This difference mean that there are more chances to automate the entire process eventually, which in turn would have a huge impact on the manufacturing industry as a whole.

The idea behind smart factory is to make goods with the maximum amount of automation possible, and not just automation at certain production stages. In fact, manufacturers are working towards full automation. Unlike the traditional factories that require human interaction, smart factories don’t need any human interaction during production because the whole process is automated.s that it will become the nature of businesses to create and control automation systems, without being limited by budgets or resources.

The industry moves toward integrating advanced technologies into the manufacturing processes using big data, artificial intelligence and robotics. The goal is to produce quality parts with less manpower and at any location in the world.

In this setting there is a better workplace for employees; depending on the application level of automation, it is possible to reduce worker participation in repetitive tasks by 80% and increase all parameters including OEE.

主批次记录旨在确保添加了所有适当的成分，并完成和记录了流程中的每个步骤。

主批次记录 MBR（又称主生产记录 MPR 或主制造配方 MMF）是详细的生产指令。 每个独特的配方和批量大小都必须有自己的 MBR.

例如，主批次记录需要以下信息：

• 产品名称标识。

• 一份材料清单，详细说明制作批次所需的每种配料的重量、度量或数量。

• 设备清单。

• 组件列表。

• 生产过程每个阶段的理论产量说明。

• 成品的预期产量。

• 生产过程中每个条件的详细说明。

• 取样和测试程序。

• 手动操作说明。

• 差异数据

每个独特的配方和批量都需要这些记录在案的说明，以确保每次生产过程的标准化和可重复性。由于 MBR 是用于复制的原始模板，因此在生产过程中无需填写。它与生产编号或零件编号相关联，但与任何特定批号无关。

计算机化的主批次记录

计算机化的主批次记录是一种现代化的生产记录保存方式，将先进的软件解决方案集成到生产流程中。这种数字化转型彻底改变了生产运营管理方式，为创建、管理和优化生产工作流程提供了一个全面的系统。

主要功能和优点

1. 实时数据整合:数字 MBR 可与各种制造系统无缝集成，实现实时数据交换。这种连接性可确保生产人员随时获得最新信息，从而提高决策和解决问题的能力。
2. 减少误差:数字 MBR 中的自动化功能通过自动输入数据和进行验证检查，大大降低了人为错误的风险。这将提高一致性和产品质量。
3. 高效的配方管理:数字 MBR 简化了对不同产品和批量的多种配方的管理。制造商可以毫不费力地创建、更新和维护配方，确保每次生产都准确无误。
4. 版本控制:DMBR 系统强大的版本控制功能可确保生产指令符合最新法规。制造商可以迅速适应不断变化的要求，而不会影响合规性。
5. 电子签名和审计跟踪:计算机化的 MBR 有利于电子签名和维护全面的审计跟踪。这一功能对于跟踪和验证关键操作、帮助遵守法规和支持调查至关重要。

The EBR record also demonstrates that the organization properly handles and records all critical steps in the production of each batch of product, whether entered electronically or manually. This record contains data related to operators, manufacturing process, equipment, materials, and supplies. It may also contain data from laboratory information management systems (LIMS), enterprise resource planning (ERP), process control systems (PCS) and others.

Unlike analog, paper-based, defined batch records, electronic batch records enable an organization to see the benefits of improved data integrity and accuracy, streamlined processes and efficient operations.

Optimizing these processes provides better resource management, improved inventory management and reduced material waste – all of which positively impact the bottom line of the operation.

It is critical to assess the following areas:

• People (organizational culture)

• Business processes

• Technology

The acronym EBR, can also refer to an end-to-end information system that allows for the electronic recording of batch records as a copy or reproduction from a master batch record. (MBR – Master Batch Record).

Industry 1.0 – human labor is replaced by steam machines.

Industry 2.0 – humanity begins mass production using electricity.

Industry 3.0 – the first automation based on computer systems occurs.

Continuous automation of old manufacturing and industrial methods progresses along with the use of current smart technologies, large-scale machine-to-machine (M2M) communications, and the Internet of Things. The overall process is translating into major changes in the way the global manufacturing and supply chain network operates. Increased automation, better communication and self-monitoring, and the use of intelligent equipment that can assess and diagnose problems without the need for human interaction are all benefits of this integration.

In the manufacturing industry, Industry 4.0 solutions are based on maximum automation of all activities performed during the production process. Industry 4.0 technologies are advanced production management systems such as MES, WMS, EMS or ERP. Industry 4.0 requires less human labor, while the supervision of operations can be carried out regardless of the physical distance from the production hall.

Industrial Revolution 4.0 also means the possibility of full remote control of the production process from anywhere in the world. The Industrial Internet of Things makes it possible to introduce changes, generate reports and, on their basis, conduct analysis of the manufacturing process, as well as changes in the production itself on the fly.

