A process reengineering method of high-end module cigarettes based on formula vertical warehouse

Abstract

The application discloses a process reengineering method of high-end module tobacco based on formula vertical warehouse, belongs to the tobacco threshing and redrying technical field, and adopts an independent high-end module processing workshop to complete independent formula; independent leaf repairing is completed in the high-end module processing workshop, and leaf spreading work is simultaneously performed; a batch high-end module tobacco leaf empty box delivery plan is written on a field industrial control screen by using the node position of the sampling station and the warehousing station; a corresponding line packing and warehousing document is issued offline through a virtual station, and an online logistics warehousing plan is automatically generated. The application does not influence the existing large production processing mode, meets the demand that the high-end module tobacco of the tobacco threshing and redrying is simultaneously performed with the daily large production, prevents the conflict with the large production module line, and is convenient for enterprise production and processing rhythm control.

Description

Technical Field

[0001] This invention relates to the field of tobacco leaf threshing and re-drying technology, and more specifically, to a process reengineering method for high-end modular tobacco based on a formula database. Background Technology

[0002] In the initial processing of re-dried tobacco leaves, high-end modular tobacco is an important component of the re-dried tobacco leaf formulation. During the cigarette manufacturing process, high-end modular tobacco is often blended with other sizes of tobacco leaves to meet the requirements of cigarette tobacco formulations. High-end modular tobacco is mostly pre-processed finished tobacco leaves. Currently, manual offline trimming is used for tobacco leaf processing. The tobacco leaf structure consists of a mixed structure with a large leaf ratio of 25%–35% (leaf size > 12.7 mm), a medium leaf ratio of 45%–55% (leaf size > 6.35 mm), and a fragment ratio of ≤5% (leaf size < 2.36 mm).

[0003] In tobacco leaf re-drying enterprises, the processing of high-end modular tobacco accounts for approximately 1%-5% of the total annual output. However, due to its importance, high priority in processing and re-drying, and the unique characteristics of the incoming leaf sheet structure, re-drying processing often needs to be interspersed within the main production process. In the existing processing model, most tobacco leaf re-drying enterprises share all or part of the main processing routes with the main production modular tobacco when processing high-end modular tobacco. This makes it impossible to control the production rhythm and stagger peak times. Key processes such as packing, warehousing, and shipping are occupied for extended periods, significantly increasing the waiting time for different specifications of tobacco leaves. For the irregularly scheduled high-end modular tobacco re-drying tasks throughout the year, this interspersed processing method is detrimental to the sustainability and stability of the large-scale production model of tobacco leaf re-drying enterprises.

[0004] Currently, the main approach is to intersperse the processing of high-end modular tobacco leaves within a large-scale production model. The processing ratio varies among different re-drying enterprises. Taking Qujing's 2022 curing season as an example, the total processing volume was 1.2 million dan (a unit of weight), of which 800,000 dan were initial-processed tobacco leaves, accounting for approximately 67% of the total annual production time; 350,000 dan were ordinary and upgraded modular tobacco leaves, accounting for approximately 30% of the total annual production time; and 50,000 dan were high-end modular tobacco leaves, accounting for approximately 3% of the total annual production time. The arrival time of high-end modular tobacco leaves is not fixed, and they are not suitable for long-term storage awaiting processing. Therefore, a common practice is to suspend large-scale production upon arrival and focus all efforts on curing high-end modular tobacco leaves. This concentrates manpower for leaf laying, sorting, and processing, as well as the capacity for managing the formula storage and inventory, on high-end modular tobacco leaves. However, with the increasing production volume, this interspersed processing disrupts the production rhythm and is detrimental to production continuity. Furthermore, the overall production flow of high-end modular tobacco leaves is small, the processing precision is high, and the processing time is long, mainly relying on manual trimming, resulting in lower yields. During the production of high-end modular tobacco, deep cleaning of existing tobacco leaf containers, conveyor channels, and elevated warehouses is required according to process requirements to prevent the mixing of tobacco leaves and subsequent quality degradation. The processing mode for high-end modular tobacco has high requirements and an irregular annual processing cycle. Mixing the processing path with the mass production mode is detrimental to tobacco quality improvement and can easily disrupt annual production plans. Building new production lines for processing would involve excessive investment. Therefore, it is urgent to rationally plan an independent processing method for high-end modular tobacco using the existing threshing and re-drying process layout of existing enterprises, in order to coordinate with the mass production mode for simultaneous processing. Summary of the Invention

