Intelligent production planning and material management method based on production scheduling and MRP

Abstract

The invention provides an intelligent production planning and material management method based on production scheduling and MRP, and relates to the technical field of industrial Internet of Things, and the method comprises the steps: defining work center information needed by production scheduling based on class system and work calendar information; generating a production scheduling relationship based on the production scheduling product group information; according to the class system, the working calendar information, the working center information and the production scheduling relation, processing main production plan production scheduling to obtain a production scheduling result; and according to the production scheduling result, a material demand plan is adjusted through MRP calculation.

Description

Technical Field

[0001] This application belongs to the technical field of industrial Internet of Things, and specifically relates to an intelligent production planning and material management method based on production scheduling and MRP. Background Art

[0002] With the rapid development of the manufacturing industry, production planning and material management have become increasingly complex. The early production management models mainly relied on manual calculations and empirical judgments, which were feasible when dealing with a small number of products and simple production processes. However, with the accelerating changes in market demand, the increasing variety of products, and the expansion of production scale, the limitations of traditional methods have gradually emerged. To address these challenges, enterprises have started to introduce computer-aided management systems (such as ERP systems) and material requirements planning (MRP) tools to automate and optimize the production planning and material management processes.

[0003] In recent years, with the progress of information technology, especially the application of technologies such as big data analysis, Internet of Things (IoT), and artificial intelligence (AI), the concepts of intelligent manufacturing and Industry 4.0 have gradually emerged, providing new solutions for production management and supply chain optimization. These advanced technologies have made real-time data collection, intelligent prediction, and dynamic adjustment possible, greatly improving production efficiency and resource utilization.

[0004] Currently, many manufacturing enterprises have adopted production planning and material management systems based on ERP systems. These systems usually include the following functions:

[0005] Production scheduling management: Arrange production tasks according to factors such as order requirements, equipment capabilities, and working calendars.

[0006] Material requirements planning (MRP): Automatically generate procurement suggestions based on the BOM (bill of materials) and inventory information to ensure the timely supply of required materials.

[0007] Supply chain management: Coordinate the information flow among suppliers, manufacturers, and distributors to improve the transparency and response speed of the entire supply chain.

[0008] Data analysis: Use historical data for trend analysis and demand forecasting to support decision-making.

[0009] Although the existing technologies have improved the efficiency of production planning and material management to a certain extent, they still have some deficiencies.

[0010] Most existing production scheduling systems are designed based on static models and cannot respond in real time to market changes or emergencies on the production line (such as equipment failures, raw material shortages). This has led to a lack of flexibility in production plans and difficulty in quickly adapting to environmental changes. There are information silos between different departments (such as production, procurement, sales), resulting in poor communication and affecting the overall coordination efficiency. For example, the production department may not be able to obtain the latest inventory information in a timely manner, thus delaying the production schedule. Traditional MRP systems often have calculation errors when dealing with complex product structures and changing demands, resulting in material shortages or surpluses. In addition, insufficient consideration of uncertain factors in the supply chain (such as delivery delays, supplier changes) further increases the risks. Although some systems integrate data analysis functions, most remain at the descriptive and diagnostic analysis levels and lack predictive and guiding suggestions. Enterprises need smarter tools to help them make forward-looking decisions. Summary of the Invention

[0011] This application provides an intelligent production planning and material management method based on production scheduling and MRP to solve one of the above technical problems.

[0012] The technical solution adopted by this application is as follows:

[0013] This application embodiment provides an intelligent production planning and material management method based on production scheduling and MRP, including:

[0014] Define the work center information required for production scheduling based on shift system and work calendar information;

[0015] Generate production scheduling relationships based on production scheduling product group information;

[0016] Process the master production plan scheduling according to the shift system, the work calendar information, the work center information, and the production scheduling relationship to obtain a production scheduling result;

[0017] Adjust the material requirements plan through MRP calculation according to the production scheduling result.

[0018] According to an embodiment of this application, the step of defining the work center information required for production scheduling based on shift system and work calendar information specifically is:

[0019] Define and input the shift system, including the shift table and the shift schedule table;

[0020] Define and input the work calendar information, including the work calendar table and the work calendar details table;

[0021] Implement the information input and output functions of the shift system, shifts, and work calendar;

[0022] Input the data of the work center table, including the basic information of each work center, and associate it with the working calendar and shift system;

[0023] Establish the scheduling work center group table and the scheduling work center table to organize and manage different work centers;

[0024] Implement the data input and output functions of relevant forms.

[0025] According to an embodiment of the present application, generating a scheduling relationship based on the scheduling product group information is specifically as follows:

[0026] Input the data of the scheduling product group table, including the basic information of the product group;

[0027] Input the data of the scheduling product table and associate the material information with the product group;

[0028] Implement the data input and output functions of the scheduling product group and the product table;

[0029] Define the relationship between different product groups and work center groups in the scheduling relationship configuration table, and set parameters such as priority, lead time, on-line time, and post time;

[0030] Implement the data input and output functions of the scheduling relationship configuration table.

[0031] According to an embodiment of the present application, processing the master production schedule scheduling based on the shift system, the working calendar information, the work center information, and the scheduling relationship to obtain a scheduling result is specifically as follows:

[0032] Obtain the list of schedules to be arranged from the master production schedule table;

[0033] Sort the list of master production schedules to be arranged in ascending order of demand date, descending order of scheduling priority, and ascending order of planned production quantity;

[0034] For each schedule to be arranged:

[0035] Determine the work center, find the corresponding product group based on the material ID, and then determine the specific work center through the scheduling relationship configuration;

[0036] Calculate the required lead time, on-line time, and post time, and allocate them to the corresponding work centers;

[0037] Schedule according to the current available start time and the required time, and update the estimated output time;

[0038] Update the latest scheduling end time and the latest available start time of the work center.

[0039] According to an embodiment of the present application, based on the production scheduling result, the material requirements plan is adjusted through MRP calculation, specifically: performing MRP calculation on the master production plan list to be scheduled after the first-round plan processing is completed to generate planned orders.

[0040] According to an embodiment of the present application, after adjusting the material requirements plan through MRP calculation based on the production scheduling result, it further includes:

[0041] Evaluating the kit completeness status according to the adjustment result.

[0042] According to an embodiment of the present application, evaluating the kit completeness status according to the adjustment result is specifically:

[0043] Checking whether there are planned orders with a net demand quantity greater than 0 according to the MRP result to determine the kit completeness status of the master production plan;

[0044] If there is no shortage of materials, set the kit completeness status = 1; if there is a shortage of materials, set the kit completeness status = 0 and take corresponding measures to adjust the plan.

[0045] A computer program product containing instructions, when running on a device, enables the device to execute the steps in the described method.

[0046] A computer-readable storage medium, on which a program is stored, and when the program is executed by a processor, it implements the steps in the described method.

[0047] An electronic device includes a memory, a processor, and a program stored on the memory and executable on the processor. When the processor executes the program, it implements the steps in the described method.

[0048] Due to the adoption of the above technical solution, the beneficial effects obtained by the present application are as follows:

[0049] By defining detailed shift systems (including shift schedules) and work calendar information (including whether a specific date is a working day), the system can accurately schedule the time of production tasks, ensuring that each task is executed within an appropriate time period. Accurate work center information enables enterprises to more effectively allocate human and equipment resources, avoiding resource waste or idleness caused by improper time arrangement. When facing emergencies (such as urgent orders or equipment failures), the system can quickly adjust the production scheduling plan according to the latest shift system and work calendar, improving the flexibility of production.

[0050] This application classifies similar products into product groups and establishes corresponding production scheduling relationships, simplifying the complex production planning process and reducing the possibility of human errors. By defining the relationships and parameters such as priorities, lead times, on-line times, and post times between different product groups and work center groups, the system can better coordinate various production links and achieve process optimization. Once market demand changes, the system can quickly adjust production strategies according to the predefined product groups and production scheduling relationships, accelerating the market response speed.

