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The core of China's manufacturing industry to accelerate the modernization process is the reconstruction of production methods, through intelligent transformation, enterprises have improved their research and development and production efficiency, so as to seize the market demand faster and more flexibly. In this process, automation is an almost necessary path, in addition to the production mode needs automation technology, more and more enterprises began to intelligent upgrade of production logistics, China kitchen and bath home industry's leading enterprise Xiamen Jianlin Health Home Co., LTD. (stock abbreviation and code: Jianlin Home 603408) (hereinafter referred to as "Jianlin Home") is one of the leaders.
The market demand for sanitary products is an excellent proof of consumption upgrading. With the improvement of consumers' requirements for science and technology home, quality and taste, energy saving and environmental protection and other elements, the once basic bathroom facilities have also ushered in the era of "science and technology and hard life", from the source, that is, new requirements for product innovation, design, manufacturing and delivery. Under such a development trend, Jianlin Home has opened the design and construction of smart factories, not only the intelligent upgrade of the production line, but also the comprehensive automatic upgrade deployment of the logistics process of the workshop production line through the traditional breakthrough, of which the most benchmarking is its Jianlin Healthy home kitchen and bath smart Park (hereinafter referred to as "kitchen and bath Smart Park"). Serving many international well-known kitchen and bathroom household brands.
Xia Xugan, senior manager of the Intelligent Engineering Research Institute of Xiamen Apis Intelligent Manufacturing System Co., LTD., which is affiliated to Jianlin Home and focuses on promoting the construction of the group's digital factory, said: "As our partner in the transformation of logistics automation, MiR started from the initial scene exploration and gradually helped us complete the large-scale AMR application scenario. The automation of factory logistics work is a new attempt of Jianlin. This cooperation allows us to successfully achieve precision, high efficiency and unmanned production line logistics in the bathroom product assembly workshop of the first phase of the kitchen and bathroom Smart Park, and establish a benchmark scheme for intelligent logistics of other parks under the Group in the future. "
【 Large MiR AMR fleet collaborates in Jianlin Home 】
A total of 12 Autonomous Mobile Robots (AMR), including six MiR250 AMRs, two MiR600 AMRs and other models, are currently deployed in the bathroom products intelligent assembly workshop of the Kitchen and Bathroom Smart Park. The robot fleet is divided into three groups to work together, and the parts and materials truck roof lifting robot, finished product recycling robot and empty pallet distribution robot are configured respectively. The three groups of robots are managed by the Fleet management software MiR Fleet and the mobile Robot scheduling System RCS3.0 (Robot Control System). At the same time, it is integrated with the TMS (Transportation Management System) system independently developed by Jianlin Home. Realize the communication with the surrounding MES (Manufacturing Execution System) and WMS (Warehouse Management System) system information, well solve the production line information resources, hardware resources allocation and task priority, and the team has a high degree of cooperation with the production line tasks. Smooth scheduling and efficient operation.
In the current deployment scenario, the average startup time of each MiR AMR is more than 12 hours per day, with 8 parts delivery beats per hour and 4 finished product recovery beats per hour per machine.
The three main daily workflows of the MiR AMR fleet in the workshop include:
1. Parts distribution: The assembly line distributes the parts transportation demand, the distribution area receives the MES system demand, the distribution personnel prepares the required materials and issues the order to the MES system, the MES system automatically distributes the task to the MiR Fleet management system, and the system dispatches the AMR to load the materials and transport them to the assembly line, and the AMR automatically brings the empty hopper back to the station after unloading the full material truck. Empty cars return to the distribution area to prepare for the next shipment.
2. Transportation of finished products: After the assembly line is completed, the Fleet dispatching system will assign AMR to pick up the goods after receiving the MES instruction, and transport them to the OQC inspection area in the factory. After the inspection is completed, the products will be loaded and transported by the AMR car to the connection point of the three-dimensional warehouse, and then distributed by artificial forklift truck to the entrance of the three-dimensional warehouse.
3. Empty pallet distribution: empty pallet transportation in the assembly line. After receiving the MES instruction, MiR Fleet fleet management system allocates AMR to the dismantling machine to pick up empty pallet, which is loaded by AMR and transported to the corresponding assembly station.
