A material list management method

Abstract

The application provides a kind of material list management method, comprising the following steps: various basic data management required by formulating single list calculation is well managed;In the "single list" management, create "single list plan" to plan driven calculation;Create "single list calculation" based on "single list plan", start formal operation;In the calculation process, first, according to bom level, recursively sort from top to bottom;Then, according to the order, match the inventory, procurement, demand of each material in turn;The calculation process forms "operation process details", which is used to view the matching result data of each material under each product;The calculation result forms the result set report of "material" and "material + product" two dimensions, and the matching result data of matching inventory, matching procurement and matching demand under each dimension is counted.

Description

Technical Field

[0001] This invention relates to the field of intelligent manufacturing technology, specifically to a material list and inventory management method. Background Technology

[0002] In factory production, optimized production control is an essential tool because it directly impacts costs and final net profit. Mature control solutions include MRP (Material Requirements Planning) and JIT (Just-in-Time) production. While these two solutions generally meet most production control requirements, they are insufficient for certain specific scenarios. For example, both are based on "demand + inventory" calculations, but to achieve a holistic calculation integrating procurement, demand, and inventory, an expanded or entirely new control plan and corresponding technical implementation are needed. Summary of the Invention

[0003] The purpose of this invention is to provide a material list management method to solve the problems existing in the background art.

[0004] To achieve the above objectives, the present invention adopts the following technical solution:

[0005] A material bill of materials settlement management method includes the following steps:

[0006] Establish a sound management system for all the basic data required for single-item settlement calculations;

[0007] Create a "Single Inventory Settlement Plan" in "Single Inventory Settlement" management to drive calculations through the plan;

[0008] Create a "Single List Settlement Calculation" based on the "Single List Settlement Plan" and start the formal calculation;

[0009] During the calculation process, the BOM hierarchy is first recursively sorted from top to bottom; then, the inventory, outstanding purchases, and outstanding demands of each material are matched sequentially according to the sorting.

[0010] The calculation process generates a "detailed calculation process" which is used to view the matching result data for each material under each product;

[0011] The calculation results are generated into two sets of reports: "Materials" and "Materials + Products". The reports summarize the matching results data for each dimension, including matching inventory, matching outstanding purchases, and matching outstanding demand.

[0012] In some embodiments, the various basic data management includes: material master data management, material requirements planning management, alternative material relationship maintenance management, inventory management, and procurement management.

[0013] In some embodiments, the creation of a "single list settlement plan" in the "single list settlement" management is used to drive the calculation: a plan selects multiple products to participate in the calculation; each product pulls a BOM tree structure as the basis for the hierarchical and sorting of recursive sorting in the calculation.

[0014] In some embodiments, the calculation process first involves recursively sorting the BOM hierarchy from top to bottom; then, according to the sorting, matching the inventory, outstanding purchases, and outstanding demands of each material in sequence; this includes: the calculation algorithm implements different calculation logics depending on whether the material is a substitute; wherein, the matching calculation for non-substitute materials is performed by matching the inventory, outstanding purchases, and outstanding demands one by one according to the material sorting; the matching calculation for substitute materials is performed by sequentially matching all inventory, then sequentially matching all outstanding purchases, and then sequentially matching all outstanding demands within this group of substitute materials.

[0015] In some embodiments, after a material has been matched with a product, if there are still materials remaining, it will continue to match the next product until the final number is 0 before stopping the matching.

[0016] In some embodiments, the matching calculation of a material in a product is a top-down layer-by-layer matching calculation starting from the root node, and it is necessary to distinguish whether a material has substitutes and whether it has child node factors; if there are substitutes, the substitutes will be placed in front of all peer nodes under the same parent node; if there are child nodes, they will be placed behind other peer nodes; after sorting, the sorted list will be traversed again and the matching calculation algorithm logic calculation will begin.

