Material pulling system

Abstract

The present invention relates to the technical field of material pulling, and provides a material pulling system, including an APS system, an MES system and a SAP terminal connected in sequence, wherein the MES system is used to calculate the number of raw material calls for the next time interval of all production lines according to production plan information, raw material inventory information and a bill of materials; the SAP terminal is used to create a reservation order corresponding to the next time interval according to the number of raw material calls for the next time interval, so that the material personnel can distribute the raw materials in the warehouse to the corresponding production line according to the reservation order. Thus, there is no need for double-box inventory, which reduces the floor space occupied by the material inventory, and there is no need to configure an SAP terminal for each production line, which reduces the investment cost. By implementing material pulling through the APS system, the MES system and the SAP terminal, the number of materials called for the next time interval can be automatically calculated, avoiding the error rate caused by manual calculation, thereby greatly reducing the probability of error and improving the efficiency of material pulling.

Description

Technical Field

[0001] The present invention relates to the technical field of material pulling, and in particular to a material pulling system. Background Art

[0002] With the popularization of informatization in manufacturing enterprises, manufacturing enterprises, especially those adopting repetitive manufacturing models, are faced with the problem of just-in-time material delivery on site and the connection of delivery information with existing informatization systems.

[0003] Since the repetitive manufacturing model requires real-time tracking of the raw material inventory and production scheduling requirements of each production line, it has high requirements for data real-time and inventory location accuracy. Current solutions usually include: (1) SAP (an ERP (Enterprise Resource Planning) system software) built-in reservation order standard module: Its disadvantage is that employees need to manually judge material requirements and manually enter the requirements in the SAP interface in advance, which is complicated to operate, has a high probability of information error, and the on-site inventory quantity is uncontrolled. (2) Custom development of SAP material pull function: Its disadvantage is that it is necessary to configure SAP terminals for each production line, use SAP terminals to complete the reporting operation in a timely manner, and it is based on the double-box pull mode. The investment cost of SAP terminals is high, the on-site inventory difference adjustment is difficult, and non-public materials must be kept in at least two boxes of inventory on site, which occupies a large area and has a high on-site inventory. (3) Offline paper document material ordering: high probability of error, low efficiency, and uncontrolled on-site inventory quantity. Summary of the invention

[0004] In order to solve one of the above technical problems, the present invention proposes the following technical solution.

[0005] The first embodiment of the present invention proposes a material pulling system for distributing raw materials in a warehouse to a production line, including an APS (Advanced Planning System) system, an MES (Manufacturing Execution System) system connected in sequence. A manufacturing execution system (MES) system and a SAP terminal, wherein the APS system is used to create production plan information for each production line and send the production plan information to the MES system; the SAP terminal is used to send the raw material inventory information and the bill of materials corresponding to each production line to the MES system; the MES system is used to obtain the material pulling frequency, the raw material inventory information and the bill of materials corresponding to each production line, and when the material pulling frequency is met, calculate the raw material call quantity of all production lines for the next time interval according to the production plan information, the raw material inventory information and the bill of materials, and send the raw material call quantity of the next time interval to the SAP terminal; the SAP terminal is used to create a reservation order corresponding to the next time interval according to the raw material call quantity of the next time interval, so that the material personnel can distribute the raw materials in the warehouse to the corresponding production line according to the reservation order, and the SAP terminal is also used to send the reservation order to the MES system after distribution, and the MES system is also used to update the raw material inventory information of the corresponding production line according to the information recorded in the reservation order corresponding to the next time interval.

[0006] In addition, the material pulling system according to the above embodiment of the present invention may also have the following additional technical features.

[0007] According to an embodiment of the present invention, the production plan information includes a production line identifier, a model of a product to be produced and a quantity of a product to be produced corresponding to each time interval, wherein the time interval includes a production start time and a production end time.

[0008] According to one embodiment of the present invention, the raw material inventory information corresponding to each production line includes the online inventory quantity of each raw material of the product to be produced.

