As an advanced manufacturing execution system, MES system provides an effective solution for lean production planning and control. This paper will be based on the MES system of lean production planning and control model for in-depth analysis, to explore its application and advantages in the modern manufacturing industry.

1 MRPII, MES, JIT, TOC comparison and analysis

MRPII (Manufacturing Resource Planning), MES (Manufacturing Execution System), JIT (Lean Manufacturing) and TOC (Theory of Constraints) are commonly used in the manufacturing industry, management and production technology. MRPII is mainly used for production planning and scheduling, it is through the integration of production planning, inventory control and purchasing and other information, optimize the production process and resource utilization. MES focuses on real-time monitoring and control of the production process to help companies track production conditions, quality control and inventory management. JIT emphasizes on-demand production, inventory reduction and waste reduction, which improves production efficiency by reducing unnecessary production and inventory.

Although they each have different characteristics and application scope, but in the actual application, according to the specific situation of the enterprise to carry out comprehensive selection and application. Comprehensive use of these technologies can achieve the coordination of production planning and execution, optimize the production process and resource utilization, improve production efficiency and product quality, thereby enhancing the competitiveness of enterprises and economic benefits.

2 Lean production planning and control model based on MES system

2.1 ERP production planning system

MES system monitors and controls the production process in real time, provides real-time data and feedback, helps enterprises to adjust the production plan and resource allocation, and ensures the efficient operation of the production process. ERP production planning system is responsible for the overall production planning and unified management of resources, including raw material procurement, inventory management, production scheduling, etc., can effectively coordinate the work between different departments to achieve the coordination and integration of the production process. Through the integration of MES system and ERP production planning system, enterprises can realize the close connection between production planning and execution, reduce the waste and unnecessary waiting time in the production process, and improve the production efficiency and resource utilization. At the same time, the lean production planning and control model also emphasizes on-demand production and inventory reduction, helping enterprises to reduce production costs and inventory risk, improve the competitiveness of enterprises and economic efficiency. Therefore, the lean production planning and control model based on MES system is a kind of efficient production management method, which is of great significance to optimize the production process, improve the production efficiency and product quality, and reduce the production cost.

2.2 MES Execution Manufacturing System

MES is mainly responsible for the execution and control of the production site, and helps enterprises realize the visualization and transparency of the production process through real-time monitoring of various data in the production process, including the production progress, equipment status, manpower and time, etc. At the same time, it can also be used in accordance with the requirements of the production process, to improve the production efficiency and product quality, as well as to reduce production costs. At the same time, it can also adjust the production plan and resource allocation according to the actual situation, to ensure the efficient operation of the production process and timely response to changes.

Through the integration of MES and lean production planning and control model, enterprises can realize the close connection between production planning and execution, thus improving production efficiency and quality, reducing production costs and resource waste. In addition, the MES manufacturing system also supports real-time data analysis and capacity assessment, helping enterprises to accurately grasp the market demand and production, in order to better adapt to market changes and improve production flexibility.

2.3 PCS control system

PCS control system is a key component of the production process, it is responsible for real-time monitoring and control of production equipment and processes, to ensure the stable operation of the production process and efficient production. Through the integration with MES system, PCS control system can respond more intelligently to the production plan and adjust the production parameters to achieve lean management and optimization of the production process control.

The integration of PCS control system and MES system realizes a high degree of synergy between production planning and actual production, and can adjust the set values and parameters of the control system in time according to the real-time data and information provided by the MES system in order to adapt to the changes in the production environment and the changes in demand. At the same time, PCS control system can collect real-time data in the production process, through the MES system for analysis and statistics, to help enterprises understand the production status, resource utilization and production efficiency, to provide a scientific basis for production decision-making.

3 MES system of lean production planning and control model application measures

3.1 Strengthen data collection and monitoring

Strengthen data collection and monitoring is based on the MES system of lean production in the planning and control model of the important application measures. Through the MES system, enterprises can collect and monitor various data in the production process in real time, including key information such as equipment operation status, production progress, raw material consumption, etc. These data are useful for lean production planning and control. These data are crucial for lean production planning and control, which can help enterprises to grasp the production situation in real time, and discover abnormalities and problems in the production process in a timely manner.

