A material completeness rate detection method, device and SAP system

Abstract

The present invention provides a material completeness detection method, device and SAP system, the method comprising: reading the next production plan from the production schedule table in turn, determining the production time of the production plan; before the set time before the production time, detecting whether the material completeness of the material required for the model and configuration of the vehicle produced by the production plan is greater than the set threshold; if the detection result is yes, detecting whether the incomplete materials are located in the key material list, if none of them are located in the key material list, a work order is issued, and the production plan is started at the production time. The materials required for the current production plan, the required amount of each material and the actual inventory are recorded by the trial production material list BOM, and then the material completeness is automatically calculated, and when the trial production material list BOM is updated, the completeness of the materials required for the corresponding work order number is automatically updated at the same time, which is accurate and real-time, and can be better adapted to the short new product development cycle.

Description

Technical Field

[0001] The invention relates to the technical field of material information, and provides a material completeness rate detection method, device and SAP system. Background Art

[0002] Amid major changes in the automotive industry, major OEMs have launched initiatives to strengthen and supplement their supply chains to ensure delivery to end users.

[0003] Material completeness is to ensure the smooth progress of the assembly process, which requires that all the materials that constitute it are in place at the same time. Otherwise, incomplete materials will cause production to stop and wait for work, wasting manpower and management costs, and affecting production progress.

[0004] The completeness rate of materials required for production vehicles is mostly manually counted offline and published. Manual statistics of material completeness rate result in insufficient information accuracy, delayed information timeliness, and time-consuming and labor-intensive. In addition, as the company's new product development cycle tends to shorten, the existing method of obtaining the completeness rate cannot meet the real-time tracking and management of plans and materials, affecting the progress of project development. Summary of the invention

[0005] In view of this, the present application provides a material uniformity detection method, aiming to improve the above-mentioned problem.

[0006] Specifically, the following technical solutions are included:

[0007] On the one hand, an embodiment of the present application provides a material uniformity detection method, and the method is specifically as follows:

[0008] (1) Read the next production plan from the production schedule table in turn and determine the production time of the production plan;

[0009] (2) Before a set time before the production time, check whether the material consistency rate of the vehicle model and configuration required for the production plan is greater than a set threshold;

[0010] (3) If the test result is yes, check whether the incomplete materials are on the critical materials list. If they are not on the critical materials list, a work order is issued and the production plan is started at production time.

[0011] In some embodiments of the present invention, the method for determining the material uniformity rate is specifically as follows:

[0012] Generate the work order number of the order based on the model and configuration of the vehicle to be produced in the production plan, and build a trial production bill of materials (BOM) for each work order number. The trial production bill of materials (BOM) includes: the work order number of the order, the material name of the material required for the order, the required quantity of each material, the inventory quantity of each material, and the completeness mark;

[0013] When materials are put into storage, determine the work order number of the order corresponding to the material, find the trial production bill of materials BOM corresponding to the work order number, update the inventory quantity of the corresponding material in the trial production bill of materials BOM based on the material name of the current incoming material, and simultaneously update the corresponding material's completeness mark and material completeness rate.

[0014] In some embodiments of the present invention, the updating process of the completeness mark of the material is as follows:

[0015] After the trial production bill of materials BOM is updated, check whether the inventory quantity of each material is greater than or equal to the required quantity. If the test result is yes, mark the completeness flag of the corresponding material as yes, otherwise mark the completeness flag of the corresponding material as no.

[0016] In some embodiments of the present invention, the calculation formula of the material uniformity rate is as follows:

[0017] Count the number of materials n1 with the completeness mark of yes and the number n2 with the completeness mark of no in the trial production material bill BOM, and the material completeness rate Y = n1 / (n1+n2).

[0018] In some embodiments of the present invention, the method for obtaining the material name and required quantity of the material required for the order in the trial production material bill BOM is as follows:

[0019] Based on the model and configuration of the planned production vehicle, the corresponding vehicle bill of materials (BOM) is searched from the database, and the material names and quantities in the vehicle bill of materials (BOM) are imported into the material names and required quantities of the trial production bill of materials (BOM);

[0020] The database stores the vehicle bill of materials (BOM) for all vehicle models and different configurations. The vehicle bill of materials (BOM) includes: the material name and quantity of the materials required for the corresponding vehicle model and configuration.

[0021] In some embodiments of the present invention, after the material names and usage in the vehicle bill of materials BOM are imported into the material names and required quantities of the trial production bill of materials BOM, an association relationship between the vehicle bill of materials BOM and the imported trial production bill of materials BOM is established;

[0022] When the vehicle bill of materials (BOM) in the database is updated, check whether the currently updated vehicle bill of materials (BOM) has an associated trial production bill of materials (BOM). If so, import the material names and quantities in the updated vehicle bill of materials (BOM) into the material names and required quantities of the trial production bill of materials (BOM).

