Manufacturing industry lean production management system based on transfer card work reporting

Abstract

The invention relates to the technical field of automobile accessories, and discloses a manufacturing lean production management system based on transfer card work reporting, and the system comprises a data collection module which is used for collecting production data in real time through scanning a code transfer card; the production plan and circulation card configuration module is used for making a production plan and generating a circulation card matched with the production plan; the production process tracking module is used for dynamically monitoring the production state of the transfer card and the use condition of equipment; and the quality inspection and batch tracing module is used for binding the quality inspection data with the circulation card to realize quality problem tracing. By scanning a code transfer card, collecting production data in real time, and updating the state and task progress of each station in the production process to the system in real time, a manager can master the current production situation at any time, find potential problems in time and quickly take countermeasures, the response speed of sudden problems and the production efficiency are effectively improved, and the production efficiency is improved. And the production lean degree is improved.

Description

Technical Field

[0001] The invention relates to the technical field of automobile and motorcycle parts, and in particular to a lean production management system for manufacturing industry based on circulation card reporting. Background Art

[0002] ERP and MES are widely used in manufacturing production management and perform well on fully automated production lines. However, in non-fully automated production lines, the existing centralized code scanning reporting solutions and production data management methods have obvious limitations. Centralized code scanning usually requires users to use a barcode scanner to batch scan the centrally printed fixed codes within a fixed time period, or to enter them uniformly through an industrial control all-in-one machine. Although this model has achieved data digitization to a certain extent, its real-time feedback effect on production data is limited, and it is easy to cause inaccurate management information due to delays or human factors.

[0003] First, the centralized scanning method requires users to uniformly enter data after a long time interval. This mode causes the real-time of production data to lag seriously, making it impossible for managers to accurately grasp the real-time status of the production site and miss the opportunity to discover and solve problems in time. At the same time, between two centralized scannings, users rely heavily on paper records, which not only increases the workload of data entry, but also easily leads to inaccurate or missing records, further affecting the correctness of management decisions. In addition, the existing system lacks an effective error prevention and verification mechanism for the reliability of data entry, and cannot timely detect human input errors, deliberate concealment of problems or tampering of data, thereby exacerbating the uncertainty in production management. For equipment monitoring and management, existing technologies usually find it difficult to associate equipment operation information with production information, and lack a bridge to prove their relevance and matching. In general, the monitoring relevance in the production process does not meet the requirements, so small and medium-sized manufacturing companies find it difficult to respond quickly when facing temporary production task adjustments or equipment replacements, which seriously affects production efficiency. At the same time, the batch information in the existing centralized reporting method is difficult to be accurately recorded and tracked, resulting in the inability to accurately associate production batches with equipment operation and quality inspection results. All of them are retained in a large production batch and cannot be refined, which is not conducive to the rapid traceability and management of defective products. Especially in emergencies, such as equipment failure and production shutdown, the existing system is often unable to separate small batches from these large batches (such as replacement of corresponding equipment on the production line, etc.), resulting in interruptions to the production process at the system level, and even requiring a large amount of manual data re-entry, which increases the company's management costs and reduces the overall reliability of production. Summary of the invention

[0004] In view of the shortcomings of the prior art, the present invention provides a lean production management system for the manufacturing industry based on circulation card reporting, which solves the problems of lagging production data, lack of data error prevention measures, poor equipment management flexibility, insufficient quality traceability and weak ability to respond to emergencies in the existing production management system.

[0005] To achieve the above objectives, the present invention is implemented through the following technical solutions: A lean production management system for manufacturing industry based on circulation card reporting, comprising: Data collection module, which is used to collect production data in real time by scanning the code of the circulation card; The production plan and flow card configuration module is used to formulate production plans and generate matching flow cards; The production process tracking module is used to dynamically monitor the production status and equipment usage of the circulation card; The quality inspection and batch traceability module is used to bind the quality inspection data with the circulation card to achieve the traceability of quality problems; Warehousing and logistics management module, which is used to manage material distribution and finished product warehousing based on circulation cards; Data analysis and decision support module, which is used to analyze the collected data, generate reports and provide optimization suggestions; Emergency response module, which is used to handle emergencies caused by data entry errors, equipment failures, production stoppages or quality problems during the production process, and dynamically update system data; The data acquisition module uses the circulation card as the smallest data unit in the production process. The user scans the circulation card in time during the production process, and binds the equipment and quality inspection information by scanning the circulation card code. Finally, the user completes the data entry and reporting. It is used to reflect the production status in real time and improve the level of lean production management.