[0051] This application comprehensively considers shift systems, work calendars, work center information, and production scheduling relationships. The system can generate optimal production scheduling results, ensuring that all tasks are completed on time while maximizing the utilization of existing resources. By performing detailed time calculations and resource matching for each production scheduling plan to be arranged, the risk of production line stagnation caused by insufficient materials or unavailable equipment is reduced. The system has the ability to dynamically adjust production scheduling plans based on real-time data and can quickly respond in case of emergencies, ensuring the continuity and stability of production.

[0052] This application performs MRP calculations based on the finally determined production scheduling results, enabling more accurate prediction of the required raw material quantities at each stage and avoiding situations of material shortages or surpluses. Through refined material requirements planning, enterprises can maintain a low inventory level while meeting production demands, thus effectively reducing inventory holding costs. The timely updated material requirements plan helps strengthen communication and collaboration with suppliers, ensuring that critical materials arrive on time and thereby enhancing the operational efficiency of the entire supply chain. BRIEF DESCRIPTION OF THE DRAWINGS

[0053] The drawings described herein are used to provide a further understanding of this application and form a part of this application. The illustrative embodiments of this application and their descriptions are used to explain this application and do not constitute an improper limitation of this application. In the drawings:

[0054] Figure 1 It is a schematic flow chart of an intelligent production planning and material management method based on production scheduling and MRP provided by an embodiment of this application. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0055] In order to more clearly illustrate the overall concept of this application, the following will be described in detail by way of examples in conjunction with the drawings of the specification.

[0056] Many specific details are set forth in the following description in order to provide a thorough understanding of this application. However, this application may be implemented in other ways different from those described herein. Therefore, the scope of protection of this application is not limited by the specific embodiments disclosed below. It should be noted that, without conflict, the embodiments of this application and the features in each embodiment may be combined with each other.

[0057] In this application, unless otherwise clearly specified and limited, the first feature being "on" or "under" the second feature may mean that the first and second features are in direct contact, or the first and second features are in indirect contact through an intermediate medium. In the description of this specification, the description with reference to terms such as "one embodiment", "some embodiments", "examples", "specific examples", or "some examples" means that the specific features, structures, materials, or characteristics described in connection with the embodiment or example are included in at least one embodiment or example of this application. In this specification, the schematic expressions of the above terms do not necessarily refer to the same embodiment or example. Moreover, the specific features, structures, materials, or characteristics described can be combined in a suitable manner in any one or more embodiments or examples.

[0058] Embodiment 1

[0059] As Figure 1 shown, an intelligent production planning and material management method based on production scheduling and MRP includes:

[0060] Define the work center information required for production scheduling based on shift system and work calendar information.

[0061] Specifically, define the shift system information

[0062] First, it is necessary to create and manage the shift system information, which involves two main data tables: the shift system table and the shift system shift table.

[0063] The shift system table contains the basic information of the shift system, such as the shift system number, shift system name, etc.

[0064] The shift system shift table details the various shifts under each shift system, including shift number, shift name, start time, end time, whether it is the last shift, and working hours (hours), etc.

[0065] Manage the shift system and its shifts through the input-output functions of this information.

[0066] Define the work calendar information

[0067] Next, define the work calendar information, which also involves two data tables: the work calendar table and the work calendar details table.

[0068] The work calendar table records the basic information of the calendar, such as the calendar number and calendar name.

[0069] The work calendar details table specifically lists whether each day is a working day, and also includes the working day serial number for easy definition of working days.

[0070] This part realizes the input-output and quick generation functions of the work calendar and its details.

[0071] Define the information of the production scheduling work center

[0072] On the basis of shift systems and work calendars, further define the information of the production scheduling work center, which mainly includes the following three tables:

[0073] Work center table: This is the core table, which not only contains the basic information of the work center (such as work center number, name), but also associates with the work calendar and shift system, and defines important parameters such as the maximum idle duration and the maximum delay duration.

[0074] Production scheduling work center group table: Used to organize multiple work centers into a group for easy management and scheduling.

[0075] Production scheduling work center table: Refined to specific work center members, showing information such as their numbers and names, and associating with the production scheduling work center group.

[0076] This part realizes the input and output functions of the work center table, production scheduling work center group table, and production scheduling work center table information, ensuring that production tasks can be flexibly arranged according to the shift system and work calendar.

[0077] The process of defining the work center information required for production scheduling based on shift system and work calendar information actually constructs a detailed framework, enabling the production plan to be accurately scheduled and arranged according to specific shift arrangements and work calendars, thereby improving the practical guiding significance and execution efficiency of the production plan.

[0078] For example, define the shift system information

[0079] Suppose there is a shift system named "Daily Shift System", which has two shifts: "Morning Shift" and "Evening Shift".

[0080] Example of shift system representation:

[0081] ID: "001"

[0082] Shift system number: "BZ001"

[0083] Shift system name: "Daily Shift System"

[0084] Example of shift system representation (for the above shift system):

[0085] For the "Morning Shift":

[0086] ID: "001-001"

[0087] Shift system ID: "001"

[0088] Shift number: "01"

[0089] Shift name: "Morning Shift"

[0090] Working hours: "08:00"

[0091] Leaving work time: "16:00"

[0092] Is it the last shift: "0"

[0093] Working hours (hours): "8.00000000"

[0094] For the "night shift":

[0095] ID: "001-002"

[0096] Shift system ID: "001"

[0097] Shift number: "02"

[0098] Shift name: "night shift"

[0099] Working hours: "16:30"

[0100] Leaving work time: "00:30"

[0101] Is it the last shift: "1"

[0102] Working hours (hours): "8.00000000"

[0103] Define work calendar information

[0104] Create a work calendar named "Standard Work Calendar", covering seven days a week, with Monday to Friday as working days.

[0105] Example of work calendar representation:

[0106] ID: "RL001"

[0107] Calendar number: "RL001"

[0108] Calendar name: "Standard Work Calendar"

[0109] Example of work calendar details representation (for "Standard Work Calendar"):

[0110] Record whether each date is a working day.

[0111] For example, if "2025-03-20" is Thursday, the record is as follows:

[0112] ID: Automatically generated

[0113] Work calendar ID: "RL001"

[0114] Gregorian date: "2025-03-20"

[0115] Is it a working day: "1"

[0116] Working day serial number: Automatically calculated

[0117] Define the production scheduling work center information

[0118] Suppose there is a production department called "Assembly Workshop", which uses the above-mentioned "Daily shift system" and "Standard working day calendar".

[0119] Example of work center representation:

[0120] Work center ID: "GZZX001"

[0121] Work center number: "ZX001"

[0122] Work center name: "Assembly Workshop"

[0123] Working day calendar: "RL001"

[0124] Shift system: "BZ001"

[0125] Maximum idle duration (minutes): "15.00000000"

[0126] Maximum overtime duration (minutes): "30.00000000"

[0127] Through such settings, the system can accurately schedule and arrange the production capacity of the "Assembly Workshop" according to the specific shift system arrangement and working day calendar, so as to ensure the effective utilization of resources and better adapt to the changes in actual production. These data structures not only support the input and output functions, but also allow users to quickly generate and adjust relevant plans to meet different production needs.

[0128] Furthermore, in addition to sorting according to the required date, production scheduling priority, and planned production quantity, other factors such as customer importance level and product profit margin can be introduced to achieve more refined production scheduling optimization. Dynamically adjust the production scheduling rules according to real-time production data (such as equipment failures and raw material shortages) to ensure the continuity and efficiency of production.

[0129] Use historical data for production capacity prediction, identify potential bottlenecks in advance, and adjust the shift system arrangement or increase temporary working hours accordingly. Before implementing a new production scheduling plan, simulate the production effects in different scenarios through simulation technology to evaluate the best plan.