[0009] According to an embodiment of the present invention, the bill of materials records the required quantity of raw materials corresponding to a single product to be produced.

[0010] According to one embodiment of the present invention, when the MES system calculates the raw material call quantity for the next time interval of all production lines based on the production plan information, the raw material inventory information and the bill of materials, it is specifically used to: calculate the raw material demand quantity within the current time interval based on the raw material demand quantity corresponding to the single product to be produced and the number of products to be produced corresponding to the current time interval; calculate the raw material demand quantity within the next time interval based on the raw material demand quantity corresponding to the single product to be produced and the number of products to be produced corresponding to the next time interval; obtain the reservation order corresponding to the current time interval, and determine the raw material to be delivered quantity within the current time interval based on the reservation order corresponding to the current time interval; calculate the raw material call quantity within the next time interval of the production line based on the raw material demand quantity within the current time interval, the raw material demand quantity within the next time interval, the raw material online inventory quantity at the current moment and the raw material to be delivered within the current time interval.

[0011] According to one embodiment of the present invention, the quantity of raw materials called for in the next time interval is calculated by the following formula:

[0012] S=S1+S2-S3-S4

[0013] Among them, S represents the quantity of raw materials ordered in the next time interval, S1 represents the quantity of raw materials required in the current time interval, S2 represents the quantity of raw materials required in the next time interval, S3 represents the online inventory quantity of raw materials at the current moment, and S4 represents the quantity of raw materials to be delivered in the current time interval.

[0014] According to an embodiment of the present invention, the information recorded in the reservation form corresponding to the next time interval includes the production line identifier, the required quantity and part number of raw materials of the production line within the next time interval.

[0015] According to one embodiment of the present invention, the MES system is also used to print box labels after delivery is completed, and at the same time, deduct the online inventory quantity of the corresponding raw materials according to the bill of materials.

[0016] The technical solution of the embodiment of the present invention does not require double-box inventory, reduces the floor space occupied by material inventory, and does not require SAP terminals to be configured for each production line, thereby reducing investment costs. Material pulling can be achieved through the APS system, MES system and SAP terminal, and the number of materials called for the next time interval can be automatically calculated to avoid the error rate caused by manual calculation, thereby greatly reducing the error probability and improving the material pulling efficiency, so that the material demand at the production site can be transmitted to the warehouse in a timely and accurate manner, and the warehouse can complete material preparation in a timely and efficient manner. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] Figure 1 It is a schematic structural block diagram of a material pulling system according to an embodiment of the present invention.

[0018] Figure 2 This is a material pulling flow chart of an example of the present invention. DETAILED DESCRIPTION

[0019] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0020] Figure 1 It is a structural block diagram of the material pulling system according to an embodiment of the present invention.

[0021] like Figure 1 As shown, the material pulling system includes an APS system 1, an MES system 2 and a SAP terminal 3 which are connected in sequence. The material pulling system is used to distribute raw materials in the warehouse to the production line.

[0022] Among them, APS system 1 is used to create production plan information for each production line and send the production plan information to MES system 2; SAP terminal 3 is used to send the raw material inventory information and material list corresponding to each production line to MES system 2; MES system 2 is used to obtain the material pulling frequency, the raw material (materials that need to be consumed) inventory information and material list corresponding to each production line, and when the material pulling frequency is met, calculate the raw material call quantity of all production lines in the next time interval according to the production plan information, raw material inventory information and material list, and send the raw material call quantity of the next time interval to SAP terminal 3; SAP terminal 3 is used to create a reservation order corresponding to the next time interval according to the raw material call quantity of the next time interval, so that the material personnel can distribute the raw materials in the warehouse to the corresponding production line according to the reservation order. SAP terminal 3 is also used to send the reservation order to MES system 2 after distribution. MES system 2 is also used to update the raw material inventory information of the corresponding production line according to the information recorded in the reservation order corresponding to the next time interval.

