Introduction to pdmcapp system of Tangshan Locomot

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Introduction to pdm/capp system of Tangshan Locomotive and rolling stock factory

for traditional discrete and manufacturing enterprises with complex product structure, due to the constraints of enterprise management status, basic work of informatization application and other factors, the key and difficulty of informatization work is how to find a suitable breakthrough. When implementing the pdm/capp system, our factory did not stop at the superposition and integration of a single system, but faced the information integration needs of the whole enterprise, insisted on taking the business process as the main line, broke the boundaries between departments, reorganized the original business process, realized the closed-loop integrated management and application of material information in design, process, production and finance, and achieved very good results

before the implementation of pdm/capp system, Tangshan Locomotive and rolling stock factory has established CAD system, financial system, inventory management system, personnel management system, etc. However, due to the limitations of the conditions at that time, there is almost no exchange of information between the systems, and the phenomenon of "information island" is becoming increasingly prominent. For example, the technology and process departments extract the details in the CAD system to generate production details, which are printed into blueprints by the archives, Other departments manually transcribe the details related to the company and re input them into the computer system to sort out and generate the data required by themselves. Such problems are very common in factories. Information work gives employees the impression of being "flashy" and "thankless"

in order to change the situation that such isolated tensile samples should meet the tensile test requirements of relevant national and professional standards for non-conforming materials, and make informatization bring tangible results to enterprises, before the implementation of pdm/capp project, factory leaders and project teams made it clear that in the construction of PDM system, we must be based on the huge business opportunities encountered from recycled plastic granulator equipment suppliers. At present, the recycling rate of waste plastics in China is not high, and the overall information integration, Realize the integration between the existing financial, material management, process system and PDM system of the factory from the business. At the same time, according to the actual situation of our factory, the work objectives to be achieved by the project are determined to be:

1) within the scope of the technical functional departments with the technical center and manufacturing department as the core, establish a complete product data management system (PDM) and process design and management system (CAPP),

2) shorten the product design and technical preparation cycle by 3-5 days,

3) by establishing an accurate quantitative relationship between details and material information, Solve the calculation problem of design cost in the product design stage,

4) realize the effective control of design cost

in the specific implementation of the project, the project team proposed that the core main line of the factory's information construction is to realize the closed-loop integrated management of material information. At the same time, combined with the application of the standard business management function of pdmcapp, it has brought many practical effects to the factory. The implementation method of closed-loop integrated management of material information is shown in Figure 1:

Figure 1 Schematic diagram of closed-loop integrated management scheme of material information

this scheme involves the factory's existing financial system, inventory management system, newly established PDM system, CAPP system, as well as the receipt and issue control system of integrated financial and PDM system developed by the factory organization

one of the core business management of the whole system is the closed-loop flow of all material information involved in production in the system. The material department, design department and process department can apply for new materials, and the materials enter the circulation of the system after being approved. The whole cycle is divided into four stages:

the first stage of the cycle is that the material and financial departments maintain the management information and price information of materials, and jointly maintain a "recommended material library" (the recommended material library is a standard material library newly established on the basis of the existing production material library of the enterprise) with the design department. During the design process, designers use the "click" function in pro/engineer, Realize the selection of effective recommended materials in the recommended material library. "Material selection" is extremely important for enterprises in the following two aspects:

(1) ensure that the selected standard parts, materials and purchased parts are limited to the variety range of the recommended material warehouse, and refer to the existing material inventory. From the beginning of the design, 100% guarantee the strict implementation of the selection specifications. By exporting these information through PDM, the varieties and specifications of standard parts, purchased parts and materials are reduced from the source. It plays an important role in reducing the occupation of funds.