[0017] The material list settlement management method provided in this application has the following beneficial effects, including but not limited to:

[0018] This solution allows a batch of material requirements planning to obtain matching data such as "matched inventory", "matched outstanding purchases", and "matched outstanding demand" after matching with the current production stages of a batch of products, thereby providing feedback to production and optimizing material management. Attached Figure Description

[0019] Figure 1 These are the various basic data required for single-item settlement calculations.

[0020] Figure 2 A schematic diagram of the single-item settlement plan.

[0021] Figure 3 This is a schematic diagram of the BOM tree structure of a product.

[0022] Figure 4 This is a diagram illustrating recursive sorting.

[0023] Figure 5This is a diagram illustrating the recursive sorting process, taking into account factors such as alternative materials and the presence of child nodes.

[0024] Figure 6 This is a diagram showing an overview of the matching calculation rules.

[0025] Figure 7 A schematic diagram of the matching calculation rules for non-substitute materials.

[0026] Figure 8 This is a general schematic diagram of the rules for matching substitute materials.

[0027] Figure 9 This is a detailed flowchart illustrating the rules for matching substitute materials.

[0028] Figure 10 This is a code diagram illustrating the use of caching.

[0029] Figure 11 , 12 This is a detailed diagram illustrating the calculation process.

[0030] Figure 13 , 14 This is a schematic diagram of the calculation results. Detailed Implementation

[0031] To make the objectives, technical solutions, and advantages of this application clearer, the following detailed description is provided in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the scope of this application.

[0032] Conversely, this application covers any substitutions, modifications, equivalent methods, and schemes made within the spirit and scope of this application as defined in the claims. Furthermore, to provide the public with a better understanding of this application, certain specific details are described in detail below. However, this application can be fully understood by those skilled in the art even without these detailed descriptions.

[0033] The following will combine Figure 1-14 This application provides a detailed description of a material list and inventory management method based on its embodiments. It is important to note that the following embodiments are merely illustrative and do not constitute a limitation thereof.

[0034] Definitions:

[0035] Outstanding purchases: refers to the quantity of a material that has been purchased – the quantity in stock.

[0036] Unsettled demand: refers to the actual quantity required for a material minus the quantity already purchased.

[0037] Matching inventory, matching outstanding purchases, and matching outstanding demand are terms used in the calculation process. (See reference...) Figure 6 , Figure 7 , Figure 9 .

[0038] "Pre-match inventory," "pre-match outstanding purchases," and "pre-match outstanding demand" are also terms used in the calculation process. These represent data prior to each matching operation, depending on data from the previous match, and also referencing... Figure 6 , Figure 7 , Figure 9 .

[0039] "Matched inventory," "Matched outstanding purchases," and "Matched outstanding demand" are terms used to describe the results of each matching operation. They are also referenced in the context of calculations. Figure 6 , Figure 7 , Figure 9 .

[0040] A material bill of materials settlement management method and system, comprising the following steps:

[0041] Step 1. Establish a comprehensive management system for all the basic data required for the single-item-to-single-item calculation. This includes material master data management, material requirements planning management, substitute material relationship maintenance management, inventory management, and procurement management.

[0042] Step 2. Create a "Single Product Listing" plan in the "Single Product Listing Plan" management to drive calculations. A plan can select multiple products to participate in the calculation. Each product will pull a BOM tree structure, which serves as the basis for the hierarchical and sorting processes during the calculation.

[0043] Step 3. Create a "Single List Calculation" based on the single list settlement plan and start the formal calculation.

[0044] Step 4. During the calculation process, the BOM (Bill of Materials) is first recursively sorted from top to bottom. Then, based on the sorting, the inventory, outstanding purchases, and outstanding demands of each material are matched sequentially. The calculation algorithm implements different calculation logic depending on whether it is a substitute material. Specifically, for non-substitute materials, the matching calculation is performed one by one according to the material sorting, matching inventory, outstanding purchases, and outstanding demands; for substitute materials, the matching calculation is performed sequentially within this group of substitute materials, matching all inventory, then matching all outstanding purchases, and then matching all outstanding demands.

