1. Case Basics 
Case Title: zhejiang Sanhe Kitchenware Co., Ltd. | MES + WMS Internet of Things Digital Factory Landing Case 

Customer Name : Zhejiang Sanhe Kitchenware Co., Ltd. 

Industry : Metal cookware manufacturing (stamping and stretching, die casting, surface painting, hardware assembly)

Enterprise scale : medium-sized manufacturing leading enterprise with more than 2000 employees, national 5G factory 

Project cycle 2022: April-January 2024 (about 21 months, four-stage implementation)

2. Customers' original pain points 
According to the actual investigation of Sanhe kitchenware workshop, the original pain points are mainly concentrated in the following four aspects:

Production pain point : there is no standardized control in stamping/die casting process, and manual recording of process parameters is easy to be distorted; Die maintenance relies on paper ledgers, and there is no automatic warning for die closing life. The production plan is out of touch with the on-site execution, the waiting loss for line change is high, the batch plan achievement rate is less than 40%, and the whole process production cycle is 45 days.

Logistics/storage pain point : multi-base semi-finished products circulation progress cannot be visualized in real time, and cross-workshop material transfer depends on manual forklift. Handwriting of labels is chaotic, pan substrates and coating batches cannot be accurately bound, inaccurate inventory data, purchased parts inventory turnover up to 12 days, inventory turnover days up to 65 days.

Quality/traceability pain point : the tensile deformation of cookware, coating shedding and other defects depend on manual paper inspection, with frequent missed inspections; Rework of defective products, wireless upper closed loop, BOM quality loss rate as high as 3%; there is no electronic full-process quality traceability system, cost accounting only to the product level, can not accurately locate production losses.

Management/system pain points : relying on empirical extensive management, equipment, production and quality data have serious isolated islands; Statistics, reports and other indirect personnel repeat heavy workload; Multi-systems are not interoperable, the data of hydraulic press, spraying line, AGV and other equipment can not be automatically collected, and the digital foundation is weak. 

3. Our solution :  this project deploys Ruihui intelligent MOM manufacturing and operation management system, with a total of 14 core functional modules, to create an [integrated solution for production and marketing coordination and manufacturing execution], covering the whole process from supplier coordination to finished product warehousing, and realizing digital closed-loop control of the whole process.

Deployment system :MOM manufacturing operations management platform, covering 14 core modules: factory modeling, planning management, workshop management, quality management, E-SOP electronic operation guidance, WMS warehouse management, lamp anomaly management, equipment management, IOT equipment networking, mold management, employee management, supplier portal, system integration, report center.

Hardware configuration :BN102 data acquisition terminal (covering 156 points in molding, packaging, painting and other workshops), IO relay, smart meter, the docking equipment category covers the whole workshop production and logistics equipment such as hydraulic press, spraying line, AGV, warehouse, robot, etc.

Implementation content : Implement in four stages without stopping production. In the first stage, the supplier portal, WMS and MES of the molding workshop will be launched. The second stage is extended to internal and external spraying and precision packaging workshops. In the third stage, the overall MES and WMS of the new factory will be landed. In the fourth stage, the intelligent logistics section will be launched to complete AGV, warehouse integration and plan optimization.

System integration : pull production with production plan and material set, link purchase order and daily material arrival plan, through basic data standard cleaning, abnormal active warning, multi-system deep integration, realize the transformation of the factory from empirical management to digital fine management. 

4. Project implementation effectiveness : the following data are based on the actual operation data of the system kanban and the design objectives of the project plan:

Efficiency class : the batch plan achievement rate is increased from less than 40% to more than 80%; the production cycle of the whole process was shortened from 45 days to 30 days (the core process was shortened to 25 days), and the overall reduction was over 30%. The overall production efficiency of the packaging line increased by nearly 40%. The overall utilization rate of equipment (OEE) increased by 7-8%.

Quality class :BOM quality loss rate decreased from 3% to 1.5, production quality loss halved; The first inspection failed to prohibit formal start-up to prevent batch quality abnormalities; to achieve the whole process of electronic quality traceability, bad root causes can be accurately positioned.

Cost category : the overall inventory turnover days decreased from 65 days to 40 days; the inventory turnover days of purchased parts were reduced from 12 days to 4 days, and the inventory and sluggish materials decreased significantly; cost accounting has been upgraded from monthly average sharing at the product level to actual cost accounting at the work order level.

Management class : statistics, reports, data transcription and other indirect personnel repeat workload reduced by more than 80%; The lamp installation event is automatically pushed to the DingTalk/enterprise WeChat group, and the alarm is automatically upgraded over time, realize the active management of "looking for people. 

5. Case Highlights the following are the core values and innovations of this project:

Full-module MOM platform coverage, creating end-to-end digital benchmark for cookware industry :14 major functional modules deeply adapted to the cooking utensils industry stamping molding, internal and external spraying, precision polishing, assembly of the whole process characteristics, and finally successfully awarded the national 5G factory, become the domestic cooking utensils manufacturing industry digital transformation sample.

Iteration without stopping production in stages, the risk controllable effect can be quantified : from the single-point pilot verification effect in the packaging workshop, it is gradually extended to the molding, spraying and finishing workshops, then cover the new factory and intelligent logistics plate, the whole process does not affect the normal production, each stage has a clear and quantifiable landing effect, the implementation risk is controllable.

Active management of "looking for people", closed loop of abnormal whole process : through task-driven + multi-channel message notification mechanism, realize production, quality, equipment abnormal active early warning, classification processing, overtime upgrade, closed-loop tracking, instead of the traditional manual follow-up passive management mode, abnormal response and processing efficiency greatly improved.