As the leader of China's independent automobile brands, Geely Automobile has formulated a clear intelligent manufacturing strategic planning and overall ideas, and has been at the forefront of many independent brands in the transformation and upgrading of logistics digital intelligence. Under the guidance of the exploration and development path of "step-by-step pilot to extensive promotion", we will independently develop smart workshops and digital factories, build an OTWB integrated logistics information platform, and explore the landing of diversified smart logistics scenarios... A series of measures are driving the accelerated formation of Geely Automobile's digital and intelligent logistics system.
Zhejiang Geely Holding Group (hereinafter referred to as "Geely") was founded in 1986, entered the automotive industry in 1997, and has now developed into a global innovative technology enterprise group integrating the design, research and development, production, sales and service of complete vehicles, powertrains and key components, and covering travel services, digital technology, financial services, education and other businesses. Geely Automobile Group (hereinafter referred to as "Geely Automobile") has developed into a leading enterprise of China's own brand, ranking first in the sales list of Chinese brand passenger cars for five consecutive years, owning the Geely brand, Lynk & Co brand and geometric brand, and owning 49.9% of the shares and all management rights of Proton Automobile, as well as 51% of the shares of the luxury sports car brand Lotus.
In 2021, Geely Automobile ranked among the top three in the annual sales list of car companies with a total annual sales volume of 1.328 million units. Behind the outstanding achievements is inseparable from Geely's series of logistics digital intelligent transformation exploration implemented with the goal of "improving quality, improving efficiency and reducing costs", and intelligent logistics scenarios such as "goods to people", line-side unmanned distribution, visual receipt, intelligent loading, automatic loading and unloading trucks are widely constructed; Xi'an "black light factory", Changxing 5G+ digital factory, Chunxiao KD smart logistics workshop and other digital factories and smart workshops are put into operation; the self-developed OTWB integrated logistics information platform is online and applied. Geely Automobile is realizing the digital and intelligent transformation of logistics at The speed of China.
Recently, the reporter of this magazine had an in-depth exchange with Mr. Dong Qingfeng, director of the smart logistics department of Geely Automobile Group, and asked him to fully share the practical experience of Geely Automobile's logistics digital intelligent transformation.
Dong Qingfeng, Director of Smart Logistics Department of Geely Automobile Group
First, the overall strategy and development overview
For automotive companies, the development of intelligent manufacturing and digital intelligent logistics has always been go hand in hand and complement each other, and Geely Automobile is no exception. Dong Qingfeng mentioned that many Chinese enterprises are not even complete in their factory management circulars, and although some have built a unified information management system internally, there is still a considerable gap between comprehensive and effective management information and comprehensive use of information. At the same time, intelligent manufacturing for procurement and supply chain management challenges brought by the impact is far-reaching, it will be the original according to the plan to manage the factory production, cut into smaller units, both can be dynamically planned to smooth the production fluctuations, can also be faster with the market response to capacity adjustment, while also can achieve the lowest raw material and finished product inventory, greatly improve the turnover efficiency of production, manufacturers can thus obtain the ability to respond quickly to user demand, market fluctuations. The development of intelligent manufacturing and smart logistics is also inseparable.
In terms of intelligent manufacturing, Geely has established an international professional industrial Internet platform "Geega", which provides independent research and development, safe and controllable, and system-feasible full-link solutions for enterprise digital transformation by building a digital base that integrates resource energy efficiency, security and credibility, data intelligence and intelligent Internet of Things. Users can directly participate in the design and place orders through the platform to achieve zero-distance interaction. Under the C2M flexible customization solution, enterprises can also quickly respond to market demand, shorten the product development and listing cycle, optimize the allocation of supply chain resources, reduce the operating costs of enterprise management, improve the flexible production capacity of multiple varieties and small batches, and continuously improve the quality of product delivery. In addition, Geega also breaks the situation that traditional factories are isolated and isolated from each other, realizes the interconnection of all factors of the factory, digitizes the manufacturing process, visualizes the production process, controls information, shortens the product manufacturing cycle, and provides a strong support and guarantee for the stable profitability of the enterprise. At present, Geega has served dozens of group enterprises and verified in 15 business application scenarios of Geely Automobile. After the platform is implemented and put into production, the production efficiency will be increased by 22%, and the ecological cycle of "from manufacturing and back-feeding manufacturing" has been truly realized.
