Intelligent billboard system and method for displaying completion rate of production workshop, and medium

Abstract

The invention relates to the technical field of product completion rate management, and discloses an intelligent billboard system and method for production workshop completion rate display, and a medium, and the system comprises a data obtaining module which obtains the total number of products planned to be produced in a production order and the number of work orders for production of each product, and after the production order is completed, the completion rate is obtained by combining the actually completed qualified product amount and the planned completion product amount, and when the completion rate is smaller than a planned completion rate threshold value, the unqualified products are classified. According to the method, products needing a small amount of repair can be brought into the completion rate, the nearly completed products are identified and displayed, resources can be distributed more quickly for repair, the reworking time is shortened, and a more comprehensive progress reflection is provided through the display board.

Description

Technical Field

[0001] The present invention relates to the technical field of product completion rate management, and in particular to an intelligent kanban system, method and medium for displaying the completion rate of a production workshop. Background Art

[0002] The completion rate of a production workshop is the ratio between the actual production volume completed by a workshop in a specific period of time and the planned production volume. This ratio can be visualized in some form (such as charts, reports or software system dashboards) to show the completion progress of the production process. The completion rate is usually expressed as a percentage, reflecting the comparison between the current production situation and the planned target.

[0003] In the actual production process, the completion of product production and the production process are closely related. Only products that have completed all the production processes are considered to be finished. The completion rate often only reflects the ratio between the number of qualified products produced and the planned quantity. In terms of the production completion of the entire order, among the unqualified products, there will be products that can be qualified after only a short time of repairing the process. Such products should also be reflected in the completion rate, thereby showing the actual progress in the production process.

[0004] To this end, the present invention provides an intelligent kanban system, method and medium for displaying the completion rate of a production workshop. Summary of the invention

[0005] In view of the problems existing in the above-mentioned prior art, the purpose of the present invention is to provide an intelligent billboard system, method and medium for displaying the completion rate of a production workshop, so as to include products that require a small amount of repair into the completion rate, provide a more comprehensive progress reflection, and help workshop managers better understand the order production status.

[0006] In order to achieve the above-mentioned purpose, the present invention provides the following technical solution: an intelligent billboard system for displaying the completion rate of a production workshop, comprising:

[0007] A data acquisition module, wherein the data acquisition module includes acquiring the total number of products planned to be produced in the production order and the number of processes used to produce each product, so as to obtain the number of unqualified products and the number of completed processes. After the production order is completed, the completion rate is obtained by combining the actual number of qualified products completed with the planned number of completed products. When the completion rate is less than the planned completion rate threshold, the unqualified products are classified;

[0008] A non-conforming product classification module, wherein the non-conforming product classification module includes obtaining the total amount of non-conforming products and the number of completed processes corresponding to each non-conforming product, and classifying the non-conforming products as repaired products or defective products according to a process number threshold;

[0009] A completion rate analysis module, wherein the completion rate analysis module includes summing the total amount of repaired products and the actual amount of qualified products completed to obtain the comprehensive product completion amount, and once again obtaining the completion rate through the comprehensive product completion amount and the planned completion product amount;

[0010] The display content feedback module includes displaying the completion rate obtained for the second time through the kanban board, comparing it with the planned completion rate threshold, and making corresponding feedback on the kanban board according to the comparison result.

[0011] In some embodiments, when the completion rate obtained for the first time is greater than or equal to the planned completion rate threshold, it means that the qualified products actually output by the production order have reached the expected output, and the completion rate is displayed as qualified on the dashboard; when the completion rate obtained for the first time is less than the planned completion rate threshold, the next step of classifying unqualified products is performed through the unqualified product classification module.

[0012] In some embodiments, a nonconforming product is classified as a repaired product or a defective product by:

[0013] Based on the comparison between the number of completed processes of each unqualified product and the process number threshold, when the number of completed processes of the unqualified product is greater than or equal to the process number threshold, it means that the unqualified product is a nearly finished product and only needs a small amount of process repair to become qualified, and is classified as a repaired product; when the number of completed processes of the unqualified product is less than the process number threshold, it means that the unqualified product is a defective product with insufficient completion and should be scrapped or require a lot of time to repair.

