2 Smart Manufacturing Ecosystem/智能制造生态系统
Standards are fundamental for enabling SMS. Different standards contribute in different ways to enabling the capabilities of smart manufacturing systems. To generate an SMS landscape, we identify the standards as within scope based on whether a standard contributes to a capability, and analyze where, when, and for what purpose the standard is used. This section defines the key capabilities and presents a visualization of a smart manufacturing ecosystem. The following section presents the standards landscape for the ecosystem.
标准是实现智能制造系统的基础。不同的标准通过不同的方式实现了智能制造系统的能力。构造智能制造标准体系,我们要识别出范围内的标准是否对一种能力有贡献,并且分析这些标准在哪里、什么时候、为什么目的被使用。本章定义了智能制造生态系统的主要能力和可视化展现。在接下来的章节中展现了智能制造生态系统的标准体系。
2.1 Smart Manufacturing Capabilities/智能制造能力
Significant and positive relationships exist between manufacturing strategies and corporate competitive strategies [47]. To achieve corporate competitive goals, manufacturing systems should be developed with capabilities aligned to a firm’s competitive strategy, which usually consists of cost control and differentiation strategies of quality, delivery, innovation, service, and environmentally sustainable production. We classify key SMS-enabling capabilities into four categories including productivity, agility, quality, and sustainability (These characteristics are discussed in more detail in [14].) Table 2 shows a mapping of SMS capabilities to corporate competitive strategies.
制造战略与公司竞争战略之间存在重要积极的关系[47]。为达到公司竞争目标,制造系统应当开发匹配公司竞争战略相对应的能力,这些能力通常包括成本控制与质量、交付、创新、服务、绿色制造等子战略。我们将智能制造系统的关键能力划分为生产率、敏捷、质量与可持续(有关这些特征的详细讨论参见[14])。表2展示了智能制造系统能力与公司竞争战略的映射关系。
To analyze the role of existing manufacturing standards, we summarize the key SMS capabilities as follows:
分析现有制造标准所处角色,我们总结了下列关键智能制造系统能力:
Productivity
: Manufacturing productivity is defined as the ratio of production output to inputs used in the production process [89]. Productivity can be broken down further to labor productivity and material and energy efficiency. As production sizes increase, typically productivity increases; however, for SMS for which customization is a hallmark, productivity measures may need to be adjusted to be more inclusive of responsiveness to customer demand.
生产率
:生产率定义为生产过程中投入产出的比率[89]。效率可以分解为劳动力效率与原材料和能源效率。比如产量增加是典型的生产率增加。然而对于智能制造系统定制化制造的生产率测量还应包含对客户需求的响应程度。
Agility
: Agility is defined as “the capability of surviving and prospering in a competitive environment of continuous and unpredictable change by reacting quickly and effectively to changing markets, driven by customer-designed products and services” [7]. Critical to the success of agile manufacturing are enabling technologies such as model-based engineering, supply chain integration, and flexible production systems with distributed intelligence. Traditional metrics to measure agility include On Time Delivery to Commit, Time to Make Changeovers, Engineering Change Order Cycle Time, and Rate of New Product Introduction[8]. New measures could include Delay Due to Supply Chain Change.
敏捷
:敏捷定义为在持续发生不可预知变化的竞争环境中以客户定制化的产品和服务驱动方式迅速反应和有效应对不断变化的市场变化的生存和繁荣的能力[7]。敏捷制造的成功要素包括基于模型的工程、供应链整合、分布式智能柔性生产系统等技术。传统衡量敏捷的指标包括准时交付率、生产转换时间、工程变更单执行时间、新产品面市率。新的指标应包含供应量变化导致的延迟时间。
Quality
: Traditional quality measures reflect how well finished products meet design specifications. In addition, for SMS, quality also includes measures of product innovation and customization. Traditional quality metrics include Yield, Customer Rejects/Returns, and Material Authorizations/Returns [8]. New quality measurement indicators for innovativeness and variety/product family and options/product to measure personalization degree are needed.
