Process Data Fusion Method Based on Heterogeneous Systems

Abstract

The present invention relates to the field of information technology, and more particularly to a process data fusion method based on heterogeneous systems. The process data fusion method based on heterogeneous systems includes the following sub-steps: Step 1: Creating a BOM structure in the PLM system and defining product parts; Step 2: Maintaining the product process BOM; Step 3: Importing the maintained BOM structure and data into the ERP system, performing fusion processing, screening out valid process data, and generating the manufacturing process of the ERP system; Step 4: Converting the manufacturing process of the ERP system into a production order process and distributing it to the corresponding workshop. This provides a process data fusion method based on heterogeneous systems for realizing process data fusion between two systems with different structures.

Description

Technical Field

[0001] The present invention relates to the field of information technology, and in particular to a process data fusion method based on heterogeneous systems. Background Art

[0002] The PLM system (Product Lifecycle Management) is both an enterprise information technology philosophy and a collection of technologies. It integrates all product-related data accumulated over years into a single database, helping companies increase revenue and accelerate product launches, providing a wide range of business value. These benefits include: faster time to market; accelerated revenue growth; reduced product and lifecycle costs; significantly improved product quality; fostered production process innovation; increased productivity; and maximized knowledge sharing. The ERP system (Enterprise Resource Planning) is a highly integrated, company-wide system. It comprehensively balances and optimizes an enterprise's resources, including people, finance, materials, information, time, and space. Its core production control management module (planning and manufacturing) organically integrates the entire production process, enabling enterprises to effectively reduce inventory, improve efficiency, and implement product production control management, procurement management, inventory management, accounting, and financial management.

[0003] PLM and ERP are the primary platforms for informatization in the current manufacturing industry. Companies implementing both ERP and PLM systems need to integrate these two systems. This is because integrating PLM and ERP is a collaborative process between product and production management. Through system integration, a robust and adaptable informatization environment is created to accelerate enterprise development and enhance product innovation. The advantages of integrating PLM and ERP include linking important upstream and downstream processes and data, strengthening the openness of both systems, and improving interoperability.

[0004] Currently, the most critical and challenging aspect of integrating PLM and ERP systems lies in the integration of product structure and configuration management. The optimal solution is to create a consistent network of product structure views, namely, the product's design BOM and process BOM. However, for companies that rely solely on ERP systems for production control and management, this integration presents a significant challenge: PLM systems can comprehensively define bills of materials, and their PDM (product data management) functionality can break down process routes down to the individual steps of each part. For companies that rely solely on ERP systems for production control and management, the manufacturing process in the ERP system only controls a few key steps within each part's process route. Downstream departments (workshops) can independently break down each step into smaller steps for production control and management based on actual needs during the manufacturing process. Given the different structures of these two systems, integrating process data from PLM and ERP requires a unique data fusion approach that breaks down conventional thinking. Summary of the Invention

[0005] The technical problem to be solved by the present invention is to overcome the deficiencies of the prior art and provide a process data fusion method based on heterogeneous systems to achieve process data fusion between two systems with different structures.

[0006] The technical solution adopted by the present invention to solve the technical problem is: a process data fusion method based on heterogeneous systems, including the following sub-steps:

[0007] Step 1: Create a BOM structure in the PLM system and define product parts;

[0008] Step 2: Product process BOM maintenance;

[0009] Step 3: Import the maintained BOM structure and data into the ERP system, perform integration processing, filter out valid process data, and generate the manufacturing process of the ERP system;

[0010] Step 4: Convert the manufacturing process in the ERP system into production order process and distribute it to the corresponding workshop.

[0011] The step 1 includes the following sub-steps:

[0012] 1-1: Create BOM structure based on the design of parent-child logical relationship;

[0013] 1-2: Completely define each part in each layer of BOM.

[0014] The second step includes the following sub-steps:

[0015] 2-1: Maintain the material quota of each self-made part;

[0016] 2-2: Maintain the process route of each self-made part, including maintaining all manufacturing processes under each process route and the ERP system manufacturing process corresponding to each manufacturing process.

[0017] In step three, after the maintenance of each part in the PLM system is completed, the operation of importing into the ERP system is executed. The data is integrated and processed in the system background. The process data is filtered according to whether the manufacturing process attribute value is in a state that can be obtained by the ERP system. Finally, valid process data is obtained and the manufacturing process of the ERP system is generated.

[0018] In step 4, the manufacturing process of the ERP system is transferred to the production department, and the production department issues an order through a production order to convert the manufacturing process into a production order process.