[0023] On the other hand, an embodiment of the present application provides a material uniformity detection device, the device comprising: a data reading unit, a uniformity calculation unit and a processing unit connected in sequence, wherein:

[0024] The data reading unit sequentially reads the next production plan from the production schedule table and determines the production time of the production plan;

[0025] Before the set time before the production time, the completeness rate calculation unit determines the work order number based on the model and configuration of the vehicle to be produced in the production plan, and calculates the completeness rate of the materials required for the corresponding production plan based on the trial production material bill BOM corresponding to the work order number;

[0026] When the processing unit detects that the material matching rate of the materials required for the production plan is greater than the set threshold and the key materials in the key material list are matched, the work order is issued and the production plan is started at the production time;

[0027] The trial production bill of materials (BOM) includes: the work order number of the order, the material name of the material required for the order, the required quantity of each material, the inventory quantity of each material, and the completeness mark.

[0028] In some embodiments of the present invention, the device includes: an updating unit connected to the uniformity rate calculation unit;

[0029] When materials are put into storage, the work order number of the order corresponding to the materials is determined, and the update unit searches for the trial production bill of materials BOM corresponding to the work order number, updates the inventory quantity of the corresponding materials in the trial production bill of materials BOM based on the material name of the current incoming materials, and simultaneously updates the completeness mark of the corresponding materials;

[0030] After the update unit updates the trial production bill of materials BOM, the consistency rate calculation unit is triggered to complete the synchronous update of the material consistency rate.

[0031] In some embodiments of the present invention, the updating unit includes: a completeness identification updating module and an association updating module;

[0032] After the trial production BOM is updated, the completeness indicator update module detects whether the inventory quantity of the updated material is greater than or equal to the required quantity. If the detection result is yes, the completeness indicator is marked as yes, otherwise, the completeness indicator is marked as no;

[0033] When the vehicle bill of materials (BOM) in the database is updated, if the currently updated vehicle bill of materials (BOM) has an associated trial production bill of materials (BOM), the associated update module will import the material name and usage in the updated vehicle bill of materials (BOM) into the material name and required quantity of the trial production bill of materials (BOM).

[0034] On the other hand, an embodiment of the present application provides a SAP system, wherein the SAP system integrates the above-mentioned material completeness rate detection device.

[0035] The present invention designs a trial production bill of materials (BOM) for calculating the material completeness rate. The trial production bill of materials (BOM) is used to record the materials required for the current production plan, the required quantity of each material and the actual inventory, and then automatically calculates the material completeness rate. When the trial production bill of materials (BOM) is updated, the completeness rate of the materials required for the corresponding work order number is automatically updated at the same time. The completeness rate is accurate and real-time, and can be better adapted to a short new product development cycle. BRIEF DESCRIPTION OF THE DRAWINGS

[0036] In order to more clearly illustrate the technical solutions in the embodiments of the present application, the drawings required for use in the description of the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present application. For ordinary technicians in this field, other drawings can be obtained based on these drawings without creative work.

[0037] Figure 1 A flow chart of a material uniformity detection method provided in an embodiment of the present invention;

[0038] Figure 2 A schematic diagram of the structure of a device for detecting the uniformity of materials provided in an embodiment of the present invention;

[0039] The above drawings have shown clear embodiments of the present application, which will be described in more detail later. These drawings and text descriptions are not intended to limit the scope of the present application in any way, but to illustrate the concept of the present application to those skilled in the art by referring to specific embodiments. DETAILED DESCRIPTION

[0040] The following will be combined with the drawings in the embodiments of the present application to clearly and completely describe the technical solutions in the embodiments of the present application. Obviously, the described embodiments are part of the embodiments of the present application, not all of the embodiments. Based on the embodiments in the present application, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of this application.

[0041] Unless otherwise defined, all technical terms used in the embodiments of the present application have the same meanings as commonly understood by those of ordinary skill in the art.

[0042] Figure 1 The flowchart of the material uniformity detection method provided by the embodiment of the present invention is as follows:

[0043] (1) Read the next production plan from the production schedule table in turn and determine the production time of the production plan;

[0044] In the embodiment of the present invention, the production schedule records the recent production plan, including: production time, production quantity, and the model and configuration of the production vehicle. The production schedule is manually scheduled and uploaded.

