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　娃哈哈的煩惱
　　飲料的生產(chǎn)要經(jīng)歷水處理、配料、制蓋、制瓶、吹瓶、灌裝、套標(biāo)，裹包和碼垛等多道工序。在娃哈哈杭州下沙第二生產(chǎn)基地內(nèi)一條長(zhǎng)達(dá)百米的水汽生產(chǎn)線上，一瓶瓶純凈水和含氣飲料快速而有序地飛過，生產(chǎn)速度達(dá)到每小時(shí)54000瓶。
　　雖然這樣的生產(chǎn)效率已是業(yè)內(nèi)領(lǐng)先，但娃哈哈的工程師們卻有一個(gè)不小的煩惱。水汽線上每臺(tái)設(shè)備都處在單機(jī)自動(dòng)控制的狀態(tài)，只知“埋頭苦干”，“兩耳不聞周圍事”。這樣一來，工廠不僅無法通過整線協(xié)調(diào)達(dá)到效率最大化，一旦生產(chǎn)線出現(xiàn)故障，原因也難以快速排查。
　　在娃哈哈遍布全國(guó)的飲料工廠里，80%至90%的設(shè)備已通過西門子的可編程邏輯控制器(PLC)實(shí)現(xiàn)了自動(dòng)化。在進(jìn)一步實(shí)現(xiàn)數(shù)字化和智能化升級(jí)改造的過程中，西門子為娃哈哈細(xì)致規(guī)劃并提供了包括S7-1500系列控制器、工業(yè)服務(wù)器和人機(jī)界面(HMI)等在內(nèi)的自動(dòng)化設(shè)備、全集成自動(dòng)化平臺(tái)(TIA Portal)、WinCC系統(tǒng)、B.Data能源管理系統(tǒng)和Profinet工業(yè)網(wǎng)絡(luò)等在內(nèi)的完整SIMATIC解決方案，幫助這條水汽線實(shí)現(xiàn)了設(shè)備的互聯(lián)互通和中央監(jiān)控，達(dá)到柔性生產(chǎn)的要求，并優(yōu)化了產(chǎn)線能源管理，也通過產(chǎn)品質(zhì)量追溯，保障了食品安全。
　從“單兵作戰(zhàn)”到互聯(lián)互通、中央監(jiān)控
　　實(shí)現(xiàn)生產(chǎn)線數(shù)字化與智能化的核心是設(shè)備的互聯(lián)互通和中央監(jiān)控。有了西門子的解決方案，水汽線的生產(chǎn)設(shè)備從“單兵作戰(zhàn)”的狀態(tài)中解脫出來，形成了高效的“團(tuán)隊(duì)”，而散落在工廠各處的數(shù)據(jù)也形成了閉環(huán)，在生產(chǎn)線上高效流轉(zhuǎn)。
　　以前，娃哈哈集團(tuán)總部到各個(gè)分廠的企業(yè)資源計(jì)劃(ERP)系統(tǒng)雖已實(shí)現(xiàn)互聯(lián)，但工廠到車間內(nèi)各設(shè)備的數(shù)據(jù)卻沒有打通?，F(xiàn)在，情況發(fā)生了徹底的改變?？偛靠梢酝ㄟ^ERP系統(tǒng)將銷售訂單發(fā)送到工廠的制造執(zhí)行系統(tǒng)(MES)中。接下來，MES會(huì)根據(jù)庫(kù)存等情況將銷售訂單拆分為不同的生產(chǎn)訂單并發(fā)送到西門子WinCC系統(tǒng)上，由它對(duì)生產(chǎn)訂單進(jìn)行分解，生成具體的生產(chǎn)方案并下發(fā)至不同的生產(chǎn)設(shè)備。
　而在底層，西門子的PLC等自動(dòng)化設(shè)備覆蓋整條生產(chǎn)線?；赑rofinet工業(yè)網(wǎng)絡(luò)，生產(chǎn)設(shè)備遵照統(tǒng)一的OMAC數(shù)據(jù)接口標(biāo)準(zhǔn)實(shí)現(xiàn)了互聯(lián)互通。生成的數(shù)據(jù)將由WinCC系統(tǒng)采集，并返回給MES系統(tǒng)。操作員可以利用TIA Portal進(jìn)行統(tǒng)一的數(shù)據(jù)管理、通訊、組態(tài)和編程，實(shí)現(xiàn)自動(dòng)化設(shè)備與系統(tǒng)的無縫連接。
　　西門子WinCC系統(tǒng)與PLC等自動(dòng)化設(shè)備組成了高效的中央監(jiān)控系統(tǒng)。借助西門子SIMATIC解決方案，娃哈哈打破了各個(gè)設(shè)備的信息孤島，讓從設(shè)備層到管理層的全部數(shù)據(jù)徹底貫通，成功實(shí)現(xiàn)了對(duì)整條生產(chǎn)線的數(shù)字化管控。
　　設(shè)備的互聯(lián)互通和對(duì)生產(chǎn)線的中央監(jiān)控為生產(chǎn)線的運(yùn)行帶來了革命性的變化。
　　借助西門子SIMATIC解決方案，所有物料供給過程都可以由系統(tǒng)自動(dòng)控制。以前，在飲料行業(yè)中，由于沒有實(shí)現(xiàn)設(shè)備的中央控制與互聯(lián)互通，操作員每次生產(chǎn)都需要根據(jù)訂單情況手動(dòng)控制物料供給。
　　如今，試點(diǎn)線上所有物料供給都可以由系統(tǒng)根據(jù)訂單信息和實(shí)際生產(chǎn)進(jìn)程自動(dòng)完成精準(zhǔn)控制。例如，如果一批產(chǎn)品中包含8000瓶飲料，當(dāng)系統(tǒng)計(jì)算出已經(jīng)通過裹包機(jī)的成品為7500瓶，而生產(chǎn)線上剩下的500瓶產(chǎn)品也即將進(jìn)入裹包階段時(shí)，系統(tǒng)就可以自動(dòng)停止前道工序供料，保證訂單的準(zhǔn)確執(zhí)行。
　　如今，故障排查也變得更加便捷、及時(shí)?，F(xiàn)在，中央監(jiān)控系統(tǒng)與分布在產(chǎn)線各處的攝像頭實(shí)現(xiàn)了聯(lián)動(dòng)。一旦設(shè)備報(bào)警，監(jiān)控系統(tǒng)就會(huì)指揮攝像頭自動(dòng)切換畫面，快速定位報(bào)警點(diǎn)，以便操作人員及時(shí)處理故障，縮短停機(jī)時(shí)間。
　　此外，中央監(jiān)控系統(tǒng)也大大方便了娃哈哈的管理人員對(duì)車間進(jìn)行整體維護(hù)和管理?，F(xiàn)在，操作員和管理人員可以通過WinCC系統(tǒng)輕松查看整條生產(chǎn)線的運(yùn)行狀況。
　　杭州娃哈哈集團(tuán)有限公司設(shè)備工程部部長(zhǎng)邵金榮切身感受到了生產(chǎn)透明化帶來的改變：“現(xiàn)在，我只要坐在辦公室里就能實(shí)時(shí)了解整條產(chǎn)線的運(yùn)行狀況。這對(duì)管理層決策有很大幫助。”

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