A digital factory should be built to reduce the order cycle by one third

Time:2021-10-23

Introduction:Based on the open ability of low code platform, fidelity launched a set of digital factory. This digital factory helps them shorten the production cycle from 60 days to 40 days, directly improves the delivery capacity and performance ability of fidelity to international customers, and enhances the competitive strength of the enterprise.

Zhejiang fudeli Wood Industry Co., Ltd., founded in 1994, is headquartered in Shaoxing, Zhejiang Province. As early as 1999, fudeli floor became the special floor for the restoration project of Tiananmen Gate Tower.

Today, the five processes of drying, pressing, grooving, painting and packaging of fidelity have been embodied in data flow. Five large digital screens in the workshop can display sales data Kanban, workshop production Kanban, equipment maintenance Kanban, work order progress Kanban, safety light call and machine real-time status kanban.

Meng Yingying, vice president of fidelity group, told reporters, “the data of all links of sales, procurement, production and quality control are available, and the market orders can be broken down into production plans on the mobile phone, up to every workbench in the workshop.”

All this benefited from the fact that in April 2021, Zhejiang Ruizhi Information Technology Co., Ltd., a nailing application service provider, built and launched a set of digital factories for Fu Deli based on the open ability of low code platform.

This digital factory helped fidelity shorten the production cycle from 60 days to 40 days. The shortening of delivery time directly improves the delivery ability and performance ability of fidelity to international customers, and the competitive strength of the enterprise has been enhanced.

A digital factory should be built to reduce the order cycle by one third

Workshop Kanban of fudeli wood foreign trade factory source: Lei Feng

Agile manufacturing demand forces digital reform

Fudeli flooring has a marketing and sales network at home and abroad, and the annual export capacity of solid wood flooring has reached more than 1 million square meters. In recent years, the changeable international market situation has brought great challenges to their production end.

In the past, the foreign trade industry mainly relied on large customers and large orders. Production factories can meet customer needs by mass production according to one order. Now, with more and more decentralized orders, personalized requirements require factories to have higher agile manufacturing capabilities.

In order to quickly transfer customer demand to the factory and ensure that new and old products are put on the production line at the same time without problems, the factory must quickly adjust the production plan.

However, in the past, fidelity relied on paper office. After the sales order is placed, the raw material application should go through the approval process level by level, which is inefficient. The purchase and warehousing of materials cannot be synchronized to the production department in time, and they need to be inspected in the warehouse. At the same time, the sales department also needs to send a special merchandiser. The merchandiser runs to the workshop every day and calls one by one, but the finished product information still can not be transmitted to the delivery link in time, and there are finished products piled up in the production workshop from time to time.

In addition to low efficiency, the production process relying on paper documents and manual tracking also has an impact on quality control. The merchandiser can’t know the product qualification rate until a single order is completely completed. The product quality mainly depends on the consciousness of operators on each production line and the patrol inspection of the quality control manager. It is also difficult to trace the causes of product nonconformity.

“In recent years, the global economy has developed from incremental to stock competition. To improve products and optimize management and operation, we hope to use some tools to help us complete it,” Meng Yingying told reporters,Digital management is one of the important directions of transformation and upgrading of fidelity.

Explore the most effective digital solutions

Enterprises like fidelity actually have a strong demand for digitization, but the cost of purchasing large overseas systems is too high for them, the operation and maintenance is also very difficult, and the implementation effect is not good.

Fidelity began to try digital transformation as early as 2017. They chose to start from the realization of office online and gradually realize business online through nailing. Taking Fidelity International Trade Division as a pilot, they built a set of production and manufacturing system in the foreign trade factory focusing on export business, so that the production and business data can really flow.

During this process, the fidelity team found that the original digital solutions could not solve the personalized problems they encountered:

The raw materials of wood flooring have particularity, and the quality of raw materials can only be known after arrival inspection and warehousing. The purchase, sales and inventory management of SAP system can not solve the problem of inconsistency between purchase orders and warehousing materials.

At that time, although fudeli had embedded the OA approval process into the nail, it only realized the online process approval, and the production progress data still existed in the form of Excel table.

