Case Study | Enotek Group digital twin system help Xingfengming group improve the efficiency of logistics, breakthrough chemical fiber industry development bottleneck

Industry pain point

Chemical fiber is a very important basic raw material, widely used in production and life. The chemical fiber industry has the characteristics of large production capacity, obvious seasonal sales and vulnerable products.

In terms of warehousing and logistics, the chemical fiber industry faces the following challenges:

1. Manual handling and palletizing are easy to cause damage to silk cake;

2. Low order information processing efficiency and poor traceability ability;

3. High labor cost and low efficiency;

4. Goods are placed flat in the reservoir area, resulting in low space utilization rate.

All these problems have become the bottleneck restricting the high-quality development of chemical fiber industry. Xingfengming Group expects to improve logistics efficiency and break through the development bottleneck through the intelligent upgrading of logistics links.

About the Xingfengming

Xingfengming Group was founded in February 2000, is located in China's chemical fiber town - Tongxiang Zhou Quan, is a collection of PTA, polyester, spinning, elastic, import and export trade as one of the modern large-scale joint-stock enterprises.

The company has 20 years of polyester filament research and development and production experience, mainly using melt direct spinning production technology, the introduction of today's world's advanced polyester equipment and spinning equipment, focusing on the field of civilian polyester fiber, Products cover the production of POY, FDY, DTY polyester filament and fabric fabric type, knitted cotton type, sewing line type, nonwoven type and other short fiber and many middle and high-end series varieties.

Zhongyi Chemical Fiber, a wholly-owned subsidiary of Xingfengming Group, has an annual production capacity of 600,000 and 5 million tons of polyester filament. The intelligent and low-carbon differentiated fiber project has been put into full operation on November 17, 2020. The project adopts low-temperature, fine, flexible five-reactor melt direct spinning process technology, introduces the world's advanced level of Baguer high-speed POY winding machine, and is equipped with world-class intelligent manufacturing equipment such as automatic falling drum, automatic packaging, three-dimensional storage, representing the advanced productivity of the industry.

The completion and operation of the project further optimized the product structure of the enterprise, improved the added value of the product, and effectively improved the core competitiveness and market share of the enterprise.

Intelligent storage solution

Enotek Group provides a complete set of logistics solutions for Xingfengming Zhongyi project, from warehousing to warehousing and order management of finished products. After the completion of the project, instead of the previous flat warehouse storage, manual handling, the establishment of automatic three-dimensional warehouse, greatly improving the storage of goods; And through the WMS and WCS system independently developed by Enotek Group, fully automated warehousing and goods inventory, realizing the warehouse unmanned.

Main equipment

1. 18 pallet-stacker machines, 20,000 + storage space;

2. A customized WMS/WCS warehouse management system to realize the whole process control from warehousing to warehousing;

3. Reasonable and efficient design of reservoir area, material flow line in line with customers' production characteristics, to realize efficient connection between warehouse and factory;

4, Enotek Group new generation of digital twin technology.

Digital twinning technology features

Enotek Group digital twin system is a 3D real-time monitoring storage environment, and can be viewed in the browser window to reflect the real-time storage monitoring system, a more intuitive reflection of the real-time storage situation.

Main functions include: 3D simulation display of real scene of stereo library, real-time physical location, status data and fault monitoring of stereo library equipment, remote camera monitoring, etc. The system can make the warehouse management personnel more quickly and intuitively obtain the implementation of the running track of equipment, fault, etc., which plays a key problem for the management personnel to obtain the problem in the first time.

Visual enrichment

High degree of visualization, fine granularity, high degree of twinning, equipment status and cargo location information can be clearly visible more intelligent devices and sensing devices access, such as temperature and humidity more data display and WMS/WCS system to achieve data connection, real-time view of the real-time operating data of equipment.

Convenient operation

A variety of customized reports, configurable functional modules, can achieve rapid deployment with duplex communication capabilities, seamless connection with PLC equipment, comprehensive update of the display interface, friendly operation interface to achieve multi-scene and multi-area display, multi-area smooth transformation.

intelligentization

Carry out big data analysis on inventory and incoming and outgoing data, optimize inventory storage structure, improve the granularity of inventory management, and integrate machine learning function to analyze and predict equipment failures and carry out equipment maintenance in advance.

In the completed intelligent logistics system: the finished products from the automatic packaging line, by the conveyor through the air corridor from the spinning floor to the entrance platform of the automatic three-dimensional warehouse, and finally by the stacker will send it to the specific space. The delivery area on the first floor of the bank is directly connected to the trucks, and the delivery line ensures smooth delivery of finished products.

Project difficulty

1. Large product size (1200*1200*1800mm) and large unit bearing capacity (nearly tons);

2. The timely storage of chemical fiber products off the line and the efficiency of order performance are very high;

3. The customer needs to realize the traceability of chemical fiber products and orders in the whole process.

Project effectiveness

The total shelf height of Zhongyi project is 24 meters, which solves the storage problem of customers; There are 12 warehouse delivery stations on the first floor, and 18 roadways can automatically deliver goods to any warehouse outlet, waiting for the direct docking between the loading warehouse and the production and packaging, realizing the automatic storage on the second floor.

The storage density of this project is high, and the total flow rate is nearly 630P/h. Enotek Group through the use of pallet stacker and automated conveyor line, products from the production area to the storage area efficient unmanned operation.

Unmanned operation not only effectively saves labor costs, but also eliminates the hidden danger of personal safety accidents. It also guarantees the quality of products during transportation, and realizes the comprehensive automation of the last process of Zhongyi chemical fiber factory.

Enotek Group WMS/WCS warehouse management system to achieve the whole process control from warehousing to warehousing, logistics information can be traced. In addition, the WMS system is able to predict shipments by analyzing past orders, even in the face of the challenges of seasonal sales with a short surge in shipments.