A dynamic production planning system

Abstract

The present invention discloses a dynamic production planning system, which relates to the field of efficient and flexible batch assembly manufacturing technology. The system decomposes the complex equipment production plan into feasible and reasonable daily production plans step by step through product plan decomposition logic and production scheduling algorithm, and realizes plan update optimization under disturbance conditions through a dynamic optimization strategy of production plan based on rolling time domain, providing two planning modes: large-scale production and small-batch supplementary production. By constructing a dynamic production planning system, the flexibility and efficiency of production and delivery are effectively improved, which plays an important role in enterprises' effective allocation of production resources and timely and high-quality completion of production orders.

Description

Technical Field

[0001] The invention relates to the technical field of efficient and flexible batch assembly manufacturing, and in particular to a dynamic production planning system for a complex equipment assembly workshop. Background Art

[0002] Complex equipment has the characteristics of numerous parts, complex structure, and long assembly cycle. How to improve the assembly efficiency of complex equipment and ensure the delivery time of products has always been a hot topic of research. With the transformation and upgrading of my country's manufacturing industry, the production line suitable for complex equipment assembly has gradually shifted to an automated and flexible mode. A variety of products are produced in the same assembly workshop with different processes. The application of automation equipment and information systems transforms the traditional personnel-intensive and scattered work mode into a digital work mode with tight time constraints. While improving the working environment, reducing the number of personnel in dangerous positions, reducing the labor intensity of personnel, and improving production efficiency, it also puts forward higher requirements for the flexibility and accuracy of workshop production plans. On the one hand, limited by the multi-level assembly manufacturing process, the materials processed in each production stage may come from one or more upstream production stages. On the other hand, limited by the warehouse space, the inventory volume is constrained by the inventory capacity and has an upper limit. There are various forms of semi-finished products in the assembly process of complex equipment. Some semi-finished products need to meet certain conditions before they can continue to be assembled. Therefore, the goal of the production planning system is to meet product demand and to balance the production rhythm among multiple levels as much as possible, to avoid the subsequent systems being in a waiting state due to lack of materials, or the mismatch between the production / consumption of semi-finished products causing the previous systems to shut down or reduce production efficiency.

[0003] The patent document with application number 202310701579.3 records a dynamic adaptive planning and scheduling method for aircraft component assembly, which includes establishing a dynamic scheduling model for aircraft component assembly, solving the start and completion time of all A0s at all stations for all flights based on the data required by the scheduling model, outputting the scheduling method, and performing assembly production according to the output scheduling plan. When disturbance factors appear in the production process, the type of disturbance is judged, different processing strategies are used for different disturbance types, and a genetic algorithm is used to solve again to obtain a production scheduling plan that meets the delivery nodes.

[0004] The overall idea of ​​this invention (202310701579.3) is also to solve the static plan first, and then dynamically update the plan according to the abnormal disturbance (production deviation from reality), but the specific static plan solving ideas and dynamic update methods are different. This invention is a station plan decomposition implemented in combination with the aircraft assembly process, and the present invention is a component plan and production day plan decomposition implemented for the hierarchical assembly process of complex equipment; this invention analyzes disturbance factors and updates the corresponding plan according to different disturbance factors. Once other types of disturbances occur, dynamic updates cannot be achieved. The idea of ​​the present invention is to use dynamic optimization based on time domain rolling, without distinguishing abnormal disturbance factors, but dynamically optimizing according to the abnormal disturbance results. The dynamic update timing and strategy are different.

[0005] The patent document with application number 202211531680.0 records the integrated production scheduling system and method for multi-stage mixed-flow automobile production workshops, including a production scheduling model management module, a factory modeling module for automobile production, a production scheduling module for each workshop, and a basic data management module. Welding, painting, and assembly are scheduled according to their respective production scheduling targets, while reducing the inventory of welding buffer and painting buffer. The rationality of production planning is guaranteed, the production process is balanced and orderly, and production orders are delivered on time.

[0006] This invention (202211531680.0) also established a basic data management module and a factory modeling module, realized multi-level assembly scheduling, and ensured material balance during the production process. However, it did not consider the situation of production disturbances, and did not explain how to update and optimize the plan when production deviates from the plan.

[0007] The paper Research on Production Planning of Multi-Product Multi-Stage Manufacturing System (Lu Shan. Doctoral dissertation of Zhejiang University, 2016.) takes the characteristics of multi-variety small batch production and actual production operation conditions into consideration, takes minimizing the total cost within the planning cycle as the goal, defines balance constraints for the material flow and information flow of raw materials, work-in-progress and products, establishes a production planning model, and designs a dynamic optimization strategy based on the rolling time domain, ultimately obtaining the optimal solution within the entire planning cycle.

[0008] A lot of academic research and exploration has been conducted on production planning models and dynamic optimization strategies, which provides important ideas and guidance for enterprises to achieve optimized management of small-batch and multi-variety production. However, there has not been much exploration of large-scale production of complex equipment, and large-scale production scheduling research has not been explored for multi-level assembly processes, which cannot meet actual production needs. Summary of the invention

[0009] In view of the above problems, the present invention provides a dynamic production planning system for overcoming the above problems or at least partially solving the above problems.