Su Da Peng, senior technical manager of Xiamen Jianlin Health Home Co., LTD., said: "Located on the third floor of the kitchen and bathroom smart Park phase I, the intelligent assembly workshop of sanitary products mainly serves Jianlin's large customers, and the sales and order mode is mostly 'small batch and variety', so the production line often faces changes in line and category, and the delivery time is compact and strict." MiR's AMR is intelligent, safe and user-friendly. It is connected to our MES system in actual scheduling, and the daily operation is very smooth, bringing fundamental improvements in production efficiency and worker performance. "
Through the scale deployment, MiR AMR has achieved a three-tier intelligent upgrade for the kitchen and bathroom smart park, including the intelligent transformation of talent skills, the improvement of the accuracy and efficiency of material transportation in the plant, and the comprehensive upgrade of the factory manufacturing process.
In terms of intelligent transformation of talent skills, thanks to the easy-to-use characteristics of MiR AMR, Jianlin Home has successfully helped most of the former porters learn AMR operating technology. MiR AMR can be operated through web control and smart devices, and the graphical programming interface is very intuitive, and front-line workers can get started directly without programming experience. With the support of MiR technical team and distributor Xiamen Jingrui Precision Equipment Co., LTD., operators can become familiar with the operation of AMR after only a few days of training.
As an important promoter of the project and MiR's partner, Lin Qingfa, general manager of Xiamen Jingrui Precision Equipment Co., LTD., said: "In the process of deployment and pre-training, we clearly felt that Jianlin Home is an innovative technology-driven enterprise, constantly actively trying various logistics intelligent technologies, and carrying out multi-scenario deployment verification. In this process, MiR's AMR technology, as an international frontier, with its safety, stability and flexibility, not only greatly meets Jianlin Home's requirements for flexible production, but also successfully promotes the skill transformation of customer production line task teams and optimizes personnel and talent allocation. "
Thanks to the large-scale deployment of AMR, on the one hand, the work intensity of workers is reduced, and on the other hand, their professional skills are improved. In addition, like manufacturing companies in other fields, Jianlin Home is also facing the difficulty of recruiting workers, and with the construction of smart factories, safer working environments and work tasks assisted by automation technology are more attractive to young people.
The improvement of the accuracy and efficiency of material transportation in the plant is mainly based on the three technical advantages of MiR AMR: safety, intelligence and flexibility, which ensures the high AMR operation rate and operation efficiency in daily work, and realizes the accurate distribution of production line logistics.
【MiR AMR ensures human-machine collaboration and safety 】
In the assembly workshop of the kitchen and bathroom smart Park, there are more people, and most of them are in a walking manner, which is a very high requirement for the fault tolerance rate and obstacle avoidance ability of AMR operation. MiR AMR has a separate safety system and control system, and according to EN 1525, the most applicable safety standard for AMR, the safety function of MiR AMR reaches the PLd level specified in the performance level of ISO 13849, which means that the probability of dangerous failure of the system is equivalent to less than once in 20 years. It can ensure safe and efficient obstacle avoidance in dynamic environment and personnel and material dense area.
In addition, a major feature of the assembly workshop in the kitchen and bathroom industry is that the transportation process is relatively discrete, and the production line is not long-term fixed, but is composed of a number of small workstations, which means that the technology responsible for the transportation of materials or finished products must be able to quickly adjust the workflow to achieve real-time coordination. MiR AMR is deployed without the need to lay tracks and without any changes to the workshop environment. Each AMR vehicle is equipped with laser scanning technology, 3D cameras, built-in sensors and excellent software, which can analyze the environment to avoid obstacles, plan and adjust the route in real time, and flexibly respond to site changes and task changes, and its intelligent flexibility is much higher than that of traditional AGVs and forklifts.
Finally, in terms of the comprehensive intelligent upgrade of the factory manufacturing process, the successful deployment of the AMR fleet of the kitchen and bathroom Smart Park assembly workshop will have a long-term positive impact on the Group from two aspects. Jianlin Group intelligent operation development platform, ApIS intelligent manufacturing division director Fan Gang said: "As the head of the bathroom industry, we began to pay attention to the logistics automation transformation of the production line and workshop very early, automated logistics can let us take a step ahead of the peers, logistics automation capability is also an important reflection of Jianlin Group manufacturing long-term competitiveness." We are confident that we can see a return on investment in logistics automation within 2-3 years. The successful deployment and experience accumulation of logistics automation in the assembly workshop of the kitchen and bathroom Smart Park will promote the rapid replication of the Group's intelligent manufacturing, and will be promoted and applied in other factories and parks under the Group in the future. We will continue to build more smart factories. "