Supply chain management method based on production demand plan

Abstract

Provided is a supply chain management method based on a production demand plan. Relates to the technical field of production enterprise supply chain management. Comprising an EPR system which is further connected with a WMS system, and then the method is carried out according to the following steps that (1) a demand is put forward; (2) the inventory of the required materials is locked; 3) delivering goods to the demand users according to the quantity locked by the WMS system, 4) purchasing by a purchasing department according to the purchasing quantity of the purchasing plan list, and arranging warehousing and entering into an ERP system.The total quantity of the entity warehouses and the virtual warehouses can be reflected timely and objectively, and then waste caused by segmentation and use and management loopholes caused by excessive distribution are avoided.

Description

Technical Field

[0001] The present invention relates to the technical field of supply chain management of manufacturing enterprises, and in particular to a management method for integrating an enterprise production management system (ERP) with a warehouse management system (WMS) to meet production planning requirements. Background Art

[0002] At present, most of the supply chain links of manufacturing enterprises are carried out manually through Excel, which is labor-intensive and has poor data accuracy. For this reason, a small number of enterprises have launched supply chain systems based on enterprise production management systems (ERP), which can improve the management level of production, procurement, inventory and other links to a certain extent. During the operation of their ERP system, the inbound and outbound data are all manually entered, which is prone to errors, wastes time and has a large workload. However, after a long period of accumulation, a basic information database of materials required for enterprise production and operation can also be formed, including the name, model, brand, and number (ID) of the materials. After all, the ERP system is a comprehensive enterprise management system. For the specific link of warehousing, there are still deficiencies: the inability to view inventory and query the specific location of materials in real time, and the inability to provide corresponding data decision support.

[0003] Therefore, some companies will consider launching a warehouse management system (WMS) when they grow in size. There are two situations: one is that the company has not established an ERP system before and launches a WMS system alone; the other is that the company already has an ERP system and adds a warehouse management system (WMS) to use with ERP.

[0004] For the former, launching a WMS system alone will encounter many problems. In the absence of an ERP system, where does the material information come from? How to solve the problem of material batches? How to trace? How to calculate the amount of materials received? And so on. It takes a lot of manpower and time to enter the above basic information of materials into the newly launched WMS system. In summary, using ERP alone is inefficient. The in and out data are manually entered into the ERP system, which is prone to errors and wastes time. It is impossible to view inventory and query the specific location of materials in real time, and it cannot provide corresponding data decision support.

[0005] As for the latter, although the isolated use of WMS can effectively manage inventory, the information between it and ERP is not synchronized. From the perspective of outbound delivery, it is easy to cause wrong shipments and missed shipments; from the perspective of incoming warehouses, it is difficult to match the actual production usage and sales, and the inventory cannot be reasonably planned, which is easy to cause inventory backlogs and unsalable, resulting in low inventory turnover.

[0006] There is no reference in the existing technology to avoid ERP and WMS being independent of each other. Therefore, how to integrate (merge, combine) the two management systems of ERP and WMS to maximize the utilization of resources, meet the needs of production planning, and achieve lightweight operation of inventory has become a technical problem that needs to be solved in this field. Summary of the invention

[0007] In response to the above technical problems, the present invention provides a supply chain management method based on production demand planning, which can efficiently "borrow" data from ERP when adding WMS when ERP is already in operation, thereby promoting communication and integration of the two systems and greatly improving management efficiency.

[0008] The supply chain management method based on production demand planning of the present invention comprises an EPR system, and the EPR system is also connected to a WMS system, and then the following steps are performed: 1) Propose a demand. The EPR system receives the material requirement list from the demanding user; 2) Lock the inventory of required materials. The ERP system sends a query to the WMS system based on the received material demand table, and the WMS system queries the physical warehouse for the inventory of the required materials. 2.1) If the inventory quantity meets the quantity requirements, the ERP system instructs the WMS system to lock the quantity and go to step 3); 2.2) If the inventory quantity cannot meet the requisition quantity requirement, issue a purchase plan, the purchase quantity of the purchase plan = project demand quantity - inventory quantity, and lock the inventory quantity; go to step 4); 3) Deliver goods to users in need according to the quantity locked by the WMS system; 4) The purchasing department purchases according to the purchase quantity in the purchase plan, arranges for warehousing, enters the data into the ERP system, and then returns to step 2.1).

