Advantech is a global leader in the intelligent systems industry. Since its inception in 1983, Advantech has focused on the three major markets of automation, embedded computing and intelligent services, and is committed to becoming the most influential leader in smarter cities and the Internet of Things. After 30 years of development, Advantech has accumulated rich experience in the electronic platform service market and leads the industry development direction, providing a full range of hardware / software / customer service / global back-office support and e-commerce infrastructure solutions for global users.
Advantech established two smart parks in Taiwan and Kunshan from 2013 to 2014, with operations all over the world. The Kunshan Manufacturing Center visited this time since 2000. With the unremitting efforts of the Chinese, we have gradually created a number of manufacturing facilities such as the board production plant, the CTOS plant, the ACSC plant, the system plant, the institutional plant, and the A+TC plant. The factory has built a complete ecosystem of its own smart solutions and is committed to becoming the world’s largest collaborative research and development and integrated manufacturing service park.
Kunshan, Jiangsu – Advantech, a global leader in intelligent systems (stock code: 2395) Advantech’s products also cover other areas of life, transportation, automotive, Internet technology and core technology server terminals.
“Workers’ work is not as cumbersome and repetitive as in the past. Just follow the instructions of various warning devices or test procedures to complete the specified actions; some previous plug-in or confirmation actions are all omitted. The employee turnover rate begins to decline, each The number of people recruited in the month is reduced, and employees with good quality can be strictly filtered and screened.” Lin DongJie continued. According to Advantech’s official data, the benefits of introducing automated production lines in 2017 were: the total number of employees in the plant area decreased by 2.2%, but the per capita output value increased by 16.9%…
Practice articles: smart factory development record
Advantech took the factory in Kunshan manufacturing base as an example. In the “Intelligent Manufacturing Practice”, it showed in an all-round way “How is a smart factory developed?” Starting from the details and practice, through the specific cases of intelligent application solutions on the production line, the industry will show the research samples of Advantech on the industrial Internet and smart factories, and provide specific and reproducible reference.
In this rapid digital transformation period, the whole industry is standing at the “crossroads” of intelligent manufacturing. Contemporary traditional manufacturing and factories need to be reconstructed, and “smart factories” have become an important boost for industrial transformation.
Under the wave of upgrading and transformation of manufacturing industry, the need for real-time collection and analysis of plant data streams and information flows to assist in rapid response and decision-making is becoming more and more obvious. This requires informatization, digitization, and intelligent technology to deepen in the industry. Fusion. What needs to be clear is that smart manufacturing is not just a simple “machine substitution”.
A lot of invisible things are often blind spots in production cost and efficiency control. For example, is the operation status of the equipment machine in the production line good? Is there any individual machine idle? Is there an abnormal failure? Is the production schedule reasonable and scientific? What is the balance of the production line? Material preparation for each node and the entry and exit of materials into and out of the warehouse, even the productivity, working status, etc. of the workers at each station.
These data scattered throughout the factory are often difficult to integrate and use in traditional factory management, and many data are often overlooked.
The “data-driven” is also the core driving force for the evolution of the Advantech Kunshan manufacturing base to smart factories. Taking the networking and visualization of equipment as a starting point, the factory is “transparent” through real-time data, so as to continuously optimize the production process at each stage, and the data-driven efficiency is improved. Advantech’s intelligent factory evolution route begins.
Advantech has taken the lead in implementing the Industry 4.0 strategy and has implemented a smart monitoring and operation system from raw material procurement to finished product shipment. From the main screen of the war room we can see that the company’s entire Industry 4.0 solution consists of equipment monitoring & preventive maintenance systems, equipment automation systems, plant energy management systems, manufacturing execution and product traceability systems, machine inspection and optimization systems, and The factory environment system consists of six major systems;
The screen on the left shows the real-time status of the key indicators of the overall operation of the Kunshan Manufacturing Center, so that the company’s management can see the overall operational indicators of the plant at any time; on the right, the production data of the two manufacturing parks in Kunshan and Taiwan are compared in real time, and the production information is shared in real time. Ensure smooth communication and communication.
