Development Of Production Monitoring System Oriented Woven Carpets Manufacturing

Under the background of "Made in China 2025",manufacturing companies have gradually realized the importance of information construction for the survival and development of enterprises.Although there have been many mature information management softwares such as MES and ERP in China,due to the individuality and particularity of the carpet production industry,these traditional information systems cannot be directly applied to the production monitoring of woven carpets.Woven carpets are rich in patterns,and have various types of colors,complex and diverse raw material varieties and manufacturing processes,as well as tight production schedules.If there is no information monitoring system suitable for the characteristics of the carpet manufacturing industry,the information islands of various manufacturing links cannot be broken and the real-time status of the orders cannot obtained by enterprise management personnel in the first time,as a result,the quality of production and the date of delivery may be affected.Therefore,carpet manufacturers urgently need to apply information technology to achieve full-process production monitoring with orders as the main line.According to the above situation,this paper has developed a production monitoring system of woven carpet manufacturing.It has realized the effective management of all aspects of the carpet production process,tracking the order real-time production progress,identifing potential manufacture quality issues and increasing manufacturing capacity.Raw materials,patterns and semi-finished coding systems suitable for carpet manufacturing standards have been established.The carpet production monitoring system is constructed based on the basic principle of MRP-II,which fundamentally solves the problems existing in the production supply chain of the woven carpet enterprise from design,sample,manufacturing to delivery,controling production cost,tracing the production process and production quality.The main contents of this paper are as follows:(1)Analyzing the characteristics of woven carpet manufacturing industry in the manufacturing process,and establishing the information model for woven carpet manufacturing by UML modeling method.It also designed and developed software architecture which including raw material classification and coding system,order management,procurement and inventory management,production planning and progress tracking,product quality inspection and delivery,and then the enterprise logistics,capital flow,information flow have been integrated.(2)For the production bottleneck of the woven carpet enterprise-printing process,the paper mainly studies the printing production plan control algorithm.Based on the order sequence,white blanket utilization rate and size specifications of the pattern to be arranged,a mathematical model for scheduling production was established.The paper also developed an auxiliary printing typesetting management module based on the improved minimum horizontal line grouping algorithm.The optimized arrangement of the printing production task was realized,the blanket have been used to the utmost extent,and the working time of the design and typesetting staffs was significantly reduced.(3)Studied the technology of real-time web production monitoring,designed the real-time message push mode.Under the B/S(Browser/Server)structure,builting the real-time commucation component to meet the production operations,based on the SignalR technology.using the communication component to achieve Web visual monitoring of order approval status,production schedule status,inventory status,equipment operation status,personnel status,etc..(4)Development of production monitoring system for woven carpet based on Visual Studio.NET platform and SQL Server database,was successfully applied to a large carpet manufacturing enterprise in Shandong.The system standardized the business operation process,which can monitor the whole production from order placing,approval,design,sample,raw and auxiliary materials procurement,inventory,production of various processes,inspection and storage,and delivery.The delivery time has been shortened and the quality has been improved,and the cost has been effectively controlled.