[0009] Furthermore, basic data of material files, supplier files, warehouse files, measurement unit files, inbound order information and outbound order information are created in the ERP system, and the basic data is packaged into json format and transmitted to the WMS system through a web application.

[0010] Furthermore, the WMS also receives the warehousing information sent from the ERP system and calls for the outbound delivery of materials in the warehouse.

[0011] Furthermore, in step 4), when the material is put into storage in the ERP system, a storage QR code is generated for the material, and the generation rule of the storage QR code is: storage order number + material code + storage line number.

[0012] Furthermore, in the step 2), the ERP system also queries the inventory levels of several virtual warehouses according to the received material requirement table.

[0013] Furthermore, the virtual warehouse is: excess materials issued to the using department.

[0014] The present invention innovatively integrates the WMS system into the ERP system, which can realize the timely transmission and sharing of warehouse management information, avoid the repeated manual data entry process, reduce the delay of information transmission, and improve work efficiency. The outbound documents in the WMS system and the sales orders in the ERP system can be connected in real time, avoiding the situation of wrong shipment or missed shipment caused by information asynchrony, and improving the accuracy and timeliness of outbound operations. In addition, according to the characteristics of the electronics industry, the present invention also proposes the concept of "virtual warehouse", that is, the disk materials that are not suitable for splitting and taking are over-issued, but the excess part forms the inventory of the "virtual warehouse" in the technical solution of the present invention. When it is subsequently taken, it can timely and objectively reflect the total amount of the physical warehouse and the virtual warehouse, thereby avoiding the waste caused by splitting and taking, and the management loopholes caused by over-issuance. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] Figure 1 It is the workflow diagram of the present invention, Figure 2 It is an operation process diagram of the present invention. DETAILED DESCRIPTION

[0016] The following combination Figure 1 , 2 The present invention will be further described.

[0017] The supply chain management method based on production demand planning of the present invention firstly operates an EPR system within the enterprise, and the EPR system is also connected to a WMS system, and then proceeds according to the following steps: 1) Propose a demand. The EPR system receives the material requirement list (hereinafter referred to as BOM list) from the user.

[0018] 2) Lock the inventory of required materials. The ERP system sends a query to the WMS system based on the received material requirement list, and the WMS system queries the physical warehouse for the inventory of the required materials.

[0019] 2.1) If the inventory quantity meets the quantity requirements, the ERP system instructs the WMS system to lock the quantity and go to step 3).

[0020] 2.2) If the inventory quantity cannot meet the quantity required, issue a purchase plan, the purchase quantity of the purchase plan = project demand quantity - inventory quantity, and lock the inventory quantity; go to step 4).

[0021] 3) Deliver goods to users in need according to the quantity locked by the WMS system.

[0022] 4) The purchasing department purchases according to the purchase quantity in the purchase plan, arranges for warehousing, enters the data into the ERP system, and then returns to step 2.1).

[0023] Furthermore, basic data of material files, supplier files, warehouse files, measurement unit files, inbound order information and outbound order information are created in the ERP system, and the basic data is packaged into json format and transmitted to the WMS system through a web application.

[0024] Furthermore, WMS also receives incoming inventory information from the ERP system and calls for the outbound delivery of materials from the warehouse.

[0025] Furthermore, in step 4), when the material is put into storage in the ERP system, a storage QR code is generated for the material, and the generation rule of the storage QR code is: storage order number + material code + storage line number.

[0026] Furthermore, in the step 2), the ERP system also queries the inventory levels of several virtual warehouses according to the received material requirement table.

[0027] Furthermore, the virtual warehouse is: excess materials issued to the using department.

[0028] According to the above general steps, when specifically implemented, there are the following specific embodiments: (1) The R&D department submits a material requirement form to the warehouse management department, which then queries the inventory through the ERP system.

[0029] (2) When the inventory quantity is sufficient, the ERP system sends the project requirements and locked quantity to the WMS system.

