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Depth interpretation | Enotek Group using pull system to design the intelligent logistics solutions for various of factories and industries. (Part 2)

Aug 30,2022


Although China is the world's largest "manufacturing country", there is still a gap with "wise manufacturing country", Chinese manufacturing enterprises automation, intelligent level, technical capacity and regional development is also unbalanced, and generally faced with high labor cost, low production efficiency, loss of raw materials, storage management chaos and other problems and short boards. As an important driving force to promote industrial integration and development, intelligent logistics plays a pivotal role in the process of promoting intelligent upgrading and technological change in the manufacturing industry.

Although China is the world's largest "manufacturing country", there is still a gap with "wise manufacturing country", Chinese manufacturing enterprises automation, intelligent level, technical capacity and regional development is also unbalanced, and generally faced with high labor cost, low production efficiency, loss of raw materials, storage management chaos and other problems and short boards. As an important driving force to promote industrial integration and development, intelligent logistics plays a pivotal role in the process of promoting intelligent upgrading and technological change in the manufacturing industry.


Intelligent logistics is under the control of the information system, the operation of all links of the logistics system, the implementation of the system comprehensive perception. Through the cross-integration of information technology and logistics technology, logistics can be automated, innovative and accurate, emphasizing the rapid, efficient and smooth operation of information flow and material flow, so as to achieve the purpose of reducing social costs, improving production efficiency and integrating social resources.


How can intelligent logistics effectively improve plant operation and production efficiency? How to combine the intelligent logistics methodology with the Qianmian application environment? As an innovation-driven full-link industrial intelligent logistics solution provider, how does Enotek Group combine pull system to achieve lean production? And how to apply lean logistics methodology to the head intelligent factory of glass fiber industry to improve production timeliness, production accuracy and production performance? Regarding the above issues, we specially invited Mr. Wu Tieli, vice president of Enotek Group, to give us an in-depth explanation on the intelligent logistics methodology, and to explain and analyze the case of Enotek Group providing intelligent logistics and warehousing system as the first process for the leading intelligent factory in the glass fiber industry.


Part 1 Methodology


What is JIT?

 Production handling necessary items, need time, only the number of necessary.



How to measure JIT level?

 Just-in-time differences in scale, 1) flow and stagnation, 2) for JIT location and standard calibration.


Why does stagnation happen?

 Batch is too large (production, handling of batch)

 Flow is too complex, the outsourcing of intermediate process, the process arrangement method)

 According to the speed with the production sold the concept of weak (takt time, standard operating)

 Poor logistics manage (to carry)

 Organizational mechanism defects (before and after the process in the same period, pull and shops and equalization, effective use of real information)

Poor management (benchmark scale too wide, schedule management, inventory management, etc.)


Five Lean principles

 value: precisely determine the specific product value

 value stream: identify each product value stream

 flow: the continuous flow of value is caused

 drive: allow the user to pull the value from producers

 perfection: the pursuit of forever


The basic principle of lean logistics is customer-driven, and the core of lean logistics thinking comes down to logistics planning and design:


· Data analysis: site survey/site; BOM table analysis; Conventional import and export, conventional material flow line analysis; Analysis of growth expectations; Vehicle, cargo type analysis; Peak-valley analysis; Replacement analysis

· Conceptual design: understand business, order structure, batch size, customer channel, etc.; According to the value stream "four no principles" and customer demand design, sales design or combination of production and marketing design; Integration of product flow, information flow, logistics process

· Detailed scheme design: non-standard design; Automation equipment "first-line flow" design


Pull production propulsion foundation

1. The first task is to determine the beat and make pulling targets

2. Preparatory work is the key to successful pulling

3. Establish the concept that the next process is the customer

4. The construction of exception handling mechanism and relevant system is the guarantee

5. Lean tools and methods can solve field problems

6. Continuous improvement requires full participation


Pull production and thinking


Lean logistics embodies the idea of JIT handling


Priority should be given to the items that will be needed, at the required time, timely handling of the amount needed, which is the idea of punctuality.


Although each production project is isolated and dispersed, the relationship between the front and rear engineering is the same


The function of handling is to achieve smooth production for the purpose


In order to achieve "just in time" and logistics efforts


Conditions for lean logistics handling


The production information of the post-engineering should be transmitted to the forward engineering as many times and quickly as possible, and the current production situation should also be reflected frequently.


With the least amount of inventory, we can deal with the maximum output of the whole production project, which is to take a variety of goods at a time.


