Among the five-stage model of digital transformation of enterprises, the SILOED stage of is the most critical stage. Through a large number of practical case analysis, we found that there can be three modes of digitally empowered innovation: intelligent hardware, intelligent services, and intelligent manufacturing.
This article will take Kaixiang Electric as an example to introduce how manufacturing enterprise provides customers with production services and data services through smart factory.
Kaixiang Electronics
Kaixiang Electronics Co., Ltd. (named Kaixiang hereafter) is a high-tech enterprise focusing on the research and development of control boards, chargers, electronic transformers, and wireless remote controls for various small household appliances.
Kaixiang cooperated with TUYA to realize “smart manufacturing” through industrial IoT, which greatly improves the productivity and efficiency of the factory.
Business background
Behind the hundreds of millions of hot selling small household appliances every year, companies that produce control boards, chargers, electronic transformers and other key components of small household appliances are crucial.
Headquartered in Foshan and Cixi, Kaixiang has been established for 17 years and has an annual output value of 300 million RMB. Kaixiang is a high-tech enterprise which develops and produces various small household appliance systems.
In recent years, although the factory’s sales are growing at an annual rate of 26%, and the monthly delivery can reach more than 2 million pieces, the factory’s information system faced great challenge in the face of the rising order volume, and it is urgent to expand the capacity and upgrade the factory.
Platform empowerment
On the one hand, TUYA’s powerful IoT PaaS capability can provide a cloud platform that connects all equipments and devices, and create an interconnected development standard; on the other hand, through the industrial IoT platform, TUYA can dynamically link the equipment, personnel, systems, products and other elements of the enterprise into a whole intelligent system, and improve the production efficiency in a one-stop manner through intelligent storage, intelligent shelves, and intelligent equipment management.
Achievements
1、The equipment in the whole plant is reduced by 50% and the annual output is increased by 16 million pieces
Kaixiang factory has AI workshop, SMT workshop, parts forming workshop and DIP workshop. These workshops have different equipments, such as spot inspection equipment, red glue machine, solder paste printing machine, SMT mounter, back welding furnace, AOI, solder furnace, etc..
The intelligent production management system built by TUYA collects and uploads all production equipment information and summarizes it in a terminal for real-time analysis and processing.
Through equipment management, the equipment productivity increased by 13%, and the overall equipment efficiency (OEE) increased by 10%; moreover, equipment overhaul rate is improved by 25% through maintenance task management and abnormal downtime is reduced by 50% through predictive maintenance.
In addition to remote monitoring over production equipment, Kaixiang can also supervise the operation of equipment in the whole plant 24 hours a day. Kaixiang’s annual output value has increased from 24 million pieces/year to 40 million pieces/year, with an increase of 40%.
2、Purchase not according to orders, warehousing turnover rate is nearly 100%
With the intelligent warehouse management system, the factory no longer purchases goods according to the order, but coordinates goods according to the standard of 100% warehouse turnover rate. By connecting the upstream and downstream, the system uses the calculation of a large amount of background data to dynamically coordinate the status of materials in and out of the warehouse in real time, so that materials can always be “just right” to fill the entire warehouse.
With this system, Kaixiang can not only fully exert the productivity efficiency, but also can analyze when and how many materials are needed according to the production scheduling work order of, so that the supplier can deliver materials as required.
Such upgrading and transformation can effectively reduce the overstock of inventory materials, the cost waste of idle warehouses, accounts payable, and also ensure the smooth replacement of incoming and outgoing materials when production schedule is tight.
3、Material search time is shortened by 8 minutes per order on average
Intelligent shelves and code scanning PDA greatly improve the efficiency of finding components. Once the required materials are indicated, all the related locations will light up. The warehouse keeper can go to the shelves with light on and find the materials needed.
Before the adoption of the intelligent shelves, the warehouse keeper’s receipt was manually entered into the system, and a material receiver will be assigned. The receiver needs to enter related information immediately, which are about 400 items a day. Now, the material receiver only need to scan the code and then the information of the whole order will be entered automatically. Then, the light over the location of the material needed will be on and the material receiver can take the material from the shelf.
It is much easier than before to locate the needed components; at the same time, the system is easy to use and will not make mistakes. It is clear on the computer what materials are ordered and what are taken, and it can also track errors quickly. According to statistics, the single search time is shortened by 8 minutes on average.
Article Source: Tuya Smart official website
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