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The worldwide automotive business is within the midst of main modifications and challenges in opposition to the pattern of electrification and intelligence. In response to the current statistics launched by a neighborhood auto business affiliation, the gross sales of China’s gas car market have declined for 3 consecutive years. With the intensification of the worth warfare, some automotive corporations have even withdrawn from the market. The auto elements producers caught in it are going through the issue of learn how to survive and develop in opposition to the more and more fierce competitors.
Yanfeng Auto International Automotive Technology Co., Ltd. (hereinafter known as “Yanfeng Auto”) is a number one Chinese language automotive elements provider specializing in automotive inside and exterior trim, automotive seats, cabin electronics and security programs. Headquartered in Shanghai, Yanfeng Auto has 9 R&D facilities, greater than 240 factories and technical facilities in 20 international locations around the globe, with over 55,000 staff. Dealing with challenges, Yanfeng Auto’s strategy is to work with corporations like IBM with superior expertise, business expertise and technical experience to speed up its personal data-driven digital transformation to cut back value, enhance effectivity and scale for company-wide innovation.
Situation 1: Robotically convert huge exterior common orders to inside orders with the pure language studying functionality of IBM Watson Discovery
Yanfeng Auto receives an enormous variety of orders from automakers and downstream producers on daily basis, and it beforehand needed to manually convert exterior common orders to inside orders primarily based on expertise. In every manufacturing unit, it took a median of 150 minutes a day for 2 employees members to kind the orders manually, accompanied by 15% classification errors. That presents huge challenges for the corporate when it comes to labor value and effectivity.
Leveraging the highly effective pure language studying functionality of IBM Watson Discovery and the hands-on help of IBM Customer Success Manager (CSM) team, Yanfeng Auto efficiently constructed up an AI mannequin that was skilled with its combined knowledge of structured knowledge and unstructured textual content, overlaying 180 million historic knowledge, with over 200 permutations and combos. The mannequin has discovered the principles behind the inner orders equivalent to common orders. The AI mannequin helps the corporate notice a totally computerized execution course of with out handbook operation, rising the order classification accuracy charge from 85% to 97%.
Situation 2: Understand high-speed transmission of huge knowledge between department manufacturing workshops and headquarters with Aspera Module of IBM Cloud Pak for Integration, establishing knowledge basis for clever stock platform with predictability.
The Clever Manufacturing Division of Yanfeng Auto hopes to work with IBM CSM workforce to discover the best way of increase its clever stock platform with predictive capabilities. To drive predictive choice making and computerized recognition, they want a considerable amount of knowledge throughout the corporate for AI mannequin coaching. Nevertheless, the primary roadblock is its outdated means of information transmission.
To keep up real-time situational consciousness of the elements stock in varied manufacturing workshops in additional than 240 factories around the globe, Yanfeng Auto must shortly transmit again to headquarters the hundreds of real-time pictures taken at every plant. Beforehand, the Clever Manufacturing Division used the normal copy and paste technique to switch the photograph information by batches. As a result of sluggish transmission pace, huge community delays, and severe packet loss, they needed to manually choose and replica the photograph information by batches and repeat the method a number of instances. This was not solely time-consuming but in addition made it simple to make errors. On the similar time, if the transmission was interrupted, it couldn’t be reconnected and resume transmission robotically, nor might they customise the transmission pace, or absolutely make the most of the transmission bandwidth of the spine community.
With help of IBM CSM workforce, Yanfeng Auto efficiently deployed Aspera Module of IBM Cloud Pak for Integration inside solely sooner or later to construct up a light-weight enterprise-level file switch answer for Yanfeng Auto, which elevated its file switch pace by 10 instances, saved handbook ready time, averted human errors, realized computerized transmission resumption and computerized community reconnection. With this answer, Yanfeng Auto now can dynamically configure transmission bandwidth and pace restrict with out affecting the efficiency of its ERP core system and maximize the transmission effectivity of its real-time monitoring information, laying the info basis for realizing the division’s imaginative and prescient of increase an clever stock platform with predictive capabilities.
Situation 3: Break the operational bottleneck brought on by Kafka, an open-source knowledge extraction instrument. With Occasion Streams Module of IBM Cloud Pak for Integration, you may simplify the method of extremely out there knowledge extraction.
Yanfeng Auto has beforehand deployed an open-source Kafka cluster in every department manufacturing unit to extract knowledge from a number of real-time manufacturing knowledge in its MES system and supply them to the MI Kanban (Dashboard) System of every manufacturing unit for question and show. Nevertheless, this open-source system poses a number of operational complexities.
For instance, for every handbook set up, deployment, configuration, improve, and upkeep, it might take days or even weeks and incur an enormous labor value. Furthermore, it was not in a position to make sure enterprise-level safety and excessive availability, and it didn’t help pure integration with the core enterprise programs and the widespread manufacturing programs. Lastly, there was no Kafka technical help or after-sales assure, ensuing within the want for ongoing funding in employees coaching and knowledgeable consulting companies.
With the help of IBM CSM workforce, Yanfeng Auto has efficiently adopted Event Streams Module of IBM Cloud Pak for Integration in one in all its factories as a prototype for real-time knowledge extraction. The information-generating utility extracts knowledge—equivalent to elements manufacturing shifts, manufacturing portions, demand portions, rework portions, sequencing and different related manufacturing knowledge—from the MES system and sends them to the corresponding knowledge matter channel. Functions that extract knowledge can use the info instantly by subscribing to the corresponding matter channel of Occasion Streams. The MI Skynet Kanban (Dashboard) system can choose specified desk fields for subsequent dashboard show and early warning evaluation.
