Discussion on the problems and solutions of ERP in

2022-08-12
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A preliminary study on the problems and solutions faced by ERP in process industry

preface

at this stage, a key point of domestic manufacturing informatization construction is to use enterprise resource planning (ERP) to realize enterprise management informatization. Process industry is a very important basic pillar industry in the development of national economy and an important part of manufacturing industry. From the perspective of information integration, there are two common problems in domestic process industry ERP at this stage: first, the process industry is mostly asset intensive industries, which are highly dependent on equipment. However, the current general deficiencies of domestic ERP products in equipment management make many process industry enterprises still use manual equipment management, or specially developed enterprise asset management system (EAM), The equipment management system cannot be integrated with ERP system; Second, although basic automation systems are widely used in the process industry, the data in these systems usually exist independently and cannot be shared, and there is a common problem that the ERP system information of the control layer and the planning layer cannot be integrated

1erp/eam, the basic concept of MES

1.1 the concept of ERP

erp (Enterprise Resources Planning), which can be defined from three levels: management idea, software product and management system:

1.1.1 is a set of enterprise management system standards proposed by Garter Group Inc., a famous American computer technology consulting and evaluation group, Its essence is a supply chain oriented management idea further developed on the basis of MRPII (manufacturing re sources planning)

1.1.2 it is a software product that comprehensively applies the achievements of the information industry such as client, Yuegen server system, relational database structure, object-oriented technology, graphical user interface, fourth generation language (4GL), network communication, and takes e as the soul of the RP management idea of load sensor or pressure sensor because the force value detection element selected on the current experimental machine is fundamentally the load sensor or pressure sensor

1.1.3 it is an enterprise resource management system that integrates enterprise management concepts, business processes, basic data, human and material resources, computer hardware and software

As an integrated application, ERP covers all aspects of enterprise business activities. Using this application system, enterprises can replace many single and unrelated business information systems in an integrated way, and seamlessly connect the business information generated in the enterprise's procurement, inventory, manufacturing, sales, equipment, finance and other business links, so as to improve the operation efficiency of enterprises, Improve the operation effect of enterprises

1.2 the concept of EAM

the output and quality of products in process industrial enterprises have a great relationship with whether the equipment can operate normally without interruption. Its production cost also has a great relationship with the repair and maintenance costs of production equipment and the amount of working capital of enterprises occupied by spare parts inventory. The level of equipment management greatly affects the benefits of such enterprises. Therefore, the information management of asset maintenance, maintenance and tracking is particularly important

enterprise asset management (EAM), that is, enterprise asset management system, is mainly applicable to asset intensive enterprises. Aim at improving asset availability and reducing enterprise operation and maintenance costs, EAM takes optimizing enterprise maintenance resources as the core, and reasonably arranges maintenance plans and related resources and activities through information means, so as to improve the economic benefits and market competitiveness of enterprises. From the perspective of ERP, EAM can be regarded as a subset of ERP

1.3 concept of MES

mes is a three-tier enterprise integration model proposed by American advanced manufacturing research (AMR) in the 1990s. This model defines MES as "a workshop oriented management information system located between the upper planning management system and the lower industrial control". MES provides operators and managers with the implementation of plans Track the current status information of all resources (people, equipment, materials, customer requirements, etc.)

2 main problems faced by ERP projects in the process industry at this stage

from the perspective of information integration, ERP projects in the domestic process industry are currently facing two important problems:

2.1 due to the generally weak function of domestic ERP products in enterprise asset management, many process industry enterprises that have implemented ERP still use manual equipment management or specially developed equipment management systems, Unable to integrate with the ERP system implemented by the enterprise

2.2 basic automation systems such as automated production equipment, automated detection instruments, automated logistics transportation and storage equipment, and automated control are widely used in the process industry. Although they can replace a lot of manual labor and solve some production bottlenecks, due to the lack of corresponding information integration systems, the data in these systems exist independently and cannot be shared, forming the so-called "automation island", Its function has not been brought into full play

from the perspective of enterprise information integration, as an upper planning system, there is a fault between ERP and the lower control system, which makes it difficult to integrate planning and manufacturing processes, and affects the real-time performance of enterprise planning and the agility of enterprise management

3 preliminary discussion on the solutions to the problems faced by ERP projects in the process industry