质量
:传统质量测量反应了最终产品符合设计规范的程度。在智能制造系统中,质量还包含了产品创新与定制化的测量。传统质量指标包括产量、客户拒收/退货、原材料授权/退货[8]。新的质量衡量指标还包括创新、产品族与多样化、产品可选择项对个性化需求的满足程度。
Sustainability
: While time and cost as measures of productivity have been the traditional drivers for manufacturing, sustainability has taken on more importance. Measurement science for manufacturing sustainability is not as mature as for time and cost and is an active area of research [18] [19]. As productivity and agility of manufacturing systems increases, the necessity for better understanding and controlling the sustainability-related impacts of those systems increases. Manufacturing sustainability is defined in terms of environmental impact (such as energy and natural resources), safety and well-being of employees, and economic viability [9].
可持续性
:当传统观念还以时间与成本作为衡量制造生产率的指标时,可持续性就变得越加重要了。对可持续制造的测量科学并不像时间和成本那样成熟,但却是一个活跃的研究领域。随着制造系统生产率和敏捷性的提升,有必要提高理解并控制可持续性对这些系统的影响。可持续制造定义为包含环境影响(包括能源与自然资源)、安全与职业健康、经济可行性为[9]。
表2:智能制造系统的关键能力
Corporate Competitive Strategy 公司竞争战略 |
SMS Key Capability 智能制造系统的关键能力 |
Capacbility Decomposition 能力构成 |
Performance Metrics 绩效指标 |
Cost Control 成本控制 |
Productivity 生产率 |
Throughput 产出物 |
Products being produced on a machine, line, unit, or plant over a specified period of time 产品在机器、生产线、生产单元、工厂的时间开销 |
OEE 设备综合效率 |
Overall Equipment Effective - a multiplier of Avaliability * Performance * Quality 设备综合效率=可用性×性能×质量 |
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Material/Energy efficiency 原材料/能源利用率 |
Material/Energy(electricity, stream, oil, gas, etc.) required to produce a specific unit or volume of production 原材料/能源(电力、蒸汽、石油、天然气等)单耗 |
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Labor productivity 劳动生产率 |
Worker hours per unit of production 工人每小时生产率 |
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Differentiation 子战略 |
Agility 敏捷 |
Response to changes 响应变化 |
Time to Make Changeovers, Rate of New Product Instroduction, Engineering Change Order Cycle Time 生产转换时间、新产品面市率、工程变更处理周期 |
On-Time Delivery to Commit 准时交付率 |
The percentage of time that manufacturing delivers a completed product on the schedule 根据计划的制造交付准时比率 |
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Resilience to faults 故障恢复能力 |
Downtime in Proportion to Operating Time 故障时间占操作时间比例 |
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Quality 质量 |
Product quality 产品质量 |
Yield, Customer Rejects/Return, and Material Authorizations/Returns 产量、客户拒收/退货量、原材料授权/退货量 |
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Innovation 创新 |
Product innovativeness 产品创新能力 |
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Varity 多样性 |
Varity/product family, Options Per Product, Personalization options 产品族多样性、产品可选项、个性化选择 |
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Customer Service 客户服务 |
Customer reviews on services 客户服务回访 |
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Sustainability 可持续性 |
Product 产品 |
Recyclability, Energy Efficiency, Durability, Remanufacturability 可回收、节能、耐用、可重新加工 |
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Process 工艺 |
Primary energy use, Greenhouse gas emission 主要能源消耗、温室气体排放 |
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Logistics 物流 |
Transportation fuel usage, Refrigeration energy usage 运输燃料消耗、制冷能源消耗 |
2.2 Smart Manufacturing Ecosystem/智能制造生态系统
The Smart Manufacturing Ecosystem encompasses a broad scope of systems in the manufacturing business including production, management, design, and engineering functions. Figure 1 illustrates three dimensions of concern that are manifest in SMS. Each dimension—product (green), production system (blue), and business (orange)—is shown within its own lifecycle. The product lifecycle is concerned with the information flows and controls beginning at the early product design stage and continuing through to the end-of-life of the product. The production system lifecycle focuses on the design, deployment, operation and decommissioning of an entire production facility including its systems. The business cycle addresses the functions of supplier and customer interactions. Each of these dimensions comes into play in the vertical integration of machines, plants, and enterprise systems in what we call the Manufacturing Pyramid (Figure 5). The integration of manufacturing software applications along each dimension helps to enable advanced controls at the shop floor and optimal decision-making at the plant and enterprise. The combination of these perspectives and the systems that support them make up the ecosystem for manufacturing software systems. Details of the lifecycle of the three dimensions, as well as the Manufacturing Pyramid, will be described in Section 3.