[0006] Preferably, the data acquisition module includes: The circulation card scanning and positioning unit is used to scan and locate the circulation card through the mobile phone scanning function, and display the current circulation card and all the production, products, equipment, quality and other information bound to it; The circulation card scanning and matching unit is used to scan the code twice in the circulation card, uniquely identify the scanning device, and match and bind it with the circulation card; The production data entry and verification unit is used to enter production data and prevent data entry errors, including production volume anomaly detection, finished product warehousing anomaly detection, equipment unbinding alarm and quality inspection result missing prompt.

[0007] Preferably, the production plan and circulation card configuration module formulates the production plan through the system, synchronizes the production targets through the circulation card, and finally transmits them to each production node. At the same time, based on the production process flow, it automatically matches the corresponding process under the current production schedule for the circulation card. There is no need to pre-bind the production equipment when formulating the production plan, and supports temporary dynamic adjustment of the equipment.

[0008] Preferably, the production process tracking module includes: The circulation card status monitoring unit is used to record the production status, production volume, operator, and operation time of each circulation card at each production node; The equipment status monitoring unit is used to monitor the production load, usage time and abnormal status of the equipment.

[0009] Preferably, the quality inspection and batch traceability module includes: The circulation card quality inspection data binding unit is used to record the quality inspection data of the corresponding batch of circulation cards in real time; The quality problem traceability unit is used to quickly locate the production batches and processes of defective products through quality inspection data and historical production records of circulation cards.

[0010] Preferably, the warehousing and logistics management module includes: Real-time inventory update unit, which dynamically updates inventory data by scanning the circulation card for warehousing; Inbound and outbound data tracking unit, which is used to achieve accurate management of product batches.

[0011] Preferably, the data analysis and decision support module includes: Data statistics and report generation unit, which is used to generate statistical reports on production efficiency, equipment utilization and quality inspection results; The exception handling and optimization suggestion unit is used to provide optimization solutions when production is abnormal.

[0012] Preferably, the emergency response module includes: Independent alarm unit for circulation cards, which is used to isolate the circulation cards that need special treatment from other normal circulation cards in case of emergencies, and mark their status for subsequent separate treatment; The dynamic task adjustment unit is used to adjust the production tasks of the circulation card according to emergencies, including pausing / resuming production, rebinding equipment and adjusting the production sequence.

[0013] The present invention provides a lean production management system for manufacturing industry based on circulation card reporting. It has the following beneficial effects: 1. The present invention collects production data in real time by scanning the code transfer card, and updates the status and task progress of each workstation in the production process to the system in real time. Managers can grasp the production status at any time, discover potential problems in time and take countermeasures quickly. Compared with the traditional centralized reporting mode, this system greatly shortens the time delay of data collection and feedback, and effectively improves the response speed and production efficiency of sudden problems.

[0014] 2. The present invention dynamically synchronizes inventory data to the system central database through a real-time inventory update unit and a circulation card-based in-and-out inventory tracking function to ensure the real-time and accuracy of the inventory status. Departments can share inventory information in real time through the system, eliminating information islands and avoiding work-in-progress backlogs and inventory waste caused by blind production or information lags, thereby optimizing overall inventory management.

[0015] 3. Through the emergency response module, the present invention can quickly isolate the circulation cards that require special treatment when emergencies such as equipment replacement, tool or mold damage, production shutdown or quality problems occur, mark their task status separately, and dynamically adjust the binding of related tasks and processes. The production tasks of other normal circulation cards can continue to advance, avoiding interruption of the entire production process due to local problems. At the same time, relevant data is automatically updated to reduce manual re-entry operations, thereby improving the reliability and continuity of the system.

