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1. Process Manufacturing
Definition:
The processed image is continuously passed through the production equipment, through a series of processing devices to make
chemical or physical changes in the raw material, and finally obtain the product. Typical process production industries are
pharmaceutical, chemical, petrochemical, electric power, steel manufacturing, energy, cement and other fields.
Process Manufacturing includes two types: Repetitive Manufacturing and Continuous Manufacturing.
Repeated production, also known as mass production, has many similarities with continuous production, the only difference is
whether the products produced can be separated. Repeated production of products can usually be separated one by one, it is a
highly standardized by discrete manufacturing, for mass production and form a way, continuous production of products is continuous
through the processing equipment, a batch of products are usually not separated.
Repetitive Manufacturing (e.g., medicine, food, beverages)
Continuous Manufacturing: petroleum, cement, smelting
Process Manufacturing Features:
In terms of production planning, the planning is simple, often issued in the way of daily output, and the plan is relatively stable, the
capacity of the production equipment is fixed, the production process control and the process is fixed, and the arrangement of the
work center is in line with the process route. Close to the same time through various work centers, work centers are specialized in
the production of a limited number of similar products, tools and equipment designed for specialized products; Materials from one
working point to another working point using machine transmission, there are some products in process inventory, the production
process mainly focuses on the quantity of materials, quality and process parameters control; Production requisition is usually carried
out by backflushing.
2. Discrete Manufacturing
Definition:
Products are often assembled from a number of parts through a series of non-continuous processes
Discrete manufacturing products are often assembled from a number of parts through a series of non-continuous processes.
Enterprises that process such products can be called discrete manufacturing enterprises. For example, rockets, aircraft, weapons
and equipment, ships, electronic equipment, machine tools, automobiles and other manufacturing industries are all discrete
manufacturing enterprises.
• Mass production such as automobiles
• Multi-variety small batch such as: aviation (95% of enterprises belong to multi-variety small batch)
• The diversity of customer needs makes multi-variety small batches the mainstream of discrete manufacturing
Features:
In terms of product form, discrete manufacturing products are relatively complex, including multiple parts, and generally have a
relatively fixed product structure and parts supporting relationship.
In terms of product types, general discrete manufacturing enterprises produce related and unrelated more varieties and series of
products. This determines the diversity of enterprise materials.
From the perspective of processing process, the production process of discrete manufacturing enterprises is a complex process
composed of different parts processing sub-processes or parallel or series, and the process contains more changes and uncertainties.
In this sense, the process control of discrete manufacturing enterprises is more complex and changeable.
Unlike continuous enterprises, the production capacity of discrete manufacturing enterprises is mainly determined by hardware
(equipment production capacity), but mainly by software (rational configuration of processing elements). With the same scale and
different hardware facilities, the results of discrete enterprises may be very different due to the difference in their management level.
In this sense, discrete manufacturing enterprises have more potential to enhance their competitiveness through the improvement of
software (here is a broad sense of software, relative to hardware facilities).
If MES is auxiliary to continuous industry (because of the rigidity of its processing process, the improvement effect of its production
cycle through software is little), it is decisive for discrete manufacturing enterprises, although specific to a certain part or component
processing process has a certain rigidity, but a number of parts are connected, combined, supporting determines its flexibility. Therefore,
the whole process can be optimized and the manufacturing cycle can be effectively shortened.
3. Comparison between process manufacturing and discrete manufacturing
The production and organization form of process manufacturing industry is closely related to its production technology. It is often
the technology itself (such as chemical industry, steelmaking, steamed bread) that determines the process of production rather
than discrete, for example, the steelmaking process requires a variety of temperatures, gases, and minerals to work closely together,
and a series of physical and chemical changes occur in the process, and change the physical and chemical properties of the final
product; The technical process requirements themselves sometimes become a source of economies of scale, such as steel blast
furnaces require large equipment investment, for small-scale production is not cost-effective, in contrast, steamed bread stoves are
economies of scale neutral.
As a by-product of technical and process requirements, the matching and matching of various production elements in the process
manufacturing process is natural and seamless to operate efficiently. However, because the products under this process are often
homogeneous and single, they may not be able to meet the various terminal needs, so the finished products of process manufacturing
often become intermediate products, and will become the "transformation object" of discrete manufacturing.
