Wen|Jiangsu Huazhang Intelligent Technology Co., Ltd
Shen Popo
Evergreen Group is a leading enterprise in the printing and manufacturing industry in mainland China, and by joining hands with Huazhang Intelligent to build an automated warehouse project, its printing equipment manufacturing center has been upgraded to achieve efficient storage and order processing, improve product warehousing efficiency and logistics efficiency, which not only helps its own business development, but also becomes a highlight and breakthrough in the printing and manufacturing industry.
With the continuous change and development of the manufacturing industry, improving the utilization rate of warehousing and warehousing efficiency, and achieving cost reduction and efficiency increase, has become a more and more concerned issue in the manufacturing industry, and the same is true in the field of printing equipment manufacturing.
During the "Thirteenth Five-Year Plan" period, the total output value of the mainland printing industry ranked second in the world, and the compound annual growth rate of digital printing exceeded 30%, showing the vigorous development momentum and huge market potential, and driving the growth of local printing equipment brand enterprises, Tianjin Evergreen Technology Group Co., Ltd. (hereinafter referred to as "Evergreen Group") is a typical representative of it. In the "14th Five-Year Plan", in order to comply with the general trend of digital and intelligent transformation of the printing industry, Evergreen Group focuses on realizing intelligent production by building intelligent factories, one of the important tasks is to work with Jiangsu Huazhang Intelligent Technology Co., Ltd. (hereinafter referred to as "Huazhang Intelligence") to build an automated warehouse project, so that the intelligent level of its equipment manufacturing and logistics operations has been significantly improved.
1. Company profile
Tianjin Evergreen Technology Group Co., Ltd. was established in 1995, headquartered in Tianjin Beichen Economic Development Zone, listed on Shenzhen Growth Enterprise Market in March 2011, the company's business mainly includes printing equipment manufacturing, medical device production and sales, financial leasing services, etc. Through continuous cultivation and innovative development, Evergreen has become a leading enterprise in China's printing equipment manufacturing and a world-renowned high-end printing equipment service provider.
Evergreen Group joined hands with Huazhang Intelligent to build an automated vertical warehouse and realize the "intelligent manufacturing" upgrade of printing equipment
At present, the company has independently developed and completed more than 100 products of 10 major product series, such as hot stamping machine, die cutting machine, inspection machine, folder-gluer, digital inkjet printer, laser die cutting machine, gravure printing machine, etc., many of which are the first in China and reached the world's advanced level, and the products are sold in more than 80 countries and regions around the world, and the market share in the domestic printing and packaging equipment segment is in a leading position for a long time.
In the process of development, Evergreen has the ability to provide system integration service solutions for related industries, and was rated as a national intelligent manufacturing system solution provider in the printing and packaging industry in 2020. Through the integration of resources, Evergreen has also continued to expand its business fields, and in recent years began to actively expand the field of medical equipment and new energy equipment manufacturing. In the future, it will also take printing equipment manufacturing as the core, develop along the upstream and downstream of the equipment manufacturing industry chain, and develop in synergy with the company's service, investment and financial leasing business. Through open cooperation with ecosystem partners, we strive to become a leader and comprehensive service provider in the industrial ecosystem, through service innovation and continuous empowerment of customers.
Second, the background of the project
With the development of the company and the changes in the printing equipment market, Evergreen Group actively promotes the transformation of intelligent manufacturing, and urgently needs to improve and upgrade the logistics system. According to the relevant person in charge of Evergreen Group, in terms of logistics operation, Evergreen Group not only faces common problems in the industry such as rising production costs, insufficient storage space, and rigid environmental protection constraints, but also has specific tests such as many enterprise SKUs, different parts specifications, different weights, and relatively large differences.
In this context, the "Tianjin Evergreen Printing Equipment R&D and Manufacturing Project" was officially launched, and chose to cooperate with Huazhang Intelligent to carry out the planning and construction of automated warehouses. Evergreen said that Huazhang Intelligent has more than 20 years of accumulation in the field of shuttle robots, and can provide full-process intelligent logistics solutions for many industries, and its technical strength and project experience are very strong, so it finally chose to work with it to build a project.
