Material requirement planning method, system, electronic device and storage medium

Abstract

The present invention relates to the technical field of material requirement planning, and specifically discloses a method, system, electronic device, and storage medium for material requirement planning, which specifically includes: establishing a bill of materials, obtaining the net demand for each material based on the bill of materials within the same demand day; in response to the substitution relationship of the material being incomplete substitution, splitting the initial gross demand for the substitute material in the bill of materials, and determining the net demand for the substitute material based on the available inventory of the substitute material; selecting the material with the smallest net demand, and splitting the material according to the minimum value of the gross demand and the available inventory so that its net demand is zero; completing the remaining gross demand of the demand item corresponding to the material with the material's substitute material; updating the bill of materials; repeating the process until all substitute materials are split; and finally generating the final net demand according to the original demand material. The method of the present invention can accurately calculate the available quantity of the substitute material and avoid stockpiling unnecessary inventory.

Description

Technical Field

[0001] The present invention relates to the technical field of material requirement planning, and in particular to a material requirement planning method, system, electronic equipment and storage medium. Background Art

[0002] The statements in this section merely provide background information related to the present invention and do not necessarily constitute prior art.

[0003] Material Requirements Planning (MRP) is an inventory management and production planning system algorithm used by manufacturing companies. Material substitution is common in modern manufacturing. For example, laptop memory modules of the same specifications may be available from multiple brands. Mobile phones, as highly modular electronic products, can have components such as screens, camera lenses, and flash memory chips from multiple suppliers, even for the same model, depending on batch size. Substitution scenarios are categorized into several main types: complete substitution, partial substitution, and non-substitution, depending on the type of substitution material used. For example, if demand 2 can consume material A or B, and demand 3 can consume material A or C, materials A, B, and C constitute a non-complete substitution relationship.

[0004] For material requirement planning, most existing technologies only perform material deductions based on preset priority rules without considering the substitutability between materials. This may cause the system to prioritize the use of a certain material, causing it to be quickly depleted, while other substitutable materials are idle, affecting subsequent production.

[0005] If the incomplete substitution relationship of materials is taken into account, the inventory calculation can be made more accurate. The existing technology takes a global overall consideration, takes the minimum overall procurement volume or the minimum total redundant inventory as the goal, enumerates all possible allocation situations, constructs the objective function, and obtains the final material requirement plan by solving the objective function; however, in this scenario of incomplete material substitution, compared with the strategy of material consumption based on preset rules, the global coordination material consumption strategy will make the calculation difficulty of MRP increase sharply. Due to the insufficient computing power of the MRP system, it is easy to fail to output a truly reasonable material requirement plan. Summary of the Invention

[0006] In order to solve the above problems, the present invention proposes a material requirement planning method, system, electronic device and storage medium, which can support the coexistence of three scenarios: no substitution, incomplete substitution and complete substitution. The implementation logic is simple and the computing power requirements are not high, but at the same time a relatively reasonable material requirement plan can be obtained.

[0007] In some embodiments, the following technical solutions are adopted:

[0008] A material requirements planning method comprising:

[0009] Create a bill of materials, including gross material requirements, available inventory, and required item information; also determine the substitution relationship and group number for each material;

[0010] Based on the bill of materials for the same demand day, obtain the gross demand and available inventory of each material required for each demand, and obtain the net demand for each material;

[0011] In response to the material substitution relationship being incomplete substitution, the initial gross demand for the substitute material is split out in the bill of materials, and the net demand for the substitute material is determined based on the available inventory of the substitute material;

[0012] Select the material with the smallest net demand and split it according to the minimum of gross demand and available inventory so that its net demand is zero; the remaining gross demand of the demand item corresponding to the material is filled with alternative materials of the material; update the material list; repeat this process until all alternative materials are split; finally, generate the final net demand according to the original demand material.

[0013] As a further solution, based on the substitution relationship of the material, the substitution relationship group number of the material is identified; each material has a unique substitution relationship group number identification.

[0014] As a further solution, modify the materials in the same substitution relationship group to have the same low-level code.

