Equipment part replacement whole-process management and control system and method

Abstract

The invention discloses a full-process management and control system and method for replacement of equipment spare and accessory parts, and belongs to the technical field of equipment full life cycle management, and the system comprises a system construction module which constructs a modular management and control system based on material picking application data of an enterprise resource planning system; the operation process specification module is used for formulating and integrating operation process specifications so as to guide part replacement and recording part destination information of maintenance records; the spare and accessory part evaluation and processing module is used for performing function evaluation on the replaced spare and accessory parts and performing classification processing on the spare and accessory parts according to an evaluation result to obtain an evaluation record; and the information recording and checking module is used for regularly checking the spare and accessory parts according to the spare and accessory part destination information and the review record in the maintenance record. According to the invention, the problems of difficult supervision, incomplete recording, nonstandard operation of maintenance personnel and the like in the replacement process of equipment parts in the cigarette factory can be solved.

Description

Technical Field

[0001] The present invention relates to the technical field of equipment full life cycle management, and more specifically, to a full-process management and control system and method for equipment spare parts replacement. Background Art

[0002] As the core production enterprise in the tobacco industry, cigarette factories have many types of cigarette making and packaging machines. These machines and equipment will inevitably have various sudden failures during continuous and high-speed operation. In order to ensure the continuity and stability of production, it is very important to replace damaged parts in a timely manner. However, due to the variety of models and large number of sets of cigarette making and packaging machines, there are many types and huge numbers of spare parts, which brings great challenges to the management and control of spare parts replacement. At present, there are mainly the following problems:

[0003] (1) Frequent replacement of spare parts and incomplete records: In actual production, equipment accidents occur every day and every shift, requiring the replacement of a large number of spare parts. Currently, although the group's unified ERP system supports the spare parts application process, in actual operation, the specific circumstances of spare parts replacement (such as replacement time, replacement personnel, replacement reasons, replacement parts, etc.) are not fully recorded, which brings difficulties to subsequent tracking and management.

[0004] (2) Large number of maintenance personnel and difficult supervision: Due to the large number of maintenance personnel, and their distribution in different maintenance positions, how to ensure that each maintenance personnel can complete the replacement of spare parts in accordance with the prescribed procedures and requirements, and correctly scrap or repair the replaced spare parts has become an urgent problem to be solved. At present, there are still large loopholes in the supervision of this part of the work.

[0005] (3) Lack of maintenance records and insufficient data analysis: Under the current management method, maintenance records are often not properly preserved. This is not only not conducive to the historical tracing of maintenance work, but also limits the possibility of optimizing maintenance strategies and improving maintenance efficiency through data analysis. Summary of the invention

[0006] An object of the present invention is to provide a full-process control system and method for equipment spare parts replacement to solve the problems of difficult supervision, incomplete records, and non-standard operation of maintenance personnel in the process of replacing equipment spare parts in the aforementioned cigarette factory.

[0007] According to a first aspect of the present invention, a full-process control system for replacing equipment parts is provided, comprising:

[0008] System building module, which builds a modular management and control system based on the material requisition data of the enterprise resource planning system;

[0009] Operation process specification module, used to formulate and integrate operation process specifications to guide spare parts replacement and record the whereabouts of spare parts in maintenance records;

[0010] Spare parts review and processing module: used to conduct functional review of replaced spare parts, classify and process the spare parts according to the review results, and obtain review records;

[0011] Information recording and inventory module: used to regularly count spare parts based on the spare parts destination information and review records in the maintenance records.

[0012] Optionally, the system building module includes:

[0013] Automatic extraction and display unit: used to automatically extract and display the repairman's material delivery order information from the ERP system;

[0014] Online claim interface unit: used for repairmen to select spare parts to claim and fill in detailed information, including but not limited to the equipment used, location and quantity;

[0015] Record generation and storage unit: used to automatically generate and store maintenance records containing detailed information on spare parts replacement.

[0016] Optionally, the system building module further includes:

[0017] Electronic management unit: used to manage the electronic records of the replaced spare parts review process.