智能制造生态系统包涵一个广泛的制造系统,其涵盖了生产、管理、设计与工程设计等环节。图1展示了关注三个维度的智能制造系统。分别展示了产品维(绿色)、生产系统维(蓝色)、业务维(橙色)的生命周期及其内在阶段。产品生命周期关注产品从早期设计到最终终结的信息流和管理。生产系统生命周期则关注整个生产装置及其自身系统的设计、安装、操作和退役的各个阶段。业务生命周期关注供应商与客户的互动过程。各个维度都将贯穿于纵向的机器、工厂、企业系统我们称之为制造金字塔(图5)中。整合各个维度的制造软件应用讲有助于实现车间先进控制、工厂与企业的优化决策。这样的透视组合与系统有助于支持建立制造软件系统的生态系统。有关各维度生命周期和制造金字塔的详细内容,将在第3章进行描述。
图1:智能制造生态系统
Historically, these dimensions have been dealt with as silos of concern. Indeed, integration along even one of these dimensions is a non-trivial challenge and is being actively worked on. We have observed that organizations that were formed to integrate single dimensions of this ecosystem are expanding in scope to address the digital thread across the dimensions (orange arrows in Figure 1). Paradigms such as continuous process improvement (CPI), flexible manufacturing (FMS), and design for manufacturing and assembly (DFMA) rely on information exchange between the dimensions as indicated in Figure 1. Tighter integration within and across the three dimensions will result in faster product-innovation cycles, more efficient supply chains, and more flexibility in production systems. The combination of these allows for optimal control of the automation and decision-making needed to make high quality, highly customized goods in tight synchronization with the demand for these goods [10].
从历史的角度,这些维度已经成型。确实,将三个维度整合到一起是一个非常大的挑战,并且这个工作还在持续。我们观察到在我们所建立的体系中的每个维度都通过数字线程与其他维度整合起来(图1中橙色的箭头)。图1中标出了在跨维度实现的一些制造范式,如持续过程改进(CPI)、柔性制造(FMS)、制造与组装设计(DFMA)。三个维度内部与之间的紧密集成将带来更快的产品研发周期、更有效率的供应链、更有柔性的生产系统。这样的组合再考虑自动化优化控制和决策的需要就能够制造更高质量、更高定制性的产品以同步满足这些商品的需求变化[10]。
Essentially, it is the seamless integrations within and across SMS dimensions and the manufacturing pyramid that lead to SMS capabilities. Table 3 shows the integration technologies highlighted in Figure 1 and the SMS capabilities supported by them.
本质上来说,智能制造系统各维度内部与之间与制造金字塔的无缝集成是实现智能制造系统能力的方式。表3说明了图1中的集成技术和智能制造系统能力的支持关系。
表3:智能制造系统生态系统与能力映射表
System 系统 |
Description 描述 |
Information Flow 信息流 |
KeyCapabilities Supported 支持的关键能力 |
PLM | production Lifycycle Management - is the process of managing the entire lifecycle of a product from inception, through engineering design and manufacture, to service and disposal of manufacturied products. 产品生命周期管理 - 是管理整个产品生命周期的过程,从产品创意到工程设计和制造、到售后服务与终止生产。 |
Bi-directal information flow through product and production system lifecycle 产品与生产系统生命周期间的双向信息流 |
Quality, Agility and Sustainability 质量、敏捷与可持续性 |
SCM | Supplying Chain Management - The management of upstream and downstream value-added flows of materials, final goods, and related information among suppliers, company, resellers, and final consumers. 供应链管理 - 管理上游和下游的原材料、最终产品的增值过程,以及供应商、公司、分销与左总消费者的信息。 |
Bi-directional information flow among supply chain stakeholders - manufacturers, customers, suppliers, and distributors 供应链主要干系人(制造者、客户、供应商和分销商)之间的双向信息流 |
Agilities, Quality, Productivity 敏捷、质量、生产率 |
DFSCM | Design for Supply Chain Management - designing products to take advantage of and strengthen supply chain. 面向供应链管理设计 - 设计产品以取得供应链中的优势 |
Bi-directional information flow between supply chain management activities and design engineers activities 供应链管理活动与设计工程活动间的双向信息流 |
Agility, Quality 敏捷、质量 |
CPI | Continuous process improvement - is the set of ongoing systems engineering and management activities used to select, tailor, implement, and assess the processes used to produce products. 持续过程改进 - 是一组持续的系统工程与管理活动,用来选择、定制、实现、评估产品生产过程的方法 |
