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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(guò)，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(lái)，工廠不僅無(wú)法通過(guò)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(guò)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(guò)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(guò)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(lái)，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(méi)有打通?，F(xiàn)在，情況發(fā)生了徹底的改變?？偛靠梢酝ㄟ^(guò)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(lái)，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。基于Profinet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(wú)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(lái)了革命性的變化。
　　借助西門子SIMATIC解決方案，所有物料供給過(guò)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(méi)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(guò)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)。現(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(guò)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(lái)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?！?br />

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ALLEN BRADLEY 150-A135NBD USPP 150A135NBD

ADEPT TECH 10332-48712 USPP 1033248712

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SIEMENS 220uF 450V Capacitor 36 x 36mm

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SCHNEIDER 170 AMM 090 00/170AMM09000 ANALOG I/O MODULE XLNT

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Schneider Modicon AS-B825-016 USPP ASB825016

Schneider Modicon AS-B581-001 MODULE

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Schneider Modicon AS-C480-000 PCB PC Board Card

SCHNEIDER TC2000 INDUSTRIAL PC OPERATOR INTERFACE 3515 KPM BROKEN NOB

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RSP720-3CXL-10GE Cisco Route Switch Processor 720 with 10 Gigabit EN uplin

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RS422/RS485 COMMUNICATIONS MODULE MITSUBISHI FR-EPE

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ALLENBRADLEY6181P-15TSXPHSER.CVersaView1500PINDUSTRIALCOMPUTER

ALLEN BRADLEY VERSAVIEW CE 6182H-12TRH4D 6182H12TRH4D

ABB E4S-A 3200 Amp SACE Breaker EMAX 600V E4SA 32 E4S3200 Bolt On BO

ADTRAN 4200663L1 USPP 4200663L1

(H2-5) 1 HORTON 912010 LH8B PHOTOHEADLINE FOLLO. H2-5.

KEYENCE CORP LS-5121 NSFP LS5121

ADEPT TECH 10332-00655 USPP 1033200655

FLUKE 720A USPP 720A

FANUC A06B-0162-B175 NSFP A06B0162B175

SEW EURODRIVE MDV60A-0220-503-4-0T USPP MDV60A022050340T

RELIANCE ELECTRIC 0-48673 NSPP 048673

ROBERTSHAW DMS-ETH-001 USPP DMSETH001

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SIEMENS 6ES5-430-8MC11 NSFP 6ES54308MC11

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Square D 8005 RT-108

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Reliance 54394-1

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SYMAX 8055-SCP-453 USPP 8055SCP453

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CONTROL TECHNIQUES 6180-8110 USPP 61808110

OMRON C500-CT041 NSFP C500CT041

MODCOMP 551-100689-001 NSPP 551100689001

GENERAL ELECTRIC 531X152IOCAKG1 USPP 531X152IOCAKG1

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KENWOOD KCA-SR50 SIRIUS RADIO INTERFACE MODULE ADAPTER

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Siemens OP27 6AV3627-1JK00-0AX0 Membrane Keypad worldwide

Power Sonic PS 670

Schneider Modicon AS-B838-032/ASB838032 Output Module OFFERS ACCEPTED

Schneider Modicon AS-584M-240 USPP AS584M240

Schneider Modicon AS-M84A-102 USPP ASM84A102

Schneider Modicon AS-9595-001 Memory Module Lot of 4

Schneider Modicon AGE B872 Analog Voltage Output - AS-B872-200

Schneider Modicon /Modicon/AS-HDT-201 Subrack 5-slot NIB

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Telemecanique Inverter Operator Panel ATV71

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8449A HP/Agilent Preamplifier 2 - 22 GHz

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ASEA BROWN BOVERI EH550G-PRL11 NSFP EH550GPRL11

ASCO 9403-70-99C USPP 94037099C

MITSUBISHI A-985-GOT-TBA USPP A985GOTTBA

INDRAMAT DKC1.1-030-3 USPP DKC110303

ALLEN BRADLEY 284D-FVD2P3Z-10-CR-3 NSFP 284DFVD2P3Z10CR3

SQUARE D 3020-CM250 USPP 3020CM250

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SIEMENS 6ES5 464-8MC11 -FS- 6ES54648MC11

SIEMENS 6ES5-103-8MA03

Siemens Positioning Cont. Module 6ES5 266-8MA11 WOW

Siemens 6ES7 352-1AH01-0XB0 6ES73521AH010XB0

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PROVOX 37A8986X012 NSPP 37A8986X012

HEWLETT PACKARD 98630A HP BREADBOARD INTERFACE MODULE

VAOVA FMT-104U IN-CAR FM MODULATOR WITH USB INTERFACE 12 MONTHS WARRANTY

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Omron 3G207-IP002

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Schneider Modicon AS-B247-001 ISOLATION INPUT MODULE

Schneider Modicon AS-E908-006 NSPP ASE908006

Schneider Modicon Gould Input Module AS-B805-016 115V 16 Port

Schneider Modicon AS-B832-016

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Schneider/Telemecanique Twido TWDLMDA20DTK

Schneider Telemecanique Advantys DDI3615

SIEMENSOPERATORKEYBOARDPANELMODELNo.6ES5-982-3AA11

Siemens 6AV6545-0CA10-0AX0 6AV6 545-0CA10-0AX0 SIMATIC TP270 6 Touch Panel

SIEMENS Simodrive Sinumerik 6RB2100-0NA21 includes 6RB2100-0SA21

GE Fanuc IC693CMM302D Communications Module Comm Enhanced Genius

SIEMENS SIMODRIVE VPM 120 6SN1113-1AA00-1JA

SIEMENS Sinumerik 6FC5114-0AA02-0AA2 E.Stand A 840C Central Service Board

SIEMENS MOORE 15532-3FM-S MULTIPLIER DIVIDER SERIES 380

Allen-Bradley MobileView Guard G750 2727-G7P20D106

AB 4100-232-RL 4100232RL 2 AXIS CONTROLLER SER.H IMC S

AC Electric Motor Drive - 25 HP - 480 Volt - Three Phase Input

A06B-0501-B001 FANUC SERVO MOTORS REMANUFACTURED

75 HP FUJI FRN075F1S-4U Variable Frequency Inverter 400-480 V 105 Amp

RELIANCE ELECTRIC 802420-R USPP 802420R

ALLEN BRADLEY 2750ASPR NSPP 2750ASPR

ALLEN BRADLEY 1771-QDC NSFP 1771QDC

HYDRAULIC VALVE DIVISION D41FHE0-2F4VB0020 USPP D41FHE02F4VB0020

XYCOM 9450 USPP 9450