[0018] Optionally, the operation process specification module includes:

[0019] Spare parts selection and confirmation unit: used to select and confirm the consistency between the claimed spare parts and the spare parts to be replaced;

[0020] Replacement information filling unit: used to fill in replacement information, including but not limited to the name of the equipment used, the location of the spare parts, and the quantity of the spare parts;

[0021] Replacement record submission unit: used to submit a maintenance record containing the above replacement information after the replacement is completed.

[0022] Optionally, the spare parts review and processing module includes:

[0023] Evaluation classification unit: used to classify spare parts into two categories: repair and reuse or scrap according to their actual conditions;

[0024] Classification processing unit: used to automatically, semi-automatically or manually start the processing flow of the two types of spare parts, namely, repairing and reusing or scrapping, according to the classification results.

[0025] Optionally, it has a RESTful API interface and an API interface, and the equipment spare parts replacement full-process management and control system is connected to the ERP system signal through the RESTful API interface, and data interaction is performed between the system construction module, the operation process specification module, the spare parts review and processing module and the information recording and inventory module through the API interface.

[0026] Optionally, the information recording and inventory module includes:

[0027] Inventory management unit: used to integrate with the enterprise's inventory management system to obtain inventory data in real time;

[0028] Data comparison unit: used to quickly compare the differences between system records and actual inventory through data comparison algorithms and generate difference reports.

[0029] According to a second aspect of the present invention, a method for controlling the entire process of replacing equipment parts is provided, comprising the following steps:

[0030] Build a modular management and control system based on the material requisition data of the enterprise resource planning system;

[0031] Develop and integrate operating process specifications to guide spare parts replacement and record the whereabouts of spare parts in maintenance records;

[0032] Conduct functional review on the replaced parts and components, classify them according to the review results, and obtain review records;

[0033] Regularly count spare parts based on the spare parts destination information and review records in the maintenance records.

[0034] The full-process control system and method for replacing equipment parts disclosed in the present invention have the following technical effects:

[0035] Improve supervision efficiency: Through systematic management and detailed records, managers can grasp the replacement of spare parts in real time, thus improving the efficiency and transparency of supervision;

[0036] Standardized operating procedures: Clear operating procedures and specifications help reduce human errors and irregular behaviors, and ensure the correct use and replacement of spare parts;

[0037] Enhanced traceability: Complete maintenance records and spare parts review process provide reliable data support for subsequent quality traceability and production analysis;

[0038] Cost saving: Through repairing and reusing old equipment and reasonable scrapping, unnecessary waste is reduced and production costs are lowered.

[0039] Further features and advantages of the present invention will become apparent from the following detailed description of exemplary embodiments of the present invention with reference to the attached drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0040] The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention.

[0041] Figure 1 A schematic diagram of the architecture of a full-process control system for replacing equipment parts and components provided by an embodiment of the present invention;

[0042] Figure 2 A flowchart of a method for controlling the entire process of replacing equipment parts and components provided in an embodiment of the present invention. DETAILED DESCRIPTION

[0043] Various exemplary embodiments of the present invention will now be described in detail with reference to the accompanying drawings. It should be noted that the relative arrangement of components and steps, numerical expressions and numerical values ​​set forth in these embodiments do not limit the scope of the present invention unless otherwise specifically stated.

[0044] The following description of at least one exemplary embodiment is merely illustrative in nature and is in no way intended to limit the invention, its application, or uses.

[0045] Technologies, methods, and equipment known to ordinary technicians in the relevant art may not be discussed in detail, but where appropriate, the technologies, methods, and equipment should be considered as part of the specification.

[0046] In all examples shown and discussed herein, any specific values ​​should be interpreted as merely exemplary and not limiting. Therefore, other examples of the exemplary embodiments may have different values.