[0045] Step 5. The calculation process generates a "detailed calculation process" which allows you to view the matching results data for each material under each product.

[0046] Step 6. The calculation results are generated into two result set reports: "Materials" and "Materials + Products". The matching result data for each dimension, including matching inventory, matching outstanding purchases, and matching outstanding demand, are statistically analyzed.

[0047] Step 7. The results of this single-list-to-single-structure matching operation will assist factory managers in the integrated management of materials, procurement, and inventory. Together with MRP, JIT, and other control solutions, it will serve as one of the multiple means of factory production control.

[0048] like Figure 1 As shown, firstly, establish various basic data management systems, which will serve as the foundation for subsequent single-item settlement calculations (such as...). Figure 1 This includes material master data management, material requirements planning management, substitute material relationship maintenance management, inventory management, and procurement management. Among these:

[0049] Material master data management maintains the most basic fields of materials.

[0050] Material Requirements Planning (MRP) involves creating a material requisition and maintaining the demand plans for a batch of materials. Depending on the type, MRP plans are categorized as batch material plans, miscellaneous material plans, risk-based material preparation plans, outsourced material plans, and independent material plans. Regardless of the plan type, it's essential to maintain the plan's own information and the detailed material list under that plan. The material list must at least include the actual required quantity.

[0051] Substitute material relationship maintenance management involves maintaining a list of alternative materials that can be used for a specific material within a product or semi-finished product. During subsequent calculations and matching of data, different algorithms are applied based on whether an alternative material is used.

[0052] Inventory management here refers to the inventory quantity of a specific material. Of course, actual inventory management is much more complex and involves far more than this. This simplified explanation is primarily for use with order-to-inventory and order-to-balance sheet calculations.

[0053] Procurement management involves creating purchase orders and maintaining a procurement plan for a batch of materials. The details of each purchase order correspond to the details of the materials in the material plan; that is, one procurement plan detail corresponds one-to-one with one material plan detail. This facilitates the calculation of "outstanding purchases".

[0054] Create a "single checkout" plan to drive computation (e.g., ...). Figure 2 A plan may be associated with multiple products, tracking the material matching status of these products. Each product pulls a BOM tree structure from the material master data (a BOM tree structure means that the product's material is the root node, and the materials used in each other production and assembly stage are descendant nodes, which can be expanded downwards into a tree structure). For example... Figure 3 .

[0055] Next, for each "single-item settlement" plan, a "single-item settlement calculation" is created based on that plan. One plan can correspond to multiple calculations, and each calculation will generate different results depending on the progress of production. This step is the core of this patent and will be described in detail here.