[0016] 4. The strong association between the circulation card of the present invention and each production node can realize the accurate traceability of the batch data of in-and-out warehouse and the quality inspection results, and provide more accurate statistical information on equipment utilization, load conditions and operation time through the equipment usage data recorded by the system. Managers can use these data to comprehensively analyze and optimize the production process and equipment resources, improve the overall resource utilization and realize lean management. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] Figure 1 It is a schematic diagram of the system module of the present invention; Figure 2 It is a schematic diagram of a data acquisition module of the present invention; Figure 3 It is a schematic diagram of a production process tracking module of the present invention; Figure 4 It is a schematic diagram of the quality inspection and batch tracing module of the present invention; Figure 5 It is a schematic diagram of the warehousing and logistics management module of the present invention; Figure 6 It is a schematic diagram of the data analysis and decision support module of the present invention; Figure 7 It is a schematic diagram of the emergency response module of the present invention. DETAILED DESCRIPTION

[0018] The technical solution of the present invention will be described clearly and completely below in conjunction with the accompanying drawings of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0019] Please refer to the attached Figure 1 The embodiment of the present invention provides a lean production management system for manufacturing industry based on flow card reporting, including: Data collection module, which is used to collect production data in real time by scanning the code of the circulation card; The production plan and flow card configuration module is used to formulate production plans and generate matching flow cards; The production process tracking module is used to dynamically monitor the production status and equipment usage of the circulation card; The quality inspection and batch traceability module is used to bind the quality inspection data with the circulation card to achieve the traceability of quality problems; Warehousing and logistics management module, which is used to manage material distribution and finished product warehousing based on circulation cards; Data analysis and decision support module, which is used to analyze the collected data, generate reports and provide optimization suggestions; Emergency response module, which is used to handle emergencies caused by data entry errors, equipment failures, production stoppages or quality problems during the production process, and dynamically update system data; The data collection module uses the circulation card as the smallest data unit in the production process. The user scans the circulation card in time during the production process and binds the equipment and quality inspection information by scanning the code on the circulation card. Finally, the user completes the data entry and reporting. It is used to reflect the production status in real time and improve the level of lean production management.

[0020] Specifically, the lean production management system for manufacturing based on the circulation card reporting system improves the production efficiency, management flexibility and data accuracy of small and medium-sized manufacturing industries in non-automatic production line environments through the collaborative work of multiple modules. The system uses the circulation card as the core data unit and implements lean management of the entire production process around it.

[0021] First, the data collection module collects production data in real time by having personnel scan the code on the circulation card, ensuring that the real-time status of the production site can be uploaded to the system without delay, avoiding the data lag problem in the traditional centralized reporting mode; at the same time, by binding equipment and quality inspection information, it provides basic support for subsequent tracking and analysis.

[0022] The production plan and circulation card configuration module generates corresponding circulation cards for each production cycle by formulating detailed production plans. Users can flexibly adjust the number of circulation cards according to actual needs. It supports dynamic binding and adjustment of equipment to ensure that the system can adapt to frequently changing production conditions, and prints out circulation cards through barcodes to realize the physical distribution of tasks and production startup.

[0023] Driven by the circulation card, the production process tracking module realizes dynamic monitoring of each production link, including recording the process progress, equipment usage, operator and operation time of each circulation card in production. Through the accurate data collected in real time, it provides managers with a comprehensive insight into the production status.

[0024] The quality inspection and batch traceability module quickly establishes the association between quality problems and specific production batches by binding quality inspection data with circulation cards, achieving accurate traceability of defective products and tracking of process responsibilities, effectively reducing rework costs and improving product quality management.

[0025] The warehousing and logistics management module manages the issuance of materials and the storage of finished products through circulation cards, realizes dynamic update and real-time status display of inventory, avoids the problem of lagging material information in traditional inventory management, and combines the scanning operation of circulation cards to ensure the accuracy and tracking ability of in-and-out data.

