Apollo Machinery: Intelligent Factory Upgrade Project Drives Manufacturing Upgrade of Nuclear Grade Pumps

Case Description

Shanghai Apollo Machinery Co., Ltd., as a professional supplier and service provider of nuclear grade pumps and related equipment for nuclear power plants, occupies an important position in the field of nuclear power and has become a qualified supplier for groups such as China National Nuclear Corporation, China General Nuclear Power Corporation, and State Nuclear Power Corporation. The intelligent factory upgrade project focuses on the production and manufacturing of nuclear grade pumps, aiming to overcome existing problems in enterprises through information technology, comprehensively improve production management efficiency and decision-making accuracy, consolidate industry position, and lead the intelligent transformation of the industry.

Application Products

     ERP            MOM     

Company Profile

Shanghai Apollo Machinery Co., Ltd. was established in 2001 and is a professional supplier and service provider specializing in nuclear grade pumps for nuclear power plants, important non nuclear grade pump systems, and nuclear power reprocessing equipment. After more than 20 years of continuous research and development, the company has achieved independent production of multiple key nuclear power pump products, especially in the fields of concrete volute seawater circulation pumps, steam assisted feedwater pumps, and electric assisted feedwater pumps, which are in a leading position globally. As one of the few domestic enterprises with core independent intellectual property rights, Apollo Machinery has become a qualified supplier for China National Nuclear Corporation, China General Nuclear Power Corporation, State Power Investment Corporation, China Huaneng Group Co., Ltd., and China Nuclear Energy Industry Association, and successfully listed on the New Third Board in 2015.

Project background

1. Data integration dilemma: Multiple systems such as CRM, ERP, PLM, and OA operate independently within the enterprise, forming data silos that hinder data flow, make sharing difficult, and make it difficult to converge into a unified information resource pool, seriously restricting the overall operational efficiency improvement and accurate decision-making of the enterprise.

2. Production control difficulties: The large, single piece, multi variety, and small batch characteristics of nuclear grade pump production have led to difficulties in traditional production planning and execution. BOM control is extensive and lacks complete analysis, resulting in frequent deviations in plan execution, delayed production progress, and extended delivery cycles.

3. Financial business disconnect: Separation of finance and business processes, lack of tracking of business trajectories, weak cost budgeting and process control, difficulty in timely and accurate reflection of business essence through financial data, and difficulty for decision-makers to effectively control the business situation based on financial information.

4. Extensive salary accounting: The time-based and piece rate business relies on manual operation, data collection is prone to errors and has poor timeliness. The adaptability of job rules is weak, and there is a lack of multidimensional report support. The management cannot accurately perceive the correlation between production efficiency and costs, and the rationality of salary distribution is lacking.

5. Chaotic account management: Apollo Machinery and Apollo Intelligent ERP system are intertwined, with chaotic architecture, unclear data ownership, and rising risks, seriously disrupting the order of enterprise financial management and the quality of financial information.

6. Lack of aging analysis: The aging business logic is chaotic, and there is no effective means to monitor fund flows. Enterprises find it difficult to accurately assess customer credit, control fund risks, and optimize fund allocation, posing potential threats to financial health.

7. Lagged operation and maintenance services: The service operation and maintenance system is chaotic, the operation process is arbitrary, the fault handling is delayed, the customer feedback channel is blocked, the service quality and user experience are deeply mired in the valley, affecting the company's market reputation and customer loyalty.

Solution

（1） Building a unified data platform

Deeply integrating CRM, ERP, PLM, and OA systems, carefully creating a unified data center. By utilizing efficient data interfaces and standardized data format conversion, we break down system barriers, integrate enterprise wide data, and achieve centralized storage, management, and sharing of data. Build a robust data governance architecture, implement data cleaning, classification, and coding standards, improve data quality and availability, and lay a solid foundation for enterprise operation analysis.

（2） Workshop fine control strengthened

Innovatively adopting a serial production planning mode, following the customized planning rules based on the production characteristics of nuclear grade pumps, and accurately issuing production instructions. Refine BOM management, deeply analyze the hierarchical structure and usage relationship of materials, combine with comprehensive analysis algorithms, accurately control the progress and completeness of material preparation, and improve the feasibility of plans. Deploy advanced data collection terminals to collect real-time data on equipment operating conditions, process parameters, personnel working hours, etc. at the production site, achieving visual monitoring and traceability of the entire production process.

