Production plan management method suitable for multi-variety discrete manufacturing

Abstract

The invention belongs to the technical field of production plan management methods suitable for multi-variety discrete manufacturing, and particularly relates to a production plan management method suitable for multi-variety discrete manufacturing, which comprises the following steps: market investigation and demand prediction: collecting information such as industry dynamics, market trends, customer demand changes and the like; according to the method, quantitative and qualitative analysis methods such as time sequence analysis, regression analysis and Delphi method are applied to predict product demands in a period of time in the future to determine a production plan and time arrangement of each product, and historical data is utilized to predict future demands, so that a corresponding production plan is formulated, and the production efficiency is improved. All materials and parts required for producing each product are listed, the required material quantity and purchase time are calculated based on a production plan MPS and a bill of material BOM, production tasks are allocated to each production unit or equipment, production resources such as the machine module and the manpower module are reasonably allocated, and possible bottle necks in the production process are identified.

Description

Technical Field

[0001] The invention belongs to the technical field of production management, and in particular is a production planning management method suitable for multi-variety discrete manufacturing. Background Art

[0002] The selection of production planning strategy is one of the most important factors in production management. In manufacturing home textile enterprises that are mainly engaged in production and manufacturing, product quality control, on-site data collection, and workshop production planning are the core concerns of such enterprises. At the same time, the importance of customer needs in the product production process is increasing, and the inevitable process characteristics and costs of the production process prompt researchers and process personnel to choose the correct production planning strategy by managing orders. Therefore, the present invention focuses on the production planning problem of process manufacturing industry, which belongs to the field of process manufacturing intelligent production system. As an important research content of smart factory, intelligent production planning must take into account the production, scheduling, logistics and management of the entire enterprise.

[0003] However, operators in each process receive production instructions, work reports and abnormal feedback through paper and telephone transmission, and the information flow is extremely blocked. Production orders from supporting factories are prone to overdue or delayed completion, which directly affects the production efficiency of the next process. Due to the complexity of manual operations, poor information flow, excess or insufficient inventory, there is often a problem of low material management efficiency, and the acquisition of information is inaccurate and delayed. Summary of the invention

[0004] In order to make up for the deficiencies of the prior art, at least one technical problem raised in the background technology is solved.

[0005] The technical solution adopted by the present invention to solve the technical problem is: a production planning management method suitable for multi-variety discrete manufacturing described in the present invention comprises the following steps:

[0006] S1: Market research and demand forecasting, collect information on industry dynamics, market trends, changes in customer demand, etc., and use quantitative and qualitative analysis methods, such as time series analysis, regression analysis, Delphi method, etc., to forecast product demand in the future;

[0007] S2: Determine the production plan and schedule for each product, using historical data to predict future demand, so as to formulate a corresponding production plan, list all materials and components required to produce each product, and calculate the required material quantity and procurement time based on the production plan (MPS) and bill of materials (BOM);

[0008] S3: Allocate production tasks to various production units or equipment, reasonably allocate production resources, such as the machine module and manpower module, identify possible bottlenecks in the production process, and optimize;

[0009] S4: Evaluate existing production capacity to ensure that it meets demand, regularly maintain and upgrade equipment, and adjust production line configuration and capacity based on changes in demand;

[0010] S5: Use a production data collection system, such as the manufacturing execution system (MES), to obtain production data in real time, monitor progress and performance, analyze real-time data, identify progress deviations, and take corrective measures in a timely manner;

[0011] S6: Use safety stock, economic order quantity (EOQ) and periodic ordering system to manage inventory levels, monitor and optimize inventory turnover, reduce holding costs and expiration risks, and classify inventory such as ABC classification to more effectively control different categories of inventory;

[0012] S7: Clarify quality standards and objectives, including product performance, reliability and compliance requirements, and implement control measures during the production process to ensure that each link meets quality standards, such as using control charts to monitor key parameters in the production process;

[0013] S8: Integrate the resources and business processes of various departments of the enterprise to realize information sharing and business automation for real-time monitoring and control of the production process, optimize production scheduling, improve production efficiency and quality, manage customer information, sales activities and after-sales services as described, and enhance customer relationships and market competitiveness.

