Hengshun Vinegar Industry —— Benchmark of Intelligent Construction of Traditional Industries

Guided reading (text/electronic works in Huang Pei, Xu Zhiying, Zhang Hefang)

Jiangsu Hengshun Vinegar Co., Ltd., founded in 1840, is a "Chinese time-honored enterprise" with a history of 180 years. The company conforms to the requirements of the times and leads the development of enterprises with the latest technology.

This article is selected from Practical Guide to Intelligent Manufacturing (author: Huang Pei, Xu Zhiying, Zhang Hefang), which is being edited and will be published soon.

0 1

brick by brick

Create a benchmark for industry transformation

On the basis of comprehensive investigation of the development status at home and abroad and the development needs of the enterprise itself, Hengshun Vinegar Industry actively explores the development trend of the industry, closely follows the development trend of the world, comprehensively launches the vinegar brewing intelligent factory project based on the industrial Internet, uses intelligent manufacturing to break through the data barriers of all links, realizes real-time and accurate control of the whole process, drives production operation management with big data, and provides "whole process" data traceability service for product safety production. It provides strong support for improving the "intelligent brewing" level and food quality and safety guarantee ability of enterprises and the same industry, and realizes the breakthrough and upgrade of the traditional production enterprise's two-in-one integration application mode.

Strive to build a first-class intelligent demonstration factory in domestic brewing industry, explore the feasible way for traditional brewing enterprises to implement intelligent manufacturing, and form a set of mature brewing intelligent factory construction scheme, which will provide reference and demonstration for the integration of industrialization and modernization of traditional condiment industry in China.

The vinegar brewing intelligent factory project based on industrial internet is mainly divided into three stages, namely, the application of intelligent equipment, the establishment of intelligent and information-based intelligent management platform and the promotion of industry standards, so as to promote the development of the industry through the improvement of its own intelligent manufacturing level.

The first stage: the intelligent control system of brewing production line consists of information system and advanced production equipment.

Using information system and advanced production equipment, the intelligent management and control system of brewing production line is established to ensure the stable operation of key technological links. Through the production management MES system, the process parameters and energy consumption parameters of the production line are monitored, recorded and analyzed, and the functions of production process monitoring, quality analysis and equipment performance analysis are realized.

The second stage: integrate BOM, MES, ERP, TMS and other systems to build an intelligent management platform for Hengshun intelligent integrated information.

We will integrate BOM, MES, ERP, TMS and other systems to build a Hengshun integrated information intelligent management platform to realize data sharing-the production management can know the current source of raw materials, inventory status and order status; The management of the company can master the data of new product development, material supply, production, inventory, logistics and sales. Break through the data barriers in all links to achieve real-time and accurate control throughout the process.

The third stage: compile the intelligent standard of the brewing industry and promote it to the whole industry.

Through cooperation with government departments, relevant professional institutions and scientific research institutes, the experience of the project of "Food Brewing and Brewing Smart Factory" was sorted out and summarized. Combined with the integrated management system of the Ministry of Industry and Information Technology, the relevant standard system of intelligent manufacturing in the brewing industry was accelerated and promoted to the whole industry.

02

Full deployment

Promote the intelligent upgrading of traditional manufacturing industries.

Hengshun Vinegar Industry established an intelligent factory management and control system based on industrial Internet by building an intelligent vinegar brewing factory based on industrial Internet.

1) Digital Central Station in Enterprise

Through the data modeling of business intelligence (BI) system, cross-domain data integration and knowledge precipitation can be realized; through the standardized data exchange platform, data encapsulation and opening can be realized, so as to meet the needs of upper-level applications such as ERP, WMS and TMS quickly and flexibly; through the mobile display of SFA system, the requirements of personalized data and applications based on the Internet can be met, thus strengthening the digital processing capabilities of the company's internal technology undertaking, business leading, specification definition construction and global connectivity extraction.

Figure 1 Hengshun Vinegar Sales Cockpit

Figure 2 Hengshun Vinegar Logistics Debugging Center

2) Industrial Internet data platform

Through the data collection of key production control points by the marginalized intelligent computing gateway of the Internet of Things, we can make full use of historical and real-time data to realize centralized management of production data, dig deep into data value, and finally effectively manage and utilize enterprise data assets to realize intelligent production.

Figure 3 Real-time monitoring of Hengshun soy sauce workshop

Figure 4 Real-time monitoring of Hengshun mature vinegar workshop

3) Logistics information management system

After obtaining the order data, the logistics information system automatically optimizes the transportation route and stowage mode according to different modes of transportation, such as vehicle, single container and LTL, and the system automatically settles the freight after the customer confirms the receipt. In this whole process, from ordering sales to goods being delivered to customers, no one is on duty. Since the operation of the system, the order processing time has been reduced from 5 days to 2 days, and the checkout cycle has been reduced from 15 days to 7 days, and the logistics carrying capacity has doubled.

4) Intelligent mobile marketing system

SFA system is applied to marketing terminal. Through the deployment of cloud computing platform based on SaaS, the supervision of market display information, promotion activities, competing products information and salesmen has been realized, and the communication with customers has also been strengthened. At present, the system has covered 25 offices, more than 600 salesmen and 65,438+more than 10,000 terminals.

