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The fastener production workshop of a state-owned enterprise in southwest China has moved from the traditional production mode to a wonderful chapter of lean and intelligent manufacturing. Through the introduction of 15 V15F 'small lifting' forklift AGVs and intelligent dispatching system, the workshop has successfully opened up the logistics network of core production lines such as cold heading, hot forging, and heat treatment, realizing the efficient flow of materials in the whole process, and becoming a model of intelligent transformation in the industry.
Customer needs
With the intensification of market competition, the logistics mode of the traditional fastener production workshop has gradually exposed the low efficiency and high labor intensity of manual operation; There is a lack of unified scheduling of material flow between different production lines, and problems such as transfer delays and path conflicts often occur. In addition, enterprises lack real-time monitoring and analysis methods for production and logistics data, unable to accurately grasp the production progress and material status, and it is difficult to achieve lean management. The company urgently needed an intelligent logistics solution to improve logistics efficiency, reduce operating costs, ensure production safety, and optimize production decisions through data-driven.
Solution
According to the on-site investigation and communication, the intelligent logistics solutions planned by AGV Robotics for the state-owned enterprise include:
1. 15 V15F forklift AGVs at the hardware level
The introduction of 15 sets of V15F 'small lifting' forklift AGVs, these AGVs have strong load capacity and precise positioning functions, can adapt to the complex operating environment of the workshop, and undertake the loading and unloading of semi-finished products between cold heading production lines, hot forging production lines and heat treatment production lines, as well as the warehousing and delivery of finished products.
2. At the software level, deploy an intelligent scheduling system
The system acts as the central brain of logistics, using advanced algorithms to assign tasks and plan paths for multiple AGVs. The system collects information such as the location and task status of AGVs in real time, dynamically adjusts the operation plan, avoids path conflicts between AGVs, and realizes efficient collaborative operations. At the same time, the intelligent scheduling system is deeply integrated with the MES system of the workshop to break through the data barriers of production and logistics. The MES system monitors the production progress and material requirements in real time, and transmits relevant instructions to the intelligent dispatching system, which deploys AGVs to perform material transfer tasks. The data generated by AGVs during operation, such as material flow time and equipment operation status, is fed back to the MES system to provide support for production data analysis and decision-making.
Difficulty
1. Spatial planning problems
The internal space layout of the workshop is compact, with both fixed production equipment and frequent personnel, so it is difficult to plan the safe and efficient operation path of AGV to avoid collision with personnel and equipment.
2. Scheduling algorithm challenges
There are differences in the production rhythm of different production lines, and the demand time and quantity of materials for cold heading, hot forging, heat treatment and other processes are different.
3. System docking dilemma
The docking of the intelligent scheduling system with the existing MES system involves the conversion of data formats, interface development and compatibility debugging of different systems, which is prone to problems such as poor data interaction and system instability.
Benefits
1. Efficiency improvement
Under the command of the intelligent dispatching system, the rapid and accurate transfer of materials has been realized, and the logistics efficiency has been increased by 30%, effectively reducing the downtime and waiting time of the production line, and improving the overall production efficiency.
2. Cost reduction
The material loss caused by human operation is significantly reduced, and the precise operation of AGV avoids the bumping and falling of materials in the handling process, and the material loss rate is reduced by 20%, which directly reduces the production cost.
3. Safety guarantee
AGVs are equipped with a variety of safety protection devices, such as lidar and anti-collision touching, which can sense the surrounding environment in time and automatically stop when encountering obstacles, which greatly reduces the probability of safety accidents such as forklift collisions and cargo dumping.
4. Intelligent management
Through the collaboration with the MES system, the enterprise realizes real-time monitoring and analysis of production data. Managers can grasp the material flow, equipment operation status, production progress and other information at any time, which provides accurate data basis for production planning and resource allocation, and promotes enterprise production management to move forward in the direction of intelligence and leanness.