[0056] From a business perspective, factory production management personnel need to know the status of every material in the Material Requirements Planning (MRP). This involves matching the actual required quantity with current inventory, outstanding purchases, and outstanding demand in sequence, and then analyzing the results of each matching. This "matched data" serves as the basis for production data, allowing management to clearly understand whether the actual material demand matches production requirements. In detail, a product is assembled from multiple materials; conversely, a single material may be used in multiple products. Therefore, after a material is matched with one product, if there are any remaining materials, it will continue matching with the next product until the result is zero. The matching calculation for a material within a product is a top-down, layer-by-layer calculation starting from the root node (the BOM tree mentioned earlier, pulled from the material master data, must be arranged in a top-down, rule-based order). This sorting is somewhat similar to the preorder traversal of a binary tree (e.g., ...). Figure 4 However, some differences exist because factors such as whether a material has substitutes and whether it has child nodes must also be considered. If substitutes exist, materials that are substitutes will be placed before all peer nodes under the same parent node; if child nodes exist, they will be placed after other peer nodes. See the diagram for a detailed sorting algorithm. Figure 5 After sorting, the sorted list will be traversed again to begin the matching algorithm's logical calculations. See the overall diagram and rules of the matching algorithm below. Figure 6 Generally, it starts with the material ranked 1 for the first product, matching inventory, then outstanding purchases, and finally outstanding demand. However, the specific matching rules differ depending on whether it's a substitute material: for non-substitute materials, the matching rule is to match inventory, then outstanding purchases, then outstanding demand in that order, and then proceed to matching the next ranked material. This is essentially a line-by-line matching process. See [link / details]. Figure 7 (Matching rules for non-alternative materials); For a set of alternative materials, the matching process must be converted to column matching within that set. This involves first matching the inventory of all alternative materials, then matching the outstanding purchases of all alternative materials, and finally matching the outstanding demand for all alternative materials. Figure 8 (A general diagram illustrating the matching rules for substitute materials). The detailed algorithm is extremely complex (e.g.) Figure 9This is equivalent to incorporating recursion of another dimension into a recursive structure. In the code implementation, a custom recursive sorting algorithm is used to solve this problem. Furthermore, during the matching calculation process, much of the basic data is retrieved from the previously mentioned basic data modules. To improve computational performance, multiple cache Map structures are used to categorize and store the corresponding basic data for the same material in the cache. If basic data for that material is encountered again, it is first searched in the cache; if not found, it is then searched in the basic data (code illustration shown). Figure 10 After all material matching calculations for all products are completed, the final results are summarized into two dimensions: one based on the material and the other based on "material + product". However, due to the complex calculation logic, to facilitate process traceability, the matching calculation process for each product is also stored separately as a process result set. This allows managers to better understand the details of the matching calculations (e.g., ...). Figure 11 , Figure 12 The calculation results are as follows: Figure 13 , Figure 14 As shown.

[0057] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A material list management method characterized by comprising: The method comprises the following steps: Formulating various basic data management required by the single list settlement calculation; Creating a single list settlement plan in the single list settlement management to plan the calculation; Creating a single list settlement calculation based on the single list settlement plan to start the formal operation; In the calculation process, first, the bom level is recursively sorted from top to bottom; then, the inventory, un-settled procurement and un-settled demand of each material are matched in sequence; The calculation process forms an operation process details for viewing the matching result data of each material of each product; The calculation result forms a result set report in two dimensions of "material" and "material + product" to count the matching inventory, matching un-settled procurement and matching un-settled demand in each dimension. In the step of creating a single list settlement plan in the single list settlement management to plan the calculation, multiple products are selected to participate in the calculation in one plan; the bom tree structure of each product is pulled as the basis for recursive sorting and sorting in the calculation; and for each single list settlement plan, a single list settlement calculation based on the plan is created, one plan can correspond to multiple calculations, and each calculation will generate different calculation results according to the time advancement of production.

2. The material list management method according to claim 1, wherein The various basic data management includes material master data management, material demand plan management, substitute material relationship maintenance management, inventory management and procurement management.

3. The material list management method according to claim 1, wherein In the step of first recursively sorting the bom level from top to bottom and then matching the inventory, un-settled procurement and un-settled demand of each material in sequence in the calculation process, the calculation algorithm implements different calculation logics according to whether the material is a substitute material; the matching calculation of non-substitute materials matches the inventory, un-settled procurement and un-settled demand one by one according to the sorting of the materials; the matching calculation of substitute materials matches all the inventory, un-settled procurement and un-settled demand in sequence in this group of substitute materials.

4. The material list management method according to claim 3, wherein If a material still has a surplus after matching a product, it will continue to match the next product until it is finally 0.

5. The material list management method according to claim 3, wherein The matching calculation of a material in a product is a layer-by-layer matching calculation from the root node top-down, and it needs to distinguish whether the material has a substitute material and whether it has a child node; if there is a substitute material, the materials that are substitutes for each other are arranged in front of all the nodes of the same parent node; if there is a child node, it is arranged behind other nodes; after sorting, the sorted list is traversed again to start the matching calculation algorithm logic calculation.

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