[0005] One objective of this invention is to provide a process reengineering method for high-end modular tobacco based on formula database, in order to solve the aforementioned problem that when processing high-end modular tobacco, it shares all or part of the main processing paths with large-scale production modular tobacco leaves, and the interleaved processing method disrupts the production rhythm, which is not conducive to the continuity and stability of the large-scale production mode of leaf threshing and re-drying enterprises.

[0006] According to a first aspect of the present invention, a process reengineering method for high-end modular cigarettes based on a formula database is provided, comprising the following steps:

[0007] The formulation process is completed using an independent high-end modular processing workshop.

[0008] The leaf trimming and leaf laying process is carried out independently in the high-end module processing workshop, and leaf laying is carried out at the same time. After the leaf laying is completed, manual packing is carried out directly.

[0009] The empty box outbound process utilizes the node locations of the sampling inspection station and the warehousing station to write outbound plans for batches of high-end module tobacco empty boxes on the on-site industrial control screen. After the batch of empty boxes is outbound through the scheduling system, the empty box information is cleared.

[0010] In the physical box receiving process, after the manual packing process is completed in batches, the boxes are delivered to the node positions of the sampling inspection station and the receiving station by forklift. The corresponding packing and receiving documents for the corresponding route are issued offline through the virtual station, and the online logistics receiving plan is automatically generated.

[0011] Optionally, the leaf trimming and laying process also includes: setting the flow rate and time of vacuum rehumidification of tobacco leaves, and equipping at least two vacuum rehumidification machines, A and B, with mass-produced tobacco leaves using line A for vacuum rehumidification and high-end modular tobacco leaves using line B for vacuum rehumidification.

[0012] Optionally, during the empty container outbound process, a forklift is used at the sampling inspection station to transport the empty containers to the designated manual loading and unloading area.

[0013] Optionally, the process may include the following steps after leaf trimming and leaf laying:

[0014] A group recycling system is adopted for the tobacco leaves that have been trimmed. The tobacco leaves are framed by the conveyor belt in the fine leaf sorting workshop, and the frames are sent offline out of the warehouse through the elevated vertical warehouse offline outbound system and then sent to the fine leaf sorting workshop through the automated logistics system.

[0015] Optionally, the process may include the following steps after leaf trimming and leaf laying:

[0016] After the manual packing process is completed, the batch of cigarette boxes is stacked at designated locations. The packed cigarette boxes are then transported to the warehouse via a forklift through a sampling inspection station, and each box is assigned an actual production number.

[0017] Optionally, the process of receiving the boxes into the warehouse also includes:

[0018] After empty boxes are filled with tobacco leaves, weight information is assigned to the corresponding box number by weighing. The box number is entered offline through a virtual station, and the box number and weight information of the batch of tobacco boxes are read.

[0019] Optionally, virtual station information can be built using the existing sampling stations or other node locations in the formula high-bay warehouse.

[0020] Optionally, the process after the actual box receiving and warehousing includes:

[0021] After the batch of high-end module cigarette boxes is put into storage, the production plan is issued, and the batch formula is released from the formula high-rise warehouse to enter the main line to complete the production and processing of high-end modules.

[0022] Optionally, the following may be included before the formulation process:

[0023] In the feeding process, after the high-end modular cigarettes are collected and stored, they are fed according to the formula structure requirements. The amount of material to be fed in each batch is evenly divided, weighed, and recorded.

[0024] In the stacking process, the amount of each batch of raw materials is evenly divided, and the tobacco leaves of each batch are sorted and stacked. The daily processing volume is calculated, and the materials are transported to the nearest location.