Information flow from run-time manufacturing system to process design activities 从制造系统运行环境到过程设计活动的信息流 |
Quality, Sustainability, Productivity 质量、可持续性、生产率 |
CCX | Continuous Commissioning - ongoing process of diagnosis, prognosis and performance improvement of production systems. 持续试车 - 生产系统持续诊断、预测、性能改善的过程 |
Bi-directional information flow between production engineering activities and production operation acitivities 生产工艺活动与生产操作活动之间的双向信息流 |
Productivity, Agility, Quality, and Sustainability 生产率、敏捷、质量与可持续性 |
DFMA | Design for Manufactring and Assembly - the design for ease of manufacture of the design of product for ease of assembly. 面向制造和组装的设计 - 设计更易制造和组装的产品 |
Information flow from production engineering activities, operation activities to production design activities 工程活动、操作活动到设计活动的信息流 |
Productivity, Agility 生产率、敏捷 |
FMS/RMS | Flexible Manufacturing System/Reconfigurable Manufacturing system - machines are flexiable and can be configured to produce changed volume or new product types with or without changed process. 柔性制造系统/可配置制造系统 - 机器具有柔性且能够通过配置来生产不同的数量或新的产品类型改变或不改变工艺。 |
Information flow from product engineering activities to production engineering activities 产品工程设计活动到生产工艺设计活动的信息流 |
Agility 敏捷 |
Manufacturing Pyramid 制造金字塔 |
The hierarchical nature of existing manufaturing systems illustrated by a three-level pyramid including ERP, MOM and shop floor. 制造系统中存在的层级结构,表现为ERP、MOM与车间三层结构 |
Bi-directional information flow among ERP, MOM activities and control system ERP、MOM与控制系统之间的双向信息流 |
Productivity, Agility, Quality, and Sustainability 生产率、敏捷、质量与可持续性 |
Fast Innovation Cycle 快速创新周期 |
To improve New Product Introduction(NPI) Cycle by anticipating trends through gathering data from product usage and feeding it back into product ideation 通过收集产品使用数据和反馈信息分析预测趋势形成产品创意的新产品研发(NPI)周期 |
Information flow from product use to product design 产品使用到产品设计的信息流 |
Quality, Agility 质量、敏捷 |
2.3 Impacts of Standards/标准的影响
Standards are fundamental and valuable tools that can enable the adoption of technologies and innovations by business owners. Accordingly, they contribute to one or more SMS key capabilities. For example, on the product dimension, PLM standards contribute to both agility (by streamlining processes) and quality (by enabling the integration of different activities along the product and production system lifecycles). In the production system area, continuous commissioning (CCX) standards can improve machine performance and systems reliability to improve productivity, quality, and sustainability (through improved energy performance). Standards for electronic commerce such as the Open Applications Group Integration Specification (OAGIS) help streamline business processes between partners in the supply chain.
标准是基础的有价值的工具,能够帮助商业拥有者实现技术与创新应用。因此,它们构成了一个或更多的智能制造系统的能力。如在产品维度,产品生命周期标准提供了敏捷(高效流程)与质量(产品与生产系统生命周期见活动信息的整合)两个能力。在生产系统领域,持续试车(CCX)标准能够改善及其性能与系统可靠性以改进生产率、质量和可持续性(通过改进能源绩效)。如电子商务标准“开放应用组织集成规范(OAGIS)”帮助供应链中的伙伴进行流程化业务处理。
The next section presents a landscape of manufacturing standards on top of the SMS ecosystem where we see clearly existing manufacturing standards and how they can enhance SMS capabilities, if adopted.
下一章将介绍智能制造生态系统的制造标准体系,在那儿我们能够更清晰的看到已有制造标准以及它们如何提升智能制造系统的能力的。