今天，结合以前在流程型与离散型企业工作的感受，聊聊这两类企业在MES方面的需求共性及差异。

一、流程型企业与离散型企业的行业差异有哪些？

制造行业有哪两大分类？制造行业主要分两大类：流程型与离散型。流程型主要是采用物理或化学的方法对原材料进行混合、分离、粉碎、加热等工业生产，使原材料增值。除了启停及异常情况外，流程工业生产中的物料呈连续状态通过整个生产流程。典型的流程制造行业包括冶金、化工、石油及像我以前从事过的造纸行业。离散型则主要是通过对原材料的物理形状进行改变或组合，使其成为产品并增值。离散型企业加工过程中物料呈离散状态，主要经物理加工和组装实现产品的工业生产。典型的离散制造行业包括械、汽车、电子、家电及像我以前从事的家具生产企业。当然，除了这两种模式之外，还有一类企业属于以上两种的混合型生产，典型像食品、烟草、还有我以前服务的几家磁材加工企业等。但今天我主要聊聊流程型与离散型的行业差异。

流程型企业与离散型企业的行业差异点一：产品结构

流程型企业与离散型企业的行业差异之一在于产品结构不同。离散工业主要生产离散型产品，如汽车、电子设备、家电等，这些产品由许多组件和部件组成。而流程工业则专注于生产连续型产品，如石油、化学品、食品等，其产品结构更为复杂，通常不存在离散的组件。

流程型企业与离散型企业的行业差异二：生产流程

流程型企业与离散型企业的行业差异之一在于生产流程不同。离散工业的生产流程通常是间歇性的，即通过一系列离散的步骤来完成产品的组装和制造。相比之下，流程工业的生产是连续的，需要经过稳定的流程来实现原料的加工、混合、反应和分离等工序。

流程型企业与离散型企业的行业差异点三：工艺流程

流程型企业与离散型企业的行业差异之一在于工艺流程不同。离散工业的工艺流程较为简单，通常涉及到零部件的装配和测试。而流程工业的工艺流程更为复杂，需要掌握各种化学、物理和生物过程，如蒸馏、反应、发酵等，以实现产品的制造。

流程型企业与离散型企业的行业差异点四：设备自动化程度

流程型企业与离散型企业的行业差异之一在于设备自动化程度不一样。离散工业的设备自动化程度较高，常采用机械化和自动化的装配线或生产线，以提高生产效率和质量。流程工业则倾向于使用连续流程设备，如反应器、分离塔等，这些设备通常需要操作员进行监控和调节。

流程型企业与离散型企业的行业差异点五：生产控制

流程型企业与离散型企业的行业差异之一在于生产控制上不同。离散工业的生产控制主要依赖于工序的顺序和时间规划，以确保产品的按时交付。流程工业则需要更加严格的过程控制，包括温度、压力、流速等参数的实时监测和调整，以确保产品的质量和安全性。

流程型企业与离散型企业的行业差异点六：产品转换

流程型企业与离散型企业的行业差异之一在于产品转换不同。离散工业可以相对容易地变换生产线来生产不同类型的产品。相比之下，流程工业的产品转换相对困难，因为它们的生产过程更为复杂，可能涉及到清洗、冲洗、改变原料供应等多个步骤。

流程型企业与离散型企业的行业差异点七：资源管理

流程型企业与离散型企业的行业差异之一在于资源管理不同。离散工业的资源管理主要关注零部件和原材料的库存和供应链管理。流程工业则需要更加重视能源、化学品以及废物处理等方面的资源管理，以确保生产过程的可持续性和环境友好性。

综上所述，离散工业与流程工业在产品结构、生产流程、工艺流程、设备自动化程度、生产控制、产品转换和资源管理等方面存在明显的差异。了解这些差异将有助于我们更好地理解两个行业的特点，并为其未来发展提供指导。

二、流程型MES与离散型MES功能的差异在哪里？

对应制造中的两在主要加工模式，MES行业一般也将产品分为离散MES型产品与流程型MES产品。流程型MES和离散型MES在产品结构管理、生产计划与执行、作业调度与任务派工、过程管理与控制、数据采集与生产监控、物料管理与追踪、质量管理通讯维护管理等方面还是存在一定显著的差异的。因此，在MES的设计与应用中，需要根据各自的特点进行综合考虑，在MES系统具体实施上，要根据行业特征区别对待。其主要差异主要表现在以下几方面。