[0015] As a further solution, the available inventory of materials is matched in the order of priority of irreplaceable, incompletely replaceable and completely replaceable, so as to calculate the net demand in the bill of materials.

[0016] As a further option, it also includes:

[0017] In response to the substitution relationship of the material being non-substitutable, obtaining a net demand for the material based on a difference between a gross demand for the material and available inventory;

[0018] Alternatively, in response to the substitution relationship of the material being complete substitution, available inventory is matched for each material in the substitution relationship group, and the sum of all available inventories is calculated; and the net demand for the material is obtained based on the difference between the gross demand for the material and the sum of the available inventories.

[0019] As a further solution, the initial gross demand for the substitute material is split out in the bill of materials, and the initial gross demand for the substitute material is the gross demand for the corresponding original demand material.

[0020] As a further solution, the materials are split according to the minimum of gross demand and available inventory, specifically:

[0021] For the material with the smallest net demand, determine the minimum of its gross demand and available inventory, and use the minimum as the gross demand and available inventory of the material, so that the net demand of the material is zero;

[0022] The remaining gross demand of the demand item corresponding to the material is used as the gross demand of the alternative material of the material. If the available inventory of the alternative material is greater than the remaining gross demand, the available inventory of the alternative material in the demand item is set to the remaining gross demand, and the remaining available inventory is transferred to other demand items of the alternative material; if the available inventory of the alternative material is less than the remaining gross demand and all alternative materials have been split, the net demand is calculated based on the remaining gross demand and the available inventory, which are used as the gross demand and net demand of the original demand material.

[0023] In other embodiments, the following technical solutions are adopted:

[0024] A material requirements planning system, comprising:

[0025] The BOM building module is used to create a BOM that includes gross material requirements, available inventory, and required item information; it also determines the substitution relationship and group number of each material;

[0026] The net demand calculation module is used to obtain the gross demand and available inventory of each material required for each demand based on the bill of materials within the same demand day, and obtain the net demand of each material;

[0027] A net demand update module is used to split the initial gross demand of the substitute material in the bill of materials in response to the substitution relationship of the material being incomplete substitution, and determine the net demand of the substitute material based on the available inventory of the substitute material;

[0028] Select the material with the smallest net demand and split it according to the minimum of gross demand and available inventory so that its net demand is zero; the remaining gross demand of the demand item corresponding to the material is filled with alternative materials of the material; update the material list; repeat this process until all alternative materials are split; finally, generate the final net demand according to the original demand material.

[0029] In other embodiments, the following technical solutions are adopted:

[0030] A terminal device includes a processor and a memory, wherein the processor is used to implement instructions; the memory is used to store multiple instructions, and the instructions are suitable for being loaded by the processor and executing the above-mentioned material requirement planning method.

[0031] In other embodiments, the following technical solutions are adopted:

[0032] A computer-readable storage medium stores a plurality of instructions, wherein the instructions are suitable for being loaded by a processor of a terminal device and executing the above-mentioned material requirement planning method.

[0033] Compared with the prior art, the present invention has the following beneficial effects:

[0034] (1) The material requirement planning method of the present invention does not need to enumerate all allocation situations, simplifies the calculation logic in the scenario of incomplete material substitution, reduces the calculation difficulty and the requirements for calculation performance; the calculation results can fully meet the material requirements of each demand item, can accurately calculate the available quantity of the substitute material, and avoid stockpiling unnecessary inventory, so that the calculation of the safety stock is more in line with actual needs and reduces capital occupation.

[0035] (2) The method of the present invention can be directly deployed in the original material requirement planning (MRP) algorithm without changing the framework of the original algorithm. It has the characteristics of low implementation cost, high practicality, novelty, versatility and ease of use.