According to Evergreen, the company has always been committed to optimizing the production structure, reducing costs and increasing efficiency through intelligent manufacturing, and enhancing the competitiveness of enterprises through digital intelligence reform. How to apply advanced technology to simplify complexity, reduce costs and increase efficiency, and win competitive advantages is the core point of its greatest concern. To this end, Huazhang Intelligent cooperated with Evergreen's subsidiary Ronglian Huizhi to customize and launch a planning scheme suitable for Evergreen Group, providing one-stop overall solutions including program consultation, planning and design, project integration, logistics equipment supply, installation and commissioning, training and after-sales, etc., to help Evergreen Group successfully complete the transformation from "people looking for goods" to "goods finding people" logistics mode.
After the project is put into use, the efficiency of raw materials in and out of storage is greatly improved
3. Project overview and main process
According to reports, the automated warehouse area of about 6870 square meters, the building height of 10 meters, according to the building scale, site conditions and business characteristics and other factors, the space layout has been customized planning and design, the overall layout includes receiving temporary storage area, quality inspection area, turnover box storage area, pallet storage area, sorting storage area, floor stacking area, shelf storage area, etc.; Among them, the turnover box storage area has a total of 4 roadways and 24,000 storage spaces; There are a total of 5,536 pallet storage areas, 4 lanes of single extension storage, more than 50,000 SKUs, and 5 picking ports and 1 intake.
As a smart logistics solution provider of the project, Huazhang Intelligent integrated and applied warehouse management system (WMS), stacker crane warehouse, multi-layer shuttle truck warehouse, "goods-to-person" picking system, KBK and other equipment in the project, realizing the process from raw material warehousing to "goods-to-person" picking automatic transportation, and its operation process includes:
1. Stacker vertical warehouse
(1) Raw materials are stored
(1) Whole support storage: the manual forklift will transport the whole material to the pallet storage port, weigh and size test qualified, and then transport it into the stacker vertical warehouse storage through the pallet line.
(2) Consolidation and storage: the manual forklift will move the loose materials to the working station, and the workers will move the flat pallet materials to the online pallet through KBK, and after the pallet is weighed and the size test is qualified, it is transported into the stacker warehouse by the pallet line for storage.
(2) Exception handling
(1) Abnormal storage of the whole support: when the whole support is put into storage, if the weighing and size detection are abnormal at the storage port, it will be reversed back to the storage port through the pallet line, and the secondary weighing and size testing will be qualified after manual processing, and it will be transported into the stacker warehouse for storage through the pallet line.
(2) Abnormal storage of assembly: When the pallet after the completion of the assembly is put into storage, if it is shown to be abnormal by weighing and size testing, it will be circulated to the assembly station through the line body, and the secondary weighing and size inspection will be qualified after manual processing, and it will be transported into the stacker warehouse for storage through the pallet line.
(3) Raw materials out of the warehouse
(1) Whole warehouse outtake: the system issues the warehouse task instruction to the stacker, and the stacker transports the outgoing whole material to the warehouse according to the task instruction, and transports it to the whole warehouse outlet through the pallet conveyor line.
(2) Picking library: the system issues the library task instruction to the stacker, the stacker transports the outbound whole material to the warehouse according to the task instruction, and transports it to each picking station through the pallet conveyor line, and the worker picks the material according to the PC display work order information, picks the material and places the work order carrier, and the tail support is returned to the warehouse for storage.
2. Multi-storey shuttle car warehouse
Huazhang intelligent shuttle system played an important role in the project
(1) Raw materials are stored
It needs to be turned into the warehouse, that is, the manual forklift will move the scattered materials to the changing station, and the workers will put the materials into the turnover box after binding the material information with the turnover box information, and after the box is turned over, they will be weighed and dimensionally tested and qualified, and transported into the multi-layer shuttle truck vertical warehouse for storage through the box line.
(2) Exception handling
(1) Abnormal weighing: the bag turning station is equipped with a weighing detection device, and if the turnover box completed by the bag turning is weighed abnormally, it will be manually processed until it is qualified and released into storage.
(2) Size detection library: the box turned over the box is tested by the box line, and the material height exceeding the box height is judged to be an abnormal box entering the abnormal port, and after manual processing, it is tested again and stored in storage.