流程型MES与离散型MES功能的差异一：流程管理与控制

-离散工业MES强调实时控制和监测离散生产流程，例如汽车制造或电子产品组装。

-流程工业MES主要应用于连续生产过程，如石化、制药或食品加工，更注重对流程参数的稳定控制。

流程型MES与离散型MES功能的差异二：生产调度与任务分配

-离散工业MES根据订单需求进行生产任务安排和分配给适当的工作站或设备。

-流程工业MES考虑物料流动、工艺参数和资源利用率等因素，以最大化生产效率。

流程型MES与离散型MES功能的差异三：资源配置

-离散工业MES管理并优化人力资源、设备和工具的使用。

-流程工业MES监测和控制原材料、能源和化学试剂等资源的供应和消耗。

流程型MES与离散型MES功能的差异四：物料管控

-离散工业MES实时跟踪物料的位置和数量，关注进出库、仓储和运输等环节。

-流程工业MES重点控制物料流动和混合过程，确保符合配比要求，以保证产品质量和工艺稳定性。

流程型MES与离散型MES功能的差异五：质量管理

离散工业与流程工业均重视质量管理，但重点略有不同。

-离散工业MES监控生产过程各环节，实时反馈数据进行质量控制。

-流程工业MES更注重关键参数的监测和调整，确保产品符合质量标准。

流程型MES与离散型MES功能的差异六：设备维护管理

-离散工业中的设备通常进行成批运行，设备维护管理主要包括预防性维护和故障处理。

-离散工业MES需要提供设备维护计划和故障报警等功能。

流程型MES与离散型MES功能的差异七：技术文档管理

-离散工业MES管理产品工艺和操作指导等技术文档，确保操作规范和一致性。

-流程工业MES则更注重处理流程参数、工艺路线和配方等方面的信息。

流程型MES与离散型MES功能的差异八：数据采集

-离散工业MES采集生产数据，如产量、质量指标和设备状态等。

-流程工业MES需要实时采集流程参数、能耗消耗和原料质量等数据。

流程型MES与离散型MES功能的差异九：性能分析

-离散工业MES用于分析生产效率、产品质量和资源利用率等关键绩效指标。

-流程工业MES分析流程稳定性、能源效率和废品率等性能指标。

鉴于离散型与流程型企业各自的特点，它们在MES功能需求上侧重点有所不同。相对于离散型企业，流程型企业的设备与工艺自动化程度较高，因此流程型MES往往以安全、稳定、低耗、质量、得率等为生产管理与控制的重点优化目标，对过程自动化和管控信息化程度要求较高。而离散型企业由于设备与工艺具有较大的柔性，因此对生产计划调度与现场管控的要求较高，往往以生产效率、订单交付、制造柔性、生成成本与产品质量等为主要管控与优化目标。

三、流程型与离散型MES产品结构差异在哪里？

从上面的分析可知，离散型MES与流程型MES在业务功能存在着明显差异，所以在进行MES产品设计需要考虑到各自的特征。

（一）离散型MES产品体系结构

离散型MES产品体系结构中一般包括数据库层、数据集成层、基础平台层、现场管理层、现场管理层、核心业务层、计划管理层6层组成。

1、数据库层

这是MES系统的基础层，用于存储和管理所有相关的数据。它可以包括多个数据库，如关系型数据库（如SQL Server或Oracle）和实时数据库（如OPC服务器），用于存储生产过程中的各种数据，如设备状态、工艺参数、生产订单等。

2、数据集成层

该层负责将来自不同源头的数据进行整合和处理。它包括了数据采集、传输和转换等功能，能够从工厂现场的各种设备和系统中采集数据，并将其转换为MES系统所需的格式。

3、基础平台层

这一层提供了MES系统的核心功能和基础设施。它包括工厂模型、工艺模型、工作流引擎、算法引擎、任务调度等功能。通过基础平台层，用户可以访问MES系统的各项功能，并进行配置、监控和管理生产过程。

4、现场管理层

该层负责对生产现场进行实时监控和控制。它与设备和机器人等现场设备进行通信，获取实时数据并控制操作。现场管理层还可以提供诸如设备调度、异常处理、质量检测等功能，以确保生产过程的高效运行。

5、核心业务层

这一层包含了MES系统的核心业务逻辑。它提供了诸如订单管理、生产调度、物料追踪、质量管理等关键功能。核心业务层根据工厂的需求和规则，协调和优化生产资源，并实现生产计划的执行。

6、计划管理层

该层负责制定和管理生产计划。它涉及到计划建模、计划编制、计划分解、传真验证、计划调整等功能，将客户需求转化为具体的生产计划，并与其他层次进行协调，以实现合理的生产调度和资源分配。

这些层次相互关联并相互作用，构成了离散型MES产品体系结构的基本框架。通过这个体系结构，企业可以实现对生产过程的全面控制和管理，提高生产效率、降低成本，并满足客户需求和质量标准。