[0014] In some embodiments, the defective product classification module also includes setting an adjustable threshold, and the adjustable threshold is less than the planned completion rate threshold. The adjustable threshold is used to compare the completion rate obtained for the first time with the adjustable threshold when the completion rate obtained for the first time cannot reach the planned completion rate threshold. When the completion rate obtained for the first time reaches the adjustable threshold, the system will perform the next step of defective product classification through the defective product classification module.

[0015] In some embodiments, the range between the adjustable threshold and the planned completion rate threshold is divided into N adjustable levels, and the adjustable level of the corresponding level is configured according to the completion rate obtained for the first time. The system can adjust the process number threshold according to the adjustable level of the corresponding level, and determine the classification of defective products according to the adjusted process number threshold.

[0016] In some embodiments, the specific method of adjusting the process number threshold M is: combining the process number threshold M with the corresponding adjustable level L to obtain the adjusted process number threshold ,in, Indicates Levels of adjustable grades.

[0017] In some embodiments, the completion rate obtained for the first time is inversely proportional to its corresponding adjustable level, which means that the lower the completion rate obtained for the first time, the higher the threshold of the number of process steps after adjustment, and the stricter the requirements for classifying unqualified products into repair products.

[0018] In some embodiments, after comparing the second completion rate with the planned completion rate threshold, if the second completion rate is less than the planned completion rate threshold, the system will feedback on the kanban board that the workshop's production does not meet the expected production plan, and the management personnel should respond immediately; if the second completion rate is greater than or equal to the planned completion rate threshold, the system will feedback on the kanban board that the workshop's production meets the expected production plan.

[0019] The present invention also provides the following technical solution: a method for displaying the completion rate of a production workshop, the method comprising the following steps:

[0020] Obtain the total number of products planned to be produced in the production order and the number of processes used to produce each product to obtain the number of unqualified products and the number of completed processes. After the production order is completed, the completion rate is obtained by combining the actual number of qualified products completed with the planned number of completed products. When the completion rate is less than the planned completion rate threshold, the unqualified products are classified;

[0021] Obtain the total amount of unqualified products and the number of completed processes corresponding to each unqualified product, and classify the unqualified products as repaired products or defective products according to the process number threshold;

[0022] The total amount of repaired products and the actual amount of qualified products completed are added together to obtain the comprehensive product completion amount, and the completion rate is once again obtained by the comprehensive product completion amount and the planned completion product amount;

[0023] The completion rate obtained for the second time is displayed on the dashboard and compared with the planned completion rate threshold. Corresponding feedback is given on the dashboard based on the comparison results.

[0024] The present invention further provides a computer-readable storage medium, wherein the computer-readable storage medium stores a computer program, and the computer program is executed by a processor to implement the above-mentioned method for displaying the completion rate of a production workshop.

[0025] Compared with the prior art, the technical solution provided by the present invention has the following beneficial effects:

[0026] First, the present invention can include products that need a small amount of repair into the completion rate. By identifying and displaying these nearly completed products, resources can be allocated more quickly for repair, reducing rework time, and providing a more comprehensive progress reflection through the display board. Although these products are not yet fully qualified, their processes are nearly completed. Through the calculation of the two completion rates, a more comprehensive production completion status assessment is provided.

[0027] Secondly, the present invention sets up adjustable levels for identifying production batches that require a large number of repairs, so as to dynamically adjust the different degrees of completion of different products and the different tolerances of orders for completion rates. Standards that meet their specific needs can be set for each order, reducing the backlog of processes and extended repair time caused by repair products.

[0028] Thirdly, the present invention can display the completion rate, proportion of repaired products and whether the threshold requirements are met in a graphical and digital manner through the dashboard, and record all completion rate and threshold comparison data. Operators in the production workshop can monitor the production progress and quality indicators in real time, so as to quickly identify and solve problems. BRIEF DESCRIPTION OF THE DRAWINGS

[0029] Figure 1 This is a module schematic diagram of an intelligent kanban system for displaying the completion rate of a production workshop according to the present invention;

[0030] Figure 2 The present invention is a schematic diagram of the steps of a method for displaying the completion rate of a production workshop. DETAILED DESCRIPTION

[0031] 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.