[0014] The specific steps of demand forecasting in S1 include:

[0015] S11: Collect information on industry dynamics, market trends, changes in customer demand, and use quantitative and qualitative analysis methods, such as time series analysis, regression analysis, and Delphi method, to predict product demand in the future;

[0016] S12: Establish an efficient order receiving and processing system to ensure that customer orders are accurately and timely entered into the production planning management system;

[0017] S13: Classify and prioritize orders, and determine the production sequence based on factors such as order urgency and customer importance;

[0018] S14: Maintain close communication with customers, provide timely feedback on order progress and possible extensions, and improve customer satisfaction.

[0019] The specific optimization of the production progress control in S5 includes: (1) production operation monitoring (2) abnormal situation handling (3) production progress adjustment.

[0020] The production operation monitoring (1) includes establishing a production progress tracking system to monitor the execution of production tasks in real time, including the production quantity, progress percentage, and process completion time, and using visual tools such as the production board, electronic display screen, etc. to display production progress information, so that management personnel and production personnel can understand the production status in a timely manner.

[0021] The abnormal situation handling (2) formulates an abnormal situation handling process to promptly handle abnormal situations such as equipment failure, quality problems, material shortages, etc. that occur during the production process. The emergency response mechanism is established and temporary measures are taken, such as adjusting production plans and allocating resources, to ensure the continuity of production.

[0022] The production schedule adjustment (3) is to timely adjust the production schedule according to the actual production situation and demand changes, maintain close communication with the sales, procurement, production and other departments, coordinate resources from all parties, and ensure the smooth implementation of the production plan.

[0023] The specific method of quality management in S7 is:

[0024] S71: Determine quality objectives Based on the company's strategic objectives and customer needs, determine product quality, including the technical standards, process standards, inspection standards, etc., and formulate a quality control plan based on the product's production process and quality requirements, and set quality control points in key processes;

[0025] S72: Inspect incoming materials such as raw materials and parts to ensure that they meet quality requirements and confirm whether the process parameters are correct; conduct inspections during the production process to promptly discover and correct quality problems in production; conduct final inspections at the end of production to ensure that the last product meets quality requirements and design requirements; test product performance to ensure that it meets usage requirements; and inspect product packaging to ensure that the packaging is intact and the labels are clear;

[0026] S73: Use the arrangement diagram to find out the main reasons, such as equipment failure, unreasonable process, etc.; take corresponding measures to solve the main reasons. In order to address the problem of low first-time qualified rate of products, set up a quality improvement project team, formulate an improvement plan, and improve the first-time qualified rate of products through measures such as optimizing processes, strengthening training, and improving equipment. Conduct an internal audit once a year to check all aspects of the quality management system, and promptly rectify problems found; and accept external audits regularly.

[0027] The specific method of ABC classification in S6 is:

[0028] Category A items: Category A items should be strictly controlled in terms of inventory, usually accounting for about 70% of the total inventory value, with regular inventory checks, accurate demand forecasts, and shortened order lead times;

[0029] Category B items: For category B items, a moderate inventory control strategy can be adopted, such as regular ordering and appropriate safety stock, which accounts for about 20% of the total inventory value;

[0030] Category C items: A more relaxed inventory control strategy can be adopted for category C items, such as bulk purchasing and a higher safety stock of about 10% of the total inventory value.

[0031] The method of establishing a matching component order according to the component information of the production plan and sending it to the matching workshop and allocating the production order according to the matching component order includes:

[0032] Read the supporting parts order information, and establish the supporting parts order according to the material information and process path attached to the supporting parts order information;

[0033] The supporting parts orders are sent to each supporting workshop. The workshop planner allocates the production orders by allocating work centers. The production staff performs production and manufacturing at the work centers according to the production orders.