[0010] The present invention provides the following scheme:

[0011] A dynamic production planning system, comprising:

[0012] Basic data management module, production planning management module, material requirement planning management module and system management module;

[0013] The basic data management module and the system management module are used to provide basic data support and operation services for the normal operation of the dynamic production planning system;

[0014] The production plan management module is used to decompose the complex equipment production plan into feasible and reasonable daily production plans step by step through product plan decomposition logic, production scheduling algorithm and production plan dynamic optimization strategy based on rolling time domain;

[0015] The material requirement planning management module is used to generate a material requirement plan according to the daily production plan and in combination with the process assembly BOM, so as to generate a material preparation plan according to the actual inventory situation.

[0016] Preferably: the product plan decomposition logic includes:

[0017] Obtaining production plan information of the workshop, wherein the production plan information at least includes products, planned production volume, production batch number, and planned start / end time;

[0018] Performing parameter preprocessing on the production plan information to determine the plan types included in the production plan information, wherein the plan types include product batch production plans and component batch production plans;

[0019] Determine a batch production plan for the product, split the batch production plan for the product into component batch production plans according to the product BOM, and determine the parallel or serial production order of the components in combination with the product assembly process during the splitting process;

[0020] It is determined whether it is large-scale production or small-scale supplementary production based on the production quantity included in the component batch production plan.

[0021] Preferably: in the splitting process, the optimal production time is taken as the goal, based on the production stage sequence constraint model, combined with the production capacity constraints and production calendar requirements, the product batch production plan is split into the component batch production plan, so as to determine the start and end dates of component production.

[0022] Preferably: the production stage sequence constraint model includes:

[0023] Let i and j represent the material and production stage respectively, then product i = 4 is assembled from i = 1, 2, 3;

[0024] Let the set {j,i} represent the product i manufactured through production stage j, and define the sets H(j,i) and Ω(j,i) to represent the set of preceding production stages and the set of subsequent production stages of manufacturing product i in production stage j, respectively.

[0025] Preferably: the production scheduling algorithm includes a large batch production scheduling algorithm and a small batch production scheduling algorithm;

[0026] Determine that the mass production is to apply the mass production scheduling algorithm to split the production into three stages: ramp-up, mass production, and closing;

[0027] Determine to apply the small batch scheduling algorithm decomposition for small amount of supplementary production;

[0028] The production day plan is generated by the production scheduling algorithm, and the production day plan mainly includes production date, component name, process code, production quantity, etc.

[0029] Preferably: the component assembly is divided into stage A1, stage A2 and stage A3, wherein the stage A1, stage A2 and stage A3 correspond to the process of assembling and generating semi-finished product 1a, semi-finished product 1b and component 1 respectively; the component assembly process is determined to include GY01, GY02, GY03, GY04, GY05 and GY06; according to the inventory capacity upper limit of temporary storage warehouse KF01 and temporary storage warehouse KF02, the production of component assembly process GY01 is determined to be subject to both production output requirements and inventory capacity constraints. When the production output requirement is greater than the inventory capacity upper limit of temporary storage warehouse KF01 and temporary storage warehouse KF02, the production of component assembly process GY01 is determined to be subject to both production output requirements and inventory capacity constraints. When the F01 inventory upper limit is reached, it is determined that production is subject to material balance constraints. During the A2 production process, when there is space in the temporary storage KF01, the A1 stage is allowed to continue production, and KF01 will maintain a dynamically balanced inventory level; it is determined that only semi-finished products that meet the curing time conditions can continue subsequent production; when executing the component assembly process GY02, it will be subject to the inventory capacity constraints of the temporary storage KF02. When the inventory of the temporary storage KF02 reaches the upper limit, it is necessary to execute the A3 stage to consume the semi-finished product 1b so that there is space in the temporary storage KF02, allowing A2 to continue production;

[0030] The small batch production scheduling algorithm does not consider the problem of dynamic balance of materials in the temporary storage warehouse, and executes the production processes of component assembly processes GY01-GY06-GY05 in sequence;

[0031] The mass production scheduling algorithm takes material balance constraints into consideration. When the daily production capacities in the A1, A2 and A3 stages are kept constant and the entire production line maintains a consistent and stable production rhythm, the ramp-up component assembly process GY01 and component assembly process GY02 ​​are first executed during component production to fill up the temporary storage warehouses KF01 and KF02, and then the component assembly process GY03 is executed for mass production, and finally the finishing component assembly process GY04 and component assembly process GY05 are executed.

[0032] Preferably: the dynamic optimization strategy for production planning based on the rolling time domain includes:

[0033] The time period for executing the same process is divided into the same area. After the daily production plan in the current area is executed every day, the actual production quantity and the quantity of materials in each temporary storage warehouse are obtained, and the subsequent daily production plan of the area is dynamically updated. The preceding area of ​​the area is determined as a fixed area, and the subsequent area is determined as a relaxed area, so as to realize dynamic optimization of the daily production plan through rolling advancement in the time domain.

[0034] Preferably: the material requirement plan includes date, material code, material name, and required quantity. The material requirement plan management module transmits the material requirement plan to the target information system through any one of API and Webservice, so that the target information system automatically generates a material preparation plan regularly based on the material inventory quantity; the target information system includes an enterprise resource planning system.