[0019] The production department issues production plans to each workshop based on the product structure, breaks down the product manufacturing into each workshop, and allows each workshop to receive the manufacturing process data related to itself, and complete the process step-by-step, flow control and other operations of the manufacturing process according to the received manufacturing order process content.

[0020] Compared with the prior art, the present invention has the following beneficial effects:

[0021] The present invention provides a process data fusion method based on heterogeneous systems. Through data fusion, after importing process data from a PLM system into an ERP system, a pre-established process mapping relationship is established. While maintaining the part process route in the PLM system, each manufacturing process in the process route is mapped to the corresponding ERP process. This data is then imported into the ERP system and processed in the backend. This completes the fusion of process data between the two differently structured systems, enabling the ERP system to retrieve effective key processes for detailed production control management within downstream departments. This unique process data fusion method not only enables the upstream PLM system to manage product lifecycles, but also enables the downstream ERP system to fully leverage its capabilities, resolving the issues that arise when merging process data between the two systems due to their differing structures. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] Figure 1 Schematic diagram of the pipe box structure in an embodiment of the present invention.

[0023] In the figure: 1-1: pipe box head; 1-2: pipe box short joint; 1-3: connecting pipe; 1-4: partition; 1-5: lifting lug. DETAILED DESCRIPTION

[0024] The embodiments of the present invention are further described below with reference to the accompanying drawings:

[0025] Example

[0026] like Figure 1 As shown, it includes the following sub-steps:

[0027] Step 1: Create a BOM structure in the PLM system and define the product parts. Create a logically clear design BOM structure in the PLM system and fully define each part of the product.

[0028] The step 1 includes the following sub-steps:

[0029] 1-1: Create a BOM structure based on the design of parent-child logical relationships; for example:

[0030] First layer BOM (pipe box)

[0031] ↓

[0032] Second-level BOM (parts: pipe box head 1-1, pipe box short section 1-2; connecting pipe 1-3; partition 1-4; lifting lug 1-5).

[0033] 1-2: Completely define each part in each layer of BOM. The so-called complete definition is the material number of the part.

[0034] Code, name, specification, quantity, unit of measurement, factory code, manufacturing method, design type and other attributes are entered

[0035] Line definition. Make sure each part contains the attributes required by PLM and ERP. For example:

[0036] Pipe box: Material code - 2021021001, Name - Pipe box, Specification - Assembly, Quantity - 1 piece, Unit of measurement - Piece, Factory code - Finished product, Manufacturing method - Self-made part, Design type - Special.

[0037] Pipe box head 1-1: Material code - 210010001, Name - Pipe box head, Specification - EHA1000x10 (8.8), Material: Q345R, Quantity - 1 piece, Unit of measurement - piece, Factory code - Semi-finished product, Manufacturing method - Self-made parts, Design type - Special.

[0038] Pipe box nipple 1-2: Material code - 210010002, Name - Pipe box nipple, Specification - Steel plate 12, Material: Q345R, Quantity - 1, Unit of measurement - Piece, Factory code - Semi-finished product, Manufacturing method - Self-made part, Design type - Special purpose.

[0039] Take-over pipe 1-3: Material code - 210010003, Name - Take-over pipe, Specification - Seamless steel pipe φ219x8, Material: 20, Quantity - 2, Unit of measurement - Piece, Factory code - Semi-finished product, Manufacturing method - Self-made part, Design type - Special purpose.

[0040] Partition 1-4: Material code - 210010004, Name - Partition, Specification - Steel plate 10, Material: Q345R, Quantity - 1, Unit of measurement - Piece, Factory code - Semi-finished product, Manufacturing method - Self-made parts, Design type - Special.

[0041] Lifting lugs 1-5: Material code - 210010005, Name - Lifting lug, Specification - Steel plate 10, Material: Q345R, Quantity - 2, Unit of measurement - Piece, Factory code - Semi-finished product, Manufacturing method - Self-made part, Design type - Special purpose.

[0042] Step 2: Product process BOM maintenance; Step 2 includes the following sub-steps:

[0043] 2-1: Maintain the material quotas for each self-made part of the pipe box (pipe box head 1-1, pipe box nipple 1-2, pipe connection 1-3, partition 1-4, and lug 1-5). Maintain the process BOM in the PLM system and maintain the material quotas for each self-made part of the pipe box (pipe box head 1-1, pipe box nipple 1-2, pipe connection 1-3, partition 1-4, and lug 1-5). For example:

[0044] Pipe box head 1-1: raw materials (steel plate 10, Q345R), material quota 150Kg.

[0045] Pipe box nipple 1-2: Raw materials (steel plate 12, Q345R), material quota 400Kg.

