Application of lighting system for the hottest mat

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The material safety light system application

the material safety light system can be established on the basis of the quality safety light system. It is an auxiliary system that installs a certain number of material call request buttons next to the production station, sets up information display boards in the workshop site and the material storage area, feeds back the material call request on the production line in real time, and indicates and assigns the feeding task. By sharing network, data server and other hardware systems, we can reduce the investment cost and maximize the benefits. The whole process of the material lighting system: materials are classified according to the number of packages, and materials of different sizes use different calling methods. As long as the remaining quantity of materials beside the assembly line reaches the trigger condition (i.e. the minimum remaining quantity), a material demand call is sent in time, which is transmitted to the data server through the network, processed by the system and automatically allocated to the appropriate material distribution personnel. The material distribution is to avoid the timely organization of material distribution online by personnel due to impurities such as water. After the distribution is completed, the corresponding call information is reset to complete one-time distribution; The system will record and analyze the time, place and response to each material request in real time

system hardware configuration

logistics lighting system can be divided into wired and wireless according to different functions and implementation methods: all information transmission of wired lighting system is realized through wired networks throughout the workshop; In wireless lighting system, information transmission is realized through wireless network and wireless communication; Between these two methods, that is, both wired and wireless networks, we call it quasi wireless lighting system. Due to space limitations, only the wireless lighting system will be described here. The network topology of the quasi wireless material lighting system is shown in Figure 1

since the position of the station is relatively fixed, we use the wired method to transfer information from the station material call button to the warehouse server computer; The distribution trolley (including forklift and tractor) moves around the workshop, so we use wireless network for information transmission from the distribution trolley to the system server. The system is divided into three layers:

1 Line side call button

the line side is equipped with call buttons for some relatively large materials, and each button corresponds to a material. The on-site button is linked to the existing PLC in the nearby equipment and enters the original network of the workshop through the PLC; This not only achieves the goal of joint operation, but also maximizes the use of the original equipment in the workshop and reduces the investment cost of the system

2. Distribution trolley information receiving and monitoring terminal

each material distribution trolley is equipped with a monitoring terminal equipment (generally industrial display) and a set of wireless signal receiving device

3. The material storage area is equipped with a data server and a monitoring and alarm system, and a wireless signal transmitting device is added to complete material calling, data processing, information sending and receiving, data sorting and archiving and other related functions

Figure 1 network topology of quasi wireless material lighting system

the advantage of such a quasi wireless lighting system architecture is that it not only ensures the stability of information transmission between the station and the material warehouse (the signal stability of the wired network is much greater than that of the wireless network), but also takes into account the function of moving and receiving information of the feeding trolley, which can be said to be the most perfect configuration

the process of information transmission is as follows: the material demand is triggered by manually pressing the line material call button, or the system judges by itself that the amount of the remaining line material is a certain amount, which is transmitted to the server through the wired network. The server-side system classifies and sorts the information, automatically assigns it to the appropriate logistics distribution personnel, transmits the information to the distribution trolley through the wireless network, and automatically displays it on the screen in front of the distribution personnel, By clicking on the relevant items on the touch screen, the deliveryman responds to the call and delivers the materials to the designated location in time. Click on the relevant items again to close the delivery request and complete a complete delivery

material calling and distribution rules

before determining the distribution rules, it is necessary to classify the workshop materials. In general, if you accidentally hit an ink that has slightly expanded after curing, you can classify it according to the following conditions: large materials: special material racks are used for storage. If the parts stored in a single material rack are less than 30, you can call by setting buttons on site; Small materials: the general material box or plastic box is used for storage. If there are more than 30 parts in each material box, the system will determine the consumption by itself, and send the material call information to make a call without adding a call button

distribution rules for large materials: by means of button calling, call buttons are set beside the workshop assembly line. Each button corresponds to a kind of material, and a Kanban card for the material is hung (see Figure 2). The card indicates the part number, part name, location of the inner warehouse, supply of the outer warehouse, sequencing and the station number on the assembly line of the material, A large number is used to indicate the minimum value of the material stock; When the remaining amount of materials is the minimum, the operator presses the button, the button light changes from normally dark to normally bright, and sends out the material demand. The request is transmitted to the data server in the material storage area through the wired network. After being judged and processed by the server, it is distributed to each distribution trolley equipped with wireless receiving device through the wireless transceiver, which is displayed on the trolley terminal, and the distribution personnel carry out distribution in time