[0047] At the current stage, due to the variety of models and large number of sets of cigarette making and packaging machines, there are many types and huge numbers of spare parts, which directly leads to great challenges in the management and control of spare parts replacement. This application can ensure that repairmen can accurately use the requested spare parts when replacing spare parts, and correctly record the replacement information, effectively supervise the repairmen's processing procedures after replacing spare parts, ensure that the replaced spare parts are reviewed and handled in compliance, and improve the transparency and traceability of spare parts replacement through systematic management methods, so that managers can conduct effective supervision and inventory.

[0048] The present invention proposes an embodiment of a full-process control system for replacing equipment parts. Specifically, Figure 1 shown, including:

[0049] The system building module builds a modular management and control system based on the material requisition data of the enterprise resource planning system (ERP system); seamless connection with the ERP system ensures the accuracy and real-time nature of the data, reducing manual errors and duplication of work in data entry.

[0050] The operation process specification module is used to formulate and integrate operation process specifications to guide the replacement of spare parts and record the whereabouts of spare parts in the maintenance record; the operation process specification module is responsible for formulating detailed operation process specifications, including but not limited to the preparation work before the replacement of spare parts, replacement steps, safety precautions, verification after replacement, etc. Standardized operation procedures reduce human judgment errors and omissions of operation steps, improve work efficiency, and all operations can be traced, which is convenient for post-audit and problem tracing.

[0051] Spare parts review and processing module: used to conduct functional review of replaced spare parts, classify and process the spare parts according to the review results, and obtain review records; accurately distinguish the status of spare parts, provide data support for accurate procurement and inventory management, and reduce inventory costs.

[0052] Information Recording and Inventory Module: It is used to regularly count spare parts according to the spare parts destination information and review records in the maintenance records to ensure that the system data is consistent with the actual objects. Any discrepancies found during the inventory process will trigger the exception handling process, requiring the relevant responsible persons to find out the reasons and take corrective measures.

[0053] In an embodiment of the present invention, the system building module includes:

[0054] Automatic extraction and display unit: used to automatically extract and display the repairman's material delivery order information from the ERP system, and realize the automatic extraction and display of the repairman's material delivery order; including parsing the data obtained from the ERP system to extract the key information of the material delivery order, such as the person who picked the material, the name of the spare parts, the quantity, the delivery time, etc. Directly grabbing data from the source system avoids the errors that may be caused by manual input.

[0055] Online claim interface unit: used for repairmen to select spare parts to claim and fill in detailed information, including but not limited to the equipment, location and quantity used; enables repairmen to select spare parts to claim online and fill in information such as the equipment, location and quantity used; designs a user-friendly form interface, including multiple input methods such as drop-down selection boxes, text boxes, and numeric input boxes to meet the requirements of entering different information. Perform logical checks before submitting the form to ensure the integrity and rationality of the input information, such as the quantity cannot be negative, the equipment name must exist in the preset list, etc. The accuracy of the claim information is ensured through preset options and logical checks. All claim records are saved online for subsequent tracking and auditing.

[0056] Record generation and storage unit: used to automatically generate and store maintenance records containing detailed information on spare parts replacement.

[0057] In an embodiment of the present invention, the system building module further includes: an electronic management unit: used to manage the electronic records of the replacement parts review process. All electronic review records are stored in a central database, realizing centralized management and rapid retrieval of data. Electronic records have extremely high traceability. Whether it is the reason for the replacement of spare parts, the replacement process or the review results, they can all be easily traced in the system.

[0058] In an embodiment of the present invention, the operation process specification module includes:

[0059] Spare parts selection and confirmation unit: used to select and confirm the consistency of the requested spare parts with the spare parts to be replaced; the system automatically retrieves the corresponding spare parts information based on the material requisition data, and compares it with the spare parts in inventory to check whether there are any differences. The fast and accurate spare parts selection process reduces the time spent on repeated confirmation and search for spare parts.

[0060] Replacement information filling unit: used to fill in replacement information, which includes but is not limited to the name of the equipment used, the location of the spare parts, and the quantity of the spare parts; the replacement information is recorded in detail to provide rich data support for subsequent equipment maintenance, fault analysis and inventory management.