In terms of smart logistics, Geely Automobile has established and built a smart logistics system based on the overall planning of the warehouse network, with the strategic idea of information platform and intelligent equipment as the two major products. According to Dong Qingfeng, Geely Automobile Group Logistics Center was formally established in January 2019, and the Smart Logistics Department was formally established in April 2021, on the basis of learning from the experience of advanced enterprises in logistics development, the planning and completion of the national 10+19 warehouse layout has been completed, and the warehouse deployment has been carried out; at the same time, various types of smart logistics technologies and means have been continuously tried and applied, and pilot applications and replication promotion have been accelerated, forming a diversified smart logistics scenario; Chunxiao KD workshop has put into use the goods-to-person AGV. At the same time, the KDMS system was established, which is the first case in the KD industry to combine the information system and intelligent equipment in an all-round way to redefine the development direction of the KD industry; the OTWB integrated logistics information platform that has been established has realized the transformation of any sales order to logistics order and the full link of logistics visualization.
Geely Logistics has formed a variety of digital and intelligent logistics application scenarios
Second, diversified smart logistics scenarios
Geely Automobile has 18 vehicle factories, 8 power bases, and some seat factories, battery, electronic control, motor factories, and other parts factories in the Yangtze River Delta, Beijing-Tianjin-Hebei, Sichuan-Chongqing and South China, and has nearly 30 warehousing/logistics centers in the country. According to Dong Qingfeng, in recent years, Geely Automobile has built many advanced and applicable smart logistics scenarios under the exploration path of first piloting and then promoting, and most of these projects have been put into operation in Geely Automobile factories, warehousing and logistics centers.
1. "Goods to people"
The goods-to-people intelligent logistics project has been officially landed in some factories of Geely Automobile.
In the supermarket area of the automobile factory, there are many picking personnel, and the walking distance produces a large number of non-value-added actions, and Geely Automobile uses AGV to realize automated logistics transceiver storage and improve operational efficiency. There are many kinds of materials in the supermarket area, and data interoperability can be achieved through IWMS system software and Geely GLES, so as to achieve real-time feedback and intelligent operation and maintenance, so that the level of production and operation management can be further improved. The warehouse area is set up as dynamic inventory, reducing a large number of repetitive planning work, and realizing dynamic inventory through intelligent systems, making material storage more flexible and agile. The "goods to people" IWMS system and the Geely GLES system establish an interface to carry and transmit material information with a box two-dimensional code, which greatly improves the efficiency of material inbound and outbound under the high-speed operation logic of the server. Using two-dimensional code navigation technology, the accuracy rate of entering and exiting the warehouse in the freight lane area is 100%, and the overall efficiency level is increased by more than 20% after the line.
The goods-to-people intelligent logistics project has been officially landed in some factories of Geely Automobile
2. Unmanned delivery on the line
In the welding workshop of Geely Automobile, the application of AGV has realized unmanned line-side distribution, and lampless operation can be realized, which greatly improves the efficiency and quality of line-side distribution, and also reduces energy consumption.
AGV automated distribution realizes system software data connectivity, opens up the upstream and downstream business information flow, the line-side material information is directly transmitted back to the picker's driver terminal, and the AGV returns the empty appliances to the distribution point, and sends the full support spare parts and accessories completed by picking to the line edge. The system's complex scheduling algorithm can select the optimal distribution route for the robot, reduce the risk of production line stoppage, and through the system verification function, it can avoid the occurrence of mismatch and leakage, reduce the intensity of operation, and greatly improve the quality of distribution.
3. Visual receipt
In the inbound logistics link, the application of visual receiving door instead of traditional manual static box-by-box scanning and receiving, to achieve dynamic station receipt, while taking photos of the arrival status, and real-time series with IWMS system and GLES system, not only improve the efficiency of incoming logistics receipt, but also ensure 100% accuracy of receiving goods.
The application of the visual receiving door not only improves the efficiency of the admission logistics receipt, but also ensures the 100% accuracy of the receipt
4. Smart loading
In the packaging and loading of Geely auto parts, the intelligent loading system is applied to automatically generate the loading scheme.
Parts loading rate is directly related to logistics costs, the traditional mode is manual according to the "big not pressure small, heavy not light pressure" and other principles to calculate the placement of parts in the box, as well as the development of the final loading program, a large number of manual accounting may not be able to achieve the optimal loading rate, the highest efficiency, and intelligent loading software can automatically calculate and generate the optimal loading program, loading rate, application efficiency and visualization have been greatly improved.
5. Explore automatic loading and unloading
In 2021, Geely Automobile began to pilot the study of automatic loading and unloading truck operations, and in the process of research, it was found that there are two more mainstream ways for automatic loading and unloading trucks in the automotive industry: one is to apply unmanned forklift trucks for loading and unloading truck operations, but the efficiency and speed of unmanned forklift loading and unloading trucks are much lower than those of labor, which is not very applicable in the automotive industry; the second is to realize the one-time loading and unloading of complete vehicle pallets through the carriage transformation of transport vehicles, but this method has relatively high requirements for the packaging of parts and the standardization of pallet size. It will also affect the vehicle loading efficiency to a certain extent.