[0130] Connect the production equipment to the system to achieve real-time monitoring and an automatic feedback mechanism, improving the accuracy of production scheduling and the response speed. Apply AI / ML algorithms to automatically optimize production scheduling parameters, learn from best practice cases, and continuously improve the production scheduling model. Not only limited to internal resource scheduling, but also consider information sharing and collaborative operations with external partners such as suppliers and distributors to enhance the efficiency of the entire supply chain.

[0131] Generate production scheduling relationships based on production scheduling product group information.

[0132] Specifically, the definition of production scheduling product group information

[0133] First, it is necessary to create and maintain production scheduling product group information, which involves two data tables: the production scheduling product group table and the production scheduling product table.

[0134] Production scheduling product group table:

[0135] It contains the basic information of a group of products, such as group number and group name.

[0136] The example data structure is as follows:

[0137] Alias Column Name Data Type Comment ID ID varchar(36) The only primary key of this table Group Number ZBH varchar(30) Required, no duplicates allowed Group Name ZMC varchar(60) Required, no duplicates allowed

[0138] Production scheduling product table:

[0139] This table details the association between each product and the material dictionary table, as well as the specific information of the product in the production scheduling product group.

[0140] The example data structure is as follows:

[0141]

[0142]

[0143] This part implements the input and output functions of the production scheduling product group table and the production scheduling product table information, ensuring that product information can be flexibly managed and organized.

[0144] Generate production scheduling relationships

[0145] The process of generating production scheduling relationships involves the production scheduling relationship configuration table, which is used to describe the relationship between a specific production scheduling product group and the work center group, including but not limited to parameters such as priority setting, lead time, on-line time, and post time.

[0146] The example data structure of the production scheduling relationship configuration table is as follows:

[0147]

[0148]

[0149] Through the above table structure, the system can match different production scheduling product groups with corresponding work center groups according to specific production scheduling requirements, and set detailed production scheduling rules and parameters, so as to achieve efficient production scheduling arrangements. This mechanism not only considers the material attributes, but also combines the capacity limitations and production scheduling priorities of work centers, making the entire production plan more reasonable and efficient.

[0150] For example, the definition of production scheduling product group information

[0151] Suppose there is an electronic product manufacturing enterprise, which includes multiple product series, such as smart phones and tablet computers. Taking smart phones as an example, a production scheduling product group is created and specific product information is added to it.

[0152] Example of production scheduling product group representation:

[0153] ID: "001"

[0154] Group number: "ZBH001"

[0155] Group name: "Smart phone series"

[0156] Example of production scheduling product representation (for "Smart phone series"):

[0157] For a certain smart phone model A:

[0158] ID: Automatically generated

[0159] Production scheduling product group ID: "001" (associated with the production scheduling product group table)

[0160] Material ID: "WL001" (uniquely identifying a record in the material dictionary table)

[0161] Material number: "WLBH001"

[0162] Material name: "Smart phone A"

[0163] For another smart phone model B:

[0164] ID: Automatically generated

[0165] Production scheduling product group ID: "001"

[0166] Material ID: "WL002"

[0167] Material number: "WLBH002"

[0168] Material name: "Smart phone B"

[0169] Generate production scheduling relationships

[0170] Next, it is necessary to configure the production scheduling relationships for these products, that is, to specify which work center groups are responsible for producing these products and set corresponding production scheduling parameters such as priority, lead time, on-line time, and post time.

[0171] Example of production scheduling relationship configuration (for the relationship between the smartphone series and a specific work center group):

[0172] Suppose there is a work center group dedicated to assembling electronic devices, called the "Electronic Assembly Group".

[0173] ID: Automatically generated

[0174] Production scheduling product group ID: "001" (associated with the production scheduling product group table)

[0175] Production scheduling work center group ID: "GZZXZ001" (assumed to be the unique identifier of the "Electronic Assembly Group")

[0176] Status: "1" (indicating that this configuration is currently in use)

[0177] Production scheduling priority: "5" (the higher the value, the higher the priority)

[0178] Fixed lead time (minutes): "30.00000000"

[0179] Variable lead time (minutes): "0.00000000"

[0180] Fixed on-line time (minutes): "60.00000000"

[0181] Variable on-line time (minutes): "5.00000000" (additional time required for each additional unit of production)

[0182] Fixed post time (minutes): "15.00000000"

[0183] Variable post time (minutes): "0.00000000"

[0184] In this example, the "smartphone series" is assigned to the "Electronic Assembly Group" and relevant production scheduling parameters are set. For example, for smartphone A or B, its lead time is a fixed 30 minutes plus 0 minutes according to the production volume change; the on-line time is a fixed 60 minutes plus an additional 5 minutes required for each additional unit of production; the post time is a fixed 15 minutes.

[0185] In this way, the system can reasonably arrange the production sequence and time according to the specific requirements and characteristics of the scheduled product groups, combined with the capabilities and limitations of the corresponding work center groups, thereby improving the production efficiency and flexibility. In addition, the scheduling relationship can be dynamically adjusted according to the characteristics of different products and market demands to ensure the effective utilization of resources and the smooth progress of production.

[0186] Furthermore, integrate sensors and Internet of Things (IoT) devices to monitor the status of the production line, equipment health, and inventory levels in real time. When abnormal situations (such as equipment failures or raw material shortages) are detected, the system can automatically recalculate and adjust the scheduling relationship to ensure production continuity. Apply machine learning algorithms to analyze historical scheduling data and production efficiency, predict potential problems in the future, and propose optimization suggestions. For example, by analyzing the production cycles of different products at specific work centers, dynamically adjust the scheduling priorities to improve overall production efficiency.

[0187] In addition to considering production time, factors such as cost control and energy consumption can also be taken into account to achieve multi-objective optimized scheduling. For example, under the premise of meeting the delivery date, select the work center with the lowest energy consumption for production. Introduce a risk assessment mechanism to score each scheduling plan (such as supply chain interruption risk, market demand fluctuations, etc.) to help managers make more robust decisions.

[0188] Process the master production plan scheduling according to the shift system, the work calendar information, the work center information, and the scheduling relationship to obtain the scheduling result.

[0189] Specifically, first, it is necessary to reset the

Latest Scheduling End Time

Latest Schedulable Start Time

[0190]

Latest Scheduling End Time

Plan Status

Scheduling Status

Estimated Output Time

[0191]

Latest Schedulable Start Time

[0192] Filter out all records in the master production plan table that meet

Plan Status

Scheduling Status

[0193] Sort the list of master production schedules to be scheduled in ascending order of demand date, descending order of scheduling priority, and ascending order of planned production quantity, and then process each master production schedule line by line in a loop.

[0194] The processing logic includes the following steps:

[0195] Determine the work center:

[0196] Locate the scheduling product group table based on the material ID;

[0197] Then locate the scheduling relationship configuration table based on the group ID in the scheduling product group table;

[0198] Then locate the scheduling work center table based on the scheduling work center group ID in the scheduling relationship configuration table;

[0199] Finally, locate the work center table based on the scheduling work center ID in the scheduling work center table;

[0200] Sort the above-located information set in ascending order of the latest available start time and descending order of scheduling priority, and select the work center in the first row as the work center for this scheduling.

[0201] Assign the work center and calculate the required time:

[0202] Assign the [Work Center] in the master production schedule table to the selected work center;

[0203] Calculate the lead time, in-line time, and post time based on the scheduling relationship configuration table and update them to the corresponding fields in the master production schedule table.

[0204] Schedule based on the assigned work center:

[0205] Set the [Planned Production Time] in the master production schedule table to the latest available start time of the selected work center;

[0206] Calculate the [Estimated Output Time], and adjust the estimated output time considering factors such as in-line time, available shift duration, maximum idle duration, and maximum delay duration.