[0045] (2) Before a set time before the production time, check whether the material consistency rate of the vehicle model and configuration required for the production plan is greater than a set threshold;

[0046] In the embodiment of the present invention, the method for determining the material uniformity rate is specifically as follows:

[0047] The work order number of the order is generated based on the vehicle model and configuration of the production plan, and a trial production bill of materials (BOM) is constructed for each work order number. The trial production bill of materials (BOM) includes: the work order number of the order, the material name of the material required for the order, the required quantity of each material, the inventory quantity of each material, and the completeness mark.

[0048] When materials are put into storage, determine the work order number of the order corresponding to the material, find the trial production bill of materials BOM corresponding to the work order number, update the inventory quantity of the corresponding material in the trial production bill of materials BOM based on the material name of the current incoming material, and simultaneously update the corresponding material's completeness mark and material completeness rate.

[0049] In the embodiment of the present invention, the updating process of the material completeness mark is as follows:

[0050] After the trial production bill of materials BOM is updated, check whether the inventory quantity of the material is greater than or equal to the required quantity. If the test result is yes, the completeness flag of the corresponding material is marked as yes, indicating that the corresponding materials are complete. Otherwise, the completeness flag of the corresponding material is marked as no, indicating that the corresponding materials are not complete.

[0051] In an embodiment of the present invention, after the material completeness flags in the trial production bill of materials BOM are updated, the material completeness rate in the corresponding trial production bill of materials BOM is synchronously updated. The calculation formula of the material completeness rate is as follows: Count the number of materials n1 with the completeness flag marked as yes and the number of materials n2 with the completeness flag marked as no in the trial production bill of materials BOM, then the material completeness rate Y = n1 / (n1+n2).

[0052] In the embodiment of the present invention, the method for obtaining the material names of the materials required for the order and the required quantities of various materials in the trial production material bill BOM is as follows:

[0053] Based on the model and configuration of the planned production vehicle, the corresponding vehicle bill of materials (BOM) is searched from the database, the material name and usage in the vehicle bill of materials (BOM) are imported into the material name and required quantity of the trial production bill of materials (BOM), and an association relationship is established between the vehicle bill of materials (BOM) and the imported trial production bill of materials (BOM). After completing the current production plan, the association between the vehicle bill of materials (BOM) and the imported trial production bill of materials (BOM) is removed.

[0054] The database stores the complete vehicle bill of materials (BOM) of all vehicle models with different configurations. The complete vehicle bill of materials (BOM) includes: the material names (parts) and quantities of the materials required for the corresponding vehicle models and configurations. Among them, the method for generating the complete vehicle bill of materials (BOM) of all vehicle models with different configurations is already available, and the present invention will not be described in detail here.

[0055] In an embodiment of the present invention, when the vehicle bill of materials (BOM) in the database is updated, it is detected whether the currently updated vehicle bill of materials (BOM) has an associated trial production bill of materials (BOM). If so, the trial production bill of materials (BOM) is updated synchronously, that is, the material name and usage in the updated vehicle bill of materials (BOM) are imported into the material name and required quantity of the trial production bill of materials (BOM). If not, there is no need to update the associated trial production bill of materials (BOM).

[0056] (3) If the test result is yes, execute step (4); if the test result is no, then tentatively set the production plan.

[0057] (4) Check whether the incomplete materials are in the key material list. If the test result is no, a work order is issued and the production plan is started at production time. If the test result is yes, the production plan needs to be suspended.

[0058] In an embodiment of the present invention, a technician selects the names of materials that are essential for production from the trial production bill of materials BOM, and then forms a key material list. If the materials in the key material list are missing, the activated production plan may be suspended. Only when the completeness identification of all materials in the key material order is marked as yes, and the material completeness rate of the trial production bill of materials BOM corresponding to the work order number of the production vehicle of the production plan reaches the set threshold, the trial production bill of materials BOM corresponding to the work order number is put into the warehouse, and the production plan is started after the production time is reached.

[0059] It should be noted that when the work order is issued, a reminder will be given for the materials with the completeness mark of "no" in the trial production bill of materials (BOM). At this time, the incomplete materials will not have a significant impact on the production, and they can be supplemented and assembled after the vehicle rolls off the production line.

[0060] The present invention designs a trial production bill of materials (BOM) for calculating the material completeness rate. The trial production bill of materials (BOM) is used to record the materials required for the current production plan, the required quantity of each material and the actual inventory, and then automatically calculates the material completeness rate. When the trial production bill of materials (BOM) is updated, the completeness rate of the materials required for the corresponding work order number is automatically updated at the same time. The completeness rate is accurate and real-time, and can be better adapted to a short new product development cycle.