[0061] Replacement record submission unit: used to submit maintenance records containing the above replacement information after the replacement is completed. Based on the submitted records, enterprises can continuously optimize the replacement process, improve service quality, and discover potential areas for improvement.

[0062] In an embodiment of the present invention, the spare parts review and processing module includes:

[0063] Review classification unit: used to classify spare parts into two categories: repair and reuse or scrap according to their actual condition. For spare parts that need to be repaired and reused, they will be put back into storage after being repaired by repairmen. For spare parts that need to be scrapped, the scrapped parts will be placed in a designated location and enter the scrapping process. The actual condition of spare parts includes the degree of wear, damage type, maintenance history, technical performance parameters and other aspects of the spare parts. Using advanced technologies such as image recognition and machine learning, the spare parts images are automatically analyzed to quickly identify the wear and damage type of the spare parts.

[0064] Classification processing unit: used to automatically, semi-automatically or manually start the processing flow of the two types of spare parts, namely, repair, reuse or scrap, according to the classification results. The workflow engine and automation scripts are used to realize the automatic execution of the processing flow, reduce manual intervention and improve efficiency. The processing tasks are assigned to the corresponding departments or personnel through the task management system, and the progress of the tasks is tracked in real time to ensure the smooth processing flow. By integrating with ERP, CRM and other systems, real-time data sharing and updating are realized to ensure that each link in the processing flow can obtain the latest information.

[0065] In an embodiment of the present invention, the system has a RESTful API (Representational State Transfer application programming interface) interface and an API interface. The equipment spare parts replacement full process control system is connected to the ERP system signal through the RESTful API interface. The RP system is the core system for integrating and managing sales, procurement, production, inventory, finance and other business processes within the enterprise. The two systems can exchange data in real time or regularly to ensure the synchronization and consistency of information; the data interaction between the system construction module, the operation process specification module, the spare parts review and processing module and the information recording and inventory module is carried out through the API interface, which realizes the close integration of the modules within the system and improves the overall performance and stability of the system. The automated and standardized data interaction process reduces manual intervention and repetitive work, and improves the work efficiency of the whole process of spare parts replacement. Furthermore, the information recording and inventory module synchronizes data with the ERP system through the API interface, ensuring the traceability of the whole process of spare parts replacement, and providing a strong guarantee for quality control and accountability.

[0066] In an embodiment of the present invention, the information recording and inventory module includes:

[0067] Inventory management unit: used to integrate with the enterprise's inventory management system to obtain inventory data in real time. The inventory data includes but is not limited to product name, quantity, batch number, expiration date, storage location and other information.

[0068] Data comparison unit: used to quickly compare the differences between system records and actual inventory through data comparison algorithms and generate difference reports.

[0069] The information recording and inventory counting module realizes real-time recording, accurate comparison and difference analysis of inventory data through the collaborative work of the inventory management unit and the data comparison unit, providing enterprises with efficient and accurate inventory management tools.

[0070] The present invention also provides an embodiment of a method for controlling the entire process of replacing equipment parts and components, specifically, Figure 2 As shown, the method comprises the following steps:

[0071] Build a modular management and control system based on the material requisition data of the enterprise resource planning system;

[0072] Develop and integrate operating process specifications to guide spare parts replacement and record the whereabouts of spare parts in maintenance records;

[0073] Conduct functional review on the replaced parts and components, classify them according to the review results, and obtain review records;

[0074] Regularly count spare parts based on the spare parts destination information and review records in the maintenance records.

[0075] It should be noted that the structure, execution process and other contents of the above-mentioned method are based on the same concept as the system embodiment of the present application, and are devices corresponding to the full-process control system for replacement of spare parts of the above-mentioned equipment. All implementation methods in the above-mentioned system embodiment are applicable to the embodiment of the method. Its specific functions and technical effects brought about can be found in the system embodiment part, which will not be repeated here.