[0207] Update the scheduling information of the work center:

[0208] Update the [Latest Scheduling End Time] in the work center table to the [Estimated Output Time] in the master production schedule table;

[0209] Recalculate and update the [Latest Available Start Time] in the work center table based on parameters such as the current time and maximum idle duration.

[0210] Execute the MRP calculation (secondary plan) on the list of master production schedules to be scheduled that have been processed once.

[0211] Based on the MRP results (planned orders) generated from the master production schedule, check if there are any planned orders with a net demand quantity greater than 0. If not, set the [Kit Completeness Status] of the master production schedule to 1 (indicating no material shortage); if there are, set the [Kit Completeness Status] to 0 (indicating a material shortage). Users can use the kit completeness status and the newly generated planned orders to guide the actual planning arrangement.

[0212] This process ensures the reasonable arrangement of production tasks according to specific shift systems, work calendars, work center capabilities, and scheduling relationships, improving production efficiency and resource utilization.

[0213] For example, suppose there is a manufacturing enterprise whose production process includes two stages: assembly and testing. Now, it is necessary to schedule production for a product.

[0214] Shift information

[0215] Daily shift system (ID: "BZ001"):

[0216] Includes the morning shift (start time: "08:00", end time: "16:00") and the night shift (start time: "16:30", end time: "00:30").

[0217] Work calendar information

[0218] Standard work calendar (ID: "RL001"):

[0219] Defines the work arrangements from March 19, 2025, to April 19, 2025, with Monday to Friday being working days.

[0220] Work center information

[0221] Assembly workshop (ID: "GZZX001"):

[0222] Uses the "standard work calendar" and the "daily shift system", with a maximum idle time of 15 minutes and a maximum overtime duration of 30 minutes.

[0223] Testing workshop (ID: "GZZX002"):

[0224] Also uses the "standard work calendar" and the "daily shift system", but with a maximum idle time of 10 minutes and a maximum overtime duration of 20 minutes.

[0225] Scheduling relationship configuration

[0226] Relationship configuration between the smartphone series (ID: "001") and the assembly workshop (ID: "GZZXZ001"):

[0227] Scheduling priority: 5

[0228] Pre-set fixed time: 30 minutes, pre-set variable time: 0 minutes

[0229] Online fixed time: 60 minutes, online variable time: 5 minutes per unit output

[0230] Post-set fixed time: 15 minutes, post-set variable time: 0 minutes

[0231] The relationship configuration between the smartphone series and the test workshop (ID: "GZZXZ002") is similar, but the parameters may be different.

[0232] Specific steps for processing the master production schedule

[0233] Step 1: Initialize the status of the work center

[0234] Reset the

latest scheduling end time

latest available scheduling start time

latest available scheduling start time

[0235] Step 2: Obtain the list of master production schedules to be scheduled

[0236] Suppose there is a master production schedule record to be scheduled as follows:

[0237] Material name: Smart phone A

[0238] Planned production quantity: 100 units

[0239] Required date: March 25, 2025

[0240] Step 3: Sort and process line by line

[0241] Determine the work center: Based on the above scheduling relationship configuration table, first select the assembly workshop as the initial work center for producing this product.

[0242] Assign the work center and calculate the required time:

[0243] Pre-set time = 30 minutes + 0 minutes * 100 = 30 minutes

[0244] Online time = 60 minutes + 5 minutes * 100 = 560 minutes

[0245] Post-set time = 15 minutes + 0 minutes * 100 = 15 minutes

[0246] Update these values to the corresponding fields in the master production schedule, set

Scheduled Start Time

Estimated Output Time

[0247] Schedule based on the assigned work centers:

[0248] According to the calculated time allocation, if the 560 minutes of online time exceeds the remaining time of the current shift, it is necessary to continue to complete the remaining part across shifts or across days.

[0249] Update the scheduling information of the work centers: Update

Latest Scheduling End Time

Latest Available Scheduling Start Time

[0250] For the testing workshop, repeat the above process, taking into account different parameter settings.

[0251] Step 4: Execute MRP calculation

[0252] Based on the above scheduling results, execute MRP calculation to ensure that all raw materials and other resources are ready.

[0253] Step 5: Set the kit status and guide the actual plan

[0254] Check if there are any material shortages or other problems that prevent meeting the scheduling requirements. If not, set

Kit Status

Kit Status

[0255] Through this example, it can be seen how to formulate a detailed production plan by combining specific shift systems, work calendars, work center information, and scheduling relationships, so as to optimize the production process and improve efficiency.

[0256] Furthermore, use historical production data for in-depth analysis to identify the key factors affecting production efficiency, and optimize the scheduling strategy accordingly. For example, by analyzing the equipment utilization rate in different time periods, adjust the shift arrangement or increase temporary working hours. Apply machine learning algorithms to predict future market demands, raw material supply situations, etc., and plan production capacity in advance. For example, use a time series prediction model to estimate future product demands, so as to formulate a production plan more accurately.

[0257] Feed the sensor data on the production line (such as equipment status, inventory level) back to the system in real time, so as to dynamically adjust the scheduling plan according to the actual situation. For example, when it is detected that a key piece of equipment fails, the system can immediately reassign tasks to reduce downtime. Develop intelligent algorithms so that the scheduling system can automatically adjust the scheduling order and schedule according to real-time data to ensure the continuity and efficiency of production.

[0258] According to the production scheduling result, adjust the material requirements plan through MRP calculation.

[0259] Specifically, the purpose of MRP calculation

[0260] Determine material requirements: Based on the production scheduling result, clarify the required time, quantity, and frequency of each material.

[0261] Optimize inventory levels: Minimize inventory costs while ensuring production continuity and avoiding production line stoppages due to material shortages.

[0262] Coordinate procurement and production: Develop a reasonable procurement plan and production schedule to ensure effective connection of all links in the supply chain.

[0263] Specific steps for MRP calculation based on the production scheduling result

[0264] Obtain the production scheduling result

[0265] First, obtain the finally determined production plan information from the production scheduling process, including but not limited to:

[0266] The start production date and expected output date of each product or material.

[0267] The planned production quantity of each product.

[0268] For example, in the production scheduling stage, it is determined that "Smartphone A" needs to start production on March 25, 2025, with an expected output of 100 units.

[0269] Analyze the Bill of Materials (BOM)

[0270] For each finished product to be produced, analyze its Bill of Materials (BOM) to understand all raw materials, components, and their usage required to manufacture the finished product. This step ensures that all direct materials are taken into account.

[0271] Suppose the BOM of "Smartphone A" includes components such as a display screen, battery, and housing, and each phone requires 1 display screen, 1 battery, and 1 housing respectively.

[0272] Calculate the net requirements

[0273] Based on the existing inventory level, expected arrival situation, and production scheduling result, calculate the net requirements of each material. Specifically:

[0274] Compare the current inventory with the total material quantity required for production.

[0275] Consider the purchase orders that have been placed but have not yet arrived.

[0276] Determine how much additional material is actually needed to meet production requirements.

[0277] If there are 50 display screens in the current inventory and no new display screens will arrive within the next month, then to produce 100 units of Smart Phone A, 50 more display screens need to be purchased.

[0278] Develop a procurement plan

[0279] Based on the net requirements and the supplier delivery cycle, develop a detailed procurement plan. This includes:

[0280] The order quantity for each type of material.

[0281] The estimated order placement date.

[0282] The expected arrival date.

[0283] For example, considering that the delivery cycle of the display screen supplier is two weeks, the system recommends placing an order for 50 display screens before March 11, 2025 to ensure they can arrive before March 25 and be used for production.

