First, the background of the project
Fusheng Logistics was established in 2000, the vice president unit of the Auto Logistics Branch of China Federation of Logistics and Purchasing, and is a national "AAAAA" level logistics enterprise. The company employs more than 2,000 people, and its business scope covers all aspects of the automotive logistics supply chain. At present, it provides after-sales spare parts supply chain services for multiple brands such as AUDI brand/Volkswagen brand/Jetta brand, FAW Hongqi, FAW Jiefang, FAW Besturn (FAW Mazda) and other brands, and provides pre-production distribution business for new energy batteries for Hongqi and Besturn; The total area of warehousing in the country exceeds 700,000 square meters, more than 60 trunk lines transport lines, more than 800 regional distribution lines, more than 1,500 self-owned and controllable transport capacity, more than 2,600 terminal stores, the comprehensive strength in the field of automotive spare parts logistics ranks the forefront in China, the annual spare parts throughput is about 35 billion yuan, and the service content covers pre-production, production, after-sales parts transfer, warehousing reception, storage management, outbound distribution, transportation services, logistics packaging, logistics equipment, information services and other integrated professional services of the whole supply chain.
With the state and Jilin Province successively issued the "Opinions on Promoting the High-quality Development of Logistics to Promote the Formation of a Strong Domestic Market", "Jilin Province's Manufacturing Digital Development "14th Five-Year Plan" and other content, it is not difficult to see that the entire policy orientation attaches importance to Industry 4.0 intelligent logistics, coupled with the fact that 5G commercial use has gradually become the mainstream in recent years, the logistics and warehousing industry is transforming to 5G, collaboration, digitalization, intelligence and transparency, and intelligent and efficient digital warehousing has become a trend.
As a high-end independent brand of domestic automobiles, Hongqi's vehicle sales have increased year by year, and the sales of spare parts have shown a rapid growth trend. However, the construction of high-standard warehouses and business operations has not yet achieved the desired results, and it is difficult to support the requirements of high-end and exquisite services of Hongqi. It coincides with the fact that Fusheng Group clarifies the necessity of digital and intelligent transformation and reform, and establishes the strategic requirement of "science and technology leading the future". In addition, after years of deep cultivation in the warehousing industry, Fusheng Logistics has completed the construction of the technical architecture of digital intelligent logistics, has the ability to form an integrated solution for supply chain logistics, and also has the core competitiveness of Hongqi business to develop the moat. Therefore, Fusheng Logistics will build an exclusive "Digital Wisdom Cloud Cabin" tailored for Hongqi's high-end and exquisiteism, and boost Hongqi's new Hongqi brand strategy of "China's first, world-famous" and "new noble brand". "Digital Wisdom Cloud Cabin" integrates management methods, operating modes, standardization, ultimate service, technology-driven, information system, intelligent logistics, intelligent equipment and other elements as a whole, creates logistics industry standards, sets up digital warehousing benchmarks, realizes digital, intelligent and lean management, shows the social influence of Hongqi spare parts, and reflects the core brand competitiveness of "Fusheng Logistics".
Therefore, adhering to the design concept of leading digital intelligence technology, first-class logistics efficiency and advanced operation mode, in 2021, Fusheng Logistics completed the "Digital Intelligence Cloud Cabin" 5G intelligent warehouse project of 24,000 square meters and 8 billion yuan of "Digital Intelligence Cloud Cabin" in 2021 at No. 0618 Tengfei Avenue, Gongzhuling Economic Development Zone, Jilin Province. The construction of "Digital Intelligence Cloud Cabin" to meet the development of Hongqi's spare parts business in the next three to five years and support Fusheng Logistics' own digital and intelligent transformation and upgrading into the overall strategic goal, through digital and intelligent means, to achieve lean production, digital management, visual monitoring and intelligent decision-making from the plan to the whole process of spare parts delivery.
"Digital Wisdom Cloud Cabin" is equipped with a 5G private network to achieve 5G coverage of the whole library, including 11 intelligent logistics technologies such as intelligent warehousing visualization digital twin system, SCV operation cockpit, WMS warehousing management system, multi-wear intelligent storage, etc., supplemented by the existing TMS waybill management system, PMS packaging material management system, spare parts inspection system, Qisheng documentary APP, etc., to achieve a comprehensive digital intelligence empowerment upgrade of the three major technologies of warehousing in, storage and exit, warehousing, transportation and packaging.