[0032] It is to be understood that the term "one" should be understood as "at least one" or "one or more", that is, in one embodiment, the number of an element may be one, while in another embodiment, the number of the element may be multiple, and the term "one" should not be understood as a limitation on the quantity.

[0033] See also Figure 1 , the present invention provides an intelligent kanban system for displaying the completion rate of a production workshop, the system comprising a data acquisition module, a defective product classification module, a completion rate analysis module and a display content feedback module;

[0034] The data acquisition module includes acquiring the total number of products planned to be produced in the production order and the number of processes used to produce each product. After the production order is completed, the completion rate is obtained by combining the actual number of qualified products completed with the planned number of completed products. When the completion rate obtained for the first time is greater than or equal to the planned completion rate threshold, it means that the qualified products actually output by the production order have reached the expected output, and the completion rate can be displayed as qualified in the production management dashboard. When the completion rate obtained for the first time is less than the planned completion rate threshold, unqualified products that have not completed all processes in production are classified;

[0035] The unqualified product classification module includes obtaining the total amount of unqualified products and the number of completed processes corresponding to each unqualified product, setting a process number threshold M, and classifying the unqualified products into repaired products and defective products based on the comparison between the number of completed processes of each unqualified product and the process number threshold M. For example, the planned completed product quantity in the production order is 100 pieces, the number of processes used to produce each product is 10, the planned completion rate threshold is 90%, and the actual number of qualified products completed is 85 pieces, that is, the completion rate obtained for the first time is 85%, which cannot meet the standard of the planned completion rate threshold of 90%. At this time, the total number of unqualified products is 15, of which 10 unqualified products have been processed to the 5th process, and the other 5 unqualified products have been processed to the 8th process. The process number threshold M is set to 7, that is, 10 unqualified products have completed process numbers less than the process number threshold, and 5 unqualified products have completed process numbers greater than or equal to the process number threshold. Therefore, the 10 unqualified products less than the process number threshold are marked as defective products, and the 5 unqualified products greater than or equal to the process number threshold are marked as repair products, which means that these 5 unqualified products are nearly finished products. Such products cannot be directly scrapped in actual production, and only need a small number of process repairs to pass.

[0036] The completion rate analysis module includes summing the total amount of repaired products and the actual amount of qualified products completed to obtain the comprehensive product completion amount. and planned product volume Once again, we get the completion rate , according to the total number of repaired products is 5, since the actual number of qualified products completed is 85, the sum of the two can get the comprehensive product completion quantity is 90, combined with the set planned completion quantity of 100, it can be concluded that the second completion rate is 90%;

[0037] The display content feedback module includes displaying the completion rate obtained for the second time through a kanban board, and comparing it with the planned completion rate threshold. Combined with the above example, since the completion rate obtained for the second time is 90%, it meets the standard of setting the planned completion rate threshold of 90%. The system can feedback the workshop's expected production plan in this production completion order in the kanban board. If the completion rate obtained for the second time is less than the planned completion rate threshold, the system will feedback the workshop's production this time in the kanban board that it does not meet the expected production plan. The management personnel should respond immediately and conduct an in-depth analysis of the production process to find out the root cause of the lower-than-expected completion rate and adjust the production plan and resource allocation.

[0038] More specifically, the system also needs to set an adjustable threshold, which is less than the planned completion rate threshold. The adjustable threshold is used to compare the first completion rate with the adjustable threshold when the first completion rate cannot reach the planned completion rate threshold. When the first completion rate reaches the adjustable threshold, the system will perform the next step of unqualified product classification. If the first completion rate also fails to reach the adjustable threshold, the system can directly determine that the output of the product produced this time does not meet the production plan and directly give feedback in the kanban. This is done to avoid too many repair products in a production order. Although the unqualified products classified as repair products are nearly finished products, the repair process and time required are less, but the production of a large number of repair products also means that the process stacking and repair time are significantly increased, and it indicates that there are systemic problems in the entire production process. After the completion rate is obtained for the first time, directly giving feedback to the management personnel through the kanban can help the management personnel take timely measures to deal with it during the production process, and reduce the time and resource waste caused by a large number of repair products.