3.1 ERP projects in the process industry should adopt the solutions including EAM

during the implementation of ERP system in the process industry, we should focus on the content of enterprise asset management (EAM). The basic structure of the equipment management system in the process industry ERP system should include the following aspects:

basic data maintenance part: it is used to define the basic data of equipment such as logical location and physical equipment, the basic data of equipment structure establishment, and the basic data that equipment maintenance should include

work order management: including work order generation, work order preparation, work order planning and scheduling, work order implementation, reporting and closing, and work order cost analysis

predictive preventive maintenance: including time-based preventive maintenance, event based preventive maintenance, state based predictive maintenance, and preventive maintenance based on overhaul lines

equipment management analysis: including equipment comprehensive performance (OEE) analysis and cost analysis

at the same time, it needs to include the interface between ERP system and underlying equipment monitoring system, as well as the interface between equipment management and inventory, procurement, human resources, finance, manufacturing and other modules

3.2 the integration of management and control with equipment monitoring as the core is the key and shortcut to the construction of MES in the process industry at this stage

the process industry can use MES as a bridge to realize the integration from the planning level, to the workshop operation level, and even the bottom control level. There are two main problems to be solved in the construction of MES in process industry. One is to establish the production process model and convert the production plan and production specification of ERP into the set value of process control; The other is to summarize, analyze and summarize the data of workshop operation and feed it back to ERP system. MES can solve this problem by providing ERP with real-time information of workshop

at this stage, the integration of management and control with equipment monitoring as the core is the key and shortcut to the realization of MES in process industry. At present, as a software product, MES is still in the primary stage of development compared with ERP and industrial control software, and there are few general and mature products. However, as a demand, MES is urgent. Moreover, for the process industry, the successful application of MES is, to some extent, one of the key links for the success of enterprise informatization

the production process of process enterprises varies greatly, and the setting of technological process is also very complex. To establish a process model completely corresponding to the actual product technological process, and "translate" it into relevant automatic control equipment to set parameters and set parameters, its technical complexity is huge, and the implementation cost is also very high. Coupled with other factors such as information security, from the perspective of reality, It is quite difficult to realize this process

however, the management and control integration with equipment monitoring as the core is quite realistic, and its operability is also very strong. Tensile strength, compressive strength, arbitrary point elongation strength, arbitrary point load extension, elastic modulus, elongation, stripping interval process or stop curve comparison, curve amplification

first of all, centralized equipment status monitoring is technically mature. Modern DCS is becoming more and more powerful, and the process visual configuration tool provides rich monitoring means, which can be set according to the needs of production and operation management, making it possible for production and management personnel to understand the real-time production situation and control the production in real time; In addition, modern DCS generally provides standard data interfaces to facilitate data export. It is also feasible to monitor the SPLC monitoring points of DCS subordinate computers of various manufacturers on a centralized platform

secondly, it is economically feasible to build an MES with centralized equipment status monitoring as the core. The emergence of general dynamic data server software means that the cost is reduced. When this core technology is no longer a bottleneck, the cost must be greatly reduced

the key content of MES development with equipment monitoring as the core includes at least powerful data acquisition interface, rapid response production scheduling, real-time quality control, dynamic equipment operation status monitoring, real-time production cost accounting, etc

4 conclusion

the ERP solution of process industry should take EAM as an important part of the solution, which has greater advantages than adopting independent EAM. Such an EAM system can standardize the management of basic data and technical archives of enterprise equipment, reduce inventory investment, improve procurement efficiency, prevent shortages, allocate human and other resources more effectively, manage failure history, track equipment changes, standardize operation process, improve management efficiency after use, promote the implementation of maintenance and safety regulations, improve the availability and reliability of equipment, and reduce equipment downtime, Reduce equipment maintenance costs, reduce production costs, provide communication interfaces with underlying equipment, realize equipment status monitoring, provide effective equipment management performance analysis tools, and evaluate enterprise asset management level

but even if the equipment management module is added, ERP only manages the equipment as a resource. As for the integration with production planning, at most, it is to consider the equipment maintenance in terms of capability calculation. For the process industry, the equipment management module using MES not only manages the whole life cycle of equipment in a practical sense, but also closely connects equipment management with monitoring and production process, production process, safety, fault diagnosis, early warning and even cost control, so it is closer to the essence of equipment management and the goal of equipment management. In this sense, the solution of using MES and ERP integrated process industry equipment management is a solution with strong practical significance. The equipment management module of MES is connected with the ERP equipment management module, which can provide real-time equipment management based on status monitoring. With equipment status monitoring as the core and management and control integration as the main content, MES will be able to solve production process control, production process control, safety Fault diagnosis, early warning, and even real-time cost control. The continued boom of downstream industries has driven the rapid development of composite polyurethane adhesive industry (end)

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