[Manufacturing] Data decision analysis helps improve lean management

FineMonkey
Post time 2020-5-11 20:50:56 | Show all posts |Read mode Print Prev. thread Next thread
Company: CRRC Guiyang Vehicle Co., Ltd.
Industry: Machinery Manufacturing
Region: Guizhou Province
Product: FineReport, Mobile
Scenario: Manufacture, Quality
Scale: 100 million
Status: Industry Leader
Year: 2018, 2019

CRRC Guiyang has a high level of informatization, it has various business information to optimize business processes. However, with the development of the company, the demand for decision support is increasingly urgent. Therefore, CRRC Guiyang built an overall decision analysis system based on FineReport, including real-time tracking and distribution of cargo repair progress, centralized scheduling and command of the production, a mobile online preview of drawings, and visual management of project quality. Re-optimization provides convenience for enterprise-level data integration and overall data analysis.

1. Company Profile

CRRC Guiyang Vehicle Co., Ltd. (referred to as "CRRC Guiyang") was founded in 1966. It was originally a direct-owned enterprise of the Ministry of Railways. It is now a wholly-owned subsidiary of CRRC Corporation. There are three major businesses in the production of railway accessories. As the only railway wagon repair base in southwest China, CRRC Guiyang has a production capacity of 12,000 repaired railway wagons and 3,000 newly built wagons and is also one of the largest wagon repair plants in China. Its market share ranks among the top in the industry and domestic. The company has advanced and powerful spring production lines with an annual production capacity of more than 18,000 tons and has entered the United States, Russia, and other international markets.
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2. Project Background

With the in-depth application of the company's informatization, CRCC Guiyang has deployed various office business systems: ERP system, E_HR system, HCM data center, PDM system, OA system, Portal system, financial system, HMIS system, manufacturing MES system, etc. The functions of each system optimize the company's business processes. However, the above-mentioned business systems are in the stage of a single application and single coverage.

With the continuous development and growth of the company's business and the continuous improvement of management requirements, enterprises have entered the era of information explosion and the increasingly urgent need for decision support from the era of difficult information integration and lack of information.

How to extract market development information from a large amount of data to meet the needs of the rapid development of the cargo repair industry?

How to feedback the production data in time; how to obtain timely and accurate information of key processes such as start-up, wood removal, and padding information from the production management system to guide the production of goods.

How to make scattered and independent massive data into valuable information, so that business personnel and managers can fully grasp and use this information, and assist decision-making; how to balance economic benefits, based on the actual situation of the enterprise, make full use of various resources. Through technological transformation and innovation to achieve continuous progress in production technology, continuous reduction in product consumption, continuous improvement in market competitiveness, and continuous enhancement of corporate vitality.

This requires that the company have a powerful decision analysis system that can deeply and flexibly utilize a large amount of data in the production process to mine potential laws, help the company to make timely, correct, feasible and effective decisions, improve the production efficiency of the enterprise, and grasp market opportunities, provide powerful data support for scientific decision-making of enterprises, and help enterprises win competitive advantages. Through the selection and comparison of products on the market, the company finally chose FineReport and began a new exploration of data decision analysis.

3. Application Scenarios

3.1 Real-time maintenance progress monitoring and timely delivery

Before the project was implemented, how many vehicles were inspected in each inspection workshop and the current inspection progress of each vehicle was manually verified at the workshop, and the demand plan for accessories could only be transmitted through the paper. The accuracy of the demand for accessories and the timeliness of delivery restrict the production of this process to the later process.

After the project is implemented, when the vehicle enters the factory building, the site operator only needs to report the vehicle number information of the entering vehicle through the mobile phone. When each team and group starts the maintenance of the entering vehicle, the information of the inspected vehicle is confirmed through the mobile phone. It can determine the completion time, and at the same time monitor and warn the vehicle's maintenance progress in real-time, as shown in the figure below: There are 7 vehicles in the maintenance of the current building A, click 7 to drill down to the current maintenance progress and countdown reminder corresponding to the 7 vehicles.

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The dispatcher can check the maintenance status of each plant through the computer or mobile phone. The distribution staff delivers to the designated plant at the specified time according to the current maintenance progress, which greatly improves the accuracy and timeliness of the distribution, and the accuracy of the demand plan reaches 98%.