[0035] Preferably: the basic data management module is used to perform production line management, organizational management, personnel management, equipment information management, product information management, process management, material information management, and production calendar management;

[0036] The production line management is used to achieve hierarchical management of production lines, workstations, and equipment by digitally modeling complex equipment assembly production lines, and to establish an associated mapping relationship between production lines, workstations, and equipment;

[0037] The organizational structure management is used to manage the production line manufacturing organizational structure, including workshops, shifts, teams and other levels, and establish the relationship between personnel and organizational structures;

[0038] The personnel management is used to manage the basic information of the workshop personnel and maintain the personnel's operation qualification certificates or skill certificates;

[0039] The equipment information management is used to uniformly manage production line process equipment, testing equipment, logistics equipment, etc., and generate a unique identity for the equipment;

[0040] The product information management is used to maintain and manage the basic information of the produced products, realize the management of product BOM data, and use a tree structure to display the multi-level product assembly relationship;

[0041] The process management is used to manage the process routes, associated processes, workstations, equipment, and materials used in the product assembly process;

[0042] The material information management is used to manage the information of various materials used in the production process of products, encode production parts and components, and associate related products according to unified rules;

[0043] The production calendar management is used to determine the specific time periods when resources are at work and to perform maintenance management on special dates when production is not performed.

[0044] Preferably: the system management module is used to perform user management, authority management, system log and security audit.

[0045] According to the specific embodiments provided by the present invention, the present invention discloses the following technical effects:

[0046] The embodiment of the present application provides a dynamic production planning system, which decomposes the complex equipment production plan into feasible and reasonable daily production plans step by step through product plan decomposition logic and production scheduling algorithms, realizes plan update optimization under disturbance conditions through a dynamic optimization strategy for production plans based on a rolling time domain, and provides two planning modes: large-scale production and small-batch supplementary production. By building a dynamic production planning system, the flexibility and efficiency of production and delivery are effectively improved, which plays an important role in the effective allocation of production resources by enterprises and the timely and high-quality completion of production orders.

[0047] Of course, any product implementing the present invention does not necessarily need to achieve all of the advantages described above at the same time. BRIEF DESCRIPTION OF THE DRAWINGS

[0048] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings required for use in the embodiments are briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention, and for ordinary technicians in this field, other drawings can be obtained based on these drawings without creative work.

[0049] Figure 1 is a framework diagram of a dynamic production planning system provided by an embodiment of the present invention;

[0050] Figure 2 It is a production plan decomposition flow chart provided by an embodiment of the present invention;

[0051] Figure 3 It is a schematic diagram of an assembly process provided by an embodiment of the present invention;

[0052] Figure 4 It is a schematic diagram of a production process provided by an embodiment of the present invention;

[0053] Figure 5 This is a component production daily schedule provided by an embodiment of the present invention. DETAILED DESCRIPTION

[0054] The technical scheme in the embodiment of the present invention will be clearly and completely described below in conjunction with the accompanying drawings in the embodiment of the present invention. Obviously, the described embodiment is only a part of the embodiment of the present invention, not all of the embodiments. Based on the embodiment of the present invention, all other embodiments obtained by ordinary technicians in this field belong to the scope of protection of the present invention.

[0055] See also Figure 1 , is a dynamic production planning system provided by an embodiment of the present invention, such as Figure 1 As shown, the system may include:

[0056] Basic data management module, production planning management module, material requirement planning management module and system management module;

[0057] The basic data management module and the system management module are used to provide basic data support and operation services for the normal operation of the dynamic production planning system; in specific implementation, the embodiment of the present application can provide the basic data management module for executing production line management, organizational management, personnel management, equipment information management, product information management, process management, material information management, and production calendar management;

[0058] The production line management is used to achieve hierarchical management of production lines, workstations, and equipment by digitally modeling complex equipment assembly production lines, and to establish an associated mapping relationship between production lines, workstations, and equipment;

[0059] The organizational structure management is used to manage the production line manufacturing organizational structure, including workshops, shifts, teams and other levels, and establish the relationship between personnel and organizational structures;

[0060] The personnel management is used to manage the basic information of the workshop personnel and maintain the personnel's operation qualification certificates or skill certificates;

[0061] The equipment information management is used to uniformly manage production line process equipment, testing equipment, logistics equipment, etc., and generate a unique identity for the equipment;

[0062] The product information management is used to maintain and manage the basic information of the produced products, realize the management of product BOM data, and use a tree structure to display the multi-level product assembly relationship;

[0063] The process management is used to manage the process routes, associated processes, workstations, equipment, and materials used in the product assembly process;

[0064] The material information management is used to manage the information of various materials used in the production process of products, encode production parts and components, and associate related products according to unified rules;

[0065] The production calendar management is used to determine the specific time periods when resources are at work and to perform maintenance management on special dates when production is not performed.

[0066] The system management module is used to perform user management, authority management, system log and security audit.