2. Construction planning
data analysis
According to the "Logistics Planning and Design Model" of Fusheng Logistics, the first step in the entire construction planning is the extraction and processing of data. Export the inbound data, outbound data, WMS master file data, personnel data, and equipment data separately, and convert various raw data into analytical tables used for business demand characteristic analysis through data conversion relationships.
Through the analysis table, the analysis content used for the analysis is extracted, and then different analysis methods are used to complete the data analysis of different modules. In the "Digital Wisdom Cloud Cabin", the analysis of the ABC classification module is realized by using the material, customer and supplier analysis methods through the basic data such as capital occupation, outbound frequency and outbound quantity; Through the four basic data of EN, EQ, IQ and IK, the data analysis of the order material analysis module was carried out using the EIQ analysis method; Through the data content of the order model and safety stock, the order system analysis module is realized; Through the five basic data of PCB-EN, PCB-EQ, PCB-capital occupation, PCB-IQ, PCB-IK and pcb-IK, the three analysis methods of PCB analysis method, PCB-EIQ analysis method and PCB-ABC analysis method were adopted to realize the data analysis of storage and transportation units.
Storage mode
For the storage of spare parts in the warehouse, due to the weight, volume and difficulty of handling, the use of shelves for storage, intelligent equipment for storage in and out of the warehouse, to achieve excessive cost and safety risks, and in and out of the warehouse efficiency and traditional forklift operations is not large, so the plan to use the pile area storage. Small and medium-sized spare parts first need to classify different types of small and medium-sized spare parts according to the parameters of the frequency of the warehouse, the value of the spare parts according to the analysis results of the ABC classification method and the EIQ analysis method, clarify the flow rate, and place different spare parts at different distances from the storage area and the outgoing area. According to the usable area, spare parts SKU, required time limit for leaving the warehouse and other contents, MTM calculation method to clarify the specific number of shelves and other accurate information, determine the storage method that can be used, in this link of the calculation needs to consider the business growth in the next few years. Then, after the calculation of relevant economic indicators such as the return on investment period, the most suitable storage method for small and medium-sized spare parts is selected.
Process development
"Digital Intelligence Cloud Cabin" optimizes the process of different operation contents according to the different modes of actual warehousing operations. Such as the warehousing mode, for the unloading and listing content, through the deployment of gravity packaging semi-automatic slide rail and WMS system access, to achieve unloading and listing process development and optimization; Material storage mode, by distinguishing ABC class combined with WMS system to achieve optimal storage design, to meet the process development and optimization of material storage mode; The storage area configuration and area measurement mode realize the process formulation and optimization of the pile area, large area and small piece area through the data analysis in the early stage and the four-way multi-wearing three-dimensional library equipped with the "Digital Intelligence Cloud Cabin"; Through data measurement and the installation of stackers, AGVs and other equipment, to achieve the process development and optimization of sorting modes such as fruit picking and seeding; Through the intelligent device RFID transmission sorting line and WMS warehouse management system to achieve the process development and optimization of the outbound mode.
Layout within the library
The planning layout of the "Digital Wisdom Cloud Cabin" first sorts out the process of the on-site business, and calculates the corresponding required number of personnel, personnel activity area, vehicle dock number, use operation area and other content through the data input of business volume (daily, weekly, monthly receipt and shipment volume). After the above content is calculated, the overall layout planning is carried out in combination with the shape of the warehouse, that is, the length and width, and the U-shape, I-type or other layout method is selected, and then the SLP layout analysis method is used in combination with the relevant national fire protection policy requirements for the division of the internal storage area, the outbound area, the storage area and other partitions, as well as the clarification of the movement lines of personnel, vehicles and intelligent equipment.
Simulation
After the storage method, operation process and layout plan planning and design of the library are completed, the "Digital Wisdom Cloud Cabin" realizes the assessment of the input and economy of warehousing resources according to the facility utilization rate, equipment busy ratio, personnel busy ratio and other contents through FlexSim simulation software; Through the calculation of cost and resource utilization, the index evaluation method is used to provide data support for the final program decision.