[0061] Figure 2 The schematic diagram of the structure of the material uniformity detection device provided in the embodiment of the present invention, for the convenience of explanation, only the part related to the embodiment of the present invention is shown, and the device includes:

[0062] The data reading unit, the uniformity rate calculation unit and the processing unit are connected in sequence, wherein:

[0063] The data reading unit sequentially reads the next production plan from the production schedule table and determines the production time of the production plan;

[0064] Before the set time before the production time, the completeness rate calculation unit determines the work order number based on the model and configuration of the vehicle to be produced in the production plan, and calculates the completeness rate of the materials required for the corresponding production plan based on the trial production bill of materials BOM corresponding to the work order number.

[0065] When the processing unit detects that the material completeness rate of the materials required for the production plan is greater than the set threshold and the key materials in the key material list are complete, the work order is issued and the production plan is started at the production time. Of course, if the material completeness rate of the materials required for the production plan is less than the set threshold, or the key materials in the key material list are not complete, the production plan is suspended and the production schedule needs to be adjusted manually.

[0066] The trial production bill of materials (BOM) includes: the work order number of the order, the material name of the material required for the order, the required quantity of each material, the inventory quantity of each material, and the completeness mark.

[0067] In an embodiment of the present invention, the data acquisition unit searches for the corresponding vehicle bill of materials (BOM) based on the model and configuration of the planned vehicle to be produced, and imports the material names and quantities in the vehicle bill of materials (BOM) into the material names and required quantities of the trial production bill of materials (BOM).

[0068] In the embodiment of the present invention, the device further comprises: an updating unit connected to the uniformity rate calculation unit;

[0069] When materials are put into storage, the work order number of the order corresponding to the materials is determined, and the update unit searches for the trial production bill of materials BOM corresponding to the work order number, updates the inventory quantity of the corresponding materials in the trial production bill of materials BOM based on the material name of the current incoming materials, and simultaneously updates the completeness mark of the corresponding materials;

[0070] After the update unit updates the trial production bill of materials BOM, the completeness rate calculation unit is triggered to complete the synchronous update of the material completeness rate. The calculation formula of the material completeness rate is as follows:

[0071] Count the number of materials n1 with the completeness mark as yes and the number of materials n2 with the completeness mark as no in the trial production material bill BOM, then the material completeness rate Y = n1 / (n1+n2).

[0072] In the embodiment of the present invention, the updating unit includes: a completeness identification updating module and an association updating module;

[0073] After the trial production BOM is updated, the completeness flag update module detects whether the inventory quantity of the updated material is greater than or equal to the required quantity. If the detection result is yes, the completeness flag of the corresponding material is marked as yes, otherwise, the completeness flag of the corresponding material is marked as no;

[0074] When the vehicle bill of materials (BOM) in the database is updated, if the currently updated vehicle bill of materials (BOM) has an associated trial production bill of materials (BOM), the associated update module will synchronously update the trial production bill of materials (BOM), and import the material name and usage in the updated vehicle bill of materials (BOM) into the material name and required quantity of the trial production bill of materials (BOM).

[0075] An embodiment of the present invention also provides a SAP system, in which the above-mentioned material completeness rate detection device is integrated in the SAP system. The SAP system stores the production schedule and the vehicle material bills (BOMs) of all vehicle models with different configurations. The material completeness rate detection device records the materials required for the current production plan, the required quantity of each material, and the actual inventory through the trial production material bill (BOM), and then automatically calculates the material completeness rate. When the trial production material bill (BOM) is updated, the completeness rate of the materials required for the corresponding work order number is automatically updated at the same time. The high accuracy and real-time performance make it better suitable for short new product development cycles.

[0076] Those skilled in the art will readily appreciate other embodiments of the present application after considering the specification and practicing the present application disclosed herein. The present application is intended to cover any variations, uses or adaptations of the present application, which follow the general principles of the present application and include common knowledge or customary techniques in the art that are not disclosed in the present application. The specification and examples are intended to be exemplary only.

[0077] It should be understood that the present application is not limited to the precise structures that have been described above and shown in the drawings, and that various modifications and changes may be made without departing from the scope thereof. The scope of the present application is limited only by the appended claims.

Claims

1. A material uniformity detection method, characterized in that: The method is specifically as follows: (1) Read the next production plan from the production schedule table in turn and determine the production time of the production plan; (2) Before a set time before the production time, check whether the material consistency rate of the vehicle model and configuration required for the production plan is greater than a set threshold; (3) If the test result is yes, check whether the incomplete materials are on the critical materials list. If they are not on the critical materials list, a work order is issued and the production plan is started at production time.