[0026] The data analysis and decision support module integrates all production data, conducts multi-dimensional analysis on production efficiency, equipment utilization rate, quality inspection results, etc., generates visual reports, and provides optimization suggestions based on abnormal situations, supporting managers to make quick decisions and improve the overall production management level.

[0027] In addition, the emergency response module provides the system with great flexibility. When emergencies such as equipment failure, process changes, production shutdowns or quality problems occur, the system can isolate the affected circulation cards in real time to ensure that other circulation cards and production processes can continue to run; at the same time, the system will automatically update relevant data to avoid data loss and work delays caused by manual re-entry, greatly improving the system's adaptability in complex production scenarios.

[0028] Overall, the system takes the circulation card as the driving core, and through the synergy of multiple modules, from data collection to task execution, from status tracking to data analysis, and then to the flexible handling of emergencies, it realizes the digitalization, leanness and intelligence of the production process, helping enterprises to complete production tasks more efficiently and cope with complex and changing production environments.

[0029] Please refer to the attached Figure 2 -Attached Figure 4 , the data acquisition module includes: The circulation card scanning and positioning unit is used to scan and locate the circulation card through the mobile phone scanning function, and display the current circulation card and all the production, products, equipment, quality and other information bound to it; The circulation card scanning matching unit is used to scan the code twice in the circulation card, scan the unique identification of the code scanning device, and match and bind it with the circulation card; Production data entry and verification unit, which enters production data and can be used to prevent data entry errors, including production volume anomaly detection, finished product warehousing anomaly detection, equipment unbound alarm and quality inspection result missing prompt; The production plan and circulation card configuration module formulates the production plan through the system, synchronizes the production target through the circulation card, and finally transmits it to each production node. At the same time, based on the production process, the circulation card automatically matches the corresponding process under the current production schedule. There is no need to pre-bind the production equipment when formulating the production plan, and it supports temporary dynamic adjustment of the equipment. The production process tracking module includes: The circulation card status monitoring unit is used to record the production status, production volume, operator, and operation time of each circulation card at each production node; Equipment status monitoring unit, which is used to monitor the production load, usage time and abnormal status of the equipment; The quality inspection and batch traceability module includes: The circulation card quality inspection data binding unit is used to record the quality inspection data of the corresponding batch of circulation cards in real time; The quality problem traceability unit is used to quickly locate the production batches and processes of defective products through quality inspection data and historical production records of circulation cards.

[0030] Specifically, the circulation card scanning and positioning unit in the data acquisition module uses a mobile phone or other device with a scanning function to scan each circulation card for unique identification, and displays the relevant information of the current circulation card in real time, including production tasks, product status, equipment information and quality data, to ensure the uniqueness and independence of the circulation card data. This unit uses the scanning and positioning function to provide real-time feedback on process, equipment and production status information, providing basic data support for subsequent tracking and analysis, while ensuring the accurate binding of the circulation card with equipment and quality data; the circulation card scanning and matching unit can uniquely match the equipment and quality inspection data through a second scanning, and its production data entry and verification unit uses a built-in error prevention mechanism, including production volume anomaly detection, equipment unbinding alarm, quality inspection result missing prompt and finished product warehousing anomaly detection function, to prevent human errors in the data entry stage and ensure the accuracy and integrity of the data.

[0031] The production plan and circulation card configuration module realizes flexible setting of production targets through circulation cards, and supports real-time synchronization of production targets, so that each production node can immediately know the latest task requirements; this module binds the corresponding process to the circulation card based on the production process flow, and abandons the limitations of traditional fixed equipment binding, and supports dynamic adjustment of equipment, thereby improving the system's flexibility and efficiency in dealing with temporary equipment changes or production task adjustments.

[0032] The production process tracking module includes a circulation card status monitoring unit and an equipment status monitoring unit. The circulation card status monitoring unit can record the operation status and specific operation time of each circulation card at each production node in real time, providing data support for production efficiency analysis and process traceability; the equipment status monitoring unit realizes refined equipment management by monitoring the production load, usage time and abnormal status of the equipment, helping enterprises optimize equipment utilization and promptly discover potential problems.