[0067] The production plan management module is used to decompose the complex equipment production plan into feasible and reasonable daily production plans step by step through product plan decomposition logic, production scheduling algorithm and production plan dynamic optimization strategy based on rolling time domain; in specific implementation, the product plan decomposition logic includes:

[0068] Obtaining production plan information of the workshop, wherein the production plan information at least includes products, planned production volume, production batch number, and planned start / end time;

[0069] Performing parameter preprocessing on the production plan information to determine the plan types included in the production plan information, wherein the plan types include product batch production plans and component batch production plans;

[0070] Determine the batch production plan for the product, split the batch production plan for the product into component batch production plans according to the product BOM, and determine the parallel or serial production order of the components in combination with the product assembly process during the splitting process.

[0071] It is determined whether it is large-scale production or small-scale supplementary production based on the production quantity included in the component batch production plan.

[0072] In the splitting process, the optimal production time is taken as the goal. Based on the production stage sequence constraint model, combined with the production capacity constraints and production calendar requirements, the product batch production plan is split into the component batch production plan to determine the start and end dates of component production.

[0073] The production stage pre- and post-sequence constraint model includes:

[0074] Let i and j represent the material and production stage respectively, then product i = 4 is assembled from i = 1, 2, 3;

[0075] Let the set {j,i} represent the product i manufactured through production stage j, and define the sets H(j,i) and Ω(j,i) to represent the set of preceding production stages and the set of subsequent production stages of manufacturing product i in production stage j, respectively.

[0076] The production scheduling algorithm includes a large batch production scheduling algorithm and a small batch production scheduling algorithm;

[0077] Determine that the mass production is to apply the mass production scheduling algorithm to split the production into three stages: ramp-up, mass production, and closing;

[0078] Determine to apply the small batch scheduling algorithm decomposition for small amount of supplementary production;

[0079] The production day plan is generated by the production scheduling algorithm, and the production day plan mainly includes production date, component name, process code, production quantity, etc.

[0080] Furthermore, the component assembly is divided into stage A1, stage A2, and stage A3, wherein the stage A1, stage A2, and stage A3 correspond to the process of assembling and generating semi-finished product 1a, semi-finished product 1b, and component 1, respectively; the component assembly processes are determined to include GY01, GY02, GY03, GY04, GY05, and GY06; according to the inventory capacity upper limit of temporary storage warehouses KF01 and KF02, it is determined that the production of component assembly process GY01 is subject to both production output requirements and inventory capacity constraints. When the production output requirement is greater than the inventory capacity upper limit of temporary storage warehouse KF01 and temporary storage warehouse KF02, the production of component assembly process GY01 is subject to both production output requirements and inventory capacity constraints. When the F01 inventory upper limit is reached, it is determined that production is subject to material balance constraints. During the A2 production process, when there is space in the temporary storage KF01, the A1 stage is allowed to continue production, and KF01 will maintain a dynamically balanced inventory level; it is determined that only semi-finished products that meet the curing time conditions can continue subsequent production; when executing the component assembly process GY02, it will be subject to the inventory capacity constraints of the temporary storage KF02. When the inventory of the temporary storage KF02 reaches the upper limit, it is necessary to execute the A3 stage to consume the semi-finished product 1b so that there is space in the temporary storage KF02, allowing A2 to continue production;

[0081] The small batch production scheduling algorithm does not consider the problem of dynamic balance of materials in the temporary storage warehouse, and executes the production processes of component assembly processes GY01-GY06-GY05 in sequence;

[0082] The mass production scheduling algorithm takes material balance constraints into consideration. When the daily production capacities in the A1, A2 and A3 stages are kept constant and the entire production line maintains a consistent and stable production rhythm, the ramp-up component assembly process GY01 and component assembly process GY02 ​​are first executed during component production to fill up the temporary storage warehouses KF01 and KF02, and then the component assembly process GY03 is executed for mass production, and finally the finishing component assembly process GY04 and component assembly process GY05 are executed.

[0083] The dynamic optimization strategy of production planning based on the rolling horizon includes:

[0084] The time period for executing the same process is divided into the same area. After the daily production plan in the current area is executed every day, the actual production quantity and the quantity of materials in each temporary storage warehouse are obtained, and the subsequent daily production plan of the area is dynamically updated. The preceding area of ​​the area is determined as a fixed area, and the subsequent area is determined as a relaxed area, so as to realize dynamic optimization of the daily production plan through rolling advancement in the time domain.

[0085] The material requirement planning management module is used to generate a material requirement plan based on the production daily plan and in combination with the process assembly BOM, so as to generate a material preparation plan based on the actual inventory situation. In specific implementation, the embodiment of the present application can provide that the material requirement plan includes date, material code, material name, and required quantity. The material requirement planning management module transmits the material requirement plan to the target information system through any one of API and Webservice, so that the target information system can automatically generate a material preparation plan regularly in combination with the material inventory quantity; the target information system includes an enterprise resource planning system.

[0086] The dynamic production planning system provided in the embodiment of the present application decomposes the complex equipment production plan into feasible and reasonable daily production plans step by step through product plan decomposition logic, production scheduling algorithm and dynamic optimization strategy of production plan based on rolling time domain, automatically adapts large-scale production scheduling algorithm or small-batch production scheduling algorithm according to production quantity, realizes plan generation and dynamic optimization under the material balance constraints of temporary storage warehouse, and automatically generates material requirement plan and material preparation plan in combination with process assembly BOM and inventory status.

[0087] The dynamic production planning system provided by this application is introduced in detail below.