[0039] After the completion rate of the product is obtained for the first time, when the completion rate fails to reach the planned completion rate threshold but reaches the adjustable threshold, it is necessary to compare the number of processes completed by each unqualified product with the process number threshold M, so as to classify the repaired products and defective products. The repaired products and defective products essentially represent unqualified products that need to be repaired with different process numbers. The smaller the difference between the completion rate obtained for the first time and the planned completion rate threshold, the fewer the number of unqualified products and the fewer the repaired products that need to be processed later. However, the larger the difference between the completion rate obtained for the first time and the planned completion rate threshold, the more the number of unqualified products and the more the repaired products that need to be processed later. In order to further avoid the situation where a large number of repaired products may need to be processed later and waste production time resources, N adjustable levels are divided in the range between the adjustable threshold and the planned completion rate threshold, and the corresponding adjustable level is configured according to the completion rate obtained for the first time, and the system can adjust the process number threshold M according to the corresponding adjustable level.

[0040] The specific method for adjusting the process number threshold M is as follows: combining the process number threshold M with the corresponding adjustable level L to obtain the adjusted process number threshold ,in, Indicates For example, if the planned completion rate threshold is set to 90%, the adjustable threshold is set to 75%, and the adjustable level is set to 3 levels, namely:

[0041] The first adjustable level corresponds to the completion rate [ ;

[0042] The second level is adjustable, and the corresponding completion rate is [ ;

[0043] There are three adjustable levels, and the corresponding completion rate is [ ;

[0044] According to the above content, we can take the example that the planned completed product quantity in the production order is 100 pieces, and the total number of unqualified products is 20 pieces. Then the first completion rate is 80%, which falls within the range of the second-level adjustable level. The process number threshold is set to 7. The adjusted process number threshold is 7+ (2-1) = 8. At this time, unqualified products with less than 8 completed process steps should be classified as defective products. When the total number of unqualified products is 22 pieces, the first completion rate is 78%, which falls within the range of the third-level adjustable level. At this time, unqualified products with less than 9 completed process steps should be classified as defective products. The smaller the completion rate obtained for the first time, the larger the corresponding adjustable level, which means that the requirements for classifying unqualified products into repair products are more stringent.

[0045] In the smart kanban system, the completion rate, proportion of repaired products and whether the threshold requirements are met should be displayed in a graphical and digital way. This can be achieved through progress bars, pie charts or bar charts, and all completion rate and threshold comparison data should be recorded for managers to analyze long-term trends and problems in the production process. Through process analysis of unqualified products, bottlenecks or links that need improvement in the production process can be identified to promote continuous improvement. Through clear data display, managers can make more accurate decisions based on the data and avoid errors caused by subjective judgment.

[0046] In general, the present invention aims to design an intelligent kanban system for displaying the completion rate of a production workshop, which is used to include products that can be repaired in a small amount into the completion rate and display them on the kanban, so that the production progress can be more comprehensively reflected by displaying the kanban. By obtaining the number of production process steps of unqualified products, the specific number of nearly completed products among the unqualified products can be understood. This not only includes qualified products, but also considers those products that can be qualified after a small amount of repair, so that the completion rate is closer to the actual production completion rate. At the same time, by identifying and displaying products that require a small amount of repair, production management can allocate resources more efficiently and give priority to these products to improve the overall completion rate. The setting of adjustable thresholds and adjustable levels can also timely feedback the situation of a large number of repaired products during the production process, avoid the accumulation of problems to a stage that is difficult to handle, thereby reducing production bottlenecks, and can timely feedback production abnormalities when a large number of repaired products exist. By classifying unqualified products, defective products and repaired products can be quickly identified, helping workshops to better manage and handle unqualified products in production. The identification of repaired products helps to take targeted measures to reduce unnecessary scrap and waste.

[0047] See also Figure 2 The present invention also provides a method for displaying the completion rate of a production workshop, the method comprising the following steps:

[0048] Obtain the total number of products planned to be produced in the production order and the number of production processes used for each product. After the production order is completed, the completion rate is obtained by combining the actual number of qualified products completed with the planned number of completed products.

[0049] Obtain the total amount of unqualified products and the number of completed processes corresponding to each unqualified product, and classify the unqualified products as repaired products or defective products according to the process number threshold;

[0050] The total amount of repaired products and the actual amount of qualified products completed are added together to obtain the comprehensive product completion amount, and the completion rate is once again obtained by the comprehensive product completion amount and the planned completion product amount;

[0051] The completion rate obtained for the second time is displayed on the dashboard and compared with the planned completion rate threshold. Corresponding feedback is given on the dashboard based on the comparison results.

