改革开放四十年，经济高速增长一直依靠制造业的推手，新兴中产阶层崛起 的发动机也是依靠于制造业。可是如今，中国制造陷入前后为难，前有高端回流 发达国家，后有中低端制造外迁东南亚国家。直面自身的缺陷，正视不断加剧的 全球化经济和日益白日化的行业竞争，特别是国际金融危机的高潮迭起，严重打 击了全世界资本，表现症状为消费市场萎缩、资本市场萎靡。四海电子昆山公司 受到重创，表现为生存和发展环境非常恶化。由于受到了通货膨胀的影响，国内 人力和材料成本节节攀升，对于代工企业来说更是雪上加霜，让制造企业的生存 形势变得极其严峻。 本论文以四海电子公司为分析对象，目的是探索出符合公司智能工厂实践方 法。本论文思路是，首先理顺生产系统的概念和依据相关智能化的知识体系，调 研四海电子现状，寻找出相关存在问题，然后予以汇总，并对问题逐步分析、从 生产手段、发展模式、组织方式、发展格局等角度分析并找出其成因，也会经过 技术、经济、组织、风险等因素严格认证，充分得出工厂实施智能化必要性和可 行性。 智能化设计整体思路为，数字化、自动化、智能化三部分设计组成；其三者 关系为，以工业大数据为基础工作平台和载体，数字化是企业基础管理和企业信 息化体系的基础平台，自动化是自动化体系设计，智能化是运用全新技术，物联 网、大数据等核心技术建设，充分实现全网全通。 本文重点介绍智能化的设计方案，数字化设计涵盖采集生产数据、采集设备 数据等诸多数字化管理应用场景；其中自动化涵盖机器视觉检测、自动贴标/扫 描系统；智能化涵盖智能化物料管理、凝露品质管理、电子看板；最后建议四海 电子在进行智能工厂建设的同时，必须还要进行组织措施，制度保障，企业文化 等相关软环境建设。 智能化设计的最终目标，评价、监控、预测、控制以及优化及决策生产中的 各个环节，使用大数据、云计算、人工智能、新材料等新一代智能制造技术手段， 从而解决基础平台瓶颈，全方位应用解决问题，从根本上提升生产系统智能化程 度，提高生产效率，帮助企业提升效益，为电子代加工行业提供应用实例。 关键词，四海电子 智能化 生产系统Abstract Forty years of reform and opening up， the rapid economic growth has been relying on the promotion of manufacturing industry， and the emerging middle class is relying on the transmitter. Today， however， Made-in-China is in a dilemma， with high-end manufacturing returning to developed countries and low-end manufacturing relocating to Southeast Asian countries. Facing its own shortcomings ， facing the ever-intensifying global economy and increasingly day-to-day industry competition ， especially the iteration of the international financial crisis， has seriously hit the world's capital， manifested in the shrinking consumer market and the sluggish capital market. Four Seas Electronics Kunshan Company has been seriously damaged ， as shown by the deterioration of the environment for survival and development. The sharp rise in the cost of manpower and materials in China has aggravated the situation of OEMs and made the survival situation of manufacturing enterprises more severe.This paper takes Sihai Electronics Company as the object of analysis. The purpose of this paper is to explore the practical method of the company's intelligent factory. The idea of this paper is: firstly ， the concept of production system is straightened out and the related intelligent knowledge system is used to investigate the current situation and existing problems of electronics in the four seas. Then ， the problems are summarized and analyzed step by step ， from the angles of production means ， development mode， organization mode and development pattern， and the reasons are found out. It will also be strictly certified by such factors as technology ， economy， organization， risk and so on， and fully concludes the necessity and feasibility of the implementation of intellectualization in factories.Intelligent design is composed of three parts: digitalization， automation and intellectualization; the relationship among them is: based on industrial big data as the working platform and carrier， digitalization is the basic framework of enterprise basic management and enterprise information system， automation is the design of automation system， and intellectualization is the application of new technology. Technology， Internet of Things， Big Data and other core technology construction， fully realize the full network. This paper focuses on the intelligent design scheme: digital design covers many application scenarios of digital management， such as collecting production data， collecting equipment data; automation covers machine vision inspection， automatic labeling/scanning system; intellectualization covers intelligent material management， condensation quality management， electronic Kanban; and finally，III construction. In addition to the construction of intelligent factory， Sihai Electronics must also carry out organizational measures， institutional safeguards， corporate culture and other related soft environment.The ultimate goal of intelligent design is: to evaluate， monitor， predict， control， optimize and make decisions in all aspects of production ， to use new generation of intelligent manufacturing technology such as big data， cloud computing， artificial intelligence， new materials， so as to solve the bottleneck of basic platform， to solve problems in all directions， and to fundamentally upgrade the production system. Intelligent level， improve production efficiency，help enterprises to improve efficiency，and provide application examples for electronic processing industry. Key words: Intelligent Production System Sanmina（KunShan）Co,.Ltd.