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论文编号：	13369
作者编号：	2320190380
上传时间：	2022/6/13 13:52:44
中文题目：	TTP公司基于精益生产的数字化车间设计与实施研究
英文题目：	TTP''s digital workshop design and implementation research based on lean production
指导老师：	李凯 教授
中文关键字：	重型装备;离散型制造;精益生产;数字化车间;智能制造
英文关键字：	Heavy equipment manufacturing;discrete manufacturing;lean production;digital workshop;intelligent manufacturing
中文摘要：	当前全球制造业格局正经历着重大调整，新一代信息技术与制造业深度融合，正在引发深远的产业变革，形成新的生产方式、产业形态、商业模式和经济增长点。各国都在加大科技创新力度，移动互联网、云计算、大数据、3D打印、生物工程、新能源、新材料等领域取得新突破，并提出了对应的制造业国家战略，包括中国制造2025，德国工业4.0，美国工业互联网，日本工业价值链等。与德国等发达国家工业基础相比，目前我国的制造业还处于相对落后的状态，如何能够实现工业4.0智能制造是各行各业都在思考的问题。? 作为锻压装备领域的龙头企业，TTP?公司产品涉及到中国制造2025、十四五规划等国家战略中的众多领域，包括高档数控机床、航空航天、海洋工程、先进轨道交通、新能源、电力装配、农机、新材料等。作为国有企业，为满足国家的战略需要，企业的快速发展，同时以打造世界一流企业为目标，必须加强信息化管理能力，提升系统集成能力，推进信息系统的平台化、专业化和规模化，实现业务流程再造，实现企业生产经营管理、产业转型升级。 在锻压装备领域，德国企业依靠100多年的长期技术积累，形成了一定的品牌效应和技术壁垒，立足于德国工业的高起点，目前正在大力推进工4.0的实施，借此提高行业高端市场的技术和品牌壁垒。相反，目前国内锻压装备制造企业仍处在激烈的价格竞争中，企业因经营不善等问题正面临破产重组和转型，与国家战略需求出现明显反差。以TTP公司为例，2016年-2020年，企业营收呈负增长趋势，企业净利润下滑。企业存在产品库存率高、交货托期严重，质量问题频发、不良率居高不下等问题，同时各生产部门存在严重的信息孤岛现象。通过对?2021?年1-7月份生产数据进行分析，公司产品创新型、改进型约?80%，属于高度客制化的离散型制造企业。作为重型装备制造企业，多数属于首台首套的重型研发型产品，产品的一次性设计生产和制造的不可逆性，造成风险性居高等特点，因此产品要求进行全流程精确管控，打破信息壁垒，做到实时反馈、快速决策。 TTP公司目前处于2.0向3.0发展的过渡阶段。企业的自动化和信息化水平偏低，其中以加工中心为代表的加工制造阶段基本实现了信息化，但以焊接和装配为主的制造阶段存在很大差距，这也加大了流程管控的难度。根据不在落后的工艺基础上进行自动化，不在落后的管理基础上进行信息化，不在没有网络化、数字化条件时发展智能化的企业数字化的三不原则，TTP公司要进行数字化，必须先进行精益生产的提升，以精益生产与车间数字化结合的方式推进数字化建设。精益生产是车间数字化的基础，数字化车间建设是企业开展精益生产的技术手段和管理方法。同时，数字化车间建设是智能制造的前提和基础，实现智能制造需要精益生产、数字化的长期落实。精益生产，数字化车间建设，智能制造者是企业不同发展阶段的解决问题的技术和管理手段，三者的关系是相互促进且密不可分的。 本文通过对战略背景、国内外行业数据、公司内部生产经营过程中的相关问题等进行分析，对TTP公司进行基于精益生产的数字化车间设计与实施，解决企业生产过程中的问题，消除过程浪费，打破信息壁垒、实现快速决策、全流程实时管控，提高现代化管理水平和决策效率。通过精益工具方法的选择和精益生产的实施，推动丰田生产方式改善活动的实践，实现企业产品完结型经营，拉动式整流化生产，缩短企业活动的周期时间（L/T），稳定企业现金流。通过车间数字化，数字化功能模块、核心功能模块、信息与生产安全的设计与实施，搭建符合企业特点的数字化网络和结构的MES制造执行系统，结合ERP企业制造资源计划，打通基础层、执行层、决策层之间的信息壁垒，实现信息实时跟踪、收集、传送、决策、执行和反馈。运用精益生产、可视化管理、标准化管理、智能制造等先进生产管理理论和方法，来设计和建造信息化车间，实现精细化管控能力，提高企业柔性敏捷制造能力。同时，企业通过制度、人才和财务保障等措施，确保数字化的顺利实施。 TTP公司通过推动基于精益生产的数字化车间设计及实施，找到适合公司特点的车间数字化经验，实现企业的数字化目标，为行业发展找到数字化解决方案，为未来实现智能制造夯实基础。TTP公司通过结合仿真技术在设计制造领域的应用、远程设备智能监测和运维管理平台建设推广、工业APP开发利用等技术，实现产品全生命周期管理，最终实现以智能设计、智能生产、智能管理、智能服务为核心，打造智能装备为载体的智能软硬件开发平台，实现客户对高度定制化、集成化、柔性化、智能化产品的需求。 展望未来，企业将结合数字孪生、5G?等技术，实现以物与信息系统为核心的智能制造企业模板，在智能制造发展的大势所趋下，TTP公司凭借自身在核心技术领域的实力，发挥TTP公司行业龙头的带头作用，联合行业内的相关企业，加快行业智能标准和智能平台的建设，着力提升企业管理能力、整体运营效率、智能化水平等，打造全流程智能化产品，为企业转型升级、行业发展提供一种智能化整体解决方案，为实现重型装备从“装备制造”向“装备智造”转变贡献一份力量。
英文摘要：	At present, the global manufacturing industry pattern is undergoing major adjustments, and the deep integration of a new generation of information technology and manufacturing industry is triggering far-reaching industrial changes, forming new production methods, industrial forms, business models and economic growth points. Countries are increasing their efforts in scientific and technological innovation, mobile Internet, cloud computing, big data, 3D printing, bioengineering, new energy, new materials and other fields to make new breakthroughs, and put forward the corresponding manufacturing national strategy, including Made in China 2025, German Industry 4.0, the United States Industrial Internet, Japan's industrial value chain, etc. Compared with the industrial base of developed countries such as Germany, China's manufacturing industry is still in a relatively backward state, how to achieve Industry 4.0 intelligent manufacturing is a problem that all walks of life are thinking about.? As a leading enterprise in the field of forging equipment, TTP products involve many areas in the national strategy such as Made in China 2025 and the 14th Five-Year Plan, including high-end CNC machine tools, aerospace, marine engineering, advanced rail transit, new energy, power assembly, agricultural machinery, new