[0088] The embodiment of the present application proposes a dynamic production planning system suitable for complex equipment assembly workshops, which mainly includes four parts: basic data management module, production planning management module, material requirement planning management module, and system management module. Figure 1 shown.

[0089] The basic data management module and the system management module provide basic data support and operation services for the normal operation of the dynamic production planning system. The production planning management module decomposes the complex equipment production plan into feasible and reasonable daily production plans step by step through product plan decomposition logic, production scheduling algorithm and dynamic optimization strategy of production plan based on rolling time domain. The material requirement planning management module obtains the daily production plan of the production planning management module and automatically generates the material requirement plan in combination with the process assembly BOM, and generates the material preparation plan according to the actual inventory situation. By building a dynamic production planning system, the flexibility and efficiency of production and delivery are effectively improved, which plays an important role in the effective allocation of production resources and the timely and high-quality completion of production orders by enterprises.

[0090] 1. Basic data management module.

[0091] Basic data is an important guarantee for the normal operation of the dynamic production planning system, mainly including: production line, process, equipment, workstation, team, personnel, parts, products, BOM, etc. The system supports docking with upper-level information systems (such as factory-level MES system, ERP system, etc.) to obtain basic information such as products, materials, processes, and personnel.

[0092] Basic data management mainly includes production line management, organizational management, personnel management, equipment information management, product information management, process management, material information management, and production calendar management. Production line management realizes hierarchical management of production lines, workstations, and equipment by digitally modeling complex equipment assembly production lines, and establishes the association mapping relationship between production lines, workstations, and equipment. Organizational management manages the production and manufacturing organizational structure of the production line, including levels such as workshops, shifts, and teams, and establishes the association relationship between personnel and organizational structures. Personnel management manages the basic information of workshop personnel, and maintains personnel operation qualification certificates or skill certificates. Equipment information management uniformly manages production line process equipment, testing equipment, logistics equipment, etc., and automatically generates a unique identity for the equipment. Product information management maintains and manages the basic information of the products produced, realizes the management of product BOM data, and can display multi-level product assembly relationships in a tree structure. Process management manages the process routes, associated processes, workstations, equipment, materials, and other parameters used in the product assembly process. Material information management manages the information of various materials used in the production process, codes production parts and associates related products according to unified rules, and can be divided into semi-finished product management and material (parts) management. Production calendar management is used to determine the specific time period for resources (equipment, personnel, etc.) to work, and to maintain and manage special dates when production is not performed.

[0093] 2. Production planning management.

[0094] The system can receive workshop production plans made by the company's upper-level information system (such as factory-level MES, ERP, etc.) through WebService, API, etc., and also supports manual compilation and batch import of workshop production plans in Excel. The production plan mainly includes products, planned production volume, production batch number, planned start / end time, etc. The production plan status is divided into undecomposed and decomposed, and the default status is undecomposed. The batch production plan is automatically decomposed into production day plans through the production scheduling algorithm. The process is as follows Figure 2 shown.

[0095] First, the production plan information is preprocessed to determine whether the production plan is a product batch production plan or a component batch production plan. If it is a product batch plan, it needs to be split into a component batch production plan based on the product BOM. During the splitting process, the parallel or serial production sequence of the components needs to be determined in combination with the product assembly process. Secondly, the production quantity determines whether it is large-scale production or small-scale supplementary production. If it is large-scale production, the large-scale scheduling algorithm is used to split the production into three stages: ramp-up, large-scale, and closing. For small-scale supplementary production, the small-scale scheduling algorithm is used to split it. Finally, the daily production plan is automatically generated through the scheduling algorithm. The daily production plan mainly includes the production date, component name, process code, production quantity, etc.

[0096] ① Product batch production plan is decomposed into component batch production plan

[0097] The assembly of complex equipment is usually multi-stage, and the material requirements of each stage in the assembly process are not independent, that is, the output material of one stage is the input material of another or more stages. Taking the assembly production of a certain product as an example, first, the parts are assembled to form parts 1 and 2, and then part 2 is assembled with other parts to generate part 3. Finally, part 1 and part 3 are assembled to form product 4. Limited by the limit of the amount of explosives in the workshop, production needs to be divided into time periods, where parts 1 and batch 2 are allowed to be produced at the same time, and batch 3 and batch 4 are allowed to be produced at the same time. Based on the fact that the production capacity of parts 1 and batch 2 is basically the same, and the production capacity of batch 3 and batch 4 is basically the same, the production stage of product 4 can be divided into four stages as a whole. Stage A is the simultaneous production of parts 1 and 2, stage B is the production of part 3, stage C is the simultaneous production of batch 3 and batch 4, and stage D is the production of batch 4. Let i and j represent the material and production stage respectively, then product i=4 is obtained by assembling i=1,2,3. Let the set {j,i} represent the material i manufactured in production stage j, and define the sets H(j,i) and Ω(j,i) to represent the preceding production stage set and the following production stage set of material i manufactured in production stage j, respectively. Taking {j,i}={B,3} as an example, it means that part 3 is manufactured in production stage B, and its preceding production stage {j,i}={A,2}, and its following production stage {j,i}={C,4}.