[0030] The method of the present invention calculates the quantity to be purchased in real time and locks the corresponding quantity according to batches, and all warehousing and outbound operations are carried out according to batches.

[0031] In the system, all project materials are locked on a first-come, first-served basis. If they are not in stock, they will be purchased by the purchasing department. If the number of materials required by the project is sufficient, there is no need to purchase them. The system automatically locks them according to the first-in, first-out and small batch number algorithm based on the batch number.

[0032] According to the quantity required by the project, if the inventory quantity is insufficient, the quantity to be purchased = project demand quantity - inventory quantity, and the locked quantity is directly locked according to the existing batch quantity in the inventory.

[0033] According to the quantity required by the project, if the inventory quantity is 0, the locked quantity is 0, and the quantity to be purchased = the quantity required by the project.

[0034] The system will record the source of all materials purchased by the purchasing department. Once they are put into storage, the batch and quantity will be automatically bound to the project. The next time you pick up materials, the WMS system will automatically issue them according to the bound batch.

[0035] This supply chain system involves the integration and interaction of two systems, namely the ERP system and the WMS system.

[0036] All basic information is created in ERP, including material files (material number, material name, specification model, etc.), supplier files, warehouse files, measurement unit files, incoming order information, outgoing order information, etc. This information is packaged into json format and transmitted to WMS through webservice.

[0037] The main function of WMS is to receive the incoming warehouse information from ERP, call the boxes in the warehouse for outbound delivery, and use a barcode scanner to scan the material QR code and the material box QR code for binding. When there is an outbound delivery order from ERP, call the boxes in the warehouse for outbound delivery again. The outbound delivery requires scanning the QR code, and finally send the outbound delivery information to ERP, which needs to calculate the outbound quantity and amount.

[0038] (3) If the quantity is insufficient, the purchase will be handled by the Purchasing Department.

[0039] (4) The head of the purchasing department assigns buyers based on the major categories of materials.

[0040] (5) The buyer generates an order (putting materials purchased from the same supplier into one order).

[0041] (6) The buyer signs a contract with the supplier.

[0042] (7) After the materials arrive, they are entered into the ERP system and affixed with a QR code.

[0043] The purpose of the QR code technology used above is to achieve material tracking and subsequent tracing.

[0044] Purchasing staff usually enters the warehouse in ERP, and the system will generate a QR code for each material. Because sometimes different batches of the same material are entered in the same warehouse entry (batch: manufacturers usually call materials with the same process and the same production date a batch, and different production dates generally correspond to different batches, which manufacturers will indicate when shipping), if there are several batches of the same material in the warehouse entry, they will be displayed as several lines, and the quantities of several batches cannot be combined. Therefore, the rule for generating the QR code is the warehouse entry number + material code + warehouse entry line number (such as: 2024083101_15010000001_1). Through this QR code, you can query the production batch number, material price, material manufacturer and other information of the material.

[0045] After the purchasing staff has put the goods into the warehouse, they will hand them over to the warehouse staff to confirm the quantity. Sometimes the warehouse staff will find that there are too many materials in the same batch and they cannot fit in one box. At this time, the WMS system needs to subcontract and encode again based on the QR code sent by ERP (such as: 2024083101_15010000001_1-1) in order to bind different material boxes.

[0046] Once problems occur with the company's products, if it is found that a certain component has a problem, the QR code of the component can be directly scanned to track the manufacturer, batch number, expiration date, production date and other information.

[0047] (8) After entering the warehouse, it is handed over to the Quality Inspection Department. The Quality Inspection Department personnel will conduct inspection through the ERP system, fill in the inspection type, inspection quantity, unqualified quantity and other information, and generate an electronic certificate of conformity.

[0048] (9) After the inspection is completed, the quantity will be confirmed by the warehouse again.

[0049] (10) After the warehouse confirms the quantity, it will send the project information, inventory quantity, and locked quantity to the WMS system again.

[0050] (11) The WMS system calls the material box.

[0051] (12) Bind the material box and the material by scanning the QR code on the material box and the material QR code.

[0052] (13) After the binding is completed, the final storage is completed.