[0052] The embodiments disclosed in the present invention, the process described above with reference to the flowchart can be implemented as a computer software program. The embodiments disclosed in the present invention include a computer program product, which includes a computer program carried on a computer-readable medium, and the computer program contains a program code for executing the method shown in the flowchart. In such an embodiment, the computer program can be downloaded and installed from the network through the communication part, and / or installed from a removable medium. When the computer program is executed by the central processing unit, the above functions defined in the method of the present application are executed. It should be noted that the computer-readable medium mentioned above in the present application can be a computer-readable signal medium or a computer-readable storage medium or any combination of the above two. The computer-readable storage medium can be, for example, but not limited to, a system, device or device of an electrical, magnetic, optical, electromagnetic, infrared segment, or semiconductor, or any combination of the above. More specific examples of computer-readable storage media can include, but are not limited to: an electrical connection with one or more wire segments, a portable computer disk, a hard disk, a random access memory, a read-only memory, an erasable programmable read-only memory, an optical fiber, a portable compact disk read-only memory, an optical storage device, a magnetic storage device, or any suitable combination of the above. In the present application, a computer-readable storage medium may be any tangible medium containing or storing a program that can be used by or in combination with an instruction execution system, apparatus, or device. In the present application, a computer-readable signal medium may include a data signal propagated in a baseband or as part of a carrier wave, which carries a computer-readable program code. Such propagated data signals may take a variety of forms, including but not limited to electromagnetic signals, optical signals, or any suitable combination of the above. A computer-readable signal medium may also be any computer-readable medium other than a computer-readable storage medium, which may send, propagate, or transmit a program for use by or in combination with an instruction execution system, apparatus, or device. The program code contained on the computer-readable medium may be transmitted using any suitable medium, including but not limited to: wireless segments, wire segments, optical cables, RF, etc., or any suitable combination of the above.

[0053] The flow chart and block diagram in the accompanying drawings illustrate the possible architecture, function and operation of the system, method and computer program product according to various embodiments of the present invention. In this regard, each square box in the flow chart or block diagram can represent a module, a program segment or a part of a code, and the module, the program segment or a part of the code contains one or more executable instructions for realizing the specified logical function. It should also be noted that in some alternative implementations, the functions marked in the square box can also occur in a sequence different from that marked in the accompanying drawings. For example, two square boxes represented in succession can actually be executed substantially in parallel, and they can sometimes be executed in the opposite order, depending on the functions involved. It should also be noted that each square box in the block diagram and / or flow chart, and the combination of the square boxes in the block diagram and / or flow chart can be implemented with a dedicated hardware-based system that performs the specified function or operation, or can be implemented with a combination of dedicated hardware and computer instructions.

[0054] Those skilled in the art should understand that the above description is only a specific implementation mode of the present application, but the protection scope of the present application is not limited thereto. Any technician familiar with the technical field can easily think of changes or substitutions within the technical scope disclosed in the present application, which should be covered by the protection scope of the present application.

Claims

1. An intelligent kanban system for displaying the completion rate of a production workshop, characterized in that: include: A data acquisition module, wherein the data acquisition module includes acquiring the total number of products planned to be produced in the production order and the number of processes used to produce each product, so as to obtain the number of unqualified products and the number of completed processes. After the production order is completed, the completion rate is obtained by combining the actual number of qualified products completed with the planned number of completed products. When the completion rate is less than the planned completion rate threshold, the unqualified products are classified; A non-conforming product classification module, wherein the non-conforming product classification module includes obtaining the total amount of non-conforming products and the number of completed processes corresponding to each non-conforming product, and classifying the non-conforming products as repaired products or defective products according to a process number threshold; A completion rate analysis module, wherein the completion rate analysis module includes summing the total amount of repaired products and the actual amount of qualified products completed to obtain the comprehensive product completion amount, and once again obtaining the completion rate through the comprehensive product completion amount and the planned completion product amount; The display content feedback module includes displaying the completion rate obtained for the second time through the kanban board, comparing it with the planned completion rate threshold, and making corresponding feedback on the kanban board according to the comparison result.

