In the era of Industry 4.0, smart manufacturing and digitalized production are essential. For companies in mattress manufacturing, the introduction of the intelligent production line not only offers convenience and energy savings but also reduces labor costs and improves product quality, making it the inevitable choice for the transformation and upgrading of mattress manufacturing processes.
Upon entering Naigu’s production workshop, it was once common to face inventory backlogs or material shortages due to complex and difficult warehouse data management. Today, with the MES system in place, the workshop can now achieve real-time, accurate inventory statistics, freeing up warehouse space and reducing labor waste. Previously, producing mattress machinery components often involved frequent changes to drawings and waiting for updated plans. Now, with the MES system, everything is instantly clear within the system.
These improvements have all come with the adoption of the MES system. In addition to the advantages mentioned, the system allows for real-time tracking of production output and pass rates, automatically calculates order losses and costs, and calculates workers' piecework wages. Employees can quickly check order progress on their mobile phones.
The MES system has not only simplified operations but also greatly improved production and management efficiency. Since implementing the MES system, production efficiency has increased by 25%, all without increasing personnel, space, or equipment. Additionally, 10 fewer employees are needed, the mechanical product delivery rate has increased from 85% to 100%, inventory has been reduced by approximately 2 million, and the company has achieved 100% paperless management. Furthermore, product quality pass rate has increased from 97.75% to 99.95%.
Currently, the entire Naigu workshop uses the MES system, which has been tailored to better suit Naigu’s specific production needs. The MES system has brought numerous changes to the company's production management, shifting production scheduling from passive to real-time, moving towards a more transparent, digitalized, and intelligent system, transforming quality control from post-production analysis to real-time monitoring, and integrating information systems into a unified model for seamless communication, coordination, and resource sharing.
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