[0284] Update the Master Production Schedule (MPS) and Material Requirements Planning (MRP)

[0285] Finally, feed the above calculation results back to the Master Production Schedule (MPS) and Material Requirements Planning (MRP), update the relevant database records, and notify the relevant departments to prepare for implementing the new plan. This includes, but is not limited to:

[0286] The production department organizes production according to the updated production schedule arrangement.

[0287] The procurement department places orders according to the new procurement plan.

[0288] The inventory management department monitors the inbound and outbound of materials to ensure timely replenishment.

[0289] Through the above steps, the enterprise can dynamically adjust the material requirements plan according to the accurate production schedule results, not only improving production efficiency but also optimizing inventory management and reducing capital occupancy. In addition, such a process also enhances the enterprise's adaptability, enabling it to respond quickly in the face of market changes and technological challenges.

[0290] For example, suppose there is a manufacturing enterprise that is preparing to produce a new type of smart phone, "SmartPhoneX". After production scheduling, the following information is determined:

[0291] Product name: SmartPhone X

[0292] Planned production quantity: 200 units

[0293] Scheduled production start time: April 1, 2025

[0294] Estimated output time: April 7, 2025

[0295] Obtain the production schedule result

[0296] Obtain the finally determined production plan information from the production scheduling process, including the production start date, estimated output date, quantity, etc.

[0297] Analyze the Bill of Materials (BOM)

[0298] Analyze the Bill of Materials (BOM) of "SmartPhone X" to understand the raw materials, components required for manufacturing each mobile phone and their usage. For example:

[0299] Display screen: 1 piece / unit

[0300] Battery: 1 piece / unit

[0301] Housing: 1 piece / unit

[0302] Main board: 1 piece / unit

[0303] Calculate the net requirement

[0304] Based on the existing inventory level, expected arrival situation and production schedule result, calculate the net requirement of each material.

[0305] Example data:

[0306] Display screen

[0307] Current inventory: 100 pieces

[0308] Expected arrival: None

[0309] Net requirement = planned production quantity - current inventory = 200 - 100 = 100 pieces

[0310] Battery

[0311] Current inventory: 80 pieces

[0312] Expected arrival: 20 pieces (expected arrival date: March 30, 2025)

[0313] Net requirement = planned production quantity - current inventory - expected arrival = 200 - 80 - 20 = 100 pieces

[0314] Housing

[0315] Current inventory: 150 pieces

[0316] Expected arrival: None

[0317] Net demand = Planned production quantity - Current inventory = 200 - 150 = 50 units

[0318] Motherboard

[0319] Current inventory: 180 units

[0320] Expected arrival: None

[0321] Net demand = Planned production quantity - Current inventory = 200 - 180 = 20 units

[0322] Formulate a procurement plan

[0323] Based on the net demand and the supplier's delivery cycle, formulate a detailed procurement plan.

[0324] Example data:

[0325] Display screen

[0326] Supplier delivery cycle: 10 days

[0327] Suggested order date: Before March 22, 2025 (taking into account shipping time and possible delays)

[0328] Battery

[0329] Supplier delivery cycle: 7 days

[0330] Suggested order date: Before March 25, 2025

[0331] Housing

[0332] Supplier delivery cycle: 5 days

[0333] Suggested order date: Before March 27, 2025

[0334] Motherboard

[0335] Supplier delivery cycle: 8 days

[0336] Suggested order date: Before March 24, 2025

[0337] Update the Master Production Schedule (MPS) and Material Requirements Planning (MRP)

[0338] Feed the above calculation results back to the Master Production Schedule (MPS) and Material Requirements Planning (MRP), update the relevant database records, and notify the relevant departments to prepare for the implementation of the new plan.

[0339] Production department: Organize production according to the updated production schedule.

[0340] Procurement department: Place orders according to the new procurement plan.

[0341] Inventory Management Department: Monitor the incoming and outgoing of materials to ensure timely replenishment.

[0342] Result Inspection and Kit Status Setting

[0343] Based on the MRP results (planned orders) generated from the master production plan, check if there are any planned orders with a net demand quantity greater than 0. If not, set the

Kit Status

Kit Status

Kit Status

[0344] Through this detailed example, it can be seen how to perform MRP calculations based on the scheduling results to adjust the material requirements plan, ensure that all materials required for production are in place on time, optimize inventory management, and reduce capital occupancy. This not only improves production continuity and efficiency but also enhances the enterprise's response ability and competitiveness.

[0345] Furthermore, for complex products, implement multi-level bill of materials (BOM) management to support comprehensive tracking and management from top-level products to bottom-level components. This helps to more accurately calculate the requirements of materials at all levels and optimize inventory allocation. Introduce batch management and traceability functions to ensure that each batch of raw materials and finished products can be accurately traced. This is very important for quality control, recall management, and regulatory compliance.

[0346] According to an embodiment of the present application, based on the shift system and work calendar information, define the work center information required for scheduling, specifically:

[0347] Define and input the shift system, including the shift table and shift schedule table;

[0348] Define and input the work calendar information, including the work calendar table and work calendar detail table;

[0349] Implement the information input / output function for the shift system, shifts, and work calendar;

[0350] Input the work center table data, including the basic information of each work center, and associate it with the work calendar and shift system;

[0351] Establish the scheduling work center group table and scheduling work center table to organize and manage different work centers;

[0352] Implement the data input / output function for relevant forms.

[0353] Specifically, define and input the shift system

[0354] Shift Schedule

[0355] Record the basic information of all shift schedules within the enterprise.

[0356] Shift Schedule Table

[0357] Describe in detail the various shift situations under each shift schedule.

[0358] Define and input the said work calendar information

[0359] Work Calendar Table

[0360] Record the basic information of all work calendars of the enterprise.

[0361] Work Calendar Detail Table

[0362] List in detail the specific dates of each work calendar and the information on whether it is a working day.

[0363] Implement the information input and output functions for shift schedules, shifts, and work calendars

[0364] Input function: Provide a user interface or API interface to allow users to enter information on shift schedules, shifts, and work calendars.

[0365] Output function: Support functions such as querying and exporting, allowing users to view or export this information for other purposes.

[0366] Input data for the Work Center Table

[0367] Work Center Table

[0368] Record the basic information of each work center and associate it with the work calendar and shift schedule.

[0369] Establish the Scheduling Work Center Group Table and the Scheduling Work Center Table

[0370] Scheduling Work Center Group Table

[0371] Organize multiple work centers into a group for easy management and scheduling.

[0372] Scheduling Work Center Table

[0373] Refine to specific work center members, display their numbers, names, etc. information, and associate it with the work center group.

[0374] Implement the data input and output functions for relevant forms

[0375] Input function: Provide a user interface or API interface to allow users to enter information on scheduling work center groups and scheduling work centers.

[0376] Output function: Supports functions such as query and export, allowing users to view or export this information for other purposes.

[0377] Through the above steps, the system can finely manage and schedule different work centers according to specific shift arrangements and work calendars, thereby improving the flexibility and efficiency of production. At the same time, this data also provides basic data support for subsequent production scheduling algorithms, making the entire production plan more reasonable and efficient.

[0378] According to an embodiment of the present application, generating a scheduling relationship based on the scheduling product group information specifically includes:

[0379] Input the data of the scheduling product group table, including the basic information of the product group;

[0380] Input the data of the scheduling product table and associate the material information with the product group;

[0381] Implement the data input and output functions of the scheduling product group and the product table;

[0382] Define the relationship between different product groups and work center groups in the scheduling relationship configuration table, and set parameters such as priority, lead time, online time, and post time;

[0383] Implement the data input and output functions of the scheduling relationship configuration table.

[0384] Specifically, input the data of the scheduling product group table

[0385] Record the basic information of all scheduling product groups to prepare for subsequent association with specific products and work centers.

[0386] Example data:

[0387] ID: "001"

[0388] Group number: "ZBH001"

[0389] Group name: "Smartphone series"

[0390] Input the data of the scheduling product table

[0391] Associate the specific material information with the scheduling product group to clarify the position of each product in a specific product group.