[0023] Among them, the production plan information includes the production line identification (code), the product model and quantity to be produced corresponding to each time interval (production time interval), among which the time interval includes the start time of production and the end time of production. For example, the production plan information of a certain production line is: produce 100 white fans of a certain model from 8 o'clock to 10 o'clock, and produce 100 black fans of a certain model from 10 o'clock to 12 o'clock.

[0024] The raw material inventory information corresponding to each production line includes the part number, box number, online inventory quantity and storage line type of each raw material of the product to be produced, such as the part number, box number, online inventory quantity and storage line type of the raw material casing, fan blades and screws of the fan product to be produced.

[0025] The bill of materials records the required quantity of raw materials for a single product to be produced, for example, the quantity of the raw material casing, fan blades, and screws corresponding to the fan to be produced.

[0026] The information recorded in the reservation order corresponding to the next time interval includes the production line identification, the required quantity and part number of the raw materials in the next time interval of the production line.

[0027] Among them, the material pulling frequency refers to the time period for material pulling, that is, delivering materials from the warehouse to the production line. For example, it can be set to 2 hours, that is, materials are pulled once every 2 hours. The frequency is set manually according to specific needs and entered into the MES system.

[0028] Specifically, Figure 2 As shown, first, according to specific production needs, the SPS system 1 creates production plan information with time accuracy to the minute for each production line, including production line identification, the model and quantity of products to be produced corresponding to each time interval, the start time and the end time of production, and other information, and the production plan information of all production lines is uniformly transmitted to the database of the MES system 2. The SAP terminal 3 sends the raw material inventory information and the bill of materials corresponding to each production line to the MES system 2. MES system 2 manages the raw material inventory information of all production lines according to the material pulling frequency, the raw material inventory information and the bill of materials corresponding to each production line, including the part number, box number, online inventory quantity and storage line type of each raw material of the product to be produced on each production line. MES system 2 automatically calculates the raw material call quantity for the next time interval according to the production plan information, raw material inventory information and bill of materials of each production line at the corresponding time node, i.e., when the material pulling trigger time point is reached, based on the set material pulling frequency, and transmits the call quantity to SAP terminal 3 through the background interface, and uses SAP's standard reservation order module to create a reservation order corresponding to the next time interval, including the production line identification, the raw material demand quantity and part number of the production line in the next time interval. The warehouse uses SAP's standard reservation order module to complete material picking and transfer, so as to distribute the raw materials in the warehouse to the corresponding production line. Afterwards, SAP terminal 3 transmits the reservation order that has been picked to MES system 2 through the background interface. When the material personnel completes the material distribution, they add the material information under the corresponding reservation order to the production line material inventory through the MES software interface, including the raw material model, box number, quantity, etc.

[0029] It should be noted that the initial raw material inventory information is manually input into SAP terminal 3 and transmitted to the MES system by terminal 3. After the subsequent raw material (material) distribution begins, SAP terminal 3 sends the reservation order to MES system 2, and then MES system 2 updates the raw material inventory information of the corresponding production line based on the reservation order. Similarly, the initial material list is also manually input into SAP terminal 3 and subsequently updated through MES system 2.

[0030] Reference Figure 2 , set the start time of material calling in MES system 2, such as 8 o'clock, which is used to calculate the time point for triggering material calling, and set the material pulling frequency, such as 2 hours, which means that material pulling is triggered every 2 hours and a reservation order is generated; the reservation order triggered at 8:00 will be delivered to the production line at 10:00 to meet the production demand of the production line from 10:00 to 12:00; the reservation order will be triggered for the second time at 10:00 and delivered to the production line at 12:00 to meet the production demand of the production line from 12:00 to 14:00, and so on.

[0031] Each time the material quantity calculation of a reservation order is triggered, the MES system 2 calculates the raw material quantity for the next time interval of all production lines based on the production plan information, raw material inventory information and the bill of materials. After the calculation is completed, the calculation result is transmitted to a SAP terminal through the background structure, and a reservation order is generated by the SAP terminal.