In the war room, relevant personnel can mobilize the operational performance of all departments and production processes at any time: through the equipment monitoring & preventive maintenance system, managers can view the operating parameters of key equipment and components, and the number of times used by the components. The analysis of the use time can realize the function of preventive maintenance. Corresponding measures are taken before the equipment is stopped to avoid the abnormal production capacity caused by the abnormality of the equipment. Through the manufacturing execution and product traceability system, the manager can view the real-time completion progress and use of any order. Scan code to achieve material input foolproof design, view production yield and efficiency reports at any time, and implement a smart scheduling system, allowing the system to complete scheduling according to order requirements, line body state intelligence, optimize scheduling design, reduce switching time And waiting for waste, it is good for Advantech to achieve an average of hundreds of line-type changes per day; through the energy management system, managers can look at the overall manufacturing center’s energy, gas, water consumption and peak consumption, Let the manager can arrange the equipment to be arranged Machines, downtime, and the government’s peak power policy, on the one hand benefiting the government, reducing the government’s peak power consumption; on the one hand, avoiding peak electricity consumption, reducing energy consumption for enterprises.
The six systems work together to perfectly realize the Advantech Technology Industry 4.0 strategy, and truly achieve a reputation for staying at home. It can be said that the operation is in the midst of it, and it is better than a thousand miles away!
The boundaries between the physical and digital world are gradually being eliminated with the development of technology.
In the current development of a series of cutting-edge technologies such as artificial intelligence, big data, cloud, sensing technology, and machine learning, and deep integration into various traditional industries, the revolution of the Internet of Things is erupting in every corner of the industry.
What is the technology and power that triggers large-scale innovation in the era of intelligent Internet? – Perception, data, and interconnection.
Starting from one sensing node, all kinds of sensors (mobile phones, cars, smart homes, public places, factory production lines…) are collected all over the corners, collecting huge amounts of data all the time, and the wisdom of industry is sprouting.
As Advantech executive director He ChunSheng pointed out, how to choose and capture data determines the degree of intelligent development.
In the past, from manufacturing to automation, the emphasis was on a password and an action. However, when data is combined with various algorithms such as artificial intelligence and deep learning, each password and action in the manufacturing process will be processed more efficiently through operational analysis, and even assist in adjusting future production processes. Manufacturing is moving towards intelligence.
▲ The industrial computer produced by Kunshan Advantech Technology is resistant to shock, dust and radiation, and can meet most industrial scenes.
Advantech is a leader in the Intelligent Systems industry, and is a trusted international brand with advanced technology and reliable quality. Since its establishment in 1983, Advantech has 7,322 full-time employees in the world, with branches in 21 countries and 92 major cities. Its three business group organizations focus on the automation market, embedded computer market and intelligent service market, and launch IPC+N strategy to provide customers with integrated solutions and services for industrial automation and embedded products.
Founded in 1983, Advantech is a leading global provider of electronic platform products and services. Its business scope includes complete system integration , hardware, software, customer-focused design services and global logistics support, all backed by industry-leading back-office e-commerce solutions .By working closely with our solution partners, we are able to offer complete solutions for a wide range of industrial applications. Advantech has been committed to high-quality, high-performance computing platforms and manufacturing innovations. The company’s mission is to create the global e-century innovation drive by providing trusted electronic platform products and services. The application and innovation of Advantech products is endless.
Advantech’s corporate mission is to drive smart cities to innovate and build a model of the industry. Domain Industrial IoT/Automation; Infrastructure/Utilities/Intelligent Transportation; Smart Healthcare/Network Communications/Games; Smart Retail/Smart Logistics.