[0053] (14) The material picker fills out the material pick list in ERP. The material pick list directly calls the materials and quantities in the previous material requirement table. The material pick list contains project information.

[0054] (15) After the department leader approves the material requisition form, the material requisition information will be sent to the WMS system.

[0055] (16) The WMS system issues shipments based on the quantity locked in the item.

[0056] The present invention innovatively proposes the concept of a virtual warehouse. Usually, all outbound shipments are picked up from the WMS system, and then the quantity, batch and other information are sent back to the ERP through webservice. Materials stored in the virtual warehouse can only be picked up in the ERP system. During the implementation of the project, a problem was encountered. Because the company's industry is the electronic component industry, the components are relatively small. These components are generally in trays, commonly known as trays. Because the components are too small, when welding these components, the workshop generally puts a whole tray of materials on the welding machine instead of disassembling them one by one for welding. The usual practice is to take a whole tray and put it on the welding machine for welding. If the next project needs to use the material, it must wait until the project is over before it can be used. This leads to a problem. The quantity of the project outbound shipment cannot be shipped according to the actual quantity required by the project, and a whole tray is required for shipment. Therefore, we put forward the concept of virtual warehouse. For example, a project needs 10 components, but the number of components in a tray is 1000. Now the number to be picked up is a whole tray of 1000. For the WMS system, it means picking up 1000, but when sending to ERP, it is sent separately, that is, the number to be picked up is 10, and the other 990 are considered to be transferred to the virtual warehouse (the workshop is regarded as the virtual warehouse). For all materials transferred to the virtual warehouse, they are picked up in the ERP system. In this way, when another project needs to use the material, the inventory in the ERP system will see 990 (there is indeed no inventory in the smart warehouse (WMS system), but there are still 990 in the virtual warehouse), instead of 0. If it is 0, the purchasing department needs to purchase it. If the project quantity is sufficient, there is no need to purchase 990. This reduces the backlog of inventory and reduces the pressure on the company's capital use. For materials transferred to the virtual warehouse, they can be shipped out of the virtual warehouse (in the ERP system), or the remaining quantity can be transferred to the smart warehouse again after the project is used up, and then shipped out from the smart warehouse. The purpose of this is to prevent waste, plan inventory more reasonably, and include the inventory quantity for management of materials that have been used by the workshop but not used up.

[0057] The present invention combines ERP and WMS, which has the following technical significance for the daily production, sales, procurement and other work of manufacturing enterprises: ‌First, improve work efficiency‌: The connection between ERP and WMS can realize the timely transmission and sharing of warehouse management information, avoid the repeated manual data entry, reduce the delay of information transmission, and improve work efficiency. For example, the outbound documents in the WMS system and the sales orders in the ERP system can be connected in real time, avoiding the situation of wrong shipment or missed shipment caused by information asynchrony, and improving the accuracy and timeliness of outbound operations‌.

[0058] The second is to optimize inventory management: The connection between WMS and ERP can achieve accurate inventory management and avoid excess or out-of-stock inventory. WMS can obtain sales orders and forecast information in a timely manner by connecting to the ERP system, thereby rationally planning inventory, avoiding inventory backlogs and unsalable products caused by sales fluctuations, and improving inventory turnover.

[0059] The third is to provide data support: the docked system can provide comprehensive data support to help enterprise managers conduct data analysis and decision-making. Through the docked system, data analysis and report generation of warehouse operations can be realized, such as monitoring and analysis of data indicators such as inventory turnover rate and goods circulation time, providing enterprises with decision support for optimizing warehouse management and supply chain.

[0060] Fourth, reduce management costs: Through automated processes, accurate inventory and accurate data support, the waste of human resources and the capital costs caused by inventory backlogs are reduced. At the same time, accurate data support and information sharing also reduce the risk of damaged brand image and reduced customer satisfaction due to inaccurate information, and reduce corporate management costs.

[0061] Fifth, improve customer service: The connection between WMS and ERP can improve the company's response speed to customer service. By connecting to the ERP system, WMS can analyze customer orders, quickly distribute goods according to customer needs, and provide real-time feedback on order fulfillment progress and cargo logistics paths through the connected information system, improving information transparency and management operability.