[0392] Example data (for "Smartphone series"):

[0393] For a certain smartphone model A:

[0394] ID: Automatically generated

[0395] Scheduling product group ID: "001" (associated with the scheduling product group table)

[0396] Material ID: "WL001"

[0397] Material number: "WLBH001"

[0398] Material name: "Smartphone A"

[0399] Implement the data input and output functions for the production scheduling product group and product table

[0400] Input function

[0401] Provide a user interface or API interface to allow users to enter information about the production scheduling product group and production scheduling products.

[0402] Users can add new product groups or edit the information of existing product groups through the interface.

[0403] Similarly, users can add new products to a product group or update the information of existing products.

[0404] Output function

[0405] Support functions such as query and export, allowing users to view or export this information for other purposes.

[0406] Provide a search function to facilitate quick search for specific product groups or products.

[0407] Support the export function to facilitate users to save or share data.

[0408] Define the relationship between different product groups and work center groups in the production scheduling relationship configuration table

[0409] Define the relationship between different production scheduling product groups and the corresponding work center groups, and set relevant production scheduling parameters such as priority, lead time, on-line time, and post time, etc.

[0410] Example data (assuming there is a work center group dedicated to assembling electronic devices, called "Electronic Assembly Group"):

[0411] ID: Automatically generated

[0412] Production scheduling product group ID: "001" (associated with the production scheduling product group table)

[0413] Production scheduling work center group ID: "GZZXZ001"

[0414] Status: "1"

[0415] Production scheduling priority: "5"

[0416] Fixed lead time (minutes): "30.00000000"

[0417] Pre-change time (minutes): "0.00000000"

[0418] On-line fixed time (minutes): "60.00000000"

[0419] On-line change time (minutes): "5.00000000"

[0420] Post-change fixed time (minutes): "15.00000000"

[0421] Post-change change time (minutes): "0.00000000"

[0422] Implement the data input and output functions of the described production scheduling relationship configuration table

[0423] Input function

[0424] Provide a user interface or API interface to allow users to enter the data of the production scheduling relationship configuration table

[0425] Users can add new production scheduling relationship configurations through the interface, specifying the relationship between product groups and work center groups and their related parameters

[0426] Allow users to modify or delete existing configurations

[0427] Output function

[0428] Support functions such as query and export, allowing users to view or export this information for other purposes

[0429] Provide a search function to facilitate quick search for specific production scheduling relationship configurations

[0430] Support the export function to facilitate users to save or share data

[0431] Through the above steps, enterprises can reasonably arrange the production sequence and time according to specific production scheduling requirements and characteristics, combined with the capabilities and limitations of the corresponding work centers, thereby improving production efficiency and flexibility. At the same time, these data also provide basic data support for subsequent production scheduling algorithms, making the entire production plan more reasonable and efficient

[0432] According to an embodiment of the present application, processing the master production plan scheduling according to the shift system, the work calendar information, the work center information, and the production scheduling relationship to obtain a scheduling result is specifically as follows

[0433] Obtain the list of production plans to be scheduled from the master production plan table

[0434] Sort the list of master production plans to be scheduled in ascending order of demand date, descending order of scheduling priority, and ascending order of planned production quantity

[0435] For each production plan to be scheduled:

[0436] Determine the work center, find the corresponding product group based on the material ID, and then determine the specific work center through the production scheduling relationship configuration;

[0437] Calculate the required lead time, on-line time, and post time, and allocate them to the corresponding work centers;

[0438] Schedule according to the current available start time and required time, and update the estimated output time;

[0439] Update the latest production end time and the latest available start time of the work center.

[0440] Specifically, obtain the list of production plans to be scheduled from the master production schedule

[0441] First, screen out the planned items that need to be scheduled from the master production schedule. These planned items usually have the following characteristics:

[0442] The plan status is "0" (indicating the initial status).

[0443] The production scheduling status is "0" (indicating unscheduled).

[0444] Sort the list of master production plans to be scheduled in ascending order of demand date, descending order of production scheduling priority, and ascending order of planned production quantity. To ensure the continuity and efficiency of production, sort the list of master production plans to be scheduled:

[0445] Ascending order of demand date: Ensure that urgent orders are processed first.

[0446] Descending order of production scheduling priority: Orders with high priority are scheduled first.

[0447] Ascending order of planned production quantity: Small batch orders may be easier to arrange, which helps to balance the production line load.

[0448] For example, assume the list of production plans to be scheduled is as follows:

[0449] ID: "MPS001", demand date: "2025-04-07", production scheduling priority: "5", planned production quantity: "100"

[0450] ID: "MPS002", demand date: "2025-04-05", production scheduling priority: "3", planned production quantity: "80"

[0451] ID: "MPS003", demand date: "2025-04-06", production scheduling priority: "4", planned production quantity: "120"

[0452] The sorted order will be: MPS002 -> MPS003 -> MPS001.

[0453] For each production plan to be scheduled

[0454] Determine the work center

[0455] For each production plan to be scheduled, find the corresponding product group based on the material ID, and then determine the specific work center through the production scheduling relationship configuration. For example, for the material ID "WL001", its corresponding production product group ID is "ZBH001", and the specific work center "GZZX001" in the associated work center group "GZZXZ001" is found through the production scheduling relationship configuration.

[0456] Calculate the required lead time, in-line time, and post time, and allocate them to the corresponding work centers

[0457] Calculate each type of time according to the parameters in the production scheduling relationship configuration table:

[0458] Lead time = fixed lead time + variable lead time * planned production quantity

[0459] In-line time = fixed in-line time + variable in-line time * planned production quantity

[0460] Post time = fixed post time + variable post time * planned production quantity

[0461] For example, assume the lead time for the material ID "WL001" is 30 minutes, the in-line time is 60 + 5 * 100 = 560 minutes, and the post time is 15 minutes. Then the total time is 30 + 560 + 15 = 605 minutes.

[0462] Schedule according to the current available start time and the required time, and update the estimated output time

[0463] Use the latest available start time of the work center as the starting point for the planned production time, and calculate the estimated output time based on the required time. Adjust the estimated output time considering factors such as shifts and maximum overtime duration.

[0464] For example, if the current time is 15:00 on March 19, 2025, and the latest available start time of the work center "GZZX001" is 16:30 (start of the night shift) on the same day, then the planned production time is 16:30. Adding the 560-minute in-line time (about 9 hours and 20 minutes), the estimated output time is around 2:00 am the next day.

[0465] Update the latest production end time and the latest available start time of the work center

[0466] Latest Scheduling End Time: Set the estimated output time of this plan as the latest scheduling end time of the work center.

[0467] Latest Schedulable Start Time: Recalculate and update the latest schedulable start time of the work center based on parameters such as the current time and the maximum idle duration.

[0468] For example, assuming the estimated output time is 2:00 am on March 20, 2025, the latest scheduling end time of the work center "GZZX001" is updated to 2:00 am on March 20, 2025. If the maximum idle duration is 15 minutes, the latest schedulable start time may be the time point of the first available shift in the following day (such as 8:00 am for the morning shift).

[0469] Through the above steps, the enterprise can effectively utilize the existing shift system, work calendar, work center information, and scheduling relationships to process the master production schedule, thereby obtaining optimized scheduling results. This not only improves production efficiency but also ensures the rational use of resources, making the production process more orderly and efficient. In addition, these data also provide a basis for subsequent MRP calculations to ensure the timely supply of raw materials and other resources, avoiding shortages or surpluses.

[0470] According to an embodiment of the present application, adjusting the material requirements plan through MRP calculation based on the scheduling result specifically includes: performing MRP calculation on the list of master production schedules to be scheduled after the first plan processing is completed to generate planned orders.

