How much does it cost for an MES system to automatically trigger RC calibration tasks?
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I. Purchase cost of hardware
Core Communication Interface Hardware: Industrial communication gateway: about 1500-3000 RMB/unit Industrial-grade PTP synchronous switch: about 2000-5000 RMB/unit Industrial network card: about 800-1500 RMB/unit
Field Signal Acquisition Hardware: High-precision RC parameter acquisition module: 498-590 RMB/unit; Temperature fluctuation monitoring sensor: 100-200 RMB/point; Electromagnetic environment monitoring module: 800-1200 RMB/unit.
Auxiliary Supporting Hardware: Industrial-grade wireless Wi-Fi module: approx. 200-500RMB/unit; Signal isolator: approx. 150-300RMB/unit; Industrial-grade handheld PAD: approx. 2000-4000RMB/unit.
Total cost of hardware per production line: between 25,000-40,000 RMB. The cost can be less than 20 000 RMB by using high performance and cost-effective domestic components.
II. Costs of Software Configuration and Integration
MES System Secondary Development Cost: The cost of custom development for adding an automatic RC calibration task trigger module is about RMB 10,000 ~ 20,000. Reusing the open APIs of the existing MES system can minimise this cost to less than RMB 5,000.
Debugging and Integration Cost On-site engineer service for communication link debugging and rule configuration, costs about RMB 8,000-15,000. If it's debugged by internal tech team then it can be zero cost.
Total Software Integration Cost per Production Line: Approx. RMB 18,000 to 35,000; Under RMB 10,000, self-developed debugging is controllable.
III. Long Term O&M Costs
Annual maintenance cost of hardware is around 5% to 8% of the overall hardware expenditure. The annual maintenance cost per production line is from RMB 1,200 to RMB 3,200.
System iteration and optimisation costs: The cost of calibrating the trigger rules in line with process changes will be RMB 2,000 - 5,000 each year.
The annual total maintenance cost of each manufacturing line is about RMB 3200-8200, which may be further reduced by the in-house maintenance of the internal maintenance team.
IV. Comparison of investment and return overall
The overall investment for the whole life cycle of one production line is around 43,00075,000 RMB, which may save about 100,000200,000 RMB yearly losses of defective goods caused by RC parameter drift, and the investment-to-return ratio is more than 1:2.
Later, when adding the injection moulding machine sites, the marginal incremental cost per machine is only around 2000~3000 RMB, thus the costs for expansion are incredibly low.