（二）流程型MES产品体系结构

流程型MES产品体系结构主要由数据集成平台层、核心业务层、生产信息监控层、数据服务层等组成。

1、数据集成平台层

这是MES的基础层，用于处理数据的采集、存储和传输。它包括与现场设备和系统集成的接口，如传感器、PLC（可编程逻辑控制器）和SCADA（监控与数据采集系统），以及与企业级系统集成的接口，如ERP（企业资源规划）系统和PLM（产品生命周期管理）系统。数据集成平台层负责将来自各种来源的数据汇总和转换，确保数据的准确性和一致性。

2、核心业务层

该层实现了MES的核心功能，包括生产订单管理、调度计划、工艺路线管理、物料追溯和质量管理等。它通过对生产过程进行实时监控和控制，确保生产按照预定计划进行，并满足质量标准。核心业务层与数据集成平台层紧密合作，获取实时数据并生成报表、指标和分析结果，以支持决策制定和优化生产过程。

3、生产信息监控层

该层提供实时的生产信息可视化和监控功能。它通过仪表盘、报表和图形界面展示关键性能指标（KPIs）、生产进度和异常情况，帮助管理人员和操作人员迅速了解生产状态，及时做出反应。生产信息监控层通常具备报警和事件触发的能力，以支持问题处理和预测维护。

4、数据服务层

该层负责提供数据分析和决策支持功能。它基于历史数据和实时数据进行数据挖掘、统计分析和预测建模，为优化生产流程、改进质量和增加效率提供依据。数据服务层还可以与其他智能系统集成，提供MES与外部系统的数据接口，包括ERP接口、企业应用集成接口（EAI）、实验室信息管理系统接口（LIMS）。

总之，流程型MES产品体系结构包括数据集成平台层、核心业务层、生产信息监控层和数据服务层。这种体系结构使得制造企业能够实时监控和控制生产过程，并通过数据分析和智能化技术优化生产效率和质量。

翻译：

In the past two years, because of the needs of work, there are more enterprises in Guangxi and Jiangxi to investigate and serve, among which there is a common industry “rare earth processing” in these two regions. Rare earth processing industry with the rise of the new energy industry in recent years is in a tuyere industry, the value of rare earth resources is also soaring (some fall back this year), but in the process of visiting, in fact, many rare earth processing enterprises processing methods are still relatively traditional, and even can be said to lag behind many processing and manufacturing industries, so many rare earth processing enterprises with the improvement of the market, Start manufacturing upgrades.

The whole process of rare earth processing basically belongs to the process manufacturing mode, which is generally batch and continuous production according to the process. In the upgrading process, many enterprises have begun to plan in the direction of digital transformation. In the process of digital transformation consulting services for some rare earth processing enterprises, I learned through consulting and research that the basic principle of many enterprises’ transformation is to extend the implementation layer and control layer on the basis of existing ERP. For the upgrading of production equipment and the improvement of automation degree, many enterprises also began to have a certain understanding of DCS. But the digital system at the executive level is still relatively unfamiliar. Today, combined with the experience of working in process and discrete enterprises before, talk about the commonalities and differences in MES requirements of these two types of enterprises.

— Analysis of industry differences between process and discrete enterprises —

The manufacturing industry is divided into two main categories: process type and discrete type. The process type mainly uses physical or chemical methods to mix, separate, crush, heat and other industrial production of raw materials to add value to raw materials. Except for start-stop and abnormal situations, the materials in process industrial production are in a continuous state through the entire production process. Typical process manufacturing industries include metallurgy, chemicals, petroleum and the paper industry, which I used to work in.

The discrete type is mainly through the physical shape of raw materials to change or combine, so that it becomes a product and adds value. In the process of discrete enterprise, the material is in a discrete state, and the industrial production of the product is mainly realized through physical processing and assembly. Typical discrete manufacturing industries include machinery, automobiles, electronics, home appliances, and furniture manufacturers like the one I used to work in. Of course, in addition to these two models, there is also a type of enterprise that belongs to the mixed production of the above two types, typically like food, tobacco, and several magnetic material processing enterprises that I have served before. But today I’m going to focus on the differences between process and discrete industries. Digital transformation www.szhzxw.cn

1. Product structure

The discrete industry mainly produces discrete products, such as automobiles, electronic equipment, home appliances, etc., which are composed of many components and components. The process industry, on the other hand, focuses on the production of continuous products, such as petroleum, chemicals, food, etc., whose product structure is more complex and usually does not have discrete components.