[0471] Specifically, obtain the scheduling result

[0472] First, it is necessary to obtain the finally determined production plan information from the scheduling process. This information generally includes but is not limited to:

[0473] Product Name: For example, "Smartphone A".

[0474] Planned Production Quantity: For example, 200 units.

[0475] Planned Production Time: For example, April 1, 2025.

[0476] Estimated Output Time: For example, April 7, 2025.

[0477] Analyze the Bill of Materials (BOM)

[0478] For each finished product to be produced, analyze its Bill of Materials (BOM) to understand all the raw materials, components, and their quantities required to manufacture the finished product. This step ensures that all direct materials are taken into consideration.

[0479] Calculate the net requirement for each material based on the existing inventory level, expected arrivals, and production scheduling results. Specifically:

[0480] Compare the current inventory with the total material quantity required for production.

[0481] Consider the purchase orders that have been placed but not yet received.

[0482] Determine how much additional material is actually needed to meet production requirements.

[0483] Execute the MRP calculation and generate planned orders

[0484] Based on the net requirements and the supplier lead times, the system will automatically generate planned orders. The specific steps are as follows:

[0485] Example data:

[0486] Display screen

[0487] Supplier lead time: 10 days

[0488] Suggested order date: Before March 22, 2025 (taking into account shipping time and possible delays)

[0489] Generate planned order: 100 display screens need to be ordered

[0490] Battery

[0491] Supplier lead time: 7 days

[0492] Suggested order date: Before March 25, 2025

[0493] Generate planned order: 100 batteries need to be ordered

[0494] Housing

[0495] Supplier lead time: 5 days

[0496] Suggested order date: Before March 27, 2025

[0497] Generate planned order: 50 housings need to be ordered

[0498] Motherboard

[0499] Supplier lead time: 8 days

[0500] Suggested order date: Before March 24, 2025

[0501] Generate planned order: 20 motherboards need to be ordered

[0502] Update the Master Production Schedule (MPS) and the Material Requirements Plan (MRP)

[0503] Feed the above calculation results back to the Master Production Schedule (MPS) and Material Requirements Planning (MRP), update the relevant database records, and notify the relevant departments to prepare for implementing the new plan. This includes, but is not limited to:

[0504] Production department: Organize production according to the updated production scheduling arrangement.

[0505] Purchasing department: Place orders according to the new purchasing plan.

[0506] Inventory management department: Monitor the material in and out situation to ensure timely replenishment.

[0507] Based on the MRP results (planned orders) generated by the Master Production Schedule, check if there are any planned orders with a net requirement quantity greater than 0:

[0508] If no planned orders with a net requirement quantity > 0 are generated, set [Kit Status] = 1 (indicating no shortage of materials).

[0509] If there are planned orders with a net requirement quantity > 0, set [Kit Status] = 0 (indicating a shortage of materials).

[0510] Users can guide the actual plan based on the [Kit Status] and the newly generated planned orders. If there is a shortage of materials, one or more of the following measures can be taken:

[0511] Urgently issue a planned order to chase materials. Transfer materials from other plans. Suspend issuing the Master Production Schedule until the materials are in place.

[0512] Through the above steps, the enterprise can perform MRP calculations based on accurate production scheduling results, thereby adjusting the material requirements plan to ensure that all materials required for production can arrive on time, while optimizing inventory management and reducing capital occupancy. This not only improves the continuity and efficiency of production but also enhances the enterprise's response ability and competitiveness.

[0513] According to an embodiment of the present application, after adjusting the material requirements plan through MRP calculation based on the production scheduling results, it further includes:

[0514] Evaluate the kit status based on the adjustment results.

[0515] The kit status (Material Availability Status or Kit Status) refers to the status of evaluating whether all required materials have been prepared or are expected to arrive on time in the production plan. Specifically, it reflects whether the existing inventory plus the materials ordered but not yet received are sufficient to meet all material requirements for a specific production task. This status is crucial for ensuring the continuity and efficiency of the production line. The following is a specific explanation of the kit status:

[0516] Kit status = 1 (Kit / fully available)

[0517] Indicates that all raw materials, components, and other resources required to complete a production task are ready or expected to arrive before the required time.

[0518] In this case, production can proceed smoothly according to the scheduled plan without being hindered by material shortages.

[0519] Kit status = 0 (Incomplete kit / shortage exists)

[0520] Indicates that the quantity of at least one or more materials is insufficient to meet the requirements of the current production task, i.e., there is a material gap.

[0521] This situation may lead to production delays and urgent measures need to be taken to address the shortage, such as accelerating procurement, finding alternative suppliers, or adjusting the production sequence, etc.

[0522] Specifically, the background after adjusting the Material Requirements Planning (MRP)

[0523] After production scheduling and MRP calculation, the system has determined the quantity of raw materials required for each product and generated corresponding purchase orders or internal production tasks. At this time, it is necessary to check whether these materials can meet the upcoming production requirements, i.e., evaluate the kit status.

[0524] Purpose of evaluating the kit status

[0525] Ensure production continuity: Ensure that all necessary materials can arrive on time to avoid production line stoppages due to material shortages.

[0526] Optimize inventory management: Identify surplus or shortage of materials in order to adjust the procurement plan or reschedule the production plan in a timely manner and reduce inventory costs.

[0527] Support decision-making: Provide key information to management to assist in making decisions regarding priority adjustments, emergency procurement, or other countermeasures.

[0528] Specific steps for evaluating the kit status

[0529] Step 1: Obtain the MRP adjustment result

[0530] Obtain the latest material requirement information from the MRP calculation, including but not limited to:

[0531] Net requirement of each material.

[0532] Details of purchase orders that have been issued but not yet arrived.

[0533] Current inventory level and expected arrival date.

[0534] For example, in the previous example, the net demand for the display screen of "Smartphone A" is 100, the net demand for the battery is 100, and so on.

[0535] Step 2: Compare demand with supply

[0536] For each material, compare its net demand with the current inventory plus the quantity of orders placed but not yet received:

[0537] If the current inventory plus the quantity of orders placed but not yet received is greater than or equal to the net demand, the material is considered "complete".

[0538] If it is less than the net demand, the material is considered "incomplete" and there is a shortage risk.

[0539] Continuing with the above example:

[0540] Display screen: Current inventory 100 + orders placed but not yet received 0 = 100 < net demand 100 → There is a shortage (assuming factors such as transportation time are not considered).

[0541] Battery: Current inventory 80 + orders placed but not yet received 20 = 100 = net demand 100 → Complete.

[0542] Step 3: Set the complete status flag

[0543] Based on the above analysis, set a complete status flag for each master production schedule item:

[0544] Complete status = 1: Indicates that all required materials are available and production can proceed as planned.

[0545] Complete status = 0: Indicates that there is a shortage of at least one material and measures need to be taken to resolve it.

[0546] In actual operation, this may involve more complex logic, such as considering factors like supplier delivery cycles and transportation time to determine if there is a real shortage.

[0547] Step 4: Notify relevant departments and take actions

[0548] Based on the evaluation results, notify the relevant responsible departments to take appropriate actions:

[0549] For items with a complete status of 1, notify the production department to execute the production tasks according to the plan.

[0550] For items with a complete status of 0, the purchasing department needs to urgently contact the supplier to expedite delivery or find an alternative supplier; meanwhile, the production management department may need to rearrange the production sequence and prioritize those items with a good complete status.

[0551] By performing MRP calculations on the production scheduling results and evaluating the kit completeness status, enterprises can effectively monitor production preparation, identify potential problems in advance, and take corrective measures in a timely manner. This process not only helps improve production efficiency but also reduces delays caused by material shortages, enhancing the enterprise's flexibility and market responsiveness. In addition, accurate evaluation of the kit completeness status provides important decision-making support for management, helping them make more informed choices in the face of uncertainties.