[0046] Connecting pipe 1-3: Raw materials (seamless steel pipe φ219x8, 20), material quota 10Kg.

[0047] Partition 1-4: Raw materials (steel plate 10, Q345R), material quota 55Kg.

[0048] Lifting lugs 1-5: Raw materials (steel plate 10, Q345R), material quota 3 kg.

[0049] 2-2: Maintain the process routes of each self-made part of the pipe box (pipe box head 1-1, pipe box short section 1-2, pipe connection 1-3, partition 1-4, lifting lug 1-5), including maintaining all manufacturing processes under each process route and the corresponding ERP system manufacturing process for each manufacturing process. For example:

[0050] 1. Part 1-1: Process route maintenance of pipe box head (cutting process route).

[0051] The manufacturing process of the pipe box head in the PLM system is as follows: head marking → head marking confirmation → head cutting and blanking → head outsourcing forming → head forming inspection → head transfer to warehouse → head beveling → head inspection. When the downstream part (workshop) uses the ERP system for production control, it only needs to control the following key processes: head blanking → head outsourcing forming → head outsourcing forming inspection → head transfer to warehouse → head beveling. Therefore, it is necessary to maintain the manufacturing process of the part process route in the PLM system while also maintaining the ERP manufacturing process corresponding to each manufacturing process (many-to-one correspondence), and set the attribute value of the PLM system manufacturing process to the ERP system unavailable state, and set the corresponding ERP system manufacturing process attribute value to the ERP system available state.

[0052]

[0053] 2. Part 1-2: The process route maintenance of the pipe box short section includes 2 process routes, namely the cutting process route and the riveting process route.

[0054] The manufacturing process for a pipe box nipple in the PLM system (cutting followed by riveting and welding) is as follows: nipple marking → nipple marking confirmation → nipple cutting and blanking → nipple beveling → nipple blanking inspection → nipple rounding → nipple longitudinal seam alignment → nipple longitudinal seam welding → nipple rounding → nipple longitudinal seam non-destructive testing → nipple circumferential seam welding → nipple transition by lathe. However, the downstream department (workshop) only needs to control the following key processes when using the ERP system for production control: nipple cutting → nipple edge planing → nipple rounding → nipple longitudinal seam welding → nipple rounding → nipple circumferential seam welding → nipple transition by lathe. Therefore, it is necessary to maintain the manufacturing processes of the part process route in the PLM system while also maintaining the corresponding ERP manufacturing processes for each manufacturing process (a many-to-one correspondence). The attribute values of the PLM system manufacturing processes should be set to be unavailable in the ERP system, while the corresponding ERP system manufacturing process attribute values should be set to be available in the ERP system.

[0055]

[0056] 3. Part 1-3: Maintenance of the process route for taking over (cutting process route).

[0057] The manufacturing process for pipes in the PLM system is as follows: pipe material inspection → pipe cutting and marking, marking confirmation → pipe cutting and blanking → pipe beveling → pipe forming inspection. However, when using the ERP system for production control, the downstream department (workshop) only needs to control the following key processes: pipe blanking → pipe lathing. Therefore, it is necessary to maintain the manufacturing processes of the part process route in the PLM system while also maintaining the corresponding ERP manufacturing processes for each manufacturing process (a many-to-one correspondence). The attribute values of the PLM system manufacturing processes must be set to be unavailable in the ERP system, while the corresponding ERP system manufacturing process attribute values must be set to be available in the ERP system.

[0058]

[0059]

[0060] 4. Parts 1-4: Process route maintenance of partition (cutting process route).

[0061] The manufacturing process of partitions in the PLM system is as follows: partition cutting → partition milling and drilling. When the downstream part (workshop) uses the ERP system for production control, it only needs to control these two processes: partition cutting → partition milling and drilling. In this case, it is necessary to maintain the part process route manufacturing process in the PLM system while also maintaining the ERP manufacturing process corresponding to each manufacturing process. The attribute value of the PLM system manufacturing process is set to the ERP system unavailable state, and the corresponding ERP system manufacturing process attribute value is set to the ERP system available state (as shown below).

[0062] PLM system manufacturing process ERP system manufacturing process

[0063] Partition blanking→Partition blanking

[0064] Partition milling and drilling → Partition milling and drilling

[0065] 5. Parts 1-5: Process route maintenance of the lifting lug (cutting process route).

[0066] The manufacturing process for a lifting lug in the PLM system is as follows: lifting lug cutting → lifting lug forming. Downstream operations (workshops) using the ERP system for production control only need to manage these two processes: lifting lug cutting → lifting lug forming. In this case, maintaining the manufacturing processes for the part routing in the PLM system requires maintaining the corresponding ERP manufacturing processes for each manufacturing process. The attribute values for the PLM manufacturing processes must be set to unavailable in the ERP system, while the corresponding ERP manufacturing process attribute values must be set to available in the ERP system.