2. The material uniformity detection method as claimed in claim 1, characterized in that: The method for determining the material uniformity rate is as follows: Generate the work order number of the order based on the model and configuration of the vehicle to be produced in the production plan, and build a trial production bill of materials (BOM) for each work order number. The trial production bill of materials (BOM) includes: the work order number of the order, the material name of the material required for the order, the required quantity of each material, the inventory quantity of each material, and the completeness mark; When materials are put into storage, determine the work order number of the order corresponding to the material, find the trial production bill of materials BOM corresponding to the work order number, update the inventory quantity of the corresponding material in the trial production bill of materials BOM based on the material name of the current incoming material, and simultaneously update the corresponding material's completeness mark and material completeness rate.

3. The material uniformity detection method as claimed in claim 2, characterized in that: The update process of the material completeness mark is as follows: After the trial production bill of materials BOM is updated, check whether the inventory quantity of each material is greater than or equal to the required quantity. If the test result is yes, mark the completeness flag of the corresponding material as yes, otherwise mark the completeness flag of the corresponding material as no.

4. The material uniformity detection method as claimed in claim 3, characterized in that: The calculation formula of material completeness rate is as follows: Count the number of materials n1 with the completeness mark of yes and the number n2 with the completeness mark of no in the trial production material bill BOM, and the material completeness rate Y = n1 / (n1+n2).

5. The material uniformity detection method as claimed in claim 1, characterized in that: The method for obtaining the material name and required quantity of the materials required for the order in the trial production material list BOM is as follows: Based on the model and configuration of the planned production vehicle, the corresponding vehicle bill of materials (BOM) is searched from the database, and the material names and quantities in the vehicle bill of materials (BOM) are imported into the material names and required quantities of the trial production bill of materials (BOM); The database stores the vehicle bill of materials (BOM) for all vehicle models and different configurations. The vehicle bill of materials (BOM) includes: the material name and quantity of the materials required for the corresponding vehicle model and configuration.

6. The material uniformity detection method of claim 5, characterized in that: After importing the material names and usage in the vehicle BOM into the material names and required quantities in the trial BOM, establish an association between the vehicle BOM and the imported trial BOM. When the vehicle bill of materials (BOM) in the database is updated, check whether the currently updated vehicle bill of materials (BOM) has an associated trial production bill of materials (BOM). If so, import the material names and quantities in the updated vehicle bill of materials (BOM) into the material names and required quantities of the trial production bill of materials (BOM).

7. A material uniformity detection device, characterized in that: The device comprises: a data reading unit, a uniformity calculation unit and a processing unit connected in sequence, wherein: The data reading unit sequentially reads the next production plan from the production schedule table and determines the production time of the production plan; Before the set time before the production time, the completeness rate calculation unit determines the work order number based on the model and configuration of the vehicle to be produced in the production plan, and calculates the completeness rate of the materials required for the corresponding production plan based on the trial production material bill BOM corresponding to the work order number; When the processing unit detects that the material matching rate of the materials required for the production plan is greater than the set threshold and the key materials in the key material list are matched, the work order is issued and the production plan is started at the production time; The trial production bill of materials (BOM) includes: the work order number of the order, the material name of the material required for the order, the required quantity of each material, the inventory quantity of each material, and the completeness mark.

8. The material uniformity detection device as claimed in claim 7, characterized in that: The device comprises: an updating unit connected to the uniformity rate calculation unit; When materials are put into storage, the work order number of the order corresponding to the materials is determined, and the update unit searches for the trial production bill of materials BOM corresponding to the work order number, updates the inventory quantity of the corresponding materials in the trial production bill of materials BOM based on the material name of the current incoming materials, and simultaneously updates the completeness mark of the corresponding materials; After the update unit updates the trial production bill of materials BOM, the consistency rate calculation unit is triggered to complete the synchronous update of the material consistency rate.

9. The material uniformity detection device as claimed in claim 8, characterized in that: The updating unit includes: a completeness identification updating module and an associated updating module; After the trial production BOM is updated, the completeness indicator update module detects whether the inventory quantity of the updated material is greater than or equal to the required quantity. If the detection result is yes, the completeness indicator is marked as yes, otherwise, the completeness indicator is marked as no; When the vehicle bill of materials (BOM) in the database is updated, if the currently updated vehicle bill of materials (BOM) has an associated trial production bill of materials (BOM), the associated update module will import the material name and usage in the updated vehicle bill of materials (BOM) into the material name and required quantity of the trial production bill of materials (BOM).

10. A SAP system, characterized in that: The SAP system is integrated with the material completeness detection device as described in any one of claims 7 to 9.

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