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In the construction of smart plants, automatic packaging production lines are a key link to the lower line of the front-end production line and the back-end automated high-bay warehouse. Many enterprises have a problem in building the packaging line: how to achieve a seamless interface between the packaging line and the front-end line, the back-end automated high-bay warehouse, and avoid the emergence of "information island" and "logistic breakpoints"? This paper analyses the path to integration of the production warehouse from four dimensions in detail.
Mechanical transport docking is the basis for the integration of the production warehouse, whereby the forward-end production line, the packaging line, the back-end automated high-bay warehouse is physically connected by the delivery equipment, resulting in the automatic flow of materials.Front-end ConsoleWhen a packaging line feeder ends directly connects the lower end of the production line through a barrel, belt or chain board conveyor line, and automatically enters the packing line sorting process after the product is offline and does not require manual handling;Centre Connection(b) Automatically connect the product through the transmission line between the various processes within the packing line (sorting, packing, sealing, labelling, packing, membranes, coding) and automatically flow between the processes;Backend ConsoleThe finished packaged finished product is automatically transported through the conveyance line, back-up lift, AGV, etc., to the automated high-bay warehouse entrance, and automatically into the WCS system;Crossing the floor.In the case of multilayered plants, the automatic trans-shipment of materials across the floors is achieved by moving to a back-up or continuous lift, and the production, packaging, storage and storage areas of different floors are accessible.
The control system interface is at the core of the integration of the production warehouse, which will result in the automation of the entire process by connecting the front-end production line, the packing line, the transport line, the automated high-bay warehouse equipment through a unified control system.Unified PLC controlEquipment such as packing lines, conveyance lines, lifters, etc., uses a unified PLC control system, which communicates between equipment via industrial Ethernet or on-site bus to achieve signal interaction and connection control;Movement of WCS equipment(c) Stereoster WCS (equipment control system) is responsible for tasking and routing of warehousing equipment such as stacker cranes, shuttles, transmission lines, sending requests to WCS upon completion of packing line completion, and automatically assigning WCS duties to the library and dispatching equipment for execution;Security link.Security locks between equipment, such as an automatic stoppage of back-end equipment when the front-end equipment fails, an automatic stoppage of equipment when a person enters a hazardous area, an automatic alarm stoppage when the equipment is overloaded, etc., to ensure the safety of all process operations;Synthetic synergy.The control system adjusts the speed of the equipment according to the operation of the chain to match the production line, the packing line, and the warehouse, so as to avoid a single link becoming a bottleneck. The control system interface requires a unified planning of communication protocols, signal definition, control logic at the programme design stage to ensure that the systems of the various equipment manufacturers are compatible.
The information system interface is the soul of an integrated warehouse that enables the real-time collection, transmission and sharing of all process data through the information system connectivity, breaking down the "information island".MES docking.The packaging line control system is interfaced with the enterprise MES (manufacturing implementation system) and receives information on the production orders issued by MES, product specifications, packaging requirements, etc., and transmits back to MES the data on the quantity of finished packaging, the results of the mass inspection, the state of equipment, etc.;WMS docking(c) Packaging lines are interfaced with the 3D WMS (storage management system), the self-generated inventory form is generated upon completion of the finished packaging, the WMS automatically allocates the stock position and the WMS automatically updates the inventory data upon completion of the inventory;ERP dockingWMS interface with Enterprise ERP systems to synchronize inventory data, procurement data, sales data and provide accurate data for enterprise management decisions;Retroactive system dockingAn information system interface requires clear specifications, data formats, communication protocols for each system, and recommends the use of a standard API interface to ensure the stability and scalability of the system interface.
The rhythm matching is key to the integrated and efficient operation of the warehouse and requires a comprehensive matching design based on the upstream production line capacity, packaging line capacity, and access to the reservoir to avoid a certain chain becoming a bottleneck.Production MatchPackaging line capacity needs to be greater than or equal to the lower of the upstream production line and automated high-bay warehouse capacity needs to be greater than or equal to the output of the finished product of the packaging line to ensure that the entire process is free of backlog and waiting;Buffer Design(c) A buffer line or a cache at each link to deal with instant-temporal fluctuations at each link and to avoid full-line stoppages due to a short pause at one link;Redundancy designKey equipment is proposed to be equipped with some redundancy capacity, such as multiple stacker cranes, multiple transmission lines, and other equipment to continue to operate in the event of a single equipment failure, thereby improving the reliability of the entire line;Smart SchedulerThrough the WCS Smart Movement Control System, tasks are assigned according to the operational state of the chain, optimize the equipment's operating path and improve the efficiency of the whole line. The meta-matching requires a system simulation at the programme design stage, simulation of the operational status of the chain, and validation of the viability and efficiency of the programme.
This post is part of our special coverage Syria Protests 2011.Automated Packaging Line The seamless interface with the front-end line, back-end automated high-bay warehouse requires integrated design matching four dimensions, from mechanical delivery, control systems, information systems, and metrography. It is recommended that the enterprise select, at the project planning stage, a supplier that can provide an integrated overall solution to the production warehouse, from the programme design stage to integrate all aspects of planning machines, controls, information, metrology, etc., and avoid the emergence of "logistic break points" and "intelligence island" at a later stage, in order to truly achieve a fully-processed, digitized, intelligent operation from the bottom line to the finished-goods warehouse.
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