[0032] The embodiments of the present invention have the following advantages: (1) the APS system and the MES system are used to automatically calculate the material demand for the next time interval, which meets the requirements of real-time inventory calculation, has strong timeliness and high accuracy, and eliminates the factors of human error; (2) the MES system calculates uniformly according to the APS planned time period, and will not generate material demand for the part exceeding the demand. There is no need to prepare double-box inventory on site for each non-public material, which reduces the on-site material inventory and floor space; the present invention uses the MES system to connect with SAP, fully utilizes the standard reserved single module of SAP, improves the warehouse picking efficiency, and does not need to configure SAP terminals for each production line, reducing the investment in equipment and SAP accounts; (3) the online inventory data of the production line is independently managed by MES and distinguished from the SAP inventory data. The inventory data can be adjusted in the MES system in time according to the actual inventory situation without affecting the financial data; (4) the production scheduling plan by time period is completed through APS without the need to adjust in SAP, reducing the SAP account investment and improving the planning efficiency.

[0033] As a result, there is no need for double-box inventory, which reduces the floor space occupied by material inventory. There is no need to configure SAP terminals for each production line, which reduces investment costs. Material pulling can be achieved through the APS system, MES system and SAP terminal, and the number of materials called for the next time interval can be automatically calculated to avoid the error rate caused by manual calculation, thereby greatly reducing the probability of error and improving material pulling efficiency. The material demand at the production site can be delivered to the warehouse in a timely and accurate manner, and the warehouse can complete material preparation in a timely and efficient manner.

[0034] In one embodiment of the present invention, the MES system 2 is also used to print box labels after delivery is completed, and to deduct the online inventory quantity of the corresponding raw materials according to the bill of materials.

[0035] Specifically, refer to Figure 2 , while printing the box labels, the MES system 2 completes the corresponding raw material inventory deduction according to the BOM (Bill of Material). The production staff regularly uses the MES system to count and correct the raw material inventory of the MES system.

[0036] In one embodiment of the present invention, when the MES system 2 calculates the raw material call quantity for the next time interval of all production lines based on the production plan information, raw material inventory information and the bill of materials, it is specifically used to: calculate the raw material demand quantity in the current time interval based on the raw material demand quantity corresponding to a single product to be produced and the number of products to be produced corresponding to the current time interval; calculate the raw material demand quantity in the next time interval based on the raw material demand quantity corresponding to a single product to be produced and the number of products to be produced corresponding to the next time interval; obtain the reservation order corresponding to the current time interval, and determine the raw material to be delivered quantity in the current time interval based on the reservation order corresponding to the current time interval; calculate the raw material call quantity in the next time interval of the production line based on the raw material demand quantity in the current time interval, the raw material demand quantity in the next time interval, the current online inventory quantity of raw materials and the raw material to be delivered in the current time interval.

[0037] Specifically, the product of the raw material demand quantity of a single product to be produced (in the bill of materials) and the number of products to be produced in the current time interval (in the production plan information) is calculated, which is the raw material demand quantity in the current time interval. Similarly, the product of the raw material demand quantity of a single product to be produced and the number of products to be produced in the next time interval is calculated, which is the raw material demand quantity in the next time interval. Get the reservation order corresponding to the current time interval (that is, the previous reservation order, which was calculated when the material pull was triggered last time), which records the information including the production line identification, the required material part number and the required quantity, and determine the number of raw materials to be delivered that have not been delivered in the current time interval based on the previous reservation order (the raw materials corresponding to the reservation order corresponding to the current time interval, that is, the previous reservation order, may have been delivered or not delivered). Finally, according to the raw material demand quantity in the current time interval, the raw material demand quantity in the next time interval, the current raw material online inventory quantity and the raw material to be delivered quantity in the current time interval, calculate the raw material call quantity of the production line in the next time interval. The calculation formula is:

[0038] S=S1+S2-S3-S4

[0039] Among them, S represents the quantity of raw materials ordered in the next time interval, S1 represents the quantity of raw materials required in the current time interval, S2 represents the quantity of raw materials required in the next time interval, S3 represents the online inventory quantity of raw materials at the current moment, and S4 represents the quantity of raw materials to be delivered in the current time interval.