After fully considering the comparison, Geely Automobile decided to continue to explore the application of the second automatic loading and unloading truck method, and taking into account the loading efficiency and the relative factors in the distance and proximity, Geely Automobile decided to give priority to the pilot implementation of short-distance transport vehicles.
Third, Chunxiao KD smart workshop
Referring to the construction and application of the smart logistics system in the digital factory and the smart workshop, Dong Qingfeng focused on the Chunxiao KD smart workshop with a richer smart logistics scene to the reporter. Geely Automobile has bulk parts export overseas business (KD business), these parts need to be in the country for flipping operations, taking into account the urgent needs of production increase, reduce workshop work intensity and other urgent needs, in 2019 Geely Automobile comprehensive financial, human, material resources, the introduction of intelligent equipment solutions, independent development of systems, opened the Chunxiao KD workshop intelligent, digital transformation.
Digital applications can not only realize big data analysis in each link, but also realize information collaboration between various departments
1. Intelligent logistics equipment application
The workshop adopts intelligent AGV picking materials, breaking the traditional manual picking of materials, realizing the mode innovation from "people looking for goods" to "goods to people", solving the traditional mode of difficulty in finding goods, long time to find goods, and complex problems of goods inventory, so as to achieve production process monitoring and 100% accuracy of accounting.
In addition to the AGV goods-to-person picking scenario, a large number of smart wearable devices are also applied in the workshop, and the smart wearable devices can collect a series of data such as personnel efficiency and machine driving path in real time, and continuously optimize the machine running path and improve the efficiency of personnel operations through data collection and analysis.
KD workshop goods to people out of the warehouse picking operation
2. Digital logistics system
(1) Self-developed KDMS execution system
In the original operation link, from the task issuance to the control of the progress, as well as to the missing parts and the replenishment record, it was completed manually. In this regard, Geely Automobile independently developed the KDMS execution system, which realizes the intelligent recording and automatic control of all execution links in the Chunxiao KD workshop.
The KDMS execution system independently developed by Geely Logistics realizes the intelligent recording and automatic control of all execution links in the KD workshop of Chunxiao
(2) Logistics operation monitoring system
Through the RCS monitoring client, the operation status of the AGV in the unmanned warehouse is monitored, so as to form a real-time dynamic simulation, the system has the data middle office information such as the efficiency statistics in the unmanned warehouse, intelligent monitoring and optimization, intelligent connection of information business, dataization, and upgrade the post-event analysis to in-event monitoring and pre-warning.
(3) Logistics operation system
The material operation system can provide functions such as automated index detection and alarming, batch centralized deployment configuration, software version management, and efficient log analysis to help users find and solve problems in a timely manner, improve delivery and O&M efficiency, and provide a strong background guarantee for the business platform. There are 7 modules: homepage, alarm handling, status monitoring, system maintenance, log analysis, knowledge base and system management. They each have different functions to help users monitor software and deal with problems more efficiently and quickly.
3. Work flow
Through the combination of intelligent hardware and digital logistics system, Chunxiao KD workshop has realized the whole process of intelligent operation, and the core operation process is as follows:
(1) The KDMS system issues a request plan to SAP, SAP issues a kanban board to the supplier, the supplier delivers to the KD workshop according to the kanban board, the receiving team first uses a forklift to unload the material, places it on the AGV rack, and then uses the GLES system PDA to scan the kanban to receive the goods, through GLES and IWMS information transmission, mobilize the AGV to move the material from the connection area to the staging area.
(2) The KDMS system publishes the work tasks, and IWMS and RCS transfer the materials from the library to the corresponding stations according to the material inventory information and the KDMS work station information.
(3) After the bag turning operation, the finished material after PDA scanning group support triggers the unmanned forklift and AGV to be transferred to the packaging line and the manual packaging area respectively.
(4) The finished product tray that has finally been packed is transferred by forklift to the finished product area for shipment, and the information is synchronized to KDMS.
KD packing station operators complete the packing work according to the KDWS system interface instructions
4. Run effect
In the above main operation process, except for the third link function is still under development, the construction of the logistics system of the rest of the links has been completed. Dong Qingfeng said that Chunxiao KD Workshop is the first comprehensive combination project of information system and intelligent equipment in the KD industry, which redefines the development direction of the KD industry.
The landing and operation of this system completely broke the previous "manpower workshop" form of Chunxiao KD workshop: the forklift handling operation from the original connection area to the temporary storage area, the temporary storage area to the line edge was replaced by AGV; the intelligent system replaced the human brain to achieve on-site operation control, and the issuance of tasks, the control of progress, the recording of missing parts and replenishment were changed from manual to KDMS system; finally through the KDMS system and GLES system, IWMS system, The RCS system links AGV to achieve highly complex operations such as automatic distribution of line edges and task outgoing.