[0098] There are turnover warehouses for parts 1, 2, and 3, and the capacity of the turnover warehouses is greater than the output of a production batch, so the component inventory capacity constraint is no longer considered when decomposing the product plan. Taking the optimal production time as the goal, based on the above-mentioned production stage sequence constraint model, combined with production capacity constraints and production calendar requirements, the product production plan is split into component production plans to determine the start and end dates of component production.

[0099] ② Production Scheduling Algorithm

[0100] After the above product plan decomposition, the product production plan is divided into component production plans. Based on the production scheduling algorithm, the component production plan is decomposed into daily production plans, and the material demand daily plan is automatically generated. The assembly process of component i=1 of a complex equipment i=4 is as follows Figure 3 As shown, in the process of assembling components, semi-finished product 1a is first generated, taken offline and temporarily stored in temporary storage warehouse KF01. After the process curing time requirement is met, it is taken out of temporary storage warehouse KF01 and put online to be assembled with other components taken out of the parts warehouse to generate semi-finished product 1b, which is taken offline and temporarily stored in temporary storage warehouse KF02. After the process curing time requirement is met, it is put online to continue assembly, and finally component 1 is generated.

[0101] like Figure 4 As shown, the component assembly is divided into three stages, A1, A2, and A3 correspond to the process of assembling and generating semi-finished product 1a, semi-finished product 1b, and component 1, respectively. There are six component assembly processes, namely component assembly processes GY01-06. Since there are inventory capacity limits for temporary storage warehouses KF01 and KF02, the production of component assembly process GY01 is constrained by both production output requirements and inventory capacity. When the production output requirement is greater than the inventory limit of temporary storage warehouse KF01, continuing the production of component assembly process GY01 will cause the output of semi-finished product 1a to exceed the upper limit of temporary storage warehouse KF01. Therefore, production is constrained by material balance. When executing A2 production, A1 will be allowed to continue production only when there is space in temporary storage warehouse KF01. Temporary storage warehouse KF01 will maintain a dynamically balanced inventory level. In addition, there are process curing time requirements for semi-finished products 1a and 1b in the temporary storage warehouse. Only semi-finished products that meet the conditions can continue subsequent production. Similarly, when executing component assembly process GY02, it will be constrained by the inventory capacity of temporary storage warehouse KF02. When the inventory of temporary storage warehouse KF02 reaches the upper limit, it is necessary to execute A3 to consume 1b so that there is space in temporary storage warehouse KF02 before A2 is allowed to continue production.

[0102] In order to achieve the goal of optimizing the production time of components, the production scheduling algorithms are divided into two types: large-scale production scheduling algorithm and small-scale production scheduling algorithm. The small-scale production scheduling algorithm does not consider the problem of dynamic balance of materials in the temporary storage warehouse, and executes the production process of component assembly process GY01-GY06-GY05. The large-scale production scheduling algorithm takes into account the material balance constraints. When the daily production capacity of A1, A2, and A3 is basically the same, that is, the entire production line maintains a consistent and stable production rhythm, the ramp-up process GY01 and GY02 ​​are first executed during component production, and the temporary storage warehouse KF01 and the temporary storage warehouse KF02 are gradually filled up. Then the component assembly process GY03 is executed for large-scale production, and finally the finishing process GY04 and GY05 are executed.

[0103] like Figure 5 The figure shows the daily production schedule of components after the execution of the mass production scheduling algorithm. The planned production quantity of the components is x, the upper limits of the inventory of temporary warehouse KF01 and temporary warehouse KF02 are K1max and K2max respectively, the daily production capacity of component assembly process GY01 is S1, the daily production capacity of component assembly process GY02 ​​is S2, the daily production capacity of component assembly process GY03 is S3, the daily production capacity of component assembly process GY04 is S4, and the daily production capacity of component assembly process GY05 is S5. Component assembly process GY01 is carried out from the 1st day to the (K1max / S1+1)th day, and component assembly process GY02 ​​is carried out on the subsequent (K1max / S1+1)th day. The inventories of temporary storage warehouses KF01 and KF02 are filled up through the production of component assembly process GY01 and component assembly process GY02. Then component assembly process GY03 is carried out for ((x-K1max-K2max) / S3+1) days, and a total of (x-K1max-K2max) components are produced. Finally, component assembly process GY04 is carried out for (K1max / S4+1) days, and component assembly process GY05 is carried out for (K2max / S5+1) days. Finally, a total of x components are produced to meet the production plan requirements.

[0104] ③ Dynamic optimization of production plans based on rolling time domain.

[0105] In actual production, there are usually various abnormal disturbances that cause actual production to deviate from the production plan. Therefore, after the plan is formulated, it is necessary to perform timely iterative updates to eliminate the impact of uncertain factors. The dynamic optimization strategy of production planning based on rolling time domain is adopted to divide the entire production planning model into fixed area, decision area and relaxation area. In practical applications, assuming that the current period is t=0, usually only the planning decision of t=1 period is implemented, and then the model is updated by rolling forward one period, and then the plan of t=2 period is implemented. Through this rolling update method, the production plan is continuously updated and optimized with the actual production to meet the actual production needs. After the production daily plan is automatically generated and issued by the scheduling algorithm, the time period for executing the same process is divided into the same area. After the daily production plan in the current area is executed, the actual production quantity and the quantity of materials in each temporary storage warehouse are obtained, and the subsequent production daily plan of the area is dynamically updated. The preceding area of ​​the area is a fixed area, and the subsequent area is a relaxation area. The dynamic optimization of the production plan is achieved through rolling advancement in the time domain.