Third, the application of 5G technology - breaking through the information boundary
For automated warehouses, the most important thing is the network. The debugging application of every smart device and every employee's handheld terminal requires a network, the linkage between different devices requires a network, and the construction and application of an information system also needs a network. It can be said that from the construction and implementation stage of the warehouse, the importance of the network is reflected. For the warehousing industry, the popularity of 5G networks has brought a new ceiling to automated three-dimensional warehouses.
Efficient transmission
"Digital Wisdom Cloud Cabin" is the first 5G enterprise private network full library coverage in Jilin Province, the whole library enjoys the high rate, high stability and low latency brought by 5G, the transmission rate is increased by more than 10 times in terms of traditional warehouses, based on normal demand of 60 milliseconds, greatly increased to 13 milliseconds, and the response speed is greatly increased by 30%-500% according to the link. Taking actual use as an example, the number of supported AGV trucks is increased from 10 to more than 1,000 under the condition that the rate delay is unchanged, and the service is not limited, and a variety of terminals are supported. The MEC edge cloud computing center, which is built in parallel with the deployment of 5G private networks, also uses hardware resource virtualization technology to pool the network latency by 30% compared with traditional servers and public cloud architectures, and the computing response rate is increased by 30%, meeting the business needs that will increase significantly by five times in the next five years.
Communication security
The construction of the "Digital Intelligence Cloud Cabin" 5G private network can effectively prevent the phenomenon of commercial espionage, because the data in the 5G private network is isolated and processed separately from the public 5G network, which can ensure that the data related to the operation process is completely protected by privacy, and at the same time, the sim card identification technology is adopted for the terminal, so that the possibility of being hacked is 0. At the same time of 5G network deployment, "Digital Intelligence Cloud Cabin" synchronously builds the MEC edge cloud computing center to realize that data traffic does not leave the park, the risk of data outflow is reduced to 0%, and it provides virtual server mirroring and snapshot functions, and the server fault data can be quickly restored without loss, ensuring the security of equipment information and making equipment operation more reliable.
Lay out the future
"Digital Intelligence Cloud Cabin" realizes the independent sale of 5G cards within the enterprise, and each device can issue cards independently, laying the foundation for the interconnection of all things in the park and the realization of the fifth-generation mobile communication network, so that thousands of devices can be networked and communicated. In the future construction, "Internet of Everything" will also gradually develop from "digital intelligence cloud cabin" to smart parks, realizing the upgrade from full-library 5G network coverage to full-park 5G network coverage.
Fourth, the application of digital intelligence technology - to break down the space barrier
The so-called "digital intelligence cloud cabin", "number", 5G as the core of the digital operation; "Wisdom", intelligent operation represented by unmanned warehouses; "Cloud", focusing on data security and shared infrastructure cloud and fast development cloud; "Cabin", focusing on the panorama of storage functions, scientific and technological sense, gives a wide range of three-dimensional space. As the name suggests, the "Digital Intelligence Cloud Cabin" integrates a variety of digital systems and intelligent equipment in the 5G environment to build a scientific and technological and modern 5G intelligent warehouse.
Unloading – Gravity packing semi-automatic slides
After the vehicle arrives at the unloading area, it is usually faced with the problem that the operation requires a worker site and a vehicle unloading site, which occupies two parts of the area but cannot fully realize the diversion of people and vehicles. At the same time, after the completion of the handling between the two parts of the site, special forklifts are also needed to place the spare parts unloaded to the operator area to generate personnel and equipment input.
The "Digital Wisdom Cloud Cabin" deploys gravity-type packaging semi-automatic slide rails to replace the traditional forklift operations, realizing the emergency order of spare parts, reducing the secondary search operation of the operators and greatly improving the operation efficiency. At the same time, the problem of intersection between personnel and vehicles has been completely solved, and the diversion of people and vehicles has been realized, and the safety of on-site operations has been guaranteed. Through the construction of gravity-type packaging semi-automatic slide rail, reduce a site, directly reduce the area of packaging operation area by 1,000 square meters, and directly reduce the rent by 350,000 yuan per year; Reduce forklift investment and reduce costs by nearly 100,000 yuan per year; Improving the efficiency of operation also ensures the safety of operation.