[0036] Other features and advantages of additional aspects of the present invention will be given in part in the following description and in part will become obvious from the following description or will be learned through practice of the present invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0037] Figure 1 A flow chart of a method for material requirement planning in an embodiment of the present invention;

[0038] Figure 2 This is a workflow diagram for an incomplete replacement scenario in an embodiment of the present invention;

[0039] Figure 3 Schematic diagram of the system architecture of material requirement planning in an embodiment of the present invention. DETAILED DESCRIPTION

[0040] It should be noted that the following detailed description is illustrative and is intended to provide further explanation of the present application. Unless otherwise specified, all technical and scientific terms used in the present invention have the same meaning as commonly understood by those skilled in the art to which the present application belongs.

[0041] It should be noted that the terms used herein are only for describing specific embodiments and are not intended to limit the exemplary embodiments according to the present application. As used herein, unless the context clearly indicates otherwise, the singular form is also intended to include the plural form. In addition, it should be understood that when the terms "comprise" and / or "include" are used in this specification, they indicate the presence of features, steps, operations, devices, components and / or combinations thereof.

[0042] Example 1

[0043] In one or more embodiments, a method for material requirements planning is disclosed, combining Figure 1 , specifically including the following process:

[0044] S101: Create a bill of materials, which includes gross material requirements, available inventory, and demand item information; at the same time, determine the substitution relationship and group number of each material;

[0045] In this embodiment, the substitution relationship of materials can include three types: irreplaceable, incomplete substitution, and complete substitution; among which:

[0046] ① Irreplaceable means that the material cannot be replaced by other materials, that is, the available inventory of substitute materials is not considered during MRP calculations.

[0047] ② Complete substitution means that all materials in the material substitution relationship can be replaced. For example, material A, material B and material C are in a complete substitution relationship, which means that material A, material B and material C can be mixed.

[0048] ③ Incomplete substitution refers to selecting substitutable subsets from the material substitution relationship and defining [substitutable materials]; for example: in demand item 2, material A or material B can be consumed, and in demand item 3, material A or material C can be consumed, then material A, material B and material C constitute an incomplete substitution relationship, and material B and material C are the substitutable subsets of material A in different demand items respectively.

[0049] Based on the substitution relationship of materials, a substitution relationship group number is identified for each material; each material has a unique substitution relationship group number identification; so when matching materials, alternative materials can be directly matched within the corresponding substitution relationship group based on the substitution relationship.

[0050] As an optional implementation, an editable material substitution relationship table can be constructed, from which the required material substitution relationship and group number can be obtained; the specific data structure of the material substitution relationship table is shown in Table 1.

[0051] Table 1 Material substitution relationship table

[0052]

[0053] At the same time, an association relationship is established between the bill of materials and the material substitution relationship table, so that the substitution relationship and group number of each material in the bill of materials can be obtained; the association relationship structure between the bill of materials and the material substitution relationship table is shown in Table 2.

[0054] Table 2 Bill of Materials - Material Substitution Relationship Table

[0055]

[0056] In this embodiment, the gross demand and available inventory of a material can be obtained from the demand list and inventory list. The demand list includes the quantity of each material required for different demand items as the gross demand of the material; the inventory list includes the existing inventory and purchase orders of each material, and the sum of the two is the available inventory of the material.

[0057] It should also be noted that the Low-Level Code (LLC) is used to indicate the hierarchical position of a material in the product structure (BOM). In this embodiment, the maximum low-level code in the same material substitution relationship group is used as the low-level code for all materials in the group, thereby ensuring that all materials in the same material substitution relationship group are at the same level, ensuring the correct order of material requirement calculation, and ensuring the accuracy of material requirement calculation.

[0058] S102: Based on the bill of materials on the same demand day, the gross demand and available inventory of each material required for each demand are obtained to obtain the net demand for each material.

[0059] In this embodiment, the net demand for a material = the gross demand for the material - the available inventory of the material.

[0060] Finally, the bill of materials shown in Table 3 can be obtained.

[0061] Table 3 Bill of Materials

[0062]

[0063] S103: Match the available inventory of each material in the order of priority of irreplaceable, incompletely replaceable, and completely replaceable, thereby calculating the net demand in the bill of materials.

