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Smart Manufacturing Planning and Consulting
With nearly 30 years of Smart Manufacturing experience in Germany and the United States and
the achievements of over 200 various factory projects,
Metal Data conducted factory Smart Manufacturing
consulting. At present, the industries with project experience
include material forming process and equipment, multi-level
computer control system (basic automation + model-based
process optimization + MES + ERP), electronic manufacturing
and chip manufacturing. Related business areas span processes,
products, equipment, automation, models, software, artificial
intelligence and so on. We have Smart Manufacturing in
both traditional industries and emerging industries. The
clients of technical consulting are spread across several
continents, such as Evraz Oregon Steel, a multinational
company in the United States and Canada, Tesla Corporation,
Nucor Corporation and former AS&W company in the United
States, DFG in Germany, POSCO in South Korea,
NISCO, Tiannuo, Shagang, TISCO, Baosteel, BYD, TCL, Guangye,
Shenzhen Quality Institute, BGI, Weifu Kaldentin and Bougward
cars, etc. These do not include companies such as Morgan and
Cascade, who used to work full-time in the United States. The
specific diagnosis, planning and consulting are as follows.
1. Technical
Consulting based on Existing Project Cases
More than 200 projects
have been introduced in the project cases section of this
website. These large number of completed projects are
distributed in various fields of engineering, such as new
energy, new materials, high-end equipment, advanced
manufacturing and other fields. Under the scenario of each
project case, high-quality technical consulting can be
conducted for customers.
The 200 projects have
accumulated more than ten technical schemes and experience. It
can carry out technology upgrading and technology development
for enterprises. The size of the project depends on the
technological upgrading needs of the enterprise and the
bearing capacity of the enterprise. While upgrading digital
manufacturing and Smart Manufacturing based on the
existing data collection status of the enterprise, offline
model is also adopted.
It also conducted
finite element simulation or finite difference method
simulation. Even according to the needs of enterprises,
optimization in broader fields such as lean manufacturing is
carried out. In terms of Smart Manufacturing, using our
engineering modeling, machine learning and
intelligent system architecture, as well
as soft sensing technology, we can improve the technical level of enterprises. For example,
the model accuracy in steel induustry can lead the world, and the technical
consulting of
the main designer to the the lithium battery manufacturing enterprise
can greatly optimize the production process of lithium battery
manufacturing.
2.
Technical Consulting based on Existing Software/APP
Metal Data has
developed a long list of software packages or online APPs to
solve field problems. They can be summarized as
MOSES. Primarily it develops Level 2 system (MOS
Manufacturing Optimization System) and integrates MES (E) and
ERP data, and production Supervisory system (S) to solve the
problem. One of the MOSES systems is the Defect Early Warning
System to reduce defect and so increase earnings. The way to
achieve MOSES is based on the established models.
The enterprise system needs the
integration of basic automation, intelligent system
(Level 2), and digital system (MES/ERP), to achieve optimized
automation.
The four major areas of business that must be completed to
realize Smart Manufacturing are: first, ensure that
mechanical equipment can realize automatic adjustment;
Secondly, ensure the feasibility and accuracy of data
acquisition; The third is to ensure that the intelligent
system (Level 2) can handle the model, logic and
various scenes well; Finally, the integration of intelligent
system (Level 2) with basic automation (primary
system), MES (tertiary system) and ERP is realized.
Through flexible
application and appropriate expansion of our existing software
/APP, the cost performance of the consulting project can be
greatly improved. In the architecture of the software systems
of
MOSES, Metal Data has developed dozens of large and small
software systems /APP. See
Technical Consulting based on existing software/APP for
discussion in multiple directions.
3. Technical
Consulting during the Construction of Smart Manufacturing
Line
The main problem in construction of
Smart Manufacturing line lies in, that the intelligent system is
at moment often ignored,
and the system is run without necessary intelligence. The
losses caused by misunderstanding of Smart Manufacturing are
quite large.
For example, when building
a Smart Manufacturing production line, only (1) advanced mechanical equipment,
(2) basic
automation control, (3) MES and ERP, are built. It is
mistakenly regarded as an Smart Manufacturing production line.
There is a lack of intelligent system
(Level 2) between MES and basic
automation. Due to the lack of intelligent system, this kind
of intelligent production line can only be operated by
engineers. Operators have considerable difficulties in facing
the problems of the production line, while they don't know how
to turn a large amount of data on the data board into measures
that should be taken to solve the problems.