In order to strengthen data collection and monitoring, companies can use advanced sensors and monitoring equipment, real-time monitoring of the operating status of equipment and production process parameters. These data can be transmitted to the MES system through the network for real-time processing and analysis. At the same time, the enterprise can also establish a perfect data collection process and standards to ensure the accuracy and completeness of the data.

Not only that, on the basis of data collection and monitoring, enterprises can also use the MES system to provide data analysis functions, in-depth analysis of the production process and mining. Through data analysis, enterprises can find bottlenecks and problems in the production process, optimize production planning, improve production efficiency. In addition, data analysis results can be used to predict production trends and changes in demand, providing a reference basis for enterprise decision-making. Strengthening data collection and monitoring can not only realize the lean management of the production process, but also help enterprises realize intelligent production. Through the analysis and processing of a large amount of real-time data, enterprises can realize intelligent monitoring and automation control of equipment, improve the automation of the production process, reduce human intervention, reduce production costs and improve product quality.

Because of this, strengthening data collection and monitoring is an important application measure in the lean production planning and control model based on MES system. Through real-time data collection, analysis and monitoring, the enterprise can realize the lean management and intelligent control of the production process, so as to improve production efficiency and product quality, and enhance the competitiveness of enterprises.

3.2 Scheduling production plan

Through the MES system, enterprises can realize real-time monitoring of the production process and data collection, so as to obtain the data of the production process, including equipment operation status, production progress, raw material inventory and other information. On this basis, enterprises can use the data analysis function of MES system to schedule and optimize the production plan.

First of all, the enterprise can through the MES system real-time understanding of the production site situation, including equipment operating conditions, production progress and output, so as to timely find the problems and bottlenecks in the production process. Through data analysis, enterprises can find the production plan may exist in the unreasonable arrangements and waste of resources, and then adjust the production plan, optimize the production process, improve production efficiency, and promote enterprise development.

Secondly, MES system can help enterprises to realize the flexible adjustment and dynamic optimization of production plan. In the production process, there may be a variety of emergencies, such as equipment failure, delayed arrival of raw materials, etc., which may affect the implementation of the production plan. Through the MES system, enterprises can quickly access real-time data, timely detection and problem solving, flexible adjustment of production plans to ensure the smooth progress of production.

Finally, MES system can also realize the intelligent management of production plan. Through the analysis and processing of large amounts of production data, MES system can predict the production trend and demand changes, providing a scientific basis for enterprise decision-making. At the same time, the MES system can also automatically adjust the production plan according to the production situation, improve the accuracy and adaptability of the production plan. Therefore, scheduling production plan is an important measure in the application of lean production planning and control model based on MES system. Through real-time monitoring and data analysis, the enterprise can find the problems and bottlenecks in the production process, flexibly adjust the production plan, optimize the production process, realize the intelligent management of the production plan, so as to improve the production efficiency and product quality, and enhance the competitiveness of the enterprise.

3.3 Quality control and traceability

Through the MES system, enterprises can realize real-time monitoring and data collection of quality data in the production process, so as to ensure that the quality of products meets the standards and trace the production process.

First of all, MES system can help enterprises to monitor the key quality indicators in the production process in real time, such as product size, weight, composition and so on. Through the monitoring of these quality indicators, the enterprise can timely find the quality problems in the production process, and take corresponding measures to adjust and improve, so as to ensure that the quality of the product meets the standard.

Secondly, MES system can realize the production process data traceability. Through the MES system, enterprises can record and store various data in the production process, including the source of raw materials, production equipment operation, process parameters adjustment and other information. These data can help the enterprise in the product quality problems, quickly traced back to the specific production links and responsible person, so as to carry out accountability and problem solving.

In addition, the MES system can also help enterprises to establish a quality management system, including the development of quality standards, the establishment of quality inspection process, the establishment of quality indicators. Through these quality management measures, enterprises can more effectively carry out quality control, improve product qualification rate and stability.

Finally, the MES system can also realize the quality data statistics and analysis. Through the statistics and analysis of a large number of quality data, enterprises can find the potential causes of quality problems, and further improve the production process and management measures to improve the quality of products. Therefore, quality control and traceability is an important measure in the application of lean production planning and control model based on MES system. Through real-time monitoring and data collection, tracing the production process, establishing a quality management system, and carrying out statistics and analysis of quality data, the enterprise can effectively control product quality, improve production efficiency and enhance the competitiveness of the enterprise.

