PLC-508

PLC-508
PLC-508
PLC-508

杭州卷烟厂卷烟的工艺流程大体上分为制丝和卷包两个流程，制丝过程包括切片，切丝，混丝三大过程，卷包过程包括卷接和包装两个主要程序，制丝过程为作业过程，卷包过程属于离散型作业，各机组都有独立的卷接和包装设备。制丝和卷包有各自的集中控制系统，分别为制丝集控和卷包数采。系统间详细流程图如图2所示，MES从ERP(Enterprise Resource Planning，企业资源计划系统)接收杭州卷烟厂卷烟生产订单生成作业计划，同时接收PDM(Product Data Management，产品数据管理)的工艺标准，质量标准，物料主数据和BOM,生成作业执行计划，指导杭州卷烟厂制丝集控，卷包数采，动力能源和物流系统的执行，根据采集的过程数据反馈，将计划执行结果等数据反馈给ERP， 关闭生产订单。
　　2.2 功能模块
　　MES主要由主数据管理、生产管理、工艺质量管理、设备管理、车间管理、实时控、批次管理、动力能源以及用户管理等九大功能模块组成，以生产执行、工艺质量管理和设备管理三大模块为主，其它六个模块为辅，实现了将上层的计划及时准确的传达给车间生产控制现场，并把车间生产控制现场的生产数据及情况实时的反馈给计划层，从而实现对整个生产过的统一指挥与调度。下面着重介绍生产管理，工艺质量管理，设备管理和主数据管理等与生产密切相关的四个模块。
　　(1) 生产管理
　　生产管理的主要功能是生产计划的调度， 它是ERP生产计划的延伸和发展，它能使制丝计划自动的分解生产工单，通过人工调整和下发，使生产现场能及时准确地进行生产作业，系统需要保证卷烟成品的供应，满足市场供货的需求。MES中生产计划调度的详细流程图如图3所示，结合杭州卷烟厂的实际设备情况，本模块主要分了制丝生产调度、制丝生产执行、卷包生产调度和卷包生产执行四个功能点。
　　a) 制丝调度
　　制丝调度主要是根据成品烟丝需求以及高架库和远程库的库存情况，在用户选择预约物料时自动推算出所需物料的数量，并能在预约物料不够的情况下给出替代方案，为了增加灵活性，还可以通过手动编辑来修改替代方案。根据各产线的产能设计、工艺逻辑和生产计划生成详细的作业工单。
　　b) 制丝执行
　　制丝执行是将作业工单发送给制丝集控系统，以及高架库系统、糖香料厨房系统等配套系统，使系统按作业工单进行作业，生产结束后，对制丝集控系统、高架库系统和糖香料厨房系统的生产结果进行统计，以报表的形式展示给终端用户。在作业过程中，可根据实时控情况对生产工单进行暂停、继续运行以及中止等操作，操作人员对未下发生产的作业工单可以进行修改。
　　c) 卷包调度
　　卷包调用主要根据从ERP计划生成喂丝机工单和卷包机生产工单。
　　d) 卷包执行
　　与制丝执行类似，卷包执行也是将作业工单下发给高架库系统和卷包数采系统，高架库系统根据喂丝机工单将相应的成品烟丝量发送至对应的喂丝机台，喂丝机将烟丝输送至相应的卷接包机组。通过MES的生产管理功能保证了批次任务之间的相互衔接和上下游工序的执行，并且能够实现生产计划层与生产车间控制现场的及时沟通。

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