Figure 2. Distribution rules for general materials in the material Kanban card

the system uses the system to push back and automatically trigger the call. Through the automatic output counter at the end of the assembly line, the system judges the consumption and remaining quantity of a certain part. When the material feeding demand is met, the system automatically sends out a material request, which is automatically distributed to the corresponding distribution personnel through wireless and displayed at the distribution trolley terminal, The delivery personnel shall deliver the goods in time

after receiving the distribution instruction, the material distribution personnel need to respond through the touch screen on the trolley terminal. After the response, the line side safety light becomes flashing, and the distribution personnel immediately distribute the material; If the material feeding has not been completed within a certain time, the system will start an audible and visual alarm to remind, and a reminder window will pop up on the terminal screen of the distribution trolley to remind the distributor to deliver the material as soon as possible; And record the delivery timeout process

after the delivery personnel successfully delivered the materials to the line, the corresponding items were reset through the touch screen in time. After the reset, the line edge indicator changed from flashing to the initial normally dark state. At this point, a complete feeding process is completed

implementation of the material call system

in addition to the above hardware equipment, the material management method must also be greatly changed: first, the material allocation method is classification, and it is necessary to establish basic database data for all materials, mainly including the following contents: part number, packaging form, packaging number, external warehouse location, internal warehouse location and line location, single vehicle consumption, lighterage or not Estimation of lightering distance and time required for one-way lightering; If it is necessary to store the materials in the material storage area, the way to send the materials in the workshop to the line side (forklift, tractor) and the estimation of the time required

it can be seen that only with the above contents can the material Kanban card shown in Figure 3 be completely produced, which is also the basis and necessary condition for the completion of the material calling system

the material call system is not only a real-time system to assist the material distribution, but also a lean system to improve the material management level. With these data, the workshop manager can clearly obtain the material inventory of the material warehouse and the site, and on this basis, optimize the relevant material inventory, reduce the inventory as much as possible on the premise of ensuring the normal production demand of the workshop, so as to achieve the purpose of lean production

here, the benefits brought by the implementation of the material call system are summarized for reference: improve the flexibility of material distribution (the system provides material distribution request notice); Provide the timeliness of material distribution (issue a distribution notice when the production site is about to need materials); Improve the accuracy of material distribution (the system only sends a distribution request notice to the places where materials need to be distributed); Improve the efficiency of material distribution and reduce man-made on-site inspection time; Through pull distribution, the production site inventory is greatly reduced and the production cost is reduced. (the system only sends a delivery request when the material is almost used up); Through flexible pull distribution, it can meet the mixed line production mode of various vehicle models in the body workshop; Through pull supply, we can get more accurate quasi material preparation of temporary material warehouse, and reduce the temporary material inventory and total material inventory; Reduce material inventory and temporary warehouse material inventory; When the pull system is extended to external logistics, it will also greatly reduce the total inventory in the warehouse, speed up the liquidity of funds, reduce the positive progress and reduce the backlog of funds; The lighting system can speed up the reaction speed of the feeders to a greater extent and speed up the distribution process. All the above advantages will be improved to varying degrees

system extension

the above discussion is limited to the material call from the workshop material warehouse to the line, and does not involve the transfer of material demand information from external warehouses or even suppliers. In fact, this is far from enough. The purpose of reducing material inventory is to reduce the inventory of the entire logistics supply chain, not just a part of the inventory. Therefore, it is necessary to extend the material calling system to external warehouses and even parts suppliers

material calling rules between the inner warehouse and the outer warehouse in the workshop: every time the inner warehouse security light system generates a box of material demand, the server immediately sends information to the outer warehouse feeding system. According to this information, the outer warehouse system can wait for other demand information within the allowable time range, and carry out simulated packing processing according to the package size and the size of the distribution truck. After a full vehicle is filled, it is assembled immediately and sent to the workshop in time

material reporting and feeding according to the above ideas can effectively avoid the phenomenon of insufficient unloading and traffic jam in the workshop caused by centralized material reporting and feeding; With the help of system prompts, internal and external warehouses can smoothly carry out the process of demand and distribution. However, it is still necessary to strengthen communication to avoid serious problems of material shortage and shutdown caused by delayed communication

rules for transferring material demand information between material warehouse and suppliers: every day or within a fixed production cycle, the warehouse collates and distributes the material consumption data to relevant suppliers, provides them with reference data for arranging production, reasonably arranges production in combination with the production plan data obtained by suppliers, and timely delivers the goods to the warehouse to ensure that production is not affected and inventory is reduced as much as possible


the essence of material management is: continuous material, no dull material and no stock up. The purpose of establishing the logistics safety lamp system is to carry out material distribution by pulling and promote timely supply; The historical data saved in the system provides the basis for output, which can effectively ensure continuous material supply from the production link; The system receives materials in such a way that the availability of incoming materials can be guaranteed and no dead materials can be guaranteed to the greatest extent; Through the system pull, the inventory can be reduced to the maximum extent, so as not to hoard materials; The pull mode is used for material distribution to reduce the aimless empty vehicle inspection time of material distribution workers and improve labor productivity

the internal material distribution in the workshop is realized by the pull system

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