Availability = actual machine running time / scheduled time

Productivity (actual production time / production capacity)

质量 (number of pieces properly produced / total production)

在制造业中，重点是在所有三个领域实现最佳绩效，这是生产线成功运营的关键，因为每个领域都对产品或服务的盈利能力和利润率做出了贡献。

OEE 也可以用实际产量除以计划时间乘以一个生产周期的分母来表示，如下式所示：

Ultimately, OEE is influenced by many factors that depend on the overall operation of the factory. Among the events that have an impact are

1. Unplanned downtime
2. Failures and repair times MTTR, MTBR, MTTF
3. Slow start-up of production
4. Late recognition that a process is unstable
   

Read more about OEE in the article “12 reasons why OEE is low”.

Calculate your OEE in no time with our OEE calculator.

A 制造执行系统（MES） 是一款独立运行的软件，可以收集生产线的运行数据，并以清晰易懂的方式将其可视化，以便根据真实数据更快地做出决策。它支持工厂操作员完成日常任务，并在无法自动收集数据的情况下进行数据输入。

MES 软件能够以表格、图形和图表的形式收集并清晰地展示信息，从而为在制造工厂实施精益管理、精益规划和持续改进方法提供支持。   

在制造企业中，影响 MES 系统所提供信息质量的主要因素是数据来源。向系统提供数据的方式主要有两种：  

• 设备连接 - 实现数据收集自动化，最大程度减少人工报告  
• 手动输入数据 由操作员  

补充 MES 系统数据的另一种可能性是与 ERP 系统集成。大多数情况下，这种集成可实现双向数据流，从而使企业资源规划系统和制造执行系统都能获得有关正在进行的生产的统一数据。   

阅读如何审核工厂实施软件系统

MES 系统的优势

1. 实时数据收集:可立即访问生产数据，以便更快地做出决策。
2. 提高效率:通过自动数据收集，简化操作并减少停机时间。
3. 强化质量控制:密切监控生产流程，确保产品质量高。
4. 更好的资源管理:优化材料、劳动力和设备的使用。
5. 可追溯性:跟踪整个生产过程，提高可追溯性和合规性。
6. 降低成本:最大限度地减少浪费和返工，从而节约成本。
7. 与企业资源规划系统整合:确保 MES 和 ERP 系统之间的数据流无缝衔接，实现统一的信息管理。

作为控制塔的 MES

将制造执行系统（MES）想象成机场的控制塔。控制塔不会驾驶飞机，但对确保所有航班安全高效地起飞、飞行和降落至关重要。

MES（或控制塔）收集来自各种飞机（生产线上的机器）的数据，并以清晰易懂的方式将这些信息可视化，就像空中交通管制员阅读雷达屏幕和飞行数据一样。这有助于控制人员做出实时决策，保持空中交通顺畅。

了解更多 关于

• MES - 制造执行系统 - MES 软件页面
• OEE - OEE 性能监测 - 简易 MES 系统
• MOM - 生产运营管理系统 - 最先进的 MES 系统

MES 系统可为哪些行业带来效益？

• 消费品
• 航空航天
• 制药
• 汽车
• 军事
• 装配

ERP system can be used by planning, purchasing, sales, marketing, finance, human resources, warehouse and other departments where integration of data within the enterprise can bring tangible benefits.  

Today ERP systems are very diverse and often specialized for a specific industry, so that they can best reflect the specifics of a particular sector of the economy. Over time, systems have evolved from desktop systems to cloud solutions, enriching the usability and flexibility of solutions.  

Technological changes taking place in the manufacturing industry and the complexity of current manufacturing processes, make it necessary to extend ERP systems with additional functions. Additional tools include independent MES, WMS, LIMS, or EMS systems, which allow two-way data exchange with the ERP system, providing more accurate information about the production process and plant status.     

Despite the many benefits of implementing an ERP system in the company, poorly planned implementation resulting from the lack of cultural and structural changes in the organization, may prove counterproductive for the entire enterprise.    

实施 APS software is often a company’s response to the lack of synchronization between departments and processes within the company, in order to bring about full optimization of work. In particular, APS allows to:

• Predicting customer orders
• Anticipation of supply capabilities
• Plan production scenarios
• Eliminate unnecessary excess inventory

An independent and complementary tool to APS is the RTS (Real-time scheduling) solution. RTS is a tool that has all the necessary functions known from APS, but it is devoid of typical ERP functions. It is designed for companies that still want to benefit from intelligent, data-driven scheduling, but do not have full knowledge of real-time production. RTS allows for simplified production planning, taking into account all current available data from the machines.