materials, etc. As a state-owned enterprise, in order to meet the strategic needs of the country, the rapid development of enterprises, and at the same time to build a world-class enterprise as the goal, it is necessary to strengthen the ability of information management, improve the ability of system integration, promote the platform, specialization and scale of information systems, realize business process reengineering, and realize enterprise production and operation management, industrial transformation and upgrading. In the field of forging equipment, German enterprises rely on more than 100 years of long-term technology accumulation, the formation of a certain brand effect and technical barriers, based on the high starting point of German industry, is currently vigorously promoting the implementation of engineering 4.0, thereby improving the industry's high-end market technology and brand barriers. On the contrary, at present, domestic forging equipment manufacturing enterprises are still in fierce price competition, and enterprises are facing bankruptcy reorganization and transformation due to problems such as poor management, which is in obvious contrast with the national strategic needs. Taking TTP as an example, from 2016 to 2020, corporate revenue showed a negative growth trend and corporate net profit declined. Enterprises have problems such as high product inventory rate, serious delivery shelf life, frequent quality problems, and high non-performing rates, and there are serious information islands in various production departments. Through the analysis of production data from January to July 2021, the company's products are innovative and improved by about 80%, which is a highly customized discrete manufacturing enterprise. As a heavy equipment manufacturing enterprise, most of them belong to the first set of heavy-duty R&D products, and the irreversibility of one-time design and production and manufacture of products causes high risk characteristics, so the product requires precise control of the whole process, breaking down information barriers, real-time feedback, and rapid decision-making. TTP is currently in the transition phase from 2.0 to 3.0. The level of automation and informatization of enterprises is low, among which the processing and manufacturing stage represented by the machining center has basically realized informatization, but there is a big gap in the manufacturing stage dominated by welding and assembly, which also increases the difficulty of process control. According to the three principles of automation on the basis of not being backward on the basis of the process, not informatization on the basis of backward management, and not developing intelligent enterprise digitalization in the absence of networking and digital conditions, TTP companies must first carry out the promotion of lean production to promote the digital construction in a way that combines lean production and workshop digitalization. Lean production is the basis of workshop digitalization, and digital workshop construction is the technical means and management methods for enterprises to carry out lean production. At the same time, the construction of digital workshops is the premise and foundation of intelligent manufacturing, and the realization of intelligent manufacturing requires lean production and long-term implementation of digitalization. Lean production, digital workshop construction, intelligent manufacturing is the technology and management means to solve problems at different stages of enterprise development, and the relationship between the three is mutually reinforcing and inseparable. Through the analysis of strategic background, domestic and foreign industry data, and related problems in the company's internal production and