[0076] The embodiments of the present invention can enable managers to grasp the replacement status of spare parts in real time through systematic management and detailed records, thereby improving the efficiency and transparency of supervision; clear operating procedures and specifications help reduce the occurrence of human errors and irregular behaviors, and ensure the correct use and replacement of spare parts; complete maintenance records and parts review processes provide reliable data support for subsequent quality tracing and production analysis; through repairing and reusing old parts and reasonable scrapping, unnecessary waste is reduced and production costs are reduced.

[0077] The above describes in detail the structure, features and effects of the present invention based on the embodiments shown in the drawings, but the above is only a preferred embodiment 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 into a variety of equivalent schemes by those skilled in the art without departing from or changing the design ideas and technical effects of the present invention; therefore, the present invention is not limited to the scope of implementation shown in the drawings, and all changes made in accordance with the concept of the present invention, or modifications to equivalent embodiments with equivalent changes, which still do not exceed the spirit covered by the specification and drawings, should be within the protection scope of the present invention.

Claims

1. A full-process control system for equipment parts replacement, characterized in that: include: System building module, which builds a modular management and control system based on the material requisition data of the enterprise resource planning system; Operation process specification module, used to formulate and integrate operation process specifications to guide spare parts replacement and record the whereabouts of spare parts in maintenance records; Spare parts review and processing module: used to conduct functional review of replaced spare parts, classify and process the spare parts according to the review results, and obtain review records; Information recording and inventory module: used to regularly count spare parts based on the spare parts destination information and review records in the maintenance records.

2. The whole process control system for equipment parts replacement according to claim 1 is characterized in that: The system building blocks include: Automatic extraction and display unit: used to automatically extract and display the repairman's material delivery order information from the ERP system; Online claim interface unit: used for repairmen to select spare parts to claim and fill in detailed information, including but not limited to the equipment used, location and quantity; Record generation and storage unit: used to automatically generate and store maintenance records containing detailed information on spare parts replacement.

3. The whole process control system for equipment spare parts replacement according to claim 2 is characterized in that: The system building blocks also include: Electronic management unit: used to manage the electronic records of the replaced spare parts review process.

4. The whole process control system for equipment parts replacement according to claim 1 is characterized in that: The operation process specification module includes: Spare parts selection and confirmation unit: used to select and confirm the consistency between the claimed spare parts and the spare parts to be replaced; Replacement information filling unit: used to fill in replacement information, including but not limited to the name of the equipment used, the location of the spare parts, and the quantity of the spare parts; Replacement record submission unit: used to submit a maintenance record containing the above replacement information after the replacement is completed.

5. The whole process control system for equipment parts replacement according to claim 1 is characterized in that: The spare parts review and processing module includes: Evaluation classification unit: used to classify spare parts into two categories: repair and reuse or scrap according to their actual conditions; Classification processing unit: used to automatically, semi-automatically or manually start the processing flow of the two types of spare parts, namely, repairing and reusing or scrapping, according to the classification results.

6. The whole process control system for equipment spare parts replacement according to claim 1 is characterized in that: It has a RESTful API interface and an API interface. The equipment spare parts replacement full-process management and control system is connected to the ERP system signal through the RESTful API interface, and data interaction is carried out between the system construction module, the operation process specification module, the spare parts review and processing module and the information recording and inventory module through the API interface.

7. The whole process control system for equipment parts replacement according to claim 1 is characterized in that: The information recording and inventory module includes: Inventory management unit: used to integrate with the enterprise's inventory management system to obtain inventory data in real time; Data comparison unit: used to quickly compare the differences between system records and actual inventory through data comparison algorithms and generate difference reports.

8. A method for controlling the entire process of replacing equipment parts, characterized in that: The following steps are involved: Build a modular management and control system based on the material requisition data of the enterprise resource planning system; Develop and integrate operating process specifications to guide spare parts replacement and record the whereabouts of spare parts in maintenance records; Conduct functional review on the replaced parts and components, classify them according to the review results, and obtain review records; Regularly count spare parts based on the spare parts destination information and review records in the maintenance records.

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