Zhao Nan, head of the production planning department of Fidelity International Trade Division, recalled that the delivery information and material information were filled in by people. The factory director, production planner, warehouse, procurement and supply, finance and other relevant personnel needed to edit this form online. It was not easy to trace the source. Once the order information update was suspended, people in all links would come to ask about the situation. “After the order is complicated, the excel table can’t hold up.”

Now, fidelity has found a more effective digital solution.

Nailing application service provider Ruizhi information is suitable to build through nailing’s low code application development platform. It took only two weeks to set up an “easy car room” for Fu deli’s foreign trade factory, which basically includes the MES functions required by a manufacturing factory.

A digital factory should be built to reduce the order cycle by one third

The upgraded digital factory will be put into operation in April 2021 and only one it staff is required for maintenance.

Today, the overall business data and process of fidelity are really “on the nail”, and the digital workshop can directly carry out production scheduling from the receiving end to get through the data of sales, procurement and production:

Sales personnel do not need to send special personnel to follow orders, orders are issued, and the production planning specialist formulates work order plans. Procurement can be carried out immediately. All interested parties can see the procurement progress, material warehousing and production progress;

The production supervisor or workshop director dispatch work for each process. Relevant workshop personnel can report work in real time and know the completion of dispatch tasks after work. Daily settlement employees can even know the salary situation on the same day (push salary slip in the form of nailing message), which improves their enthusiasm;

In case of production delay, it can also be improved in time through data analysis chart;

In terms of quality control, in addition to incoming and outgoing quality inspection, there are also key process quality inspection and patrol inspection, so as to leave quality inspection marks in all production links;

The operator can report for repair by scanning the QR code on the equipment with nails. At the same time, the factory maintenance workers can timely receive the repair information through the light billboard or nail to do, and rush to the site for repair in time. Support the planned maintenance of equipment to minimize the impact of equipment on production progress

These changes made Zhao Nan very emotional: “this is from people managing production to digital system managing production.”

Low cost digitization with low code

One it staff can maintain the MES system of a manufacturing plant and realize the digitization of the plant in two weeks… Fidelity has truly experienced the benefits of building open low code capability and enabling enterprises to realize digital upgrading at low cost.

He Shiwei, head of Ruizhi information, told reporters that in building an “easy car room” for fidelity, they have developed and completed solutions for common needs of manufacturing enterprises in advance with Yida.

By the end of 2020, it is advisable to set up a power nail service provider to collect the common needs of users, complete the R & D and internal test of the industry scheme, then conduct scale test in multiple cities, quickly iterate the common needs of customers into the scheme, and finally present them in one “easy car room” application.

He Shiwei imagined,Through the appropriate low code development ability, the futureChanging roomThe digital Kanban can also display the equipment failure rate and maintenance cost, compare the equipment capacity, form a data analysis chart, and use the data to predict the equipment situation

What is exciting is that the story of digital upgrading in fidelity is unfolding on a local scale. In 2020, Shaoxing will deeply implement the “No. 1 project” of digital economy and complete the intelligent transformation of 247 traditional industries.

Che Fei, general manager of fudeli international trade division, told reporters: “next, fudeli will integrate the ERP system into the nail, hoping to integrate the upstream and downstream management. For example, the production progress and quality report of a customer’s order can be directly connected with the customer, so that overseas customers can have a more intuitive understanding of made in China.”

Chefei is full of vision for the digital future. He expects the digital factory in the future to further improve the automation and intelligence of equipment, so that the flowing data can form analysis results and become a part of production basis and decision-making basis, which will become a reality step by step through such a platform.

Copyright notice:The content of this article is spontaneously contributed by Alibaba cloud real name registered users, and the copyright belongs to the original author. Alibaba cloud developer community does not own its copyright or bear corresponding legal liabilities. Please refer to Alibaba cloud developer community user service agreement and Alibaba cloud developer community intellectual property protection guidelines for specific rules. If you find any content suspected of plagiarism in the community, fill in the infringement complaint form to report. Once verified, the community will immediately delete the content suspected of infringement.