operation process, this paper designs and implements the digital workshop based on lean production for TTP companies, solves problems in the production process of enterprises, eliminates process waste, breaks down information barriers, realizes rapid decision-making, real-time control of the whole process, and improves the modern management level and decision-making efficiency. Through the selection of lean tools and methods and the implementation of lean production, we will promote the practice of Toyota's production method improvement activities, realize the completion of enterprise product management, pull rectification production, shorten the cycle time (L/T) of corporate activities, and stabilize corporate cash flow. Through the design and implementation of workshop digitalization, digital function module, core function module, information and production safety, the MES manufacturing execution system that meets the characteristics of the enterprise is built, combined with the ERP enterprise manufacturing resource plan, the information barrier between the basic layer, the execution layer and the decision-making layer is broken, and the information tracking, collection, transmission, decision-making, execution and feedback of information are realized in real time. Using advanced production management theories and methods such as lean production, visual management, standardized management, and intelligent manufacturing, we design and build information workshops, realize refined control capabilities, and improve the flexible and agile manufacturing capabilities of enterprises. At the same time, in order to ensure the smooth implementation of digitalization, enterprises have adopted measures such as institutional, talent and financial security. By promoting the design and implementation of digital workshops based on lean production, TTP Company finds workshop digital experience suitable for the company's characteristics, realizes the digital goals of enterprises, finds digital solutions for the development of the industry, and lays a solid foundation for the realization of intelligent manufacturing in the future. TTP company through the combination of simulation technology in the field of design and manufacturing applications, remote equipment intelligent monitoring and operation and maintenance management platform construction and promotion, industrial APP development and utilization and other technologies, to achieve product life cycle management, and finally to achieve intelligent design, intelligent production, intelligent management, intelligent service as the core, to create intelligent equipment as the carrier of intelligent software and hardware development platform, to achieve customer demand for highly customized, integrated, flexible, intelligent products. Looking forward to the future, enterprises will combine digital twins, 5G and other technologies to achieve intelligent manufacturing enterprise templates with objects and information systems as the core, under the general trend of intelligent manufacturing development, TTP company relies on its own strength in the core technology field, plays the leading role of TTP company industry leaders, unites relevant enterprises in the industry, accelerates the construction of industry intelligent standards and intelligent platforms, and strives to improve enterprise management capabilities, overall operational efficiency, intelligent level, etc., to create full-process intelligent products, for enterprise transformation and upgrading, The development of the industry provides an intelligent overall solution, contributing to the transformation of heavy equipment from "equipment manufacturing" to "equipment intelligent manufacturing".
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