[0040] In a specific example, each time the material demand calculation of the reservation order is triggered: for example, at 10:00, the system triggers the material demand calculation. At this time, the MES system 2 calculates the following based on the production plan and the BOM:

[0041] The demand quantity of raw material model R000001 from 10:00 to 12:00 is 700 pieces, that is, the demand quantity of raw materials in the current time interval = 700;

[0042] The demand quantity of raw material R000001 from 12:00 to 14:00 is 600 pieces, that is, the demand quantity of raw materials in the next time interval = 600;

[0043] The quantity of R000001 that should be delivered to the production line at 10:00 is 600 pieces, and the actual delivery is 500 pieces, so the number of undelivered reserved orders is 100 pieces, that is: the number of raw materials to be delivered = 100;

[0044] At 10:00, the inventory of R000001 on the production line in MES is 600 pieces, that is, online inventory quantity = 600;

[0045] The demand quantity of R000001 in the next time interval (12:00-14:00):

[0046] S = 700 + 600 – 600 – 100 = 600

[0047] After completing the calculation, the MES system passes the information that R000001 requires 600 pieces to SAP through the background interface, and SAP generates a reservation order.

[0048] To sum up, the embodiment of the present invention provides a method for material pulling that connects the production site and the warehouse. It does not require manual input of material requirements, nor does it require a double-box pulling mode. It can realize automatic calculation and transmission of material demand, so that the material demand of the production site can be delivered to the warehouse in a timely and accurate manner, and the warehouse can complete material preparation in a timely and efficient manner.

[0049] In the description of the present invention, the terms "first" and "second" are used for descriptive purposes only and should not be understood as indicating or implying relative importance or implicitly indicating the number of the indicated technical features. Therefore, the features defined as "first" and "second" may explicitly or implicitly include one or more of the features. "Multiple" means two or more, unless otherwise clearly and specifically defined.

[0050] In the description of this specification, the description with reference to the terms "one embodiment", "some embodiments", "example", "specific example", or "some examples" etc. means that the specific features, structures, materials or characteristics described in conjunction with the embodiment or example are included in at least one embodiment or example of the present invention. In this specification, the schematic representations of the above terms do not necessarily refer to the same embodiment or example. Moreover, the specific features, structures, materials or characteristics described may be combined in any one or more embodiments or examples in a suitable manner. In addition, those skilled in the art may combine and combine the different embodiments or examples described in this specification and the features of the different embodiments or examples, unless they are contradictory.

[0051] Any process or method description in a flowchart or otherwise described herein may be understood to represent a module, segment or portion of code that includes one or more executable instructions for implementing the steps of a specific logical function or process, and the scope of the preferred embodiments of the present invention includes alternative implementations in which functions may not be performed in the order shown or discussed, including performing functions in a substantially simultaneous manner or in the reverse order depending on the functions involved, which should be understood by those skilled in the art to which the embodiments of the present invention belong.

[0052] It should be understood that the various parts of the present invention can be implemented by hardware, software, firmware or a combination thereof. In the above-mentioned embodiments, a plurality of steps or methods can be implemented by software or firmware stored in a memory and executed by a suitable instruction execution system. For example, if implemented by hardware, as in another embodiment, it can be implemented by any one of the following technologies known in the art or their combination: a discrete logic circuit having a logic gate circuit for implementing a logic function for a data signal, a dedicated integrated circuit having a suitable combination of logic gate circuits, a programmable gate array (PGA), a field programmable gate array (FPGA), etc.