The production capacity of Chunxiao KD workshop has been increased from the initial 120 sets/day to 180 sets/day, which effectively improves the efficiency of on-site operations, simplifies the difficulty of on-site management, and achieves the ultimate goal of cost reduction and efficiency increase. Dong Qingfeng also mentioned that after the completion of all the links, the workshop capacity is expected to reach 240 sets / day.
Fourth, OTWB integrated logistics information platform
Under the layout of multiple factories, multiple warehousing/logistics centers, multiple parts suppliers, and multiple 4S stores, how to convert purchase orders and production orders into logistics orders? How can logistics orders be integrated with transportation and distribution to optimize logistics costs while maintaining efficiency? How is the logistics order information transmitted to parts suppliers and factories? To what point is the logistics order executed? How to update the information of the order in transit? What is the internal receipt, storage and delivery of goods in the transit warehouse? When will it be delivered to the OEM? Which route is optimal for shipping and distribution? It is not an easy task to integrate the order demand of thousands of 4S stores on the factory side, the transportation end, and the entire after-sales spare parts thousands of 4S stores, and to integrate all logistics orders and coordinate the warehousing operation, on this basis, but also to grasp the whole chain information of all parts in the pre-production, warehousing, production, transportation and after-sales in real time is undoubtedly to escalate the difficulty again.
In 2021, Geely independently developed the OTWB integrated logistics information platform landing application, which covers the order needs of all vehicle and parts factories, aftermarket spare parts factories, and thousands of 4S stores of Geely Automobile, and refines to the basis of logistics transportation, warehousing, sorting, packaging, distribution, etc., integrates and distributes logistics orders to the corresponding transportation, warehousing, distribution and other systems, and finally connects with the settlement system, forming a closed loop. Let the information flow of all parts and vehicles under Geely Automobile Group be integrated with real logistics, so that each individual product and part can be monitored and managed in real time in the whole process of production, and pre-prediction, operation and post-event tracking can be achieved.
Geely Logistics independently developed the OTWB integrated logistics information platform
It is understood that similar logistics information integration platforms have been relatively mature applications in e-commerce or express delivery companies such as JD.com and SF, but in the Chinese automotive industry, Geely Automobile is the first company to innovate and apply this system. Dong Qingfeng said that next, Geely Automobile will continue to optimize the OTWB integrated logistics information platform, connect the big data platform, add intelligent algorithms, supporting loading software, and finally achieve intelligent decision-making on the basis of intelligent analysis.
Fifth, "digital intelligence + low-carbon" to meet the future
"We believe that the future development trend of China's logistics should be viewed with a strategic vision of 'three years to see, five years to see'." In 2021, our department has sorted out internally: the visible development trend from 2022 to 2024 is the 'digital and intelligent transformation of logistics' and 'low-carbon development of logistics'. The development trend after 2025 and the new technological innovation points need to be explored simultaneously, and next, we will adhere to the development path of first pilot and then promotion." Dong Qingfeng told reporters.
Green logistics park, to build a self-produced green ecological park
Digitalization: First, do a good job of data collection, comprehensively collect basic data; second, to promote the agile development of logistics software, the current stage of software development is no code development, but basically through IT personnel development, and in the future, hope that business personnel can also be able to rapidly develop in the software application system; third, in the data analysis layer, most of the current is still in the auxiliary analysis and decision-making stage, the future will be towards the direction of AI independent analysis, independent decision-making, independent adjustment, to achieve operational optimization.
Logistics facilities and equipment: So far, Geely Automobile has planned the national 10+ 19 warehouse layout, in 2022 will fully carry out warehouse deployment, increase the landing of 2C terminal warehouse network, and strengthen the intelligent equipment application of warehousing, transportation, distribution and other links, effectively realize the unified warehouse co-allocation, reduce roundabout transportation, and maximize the efficiency of warehousing and logistics.
Low carbon: According to the carbon peak and carbon neutrality timetable, Geely Automobile Group has formulated two blue action plans, which not only retain the advantages in the field of intelligent energy-saving and new energy vehicles, but also open up a new situation of intelligent pure electric vehicles. In terms of logistics, Geely Automobile actively tries to apply electric trucks in short-distance transportation, and has been laid out around "producing green electricity, using green electricity", at present, Geely Automobile has more than 1 million square meters of storage area in the country, we will optimize the layout of these warehousing outlets, continuously implant green concepts, vigorously develop green logistics parks, and build self-sufficient green ecological parks, such as: the resulting green electricity will be used for electric freight vehicles in logistics and transportation. In the near future, Geely Automobile will realize a virtuous cycle system of generating and using green electricity in the logistics business.
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