[0067] PLM system manufacturing process ERP system manufacturing process

[0068] Lifting lug blanking → Lifting lug blanking

[0069] Lug forming → Lug forming

[0070] Step 3: Import the maintained BOM structure and data into the ERP system, perform fusion processing, filter out valid process data, and generate the manufacturing process of the ERP system; in step 3, after the process routes of each part of the pipe box in the PLM system are maintained, the import operation into the ERP system is executed, and the data is fused in the system background. The process data is filtered according to whether the attribute value of the manufacturing process is in a state that can be obtained by the ERP system, and finally valid process data is obtained, and then the manufacturing process of the ERP system is generated, thereby realizing the fusion of process data between two systems with different structures. For example:

[0071] Pipe box head: head cutting → head outsourcing forming → head outsourcing forming inspection → head transfer to warehouse → head beveling.

[0072] Pipe box short section: short section cutting → short section planing → short section rolling → short section longitudinal seam welding → short section rounding → short section circumferential seam welding → short section transition turning.

[0073] Partition: Cutting of partition → Milling and drilling of partition.

[0074] Taking over: Cutting the taking over → Processing the taking over by lathe.

[0075] Lifting ear: cutting the lifting ear → forming the lifting ear.

[0076] Step 4: Convert the manufacturing process in the ERP system into a production order process and distribute it to the corresponding workshop. In step 4, the manufacturing process in the ERP system is transferred to the production department through the process flow. The production department issues a production order to convert the manufacturing process into a production order process.

[0077] The production department issues production plans to each workshop based on the product structure, breaking down product manufacturing into its own sub-workshops and allowing each workshop to receive relevant manufacturing process data. The workshops then complete operations such as step-by-step manufacturing process decomposition and flow control based on the received manufacturing order process data.

[0078] The above data comparison shows that for companies that only rely on the ERP system to control large processes for production control management, after data fusion, the ERP system only obtains the ERP system processes corresponding to the part manufacturing processes maintained in the PLM system. These processes are precisely the key processes of the parts in the ERP system. This shows that this unique process data fusion method can achieve the fusion of process data between two systems with different structures, making it a very feasible process data fusion method.

Claims

1. A process data fusion method based on heterogeneous systems, characterized in that: The following sub-steps are included: Step 1: Create a BOM structure in the PLM system and define product parts; The step 1 includes the following sub-steps: 1-1: Create BOM structure based on the design of parent-child logical relationship; 1-2: Completely define each part in each BOM layer. This includes the part's material code, name, specification, quantity, unit of measurement, factory code, manufacturing method, and design type, ensuring that each part includes the attributes required by the PLM and ERP systems. Step 2: Product process BOM maintenance; Step 2 includes the following sub-steps: 2-1: Maintain the process BOM in the PLM system and maintain the material quota of self-made parts; 2-2: Maintain the process routes of each self-made part, including maintaining all manufacturing processes under each process route and the ERP system manufacturing process corresponding to each manufacturing process. The specific process is as follows; Maintain all manufacturing processes under the process routing of self-made parts in the PLM system; Maintain the key processes that need to be controlled when conducting production control of self-made parts in the ERP system; Multiple or single manufacturing processes of self-made parts in the PLM system correspond to single manufacturing processes of self-made parts in the ERP system; The attribute values of the manufacturing process in the PLM system are set to be unavailable in the ERP system, and the corresponding attribute values of the manufacturing process in the ERP system are set to be available in the ERP system. Step 3: Import the maintained BOM structure and data into the ERP system, perform integration processing, filter out valid process data, and generate the manufacturing process of the ERP system; After the maintenance of each part in the PLM system in step 3 is completed, the data is imported into the ERP system. The data is integrated and processed in the system background. The process data is filtered according to whether the manufacturing process attribute value is in a state that can be obtained by the ERP system. Finally, valid process data is obtained and the manufacturing process of the ERP system is generated. Step 4: Convert the manufacturing process in the ERP system into a production order process and distribute it to the corresponding workshop; In step 4, the manufacturing process of the ERP system is transferred to the production department, and the production department converts the manufacturing process into a production order process by issuing a command through a production order; a production plan is issued to each workshop based on the structure of the product, and the manufacturing of the product is decomposed into each workshop, so that each workshop receives the manufacturing process data related to itself and completes the operations in the manufacturing process according to the content of the received production order process.

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