[0025] The process reengineering method for high-end modular cigarettes based on a formula database disclosed herein has the following technical advantages:

[0026] Independent high-end modular tobacco processing workshops are used to complete independent formulas; independent leaf trimming and leaf laying are also carried out in these workshops; using the node locations of sampling and warehousing stations, batch high-end modular tobacco empty box outbound plans are created on the on-site industrial control screen; offline issuance of corresponding packing and warehousing documents for the corresponding routes is achieved through virtual stations, and online logistics warehousing plans are automatically generated. This solution does not affect the existing large-scale production processing mode. Simply planning the independent processing route for modular tobacco leaves according to this method can meet the needs of simultaneous high-end modular tobacco leaf trimming and re-drying with daily large-scale production, while preventing conflicts with shared large-scale production modular lines. By planning and streamlining several high-end modular tobacco processing steps and forming a workflow independent of the main production line, independent processing of modular tobacco leaves is achieved using formula-based offline outbound and online warehousing functions. This facilitates the enterprise's production and processing rhythm control, prevents mixing of tobacco leaves of different specifications during simultaneous processing, and avoids issues such as suspending large-scale production plans to process high-end modular tobacco leaves.

[0027] Other features and advantages of the invention will become clear from the following detailed description of exemplary embodiments of the invention with reference to the accompanying drawings. Attached Figure Description

[0028] The accompanying drawings, which are incorporated in and form part of this specification, illustrate embodiments of the invention and, together with their description, serve to explain the principles of the invention.

[0029] Figure 1 A flowchart illustrating the process reengineering method for high-end modular cigarettes based on a formula database provided in an embodiment of the present invention;

[0030] Figure 2 The diagram shows the path from empty box outbound to full box inbound in the process reengineering method for high-end modular cigarettes based on formula storage provided in this embodiment of the invention. Detailed Implementation

[0031] Various exemplary embodiments of the present invention will now be described in detail with reference to the accompanying drawings. It should be noted that, unless otherwise specifically stated, the relative arrangement, numerical expressions, and values ​​of the components and steps set forth in these embodiments do not limit the scope of the invention.

[0032] The following description of at least one exemplary embodiment is merely illustrative and is in no way intended to limit the invention or its application or use.

[0033] Techniques, methods, and equipment known to those skilled in the art may not be discussed in detail, but where appropriate, such techniques, methods, and equipment should be considered part of the specification.

[0034] In all the examples shown and discussed herein, any specific values ​​should be interpreted as merely exemplary and not as limitations. Therefore, other examples of exemplary embodiments may have different values.

[0035] In existing processing models, most tobacco leaf re-drying enterprises share all or part of the main processing routes when processing high-end modular tobacco leaves with large-scale modular tobacco leaves. This results in an inability to control production rhythm and stagger peak times. Key processes such as tobacco boxing, warehousing, and shipping are occupied for extended periods, significantly increasing the waiting time for different specifications of tobacco leaves. For the irregular high-end modular tobacco leaf re-drying tasks each year, this interleaved processing method is detrimental to the continuity and stability of the large-scale production model of tobacco leaf re-drying enterprises. This invention addresses the shortcomings of the high-end modular tobacco processing line by providing a method for re-engineering the high-end modular tobacco process, including the high-end modular tobacco processing flow, elevated warehouse scheduling method, and processing route planning. It does not affect the existing large-scale production processing model. By simply planning an independent processing route for modular tobacco leaves according to this method, the needs of simultaneously processing high-end modular tobacco leaves and daily large-scale production can be met.

[0036] This invention proposes an embodiment of a process reengineering method for high-end modular cigarettes based on a formula database. Specifically, as follows: Figure 1 As shown, it includes the following steps:

[0037] The formulation process is completed in a separate high-end modular processing workshop. It's important to note that the leaf-laying and bagging workstations are avoided; instead, a separate high-end modular processing workshop (fine leaf sorting workshop) is used. Each small batch has a feed rate of 8000kg. Based on the on-site layout of the leaf-laying and bagging workstations and the effective operating rate of the rehumidifier, this 8000kg is subdivided into 8 units, each unit being 1000kg. Then, based on the formulation ratio of the 8000kg batch, the formulation ratio of the 1000kg unit is calculated, and then the feed weight for each grade within the small unit is calculated based on the 1000kg formulation ratio.