Based on the strict requirements of the process, the process manufacturing naturally has the characteristics of tight coupling of "man,
machine, material and method", and the pursuit of "success in one battle"; However, discrete manufacturing requires much looser
coupling of various element conditions, which on the one hand provides a larger fault-tolerant space, while objectively reducing the
efficiency of the entire production process.
The discrete manufacturing industry compromises more on demand, and carries out a variety of processing, assembly and
transformation of raw materials to meet the individual needs of various terminals (the final product of process manufacturing is often
homogeneous, and the final product of discrete manufacturing is a variety of forms, etc.). Only a variety of final products can be
matched to "individual, spatially and temporally dispersed" needs).
The core of process manufacturing is the process, its production process is relatively efficient but the product and delivery mode is
single; The core of discrete manufacturing is the matching of demand, and the process is flexible but sacrifices production efficiency.
The key problem for discrete manufacturing to solve is to design, produce and sell for demand/preference - this is an important value
point for discrete manufacturing.
It can be said that the core of narrow discrete manufacturing (does not include design) is "assembly", is "demand-oriented assembly",
and can be said to be "demand-oriented programming", is a series of materials and manpower organization according to user needs,
its core is a set of information system + control (management) system.
4. Process transformation of discrete manufacturing
Discrete manufacturing enterprises often produce more types/models of products, and the multi-category bill of materials greatly
increases the complexity of management, and further objectively reduces the "orderliness" in the discrete manufacturing process.
The "loose and disorderly" of discrete manufacturing and the "precise and orderly" of process manufacturing form a sharp
contrast - if you can provide an "order" to the discrete manufacturing process, you can greatly improve the operational efficiency
of such enterprises. The process transformation of discrete manufacturing industry is actually hoping to introduce "order" in the
loose and disorderly discrete manufacturing industry, so that the process of discrete manufacturing is also like the process
manufacturing, and the elements are closely coordinated (reduce waste, reduce semi-finished products) to achieve fast, accurate
and high consistency of production.
There may be several different paths to this order, but the core lies in:
The longer the digitalized chain, the greater the influence of the new order and the greater potential for optimization and
improvement.
Digitalization is a means, not an end. The next step in digitalization is process optimization based on full chain data: This
optimization may be the improvement of OEE/ equipment utilization for equipment scheduling, the rapid response based on
the multi-link collaboration of "design-proofing - trial production", the APS optimization based on the digitalization of the whole
process and dynamic scheduling, the product consistency based on the digitalization of BOM/ process chain or the improvement
of intelligent perception of the whole production process. Or it could be a combination of the effects described above.
As long as the digitalization and online of the whole process can be realized, even at a lower level of automation, the cooperation
efficiency of different links and different elements can still be greatly improved. The introduction of this order in discrete manufacturing
- an order that allows the elements of production to seamlessly connect and the efficient operation of various equipment and personnel
- will be a huge challenge, but through the introduction of the whole process of material and production process management, the whole
process can be effectively realized online.
Project Case:
1. Bosch Cell line, through the noodle diagram of personnel movement, to find out redundant actions, to achieve rapid optimization of
production line efficiency;
2, Raleigh factory, through the real-time management of personnel, to achieve the output and actual working hours;
3, under the production enterprise of P&G, the digital management of the warehouse has been realized, and the material of the
warehouse along the line has been automatically supplemented to ensure that the production line does not stop;
4, Yutong bus, the assembly Process to achieve process Automation (Process Automation), each process working time accurate to
seconds, even if any customized products, also recorded. The system can automatically identify and analyze the bottleneck.
5, the management of Midea material car, the material to achieve automatic record warehouse location, warehousing, warehousing,
warehousing, intermediate logistics time are automatically recorded.
Through the real-time location management of materials, material processing process, and personnel, the management that was out
of control when it left the assembly line in the past will be returned to a virtual assembly line, and the process transformation of discrete
manufacturing will be realized, which will significantly improve the cost reduction and efficiency of enterprises.