2. According to claim 1, the intelligent billboard system for displaying the completion rate of a production workshop is characterized in that: When the completion rate obtained for the first time is greater than or equal to the planned completion rate threshold, it means that the actual output of qualified products of the production order has reached the expected output, and the completion rate is shown as qualified in the dashboard; when the completion rate obtained for the first time is less than the planned completion rate threshold, the next step of unqualified product classification operation is performed through the unqualified product classification module.

3. The intelligent billboard system for displaying the completion rate of a production workshop according to claim 2 is characterized in that: The way to classify nonconforming products as repaired or defective is: Based on the comparison between the number of completed processes of each unqualified product and the process number threshold, when the number of completed processes of the unqualified product is greater than or equal to the process number threshold, it means that the unqualified product is a nearly finished product and only needs a small amount of process repair to become qualified, and is classified as a repaired product; when the number of completed processes of the unqualified product is less than the process number threshold, it means that the unqualified product is a defective product with insufficient completion and should be scrapped or require a lot of time to repair.

4. The intelligent billboard system for displaying the completion rate of a production workshop according to claim 1 is characterized in that: The defective product classification module also includes setting an adjustable threshold, and the adjustable threshold is less than the planned completion rate threshold. The adjustable threshold is used to compare the first obtained completion rate with the adjustable threshold when the first obtained completion rate cannot reach the planned completion rate threshold. When the first obtained completion rate reaches the adjustable threshold, the system will perform the next step of defective product classification through the defective product classification module.

5. The intelligent billboard system for displaying the completion rate of a production workshop according to claim 4 is characterized in that: The range between the adjustable threshold and the planned completion rate threshold is divided into N adjustable levels, and the adjustable level of the corresponding level is configured according to the completion rate obtained for the first time. The system can adjust the process number threshold according to the corresponding level of the adjustable level, and determine the classification of defective products according to the adjusted process number threshold.

6. The intelligent billboard system for displaying the completion rate of a production workshop according to claim 5 is characterized in that: The specific method of adjusting the process number threshold M is: combining the process number threshold M with the corresponding adjustable level L to obtain the adjusted process number threshold ,in, Indicates Levels of adjustable grades.

7. The intelligent billboard system for displaying the completion rate of a production workshop according to claim 6 is characterized in that: The completion rate obtained for the first time is inversely proportional to its corresponding adjustable level, which means that the lower the completion rate obtained for the first time, the higher the threshold of the number of process steps after adjustment, and the more stringent the requirements for classifying unqualified products into repair products.

8. The intelligent billboard system for displaying the completion rate of a production workshop according to claim 1 is characterized in that: After comparing the second completion rate with the planned completion rate threshold, if the second completion rate is less than the planned completion rate threshold, the system will feedback in the dashboard that the workshop's production does not meet the expected production plan, and the management personnel should respond immediately; If the second completion rate is greater than or equal to the planned completion rate threshold, the system will feedback on the kanban that the workshop's production is in line with the expected production plan.

9. A method for displaying the completion rate of a production workshop, characterized in that: Based on the intelligent kanban system for displaying the completion rate of a production workshop according to any one of claims 1 to 8, the method comprises the following steps: Obtain the total number of products planned to be produced in the production order and the number of processes used to produce each product to obtain the number of unqualified products and the number of completed processes. After the production order is completed, the completion rate is obtained by combining the actual number of qualified products completed with the planned number of completed products. When the completion rate is less than the planned completion rate threshold, the unqualified products are classified; Obtain the total amount of unqualified products and the number of completed processes corresponding to each unqualified product, and classify the unqualified products as repaired products or defective products according to the process number threshold; The total amount of repaired products and the actual amount of qualified products completed are added together to obtain the comprehensive product completion amount, and the completion rate is once again obtained by the comprehensive product completion amount and the planned completion product amount; The completion rate obtained for the second time is displayed on the dashboard and compared with the planned completion rate threshold. Corresponding feedback is given on the dashboard based on the comparison results.

10. A computer-readable storage medium, characterized in that: The computer-readable storage medium stores a computer program, and the computer program is executed by a processor to implement the method for displaying the completion rate of a production workshop as described in claim 9 above.

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