[0033] The quality inspection and batch traceability module includes the circulation card quality inspection data binding unit and the quality problem traceability unit. The circulation card quality inspection data binding unit records the correlation information between the circulation card and the quality inspection results in real time during the quality inspection process, laying the foundation for product quality management; the quality problem traceability unit uses the quality inspection data and the historical production records of the circulation card to quickly locate the production batches and problem processes corresponding to defective products, achieve accurate traceability, effectively reduce rework costs and improve quality management efficiency. The coordinated operation of the above-mentioned module units in the system can comprehensively improve the real-time, accuracy and traceability of production data, significantly optimize the production efficiency and management capabilities of the enterprise, and reduce the additional costs caused by human errors and equipment problems.

[0034] Please refer to the attached Figure 5 -Attached Figure 7 , warehousing and logistics management modules include: Real-time inventory update unit, which dynamically updates inventory data by scanning the circulation card for warehousing; Inbound and outbound data tracking unit, which is used to achieve accurate management of product batches; Data analysis and decision support modules include: Data statistics and report generation unit, which is used to generate statistical reports on production efficiency, equipment utilization and quality inspection results; Exception handling and optimization suggestion unit, which is used to provide optimization solutions when production is abnormal; The emergency response module includes: Independent alarm unit for circulation cards, which is used to isolate the circulation cards that need special treatment from other normal circulation cards in case of emergencies, and mark their status for subsequent separate treatment; The dynamic task adjustment unit is used to adjust the production tasks of the circulation card according to emergencies, including pausing / resuming production, rebinding equipment and adjusting the production sequence.

[0035] Specifically, the warehousing and logistics management module includes a real-time inventory update unit and an in-and-out data tracking unit. The real-time inventory update unit dynamically records the in-and-out status of materials and finished products through the user's scanning operation on the circulation card, and synchronizes the inventory data to the system's central database in real time to ensure the accuracy and timeliness of inventory information; through this unit, enterprises can eliminate the problem of inventory information lag caused by manual recording or delayed updates, and optimize inventory management efficiency. The in-and-out data tracking unit records the in-and-out information of each batch of products in detail through the circulation card identification and the user's scanning operation, and refines batch management to the circulation card level, providing accurate data support for subsequent quality traceability, shipment scheduling and inventory optimization.

[0036] The data analysis and decision support module includes the data statistics and report generation unit and the exception handling and optimization suggestion unit. The data statistics and report generation unit generates multi-dimensional statistical reports and visual data by integrating key indicator data such as production efficiency, equipment utilization, and quality inspection results, providing managers with an intuitive panoramic view of the production process; this unit can help companies quickly identify production bottlenecks, inefficient links, and unreasonable equipment use, so as to formulate targeted improvement measures. When production anomalies occur, the exception handling and optimization suggestion unit automatically analyzes the abnormal data, combines historical data with the current production status, and generates optimization plans, such as optimizing the distribution of circulation card tasks or optimizing equipment utilization, thereby supporting managers to make quick decisions and improve the overall production management level, improve production efficiency, and reduce waste.

[0037] The emergency response module includes an independent alarm unit for flow cards and a dynamic task adjustment unit. In the event of an emergency such as equipment failure, process change, quality problem or data entry error, the independent alarm unit for flow cards will isolate the flow cards that require special treatment from other normal flow cards and mark their status specially. At the same time, it supports suspending or resuming the production tasks of related flow cards to prevent the problem from spreading further. This function ensures that the impact of the emergency problem is limited to a small range and reduces the interference to the overall production line. The dynamic task adjustment unit makes real-time adjustments to the production tasks of the flow cards according to the emergency, including suspending or resuming the production of specific flow cards, rebinding appropriate processes and equipment, or temporarily suspending certain tasks, to ensure the normal progress of the production tasks of other flow cards and improve the flexibility and adaptability of the system. The coordinated operation of these module units ensures the continuity, reliability and efficiency of the system under abnormal production conditions, and provides comprehensive support for enterprises to cope with complex and changing production scenarios.

