing typical processes, parameterized processes and other means, accumulate process design experience and knowledge, improve the reusability and sharing of process knowledge, reduce repetitive and tedious work, and promote process technology innovation.
The construction of the project is intended to follow the following basic principles.
(1) Follow the group's unified information planning principle
(1) Follow the group's unified informatization planning principle: (1) Consider the business needs of the enterprise's own process design and process management, and also consider the integration of the information system with the group's unified informatization planning to ensure the integration and sustainable development of the system.
(2) The principle of combining advancedness and practicality
Introduce advanced process management ideas and technical means, and use advanced information technology to improve the process management level of the enterprise. Emphasize the practicality of the system and focus on practicality and effectiveness. Guided by the needs of the enterprise, the functions are comprehensive and practical. Practicality and generating benefits are important criteria for judging the success of the system.
(3) Based on the principle of mature and advanced products and technologies
In order to reduce the risk of project application implementation, the system must be built based on existing mature, advanced and applicable products and technologies. The principles are: mature (has been used in similar industries), advanced (advanced in technology and management ideas), applicable (can effectively meet the business needs of enterprises).
(4) Emphasis on implementation and service principles
The process has obvious personality, while taking into account the subsequent integration and secondary development, implementation services are important, which is also an important principle in selecting software suppliers and partners.
Detailed introduction of project implementation and application
From the perspective of business requirements, the project is to meet the core business needs of the enterprise.
(1) Uniform standardization of card preparation, establishment of process management platform, and unified management of data files
(2) Preparers can access the archived process cards, copy and modify them, generate new process cards (schematics can be inserted in the process cards), and refer to standard process terminology. The design product drawings (archived and unarchived), tooling library, tooling library, etc. can be accessed during the countersigning.
(3) The management of the whole life cycle of tooling and the establishment of TS16949 management system.
After the preliminary communication with Suzhou Golden Dragon process department, the implementation content and time for this process management system is planned as follows.
(2) Phase I implementation: process card specification and process platform establishment
(1) Process basic data standardization
Through the implementation of CAPP, standardize and centralize the management of various existing process resources of the enterprise.
(2) Solidify and standardize enterprise process business process
Through CAPP implementation, establish electronic process design, process review and approval, process change process, realize process task assignment, process project management and monitoring, and solidify in the software. Through the continuous testing and adjustment of the process in practice, we can realize the continuous optimization of enterprise business process.
(3) Unified control of process diagram documents
Through the first phase of CAPP implementation, we provide auxiliary tools such as fast process editing, formula calculation and process graphics processing for process designers, and at the same time unified system management for enterprise process-related documents, changing the situation that documents are scattered and cannot be tracked and utilized efficiently, and shortening the process technology preparation cycle.
Through the implementation of the KAIME process module, it is not only the integration of the design data of the enterprise, but more importantly, the effective management of the whole process of process design. With the structured organization of process BOM, the management of process data includes unified storage of various process documents/technical information, scientific organization, authority management, access control, etc.; the management of process design process, including process route preparation, process task assignment, process card editing, process summary, process change management, etc., involves personnel, progress, process, tasks, documents and other resources in the design process of multiple stages. and other resources are unifiedly managed and monitored.
(4) Effective accumulation of process knowledge
Through the implementation of CAPP, a process knowledge accumulation mechanism is established to convert process experience and process knowledge such as typical process, group process, characteristic process, common process, common process terminology, process standard, process calculation formula, work hour/material quota parameter, national standard parameter, etc. accumulated by the enterprise in the process of long-term production practice into enterprise knowledge assets for storage and management, and at the same time, tools are provided to enable designers to conveniently manage the process knowledge in process design. personnel to conveniently query, retrieve and use such process knowledge when conducting process design.
Benefit Analysis
Through the implementation of Phase I and Phase II projects, Suzhou Golden Dragon Bus Company will be positively impacted in the following aspects.
(1) Significantly improve the efficiency of process design
Previously, most of the working time of process personnel was spent on finding existing information, exchanging information with other professional process personnel and exchanging information with the design department. With the perfect process knowledge base and convenient and quick search tools of CAPP system, the accuracy and speed of retrieving information is improved, and unnecessary inter-departmental coordination is reduced. At the same time, CAPP's own fast process preparation function and intelligent process generation function have greatly improved the efficiency of process design.
(2) Promote the standardization of the company's process construction work
The application of CAPP system has standardized various bus process resources (process terms, tooling, equipment, materials, etc.), process document formats, process audit process, process change process, process document management, etc., which has strongly promoted the standardization of process and facilitated technical communication.
(3) Improve the company's process design level and quality
Applying CAPP system, we can summarize and learn the design experience and design knowledge of process experts, which will become the optimized process design knowledge of the company after being refined and organized. With the help of these process design experts' knowledge, the quality of bus product process design is improved, which in turn improves the reliability of the product. The process of applying CAPP is also the process of continuous accumulation and enrichment of process design knowledge, which is conducive to improving the level of bus process design as a whole.
(4) Laying a solid foundation for the company's comprehensive integrated use of information technology
CAPP provides detailed information of product processing and manufacturing, is the information bridge connecting design and manufacturing, is also the information hub of technical information integration system, and is an important information source for enterprise informatization construction. the application of CAPP system lays a solid foundation for deepening the use of ERP and PDM system of the company.
(5) To build the leading process knowledge, process technology and TS16949 management platform of Suzhou Golden Dragon in the bus industry, to move forward to 3D process and maintain the leading position of Suzhou Golden Dragon in process level.