Sennics Deployed MES to Build Smart Factory

◎ Yang Honghui

In November 2017, “First Phase Project of Sennics MES System” was initiated in Anhui Sennics, in November 2018, the project was successfully implemented. As a pilot project of integrating IT information with industrialization, by deploying Honeywell Intelligent Production Management Execution System, Anhui Sennics not only realizes efficient production and operation management as well as intelligent production, but also improves excellent operation and profit-making capacity in an all-round way.

According to the requirements of information construction of Sennics, Honeywell provided its Tongling Factory with a whole set of production execution system solution. This solution can collect the distributed control system (DCS) data of the whole factory in a real-time way, integrate weighbridge data, SAP data, packaging and production data, quality data, etc. and build the whole factory data center and uniform information distribution platform to display the technological process control, quality testing data, production and operation conditions, production order completion conditions, inventory conditions, etc. of the whole factory in a dynamic and real-time way. Meanwhile, Honeywell Intelligent Production Management Execution System also connects SAP with production control system to realize unity of the whole operation process.

The journalist experienced the efficient production and operation management and intelligent production system in Anhui Sennics Factory.

In the entry and exit operation point, the entry and exit operation tasks of Sennics are automatically generated according to the purchase and sale arrangement, the large screen displays the operation status in a real-time way, the weighbridge is unattended, the system automatically recognizes the license plate number and has self-help weighing, the quality inspection task is automatically triggered, PDA realizes electronic signature, the entry and exit operation is self-helped throughout and completed all in one go.

In the input and output operation point, the warehouse automatically accepts the delivery tasks according to the sale arrangement, the operation arrangement is displayed on the large screen, and operation shall be carried out ac-cording to the large screen throughout. PDA automatically scans the code and picks the goods and confirms the packaged goods, electronic signature of the outputting driver is supported, the whole packaged product delivery business process realizes automation and transparency.

In the packaging line of finished products, packaging tasks are automatically generated according to the production orders; the completion status of the orders is displayed on the large screen and updated in a real-time way; additional code scanning system automatically counts; handheld PDA “delivers for inspection” independently; the order completion is automatically confirmed, reported and warehoused.

In Central Control Room, process indexes, abnormal warning, key production performance, operation status of key equipment and energy consumption are monitored in a real-time way; multiple large screens, like numerous sharp eyes, witness every action in factory production in a real-time way, a digital and transparent factory is clear at a glance. This Central Control Room was completed for use in May 2017, which facilitates the exchange and communication between the devices as well as the management of the management personnel. If one device has abnormality, relevant devices can quickly learn about it and timely give response.

“We implement Intelligent Production Management Execution System to create substantial value with an attitude of being responsible to the shareholders instead of showing it to the others. After MES was put into service, Anhui Sennics Factory realizes automatic information collection, the state of artificially collecting data in the past becomes history and the staff “reading the meters” are all ‘laid-off’.” Su Fu, deputy general manager of Sinochem International and CEO of Sennics, introduced that after the system was put into service, Anhui Sennics realized automatic material entry and exit operation, with the quality inspection efficiency improved by 30%, counting efficiency improved by 78% and labor cost for statistics lowered by over 60%.

“While helping Anhui Sennics to standardize the production operation, simplify production management process and improve the enterprise management efficiency, Honeywell Intelligent Production Management Execution System also improves the coordinated operation ability between various departments and posts to ensure smooth implementation of Pilot Informationization Construction Project of Sennics Intelligent Factory.” Su Fu expressed, improving “intelligent production capacity” in an all-round way was the core target of “smart factory” of Sennics, which, while getting through data transmission, further improved the visualization and standardization degree of business process, realized efficiency optimization, constantly promoted technical progress and innovative development of the enterprise by virtue of digitization and finally created larger value for the customers.

According to the information, at present, the internal management system, standard, process, etc. of three production bases of Sennics in China are consistent. In this March, the Second Phase Project of MES System of two factories, Tai’an Sennics and Shandong Sennics, was initiated, and planned to be put into service in August and October respectively.