[0038] Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions and variations may be made to the embodiments without departing from the principles and spirit of the present invention, and that the scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. A lean production management system for manufacturing industry based on circulation card reporting, characterized by: include: Data collection module, which is used to collect production data in real time by scanning the code of the circulation card; The production plan and flow card configuration module is used to formulate production plans and generate matching flow cards; The production process tracking module is used to dynamically monitor the production status and equipment usage of the circulation card; The quality inspection and batch traceability module is used to bind the quality inspection data with the circulation card to achieve the traceability of quality problems; Warehousing and logistics management module, which is used to manage material distribution and finished product warehousing based on circulation cards; Data analysis and decision support module, which is used to analyze the collected data, generate reports and provide optimization suggestions; Emergency response module, which is used to handle emergencies caused by data entry errors, equipment failures, production stoppages or quality problems during the production process, and dynamically update system data; The data acquisition module uses the circulation card as the smallest data unit in the production process. The user scans the circulation card in time during the production process, and binds the equipment and quality inspection information by scanning the circulation card code. Finally, the user completes the data entry and reporting. It is used to reflect the production status in real time and improve the level of lean production management.

2. The lean production management system for manufacturing industry based on circulation card reporting according to claim 1 is characterized in that: The data acquisition module comprises: The circulation card scanning and positioning unit is used to scan and locate the circulation card through the mobile phone scanning function, and display the current circulation card and all the production, products, equipment, quality and other information bound to it; The circulation card scanning and matching unit is used to scan the code twice in the circulation card, and the scanning device uniquely identifies and matches and binds with the circulation card; The production data entry and verification unit is used to enter production data and prevent data entry errors, including production volume anomaly detection, finished product warehousing anomaly detection, equipment unbinding alarm and quality inspection result missing prompt.

3. The lean production management system for manufacturing industry based on circulation card reporting according to claim 1 is characterized in that: The production plan and circulation card configuration module formulates the production plan through the system, synchronizes the production targets through the circulation card, and finally transmits it to each production node. At the same time, based on the production process flow, it automatically matches the corresponding process under the current production schedule for the circulation card. There is no need to pre-bind the production equipment when formulating the production plan, and supports temporary dynamic adjustment of the equipment.

4. The lean production management system for manufacturing industry based on circulation card reporting according to claim 1 is characterized in that: The production process tracking module includes: The circulation card status monitoring unit is used to record the production status, production volume, operator, and operation time of each circulation card at each production node; The equipment status monitoring unit is used to monitor the production load, usage time and abnormal status of the equipment.

5. The lean production management system for manufacturing industry based on circulation card reporting according to claim 1 is characterized in that: The quality inspection and batch traceability module includes: The circulation card quality inspection data binding unit is used to record the quality inspection data of the corresponding batch of circulation cards in real time; The quality problem traceability unit is used to quickly locate the production batches and processes of defective products through quality inspection data and historical production records of circulation cards.

6. The lean production management system for manufacturing industry based on circulation card reporting according to claim 1 is characterized in that: The warehousing and logistics management module includes: Real-time inventory update unit, which dynamically updates inventory data by scanning the circulation card for warehousing; Inbound and outbound data tracking unit, which is used to achieve accurate management of product batches.

7. The lean production management system for manufacturing industry based on circulation card reporting according to claim 1 is characterized in that: The data analysis and decision support module includes: Data statistics and report generation unit, which is used to generate statistical reports on production efficiency, equipment utilization and quality inspection results; The exception handling and optimization suggestion unit is used to provide optimization solutions when production is abnormal.

8. The lean production management system for manufacturing industry based on circulation card reporting according to claim 1 is characterized in that: The emergency response module includes: Independent alarm unit for circulation cards, which is used to isolate the circulation cards that need special treatment from other normal circulation cards in case of emergencies, and mark their status for subsequent separate treatment; The dynamic task adjustment unit is used to adjust the production tasks of the circulation card according to emergencies, including pausing / resuming production, rebinding equipment and adjusting the production sequence.

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