MPDV MES成功案例-上海鹰峰
【概要描述】
关于鹰峰 / About EAGTOP
上海鹰峰电子科技股份有限公司是以专业研发、生产电力电子无源器件为发展方向的高新技术企业，是国内领先的无源器件解决方案供应商。主要产品有薄膜电容器，电抗器，叠层母排，水冷散热器，相变热管散热器，电阻器等。电容器的生产工艺包括卷绕、喷金、热处理、赋能、焊接装配、真空灌注、老化测试、成品检测和包装。
Shanghai EAGTOP Electronic Technology Co., Ltd. specializes in researching, developing and manufactures passive power electronic devices as a leading solution provider in China. The product portfolio ranges from film capacitors, reactors, laminated busbars, liquid-cooling radiators, 3D phase change heat sinks and resistors. The typical capacitor manufacturing processes consist of winding, metal spraying, heat-treatment, charging, wielding, vacuum dosing, aging, final inspection and packaging.
引入HYDRA MES的背景 / MES Hydra introduction background
为了满足客户质量控制要求，鹰峰管理层决定在2014年底引入MES系统。同时也希望通过应用MES来打开生产现场的黑盒子，以提高生产效率。与许多传统的中小型民营企业一样，鹰峰选择相对来说初期投入比较低的国产定制化MES软件，以满足最基本的生产数据采集和追溯需要。然而，定制化软件的不利之处在实施过程中已经暴露出来，即实施周期比较长，厂商总是要问用户应该怎么做，而用户只能提出概要的需求。故而，在实施过程中，不断有需求变更。最终在双方妥协下，系统在一年后终于上线。
To meet the growing compliance- and quality control requirements from customers and in order to improve the overall production effectiveness, EAGTOP Management decided to introduce an MES by the end of 2014. Like many small- to medium-sized private enterprises in China, EAGTOP instinctively preferred to invest less in software. In first consequence, EGTOP chose a local vendor proving with an entirely customized MES solution, given the seemingly low initial cost. The disadvantages of the customized MES solution soon emerged on repeated basis throughout the entire implementation period. Besides a prolonged implementation time due to time-consuming customizations, each new requirement or change request resulted in new additional delays and conflicts, due to miscommunications. Ultimately, the heavily compromised local MES solution started to go live after over one year.
2016年，随着新产品的导入，鹰峰引入一些新设备替代原先一些手工工位，并对工艺路线和物料流进行了优化。另外，管理层对生产控制与数据呈现也有了新的需求。这时，他们发现现有的MES系统无法灵活更改，必须要投入与首次导入系统时相同的时间和成本来重新满足新的管理需求。相当于现有的系统等于被废弃后重新建一套。鹰峰的管理层这时才意识到这种定制化的MES系统存在巨大的拥有风险，因为他们无法预测未来管理需求的变化。他们试图寻找一套能够在4个月内完成上线、灵活配置和扩展的系统，已满足鹰峰不断发展的生产管理要求。
In the course of 2016, EAGTOP commissioned new automated machines to replace older manual work stations. Production processes and material flows were optimized and adjusted for new products, too. EAGTOP Management expected the necessary flexibility within the existing local MES solution. Instead, the existing customized MES architecture needed to be broken up re-customized again, with a projected timeline of yet another one year. Now being aware of the inherent risk for any future changes, EAGTOP Management decided to look out for a new flexible solution that could be deployed in a lean approach in a short time frame of less than 4 months, with high configuration flexibility and expandability, to fit into the continuous growth strategy of EAGTOP.
实施 / Implementation
2017年4月，鹰峰的董事长开始和MPDV接触，并亲自主导了需求分析，且至始至终参与方案评审，包括系统建设目标、一期功能划分、物理实施范围以及项目实施计划。最终，项目在2017年5月正式启动，7月正式上线，8月完成最终验收。
By April 2017, EAGTOP Management engaged in relevant pre-sales activities of proposal generation, target definitions, functional & physical scope definitions, together with MPDV Shanghai, ultimately leading to a project kickoff in May 2017. Within a short time frame of 3 months, MES Hydra started to go live in July 2017, with a final acceptance and signed-off by August 2017.
主要应用 / Main application
复杂的制造流程对生产管控要求非常严格，对于每道工序每件产品必须确保其工艺参数的稳定和精确，并能实现完整的追溯。这是鹰峰对本次MES系统建设提出的基本要求。
The complexity of the production requires very strict production control. The essential requirements are stability of process values within strict tolerance limits and traceability of every single product.
系统集成 / System integration
HYDRA系统的功能完整性使得鹰峰的IT系统非常简单：应用于商业管理的Kingdee ERP和应用于制造管理的HYDRA。而且两个系统之间的集成也非常可靠。
The broad & configurable Hydra standard function scope resulted in a very simple IT layer architecture at EGATOP: The ERP system Kingdee caters for the entire business management, whereas Hydra caters for all aspects of production. The logical interfacing model and physical interfacing process between Kingdee and Hydra turned out very reliable and robust.
