解决方案 秉持“先医后药，先软后硬”的理念，施耐德电气上海工厂的精益生产专家为汉威科技进行了细致入微的实地调研。精益生产专家和汉威科技的团队一起，对生产线上的逐个工位、人员的逐个动作进行观察、测算和分析，并对整个生产管理的流程进行了详尽的了解。 此后，施耐德电气为汉威科技提供的基于面向工业的EcoStruxure架构的透明智造解决方案，在无需进行大规模自动化改造的前提下，帮助汉威科技顺利完成了实现“透明工厂”的关键步骤。 该数字化改造解决方案集成了订单管理，作业指导管理，执行与追溯管理，即时化绩效、任务、响应管理等多个模块，打通了汉威科技生产运营的各个环节。在进行改造后，汉威科技的整个生产运营过程中产生的各类数据都清晰可见，为各级人员的生产运营工作提供了质的飞跃。 订单管理系统：让工厂对生产订单的实时化管理变得易如反掌。系统在每一道工序处，都会对每个工单里的每个产品进行扫描，并时地记录下各种相关信息。这使得管理人员能够对每一件产品的工序状态，订单的完成进度、异常情况和交付预期了如指掌，并掌握整个产线的产能资源分配情况。 作业指导管理模块：实现防呆防错，工人只要扫描工件的条码，系统就会自动地把工位的作业指导书推送到员工面前的看板上，可以非常直接快速地指导员工作业，避免出现人为差错。 即时化绩效、任务、响应管理模块：一旦产线上发生异常情况，工人可以立刻通过安灯系统进行报警，并由系统自动通知相关的维修人员进行处理，直至故障解除。系统自动记录故障种类、发生时间、解决故障时间、人员信息，并作为事后统计和分析的数据基础，以及对相关人员考核的依据，从而实现对责任和KPI的精准管理。 执行与追溯管理模块：实现闭环的追溯，对单个产品在物料、产品、员工、工位等信息上进行绑定，并由系统记录在案。一旦产品或原材料出现问题，可以迅速定位对应的原材料、人员信息或受到影响的产品批次和客户范围，为分析问题和减少客户损失提供信息支持。 此外，施耐德电气的精益专家还对汉威科技的产线进行了一些具体的精益化改善。例如，将原有的单工位生产模式改为了L型和U型的单元式生产线，让员工通过分工配合实现生产节奏的协调性，无形中减少了由于员工个人差异而产生的效率短板。

客户效益 在透明的流程和数据的支撑下，汉威科技在生产管理上的颗粒度和可视化能力产生了质的飞跃，对每周、每天甚至每小时生产状况的随时掌握，使其能够迅速应对各类变化带来的挑战，甚至提前做出应对决策。改造后三个月，汉威科技产线的生产效率提升了12%，产能提升了22%，人均产值提升了14%，市场反馈的故障率降低了25%。 此外，通过将生产的各项KPI信息和薪酬、职业发展挂钩，员工的积极性也得到了质的提升。在施耐德电气精益专家的帮助下，汉威科技的员工团队还掌握了自主改善的能力，成为了持续改善的“生力军”，为汉威科技在物联网产业的持续腾飞打下了坚固的基础。 软件中可快速轻松地设置系统参数。 

成果

• 高效快速的系列化生产，数量更大，品质更高 • 由于仅使用两个标准模块标准实施所有必需的起重机功能，因此可以更快地处理起重机生产 • 更快速灵活地开发新产品 - 更快地响应客户需求 • 舒适而安全 • 更高的起重机可用性 - 减少停机时间 • 节能高达 40% Modicon M241 控制解决方案与联网变频器一起提供额外的安全性和便利性，并减少起重机系统的停机时间。通过 Altivar 变频器的再生单元，制动过程中产生的能量可以反馈到电网中，从而节省高达 40％ 的能源。 数字化：网络解决方案的进一步发展以及数据的收集和利用是 IIoT 的门户，帮助 ABUS 开拓更多机会 - 例如预测性维护和全球服务能力 - 以便扩展其业务。 施耐德电气的解决方案帮助 ABUS 变得更具竞争力。凭借这种合作，ABUS 正在推出创新的起重开发项目，以提高起重机的可用性，并在全球范围内实现有针对性的维护措施。 