（3） Promotion of financial business integration

Implant business and financial integration system, deeply embed key nodes in business processes. Drive financial accounting with business events, accurately track business trajectories, build an expense budget control system, set multi-dimensional budget indicators and warning thresholds, monitor expense deviations in real time, and strengthen cost control. The finance department is deeply involved in business decision-making, providing quantitative analysis and risk assessment based on real-time financial data to assist management in making scientific decisions.

（4） Design and Manufacturing Collaborative Upgrade

Expand PLM system functionality to cover product lifecycle management. Organize collaboration among over 100 users, integrating document management, BOM management, project task management, and material management modules to achieve real-time interaction and version collaboration of product design, process planning, and manufacturing execution data, ensuring precise implementation of design intent in the manufacturing process, shortening product development cycles, and enhancing product innovation capabilities.

（5） Accurate optimization of timing and piece counting

Develop a dedicated timing and piece rate system, seamlessly integrate with existing MES systems, collect real-time production time data, and accurately transmit it to the salary accounting module after verification and cleaning. Design a flexible configuration interface, customize timing and piece rate rules based on job characteristics and process complexity, and adapt to diverse business scenarios. Generate multidimensional reports that cover analysis dimensions such as personnel efficiency, work order costs, and workshop output, providing detailed data support for management decision-making.

（6） Reshaping the Account Set Architecture

Comprehensively split Apollo Machinery and Apollo Intelligent ERP system, build independent databases, application layers, and user permission systems, implement physical isolation, clarify data boundaries and business processes. Newly built Apollo intelligent ERP system, optimized functional modules based on enterprise strategy and business architecture, ensuring stable and efficient operation of core businesses such as financial accounting, supply chain management, and production manufacturing.

（7） Intelligent Construction of Aging Analysis

Sort out the aging business process and logical rules, identify key influencing factors and data nodes. Customize an aging analysis system to automatically calculate customer aging and overdue accounts according to preset rules, generate visual aging reports and risk warning prompts. The management dynamically monitors the withdrawal of funds, evaluates customer credit risks, adjusts credit policies and collection strategies in a timely manner, and ensures the smooth flow of the fund chain.

（8） Complete service operation and maintenance system

Develop a standardized service operation and maintenance process manual, covering the entire process of problem acceptance, diagnosis, handling, and feedback, clarifying operational norms, responsible parties, and time requirements for each link. Build a customer feedback management platform that integrates telephone, email, and online customer service channels to achieve one-stop submission, tracking, and processing of issues. Regularly collect customer feedback and suggestions, deeply explore service shortcomings, continuously iterate and optimize service strategies and processes, and improve customer satisfaction.

Cooperation achievements

1. After applying the intelligent solution of Caijiang, enterprises can achieve comprehensive upgrading.

2. In terms of data-driven decision-making, the unified data platform integrates massive business data, generates accurate insights through deep mining and analysis, and helps management to control the overall operation of the enterprise in real time, formulate precise strategic planning and resource allocation strategies, greatly improve decision-making efficiency and accuracy, and drive the market response speed and competitiveness of the enterprise to significantly leap.

3. In terms of production efficiency, the workshop fine controls and optimizes the production process, significantly improving the on-time completion rate of plans, shortening production cycles, improving material utilization, reducing production costs, enhancing delivery capabilities, and stabilizing market share.

4. At the level of financial control, the integration of financial business achieves full process cost control and risk warning, providing solid guarantees for enterprise profit growth and stable operation.

5. In salary management, the timing and piece rate system accurately calculates hourly wages, optimizes salary distribution, stimulates employee enthusiasm and creativity, and helps build an efficient incentive mechanism.

6. In terms of account set management, the separation and reconstruction of account sets clarify the financial structure, improve the efficiency and accuracy of financial statement preparation, and lay a solid foundation for enterprise listing preparations.

7. In terms of fund risk prevention and control, the aging analysis system accurately monitors fund dynamics, optimizes fund structure and liquidity, and enhances risk resistance capabilities. The service quality has also been significantly improved, and the optimization of the service operation and maintenance system has shortened the problem-solving cycle, greatly enhanced customer satisfaction, strengthened brand image and market reputation, and expanded business cooperation networks.