Usually the intelligent production line costs tens of millions
of US Dollar. If it can not form a return soon, it would
easily drag the whole factory to death.
Therefore, our consulting should help enterprises avoid such
problems and provide solutions, that is, how to provide or
construct intelligent systems in time to avoid the above
problems.
After selecting the hardware supplier, the enterprise building
the intelligent production line should start the development
of intelligent system (model and logic system, etc.).
4.
Planning based on Diagnosis of
Enterprise Technology Status
Many enterprises are in urgent need of upgrading in
automation and digitization. It
can be diagnosed in advance,
produce a
technology upgrading plan for the current situation of the
enterprise. This customized scheme specially considers the
affordability of the enterprise, in case of insufficient funds
for enterprise technology upgrading.
5.
Overview of technical
consulting field
Today's the factories mainly
produce micro-alloyed materials with thermechanical processing
(higher reduction, lower processing temperature and higher
after-processing cooling rate). With addition of micro-alloyed
materials (steels, e.g. X80 steels), new-Generation Level 2
system with metallurgical model, intelligent learning and
advanced software engineering, is required for such materials
manufacturing. The system is also good for high-end equipment.
This series, Level 2 Model Optimization and New Product
Development, include following articles:
1.
Technical Summary
2.
Micro-Alloy and Model Modification (1)
3. Micro-Alloy and Model Modification (2)
4.
A Simple and Efficient Way to Integrate New Models into
Level 2
5. Characteristics and advantages of the model and software
(1)
6.
Characteristics and advantages of the model and software
(2)
7.
A New-Generation Level 2 and the development of new
products
8.
Quality management system for new variety of development
(1)
9.
Quality management system for new variety of development
(2)
10.
Advantage and History of New-Generation Level 2 System
6.
Overview of technical
consulting field
The main business areas are
summarized as follows：
See also:
Training based on Smart Manufacturing Projects Cases.
7.
Diagram of Consulting Business Area
Taking nearly 30 business areas of a large
high-end manufacturing company as an example, here are 13
technical advantages of our team to show their applicability
in these areas. See
Diagram of consulting business area.
8.
15 Detailed Technical Consulting Fields in Emerging Industries
There are 5 categories and
15 technical consulting areas listed here:
See
15 technical consulting fields in emerging industries.
9. Enterprise
common system consulting
（1）Management Consulting
Suggestions and standardization
consulting are the main business points.
（2）Digital plant planning
Consulting on the top-level design of
software architecture, such as the formation of data
structure, class and database in software engineering. The
consistency of data types can make the data more concise.
（3）Smart Manufacturing planning
See
Maturity assessment
and
Smart Manufacturing planning Special discussion.
（4）Intelligent factory planning
Ensure that intelligent systems are not ignored due to lack of
understanding of Smart Manufacturing. Only
mechanization, automation and digitization are built, as
discussed above.
（5）Digital twin
At the same time, it takes into account the coordination
between the digital world described by the model and the real
physical world. Based on the engineering modeling of
engineering process, products, equipment and automation, as
well as a large number of project experience in software
fields such as model, software and machine learning, our team
has always been in a leading position in the competition of
European and American peers.
（6）Digital system
MES: The production process data structure
designed based on the advantages of the engineering field and
the defect early warning system based on the existing data of
the enterprise are one of the advantages of the team.
QMS: Integrate the mature defect early
warning system developed by our team into the enterprise's QMS
(quality management system) to improve and optimize product
quality and reduce defective products.
（7）IOT integration: network
interconnection
The system based on the Internet of
things is equivalent to the primary system (basic automation
system) of the team. Adding models and logic systems
(Level 2s) on this is one of the technical advantages
of the team. Network security can also be understood as one of
the functions of the Level 2.
（8）Advanced manufacturing: intelligent
perception
Intelligent control and model LED
intelligent perception are one of the technical advantages of
our team.
（9）Ecological increment
One of the advantages of our team is to
improve data value-added and improve the knowledge and
algorithm base based on model and manufacturing logic;
Improving the customized model in the industry platform is one
of the main business areas of the team.
More detailed
documents: 15 common technical consulting areas.
Planning &
Consulting
Biz discuss, Planning, Maturity,
Consulting Area,
Predict Maint.
Defect
Early Warning, Models, Manufacturing, Li-Battery, Steel
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