[0038] The leaf trimming and laying process is carried out independently in the high-end modular processing workshop, with leaf trimming and laying occurring simultaneously. After laying, the leaves are directly packed manually. The leaves are manually selected and torn, avoiding the use of a leaf-laying table for trimming and increasing the flexibility of the main processing line. Specifically, five trimming teams are set up, with at least two trimming workers at each workstation. For special formula raw materials such as American tobacco, an additional double-workstation team is added. The trimming time for each small batch is controlled within 20-30 minutes to ensure that the stem content and oversized leaf rate meet the process requirements. Each time, an appropriate amount of tobacco leaves is taken from the bag and piled in the center of the trimming table. The trimming workers take out small amounts of trimmed tobacco leaves and lay them flat in front of them, completing the processes of removing impurities, stems, and leaves, and feeding them into the machine. At the end of the manual trimming process, the tobacco bag is collected, the hemp fibers are removed, and the trimmed leaves are returned to the framing process to await the next step of processing.

[0039] Specifically, during the manual packing process, a group-based recycling system is implemented for the trimmed tobacco leaves, and the tobacco leaves are framed via a conveyor belt in the fine leaf sorting workshop. The tobacco frames are then removed offline from the elevated warehouse via an offline outbound system and transported to the fine leaf sorting workshop through an automated logistics system. After the manual packing process is completed, the batches of tobacco boxes are stacked at designated locations to check the uniformity of packing. Forklifts are then used to move the packed tobacco boxes into the warehouse via the existing 171 sampling inspection station. By improving the elevated warehouse scheduling system, an existing offline inbound route (referred to as Line C) has been established. This allows for assigning actual production numbers to the boxes entering the warehouse at station 171, facilitating outbound processing and quality sampling management from the elevated warehouse.

[0040] The empty box outbound process utilizes the node locations of the sampling inspection station and the warehousing station to write outbound plans for batches of high-end module tobacco empty boxes on the on-site industrial control screen. After the batch of empty boxes is outbound through the scheduling system, the empty box information is cleared.

[0041] Specifically, the redesigned empty box outbound process is divided into five closed-loop procedures: empty box outbound planning and processing, empty box unloading station outbound, forklift handling of empty boxes, empty box cleaning, and manual packing. Compared with the original high-end modular tobacco feeding method, an offline empty box outbound function has been added, which can extract the required empty boxes in batches and transport them to designated locations by forklift to avoid sharing with the main production line of tobacco leaves. According to actual production, the number of empty boxes required per day is about 50-60. The empty boxes are manually loaded from the 171 sampling station to the industrial grading area by forklift. The tare weight of the empty box is determined to be an average of 310KG, and the packing weight is 400-550KG. The actual weight of the tobacco leaves (net weight) is recorded according to the box number. The tobacco boxes are randomly inspected on-site for any residues and cleaned up in a timely manner. The elevated warehouse scheduling system was upgraded by modifying the original No. 171 raw tobacco sampling station. Station No. 171 was designated as a virtual station, and a new route for empty boxes was planned for outbound shipment. This allows for batch-based allocation of empty boxes from the elevated warehouse to supply high-end module formulation routes, forming a closed-loop control independent of the main line. Specifically, the number and batches of empty boxes outbound are precisely controlled by the node positions of the sampling and receiving stations, ensuring they match the packing tasks. After outbound shipment, empty box information is promptly cleared to avoid information redundancy and errors.

[0042] In the physical box warehousing process, after the manual packing process is completed in batches, the boxes are delivered to the node positions of the sampling inspection station and the warehousing station by forklift. The corresponding packing and warehousing documents for the corresponding route are issued offline through the virtual station and an online logistics warehousing plan is automatically generated.