[0034] Provide visual reports and charts to intuitively display production data and analysis results, helping managers make decisions;

[0035] Integrate with the Manufacturing Execution System (MES) to obtain real-time data from the production site and achieve refined management of the production process;

[0036] Conduct inspections when processing the first product to confirm whether the process parameters are correct; conduct inspections during the production process to promptly discover and correct quality problems in production; conduct final inspections at the end of production to ensure that the last product meets quality requirements;

[0037] After the final process is completed, the parts that have been produced and processed are off the production line, and the first inspection ticket is generated for on-site inspection and confirmation. Production is reported and the warehouse entry ticket is printed based on the actual warehouse quantity.

[0038] The beneficial effects of the present invention are as follows:

[0039] 1. The present invention can realize the digital and intelligent management of discrete manufacturing by establishing a complete production plan management system, data analysis and decision support system, information infrastructure and information security management mechanism, and at the same time establish a complete quality management system to ensure that product quality meets the requirements and improve the competitiveness of the enterprise, so that it can cope with both small batch production mode and large batch production mode, improve the adaptability and executability of the production plan, and ensure the smooth implementation of the production plan.

[0040] 2. The present invention can provide relevant information of current accessory management by acquiring real-time accessory management data, such as the quality and classification of accessories, providing basic data for subsequent accessory management and analysis. The acquisition of real-time monitoring images of accessories can provide intuitive visual information on the appearance and location of accessories, helping with subsequent accessory analysis and processing.

[0041] 3. The present invention reduces sales losses, customer churn, and the costs of emergency procurement and production adjustments due to out-of-stock situations through accurate demand forecasting and inventory control, and reduces risk reserves. A certain amount of inventory can cope with the risk of supply interruptions caused by supplier delivery delays, quality problems or other force majeure factors, and promote information construction. Inventory management requires the use of advanced information technology, such as inventory management software, barcode technology, etc., which helps promote the information construction of enterprises and improve management efficiency and accuracy. BRIEF DESCRIPTION OF THE DRAWINGS

[0042] The present invention will be further described below in conjunction with the accompanying drawings.

[0043] Figure 1 This is a conceptual flow chart of a production planning management method applicable to multi-variety discrete manufacturing of the present invention.

[0044] Figure 2 This is a quality management flow chart of a production planning management method suitable for multi-variety discrete manufacturing of the present invention.

[0045] Figure 3 It is an execution flow chart of a production planning management method suitable for multi-variety discrete manufacturing of the present invention. DETAILED DESCRIPTION

[0046] In order to make the technical means, creative features, objectives and effects achieved by the present invention easy to understand, the present invention is further explained below in conjunction with specific implementation methods.

[0047] Embodiment 1: Figure 1 As shown, the embodiment of the present invention includes the following steps:

[0048] S1: Market research and demand forecasting, collect information on industry dynamics, market trends, changes in customer demand, etc., and use quantitative and qualitative analysis methods, such as time series analysis, regression analysis, Delphi method, etc., to forecast product demand in the future;

[0049] S2: Determine the production plan and schedule for each product, use historical data to predict future demand, and then develop a corresponding production plan, list all the materials and components required to produce each product, and calculate the required material quantity and procurement time based on the production schedule (MPS) and bill of materials (BOM);

[0050] S3: Allocate production tasks to various production units or equipment, reasonably allocate production resources, such as machine modules and human resources modules, identify possible bottlenecks in the production process, and optimize them;

[0051] S4: Evaluate existing production capacity to ensure that it meets demand, regularly maintain and upgrade equipment, and adjust production line configuration and capacity based on changes in demand;

[0052] S5: Use production data collection systems, such as manufacturing execution systems (MES), to obtain production data in real time, monitor progress and performance, analyze real-time data, identify progress deviations, and take corrective measures in a timely manner;

[0053] S6: Use safety stock, economic order quantity (EOQ) and periodic ordering systems to manage inventory levels, monitor and optimize inventory turnover, reduce holding costs and expiration risks, and classify inventory such as ABC classification to more effectively control different categories of inventory;

[0054] S7: Define quality standards and objectives, including product performance, reliability and compliance requirements, and implement control measures during the production process to ensure that each link meets quality standards, such as using control charts to monitor key parameters in the production process;

[0055] S8: Integrate the resources and business processes of various departments of the enterprise to realize information sharing and business automation for real-time monitoring and control of the production process, optimize production scheduling, improve production efficiency and quality, such as managing customer information, sales activities and after-sales services, and enhancing customer relationships and market competitiveness.

