Client Introduction

       Ltd. is a new energy battery system solution provider, which is jointly funded by Beida Advance Technology Industry Co. The plant is located in Beijing Caiyu Economic and Technological Development Zone.

       Pride-Power's lithium-ion battery packs and management systems have the unique advantages of safety, high quality, high efficiency and environmental protection, and can be perfectly matched for new energy vehicles, new energy vehicle charging stations and grid energy storage systems. The products are produced in accordance with the requirements of TS16949 quality system on the self-developed automatic production line and are strictly tested and verified by the company's own national standard laboratory.

       Pride-Power has established long-term strategic cooperation alliances with many famous brand enterprises and scientific research institutions at home and abroad, and is gradually developing into an international clean energy enterprise with leading technology, first-class management, people-oriented and customer-oriented, based on the concept of pursuing excellence and serving the country. Pride-Power has many patents in product development, such as material, battery cell, battery safety structure design, battery management system, etc., and can be flexibly customized according to customer needs and provide one-stop after-sales tracking service through a perfect traceability system.

Business Background

       Battery pack production has the objective situation of many varieties and small batches, and a batch of parts is often used in multiple product models and different batches of orders. When there is a problem with a batch of parts, in order to lock the problematic parts in which orders and batches, a large number of existing paper documents need to be queried, which is often slow and inefficient.

      As the products put into the market continue to accumulate and increase, the problem of accuracy and timeliness of product tracing is increasingly prominent, the original production and quality system can no longer meet the needs, the enterprise urgently needs to establish a set of perfect product quality tracing system as the core of the MES.



Current situation and the main problems faced

      1. The information related to incoming materials, production process, shipment and after-sales maintenance cannot be efficiently associated to achieve fast traceability inquiry.

      2. The country has access standards for new energy batteries, and the current system cannot meet the requirements.

Current status of existing production and quality system

      1. records the incoming material information of electric cells.

      2. records the production material information and test data of cells, modules and battery packs in the before and after processes.

      3. only provides simple production statistics report and performance test report.

Existing production and quality system problems

      1. no record of key material information and test information of BMS, fuse, high-voltage integrated box, etc.

      2. after-sales maintenance information of battery packs is not maintained in the existing system.

      3. more detailed records of people, machines, materials, methods and environment were not recorded and system traceability could not be achieved.

      4. positive and negative quality tracing functions cannot be realized

      5. cannot realize direct communication with equipment, and key equipment cannot be fully automated.

      6. are currently human intervention to determine the results, often wrong.

      7. the collected quality data and equipment status information are incomplete and cannot provide a basis for analysis.

      8. the production product recipes (BOM, etc.) and equipment recipes (such as upper and lower limits, program numbers/version numbers, etc.) are not managed and are not conducive to future traceability and analysis.

      9. The system is completely customized according to Pride-Power's existing situation, and new products or changes need to modify the system source code, which brings a lot of risks due to frequent changes and staff turnover;

      10. no standardized workshop production line and equipment interface, equipment docking difficulties.


MES implementation goals

       In the three workshops of Beijing factory and Changzhou Liyang factory, we realize the material information as the core, and correlate the information of all links involved in it, such as human, machine, law and environment, to realize the traceability of battery pack and key materials in the whole life cycle. With the MES system as the center of the tandem production, quality, maintenance, logistics, warehouse, after-sales, self-made BMS and other departments, integrate ERP, OA, WMS, TMS and other existing systems, seamlessly replace the existing production and quality systems, avoid the formation of information islands, and open up the information flow of the entire enterprise.

Terminology explanation

       1. key materials: refers to the main components used in the production process of battery packs, such as cells, modules, electric boxes, battery packs, BMS, wiring harnesses, electrical integration boxes, high-voltage plugs, fuses, high-voltage boxes, top covers, etc..

      2. Production line through ACC: MES system with data collection and data traceability as the core. At present, the system is commonly used and verified in more than 400 production lines in more than 30 factories around the world of many of the top 50 global players in the auto parts industry.

      3.PAA: ACC provides the interface standard between auto parts industry and PLC with independent patent technology, which has been adopted and promoted by National Institute of Intelligent Manufacturing, supporting mainstream PLCs, such as Siemens, AB, Mitsubishi, Omron, Beckhoff, LG LS, WinCC, Shihlin, Goodco, Xinjie, etc.

      4.ACC-Comm: ACC provides ActiveX control communication library and communication protocol, supports various programming languages (.NET, JAVA, VB, VC, C, C++, DELPHI, BCB...), Labview, etc.

Overall system introduction

        The material part of the system mainly includes supplier incoming material IQC, warehouse picking up material out, material sorting box, material loading scanning, barcode scanning of key parts, after-sales replacement parts association and record query (UFIDA A8 system), material inventory information query (UFIDA ERP U8), etc. ACC realizes material scanning and barcode printing through PDA, PC client, etc.

       The system provides production error prevention, dummy prevention, data collection, material batch collection and verification and quality control for self-made BMS production line, ultrasonic welding line, module pre-process line, manual Pack line, Pack automatic line, lab charging and discharging test line, snap cover and lifting storage line, etc. Interfacing with field devices such as program download and test programs, CMT and laser welding machines, internal resistance meters, ALAS tightening guns, EOL testers, Pack automatic line PLC (Siemens), lab charging and discharging testers, and other devices or third party programs is implemented. ACC collects test result data and process data for later analysis. ACC communicates with equipment through PAA and ACC-Comm with proprietary technology, ACC also provides a large number of production and quality reports, data query, SPC analysis, OEE statistics, CPK calculation, equipment status and downtime cause analysis, and other standard statistics and reports.

       ACC system supports interfacing with mainstream ERP systems and WMS, such as SAP, QAD, U8, K3, etc. It also provides flexible external interfaces to third-party systems such as Web Service, WCF, ACC-Comm, Socket, XML/JSON, etc. This project has realized the interface with UFIDA ERP and OA through Web Service, ACC has replaced the original system with zero risk by integrating the original data, and has opened up each isolated system by calling upstream and downstream system interfaces and providing standard interfaces to realize the flow and integration of data within the enterprise.