[0064] In this embodiment, the substitution relationship of each material under different requirements is determined by associating the material substitution relationship table; the non-substitutable materials are processed first, then the partially substituted materials, and finally the fully substituted materials; the specific processing process is as follows:

[0065] ① If the substitution relationship of a material is non-substitutable, then the material cannot be replaced by other materials. The net demand for the material is obtained directly based on the difference between the gross demand and the available inventory of the material.

[0066] ② In response to the material substitution relationship is incomplete substitution, combined with Figure 2 The specific process is as follows:

[0067] S1031: Split out the initial gross demand for the substitute material in the bill of materials and determine the net demand for the substitute material based on the available inventory of the substitute material;

[0068] S1032: Select the material with the smallest net demand, and split the material according to the minimum of gross demand and available inventory so that its net demand is zero;

[0069] S1033: The remaining gross demand of the demand item corresponding to the material is filled by the material's alternative materials;

[0070] S1034: Update the bill of materials;

[0071] S1035: Repeat this process until all substitute materials are split;

[0072] S1036: Finally, the final net demand is generated based on the original demand materials.

[0073] As a specific implementation method, based on the available inventory of materials in Table 3 and the gross demand for materials under different demands, first, the initial gross demand for alternative materials is split out in the bill of materials. In this embodiment, the initial gross demand for alternative materials is set as the gross demand for the original demand material, and then the net demand for alternative materials is determined based on the available inventory of alternative materials. This allows the original demand material and the alternative material to have equal opportunities to participate in subsequent allocation operations, so that materials with large inventory can be allocated first, avoiding unnecessary inventory redundancy.

[0074] The details are shown in Table 4.

[0075] Table 4 Alternative material matching table

[0076]

[0077] Next, select the material with the smallest net demand. In Table 4, the net demand for material A is 250, the net demand for material B is 10, and the net demand for material C is 260. Therefore, material B has the smallest net demand in demand item 2, so it is split. The specific splitting principle is: set the gross demand and available inventory of material B to the minimum of 110, thereby reducing its net demand to zero and removing material B from the list of materials available for continued substitution. At this point, the remaining gross demand for demand 2 becomes 10, and material A is used to fill it. Since the available inventory of the material is greater than the remaining gross demand, the available inventory of material A in demand item 2 is set to the remaining gross demand. After the split, the remaining available inventory of material A is used to meet other demands (such as demand 3). The updated bill of materials is shown in Table 5.

[0078] Table 5 Updated Bill of Materials

[0079]

[0080] Furthermore, continue to select the material with the smallest net demand. In Table 5, the net demand of material A is the smallest. Material a is split, and the splitting principle is the same as above; then material A is removed from the materials that can continue to be allocated alternatively; the updated material list is shown in Table 6.

[0081] Table 6 Updated bill of materials

[0082]

[0083] Furthermore, we continue to select the material with the smallest net demand, which is material C, and split it. Since the available inventory of material C is less than the remaining gross demand at this time, and all alternative materials have been split, the net demand is calculated based on the remaining gross demand and available inventory at this time, and the net demand is 100. The net demand is generated according to the original demand material, that is, the net demand of material A is determined to be 100; as shown in Table 7.

[0084] Table 7 Net Requirements of Bill of Materials

[0085]

[0086] ③ In response to the complete substitution relationship of the material, all materials in the material substitution relationship group are substitutable. The available inventory is matched for each material in the material substitution relationship group, and the sum of the available inventory of all materials is calculated; the net demand for the material is obtained based on the difference between the gross demand for the material and the sum of all available inventory.

[0087] In this embodiment, the material planning method under the incomplete substitution scenario is considered. It does not require a complex calculation process and can accurately calculate the available quantity of the substitute material. At the same time, it avoids stockpiling unnecessary inventory, reduces the requirements for the calculation performance of the MRP system, and improves the calculation efficiency.

[0088] The material planning method in the prior art that does not consider the substitution relationship and performs material deduction according to the preset priority rules is taken as Example 1, the material planning method in the prior art that uses a global coordination method to perform material deduction is taken as Example 2, and the material planning method of this embodiment is taken as Example 3. The material inventory and demand of the three examples are exactly the same. Tables 8-10 respectively give the demand planning orders calculated for different examples.