[0056] By establishing an efficient order receiving and processing system, we ensure that order information is accurately and timely entered into the production planning management system, and classify and prioritize orders. We determine the production sequence based on factors such as the urgency of the order and the importance of the customer. At the same time, based on the order receiving information, we formulate a production plan that takes into account the constraints of production capacity, material supply and equipment status, and dynamically track and adjust material requirements to ensure the timeliness and accuracy of material supply. Subsequently, based on the production operation plan and the status of resources such as equipment and personnel, we calculate the capacity requirements required for production, and continuously monitor and optimize production capacity to improve production efficiency and resource utilization. We use visual tools to facilitate management personnel and production personnel to understand production in a timely manner. status, formulate abnormal situation handling procedures, and promptly handle abnormal situations such as equipment failure, quality problems, material shortages, etc. that occur during the production process. At the same time, according to the actual production situation and changes in demand, timely adjust the production schedule, formulate product quality goals and quality plans in component production, clarify the focus and key links of quality control, establish quality inspection standards and inspection processes, and ensure that product quality meets the requirements. The overall information-based management collects and analyzes various data in the production process, such as production progress, quality data, inventory data, etc., to provide decision support for production planning management, use data mining, artificial intelligence and other technologies to analyze historical data, predict future production trends and demand changes, and optimize production plans.

[0057] The specific steps of demand forecasting in S1 include:

[0058] S11: Collect information on industry dynamics, market trends, changes in customer demand, and use quantitative and qualitative analysis methods, such as time series analysis, regression analysis, and Delphi method, to predict product demand in the future;

[0059] S12: Establish an efficient order receiving and processing system to ensure that customer orders are accurately and timely entered into the production planning management system;

[0060] S13: Classify and prioritize orders, and determine the production sequence based on factors such as order urgency and customer importance;

[0061] S14: Maintain close communication with customers, provide timely feedback on order progress and possible extensions, and improve customer satisfaction.

[0062] The specific optimization of production progress control in S5 includes: 1. Production operation monitoring 2. Abnormal situation handling 3. Production progress adjustment.

[0063] Production operation monitoring 1 includes establishing a production progress tracking system to monitor the execution of production tasks in real time, including production quantity, progress percentage, process completion time, and using visual tools such as production boards, electronic display screens, etc. to display production progress information, so that managers and production personnel can understand the production status in a timely manner.

[0064] Abnormal situation handling 2. Develop an abnormal situation handling process to promptly handle abnormal situations such as equipment failure, quality problems, material shortages, etc. that occur during the production process, establish an emergency response mechanism, and take temporary measures such as adjusting production plans and allocating resources to ensure the continuity of production.

[0065] Production schedule adjustment 3 Adjust the production schedule in a timely manner according to the actual production situation and demand changes, maintain close communication with sales, procurement, production and other departments, coordinate resources from all parties, and ensure the smooth implementation of the production plan

[0066] Example 2 Figure 2 The specific methods of quality management in S7 are shown as follows:

[0067] S71: Determine quality objectives Based on the company's strategic objectives and customer needs, determine product quality, including technical standards, process standards, inspection standards, etc., and formulate quality control plans based on the product's production process and quality requirements, and set quality control points in key processes;

[0068] S72: Inspect incoming materials such as raw materials and parts to ensure that they meet quality requirements and confirm whether the process parameters are correct; conduct inspections during the production process to promptly discover and correct quality problems in production; conduct final inspections at the end of production to ensure that the last product meets quality requirements and design requirements; test product performance to ensure that it meets usage requirements; and inspect product packaging to ensure that the packaging is intact and the labels are clear;