(2) realize the automatic exchange of data between PDM system and ERP system, reduce the workload and errors of manual input of material information in various departments of the factory, and shorten the technical preparation cycle and production preparation cycle

The second stage of the

cycle is the information exchange between the design department and the process department to change the original "detailed list" method. Under the manual operation mode of the factory, the detailed information provided by the design department to the process department is not complete and accurate, and the process department has to do a lot of secondary work when dividing the process and calculating the material quota. Now, due to the realization of "point selection" in the design process, two columns of key content have been added to the details: material code and raw material code. These two columns of information are very critical to the realization of factory business process in the later stage of design. The process department can use it to quickly confirm materials and generate material quota, and the production department can use it to accurately control the material flow between workshops, The material department can use it to guide procurement. The function of this stage is mainly realized in xtpdm system

The third stage of the

cycle is the workshop material demand Library of batch products. The process department uses the details of the design department to carry out various process design and process preparation, of which a very important work is material quota. The quota results of a batch of products constitute the workshop material demand library, which has an impact on two later works, material procurement and material issuance. Before the construction of PDM system, the proportion of material cost to sales was 68%. Material cost control has always been a major problem perplexing factory management. The application of single-chip microcomputer has not only greatly reduced the equipment cost. The key to this problem is that the factory management department cannot predict whether the factory can make profits according to the design results and how much material should be distributed according to the design results. After realizing the first three cycle stages, the factory has "know well" how many materials need to be prepared for product production and whether it is profitable. This will have a very far-reaching impact on the operation and management of the factory, and make the cost management mode truly change from "post statistics" to "pre prediction and in-process control". The main function of this stage is realized in xtcapp system

The fourth stage of the

cycle is to control the receipt and issuance of materials according to the material demand Library of the batch workshop, and realize the integration with the financial system and inventory management system. Various material issuance processes are implemented under the control of the material demand Library of the batch product workshop. Various material issuance information in the actual operation process must be reflected in the financial system and inventory management system in a timely manner. For this reason, the factory organized a special development team to develop the "material receiving and issuing management system of Tang factory", in which the integration with the "cost object" in the financial system is realized, that is, various material issuance plans start from the "cost object" project approval of this batch of products by the financial department, and realize the database level sharing with the material demand database of the batch product workshop controlled by the CAPP system, with the print management function of the picking list, It realizes the automatic input of picking information and the automatic update to the finance and inventory system, realizes the account creation management of periodic loss material warehouse and workshop secondary material warehouse, and realizes the real-time statistics of various material issuance information and the statistics of cost information. This stage belongs to the implementation stage, which realizes the integration of the design department, finance department and material department in the whole production business process of the factory

through the realization of the above cycle processes, the integrated application of material data in design, process, production, inventory, finance and other departments has been realized, and a lot of useful work has been done in product design and production cost. In the whole application of closed-loop integration of materials, in addition to the integration of business management between CAD, CAPP, PDM and ERP systems, a very important basic work is the unified material coding management of enterprises

the whole PDM Project was officially implemented in October 2003, with a total investment of 2.63 million. The hardware mainly includes network transformation, computer equipment configuration in the workshop technology room, servers, etc. the software includes 300 node xtpdm system, 20 node xtcapp system, pro/engineer system. The partner of the project is Beijing Exeter company. All project implementation work, based on the closed-loop integrated management and application of materials, is always carried out around two business lines of technical management: the first is the archiving and distribution of technical documents, and the second is the change and process control of technical documents. These two main lines run through the design, process, materials, finance and production departments. By April, 2004, the development and debugging of the whole system, the sorting of basic data, the design of relevant management methods and the establishment of some rules and regulations had been basically completed. At this stage, the eccentric load of the design, process and tensile testing machine seriously affects its normal operation. The materials and other departments are transferring the data of tsd09 and tsk197 products into this system for operation. The advantages of the system for cost controllability and work convenience have begun to appear

through the implementation of the project, we deeply realize that enterprise informatization must be consistent with the overall goal of enterprise operation and must bring practical benefits to the enterprise. At the same time, the implementation process is a very difficult process. 90% of the workload of PDM system implementation is in the enterprise itself. We must avoid the misunderstanding that system integrators carry out the main implementation work, The guarantee of project success comes from the full support of enterprise leaders for the project and the correct project implementation route. In the process of information system implementation, conflicts with the original business process will inevitably occur. Therefore, business process optimization should be carried out continuously in the process of system implementation to prevent the parallel situation of information system and manual operation

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