Inbound link - AGV
After the packaging operator completes the secondary packaging, the traditional warehouse uses forklifts to store the packaged spare parts into storage. Point-to-point forklift handling reciprocating operations waste manpower, equipment resources and low efficiency.
In the "digital intelligence cloud cabin", the introduction of AGV unmanned trucks to replace the traditional forklift handling, the operator can issue instructions through the PAD, call the AGV trolley to achieve automatic handling from the packaging area to the multi-wear three-dimensional library area, the attic area. In the "Digital Intelligence Cloud Cabin", the AGV car used is a latent jack-up AGV in the 5G environment, with a bicycle speed of up to 1.5m/s, which can handle the handling of 60 consignments of goods per hour, directly improve the efficiency of small and medium-sized pieces into the warehouse by 50%, and indirectly improve the packaging efficiency by 30%. Reduce the number of people in the handling operation, it is expected to save 350,000 labor costs per year, and at the same time realize the unmanned handling and the diversion of people and vehicles in the storage stage.
Warehousing link - four-way multi-wear three-dimensional library
In traditional warehouses, traditional shelves are often used for spare parts storage. The number of spare parts stored per unit area is small, and the utilization rate of warehouse area is also low. In the face of the increasing number of spare parts warehousing and logistics categories year by year, there will also be an increase in management difficulty and a decrease in picking efficiency.
The storage selection application for small and medium-sized spare parts in the "Digital Intelligence Cloud Cabin" is equipped with a multi-wear three-dimensional library of four-way shuttles. The whole area covers an area of 800 square meters, a total of 16 rows, 8 roadways, 60 columns and 13 floors, 12480 6433 TEUs, to meet the use of more than 36,000 cargo spaces, can achieve 600 boxes per hour operation efficiency. The equipment adopts three-dimensional intensive, multi-layer shuttle technology and 8-to-5 sorting technology, and through the self-developed reservoir-level WMS system and WCS scheduling system, it has functions such as warehousing detection, hierarchical storage, automatic inventory, etc., and realizes the automatic arrival of goods on and off the shelves.
Through the construction of the four-way multi-pass three-dimensional library, the storage height is increased from 6 meters to 8 meters, the roadway is reduced from 1.2-3.2 meters to 0.8 meters, the unit area capacity rate is increased by 2.8 times, the effective inventory area is saved by 2,000 square meters, and the rent is directly reduced by 700,000 yuan per year; the picking efficiency is increased from 30 lines / h to 300 lines / h, and the number of small and medium-sized pickers is reduced by 62%. Reduce 10 sets of logistics equipment, 10 people to pick goods, and reduce logistics costs by nearly 2 million yuan per year; Through scanning code into the warehouse, intelligent equipment to pick up goods, scanning code out of the warehouse to achieve 100% of the accuracy of small and medium-sized parts, parts picking accuracy increased to 100%, logistics accuracy of 100%.
At the same time, the "Digital Wisdom Cloud Cabin" has also been adapted to the improvement of enterprise characteristics and the research and development of better auxiliary devices, such as due to the excessive number of spare parts in the automotive aftermarket industry, the "Digital Wisdom Cloud Cabin" will be partitioned for each spare parts box, and system improvement and upgrading will be carried out to adapt to the situation that a material box contains a variety of spare parts. In order to better facilitate the operation of multi-wear intelligent storage employees, the "Digital Wisdom Cloud Cabin" has also carried out the research and development of relevant utility model patents - easy-to-use manual picking positions, and optimized and improved the operation efficiency and operation safety of operators through the study of human body mechanics.
Outbound link - RFID transmission sorting line
In the outbound process, the logistics industry has the two characteristics of corresponding target customers and many types of spare parts. Therefore, the long handling distance in the warehouse, the high frequency of handling, the time-consuming sorting and the low sorting accuracy rate have become the common pain points of the entire industry.
"Digital intelligence cloud cabin" adopts the RFID transmission sorting line of the collection of WCS scheduling system, RFID technology and two-dimensional code recognition technology to realize the distribution of operators by address according to the destination area, the outbound sorting efficiency can reach 1800 boxes per hour, the overall operation efficiency is increased by 200%, the sorting accuracy of small and medium-sized parts is increased by 100%, and the delivery accuracy is improved by 30% compared with traditional manual sorting. One-time reduction of the investment in handling and picking personnel and forklifts for enterprises, reducing costs by nearly 1.5 million yuan per year. The realization of unmanned handling and sorting reduces the crossover of people and vehicles, and improves the safety of outgoing operations.