[0106] 3. Material requirement planning management module.

[0107] When the production plan is decomposed into the daily production plan, the material requirement plan is automatically generated in combination with the process BOM. The material requirement plan mainly includes date, material code, material name, required quantity, etc. It supports the transmission of the material requirement plan to other information systems (such as ERP enterprise resource planning, etc.) through API, Webservice, etc. The material preparation plan can be automatically generated regularly in combination with the material inventory quantity to ensure the stable supply of materials on the production line and reduce production interruptions and downtime due to material shortages.

[0108] 4. System management module.

[0109] System management mainly includes user management, authority management, system log, and security audit modules, which provide basic services for the normal operation and maintenance of the dynamic production planning system. User authority is based on the "role-based authority management" (RBAC) model, and adopts the "three-member separation" method, namely the system administrator, authorization administrator, and security auditor, to achieve independent and mutually restricted authority settings, and complete the unified management of user usage permissions. The business function of user authority management is manifested in the management of users, menus, roles, and authorizations. The system log mainly records the user's operation log, error log and other records during use, and when a bug occurs in the system, it allows system operation and maintenance personnel to quickly locate the problem. Security audit management mainly audits specific events in the system, such as user authority changes, user additions and deletions, and other events.

[0110] In summary, the dynamic production planning system provided by this application decomposes the complex equipment production plan into feasible and reasonable daily production plans step by step through product plan decomposition logic and production scheduling algorithms, realizes plan update optimization under disturbance conditions through a dynamic optimization strategy for production plans based on a rolling time domain, and provides two planning modes: large-scale production and small-batch supplementary production. By building a dynamic production planning system, the flexibility and efficiency of production and delivery are effectively improved, which plays an important role in enterprises' effective allocation of production resources and timely and high-quality completion of production orders.

[0111] It should be noted that, in this article, relational terms such as first and second, etc. are only used to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Moreover, the terms "include", "comprise" or any other variants thereof are intended to cover non-exclusive inclusion, so that a process, method, article or device including a series of elements includes not only those elements, but also other elements not explicitly listed, or also includes elements inherent to such process, method, article or device. In the absence of further restrictions, the elements defined by the sentence "comprise a ..." do not exclude the existence of other identical elements in the process, method, article or device including the elements.

[0112] It can be known from the description of the above implementation methods that those skilled in the art can clearly understand that the present application can be implemented by means of software plus a necessary general hardware platform. Based on such an understanding, the technical solution of the present application can be essentially or partly embodied in the form of a software product that contributes to the prior art. The computer software product can be stored in a storage medium such as ROM / RAM, a magnetic disk, an optical disk, etc., and includes several instructions for enabling a computer device (which can be a personal computer, a server, or a network device, etc.) to execute the methods described in the various embodiments of the present application or certain parts of the embodiments.

[0113] Each embodiment in this specification is described in a progressive manner, and the same or similar parts between the embodiments can refer to each other, and each embodiment focuses on the differences from other embodiments. In particular, for the system or system embodiment, since it is basically similar to the method embodiment, the description is relatively simple, and the relevant parts can refer to the partial description of the method embodiment. The system and system embodiments described above are merely schematic, wherein the units described as separate components may or may not be physically separated, and the components displayed as units may or may not be physical units, that is, they may be located in one place, or they may be distributed on multiple network units. Some or all of the modules may be selected according to actual needs to achieve the purpose of the scheme of this embodiment. Ordinary technicians in this field can understand and implement it without creative work.

[0114] The above description is only a preferred embodiment of the present invention and is not intended to limit the protection scope of the present invention. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present invention are included in the protection scope of the present invention.

Claims

1. A dynamic production planning system, characterized in that: Including basic data management module, production planning management module, material requirement planning management module and system management module; The basic data management module and the system management module are used to provide basic data support and operation services for the normal operation of the dynamic production planning system; The production plan management module is used to decompose the complex equipment production plan into feasible and reasonable daily production plans step by step through product plan decomposition logic, production scheduling algorithm and production plan dynamic optimization strategy based on rolling time domain; The material requirement planning management module is used to generate a material requirement plan according to the daily production plan and in combination with the process assembly BOM, so as to generate a material preparation plan according to the actual inventory situation.

2. The dynamic production planning system according to claim 1, characterized in that: The product plan decomposition logic includes: Obtaining production plan information of the workshop, wherein the production plan information at least includes products, planned production volume, production batch number, and planned start / end time; Performing parameter preprocessing on the production plan information to determine the plan types included in the production plan information, wherein the plan types include product batch production plans and component batch production plans; Determine a batch production plan for the product, split the batch production plan for the product into component batch production plans according to the product BOM, and determine the parallel or serial production order of the components in combination with the product assembly process during the splitting process; It is determined whether it is large-scale production or small-scale supplementary production based on the production quantity included in the component batch production plan.

3. The dynamic production planning system according to claim 2, characterized in that: In the splitting process, the optimal production time is taken as the goal. Based on the production stage sequence constraint model, combined with the production capacity constraints and production calendar requirements, the product batch production plan is split into the component batch production plan to determine the start and end dates of component production.