[0053] A person of ordinary skill in the art can understand that all or part of the steps carried by the method of the above-mentioned embodiment can be completed by instructing the relevant hardware through a program, and the program can be stored in a computer-readable storage medium, and the program, when executed, includes one or a combination of the steps of the method embodiment. In addition, each functional unit in each embodiment of the present invention can be integrated into a processing module, or each unit can exist physically separately, or two or more units can be integrated into one module. The above-mentioned integrated module can be implemented in the form of hardware or in the form of a software functional module. If the integrated module is implemented in the form of a software functional module and sold or used as an independent product, it can also be stored in a computer-readable storage medium.

[0054] Although the embodiments of the present invention have been shown and described above, it is to be understood that the above embodiments are exemplary and are not to be construed as limitations of the present invention. A person skilled in the art may change, modify, replace and vary the above embodiments within the scope of the present invention.

Claims

1. A material pulling system for distributing raw materials from a warehouse to a production line, characterized in that: Including the APS system, MES system and SAP terminal connected in sequence, The APS system is used to create production plan information for each production line and send the production plan information to the MES system; The SAP terminal is used to send the raw material inventory information and bill of materials corresponding to each production line to the MES system; The MES system is used to obtain the material pulling frequency, the raw material inventory information and the material list corresponding to each production line, and when the material pulling frequency is met, calculate the raw material call quantity of all production lines in the next time interval according to the production plan information, the raw material inventory information and the material list, and send the raw material call quantity of the next time interval to the SAP terminal; The SAP terminal is used to create a reservation order corresponding to the next time interval according to the quantity of raw materials ordered in the next time interval, so that the material personnel can distribute the raw materials in the warehouse to the corresponding production line according to the reservation order. The SAP terminal is also used to send the reservation order to the MES system after distribution. The MES system is also used to update the raw material inventory information of the corresponding production line according to the information recorded in the reservation order corresponding to the next time interval. The production plan information includes the production line identification, the product model and quantity of the products to be produced corresponding to each time interval, wherein the time interval includes the start time of production and the end time of production, The raw material inventory information corresponding to each production line includes the online inventory quantity of each raw material of the product to be produced. The bill of materials records the required quantity of raw materials for a single product to be produced. When the MES system calculates the quantity of raw materials to be ordered for the next time interval of all production lines according to the production plan information, the raw material inventory information and the bill of materials, it is specifically used to: Calculate the required quantity of raw materials in the current time interval according to the required quantity of raw materials corresponding to the single product to be produced and the quantity of the product to be produced corresponding to the current time interval; Calculate the required quantity of raw materials in the next time interval according to the required quantity of raw materials corresponding to the single product to be produced and the quantity of the product to be produced corresponding to the next time interval; Obtaining a reservation order corresponding to the current time interval, and determining the quantity of raw materials to be delivered within the current time interval according to the reservation order corresponding to the current time interval; Calculate the raw material quantity required for the production line in the next time interval according to the raw material demand quantity in the current time interval, the raw material demand quantity in the next time interval, the current online inventory quantity of raw materials, and the raw material to be delivered quantity in the current time interval. The quantity of raw material to be called in the next time interval is calculated by the following formula: S=S1+S2-S3-S4 Among them, S represents the quantity of raw materials ordered in the next time interval, S1 represents the quantity of raw materials required in the current time interval, S2 represents the quantity of raw materials required in the next time interval, S3 represents the online inventory quantity of raw materials at the current moment, and S4 represents the quantity of raw materials to be delivered in the current time interval.

2. The material pulling system according to claim 1, characterized in that: The information recorded in the reservation order corresponding to the next time interval includes the production line identifier, the required quantity and part number of raw materials of the production line within the next time interval.

3. The material pulling system according to claim 1, characterized in that: The MES system is also used to print box labels after delivery is completed, and to deduct the online inventory quantity of the corresponding raw materials according to the bill of materials.

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