[0043] Specifically, the original design for the physical box warehousing process did not allow manual entry of cigarette box information and generation of logistics warehousing plans. After redesign, the physical box warehousing process is divided into several stages: offline information entry of the box number at station 171 (virtual station); generation and issuance of the warehousing plan at station 171; reading the batch cigarette box number and weight information; automatic generation of the online logistics warehousing plan; and completion of the batch cigarette box warehousing task in the high-bay automated warehouse. Manual forklifts transport the packed boxes from the high-end module processing area to the original sampling station (171), then via the first-floor warehousing conveyor system to the formula warehouse picking station. Stacker cranes in the aisle deliver empty boxes to designated storage locations based on the location information allocated by the upper-level management system. This embodiment utilizes virtual station technology to issue packing and warehousing documents offline and automatically generate online logistics warehousing plans. This significantly improves logistics efficiency and accuracy, and reduces human error.

[0044] Specifically, when preparing the warehousing plan at platform 171, the operation process is as follows: after the boxes are manually packed, a packing and warehousing document is prepared and issued. After the cigarette boxes are placed at platform 171, a manual application for warehousing is submitted.

[0045] Furthermore, following the formulation process, a leaf-loosening and bagging process is also included. This specifically involves setting up leaf-loosening tables according to the formulation plan, typically five tables. Each table handles the leaf-loosening and bagging of an equal quantity of high-end modular tobacco. The formulated tobacco leaves are loosened to a thickness of 5-8cm and packed into cotton bags. Each small unit / batch is packed into 12 bags, and each small batch is placed in a rehydrated tobacco frame for further processing. After the leaf-loosening and bagging process is completed, the tobacco leaf cartons, binding straps, and cardboard are collected at the end of the process, and the batch of tobacco leaf cardboard is checked for adulteration to prevent it from flowing into the next process.

[0046] Furthermore, the leaf trimming and laying process also includes: setting the vacuum rehumidification flow rate and time for tobacco leaves, and equipping at least two vacuum rehumidification machines (A and B). Large-scale production tobacco leaves use line A for vacuum rehumidification, while high-end modular tobacco leaves use line B. Specifically, each rehumidification flow rate is 5 * 400 = 2000 kg, with four batches completing a total feed of 8000 kg. When not processing high-end modular tobacco leaves, both lines can be used simultaneously for large-scale production tobacco leaves. Based on the trimming time for each batch at the on-site trimming station, the timing of the rehumidification and trimming processes is strictly controlled to ensure that the rehumidified tobacco leaves can be trimmed and packed within the specified time.

[0047] Furthermore, in the empty container outbound process, forklifts are used at the sampling inspection station to transport empty containers to the designated manual loading and unloading area.

[0048] Furthermore, after the leaf trimming and laying process, the process also includes: adopting a group recycling system for the trimmed tobacco leaves, completing the framing process of the tobacco leaves through the conveyor belt in the fine leaf sorting workshop, removing the tobacco frames offline from the high-rise warehouse through the offline outbound system, and sending them to the fine leaf sorting workshop through the automated logistics system.

[0049] Furthermore, after the leaf trimming and leaf laying process, the process also includes: after the manual packing process is completed, the batch of cigarette boxes is stacked at designated locations, and the packed cigarette boxes are put into storage through the sampling inspection station by forklift. The actual production number is assigned to the actual boxes put into storage at the sampling inspection station.

[0050] Furthermore, the actual box warehousing process also includes: assigning weight information to the corresponding box number after empty boxes are filled with tobacco leaves by weighing, entering the warehousing information box number offline through a virtual station, and reading the batch tobacco box number and weight information.

[0051] Furthermore, virtual station information can be built by utilizing the existing sampling stations or other node locations in the formula high-bay warehouse.

[0052] Furthermore, the process following the actual box receiving and warehousing also includes:

[0053] After the batch of high-end module cigarette boxes is put into storage, the production plan is issued, and the batch formula is released from the formula high-rise warehouse to enter the main line to complete the production and processing of high-end modules.

[0054] Furthermore, the process prior to the formulation step also includes:

[0055] In the feeding process, after the high-end modular cigarettes are collected and stored, they are fed according to the formula structure requirements. The amount of material to be fed in each batch is evenly divided, weighed, and recorded.

[0056] In the stacking process, the amount of each batch of raw materials is evenly divided, and the tobacco leaves of each batch are sorted and stacked. The daily processing volume is calculated, and the materials are transported to the nearest location.