[0552] According to an embodiment of the present application, evaluating the kit completeness status according to the adjustment result specifically includes:

[0553] Checking whether there are planned orders with a net demand quantity greater than 0 according to the MRP results to determine the kit completeness status of the master production plan;

[0554] If there is no material shortage, set the kit completeness status = 1; if there is a material shortage, set the kit completeness status = 0 and take corresponding measures to adjust the plan.

[0555] Specifically, check the net demand quantity according to the MRP results

[0556] After completing the MRP calculation, the system generates a series of planned orders, which reflect the specific quantities of raw materials, components, and other materials required to meet production demands. The key step at this time is to analyze these planned orders to determine the net demand quantity of each material.

[0557] Net demand quantity: refers to the quantity of materials that must be purchased or produced to meet the production plan, which is equal to the total demand minus the existing inventory and the quantity of purchase orders that have been placed but not yet received.

[0558] For example, assume that a certain product requires 100 specific components for production:

[0559] There are 80 of these components in the current inventory;

[0560] There are 20 purchase orders for these components expected to arrive in the next few days;

[0561] Then for this component, the net demand quantity is 100 - (80 + 20) = 0, that is, there is no material shortage.

[0562] If the net demand quantity is greater than 0, it means there is a material gap and the corresponding quantity of materials needs to be replenished to meet the production demand.

[0563] Determine the kit completeness status of the master production plan

[0564] Based on the above inspection results of the net demand quantity, the system will determine the kit completeness status of the master production plan.

[0565] Kit status = 1: It means that all required materials are complete and production can proceed according to the plan. This implies that all net requirement quantities are 0 or less (i.e., there is no shortage of materials).

[0566] Kit status = 0: It means that there is a shortage of at least one material and production requirements cannot be fully met. This implies that the net requirement quantity of at least one material is greater than 0.

[0567] Set the kit status and take measures

[0568] If there is no shortage of materials (kit status = 1)

[0569] When the net requirement quantities of all materials are 0 or lower, it indicates that the current inventory level plus expected arrivals are sufficient to support the upcoming production activities. At this time, the system should set the kit status of the master production plan to 1 and notify the relevant departments to arrange production and logistics activities according to the established plan.

[0570] If there is a shortage of materials (kit status = 0)

[0571] Once it is found that the net requirement quantity of any material is greater than 0, it indicates that there is a shortage of materials and all production requirements cannot be met. At this time, the system should set the kit status of the master production plan to 0 and trigger the corresponding countermeasures:

[0572] Emergency procurement: Immediately contact the supplier and try to expedite delivery or increase the purchase quantity to replenish the shortage of materials as soon as possible.

[0573] Reschedule the production sequence: Prioritize the production of products with complete materials and postpone or adjust projects that cannot be produced on time due to material shortages.

[0574] Find alternative solutions: Consider using alternative materials or components, or find other suppliers to provide the required materials.

[0575] Suppose an enterprise is preparing to produce "Smartphone X". After production scheduling and MRP calculation, the following information is obtained:

[0576] Display screen: The net requirement quantity is 50;

[0577] Battery: The net requirement quantity is 0;

[0578] Housing: The net requirement quantity is 20;

[0579] Motherboard: The net requirement quantity is 10;

[0580] In this case, since the net required quantities of the display screen, the housing, and the main board are all greater than 0, the kit completeness status of the entire master production plan should be set to 0, indicating a shortage of materials. Next, the enterprise needs to take actions such as urgently purchasing the display screen, the housing, and the main board, or re-planning the production sequence to give priority to producing products with complete materials.

[0581] In this way, the enterprise can identify potential supply chain problems in a timely manner and take effective countermeasures to ensure that production activities can be carried out efficiently and orderly.

[0582] A computer program product containing instructions, when running on a device, causes the device to execute the steps in the method as described.

[0583] A computer-readable storage medium, on which a program is stored, and when the program is executed by a processor, it realizes the steps in the method as described.

[0584] An electronic device, including a memory, a processor, and a program stored on the memory and executable on the processor, and when the processor executes the program, it realizes the steps in the method as described.

[0585] What is not described in this application can be implemented by adopting or referring to existing technologies.

[0586] Each embodiment in this specification is described in a progressive manner. The same or similar parts among the embodiments can be referred to each other, and the key points of each embodiment are the differences from other embodiments.

[0587] The above are only the embodiments of this application and are not used to limit this application. For those skilled in the art, various changes and modifications can be made to this application. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of this application shall be included within the scope of the claims of this application.

Claims

1. An intelligent production planning and material management method based on production scheduling and MRP, characterized in that, Including: Define the work center information required for production scheduling based on shift system and work calendar information; Generate production scheduling relationships based on production scheduling product group information; Process the master production schedule according to the shift system, the work calendar information, the work center information, and the production scheduling relationship to obtain a production scheduling result; Adjust the material requirements plan through MRP calculation according to the production scheduling result.

2. The method according to claim 1, characterized in that, The step of defining the work center information required for production scheduling based on the shift system and work calendar information is specifically: Define and input the shift system, including the shift table and the shift schedule table; Define and input the work calendar information, including the work calendar table and the work calendar detail table; Implement the information input / output function of the shift system, shift, and work calendar; Input the work center table data, including the basic information of each work center, and associate it with the work calendar and shift system; Establish a production scheduling work center group table and a production scheduling work center table to organize and manage different work centers; Implement the data input / output function of relevant forms.

3. The method according to claim 1, characterized in that, The step of generating production scheduling relationships based on production scheduling product group information is specifically: Input the production scheduling product group table data, including the basic information of the product group; Input the production scheduling product table data and associate the material information with the product group; Implement the data input / output function of the production scheduling product group and product table; Define the relationship between different product groups and work center groups in the production scheduling relationship configuration table, and set parameters such as priority, lead time, on-line time, and post time; Implement the data input / output function of the production scheduling relationship configuration table.

4. The method according to claim 1, wherein The step of processing the master production schedule according to the shift system, the work calendar information, the work center information, and the production scheduling relationship to obtain a production scheduling result is specifically: Obtain the list of production schedules to be arranged from the master production schedule table; Sort the list of master production schedules to be arranged in ascending order of demand date, descending order of production scheduling priority, and ascending order of planned production quantity; For each production schedule to be arranged: Determine the work center, find the corresponding product group based on the material ID, and then determine the specific work center through the production scheduling relationship configuration; Calculate the required lead time, on-line time, and post time, and allocate them to the corresponding work centers; Schedule according to the current available start time and required time, and update the expected output time; Update the latest production scheduling end time and the latest available start time of the work center.

5. The method according to claim 1, characterized in that The step of adjusting the material requirements plan through MRP calculation according to the production scheduling result is specifically: perform MRP calculation on the list of master production schedules to be arranged after the first plan processing is completed to generate planned orders.

6. The method according to claim 1, characterized in that After the step of adjusting the material requirements plan through MRP calculation according to the production scheduling result, it further includes: Evaluate the kit status according to the adjustment result.

7. The method according to claim 6, characterized in that The step of evaluating the kit status according to the adjustment result is specifically: Check whether there are planned orders with a net demand quantity greater than 0 according to the MRP result to determine the kit status of the master production plan; If there is no shortage of materials, set the kit status = 1; if there is a shortage of materials, set the kit status to 0 and take corresponding measures to adjust the plan.

8. A computer program product comprising instructions, when run on a device, characterized in that, Cause the device to execute the steps in the method according to any one of claims 1-7.

9. A computer-readable storage medium having a program stored thereon, characterized in that, When the program is executed by a processor, the steps in the method according to any one of claims 1-7 are implemented.

10. An electronic device, comprising a memory, a processor, and a program stored on the memory and executable on the processor, characterized in that, When the processor executes the program, the steps in the method according to any one of claims 1-7 are implemented.

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