(3) Raw materials out of the warehouse
(1) Picking library: the system issues the library task instruction to wear up to the car, and the multi-pass vehicle moves the outbound full box of materials to the warehouse according to the task instruction, and sends them to each picking station through the box-type conveyor line, and the workers carry out the picking operation of the materials according to the PC display work order information, pick the materials and place the work order carrier, and return the tail box to the warehouse for storage.
(2) Pre-picking operation: the system issues a library task instruction to more than one car, and the multi-pass vehicle moves the outbound full box of materials to the warehouse according to the task instruction, and sends them to each picking station through the box conveyor line, and the workers carry out the picking operation of the material according to the PC display work order information, the picking materials are placed in the turnover box bound to the work order, the tail box of the picking is returned to the warehouse for storage, the work order box is temporarily stored, and the outbound instruction is waiting for the outbound instruction for operation.
Fourth, the highlights of the project
On the whole, the project planning and construction comprehensively considers the actual logistics pain points and transformation and upgrading needs of Evergreen Group, and has outstanding performance in space utilization, flexible storage, flexible expansion and other aspects. Compared with similar projects, the project mainly presents four highlights:
Highlight 1: Different product specifications, box type and pallet storage methods are shared
The parts involved in the project have different specifications and sizes, Huazhang Intelligent adopts box-type storage and pallet-type storage sharing mode according to the characteristics of user products, and the turnover box storage area has a total of 4 roadways and 24,000 storage spaces; There are a total of 5,536 pallet storage areas, and 4 roadways for single-extension storage. At the same time, due to the different weights of the goods, Huazhang Intelligent will match the light and heavy items well during the storage process to ensure the stability of the system operation.
Highlight 2: Rainbow storage, solving the problem of multiple SKUs and categories
The project has many product categories, the number of SKUs has reached more than 50,000, Huazhang Intelligent adopts the principle of rainbow storage method in the design to achieve one box/one tray of multiple products, which greatly increases the storage volume ratio.
Highlight 3: Flexible combination of software and hardware, picking and warehousing at will
According to the user's storage needs, Huazhang Intelligent converts the "4+2" mode (4 picking ports, 2 inbound ports) into "5+1" (5 picking ports, 1 incoming port), provides flexible software and hardware combinations, sets up box warehouses and pallet warehouses, and each "goods-to-person" platform can carry out picking and warehousing operations, and can be switched at any time.
Highlight 4: Single-sided hoist and unilateral temporary storage module, reducing costs and increasing efficiency
In order to solve the overall budget, a single-sided hoist and a unilateral temporary storage module were adopted (similar companies did not have much successful experience before), as well as a two-way operation mode. In the industry, the efficiency of the layer change hoist is mostly 60~80 sets / hour, Huazhang Intelligent can achieve 120 sets / hour, and the value set by Evergreen Project is 96 times / hour, which can well meet the efficiency of shuttle car layer change.
Fifth, the effect is remarkable
The successful landing and smooth operation of the automated warehouse project have provided great help for the business development and transformation and upgrading of Evergreen Group, and the overall capability and service level of Huazhang Intelligent have also been fully affirmed. The relevant person in charge of Evergreen Group said: "With the help of Ronglian Huizhi and Huazhang Intelligence, the production, operation and management efficiency of our manufacturing center has made a great leap, and the replacement of labor by machines not only reduces the number of front-line personnel in production, reduces the labor intensity of employees, but also helps to reduce the impact of human factors on the quality of the production process, making the process more standard and transparent." ”
It is worth mentioning that the project not only solves the various bottlenecks in the actual operation of Evergreen Group, but also provides new ideas for the intelligent upgrading of the printing and manufacturing industry. At the "2023 Global Logistics Technology Conference" held in March this year, Huazhang Intelligent won the "2023 Logistics Technology Innovation Case" award with the declared "Tianjin Evergreen Printing Equipment R&D and Manufacturing Project Automation Warehouse (and Secondary Node Training Platform) Procurement and Construction" project, which shows that all parties recognize the project effect and demonstration significance, which can be called a new benchmark in the industry.