2. Production process

The production process of discrete industry is usually intermittent, that is, through a series of discrete steps to complete the assembly and manufacture of products. In contrast, the production of the process industry is continuous and requires a stable process to achieve the processing, mixing, reaction and separation of raw materials.

3. Process flow

The process flow of the discrete industry is relatively simple, usually involving the assembly and testing of parts. The process process of the process industry is more complex, and it is necessary to master a variety of chemical, physical and biological processes, such as distillation, reaction, fermentation, etc., in order to achieve the manufacturing of products.

4. The degree of equipment automation

Discrete industry equipment automation is high, often using mechanized and automated assembly lines or production lines to improve production efficiency and quality. Process industries tend to use continuous process equipment, such as reactors, separation towers, etc., which often require an operator to monitor and regulate.

5. Production control

Production control in discrete industries mainly relies on the sequence and timing of processes to ensure on-time delivery of products. The process industry requires more stringent process control, including real-time monitoring and adjustment of temperature, pressure, flow rate and other parameters to ensure product quality and safety.

6. Product conversion

Discrete industries can switch production lines relatively easily to produce different types of products. In contrast, product conversion in process industries is relatively difficult because their production processes are more complex and may involve multiple steps such as cleaning, rinsing, changing raw material supply, and so on.

7. Resource management

Resource management in discrete industries focuses on inventory and supply chain management of components and raw materials. Process industries need to pay more attention to resource management in areas such as energy, chemicals and waste disposal to ensure that production processes are sustainable and environmentally friendly.

To sum up, there are obvious differences between discrete industry and process industry in product structure, production process, process flow, equipment automation degree, production control, product conversion and resource management. Understanding these differences will help us better understand the characteristics of the two industries and provide guidance for their future development.

— Difference analysis of process and discrete MES functions —

Corresponding to the two main processing modes in manufacturing, the MES industry generally divides products into discrete MES products and process MES products. There are some significant differences between process MES and discrete MES in product structure management, production planning and execution, job scheduling and task assignment, process management and control, data collection and production monitoring, material management and tracking, quality management, communication and maintenance management. Therefore, in the design and application of MES, it is necessary to carry out comprehensive consideration according to their characteristics, and in the specific implementation of MES system, it is necessary to treat it differently according to the characteristics of the industry. The main differences are mainly manifested in the following aspects. Digital transformation www.szhzxw.cn

1. Process management and control

Discrete Industrial MES emphasizes real-time control and monitoring of discrete production processes, such as automotive manufacturing or electronic product assembly.

Process industry MES is mainly used in continuous production processes, such as petrochemical, pharmaceutical or food processing, and pays more attention to the stable control of process parameters.

2. Production scheduling and task allocation

Discrete industrial MES arranges production tasks and assigns them to appropriate workstations or equipment according to order requirements.

Process industry MES considers factors such as material flow, process parameters and resource utilization to maximize production efficiency.

3. Resource allocation

Discrete industrial MES manages and optimizes the use of human resources, equipment and tools.

Process industry MES monitors and controls the supply and consumption of resources such as raw materials, energy and chemical reagents.

4. Material control

Discrete industrial MES tracks the location and quantity of materials in real time, focusing on inbound and outbound storage, warehousing and transportation.

Process industry MES focuses on controlling the material flow and mixing process to ensure that the ratio requirements are met to ensure product quality and process stability.

5. Quality management

Both discrete industry and process industry attach importance to quality management, but the emphasis is slightly different. Digital transformation www.szhzxw.cn

Discrete industrial MES monitors all aspects of the production process and feeds back data in real time for quality control.

Process industry MES pays more attention to the monitoring and adjustment of key parameters to ensure that products meet quality standards.

6. Equipment maintenance and management

Equipment in discrete industries is usually run in batches, and equipment maintenance management mainly includes preventive maintenance and fault handling.

Discrete industrial MES need to provide functions such as equipment maintenance planning and fault alarm.

7. Technical document management

Discrete industrial MES manages technical documentation such as product process and operational guidance to ensure operational specifications and consistency.

Process industry MES is more focused on processing information such as process parameters, process routes and formulations.

8. Data collection

Discrete industrial MES collects production data, such as output, quality indicators and equipment status.

Process industry MES requires real-time collection of data such as process parameters, energy consumption and raw material quality.

9. Performance analysis

Discrete industrial MES are used to analyze key performance indicators such as production efficiency, product quality and resource utilization.

