Other Smart Factory Construction of Organic Metal Chemical Company
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Smart Factory Construction of Organic Metal Chemical Company
This is Impix's smart factory solution, which constructed a smart factory based on data integration management and LOT tracking to improve the safety and efficiency of high-risk organic metal chemical processes.
1. Pain Point
Process Characteristics and Technical Aspects
- The oxidizing reagents manufactured by the company have the potential for spontaneous combustion and chain reactions leading to explosions, and there is also the possibility of toxic decomposition products being generated, making advanced technical expertise essential.
Data Collection and Integrated Management Aspects
- While data is collected using PLCs in major manufacturing processes, data from various manufacturing process inspection devices is manually aggregated, making integrated data management challenging.
System Integration Aspects
- While data is managed through the ERP system, it operates separately from data generated in manufacturing processes, preventing effective integration and management of manufacturing site data.
2. Smart Factory Construction Details
Manufacturing Management System Enhancement
- Introduce a POP system to link with process equipment PLC data and establish a field manufacturing process management system optimized for field operations support.
- Establish a decision-support system for production planning linked to current status and sales plans, manufacturing work order management, production progress management, material requirements planning, process status analysis, and manufacturing process management.
Quality process analysis through real-time process data collection based on OPC-UA
- Defining standard data collection protocols and protocols for each piece of equipment.
- Based on the collected data, establishing a management system for key indicators such as production performance efficiency analysis by process and quality standard deviation analysis using MR charts based on quality standards for each production item.
Integrated manufacturing execution support through logistics management optimization
- Establishment of a system for recognizing barcode and QR code images for real-time execution management of filling container inspection, inventory, and tracking, which are central to material receipt and shipment, shipping, and production LOT management.
- Introduction of an IoT operation system for real-time collection, monitoring, and trend analysis of temperature and humidity data, which are key management indicators for hazardous material storage warehouses (response to quality issues).
SPC establishment
- We aim to establish a management system and decision-making support system for analyzing aggregated data from sensing (weight, flow, pressure, etc.) during the manufacturing process, raw material import inspections, and sample analysis.
- We aim to establish an integrated management system for manufacturing execution data, analysis execution data, and quality issues to manage the current status of quality issues.
Establishment of a LOT tracking management system based on equipment data collection
- We aim to track material issuance based on manufacturing instructions and production process receipts, and to establish a LOT tracking system for finished product tracking by automatically generating LOTs upon production receipt.
- When quality issues arise, we aim to establish a system that can respond to quality issues by tracing the relevant LOT backward, tracking the period and process materials, and viewing the details.
Establishment of a manufacturing execution support and decision-making support system
- We aim to systematically manage specifications and approved quantities for strategic materials and hazardous materials.
- We aim to strengthen the linkage of manufacturing processes, taking into account international standards and certification validity periods.
- We aim to integrate order status and container certification information to predict container shortages in advance.
3. Effects of Smart Factory Construction
Shortening of order-to-shipment lead time
- 12 days before introduction, 8 days after introduction