[0057] In another embodiment of the present invention, it is described as follows:

[0058] Simultaneously processing Yunnan-produced Class A high-end modular tobacco leaves and large-scale production modular tobacco leaves includes the following steps:

[0059] 1. In the large-scale production module, tobacco leaves are processed according to the original route, and the automated logistics system is used normally for packing and warehousing.

[0060] 2. Set up a high-end module processing area for feeding, stacking and formulation processes, and process tobacco leaves simultaneously with the main production module to avoid sharing the same process path as the main production.

[0061] 3. In the production scheduling system, after completing the setup of the A-line large-scale production module and the B-line high-end formula module for the re-moistening process, the task of processing tobacco leaves of different specifications on both lines can be completed simultaneously.

[0062] 4. Set up a high-end module processing area to carry out processes such as leaf trimming and leaf laying, which does not conflict with the leaf laying and handling path of the main production module, and can complete processing tasks of different specifications at the same time.

[0063] 5. For example Figure 2 At platform 171, an offline dispatch plan for empty containers on Line B is issued. For empty container sampling and dispatch: In the logistics dispatch system, find the basic business section, select the sampling and dispatch option, and click to dispatch the required number of empty containers. Specifically, this includes:

[0064] (1) Open the logistics dispatch system, select the empty box outbound option, enter the required number of empty boxes in the outbound quantity, and click "confirm" to outbound. The system will automatically generate the task of outbounding empty boxes to platform 171.

[0065] (2) Empty box outbound is consistent with the normal empty box replenishment outbound strategy. It is divided equally in the lanes and generates the number of empty box outbound tasks according to the input quantity. The outbound tasks currently being executed can be viewed at the bottom of the interface to keep track of the outbound progress and avoid duplicate operations.

[0066] Note: To prevent conflicts between inbound and outbound paths, the system restricts the dispatch of empty boxes when there are inbound tasks. Please complete the inbound task before initiating the empty box dispatch operation.

[0067] (3) Use a forklift to deliver the empty boxes that have been cleared of information to the designated stacking location in the high-end module formula processing workshop, and wait for manual packing. This will avoid using the main line packing station for packing and ensure that the common path of the main line processing is not used.

[0068] 6. For example Figure 2 As shown, the function of loading and unloading boxes at station 171 has been added to the on-site and central control logistics scheduling system. When loading and unloading boxes manually, an offline loading plan needs to be issued in advance. Select the function interface in the logistics scheduling system, select the offline loading and unloading

[23003] option, and the operation steps are as follows:

[0069] (1) After selecting the class and class number, click the [Add] button.

[0070] (2) After entering the weight of a single box, select the place of origin and year, click the "Automatic Material Numbering" selection box in the planning information.

[0071] (3) A material selection interface will pop up. After selecting the material grade information to be put into the warehouse, click Return.

[0072] (4) After returning, you can choose to fill in the "Planned Number of Boxes", which is the planned number of cigarette boxes to be received, or you can leave it blank and click the "Save" button.

[0073] (5) After saving successfully, check the information and confirm that it is correct, then click the [Confirm] button to issue the plan for packing and storing the film.

[0074] It should be noted that after successful confirmation, the manual forklift will place the cigarette box on the 171 rack. After the electronic control is set to offline packing mode, the electronic control will automatically request the corresponding pallet information on the 171 rack and automatically put it into storage.

[0075] (6) After the warehousing is completed, click the "End" button to complete the current warehousing plan for platform 171;

[0076] [Cancel]: If you find any errors in the information of a newly added inbound plan, you can click the "Cancel" button to cancel the inbound plan. Note that plans that have already been confirmed cannot be canceled.

[0077] [Pause]: For confirmed inbound plans, if you do not want to continue inbound operations for the time being, you can click the "Pause" button to pause the document.

[0078] [Plan Number Inquiry]: Click the selection button in the plan number, and then click "Inquire All" in the pop-up window to find all valid inbound plan documents. Click "Return" to load the selected document information.

[0079] (7) After completing the actual box warehousing operation, wait for the production scheduling system to normally retrieve the batch of high-end module cigarettes from the formula high-rise warehouse for processing.

