Wen Lisheng: Construction of clothing ultra-flexible manufacturing mode (middle)

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Third, the construction of clothing super flexible sewing manufacturing mode

1) Modular production is the basis for achieving ultra-flexible manufacturing mode

What is the ultra-flexible sewing manufacturing mode of clothing? In the application of modular operation mode, the sewing process and equipment used in the garment sewing station or production line are intelligent ; or the garment ultra-flexible sewing manufacturing mode is an intelligent upgrade of the traditional modular manufacturing mode.

Modularized Producing System (MPS), proposed by Baldwin of Harvard University in 1997, and became the main production method in the 21st century, it is embodied in ultra-high flexible production, module outsourcing, mass customization manufacturing (MC) In the production mode. The modular approach is based on the overall design rules of the product or system, which can reduce a lot of repetitive work and increase production efficiency.

The modular production of garments includes the modular production of garments and the modularization of garment production stations (equipment). In the garment production process, the high flexibility of the modular production method includes the modularization of the product; the modularization of the production process; and the modularization of the product supply. For example, the modularity of the shirt products includes: 1 front and rear body modules (where the pocket hem is customizable); 2 collar modules (where the collar tip is narrow and can be customized); 3 sleeve modules (including the sleeves, Kraft) Customized); 4 assembly modules; 5 ironing package modules.

Flexible modular operation mode of garment production station (equipment), with independent production scheduling function, and order priority judgment based on factors such as process processing time, handling time, order quantity, scheduling time, etc., for the incident of flexible line The feedback mechanism promotes real-time response of relevant departments. Because lean production aims to eliminate waste, reduce unnecessary processing steps, material or personnel flow, waiting time, excess inventory and overproduction defects in the work process, lean production and flexible line production methods are very compatible, flexible line will work Integration of production and logistics management.

In the flexible production line, the material circulation line is short, and the on-site materials and equipment can be quickly managed. The flexible mode production takes up less space than the single machine processing saves space. The pieces are changed from the external circulation between the stations to the internal circulation of the system. All the flexible lines will unify the entrance and exit of the work place, and the material management area will also change from multiple pieces to one piece, as shown in Figure 2, U-shaped and semi-circular. Type station placement method, the traditional assembly line station is 3 to 7 stations, each station has 2 to 3 units plus one equipment, one station for one person, and each station completes 4 to 7 procedures. Single piece flow production. This modular form is the basis for an ultra-flexible implementation.

2) The ultra-flexible manufacturing mode must be dynamic modular manufacturing

The important symbol of the industrial 2.0 era is the electrification technology and the production line technology of Ford. In particular, the Ford assembly line production method has been borrowed from the manufacturing industry of various industries. Our clothing industry is no exception. This kind of assembly line manufacturing method has been used for many years. However, this production method is subject to many restrictions, and the fault tolerance of the entire production line is low, which easily leads to the process bottleneck of the entire production line. At the Hannover Fair in Germany in May this year, Audi introduced the concept of “modular production without fixed assembly line” in its 2030 smart factory planning blueprint. Its factory inherits the concept of vertical integration and customized product production. SAP's "Dynamic Modular Production" technology OIF3.0 (SAP Open Integrated Factory 3.0) for production scheduling without flow-through, through unmanned AGV (Automatic Guided Transport Vehicle) trolley and DVP (Design Data Verification) Technology, dynamic modular production, which is different from the production method of automobile assembly parts modules arranged by the previous production line production equipment around the conveyor belt, but a module, and then the vertical and end-to-end integration of the production by the MES system .

The “dynamic modular production” technology can provide services for the production of non-fixed assembly lines, and also puts forward higher requirements for the business processes and information infrastructure of the current garment manufacturing enterprises. First, the "dynamic modular production" technology breaks the traditional rhythm of manufacturing enterprises. The system will implement machine learning based on rule algorithms and artificial intelligence methods. The production planning method is also dynamically adjusted. Second, the operation of "dynamic modular production" has high requirements for the stability of enterprise information systems and equipment. The operation of the mobile station, the transfer, loading and unloading, positioning of the parts and materials, etc., the level of automation is very high, which will have higher requirements for the stability of the equipment on the entire production line and trouble-free operation. Third, the connectivity requirements for all device packages on the production line are higher. Edge calculation is used to avoid the collision of AGV cars with each other, which puts higher requirements on the network environment and data transmission management in the assembly shop.