CRC Bogie Manufacture Center The MES Improved Program Based On Enterprise Resource Planning

The running reliability and safety of railway vehicles are embodied in bogie quality, which therefore is significantly important. With the growth of company market share and growing number of projects, the production management becomes more and more complex that created plan cannot satisfy practical production needs and production cannot be planned in balance. due to the fact that the workshop production scope is big, each workshop is not clearly aware of the processing and equipment running status of last step, equipment failure or a bottleneck production step may lead to production delay and make production forecast and proper production arrangement impossible and further lead to a production management chaos, low realization of production plan and failure to reaching customer requirement.Production manager cannot accurately and timely acquire production information of processing facilities and abnormal information of each producing parts during its production process and cannot setup proper and quick solution against abnormal disturbance of production site, so the production cannot run fast and orderly.Therefore, the needs of detail and accurate planning scheduling, operation coordination, production track, field stock management, material management, ration management of fixtures and tools, and equipment management forces CRC Bogie Manufacture Center to introduce a workshop-level information management system. Therefore the MES is introduced. The MES is required to timely give feedback on production information on-site, acquire production progress and status of each step, provide alarming mechanism for obvious abnormity to enable the manager to find and solve abnormity quickly according to system messages so as to cause no production delay. The system is required to have tracking function that contains information regarding material origin, manufacturing staff and inspection staff. In case of a quality problem, the system shall be able to track and find relevant person and company liability. The system shall be capable of material management that clearly record stock information of each part in each workshop and center and record warehouse material shortage status. The system shall be capable of equipment management that manages operation, repair and maintenance status. When there is any facility needs inspection, the system shall give early warning to try to cause no impact to normal production.The paper describes the MES system implementation in Bogie Manufacture Center mainly from two aspects. Firstly, field production status tracking system. The system mainly tracks production status, abnormal situation of each single component of bogie, material and operators. By such tracking system, people can acquire field production status, abnormity and production progress of each step in each workshop and get knowledge about practical production capacity of each step, including: overall capacity factors such as practical processing man-hour, material transfer man-hour, facility status and capacity, work group capacity and especially about practical operation capacity of bottleneck section, so that detect and deal with problem tendency in advance or find and tackle with problems timely to avoid further expansion. Meanwhile, the tracking system will enable automatic production completion report to SAP system based on basic data collected by tracking system, statistically collect field data, correct data in SAP system and provide basic data for scheduling system. Secondly, scheduling system. This system setup different kinds of binding regulations, then schedule the production plan based on finite capacity principle so as to compensate the shortcomings of SAP such as inaccurate scheduling based on infinite capacity principle, and increase feasibility of production plan. The scheduling result based on finite capacity is closer to practical status of workshop, more time-bonded and can guide production more accurately and so balances production, increase production efficiency and satisfy customer requirement.Owing to great amount of production parts and big production scope of Bogie Manufacture Center, the overall MES system is expected to be implemented in phases to reduce risk. The scope of the first phase is as following: implement workshop field production status tracking system, realize workshop production status track and material and staff management. In the second phase, the scheduling system will be implemented. The scheduling system will be implemented based on experience and date accumulated during the first phase. In this way, the effect of the program will be present quickly; the production can run in normal, the system works even well and meets practical needs will be met.