Production process visualization
Production equipment data networking and benefits
SMT data networking and benefits
Intelligent production station
Production environment and waste discharge monitoring
Factory energy management
AI intelligent optical identification
Predictive maintenance of production equipment
Customer demand is forced to smart manufacturing
Another reason for the development of smart manufacturing comes from the pressure on customer demand. “Electronic and 3C hardware manufacturing companies generally choose to be stationed in Suzhou and Shenzhen. Compared with Shenzhen, the factories in Suzhou are more medium-sized and large, so we are facing a concentrated customer base and saving staffing. There are usually 3 to 6 month cycles, and factories in Shenzhen limit the cycle to 1 to 3 months. Kunshan is more suitable for R&D.” Lin ShaoYuan, general manager of Kunshan Xi Meng Automation Technology Co., Ltd. is a Fujianese, and his speech is logical. Thoughtful, slowly coming.
Lin ShaoYuan believes that the reason why the development of Suzhou manufacturing enterprises is relatively stable and planned is inseparable from the industry aggregation pattern of the early foreign companies. Second, the local government is leading the regional reforms in a market-oriented manner, such as providing relevant financial support for the innovation and development of the intelligent manufacturing industry.
Xi Meng provides automation equipment for the screen production of mobile phone brands. In recent years, the 3C industry has developed rapidly, capital is intensive, and the mobile phone industry has been updated rapidly. The screen industry has also become a fast-moving technology and capital-intensive industry. At the end of 2016, a mobile phone brand company proposed to Lin ShaoYuan that it needed to produce fully automated production line equipment for full-screen mobile phones. From the end of the year to April 2017, Xi Meng provided the equipment needed by the brand merchants according to the requirements of mobile phone brands – 10 fully automatic production lines. The automated production line produces a mobile phone screen every 3 seconds, 20 pieces a minute. This order made Lin ShaoYuan think: “A new era of intelligent manufacturing is coming. The existing manufacturing industry chain model consists of three major segments: brand, OEM and automation company, but each sector needs The labor of different attributes has not reached the limit, and the combination of these factors is not the most efficient production method. At present, the brand has begun to get involved in the process, and more contact with automation manufacturers. The use of fully automated production lines will It enables the brand manufacturers to produce their own products, so that the foundry may not be stripped of the R&D capability in the future.
This is a new era. This single makes Lin ShaoYuan realize: “The foundry is being forced by the brand to launch the smart manufacturing. This kind of crush can be dismantled into three points: delivery – automation makes the production cycle more Faster and more accurate; price – stable production and low management costs. Yield – to avoid the problem of early and late shifts in the factory, to solve the problem of unstable quality.”
Extend from full automation
Automation is not done overnight, but rather gradual. Zhang Fan, CEO of the soft-touch robot, agrees that the normal process of producing a product is from manual labor to semi-automation plus human, and finally to full automation. Just like drawing a draft first, then adding a color after determining the posture, complete the painting. If the semi-automated process is skipped, there is a risk of direct automation, and development costs are the most uncontrollable risk. From manual to semi-automated processes, step-by-step verification of functionality is required. Next is a large number of tests that can include functional experiments as well as durability and reliability experiments. “Only from the function, fatigue strength to the harshness of the environment are in line with the standards, the automated production line can be put into production.” Industry experts stressed.
It is not wise to start a fast automated production line because the early upgrade process is full of trial and error and the cost is large. “Some domestic companies are also doing smart manufacturing, but in the end there is no way to use them, because the inventory, turnover rate, labor costs, depreciation costs, management costs, etc., the cost is too high, and the intelligence is only for visiting. The quality of the products. It is also unstable. To measure the level of intelligent manufacturing, it is necessary to pass a quantitative indicator.” Fu SiMin, deputy director of the Information Management Department of XuGong Group, said in an interview with Business Week/Chinese.
Advantech did not take the initiative to fully automate in the process of intelligent manufacturing upgrades, but to evaluate the cost-benefit of cases that can be changed and improved. “If this investment can recover costs in two and a half to three years, we will invest all at all costs.” Lin DongJie emphasized to Business Week/Chinese that Advantech is not automated for automation, because in actual evaluation, 80% of the scenes are not profitable. Lin DongJie believes that “it is not recommended to introduce a large number of automation equipment directly. It is necessary to consider man-machine coordination, that is, to find an automation mode suitable for the factory itself. For example, handling and automatic sealing are too boring for manual operation, and it is suitable to introduce automation equipment in one step.”