[0089] Table 8 Calculation results of Example 1

[0090]

[0091] Table 9 Calculation results of Example 2

[0092]

[0093] Table 10 Calculation results of Example 3

[0094]

[0095] From the results of Tables 8 to 10, it can be seen that according to the method of Example 1, 260 copies of material A need to be purchased, and 60 copies of material B are redundant; according to the method of Example 2, 200 copies of material A need to be purchased, and there are no other redundant materials; according to the method of Example 3, only 100 copies of material A need to be purchased, and there are no other redundant materials; therefore, the method of this embodiment makes the procurement plan more reasonable, makes use of existing inventory materials as much as possible, and does not cause waste in procurement and inventory.

[0096] Example 2

[0097] In one or more embodiments, a system for material requirement planning is disclosed, combining Figure 3 ,include:

[0098] The BOM building module is used to create a BOM that includes gross material requirements, available inventory, and required item information; it also determines the substitution relationship and group number of each material;

[0099] The net demand calculation module is used to obtain the gross demand and available inventory of each material required for each demand based on the bill of materials within the same demand day, and obtain the net demand of each material;

[0100] A net demand update module is used to split the initial gross demand of the substitute material in the bill of materials in response to the substitution relationship of the material being incomplete substitution, and determine the net demand of the substitute material based on the available inventory of the substitute material;

[0101] Select the material with the smallest net demand and split it according to the minimum of gross demand and available inventory so that its net demand is zero; the remaining gross demand of the demand item corresponding to the material is filled with alternative materials of the material; update the material list; repeat this process until all alternative materials are split; finally, generate the final net demand according to the original demand material.

[0102] It should be noted that the specific implementation methods of the above modules are exactly the same as those in Example 1 and will not be described in detail.

[0103] Example 3

[0104] In one or more embodiments, a terminal device is disclosed, which includes a processor and a memory, wherein the processor is used to implement instructions; the memory is used to store multiple instructions, and the instructions are suitable for being loaded by the processor and executing the material requirement planning method described in Example 1.

[0105] It should be understood that in this embodiment, the processor may be a central processing unit (CPU), or may be other general-purpose processors, digital signal processors (DSP), application-specific integrated circuits (ASIC), off-the-shelf field-programmable gate arrays (FPGA), or other programmable logic devices, discrete gate or transistor logic devices, discrete hardware components, etc. The general-purpose processor may be a microprocessor or any conventional processor, etc.

[0106] The memory may include a read-only memory and a random access memory, and provides instructions and data to the processor. A portion of the memory may also include a non-volatile random access memory. For example, the memory may also store information about the device type.

[0107] During implementation, each step of the above method may be completed by an integrated logic circuit of hardware in a processor or by instructions in the form of software.

[0108] Example 4

[0109] In one or more embodiments, a computer-readable storage medium is disclosed, in which a plurality of instructions are stored. The instructions are suitable for being loaded by a processor of a terminal device and executing the material requirement planning method described in the first embodiment.

[0110] Although the above describes the specific embodiments of the present invention in conjunction with the accompanying drawings, it is not intended to limit the scope of protection of the present invention. Those skilled in the art should understand that various modifications or variations that can be made by those skilled in the art on the basis of the technical solution of the present invention without any creative work are still within the scope of protection of the present invention.

