I. Corporate Profile
Founded in 2002, Nanjing UBE Electric Technology Co., Ltd. is a national standard chief editor unit of R&D and manufacturing of intelligent safety instrumentation products, and a leading enterprise in domestic technology and market, with its products widely used in petrochemical, metallurgy, electric power, and other industries, and has made outstanding contributions to a number of major strategic projects of the country. The enterprise invested and constructed an intelligent factory in Jiangning Development Zone in 2021, which has been awarded by the Ministry of Industry and Information Technology of the Ministry of Intelligent Manufacturing Excellent Demonstration Scene, National Digital Transformation Training Base and other awards.
II. Key lessons learned from the "smart change to digital to online" approach
First, the enterprise planned the overall program of digital transformation based on specific strategic development and operational objectives, with cost, quality and efficiency at the core.
✦ During the construction of the new factory, a large number of robot debugging and assembling, intelligent stand-up storage and other intelligent equipment were applied to save labor and improve production efficiency;
✦ In terms of digitization, digital design software such as Altium and Solidworks are introduced at the R&D end, and information integration is formed with the enterprise's ERP, MES and other software, and an integrated R&D-manufacturing network system has been realized through the deployment of the industrial Internet and private and hybrid clouds;
✦ In terms of resource optimization, a mathematical model is established for all production resources, and the discrete events of each production element and production process are modeled, providing the optimal solution of production efficiency through virtual simulation and digital twin technology, and realizing the optimization prediction before going into production.
At the same time, relying on 5G, industrial PON, TSN and other network communication technologies, a low-latency, highly reliable Internet of Things (IOT) system has been established to achieve full connectivity for all production equipment in the workshop, and the motion signals and equipment operating parameters of each device are integrated with the digital twin system, which realizes data mapping between the physical and the virtual and reaches the ability of dynamic optimization.
III. Main results
Through the construction of the intelligent factory, a significant reduction in production personnel, from 87 people in the past to the current 40 people, this saving labor costs of about 4.7 million yuan / year; raw materials, finished products, semi-finished goods inventory funds to reduce the 20%, about 5.5 million yuan; to improve the efficiency of R & D 30%, this annual reduction of R & D expenditure of about 2.5 million yuan; to reduce the waste of raw materials, energy consumption and so on about 2 million yuan/year.