Process industry MES analyzes performance indicators such as process stability, energy efficiency and scrap rate. Digital transformation www.szhzxw.cn

In view of their respective characteristics, discrete and process enterprises have different emphases on MES functional requirements. Compared with discrete enterprises, process-based enterprises have a higher degree of equipment and process automation, so process-based MES often take safety, stability, low consumption, quality and yield as the key optimization goals of production management and control, and have higher requirements for process automation and control informatization. Because of the greater flexibility of equipment and process, discrete enterprises have higher requirements for production planning and scheduling and on-site control, and often take production efficiency, order delivery, manufacturing flexibility, generation cost and product quality as the main control and optimization goals.

— Analysis of product structure difference between process and discrete MES —

From the above analysis, it can be seen that there are obvious differences between discrete MES and process-based MES in business functions, so it is necessary to take their respective characteristics into account in MES product design. Digital transformation www.szhzxw.cn

First, discrete MES product architecture

The discrete MES product architecture generally consists of six layers: database layer, data integration layer, basic platform layer, field management layer, field management layer, core business layer and plan management layer.

1. Database layer

This is the base layer of the MES system, used to store and manage all the relevant data. It can include multiple databases, such as relational databases (such as SQL Server or Oracle) and real-time databases (such as OPC servers), for storing various data in the production process, such as equipment status, process parameters, production orders, etc. Digital transformation www.szhzxw.cn

2. Data integration layer

This layer is responsible for integrating and processing data from different sources. It includes functions such as data acquisition, transmission and conversion, which can collect data from various equipment and systems on the plant site and convert it into the format required by the MES system.

3. Basic platform layer

This layer provides the core functions and infrastructure of the MES system. It includes factory model, process model, workflow engine, algorithm engine, task scheduling and so on. Through the basic platform layer, users can access the functions of the MES system, and configure, monitor and manage the production process. Digital transformation www.szhzxw.cn

4. Site management

This layer is responsible for real-time monitoring and control of the production site. It communicates with field equipment such as equipment and robots to obtain real-time data and control operations. Field management can also provide functions such as equipment scheduling, exception handling, quality inspection, etc., to ensure efficient operation of the production process.

5. Core business layer

This layer contains the core business logic of the MES system. It provides key functions such as order management, production scheduling, material tracking, and quality management. The core business layer coordinates and optimizes production resources according to the requirements and rules of the plant, and implements the execution of production plans.

6. Plan management

This layer is responsible for developing and managing production plans. It involves the functions of plan modeling, plan preparation, plan decomposition, fax verification, plan adjustment, etc., transforming customer needs into specific production plans, and coordinating with other levels to achieve reasonable production scheduling and resource allocation.

These levels are interrelated and interact with each other, constituting the basic framework of discrete MES product architecture. Through this architecture, enterprises can achieve comprehensive control and management of the production process, improve production efficiency, reduce costs, and meet customer needs and quality standards.

Second, process MES product architecture

Process MES product architecture is mainly composed of data integration platform layer, core business layer, production information monitoring layer, data service layer and so on.

1. Data integration platform layer

This is the base layer of MES and is used to deal with the acquisition, storage and transmission of data. It includes interfaces for integration with field devices and systems such as sensors, PLCS (Programmable logic controllers) and SCADA (Monitoring and data acquisition systems), as well as enterprise-class systems such as ERP (enterprise resource planning) systems and PLM (product lifecycle management) systems. The data integration platform layer is responsible for aggregating and transforming data from various sources to ensure accuracy and consistency. Digital transformation www.szhzxw.cn

2. Core business layer

This layer realizes the core functions of MES, including production order management, scheduling, process route management, material traceability and quality management. Through real-time monitoring and control of the production process, it ensures that the production is carried out according to the predetermined schedule and meets the quality standards. The core business layer works closely with the data integration platform layer to capture real-time data and generate reports, metrics, and analytics to support decision making and optimize production processes.

3. Production information monitoring layer

This layer provides real-time production information visualization and monitoring functions. It displays key performance indicators (KPIs), production schedules, and anomalies through dashboards, reports, and graphical interfaces to help managers and operators quickly understand production status and respond in a timely manner. The production information monitoring layer typically has alarm and event triggering capabilities to support problem handling and predictive maintenance. Digital transformation www.szhzxw.cn

4. Data service layer

This layer is responsible for providing data analysis and decision support functions. It performs data mining, statistical analysis and predictive modeling based on historical and real-time data to provide the basis for optimizing production processes, improving quality and increasing efficiency. The data service layer can also be integrated with other intelligent systems to provide data interfaces between MES and external systems, including ERP interfaces, Enterprise Application Integration interfaces (EAI), and Laboratory Information Management system interfaces (LIMS).

In short, the process MES product architecture includes data integration platform layer, core business layer, production information monitoring layer and data service layer. This architecture enables manufacturing companies to monitor and control the production process in real time and optimize production efficiency and quality through data analysis and intelligent technology.

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