[0080] In another embodiment of the present invention, it is described as follows:

[0081] The steps for processing only Yunnan-produced Category B high-end modular blend tobacco leaves are as follows:

[0082] 1. The original A-line of the large-scale production module can be shut down for maintenance and repair as usual, while the high-end module tobacco leaves are processed according to the predetermined path.

[0083] 1. Set up a high-end module processing area for feeding, stacking, and formulation processes, while the main production module tobacco leaf processing path is normally shut down for maintenance and repair.

[0084] 2. In the production scheduling system, lines A and B can simultaneously carry out high-end module tobacco leaf processing.

[0085] 3. A high-end module processing area is set up to perform processes such as leaf trimming and leaf laying.

[0086] 4. For example Figure 2 At platform 171, an offline dispatch plan for empty containers on line B is issued. For empty container sampling and dispatch: in the logistics dispatch system, find the basic business, select the sampling and dispatch option, and click to dispatch the required number of empty containers.

[0087] 5. After empty containers are dispatched to platform 171, the existing information for the empty containers needs to be cleared using the logistics dispatch system. Locate the "Basic Business" option, select "Pallet Information Maintenance," and delete the corresponding empty container information. Empty Container Sampling and Dispatch: In the logistics dispatch system, locate the "Basic Business" option, select "Sampling and Dispatch," and click to dispatch the required number of empty containers. Specifically, this includes:

[0088] (1) Open the logistics dispatch system. Select the empty box outbound option, enter the required number of empty boxes in the outbound quantity field, and click "confirm" to outbound. The system will automatically generate a task to outbound empty boxes to platform 171.

[0089] (2) Empty box outbound is consistent with the normal empty box replenishment outbound strategy. It is divided equally in the lanes and generates the number of empty box outbound tasks according to the input quantity. The outbound tasks currently being executed can be viewed at the bottom of the interface to keep track of the outbound progress and avoid duplicate operations.

[0090] Note: To prevent conflicts between inbound and outbound paths, the system restricts the dispatch of empty boxes when there are inbound tasks. Please complete the inbound task before initiating the empty box dispatch operation.

[0091] (3) Use a forklift to deliver the empty boxes that have been cleared of information to the designated stacking location in the high-end module formula processing workshop, and wait for manual packing. This will avoid using the main line packing station for packing and ensure that the common path of the main line processing is not used.

[0092] 6. For example Figure 2 Offline packing and warehousing documents for Line B are issued at platform 171. A physical box warehousing function for platform 171 has been added to the on-site and central control logistics dispatch system. When manually packing and warehousing, an offline packing plan needs to be issued in advance. Select the offline packing and warehousing option in the function interface of the logistics dispatch system. The operation steps are as follows:

[0093] (1) After selecting the class and class number, click the [Add] button.

[0094] (2) After entering the weight of a single box, select the place of origin and year, click the "Automatic Material Numbering" selection box in the planning information.

[0095] (3) A material selection interface will pop up. After selecting the material grade information to be put into the warehouse, click Return.

[0096] (4) After returning, you can choose to fill in the "planned number of boxes", that is, the planned number of cigarette boxes to be put into the warehouse, or you can leave it blank and click the [Save] button.

[0097] (5) After saving successfully, check the information and confirm that it is correct, then click the [Confirm] button to issue the plan for packing and storing the film.

[0098] Note: After successful confirmation, the manual forklift will place the cigarette box on rack 171. Once the electronic control is set to offline packing mode, it will automatically request the corresponding pallet information on rack 171 and automatically put it into storage.

[0099] (6) After the warehousing is completed, click the "End" button to complete the current warehousing plan for platform 171;

[0100] Among them,

Cancel

[0101] [Pause]: For confirmed inbound plans, if you do not want to continue inbound operations for the time being, you can click the "Pause" button to pause the document.

[0102] [Plan Number Inquiry]: Click the selection button in the plan number, and then click "Inquire All" in the pop-up window to find all valid inbound plan documents. Click "Return" to load the selected document information.

[0103] (7) After completing the actual box warehousing operation, wait for the production scheduling system to normally retrieve the batch of high-end module cigarettes from the formula high-rise warehouse for processing.