目 录 摘要...........................................................................................................................................I Abstract...................................................................................................................................... II 目 录.........................................................................................................................................1 第 1 章 绪论...............................................................................................................................1 1.1 研究背景与意义..................................................................................................................1 1.1.1 研究背景....................................................................................................................1 1.1.2 研究意义....................................................................................................................2 1.2 国内外研究综述..................................................................................................................2 1.2.1 国外研究综述............................................................................................................2 1.2.2 国内研究综述............................................................................................................3 1.3 论文研究解决的关键性问题..............................................................................................5 1.4 主要研究方法与技术路线图..............................................................................................5 第 2 章 相关理论基础...............................................................................................................7 2.1 生产系统的概念..................................................................................................................7 2.2 智能化的相关知识..............................................................................................................7 第 3 章 四海电子昆山有限公司生产系统现状分析.............................................................10 3.1 四海电子昆山有限公司公司简介....................................................................................10 3.2 四海电子昆山有限公司生产系统现状介绍....................................................................11 3.3 四海电子昆山有限公司生产系统存在的问题分析........................................................11 3.3.1 公司生产系统存在问题梳理..................................................................................11 3.3.2 四海电子昆山有限公司生产系统存在问题的原因分析......................................13 3.3.3 公司生产系统存在问题的影响因素和战略意义..................................................14 3.4 四海电子昆山有限公司生产系统智能化的必要性与可行性........................................16 3.4.1 四海电子昆山有限公司生产系统智能化的必要性...............................................16 3.4.2 四海电子昆山有限公司生产系统智能化的可行性...............................................16 第 4 章 四海电子昆山有限公司智能化生产系统设计.........................................................18 4.1 四海电子昆山有限公司智能化生产系统设计的原则.....................................................18 4.2 四海电子昆山有限公司智能化生产系统设计目标.........................................................18 4.3 四海电子昆山有限公司智能化生产系统设计.................................................................19 4.3.1 公司智能化生产系统构架.......................................................................................19 4.3.2 公司智能化子系统耦合关系...................................................................................20 4.3.3 工业大数据中心方案设计.......................................................................................21 4.4 数字化模块.........................................................................................................................23 4.4.1 生产数据采集...........................................................................................................23 4.4.2 设备数据采集...........................................................................................................24 4.5 自动化模块.........................................................................................................................28 4.5.1 机器视觉检测...........................................................................................................28 4.5.2 自动贴标/扫描系统................................................................................................. 30 4.6 智能化模块.........................................................................................................................31 4.6.1 智能物料管理系统方案...........................................................................................31 4.6.2 凝露品质管理品质质量管理系统方案...................................................................34四海电子昆山有限公司智能化生产系统研究 4.6.3 电子面板品质质量管理系统方案...........................................................................37 第 5 章 四海电子智能化生产系统设计方案实施保障措施.................................................39 5.1 高层领导应重视企业智能化改造.....................................................................................39 5.2 建立适用于智能化生产的组织.........................................................................................39 5.3 完善企业制度建设.............................................................................................................40 5.4 建立良好的企业文化.........................................................................................................40 第 6 章 结论.............................................................................................................................42 6.1 主要研究结论.....................................................................................................................42 6.2 研究的不足及未来展望.....................................................................................................42 主要