Like Advantech, Delta’s WuJiang factory, which is not far apart, does not promote smart manufacturing solutions on a large scale. Instead, it seeks to establish a “demonstration line” in the process of advancing to find a balance between capacity and economy. For example, in the packaging production line, the demand for flexible work in individual steps is high, and the actions that people can accomplish are ever-changing. It is difficult for the machine to complete, and Delta will choose to continue to let the workers work in this position. Delta is currently renovating production lines such as inverters and trial operation on demonstration lines, achieving high intelligence through equipment and process improvements. According to official data provided by Delta, a standard-compliant production line can increase production capacity by 40% while reducing the number of production line operators by nearly 90%.
Smart manufacturers are beginning to transform into the service industry. In the Delta office, all projectors are produced by themselves. Founded in 1971, Delta started its power management and cooling solutions. It has a power electronics laboratory in Lari, the capital of North Carolina, and a dedicated power electronics R&D center in Shanghai, Jiangsu and Guangdong. Delta’s Zhongda Electronics (Jiangsu) Co., Ltd. is located in Wujiang, Jiangsu. The compound growth rate since its inception was 40%. In 2016, Wujiang’s factory revenue was 20.73 million US dollars, accounting for nearly one-third of Delta’s overall revenue. Delta’s products can be divided into three major business areas: power supply and components, automation, and infrastructure. In industrial automation, Delta offers products such as inverters, as well as horizontal joint industrial robots and vertical multi-joint industrial robots.
The Delta WuJiang factory can accommodate 30,000 employees and provide a living environment that integrates leisure and entertainment, as well as physical and mental health management, to create a convenient living and working environment for employees. The factory has a 24-hour community medical service and training institution, Delta Enterprise College. The factory also often hosts a series of activities, such as square dance, tree planting festival, sports meeting and photography contest.
Intelligent manufacturing production line
Let front-line employees know the production schedule and machine operation in real time.
In the past few years, Delta has strengthened its investment in software research and development, and established a software-based research and development team in Delta’s industrial automation business group, and upgraded its automation software development capabilities through mergers and acquisitions. In April 2018, the Electromechanical Division of Delta Electronics Co., Ltd., a subsidiary of Delta Group, announced that its new head, Chen MinRen, is fully responsible for the future management, operation and business development of Delta’s industrial automation business in mainland China. “Delta is an automation product supplier and an automation and intelligent system solution provider,” said Chen MinRen. In 2017, Delta’s share of the automation market grew by more than double digits.
Li FengYi, global director of the intelligent manufacturing business of the Delta Group’s electromechanical business group, said in an interview with Business Week/Chinese: “The automation department of Delta was established in 1995 and gradually found that large manufacturing companies will encounter the same as Delta. Staged problems – a small number of different, less people. We use the technology, the development of technology, there is a market, so began to adjust the layout. From 1995 to the present, the proportion of the performance of the automation sector compound growth is very high, also accounted for the group’s business More than 15% of the amount has become a very important pillar within Delta.”
He ChunSheng, founder of Advantech, agrees with Ren ZhengFei, the founder of Huawei: “Don’t show off the gimmick and forget to plant the land.” He believes that the meaning behind this sentence is actually, if we sing new retail every day, but ignore factory production, The real economy will gradually be destroyed by the virtual economy. As a strong country, manufacturing cannot be lost because manufacturing will bring the most job opportunities. “This world is highly competitive. A company is originally an industry leader. If you are not careful, you will be surpassed in an instant, such as Nokia mobile phones and Kodak. Some companies will emerge in another instant, such as Google, Facebook. The leader is subverted. Every day is happening, the manufacturing industry itself needs a standardized production process in one go, but when you enter the innovative industry, you need a new management model.” He ChunSheng concluded.