By deploying Occasion Streams, the enterprise-level knowledge extraction answer, Yan Feng can obtain “one-click” deployment, out-of-the-box use, zero downtime rolling upgrades, and all the time have the newest steady model of Kafka. Occasion Streams comes with a graphical operation interface, which requires little extra abilities coaching. It additionally takes benefit of high-security, geo-replication, and enterprise-grade catastrophe restoration capabilities of the product. Furthermore, different functionalities like superior schema registries and wealthy Kafka connectors and extensible REST APIs make it simple to scale. As well as, IBM offers enterprise-level after-sales service, knowledgeable session, and well timed troubleshooting, serving to the shopper to acquire the technical experience they want.
Situation 4: Understand clever manufacturing capability estimation and planning for core manufacturing tools with Determination Optimization Module of IBM Cloud Pak for Knowledge to cut back prices and enhance effectivity.
In auto elements manufacturing, injection molding is among the necessary processes. Yanfeng Auto offers varied automakers with inside elements equivalent to instrument panels, which require a core tools of injection molding machine to supply. Because of the totally different specs of the instrument panels of assorted car fashions, the manufacturing course of requires tools changeovers. For instance, when the fabric is switched from black to white, the tools must be cleaned; when switching from white to black, it doesn’t should be cleaned. Switching from gold to crimson requires different extra actions.
Gear switching won’t solely contain value, however have an effect on manufacturing scheduling and stock administration. For instance, how do they decide the optimum financial batch measurement of various merchandise whereas decreasing stock prices? How do they steadiness the capability of a number of machines for a whole yr whereas assembly buyer wants? How can they estimate the capability of the machine to raised modify the plan, maximize the effectivity of the machine, enhance productiveness, and scale back additional time? How will they be sure that the plan might be carried out in manufacturing and that modifications might be responded to in a well timed method once they come？
Within the context of the continual enlargement and alter of demand for varied auto elements, and the truth that productiveness and manufacturing assets are very restricted, the normal manufacturing planning technique relies on expertise and handbook calculation, which simply causes issues equivalent to low manufacturing effectivity, excessive stock value, heavy labor burden and extra. All of this might severely have an effect on the manufacturing effectivity of the corporate, so it’s vital to search out new methods to develop cheap manufacturing planning and scheduling schemes.
After rounds of discussions with consultants from IBM CSM workforce, IBM Specialists Lab and IBM China Improvement Lab, IBM consultants developed a complete and agile answer for Yanfeng Auto with Decision Optimization Module of IBM Cloud Pak for Data. The answer has two complementary elements—the general multi-machine, multi-month planning scheme and the single-month high-quality scheduling scheme.
The answer helps practically 100 employees in additional than 20 factories to plan the capability of lots of of injection molding machines with extremely detailed and particular plans. Every define plan is accompanied by an correct scheduling plan, which is extremely sensible for follow-up steerage for manufacturing. Additionally it is an agile answer: planning a set of schemes solely takes a couple of or dozens of minutes, enormously bettering the responsiveness to future modifications. If the shopper wants or manufacturing assets change, Yanfeng Auto can modify the plan at any time. Based mostly on an agile and customary platform, this business-friendly answer might be simply tailored and scaled to different manufacturing amenities and different comparable areas.
The IBM CSM workforce has accompanied Yanfeng Auto on its journey of digital and clever transformation for 2 years: from the preliminary realization of computerized conversion of exterior orders to inside orders; from fixing the issue of high-speed knowledge transmission in department factories around the globe to the headquarters; from changing its open-source instrument with an IBM enterprise instrument constructed on open supply to simplify its IT operational complexity for high-availability knowledge extraction, to the newest AI-powered options to understand manufacturing capability estimation and planning for its core manufacturing tools. From knowledge integration and administration to making use of AI to its enterprise course of and planning, Yanfeng Auto has been actively co-creating with IBM technical and enterprise consultants to show applied sciences to tangible enterprise values.
Yanfeng Auto is among the business pioneers in China to handle enterprise challenges with a “data-first” technique. Yanfeng Auto can also be the pioneer shopper of IBM in China that has been working carefully with IBM to co-create first-of-a-kind scenario-based options with IBM Cloud and AI applied sciences.
About Yanfeng Auto
Yanfeng Auto Worldwide Automotive Expertise Co., Ltd. (known as “Yanfeng Auto”) is a world automotive elements provider, dedicated to offering carmakers and different customers with inside and seating options that meet the wants of at present’s and tomorrow’s driving, redefining the best way you loosen up, work and play within the automotive. Headquartered in Shanghai, the corporate has 9 R&D bases, greater than 4,200 R&D groups, greater than 240 factories and technical facilities in 20 international locations around the globe, and greater than 55,000 staff worldwide, offering world car producers with the design, growth and manufacture of auto elements merchandise. With product innovation and forward-looking analysis, Yanfeng Auto will assist automakers discover the long run, carry higher human-car interplay expertise to world auto shoppers, and actively promote the evolution of automotive driving expertise.
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