[0104] This invention provides a method for re-engineering the high-end modular tobacco processing flow, including a high-end modular tobacco processing procedure, an elevated warehouse scheduling method, and processing route planning. It plans an independent processing route for high-end modular tobacco, avoiding intersections with daily mass production lines and reducing interference. After processing, the finished tobacco leaves are directly stored in the elevated warehouse via online warehousing, achieving rapid turnover. By planning and streamlining several high-end modular tobacco processing steps and forming a workflow independent of the main production line, it facilitates the control of the enterprise's production and processing rhythm, preventing issues such as mixing of tobacco leaves of different specifications during simultaneous processing, and the need to suspend mass production processing plans to process high-end modular tobacco leaves.

[0105] The above description of the structure, features, and effects of the present invention is based on the embodiments shown in the figures. However, the above are only preferred embodiments of the present invention. It should be noted that the technical features involved in the above embodiments and their preferred methods can be reasonably combined and matched by those skilled in the art to form a variety of equivalent solutions without departing from or changing the design concept and technical effects of the present invention. Therefore, the present invention is not limited to the scope of implementation shown in the figures. Any changes made in accordance with the concept of the present invention, or modifications to equivalent embodiments, that do not exceed the spirit covered by the specification and figures, should be within the protection scope of the present invention.

Claims

1. A process reengineering method for high-end modular cigarettes based on a formula database, characterized in that, Includes the following steps: The formulation process is completed independently in a dedicated high-end modular tobacco processing workshop. The leaf trimming and laying process involves independent leaf trimming and laying in the high-end modular tobacco processing workshop, followed by manual boxing. This process also includes setting the flow rate and time for vacuum rehydration of tobacco leaves, and equipping at least two vacuum rehydration machines (A and B). Mass-production tobacco leaves use line A for vacuum rehydration, while high-end modular tobacco leaves use line B. Following this process, the trimmed tobacco leaves are grouped and recycled. They are then boxed via a conveyor belt in the sorting workshop, and the boxes are shipped offline through the formula warehouse's offline outbound system and delivered to the sorting workshop via an automated logistics system. After manual boxing, the boxes are stacked at designated locations, and forklifts are used to inspect and store them at a sampling station. Each box is assigned a production number. The empty box outbound process utilizes the node locations of the sampling inspection station and the warehousing station to create a batch of high-end module tobacco empty box outbound plan, and clears the empty box information after the batch of empty boxes is outbound through the scheduling system; The actual box receiving process involves manually packing boxes in batches, then transporting them to the sampling inspection station and the receiving station via forklift. A virtual station is used to offline issue the corresponding packing and receiving documents and automatically generate an online logistics receiving plan. The actual box receiving process also includes: assigning weight information to the corresponding box number after empty boxes are filled with tobacco leaves using weighing; offline entry of the receiving information box number via the virtual station; and reading the batch tobacco box number and weight information. The virtual station information is constructed using the existing sampling inspection station or other node locations in the formula warehouse.

2. The process reengineering method for high-end modular cigarettes based on formula database as described in claim 1, characterized in that, During the empty box outbound process, forklifts are used at the sampling inspection station to transport empty boxes to the designated manual loading and unloading area.

3. The process reengineering method for high-end modular cigarettes based on formula database as described in claim 1, characterized in that, Following the process of receiving the boxes into the warehouse, the following also applies: After completing the warehousing of the full boxes of high-end modular cigarettes in batches, the production plan is issued, and the batch formulas are released from the formula warehouse to enter the main production line to complete the production and processing of high-end modular cigarettes.

4. The process reengineering method for high-end modular cigarettes based on formula database as described in claim 1, characterized in that, This also includes the following steps before the formulation process: In the feeding process, after the high-end modular cigarettes are collected and stored, they are fed according to the formula structure requirements. The amount of material to be fed in each batch is evenly divided, weighed, and recorded. In the stacking process, the amount of each batch of raw materials is evenly divided, and the tobacco leaves of each batch are sorted and stacked. The daily processing volume is calculated, and the materials are transported to the nearest location.

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