The solution adheres to the concept of "first medicine, then medicine, first soft, then hard". Lean production experts from Schneider Electric's Shanghai factory conducted meticulous on-site research for Hanwei Technology. Lean production experts and the team of Hanwei Technology observed, calculated, and analyzed the individual actions of each workstation and personnel on the production line, and provided a detailed understanding of the entire production management process. Afterwards, Schneider Electric provided Hanwei Technology with a transparent intelligent manufacturing solution based on the EcoStruxure architecture for industry, which helped Hanwei Technology successfully complete the key steps of achieving a "transparent factory" without the need for large-scale automation transformation. This digital transformation solution integrates multiple modules such as order management, job guidance management, execution and traceability management, real-time performance, task, and response management, and connects all aspects of Hanwei Technology's production and operation. After the renovation, various data generated during the entire production and operation process of Hanwei Technology are clearly visible, providing a qualitative leap for the production and operation work of personnel at all levels. Order management system: making real-time management of production orders by factories easy. At each process, the system scans each product in each work order and records various relevant information in a timely manner. This enables managers to have a clear understanding of the process status of each product, the progress of order completion, abnormal situations, and delivery expectations, as well as the allocation of production capacity resources throughout the entire production line. Job guidance management module: To achieve foolproof and error proof, workers only need to scan the barcode of the workpiece, and the system will automatically push the work instructions of the workstation to the dashboard in front of the employees, which can guide employees' work very directly and quickly, avoiding human errors. Real time performance, task and response management module: once an abnormal situation occurs on the production line, workers can immediately alarm through the andon, and the system will automatically notify the relevant maintenance personnel to deal with it until the fault is removed. The system automatically records the type of fault, occurrence time, resolution time, and personnel information, and serves as the data basis for post event statistics and analysis, as well as the basis for assessing relevant personnel, thus achieving precise management of responsibilities and KPIs. Execution and Traceability Management Module: Achieve closed-loop precise traceability, accurately bind individual products on information such as materials, products, employees, workstations, etc., and record them in the system. Once there is a problem with the product or raw materials, it is possible to quickly locate the corresponding raw materials, personnel information, or affected product batches and customer ranges, providing information support for analyzing the problem and reducing customer losses. In addition, Schneider Electric's lean experts have also made some specific lean improvements to Hanwei Technology's production line. For example, by changing the original single workstation production mode to L-shaped and U-shaped unit production lines, employees can achieve coordinated production rhythm through division of labor and cooperation, which invisibly reduces efficiency shortcomings caused by individual differences among employees.



Supported by transparent processes and data, customer benefits have led to a qualitative leap in the granularity and visualization capabilities of Hanwei Technology in production management. With real-time control of weekly, daily, and even hourly production conditions, Hanwei Technology is able to quickly respond to challenges brought about by various changes and even make response decisions in advance. Three months after the renovation, the production efficiency of Hanwei Technology's production line has increased by 12%, production capacity has increased by 22%, per capita output value has increased by 14%, and the market feedback has reduced the failure rate by 25%. In addition, by linking the KPI information of production with salary and career development, the enthusiasm of employees has also been qualitatively improved. With the help of Schneider Electric's lean experts, the staff team of Hanwei Technology has also mastered the ability to improve independently, becoming a "new force" for continuous improvement, laying a solid foundation for Hanwei Technology's continuous takeoff in the Internet of Things industry. The software allows for quick and easy setting of system parameters.



achievements



Efficient and fast serial production, with larger quantities and higher quality. Due to the use of only two standard modules to implement all necessary crane functions, Therefore, it is possible to handle crane production faster • Develop new products more quickly and flexibly • Respond more quickly to customer needs • Comfort and safety • Higher crane availability • Reduce downtime • Energy saving up to 40% Modicon M241 control solution, combined with networked frequency converters, provides additional safety and convenience, and reduces downtime of crane systems. Through the regeneration unit of the Altivar frequency converter, the energy generated during the braking process can be fed back to the power grid, thereby saving up to 40% of energy. Digitalization: The further development of network solutions and the collection and utilization of data are the portals of IIoT, helping ABUS explore more opportunities - such as predictive maintenance and global service capabilities - to expand its business. Schneider Electric's solutions help ABUS become more competitive. With this collaboration, ABUS is launching innovative lifting development projects to improve crane availability and implement targeted maintenance measures globally.