4. The dynamic production planning system according to claim 3, characterized in that: The production stage pre- and post-sequence constraint model includes: Let i and j represent the material and production stage respectively, then product i = 4 is assembled from i = 1, 2, 3; Let the set {j,i} represent the product i manufactured through production stage j, and define the sets H(j,i) and Ω(j,i) to represent the set of preceding production stages and the set of subsequent production stages of manufacturing product i in production stage j, respectively.

5. The dynamic production planning system according to claim 2, characterized in that: The production scheduling algorithm includes a large batch production scheduling algorithm and a small batch production scheduling algorithm; Determine that the mass production is to apply the mass production scheduling algorithm to split the production into three stages: ramp-up, mass production, and closing; Determine to apply the small batch scheduling algorithm decomposition for small amount of supplementary production; The production day plan is generated by the production scheduling algorithm, and the production day plan mainly includes production date, component name, process code, production quantity, etc.

6. The dynamic production planning system according to claim 5, characterized in that: The component assembly is divided into the A1 stage, the A2 stage and the A3 stage, wherein the A1 stage, the A2 stage and the A3 stage correspond to the process of assembling and generating the semi-finished product 1a, the semi-finished product 1b and the component 1 respectively; the component assembly processes are determined to include GY01, GY02, GY03, GY04, GY05 and GY06; according to the inventory capacity upper limit of the temporary storage warehouse KF01 and the temporary storage warehouse KF02, it is determined that the production of the component assembly process GY01 is constrained by both the production output requirement and the inventory capacity. When the production output requirement is greater than the inventory capacity upper limit of the temporary storage warehouse KF01, the production of the component assembly process GY01 is constrained by both the production output requirement and the inventory capacity. When the inventory upper limit is 1, it is determined that production is subject to material balance constraints. When there is space in temporary storage KF01 during the production process of stage A2, stage A1 is allowed to continue production, and KF01 will maintain a dynamically balanced inventory level; it is determined that only semi-finished products that meet the curing time conditions can continue subsequent production; when executing component assembly process GY02, it will be constrained by the inventory capacity of temporary storage KF02. When the inventory of temporary storage KF02 reaches the upper limit, stage A3 needs to be executed to consume semi-finished product 1b so that there is space in temporary storage KF02, allowing A2 to continue production; The small batch production scheduling algorithm does not consider the problem of dynamic balance of materials in the temporary storage warehouse, and executes the production processes of component assembly processes GY01-GY06-GY05 in sequence; The mass production scheduling algorithm takes material balance constraints into consideration. When the daily production capacities in the A1, A2 and A3 stages are kept constant and the entire production line maintains a consistent and stable production rhythm, the ramp-up component assembly process GY01 and component assembly process GY02 ​​are first executed during component production to fill up the temporary storage warehouses KF01 and KF02, and then the component assembly process GY03 is executed for mass production, and finally the finishing component assembly process GY04 and component assembly process GY05 are executed.

7. The dynamic production planning system according to claim 1, characterized in that: The dynamic optimization strategy of production planning based on the rolling horizon includes: The time period for executing the same process is divided into the same area. After the daily production plan in the current area is executed every day, the actual production quantity and the quantity of materials in each temporary storage warehouse are obtained, and the subsequent daily production plan of the area is dynamically updated. The preceding area of ​​the area is determined as a fixed area, and the subsequent area is determined as a relaxed area, so as to realize dynamic optimization of the daily production plan through rolling advancement in the time domain.

8. The dynamic production planning system according to claim 1, characterized in that: The material requirement plan includes date, material code, material name, and required quantity. The material requirement plan management module transmits the material requirement plan to the target information system through any one of API and Webservice, so that the target information system can automatically generate a material preparation plan regularly based on the material inventory quantity; the target information system includes an enterprise resource planning system.

9. The dynamic production planning system according to claim 1, characterized in that: The basic data management module is used to perform production line management, organizational management, personnel management, equipment information management, product information management, process management, material information management, and production calendar management; The production line management is used to achieve hierarchical management of production lines, workstations, and equipment by digitally modeling complex equipment assembly production lines, and to establish an associated mapping relationship between production lines, workstations, and equipment; The organizational structure management is used to manage the production line manufacturing organizational structure, including workshops, shifts, teams and other levels, and establish the relationship between personnel and organizational structures; The personnel management is used to manage the basic information of the workshop personnel and maintain the personnel's operation qualification certificates or skill certificates; The equipment information management is used to uniformly manage production line process equipment, testing equipment, logistics equipment, etc., and generate a unique identity for the equipment; The product information management is used to maintain and manage the basic information of the produced products, realize the management of product BOM data, and use a tree structure to display the multi-level product assembly relationship; The process management is used to manage the process routes, associated processes, workstations, equipment, and materials used in the product assembly process; The material information management is used to manage the information of various materials used in the production process of products, encode production parts and components, and associate related products according to unified rules; The production calendar management is used to determine the specific time periods when resources are at work and to perform maintenance management on special dates when production is not performed.

10. The dynamic production planning system according to claim 1, characterized in that: The system management module is used to perform user management, authority management, system log and security audit.

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