“Nowadays, many enterprises will use ERP as the main body during digital transformation, and cooperate with MES, SCADA and other systems to build the skeleton of digital applications for the factory. However, in the face of customers’ increasing demand for customized applications and products, flexible production and short delivery time How can Industrial enterprises improve the efficiency of software system design, configuration and debugging, and seize market opportunities?”
As a leading industrial software manufacturer in China, Yakong Technology proposed to use configuration technology to solve the application problems of industrial software. As we all know, configuration software is a sharp tool that allows users to realize the required software functions like “building blocks”. How does the configuration software solve the problem of integration of various systems? What convenience and value will it bring to the enterprise?
Three Challenges of Digital Transformation Construction
Generally speaking, if factories want to do digital transformation, they will adopt a unified planning and step-by-step implementation method. As shown in the figure, there are various systems such as ERP, BI, electronic contract, MES, SCADA, and APS in a factory. After completing the planning, the enterprise will choose different suppliers to gradually carry out customized development. In the process of project promotion and implementation, there are three major challenges.
Conventional smart factory multi-system construction strategy
01 The first challenge is the difficulty of system integration and continuous change.
There are 3 reasons for this problem:
First of all, since each single system uses different operating systems and high-level languages, various databases, relational libraries, real-time file libraries, etc. are also used in the development process, so the difficulty of each system from delivery, debugging to final iteration is different. Very big;
Secondly, these systems will expose obvious disadvantages when they are integrated, such as business rule conversion, data format conversion, authority unification, and protocol conversion will be more difficult. It is difficult to synchronize and coordinate on the network architecture;
Finally, due to the high degree of customization of the software, the high degree of coupling will bring obstacles to continuous improvement, and it is very difficult to open it for refactoring.
02 The second challenge is that inquiries are not allowed.
Many existing systems are built with ERP as the main body. In the past, under the market demand of large batches and small varieties, it can perfectly solve the problem of enterprise business and financial integration. However, under the development trend of small batches and multiple varieties, the use of The ERP of the classic MRP theory will lack the ability to inquire. In the actual production process, when new potential orders come in and there is a shortage of materials, it is difficult to reverse calculate which orders or contracts can be adjusted, and since there is only one factory model, it is very difficult to double-count selected orders.
03 The third challenge is the difficulty in ensuring the delivery date.
Generally speaking, the production capacity of the production line changes dynamically, and static evaluation will lead to inaccurate delivery dates. If dynamic evaluation is required, because ERP, MES, and SCADA need to be linked, real-time data of the production process is required. When scheduling production, many companies will use the method of experience + tables + brain-slapping decision-making to organize production. Even with APS, due to the lack of relevant data on production line changes, it is difficult to formulate a very accurate production plan, making it difficult to guarantee the delivery date.
The way to break the situation: fully configurable production control platform
Faced with the above challenges, since 1996 when it started SCADA, Yakong Technology has been committed to innovation and developed products to solve problems. In recent years, Yakong has developed a complete product system, including KingFactory3.8, a production control platform for discrete manufacturing developed based on the WellinOS cloud operating system.
KingFactory covers nine management and control subsystems of all production operations in the whole factory
This is a digital production that covers sales order management, product process management, production scheduling, material management, warehouse management, workshop control, quality control, equipment control, energy control, and other full-business processes in the production process of the enterprise An integrated platform solution for management and control. The countermeasures and specific functions that KingFactory can provide are as follows:
01KingFactory can provide a complete control system
KingFactory can provide three core planning and auxiliary scheduling systems. As shown in the figure above, the sales plan will be decomposed into the master production plan, and then to the plan execution and tracking of the workshop operation plan, and finally fed back to the master production plan, thus forming a closed-loop control of the three core plans. The closed-loop management and control system that assists production scheduling, for example, in the master production plan, will decompose material demand planning, material procurement execution, procurement tracking, etc.
02KingFactory has the ability to change on demand
Fully-configured digital factory background business model to build a twin factory for global business
KingFactory is a fully configurable system, including models of physical space (things), plant scheduling/maintenance plans (things), and all basic data of organizations and personnel. In terms of production activities, KingFactory will also model functional units such as production, transportation, and storage. For the nine major business systems, in addition to standard business models, the platform can also establish corresponding business models and front-end models for personalized applications for different market segments, which can be integrated with the standard model to build a global business twin factory.
It is worth mentioning that all configurations are based on the actual physical space, using the “what you see is what you get” approach. Organizational modeling is also built according to the parent-child structure. Role modeling includes association with organizations and role matching. Personnel modeling also includes associations with corresponding organizations and associations with different roles. Businesses are formed in a configurable way. After the user configures according to actual needs, all functional units can be formed.