Digital Operations – WMS Warehouse Management System
If the business process of "Digital Intelligence Cloud Cabin" is sorted out, it is not difficult to find the importance of the WMS warehouse management system, and the whole process of warehousing of receiving, warehousing, listing, inventory, removal and outgoing storage is inseparable from the support of the WMS system. In contrast, if the traditional warehouse does not have such a set of system support, while losing market competitiveness, it will also face many core pain points such as the large time difference between real logistics and information flow, opaque business process management, no precipitated data to support decision-making, labor load cannot be automatically counted, and work efficiency cannot be quantified.
Under the premise of doubling the Hongqi business, due to the use of the WMS system, the on-site operation has not increased the input of personnel and also met the requirements of the outbound production beat, saving 500,000 yuan in operating expenses every year. At the same time, through the construction of WMS warehouse management system, the accuracy rate of on-site receiving, listing, picking and reviewing business has reached 100%, which is 230% higher than that of the system before deployment, the picking time is increased by 78%, and the packing efficiency is increased by 31%. The construction of WMS systems in terms of other implied values provides data support for wave logic, batch management, expiration date management, and ABC classification; For the management of the import, sale, storage and other aspects of the spare parts, it is well documented and traceability is improved; For inventory discrepancies to be found in time, the scope of inquiry can be greatly narrowed after the discrepancies; Provide accurate data basis for various lean management improvements.
Visual Management – SCV Operational Cockpit
Based on the industry data scattered in multiple systems and local files, the traditional report in the display of data trends, problem traceability data layer by layer drilling performance is not satisfactory, can not meet the requirements of data analysis and data collection workload is large and timeliness is low, data files can not be unified management, low security and data report production inconvenient pain points, "digital intelligence cloud cabin" development equipped with SCV operation cockpit.
SCV operation cockpit is a digital decision-making support system based on data extraction technology, which transforms the operation status data of Hongqi's 9 warehouses from traditional manual collection to real-time automatic collection of digital systems, and displays the report implementation in large screens, PCs, and mobile terminals, so that data analysis work can sink to the information clerk without the need to set up data analyst positions, data analysis efficiency is increased by 90%, data collection accuracy rate reaches 100%, and quantitative annual operating costs are saved by 280,000 yuan. The deployment of SCV operation cockpit makes operations visible, data credible, and decision-making more intelligent, realizing the transformation from empirical management to digital management, and providing real digital support for operational evaluation and resource allocation decisions.
Control Hub – Intelligent Warehouse Visualization Digital Twin
For traditional warehouses or automated three-dimensional warehouses that have gradually undergone digital and intelligent transformation, they will face the problem that each business system is relatively independent, forming a data island and there is no intuitive all-scenario visualization and comprehensive display platform. And this problem will be more and more aggravated with the transformation of digital intelligence, with the investment of various intelligent equipment, a variety of systems will be more and more, coupled with the company's own warehousing, transportation, packaging, monitoring and other systems, the work of managers will become more and more complex. In this regard, "Digital Intelligence Cloud Cabin" provides a solution for intelligent warehousing visualization digital twin systems.
Through data acquisition and intelligent perception, the digital twin system accesses the data of various systems such as AGV, multi-wear three-dimensional library, transmission sorting line, WCS, WMS, UWB, camera monitoring, etc., connects applications and controls equipment, solves the problem of data islanding, and realizes full-link data collection, system-wide data fusion, and all-scenario digital twins of logistics. Through the deployment of the digital twin system, the intelligent equipment operation and maintenance mode is transformed from passive to active operation and maintenance mode, the equipment utilization rate is increased by 30%, the operation and maintenance efficiency is increased by 50%, the management personnel reduce the labor cost by 200,000 yuan per year, and the equipment damage maintenance cost is saved by 100,000 yuan per year; Through the all-factor visual display platform, the efficiency of personnel and equipment scheduling and management is increased by 50%; Through the prediction model, situation awareness, data analysis efficiency is increased by 100% compared with the original manual statistical mode, intuitively reflecting the dynamics of warehousing business, providing data support for enterprise decision-making. It provides managers and customers with a "God perspective" to provide visual tool support for lean process optimization.
