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Received: 2023 July 31 / Revised: 2023 August 21 / Adopted: 2023 August 26 / Published: 2023 August 29
Can Artificial Intelligence Replace Human Intelligence?
Visualizing shop floor information can impact production management and efficiency. Information can be presented both graphically and non-graphically (for example, in the form of data lists or tables). Graphical images are intuitive and clear, but currently most of them are based on statistical data, which makes it difficult to convey logical relationships between information and cannot help managers make effective decisions. In order to design a shop floor production system with visual processes in small enterprises, the basic process diagram visualization technologies, including visual process diagram design, process card management, process diagram output, process control and production schedule monitoring, were all discussed in detail. On that basis, a production control system for a mechanical production shop was developed using C#.NET as a programming language. The main contribution of the study is that the developed system used the process diagram as the main line through all the functional modules and integrated all the process data in the process nodes of the process flow diagram to realize the graphical monitoring of the shop floor production schedule. Process diagram visualization technology makes using the system simple and easy to understand, which significantly improves information management and work efficiency in the workshop. In addition, it provides a technical basis for the flow-controlled transfer of production information on the shop floor and can be a universal process module standard for shop floor production control systems.
The management of shop floor production computerization has historically been a somewhat weak link in the development of production computerization . In order to improve the level of workshop information management and help promote the overall competitiveness of enterprises, various workshop production management systems and HMMs have been developed, solving the problem of poor information communication between equipment automation systems and ERP, PDM and other systems.
Currently, there are many related commercial software on the market, such as SAP S/4HANA Manufacturing, Beas Manufacturing for SAP Business One, MS Dynamics 365, and many Chinese commercial software with independent copyrights (such as Yonyou (Beijing, China), Kingdee (Shenzhen, China) etc.). One of the leading developers of business process management software, SAP helps companies of all sizes and industries achieve end-to-end enterprise resource management. SAP S/4HANA can now process large amounts of data using advanced technologies such as artificial intelligence and machine learning, and its integrated applications can connect all parts of the business into an intelligent suite on a fully digital platform. However, the price is prohibitive and not suitable for small and medium enterprises. Beas Manufacturing for SAP Business One is particularly suitable for the production of small and medium-sized companies. It combines the core functions of ERP and the digital core MES platform and allows users to easily manage and monitor all processes and costs of the manufacturing process. MS Dynamics 365 integrates CRM and ERP functions and processes and can be integrated with more Microsoft services for continuous intelligent evolution.
Although the commercial system is very mature and comprehensive, for some small companies (1) its corporate structure may be incomplete and comprehensive, so the ERP system may not be suitable for small companies. (2) small firms tend to concentrate on the production of certain products that are very similar to each other, and their production processes are similar; thus, the requirements for the system are not too complex, but can quickly complete the production planning of the products. (3) Small businesses must respond quickly to market changes with their products to remain competitive; for example, when a customer’s order needs change, a new product must be produced quickly and delivered on schedule. Made-to-order, small-batch manufacturing is not well-suited to a standard ERP system, which is often built for high-volume items. (4) In order to keep up with the computerization of the company, small companies must also be informed about digital transformation. However, due to financial constraints, small businesses are more concerned with information and digital transformation in their core industries: the manufacturing sector.
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China’s Jiangsu and Zhejiang regions have many small enterprises and are active in the market economy. This study developed a shop floor production management system based on the product process for a machinery manufacturing company in Ningbo, China. The company has more than 70 different product types divided into five different categories and specifications. Regardless of the size of the business, the shop floor production management process includes many business processes in various departments of the shop floor and production processes. The common business processes between the various departments of the workshop are shown in Figure 1. They are as follows:
As a vital link between product design and production, process flow is very important to the entire manufacturing procedure and has a significant impact on product quality and production cost. The actual process flow is usually more complex, as shown in Figure 2. Processes can interact with each other serially or in parallel. There is a strict constraint that the previous procedure must be completed before the next procedure can be started. Traditionally, production is organized on the shop floor after the foreman manually completes the process flow and process card based on the detail drawings. During this time, a lot of technical data will be generated, and the management of this technical information depends on how well the relevant managers remember it and on the professional level of the relevant managers.
In addition to process data, the workshop also produces various additional production data, including equipment information, material data, personnel information, product information, etc. The interaction and presentation of this data can affect the operation of the workshop. is managed in real time and how decision makers draw conclusions. Many researchers are currently using the Internet of Things to improve data collection on workshop equipment. Since the data used in workshop production is complex, it is appropriate to present the data visually so that the workshop workers can better use the information and increase production efficiency. Although domestic and foreign researchers have carried out extensive research and practice in workshop information management and computer-aided process planning (CAPP) and solved many problems such as production planning, data collection, process monitoring, logistics planning, etc., most workshop production management systems are still present complex manufacturing processes as data lists or tables that lack intuitive and visual graphical representation. As a result, the overall structure of the process flow and the relationships between different process nodes cannot be clearly depicted, which negatively affects the user experience. Some systems are visual, but their focus is not on process flow, but on displaying statistical data such as equipment statistics. As a result, the logical relationships between the data are unclear and should be better used to help managers make decisions.
The visualization technology of the production process of the mechanical production shop has been carefully examined in order to find a solution to this problem. A workshop production process diagram model and a process flow chart storage scheme are proposed, and then a mechanical production workshop production control system is developed. The system has the following functions: visual design of process diagrams, management of process cards, control of the production process and monitoring of the production progress according to process diagrams. The management of the production process has become more intuitive and visible in use
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