Hydra采集车间现场的生产、物料批次、工艺参数、质量和人员数据，并加以整理和分析。本期项目引入ERP系统集成（EIS-ERP）、生产订单数据管理（BDE）、和物料追溯（MPL&TRT），过程检验管理（FEP）。Hydra办公室客户端MOC提供标准的、丰富的各类统计分析报表，无需任何报表方面的定制开发。
The Hydra modules BDE, MDE, MPL/TRT and CAQ capture and process the entire spectrum of shop-floor data. The Hydra standard reports in the Hydra “MOC” office client are being used without any necessary report customization.
为能够在生产中以及产品回召时清楚知道产成品的追溯记录，工人除了在车间终端AIP上登录工序信息，在生产中采集原材料批次信息和生产工位。对于每个半成品都分配一个新的批次或单件系列号，形成批次追溯树。如此，不仅可以反向追溯原材料批次，还可以知道相同缺陷材料的供应商信息。Hydra提供批次树图和数据表两种方式查询追溯记录。
Operations are logged on by the operator at the “AIP” shop floor client. All relevant information objects of order, work place/machine, operator ID, input material batch ID’s are recorded. During execution, process values and various quality characteristics are being captured. New output batches are generated along with their relevant unique batch ID’s as well as serial numbers, through real-time reporting through user-friendly transaction points on the shop floor.
Hydra的产品追溯已经帮助鹰峰通过德尔福等主要客户的审核。
The entire Hydra traceability has helped EAGTOP successfully pass the audit by their key customers like Delphi Automotive.
工艺参数管理确保工艺稳定 / Process data control – to ensure process stability
稳定的工艺参数确保生产可靠性。通过与赋能设备的集成，采集赋能参数值，并与每个元件号关联，充分了解每个电容的过程质量。
Stable process values ensure reliable production. Hydra captures all charging data by integrating the charging machines, amongst others, and correlates the data with captured serial IDs. Users can efficiently obtain a clear and detailed view of their production process quality.
质量管理 – 一切尽在掌握 / Quality management – all under control
根据客户要求采用全检和抽检，由产线作业员和质检实验室分别执行。可以人工或通过接口自动汇报在线检测结果或实验室测试值。根据质检结果确定该批次产品是否合格并流转。由于与ERP的无缝集成，在开始生产工单时，检验计划也随之自动下达，使作业员及时知晓，以确保质检作业按时执行。
Full inspection or sampling can be set upon customers’ request, and performed by operators online in the field (IPQC) or in separate QC labs. Inspection data is captured in Hydra both manually at shop-floor “AIP” as well as automatically via connectivity protocols. Whether a single WIP unit is allowed to pass forward into next operation is dictated by the inspection results at the predecessors. A pre-defined inspection plan contains all relevant quality characteristics to be checked, and the relevant inspection points are triggered automatically, based on the defined sampling schemes. Thus, operators never forget to conduct necessary QC-inspections.
用户之声 / Voice of users
董事长洪先生：集成式、模块化的产品架构有利于按需分步导入各种功能模块，而无需考虑各功能模块之间的系统集成。配置选项能够帮助用户灵活响应生产管理变更。丰富的MES应用功能让我们无需担心系统建设的滞后，和国际领先的MPDV合作能够让我们更好地把最佳生产实践经验和先进的数字化管理系统有效融合。
Mr. Hong, EAGTOP President: The integrated and modulized Hydra MES makes it possible to implement MES applications step by step by real needs, without consideration of the weary integration between individual applications. Configurability gives the right answer regarding flexibility of production changes. The very comprehensive functional scope of Hydra has eliminated our concerns whether it can meet our future demands. In our cooperation with MPDV as a leading global MES solution provider, we are now finally able to leverage on best practice approaches and experiences with digital manufacturing management systems.
生产总监丁先生：引入HYDRA后，生产环节更加稳定和可控，车间管理更为透明。原先的MES系统只是完成了数据采集功能。HYDRA系统不仅能够更有效规范生产现场执行，系统提供的统计分析信息能够帮助我们迅速发现改进之处并监控改进措施的落实效果。HYDRA帮助我们成为世界级制造工厂。标准的IT架构最大程度降低了实施风险。我们现在已经准备预算，将现在的应用成果扩展到其他车间。此外，我们还打算在下一期同步引入设备绩效管理和人员资质管理。
Mr. Ding, EAGTOP Production Director: The production has become much more transparent so that it’s more controllable and stable with the help of Hydra MES. All shop-floor activities are standardized and manageable. Precise statistic information are timely presented to management so that the right decision can be made and proper actions can be taken. Hydra helps us to build up a world-class manufacturing environment. We are planning the rollout towards other EAGTOP shops as well as towards further Hydra function areas, namely Machine Performance Data (MDE) and Workforce Requirement Planning & Qualifications Management (PEP).
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