3.4 Carry out inventory management

In the application of lean production planning and control model of MES system, inventory management is a key measure. Through the MES system, enterprises can monitor and manage the inventory of raw materials, work in progress and finished products in real time, so as to realize the optimization of inventory and reduce inventory costs.

First of all, MES system can realize the real-time monitoring and management of raw materials. Through the data connection with suppliers and warehouses, MES system can understand the raw material purchase situation, inventory quantity and inventory turnover rate and other information. Enterprises can be based on these data to prepare accurate raw material procurement plan, to avoid over-purchasing caused by inventory backlog and capital consumption, while ensuring the timeliness and stability of the supply of raw materials.

Secondly, MES system can realize the monitoring and tracking of work-in-process. Through the production line sensors and data acquisition equipment, MES system can monitor the production progress and production quality of the work in progress in real time, to help companies find problems in the production process and make adjustments in a timely manner. In addition, MES system can help enterprises optimize production scheduling, avoid excessive product backlog, improve production efficiency and resource utilization.

Finally, MES system can also realize the accurate management of finished product inventory. Through the analysis and prediction of sales data, MES system can help enterprises accurately predict the market demand, develop a reasonable sales plan, to avoid economic losses due to high or low inventory. At the same time, MES system can help enterprises optimize warehousing and logistics management, reduce logistics costs and improve the efficiency of the supply chain. Therefore, inventory management is an important measure in the application of lean production planning and control model based on MES system. Through real-time monitoring and management of raw materials, work in progress and finished goods inventory, optimization of procurement planning, production scheduling and sales planning, enterprises can achieve accurate control of inventory, reduce inventory costs, improve production efficiency and enhance the competitiveness of enterprises.

3.5 Strengthen communication assistance

In the modern manufacturing industry, the production process involves a number of links and departments, the information transfer and collaboration between the various links is very complex, therefore, strengthen the communication assistance is to realize the production planning and control of effective means.

First of all, MES system can realize the real-time transmission and sharing of production information. Through the installation of sensors and data acquisition equipment in the production line, the MES system can monitor the production process in real time a variety of data, such as equipment status, production progress, quality indicators. At the same time, these data can be shared among various departments through the MES system, realizing the seamless transmission of information and helping enterprises realize efficient collaboration and decision-making.

Secondly, MES system can realize the production plan instant adjustment and feedback. In the production process, there may be a variety of emergencies, such as equipment failure, raw material shortages, order changes, etc., these situations will affect the implementation of the production plan. Through the MES system, the relevant departments can receive this information in time, and according to the actual situation of the production plan to adjust and optimize, in order to ensure the stability and efficiency of the production schedule.

Finally, the MES system can also realize the remote delivery and execution of production orders. In some large enterprises or cross-regional enterprises in the production process, the transmission of production instructions may have time delays and errors, affecting the accurate implementation of the production plan. Through the MES system, production instructions can be remotely sent to each production unit through the network, reducing human intervention and misuse, and improving the accuracy and execution efficiency of production instructions. At the same time, strengthen the communication assistance can also help enterprises to realize the monitoring and tracing of the production process. Enterprises can monitor the production process in real time data and indicators, timely detection of problems and corrective action. At the same time, the MES system can also record and trace the production data to help companies understand the production process and quality information to ensure that the quality of the product can be controlled and can be traced.

Because of this, strengthen the communication assistance is based on the MES system of lean production planning and control model application of important measures. By realizing real-time transmission and sharing of production information, immediate adjustment and feedback of production plan, remote ordering and execution of production instructions, as well as monitoring and tracing of production process, enterprises can realize efficient operation of production planning and control, improve production efficiency and product quality, and enhance the competitiveness of the enterprise. Strengthening communication to assist in the realization of intelligent manufacturing and digital transformation process plays an important role, is one of the important direction of the future development of manufacturing industry.

4 Conclusion

In summary, based on the MES system of lean production planning and control model for manufacturing enterprises to provide a comprehensive and effective production management solutions, so that enterprises can maintain a competitive advantage in the fierce market competition. For this reason, enterprises need to apply MES system in the process, combined with their own actual situation, scientific planning and rational layout, in order to ensure its long-term benefits and sustainable development in lean production planning and control.