Claims

1. A material requirement planning method, characterized in that: include: Create a bill of materials, which includes gross material requirements, available inventory, and demand item information; At the same time, determine the substitution relationship and group number of each material; Based on the bill of materials for the same demand day, obtain the gross demand and available inventory of each material required for each demand, and obtain the net demand for each material; In response to the material substitution relationship being incomplete substitution, the initial gross demand for the substitute material is separated from the bill of materials, and the net demand for the substitute material is determined based on the available inventory of the substitute material; the initial gross demand for the substitute material is the gross demand for the corresponding original demand material; Select the material with the smallest net demand, split the material according to the minimum of the gross demand and the available inventory, so that its net demand is zero; for the material with the smallest net demand, determine the minimum of its gross demand and the available inventory, and use the minimum as the gross demand and the available inventory of the material, so that the net demand of the material is zero; the remaining gross demand of the demand item corresponding to the material is supplemented by the alternative material of the material, and the remaining gross demand of the demand item corresponding to the material is used as the gross demand of the alternative material of the material; if the available inventory of the alternative material is greater than the remaining gross demand, the available inventory of the alternative material in the demand item is set to the remaining gross demand, and the remaining available inventory is transferred to other demand items of the alternative material; update the bill of materials; Repeat this process until all substitute materials are split; finally, the final net demand is generated based on the original demand materials; If the available inventory of the alternative material is less than the remaining gross demand and all alternative materials have been split, the net demand is calculated based on the remaining gross demand and the available inventory as the gross demand and net demand of the original demand material.

2. A material requirement planning method according to claim 1, characterized in that: Based on the material's substitution relationship, identify the material's substitution relationship group number; each material has a unique substitution relationship group number identifier.

3. A material requirement planning method according to claim 1 or 2, characterized in that: Modify the materials in the same substitution relationship group to have the same low-level code.

4. A material requirement planning method according to claim 1, characterized in that: Match the available inventory of materials in the order of priority of irreplaceable, incompletely replaceable, and completely replaceable, and then calculate the net demand in the bill of materials.

5. A material requirement planning method according to claim 1 or 4, characterized in that: Also includes: In response to the substitution relationship of the material being non-substitutable, obtaining a net demand for the material based on a difference between a gross demand for the material and available inventory; Alternatively, in response to the substitution relationship of the material being a complete substitution, available inventory is matched for each material in the substitution relationship group, and the sum of all available inventories is calculated; The net demand for the material is obtained based on the difference between the gross demand for the material and the sum of the available inventory.

6. A material requirement planning system, characterized in that: include: The Bill of Materials (BOM) building module is used to build a BOM, which includes gross material requirements, available inventory, and required item information. At the same time, determine the substitution relationship and group number of each material; The net demand calculation module is used to obtain the gross demand and available inventory of each material required for each demand based on the bill of materials within the same demand day, and obtain the net demand of each material; a net demand update module configured to, in response to a material substitution relationship being an incomplete substitution, separate an initial gross demand for the substitute material from the bill of materials and determine a net demand for the substitute material based on the available inventory of the substitute material; the initial gross demand for the substitute material being the gross demand for the corresponding original demand material; Select the material with the smallest net demand, split the material according to the minimum of the gross demand and the available inventory, so that its net demand is zero; for the material with the smallest net demand, determine the minimum of its gross demand and the available inventory, and use the minimum as the gross demand and the available inventory of the material, so that the net demand of the material is zero; the remaining gross demand of the demand item corresponding to the material is supplemented by the alternative material of the material, and the remaining gross demand of the demand item corresponding to the material is used as the gross demand of the alternative material of the material; if the available inventory of the alternative material is greater than the remaining gross demand, the available inventory of the alternative material in the demand item is set to the remaining gross demand, and the remaining available inventory is transferred to other demand items of the alternative material; update the bill of materials; Repeat this process until all substitute materials are split; finally, the final net demand is generated based on the original demand materials; If the available inventory of the alternative material is less than the remaining gross demand and all alternative materials have been split, the net demand is calculated based on the remaining gross demand and the available inventory as the gross demand and net demand of the original demand material.

7. A terminal device comprising a processor and a memory, wherein the processor is used to implement instructions; the memory is used to store multiple instructions, characterized in that: The instructions are suitable for being loaded by a processor and executing the material requirement planning method according to any one of claims 1 to 5.

8. A computer-readable storage medium storing a plurality of instructions, characterized in that: The instructions are suitable for being loaded by a processor of a terminal device and executing the material requirement planning method according to any one of claims 1 to 5.

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