问渠WenQuest Robotics 数字工厂 · 典型应用Digital factory · cases › 一台报警,追到砂轮From one complaint to one grinding wheel

专题案例 04 · 减速器厂 · 数字主线Topic case 04 · gearbox plant · digital thread

客户一个电话,追到车间里的那片砂轮,再找出还有谁家的设备有同样的隐患One customer call, traced back to one grinding wheel, then forward to every machine that shares the risk

北方矿业来电:2 号主运皮带上的减速器有异响、振动变大。厂情中枢沿着数据往回追:这台减速器装的哪根输出轴、在哪台磨床上用哪片砂轮磨的;再往前追:同一片砂轮还磨了哪些轴、装进了哪些客户的设备。然后按数字孪生的健康度排出风险,给出三个服务方案,算好人、天数和费用,人批准后派工。Northern Mining calls: the gearbox on belt line 2 is noisy and vibrating more. The command center walks the data back — which output shaft is in this gearbox, which grinder and which wheel ground it — then forward: what else that wheel ground, and whose machines those shafts went into. It ranks the risk with the digital twins, prices three service options in engineers, days and dollars, and dispatches once a person approves.

追溯链Trace chain
6环links
同批另外装在Same batch also in
2台设备units
推荐方案费用Recommended option
$973
推荐方案漏掉高风险High-risk units missed
0台
投诉的设备Reported unit可能的源头Likely source高风险High risk点任意一环看记录和依据Click a link for the record and its basis

三个服务方案,按排班算好Three service options, priced against the schedule

三台都已过保修期,费用全部向客户收取;备件都是 2 套 6206-2RS 轴承(BRG-6206)。工程师按区域排班:北部赵岩、东部周海、南部林青,同区域每人每天最多 2 单。中枢推荐 B:比 C 少通知一家客户、少花 $480,又不漏掉高风险的那台。All three units are out of warranty, so customers are billed; each option uses 2 sets of 6206-2RS bearings (BRG-6206). Engineers are scheduled by region — Zhao Yan north, Zhou Hai east, Lin Qing south — at most 2 jobs per person per day. The command center recommends B: one fewer customer to notify and $480 less than C, without missing the high-risk unit.

方案Option上门台数Units visited工程师Engineers天数Days人天Person-days费用Cost通知客户Customers漏掉的高风险High-risk missed
A · 只修出问题的Repair the reported unit only1赵岩Zhao Yan20.5$49311 台(WQR105-H2408-05)1 (WQR105-H2408-05)
B · 修 + 高风险上门点检Repair + inspect high-risk units中枢推荐Recommended2赵岩、周海Zhao Yan, Zhou Hai21.0$973200
C · 整批排查Inspect the whole batch3赵岩、周海、林青Zhao Yan, Zhou Hai, Lin Qing21.5$1,453300

选定之后After the choice

  1. 起草动作Draft actions采纳 B,AI 起草三个动作:服务派工、备件出库、给东港码头的预防性服务通知。Adopting B, the AI drafts three actions: service dispatch, spare-parts issue and a preventive-service notice to East Port.
  2. 人来批准A person approves派工和出库要花钱,只有厂长能批;客户通知由另一位售后或老师批,不能批自己发起的。Dispatch and parts cost money, so only the plant manager can approve; the notice needs another service person or the teacher — never its author.
  3. 落到 ERPNextInto ERPNext批准后 ERPNext 里有服务单(写明工程师和上门日)和备件出库单;工程师日历多了单子。After approval ERPNext holds the service issues (engineer and visit date) and the stock entry; the engineers’ calendars fill in.
  4. 回访Follow-up工程师按日子上门换轴承,孪生健康度回到绿;第二天客户回访打分,响应慢、拖期、修完又坏都会扣分。Engineers replace the bearings on schedule and the twin returns to green; the next day the customer scores the service, losing points for slow response, delay or a repeat failure.

生活里的同一件事:汽车厂发现某批刹车片有问题,按车架号查出用了这批零件的车,给车主寄召回通知。The everyday version: a carmaker finds a bad batch of brake pads, looks up every VIN that got them, and mails recall notices.

留给课堂讨论的Open for class discussion

只看同一片砂轮够吗Is one wheel the right batch?

批次还可以按同一张工单、同一炉热处理、同一批轴承来划。范围划窄会漏,划宽会多花钱、多惊动客户。Batches can also be cut by work order, heat-treat lot or bearing lot. Too narrow misses units; too wide costs more and alarms more customers.

这笔钱算谁的Whose budget pays?

保修内由工厂出钱。该算售后、质量还是生产?怎样从源头少花这笔钱,比如把砂轮修整间隔从 30 件改为 20 件?In warranty the factory pays. Should it land on service, quality or production? How do you cut it at the source — say, dressing the wheel every 20 parts instead of 30?

演练是教学情景This run is a teaching scenario

客户、设备和砂轮批次都是教学工厂的情景数据,现场时钟 1 分钟 = 1 天。追溯和方案的算法与线上一致。Customers, units and wheel batches are scenario data in the teaching factory, with a field clock of 1 minute = 1 day. The tracing and option logic are the same code that runs live.

这个案例用到的课Courses behind this case

  • 质量管理与 SPCQuality Management and SPC批次追溯、不合格品处理、CAPABatch traceability, nonconformance, CAPA特色选修 · 建设中Elective · planned
  • 设备管理与预测性维护Equipment Management and Predictive Maintenance数字孪生、轴承寿命、维护时机Digital twins, bearing life, maintenance timing特色选修 · 建设中Elective · planned
  • 智能制造与数字孪生Smart Manufacturing and Digital Twins工厂本体、异常、追因、推演与动作Factory ontology, anomalies, root cause, what-if and actions特色选修 · 建设中Elective · planned
  • 工业数据与 AI 代理Industrial Data and AI AgentsAI 代理怎样调工具、引依据、只起草不擅自执行How the AI agent calls tools, cites evidence and only drafts特色选修 · 建设中Elective · planned
  • 机械制造技术Manufacturing Technology磨削、砂轮修整与加工误差Grinding, wheel dressing and machining error教材编写中In writing

自己做一遍Do it yourself

  1. 实验 16Lab 16:客户投诉的追溯、召回与服务决策: Complaint traceability, recall and service decisions
  2. 实验 15Lab 15:车间异常的追因、推演与决策: Shop-floor anomalies: root cause, what-if, decision
  3. 实验 13Lab 13:减速器数字孪生与预测性维护: Gearbox digital twin and predictive maintenance

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