The purpose of logistics handling


The first: moving things is the end in itself

The second: timely scattered around the production project in series


In order to achieve the purpose of smooth production


Principles of material handling


Quantitative timing

Timing unquantification


Improvements to pull production and thought-handling




The mixed transport, relay transport and transfer station transport adopted after the improvement have greatly improved efficiency and reduced labor costs


Thinking about pull production - How to design


Overall planning and design ideas: demand planning for each part (PFEP)> demand for each station (PFES)> transportation path planning for each part > material storage plan > material management procedures > human resource Settings required > Design of external pull system > performance analysis of benefits and costs


Thinking about Pull Production -TOC


Bottleneck theory and constraint theory were developed by Israeli physicist Eli. It took Dr. Gaudrath 20 years to develop. TOC consists of two core elements: "Production improvement Method" with production scheduling as the core; Thought Process TP for problem analysis and solution. In a nutshell, TOC is "the method of focusing for the purpose of achieving the overall best."


DBR planning and scheduling

Order delivery cycle = production lead time + in-process quantity *CT+(order number -1)*CT+ abnormal wide release


SDBR (Simplified Drum-Buffer-Rope)

Simplified drum - buffer - rope, equivalent to MTO supply and demand: supply exceeds demand



Thoughts on Pull Production -TOC-DBR


Pros and cons of DBRS

The DBR method of TOC theory is the most effective production scheduling method for MTS and MTO order mode. It overcomes the fatal defect of MRP model "infinite production capacity" in the traditional ERP system, and is different from the strict beat TT, production capacity balancing and fine management brought by Kanban management required by Toyota pull production scheduling. So for small and medium-sized enterprises more practical!

However, DBR planning does not involve much rolling forecasting, which is not a problem for small and medium enterprises (especially the full MTO model), but for large enterprises, especially the MTS model, will affect purchasing planning, capacity planning and production structure planning over several months. The rolling forecasting program is known in the industry as the PSI program of production, supply and marketing

DBR solves the problem of a basically fixed production bottleneck in an enterprise's internal production process in a market environment where demand exceeds supply. How to maximize the bottleneck capacity, so as to maximize the overall effective output and profit of the enterprise

SDBR solves the oversupply of enterprises in the market environment, market demand is the bottleneck, how to meet the primary goal of 100% delivery, has gained competitive edge


To sum up:


 no cookie-cutter pull,

 no everything must lean,

 landing automation solution design, only understand customer business model, discussed about, understand the business,

 understanding demand, can on the thousand thousand factory environment, design the most suitable for customer win-win solutions


Part 2 Case sharing


Enotek Group provides intelligent logistics and storage system as the first process intelligent factory project for the leading intelligent factory in glass fiber industry. In terms of hardware, according to the production process and the characteristics of receiving, storing, sending and sending in the flow of materials between factories, it is closely combined with information technology, and adopts automatic storage, automatic transportation and RGV ring through transportation system.


The system integrates computer control, network, data communication, infrared transmission, field bus and other advanced technologies. Through the establishment of warehouse information management system, it realizes the automation of sending and receiving operations, the automation of workshop logistics, the digital traceability of product quality, the digitalization of warehouse management, the three-dimensional storage unit, the network of information transmission, and the visualization of operation monitoring.


This project is a turnkey project of automatic storage and transportation of Qiantao products. Enotek Group is responsible for the design, manufacturing, installation, commissioning, training and after-sales service of automated three-dimensional warehouse system and logistics system.


Design basis: exchange of on-site technology and process.


The innovative and advanced nature of the program


1. The automatic repository and RGV loop-through system are adopted to perfectly combine the previous process of glass fiber production with special production equipment, realizing the automation of the whole process of finished product warehouse from drawing, twisting, preparation, weaving to post-processing before production.

2. According to different production processes and different waiting time, the cargo handling time of RGV looping system in different processes is designed to realize the relay operation function of different looping systems under the precondition of meeting the process requirements.

3. The design of one track and two cars satisfies the design requirements of the business process and flow of glass fiber in-process products entering and leaving from different directions at the same time with the automatic repository as the intermediate cache.

4. Through the system simulation calculation, not only the whole system was simulated, especially the automatic library of one track and two cars and the foreway 1#-6#RGV loop-through system and equipment simulation and demonstration for many times, to ensure the stability of the system and the implementation of the scheme.

5. The original complex and varied processes and waiting time are simplified by the automatic system, which improves the efficiency of production and storage.



Intelligent manufacturing is the external manifestation of high quality development of economy and the only way to realize the national industrial strategy transformation from "Made in China" to "created in China". The planning and construction of intelligent manufacturing factories will also attract more and more attention.


Mr. Wu Tieli, vice president of Enotek Group, said that for the process efficiency of different industries, there is a big gap between us and the world's first-tier level. In the manufacturing industry, the general process efficiency we can achieve is 10%, while the world-class process efficiency can reach 25%. Therefore, we have great room for improvement in the smart factory pulling design. This is also why China needs to upgrade smart factories. In addition to adapting to and meeting the needs of the market and customers, our business also requires that we must automate. Only by realizing automation can we better support the lean model of smart factories in the future.