Fully configurable functional unit modeling
Not only that, KingFactory can also provide the ability to personalize the development of APP. The platform can provide 80% of standard APPs and 20% of customized APPs. Based on the built-in simple and easy-to-use meta-language of Yakong WellinOS cloud operating system, business engineers can also be programmers, and users can develop, adjust and deploy personalized APPs according to business needs, greatly reducing the difficulty of development.
03KingFactory provides new theoretical system support
New digital twin theory builds factory model
Nowadays, many management and control systems on the market mostly use a single model, which carries a large amount of information, is highly complex, lacks pertinence, and is difficult to grasp. For example, many ERP manufacturers have as many as one or two thousand model parameters. To make good use of these models, business consultants who are very knowledgeable about applications are needed to help users implement them. As shown in the figure above, KingFactory adopts a new digital twin construction theory, which can build different factory models according to different tenses and the main problems to be solved by each business system, and each subsystem can be constructed and operated completely independently.
Planning system based on limited material supply capacity
In addition, KingFactory is a planning system based on limited material supply capacity. For example, in the process design, the bottleneck material is first determined, and the procurement capacity of the bottleneck material is determined before signing the order. The sales system can calculate the specific customer delivery time, and finally provide support for real-time response to customer inquiries and order insertion needs.
Not only that, KingFactory comprehensively considers the APS-assisted optimization scheduling theory of limited (production, storage, transportation) capacity. All inquiry, main production and workshop operation planning systems in the platform are separated, and each plan can be “prescribed to the case, divide and conquer” to effectively solve the needs of different systems.
create value for customers
On the whole, KingFactory, with its very complete management and control system, can bring customers the value of more accurate order delivery, higher product quality, and lower production costs. Based on the constraints on the limited procurement capabilities and production capacity of enterprises, the platform can create a real-time, closed-loop planning control system, laying the foundation for precise control of delivery dates. In the production process, the platform integrates all orders and production process parameters, and users can trace all the information to continuously improve product quality.
In terms of intelligent production scheduling, KingFactory can reduce the waste of workshop production, make tasks more coherent and non-conflicting, and accurately calculate the latest start and end time of the production plan, avoiding the risks of task overdue and failure to respond to customers, thereby reducing Cost of production.
Today, KingFactory is the only platform system in the world that covers all production management and control services except financial modules and CAD/CAE related services. Therefore, whether customers are deploying privatized systems or using public cloud-based applications, they do not need to purchase other third-party databases and middleware, nor do they need to do project promotion and coordination with each supplier, and can realize one-click installation , Self-maintenance and self-upgrade, reducing construction costs, implementation and after-sales service costs.
In the past, in the process of building different systems, as the project continued to advance, the system carried more and more services and applications, and it was like walking in a swamp. However, KingFactory uses a spatio-temporal database to integrate all systems together, and the system integration effect is better, helping customers to bid farewell to the difficulties of system integration in the initial stage of the project.
In addition, in order to facilitate the integration of various brands of ERP, PLM, MES and other systems, KingFactory can provide various standard excuses, and can also help enterprises with incomplete business capabilities to further improve subsystems. Through the tailoring of functions and the integration with the original system, while helping customers solve difficult problems, the original system investment of customers is guaranteed.
Since the implementation of KingFactory adopts configuration, comparatively speaking, the period of commissioning will be shorter. Taking the MOM project of a group as an example, its personalized APP development only accounted for 17.6%, which shortened the implementation cycle very well. Taking single-factory MES as an example, after the subsystems and APP are completed, research and design, configuration development, joint debugging and commissioning are required, which generally can be completed within 4 to 8 weeks.
KingFactory can reduce IT system basic software investment
In addition, for many enterprises, the integrity and reliability of data is a very important part of system construction. Since KingFactory uses the WellinOS spatio-temporal object database in the background, the data in the cloud, edge, and terminal can be automatically synchronized, which can provide a solid guarantee for data integrity and security. With the support of the meta-language and real-time database, the customer’s business engineers can also change as needed, expand and maintain the system’s functions more conveniently, so as to ensure the availability and rapid iteration of the system.
In the future, according to the individual needs of customers in the automotive, machinery and electronics, military industry, tobacco and other industries, Yakong will provide “full configuration” solutions for subdivided industries through the cloud platform developed by WellinOS and the configurable KingFactory. Weeks to wait.”
Over the years, Yakong has created a huge ecosystem of cooperative and win-win partners. Yakong also looks forward to working with more partners to independently develop solution products that are fully suitable for market segments in various industries, helping more companies to achieve digital transformation.