[0069] S73: Use the arrangement diagram to find out the main reasons, such as equipment failure, unreasonable process, etc.; take corresponding measures to solve the main reasons. In view of the low first-time qualified rate of products, set up a quality improvement project team, formulate an improvement plan, and improve the first-time qualified rate of products through measures such as optimizing processes, strengthening training, and improving equipment. Conduct an internal audit every year to check all aspects of the quality management system, and promptly rectify problems found. Regularly accept external audits,

[0070] Example 3 Figure 3As shown, according to the supporting parts information of the production plan, a supporting parts order is established and issued to the supporting workshop, and the production order is allocated according to the supporting parts order, including: reading the supporting parts order information, and establishing the supporting parts order according to the material information and process path issued by the supporting parts order information; the supporting parts order is issued to each supporting workshop, and the workshop planner allocates the production order by allocating the work center, and the production personnel carry out production and manufacturing on the work center according to the production order; providing visual reports and charts to intuitively display the production data and analysis results to help managers make decisions; integrating with the manufacturing execution system MES to obtain real-time data from the production site and realize the refined management of the production process; inspecting when processing the first product to confirm whether the process parameters are correct; conducting inspections during the production process to promptly discover and correct quality problems in production; conducting final inspections at the end of production to ensure that the last product meets the quality requirements; after the final process is completed, the parts that have completed production and processing are offline, and the first inspection ticket is generated for on-site inspection and confirmation, and production reporting and printing of the entry ticket are carried out according to the actual warehousing quantity.

[0071] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. For those skilled in the art, the present invention may have various modifications and variations. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present invention shall be included in the protection scope of the present invention.

Claims

1. A production planning management method suitable for multi-variety discrete manufacturing, characterized by: The following steps are involved: S1: Market research and demand forecasting, collect information on industry dynamics, market trends, changes in customer demand, etc., and use quantitative and qualitative analysis methods, such as time series analysis, regression analysis, Delphi method, etc., to forecast product demand in the future; S2: Determine the production plan and schedule for each product, using historical data to predict future demand, so as to formulate a corresponding production plan, list all materials and components required to produce each product, and calculate the required material quantity and procurement time based on the production plan (MPS) and bill of materials (BOM); S3: Allocate production tasks to various production units or equipment, reasonably allocate production resources, such as the machine module and manpower module, identify possible bottlenecks in the production process, and optimize; S4: Evaluate existing production capacity to ensure that it meets demand, regularly maintain and upgrade equipment, and adjust production line configuration and capacity based on changes in demand; S5: Use a production data collection system, such as the manufacturing execution system (MES), to obtain production data in real time, monitor progress and performance, analyze real-time data, identify progress deviations, and take corrective measures in a timely manner; S6: Use safety stock, economic order quantity (EOQ) and periodic ordering system to manage inventory levels, monitor and optimize inventory turnover, reduce holding costs and expiration risks, and classify inventory such as ABC classification to more effectively control different categories of inventory; S7: Clarify quality standards and objectives, including product performance, reliability and compliance requirements, and implement control measures during the production process to ensure that each link meets quality standards, such as using control charts to monitor key parameters in the production process; S8: Integrate the resources and business processes of various departments of the enterprise to realize information sharing and business automation for real-time monitoring and control of the production process, optimize production scheduling, improve production efficiency and quality, manage customer information, sales activities and after-sales services as described, and enhance customer relationships and market competitiveness.

2. A production planning management method applicable to multi-variety discrete manufacturing according to claim 1, characterized in that: The specific steps of demand forecasting in S1 include: S11: Collect information on industry dynamics, market trends, changes in customer demand, and use quantitative and qualitative analysis methods, such as time series analysis, regression analysis, and Delphi method, to predict product demand in the future; S12: Establish an efficient order receiving and processing system to ensure that customer orders are accurately and timely entered into the production planning management system; S13: Classify and prioritize orders, and determine the production sequence based on factors such as order urgency and customer importance; S14: Maintain close communication with customers, provide timely feedback on order progress and possible extensions, and improve customer satisfaction.

3. The production planning management method applicable to multi-variety discrete manufacturing according to claim 1 is characterized in that: The specific optimization of the production progress control in S5 includes: (1) production operation monitoring (2) abnormal situation handling (3) production progress adjustment.