Figure 5 Full Intelligent Verification

Figure 6 Commodity Count

5) automatic three-dimensional altar library

2065438+In May 2009, we invested nearly 50 million yuan (including capital construction) to build a new 2000-square-meter automatic three-dimensional altar library. Tanku consists of three-dimensional shelf, master-slave vehicle system, conveying system and WCS control system. The warehouse * * * has 10659 pallets, with a maximum storage capacity of nearly 5,500 tons of high-end vintage vinegar and a maximum storage capacity of 200 cans per day, which is nearly 10 times higher than the existing manual storage efficiency.

Fig. 7 Automatic three-dimensional altar library

6) Intelligent fermented grains turning machine

The intelligent distiller adopts the automatic temperature measurement function and the multi-point temperature measurement strategy of the cross section of the material pile, and sends the measured parameter information to the intelligent distiller console through wireless communication. The console adjusts the technological parameters of the distiller according to the temperature distribution model, and automatically starts the distiller to work, thus rationalizing the whole vinegar fermentation.

Fig. 8 Intelligent fermented grains turning machine

7) Intelligent vinegar brewing machine

Intelligent improvement in the whole process of vinegar brewing, automatic feeding and discharging. The fermentation tank rotates instead of turning over the fermented grains, monitoring the physical and chemical indexes of fermented grains, and automatically collecting the physical and chemical indexes in the fermentation process. Intelligent analysis, deep learning and intelligent control are carried out according to the fermentation model. Greatly reduce labor intensity, improve production efficiency and ensure stable product quality.

8) Industrial intelligent robot

In-depth cooperation with internationally renowned companies such as KUKA, ABB and FANUC. A large number of industrial intelligent robots are used in the production line, and the automation transformation of the original equipment has greatly improved the automation control degree of the workshop. The automatic data acquisition rate and automatic control putting-in-service rate of the workshop production process data have reached more than 95%.

Fig. 9 industrial robot application

9) Machine vision inspection system

Cooperate with internationally renowned companies such as HEUFT, cognex, DATALOGIC, etc., fully apply the machine vision inspection system, and safely identify the bottle body, trademark, liquid level, bar code and other quality control elements, which significantly improves the inspection speed and accuracy of the production line. Through the linkage with the automatic rejection system, the possibility of human error was eliminated, and the defective rate decreased from 0.2‰ to 0.0 1‰.

Figure 10 Machine Vision Inspection System

10) intelligent three-dimensional warehouse

Cooperate with domestic manufacturers to build 3,000 intelligent three-dimensional warehouses, including five lanes, 10 rows of shelves and five stackers, with a storage capacity of 55,000 boxes/day, and the efficiency is improved 100%.

Figure 1 1 Intelligent Stereo Warehouse

1 1) full life cycle product traceability system

Applying the whole life cycle product traceability system and intelligent visual identification system, each product is given a unique traceability monitoring code compiled according to international coding rules. The products are given numbers and barcodes by means of spray printing and labeling, and relevant information is collected by visual recognition and stored on the network, so as to realize the fine control of product circulation and logistics information.

Figure 12: Numbers and barcodes are assigned to products by spray printing and labeling.

12) smart microgrid

A new 300KW intelligent energy storage system is constructed, which consists of battery energy storage system, control system, monitoring system and energy management system. Among them, the control system can realize remote control of distributed power supply, load device and energy storage device, the monitoring system can comprehensively monitor the real-time operation information and alarm information of distributed power supply and make statistics and analysis in all aspects, so as to realize all-round control of distributed power supply, and the energy management system can control the smooth output and energy economic dispatch of distributed power supply.

Figure 13 Energy Management System of Reservoir Power Station

13) intelligent photovoltaic power station

In the "Golden Roof" project, the company used idle roof resources to implement distributed photovoltaic power generation, promoted energy conservation and emission reduction, and built a 4.5MW photovoltaic power station with a roof area of 56000m2. 2065438+August 2006 has been connected to the grid for power generation, with an average annual power generation of about 2120,000 kW·h, which can save 765t standard coal and reduce CO2 emission by 2 1 17t per year. Through the mode of "spontaneous self-use, surplus electricity goes online", the company's electricity price drops by 15% on the basis of the State Grid.

Figure 14 electricity bill and electricity bill analysis

Generally speaking, Hengshun vinegar brewing smart factory based on industrial internet drives production and operation management with big data, breaks through data barriers in all links, builds a digital data platform of China and industrial internet within the enterprise, and applies intelligent equipment (intelligent vinegar brewing machine, intelligent turnover machine, etc.), mobile marketing, industrial robots, three-dimensional warehouses, machine vision inspection, intelligent microgrid, intelligent photovoltaic power station, etc. To realize the operation monitoring and control of the production process.

The production efficiency of enterprises has been greatly improved. The output of Class A products increased by 22%, and the unit comprehensive cost decreased by 2%. At the same time, the real-time monitoring of various data trends is realized, which provides accurate data analysis for decision makers and greatly improves the management level of the company.

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