3.2 PLM collaborative management (online preview of drawings, work instructions, etc.)

The company chart document was managed by the "CAXA PLM collaborative management system". When each craftsman or manager needs to find documents such as drawings and work instructions, the corresponding "CAXA collaborative management tool" must be installed on the computer.
The corresponding interface was provided when the system was implemented, but the online preview of mobile phones such as drawings and work instructions could not be achieved through the interface, and the production site environment of the inspection vehicle was complicated and special, and there was no office computer. If on-site operators need to find the required drawings, they need to go back to the office to find them, which greatly affects the work efficiency.

Based on the requirements of the mobile office and production site, the PLM system and BI system are integrated and developed. Through the third-party document preview conversion, the online preview of drawings such as work instructions is innovatively implemented without downloading attachments. As shown in the following figure, the filter conditions can satisfy the search and online preview including "70" and "work instruction" at the same time.

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3.3 Visual management of quality inspection

Before the project is implemented, the quality inspector will be notified by phone after the procedure is reported, and the quality inspector will manually accept the completion of each inspection vehicle. If there is a fault, you need to open a paper repair process sheet and check the defect with chalk.
This kind of quality inspection is recorded on paper. As a result, the inspection pass rate and the statistical analysis of quality require manual statistics, which not only cannot guarantee the accuracy and timeliness but also is not conducive to tracing quality problems.

After the project is implemented, the on-site operators report work, and the system automatically reminds the quality inspectors to check the reported vehicles. After the quality inspectors arrive at the scene, they check the quality of the vehicles checked by mobile phones. If the inspection vehicle has no faults, the quality inspector selects the vehicle number and clicks submit, which indicates that the inspection has passed;
If the inspection vehicle has a fault, the quality inspector also needs to take a photo on the spot of the faulty defect site for rework processing and quality tracking. At the same time, the system automatically analyzes the quality inspector's work efficiency, that is, quality inspection time, and it also analyzes the time spent in repairing the fault as well as the one-time inspection pass rate.
The successful implementation of the project not only provides a basis for the traceability of quality problems but also has photos of on-site quality problems as empirical evidence. Therefore, fundamental quality problems can be solved from the source.

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3.4 Production site visualization

Before the company realizes the visualization of the production site, the production site of each workshop must be watched at all times in order to conduct production scheduling command and coordination. The disadvantage of this is that it cannot find various hidden problems on the production site in time, which often leads to blockage between processes.

Therefore, we use FineReport to seamlessly connect the production site video surveillance with the production site dynamic data to achieve the following figure: Double-click 'camera' logo to see the workshop site, double-click the station logo to track the production dynamic information, data analysis and processing, and comprehensive evaluation of related business data.

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After the implementation of the project, the production scheduling of each workshop can be conducted by simply using a computer in the office. Centralized scheduling and unified command are truly realized, and the on-time production of the maintenance section is standardized and improved. At the same time, the problem of clogging between processes can be resolved in time, greatly improving work efficiency.

All in all, the overall decision analysis system provides users with a unified, complete, three-dimensional, multi-perspective, and penetrating data analysis report management platform, which provides convenience for enterprise-level data integration and global-oriented data analysis.

It solves the problems of information association and information sharing within the organization, facilitates enterprise report applicators and decision leaders to quickly find the data they need, and effectively improves the efficiency of business personnel and decision management. At the same time, it provides predictive and potential market information, which makes up for the lack of analytical functions of business systems.

4. Project Experiences

Deploying an enterprise BI platform to truly give play to the value of enterprise business intelligence, provide comprehensive enterprise decision-making information, and help companies make informed business operation decisions. It is a complex and continuously optimized system project that cannot be achieved overnight. It needs to be implemented in stages and repeated practice.

BI involves all aspects of business management. It is a process in which an enterprise reorganizes management methods, management processes, and management systems. Therefore, before implementing the BI data decision analysis platform, you need to fully and systematically understand the enterprise, clarify various activities in the enterprise, summarize the standard business processes and specific content of business activities, sort out the management goals of the management and decision-making layers of the enterprise. The goals and standard business processes are brought together into a system so that the analysis view of BI corresponds to the management theme one by one.

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