Future Exploration - Intelligent Equipment Lab
Focusing on the future, in order to ensure the future "digital wisdom pilot", "Digital Intelligence Cloud Cabin" has built a 5G intelligent equipment laboratory, based on the 5G-SA enterprise private network, intelligent equipment + intelligent logistics practical application as the landing scenario, focusing on intelligent interaction, intelligent perception, intelligent production, intelligent management, digital intelligence research and research, supporting the incubation and application of "digital intelligence cloud cabin" digital intelligence technology. For various cutting-edge technologies in the industry, the method of simulating the on-site working environment inside the warehouse through the intelligent equipment laboratory is used to judge the feasibility of the implementation of the technology and the economic benefits of the enterprise, and to determine the "digital intelligence pilot" technology that is most suitable for the development of the enterprise.
5. Project construction management
With reasonable planning, a set of supporting good project management system is also required to ensure the perfect implementation of the project. In the construction process of "Digital Wisdom Cloud Cabin", a project management system with a four-level management model is proposed, namely the strategic layer, the tactical layer, the implementation layer and the precipitation layer.
Strategic layer
From the strategic level, the project is controlled as a whole, and the overall project "digital wisdom cloud cabin" is divided into 9 key "campaigns" in the order of priority, and the responsible person, construction period and strategic deliverables expectations are formulated for each "campaign", and reviewed every month.
Similar logistics warehouse construction projects can refer to the nine "battles" of this project to control the overall project process: project planning; Building construction; Formalities; Intelligent equipment recruitment; Debugging of smart devices; Joint commissioning; Procurement of storage equipment; Installation of storage equipment; Warehouse relocation.
Tactical layer
For each "battle", according to the type of project, professionals are matched, and the progress of sub-projects is controlled by item, and the inspection is carried out every half month.
For similar logistics warehouse construction projects, each "battle" can be divided into three types of "tactics" that are the same as the "digital wisdom cloud cabin": civil construction; Smart devices; Warehouse relocation class.
Implementation layer
For each task holder, from the specific implementation level, the Project project management software and professional project management system are adopted to accurately control the progress of each task according to the key nodes and track it weekly.
Taking the smart device project in the "Digital Intelligence Cloud Cabin" as an example, it can be divided into the following implementation steps: demand analysis; Technical demonstration; Manufacturer collection; Vendor screening; Manufacturer inspection; Preparation of technical mandates; Commercial procurement; Product production; Preparation before admission; Installation and commissioning; Acceptance; O&M tracking.
Precipitation layer
For the documents and photos generated during the entire project process, the folder tree structure is adopted for real-time archiving and preservation, which is convenient for mode precipitation and project review.
After the completion of the entire project, the "Digital Intelligence Cloud Cabin" project team conducts a review analysis according to the following steps to prepare for the next "Digital Intelligence Cloud Cabin": document collection; Documentation collation; Problem generalization; Analysis and review; Pattern precipitation; Effect verification; Improved upgrades.
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Sixth, the cloud cabin opens
After data analysis, program planning, logistics simulation and program demonstration in recent months, the one-year "Digital Wisdom Cloud Module" was officially completed today under the orderly progress of all projects. As the central library of Changchun Hongqi spare parts, Hongqi "Digital Wisdom Cloud Cabin" has created a new chapter in the sustainable development of Fusheng Logistics and the transformation of digital intelligence, and will surely become an important force to help the strategic development of Hongqi brand.
Through the empowerment of eleven digital intelligence technologies, the "Digital Wisdom Cloud Cabin" effectively saves 6791 square meters of storage area, achieves a 70% improvement in overall efficiency, saves 20% of operation management personnel, doubles the amount of storage and does not increase the storage area and operators. In the next three years, the annual throughput capacity of the "Digital Wisdom Cloud Cabin" can reach 45 million pieces, which will provide low-cost, high-efficiency, low-consumption and high-yield digital intelligence supply chain services for a total of 315 Hongqi dealers and more than 700 suppliers in 34 regions across the country, and export the mature digital intelligence operation system of the digital wisdom cloud cabin to more automotive spare parts supply chains, further accelerating the development of smart logistics.
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Article source: FAW Fusheng Logistics
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