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Smart Manufacturing
Consulting and product development based on existing
software
I. Smart Manufacturing technology consulting
Smart Manufacturing technology consulting customers are
as follows. Here, we focus on benchmark customers, such as
PRIMetal, SMS and Danieli, etc. in engineering technology
industry; EOS (Evraz Oregon Steel) , NISCO, and South Korea POSCO
etc. in the iron and steel industry; BYD in the lithium battery industry,
Skyworth & TCL, etc.
The benchmark projects
are
shown in the figure below. It mainly includes the DFG finite
element artificial intelligence project in Germany, Morgan
(now PRIMETAL)
large-scale model project in the United States, the three sets
of Level 2 project in Cascade Steel, the New-Generation
Level 2 project in Oregon and Nanjing, and the
lithium battery Smart Manufacturing project of BYD and Tesla,
etc.
During the period of completing a series of BYD projects in
Shenzhen, it also completed a number of emerging industry
projects, as shown in the figure below.
II. Consulting and product
development based on existing software
1.
Defect early warning system
The main contribution of the team in Smart Manufacturing
is to collect data on the factors related to on-site defective
products or analyze data based on other data sources,
establish engineering models, carry out machine learning and
optimize production operation. The ultimate goal is to
eliminate or reduce defective products in the production
process, and improve the yield.
This is to refer to the
customer's MES or industrial Internet or other data obtained
based on SCADA, and to carry out defect early warning based on
the existing software. Before the products is
produced, the model is established through the idea of
historical prediction of the future, and machine learning is
carried out. The generated model is used to predict whether
the relevant products will become defective after the
production is completed; If it is a defective product in the
future, the alarm will be given before the production is
completed. The operator can make the product genuine by
changing the parameter combination or even changing the wear
parts (knife or mould). The existing software suggests the recommended value of
the best parameter combination.
2. Equipment intelligent system
It is simplified by the omni-directional Smart Manufacturing system, which
enabled the production equipment
system to achieve the optimal operation and to provides equipment
software for the existing equipment hardware. Equipped with
intelligent system, the price of equipment can therefore
increase by 2 to 10 times. For example, the price of 5G
material production line of a fortune 500 company is 180
million RMB when equipped with intelligent system. When only
equipment hardware is available, its value is only 30 million
RMB! Based on the online data of existing equipment,
engineering modeling is carried out. The established model is
based on the existing online data for machine learning, so
that the model is fully bound with the existing production
line (that is, the model is extremely accurate on the existing
production line). Based on the model, various operation
parameters of the existing production line can be well
coordinated. The intelligent system is equipped at the
production site. When the production line has superior basic
automation and manufacturing execution system, the optimal
full-automatic operation can be realized through system
integration.
3. Tool Optimization and management system
In the absence of this system, the tool can be used for a
specific length of time and then removed for the next round of
grinding. When using this system, the possible cutting process
in the production process is simulated based on the initial
knife gap until the end knife gap is reached. Therefore, it is
necessary to know the defect of the object cut by the tool in
the production process. The system can use the existing
high-power microscope on the production line to measure the
initial knife notch and the end knife notch, combined with the
field application simulation to form machine learning. If more
effective automatic measurement is needed, the automatic tool
detection system that has been successfully developed by our
team and used in a large lithium battery production line can
be used; The system can also classify the initial quality of
the tool after grinding based on the initial tool notch, and
give priority to the use of tools of the same grade in the
same environment to avoid too frequent tool change. The system
can also track and simulate the use of existing tools in the
tool library. When the number of tools in the tool library
reaches a certain number, it will give an early warning and
urge the site to send the tools to the grinding consumer for
re-grinding. This ensures that a sufficient number of tools are
available in the tool magazine.
4. Optimal use and management system of mould
You can refer to the above Tool Optimization and Management
System. Five sets of rapid design systems have been completed.
Based on a large number of models, the interface only displays
production operation terms, which can enable non designers to
carry out high-quality design! There are also two sets of
high-level design systems developed for professional
designers, considering the internal correlation of all
operating parameters. The system has been strictly verified by POSCO, TISCO and other large international enterprises, and is
completely consistent with the site, which makes customers
very surprised!
III. Future business priorities
1. Overview of
defect early warning system
Business model. Put
the mature technology completed in BYD and other projects into
the computer system or chip to form products that can be sold
on a large scale. The price is 1 / 10 of the price developed
by our team. This development is based on the rewriting of the
existing intelligent system source program. If we sell only
one copy at 100% price, our profit will be more than 80% and
the customer's profit will be more than 10 times a year!
Moreover, as an intelligent system, governments at all levels
have subsidies and special personnel apply for it.
Operation mode. History
is the way to predict the future! For example, there are 10
stages of production. In the first or second stage, we can
know whether the products after completing the 10 stages are
defective under the existing production conditions; If yes,
the system will give an alarm in the first or second stage,
adjust the parameters in the second or third to tenth stages,
and even replace the worn parts (tools or molds, etc.) to make
the product genuine! This can reduce the defective rate and
improve the product quality!
2. Later business development
Upgrade to
equipped with intelligent system. After 2 to 3 years of
operation of the defect early warning system (it can also be
now with the support of large companies), it will be upgraded
for another round. This is another huge field! This system can
increase the price of equipment by 2 to 10 times! For example,
the example of AMER group (world top 500) 5G
material production line is 6 times! The main reason for the
low export price of China's equipment is the lack of software
(intelligence and data of equipment), only hardware; China's
industrial core software is extremely lacking!
Then upgrade to
an all-round Smart Manufacturing System. This has
been restored to the system developed by us for more than 30 years. During this period, more
than 200 Smart Manufacturing projects have been
completed in Europe, America and other countries! This is
based on our technical advantages as German Ph.D. of
engineering and US Ph.D. of software, and at least 3
years of working experience in 7-8 professional fields. Below
is our development in Level 1 basic automation (Industry 2.0),
Level 2 model and logics (Industry 4.0), Level 3 MES and Level
4 ERP (all in Industry 3.0, below Industry 3.5). This Mylti-Level
Automation is our primary work area. A list of publications
and presentation PPTs are showed in Meta4-0.com/pub/index.htm.
Planning &
Consulting
Biz discuss, Planning, Maturity,
Consulting Area,
Predict Maint.
Defect
Early Warning, Models, Manufacturing, Li-Battery, Steel
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Contact us: Please scan the figure below to add
Wechat (e.g. myQQfriend); Tel: 13400064848 or 13430699003; E-mail
BLi68@QQ.com. See
Profile of the
key consultant.
 
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