4. The production planning management method applicable to multi-variety discrete manufacturing according to claim 3 is characterized in that: The production operation monitoring (1) includes establishing a production progress tracking system to monitor the execution of production tasks in real time, including the production quantity, progress percentage, process completion time, and using visual tools, such as the production board, electronic display screen, etc., to display production progress information, so that management personnel and production personnel can understand the production status in a timely manner.

5. The production planning management method applicable to multi-variety discrete manufacturing according to claim 3 is characterized in that: The abnormal situation handling (2) formulates an abnormal situation handling process to promptly handle abnormal situations such as equipment failure, quality problems, material shortages, etc. that occur during the production process. The emergency response mechanism is established and temporary measures are taken, such as adjusting production plans and allocating resources, to ensure the continuity of production.

6. The production planning management method applicable to multi-variety discrete manufacturing according to claim 3 is characterized in that: The production schedule adjustment (3) is to timely adjust the production schedule according to the actual production situation and demand changes, maintain close communication with the sales, procurement, production and other departments, coordinate resources from all parties, and ensure the smooth implementation of the production plan.

7. The production planning management method applicable to multi-variety discrete manufacturing according to claim 1 is characterized in that: The specific method of quality management in S7 is: S71: Determine quality objectives Based on the company's strategic objectives and customer needs, determine product quality, including the technical standards, process standards, inspection standards, etc., and formulate a quality control plan based on the product's production process and quality requirements, and set quality control points in key processes; S72: Inspect incoming materials such as raw materials and parts to ensure that they meet quality requirements and confirm whether the process parameters are correct; conduct inspections during the production process to promptly discover and correct quality problems in production; conduct final inspections at the end of production to ensure that the last product meets quality requirements and design requirements; test product performance to ensure that it meets usage requirements; and inspect product packaging to ensure that the packaging is intact and the labels are clear; S73: Use the arrangement diagram to find out the main reasons, such as equipment failure, unreasonable process, etc.; take corresponding measures to solve the main reasons. In order to address the problem of low first-time qualified rate of products, set up a quality improvement project team, formulate an improvement plan, and improve the first-time qualified rate of products through measures such as optimizing processes, strengthening training, and improving equipment. Conduct an internal audit once a year to check all aspects of the quality management system, and promptly rectify problems found; and accept external audits regularly.

8. The production planning management method applicable to multi-variety discrete manufacturing according to claim 7, characterized in that: The specific method of ABC classification in S6 is: Category A items: Category A items should be strictly controlled in terms of inventory, usually accounting for about 70% of the total inventory value, with regular inventory checks, accurate demand forecasts, and shortened order lead times; Category B items: For category B items, a moderate inventory control strategy can be adopted, such as regular ordering and appropriate safety stock, which accounts for about 20% of the total inventory value; Category C items: A more relaxed inventory control strategy can be adopted for category C items, such as bulk purchasing and a higher safety stock of about 10% of the total inventory value.

9. A production planning management method applicable to multi-variety discrete manufacturing according to claim 8, characterized in that: The method of establishing a matching component order according to the component information of the production plan and sending it to the matching workshop and allocating the production order according to the matching component order includes: Read the supporting parts order information, and establish the supporting parts order according to the material information and process path attached to the supporting parts order information; The supporting parts orders are sent to each supporting workshop. The workshop planner allocates the production orders by allocating work centers. The production staff performs production and manufacturing at the work centers according to the production orders. Provide visual reports and charts to intuitively display production data and analysis results, helping managers make decisions; Integrate with the Manufacturing Execution System (MES) to obtain real-time data from the production site and achieve refined management of the production process; Conduct inspections when processing the first product to confirm whether the process parameters are correct; conduct inspections during the production process to promptly discover and correct quality problems in production; conduct final inspections at the end of production to ensure that the last product meets quality requirements; After the final process is completed, the parts that have been produced and processed are off the production line, and the first inspection ticket is generated for on-site inspection and confirmation. Production is reported and the warehouse entry ticket is printed based on the actual warehouse quantity.

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