[0062] Sixth, improve the accuracy and efficiency of operations: WMS supports barcode technology. When combined with PDA handheld devices, the product label data scanned by the PDA will be automatically checked with the WMS for correctness. After the warehousing and outbound operations are completed, the storage location information and quantity will be automatically updated, thereby greatly improving the efficiency and accuracy of operations within the warehouse.

[0063] Seventh, real-time operation adjustment: Employees can use PDA devices to scan product labels to automatically collect operation information and display it on the dashboard in real time. Warehouse managers can understand the current operation completion status and whether the employee's operation is correct in real time, so as to correct operation errors in real time to avoid affecting the next process and ensure that the operation is completed on time and accurately.

[0064] Eighth, accurate demand forecasting: Product in-and-out reports and inventory reports can help managers make demand forecasts. For example, the in-and-out reports can help you understand which products have more and less in-and-out times, so that you can make adjustments in future purchases and production to ensure profits; the inventory reports can help you understand the current inventory quantity, storage location, and entry time of various products, providing more accurate data for purchases, production, and sales to avoid out-of-stock, overselling, and repeated purchases.

[0065] Ninth, batch management and quality traceability: WMS supports batch management and can recommend shelf locations or picking locations based on various strategies such as first-in-first-out or last-in-first-out to improve inventory turnover. At the same time, it can automatically record the operation status of each link, and when problems occur, they can be quickly traced back to the original link and responsible person.

[0066] Tenth, complete the warehouse entry and exit on time: WMS's precise warehouse entry and exit order management function allows users to complete the order entry and exit on time and improve the order fulfillment rate. The overall efficient process reduces the cycle time and completes the warehouse entry and exit on time.

[0067] It should be noted that the above specific implementations are only preferred embodiments of the present invention and the technical principles used. Those skilled in the art should understand that various modifications, equivalent substitutions, changes, etc. can be made to the present invention based on the technical content disclosed in this application document. However, as long as these changes do not deviate from the spirit of the present invention, they should be within the scope of protection of the present invention. In addition, some terms used in the specification and claims of this application are not restrictive, but are only for the convenience of description.

Claims

1. A supply chain management method based on production demand planning, including an EPR system, characterized in that: The EPR system is also connected to a WMS system, and then the following steps are performed: 1) Propose a demand. The EPR system receives the material requirement list from the demanding user; 2) Lock the inventory of required materials. The ERP system sends a query to the WMS system based on the received material demand table, and the WMS system queries the physical warehouse for the inventory of the required materials. 2.1) If the inventory quantity meets the quantity requirements, the ERP system instructs the WMS system to lock the quantity and go to step 3); 2.2) If the inventory quantity cannot meet the requisition quantity requirement, issue a purchase plan, the purchase quantity of the purchase plan = project demand quantity - inventory quantity, and lock the inventory quantity; go to step 4); 3) Deliver goods to users in need according to the quantity locked by the WMS system; 4) The purchasing department purchases according to the purchase quantity in the purchase plan, arranges for warehousing, enters the data into the ERP system, and then returns to step 2.1).

2. The supply chain management method based on production demand planning according to claim 1 is characterized in that: In the ERP system, basic data of material files, supplier files, warehouse files, measurement unit files, inbound order information and outbound order information are created. The basic data is packaged into json format and transmitted to the WMS system through a web application.

3. The supply chain management method based on production demand planning according to claim 1 is characterized in that: The WMS also receives incoming warehousing information from the ERP system and calls for the outbound delivery of materials from the warehouse.

4. The supply chain management method based on production demand planning according to claim 1 is characterized in that: In step 4), when the material is put into storage in the ERP system, a storage QR code is generated for the material, and the generation rule of the storage QR code is: storage order number + material code + storage line number.

5. The supply chain management method based on production demand planning according to claim 1 is characterized in that: In step 2), the ERP system also queries the inventory levels of several virtual warehouses according to the received material requirement table.

6. The supply chain management method based on production demand planning according to claim 5 is characterized in that: The virtual warehouse is: excess materials issued to the using department.

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