Cold rolling process-oriented steel coil cost fine accounting method

Abstract

The invention discloses a cold rolling process-oriented steel coil cost fine accounting method, which comprises the following steps of: acquiring steel coil production related data in a cold rolling process, and performing data processing on the steel coil production related data; and calculating the steel coil production related data according to set cost elements and cost element calculation rules to obtain steel coil cost and a cost accounting report. According to the method, comprehensive and fine accounting of the steel coil cost is realized, and a basis is provided for cost control of steel coil manufacturing.

Description

Technical Field

[0001] The present invention relates to the field of steel manufacturing cost accounting, and in particular to a method for fine-grained steel coil cost accounting for a cold rolling process. Background Art

[0002] The cold rolling process is a critical step in steel manufacturing, involving multiple complex steps such as pickling, annealing, and leveling. Traditional cost accounting methods, which rely on average allocation, fail to accurately reflect the actual resource consumption of different steel coils. This leads to problems such as crude cost calculations, untimely data, and inaccurate allocations, making it unable to meet the needs of refined cost control. Therefore, developing a refined cost accounting method for steel coils in the cold rolling process is of great practical significance. Summary of the Invention

[0003] The purpose of the present invention is to provide a method for calculating the cost of steel coils in a refined manner for a cold rolling process, so as to achieve a refined and accurate calculation of the cost of steel coils.

[0004] To solve the above technical problems, the present invention provides a method for calculating the cost of steel coils in a refined manner for a cold rolling process, comprising the following steps: S1. Collecting data related to steel coil production in the cold rolling process and processing the data related to steel coil production; S2. Calculate the steel coil production related data according to the set cost elements and cost element calculation rules to obtain the steel coil cost and cost accounting report.

[0005] According to the above scheme, the relevant data of steel coil production includes production raw material data, production performance data, steel coil production line history data, energy consumption data, and auxiliary material consumption data; Production raw material data, production performance data, and auxiliary material consumption data are obtained through the unit's raw material table, performance table, and auxiliary material data table; Energy consumption data is obtained by reading the unit controller information; The time data of steel coil production lines are divided into continuous production lines and non-continuous production lines according to the production process of cold rolling production lines. For continuous production lines, the time data of steel coil production lines are obtained by tracking the welds of steel coils on the production line and calculating the time period when the steel coils pass through the set energy metering position; for non-continuous production lines, the time data of steel coil production lines are obtained by tracking the time points when the steel coils pass through the positions of each unit.

[0006] According to the above plan, data processing includes data cleaning, format conversion, and outlier processing.

[0007] According to the above plan, the cost elements include fixed cost, raw material cost, variable cost, and auxiliary material cost, which respectively represent the labor cost, raw material cost, energy consumption cost, and auxiliary material cost required to produce a unit of steel coil.

[0008] According to the above scheme, the cost element calculation rules for fixed costs are as follows: fixed costs are the product of the average daily labor cost and the number of production days required for each ton of product steel coil; The cost element calculation rule for raw material cost is: the final cost of the previous process is used as the raw material cost of the subsequent process. The raw material cost of the initial process is the ratio of the raw material price of the steel coil to the actual yield rate of the steel coil. The cost element calculation rule for variable cost is as follows: obtain variable cost based on the historical data of the steel coil production line and the energy consumption data corresponding to the historical data of the steel coil production line; The cost element calculation rule for auxiliary material costs is: average the auxiliary material consumption data with the production performance data.

[0009] According to the above scheme, the method includes: S3, analyzing the cost accounting report and proposing cost reduction optimization suggestions.

[0010] According to the above scheme, the method includes: S4, performing cost visualization based on the cost accounting report.

[0011] According to the above solution, step S4 includes: performing multi-level cost visualization display of steel coil costs of different steel coils, brands, mills, operating areas, and cold rolling mills.

[0012] The present invention also provides a computer comprising a memory, a processor, and a computer program stored in the memory and executable on the processor. When the processor executes the computer program, the steps of the above-mentioned method for refined cost calculation of steel coils for cold rolling processes are implemented.

[0013] The present invention also provides a computer storage medium having a computer program stored thereon, which, when executed by a processor, implements the steps of the above-mentioned method for refined calculation of steel coil costs for cold rolling processes.

[0014] Beneficial effects The present invention processes data related to steel coil production to ensure the accuracy and consistency of the data, providing a basis for subsequent steel coil cost accounting; by dividing the steel coil cost into multiple cost elements and adopting different cost element calculation rules for different cost elements to perform cost accounting, the obtained steel coil cost is more comprehensive and accurate, and can provide a detailed cost accounting report, providing guidance for the analysis and optimization of steel coil costs. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] Figure 1 This is a flow chart of a method for calculating the cost of steel coils in a refined manner for a cold rolling process according to a first embodiment of the present invention; Figure 2 This is a flowchart of the operating steps of a method for calculating the cost of steel coils in a cold rolling process according to a first embodiment of the present invention; Figure 3 This is a cost calculation rule framework diagram of the first embodiment of the present invention. DETAILED DESCRIPTION

[0016] To make the purpose, technical solutions, and advantages of the embodiments of the present disclosure more clear, the technical solutions of the embodiments of the present disclosure will be clearly and completely described below in conjunction with the accompanying drawings of the embodiments of the present disclosure. Obviously, the described embodiments are part of the embodiments of the present disclosure, not all of the embodiments. Based on the described embodiments of the present disclosure, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present disclosure.

[0017] Example 1: See also Figures 1 to 3 This embodiment provides a method for calculating the cost of steel coils in a cold rolling process, comprising the following steps: S1. Collecting data related to steel coil production in the cold rolling process and processing the data related to steel coil production; S2. Calculate the steel coil production related data according to the set cost elements and cost element calculation rules to obtain the steel coil cost and cost accounting report.

[0018] Furthermore, the steel coil production related data includes production raw material data, production performance data, steel coil production line duration data, energy consumption data, and auxiliary material consumption data; Production raw material data, production performance data, and auxiliary material consumption data are obtained through the unit's raw material table, performance table, and auxiliary material data table; Energy consumption data is obtained by reading the unit controller information; in this embodiment, the data of each energy medium point is collected by connecting to the unit's PLC; Steel coil production line history data is divided into continuous production lines and discontinuous production lines according to the production process of the cold rolling production line. For continuous production lines, steel coil production line history data is obtained by tracking the welds of the steel coils on the production line and calculating the time period when the steel coils pass through the set energy metering location. For discontinuous production lines, the data is obtained by tracking the time points when the steel coils pass through the locations of each unit. Assume that the position sequence of the steel coil on the production line is ,in Indicates the i-th process section or position point; the steel coil head enters The start time of the location is , the tail of the steel coil leaves The location ends at The steel coil duration of each process section or position point is It can be calculated by the following formula: .

[0019] Furthermore, data processing includes data cleaning, format conversion, and outlier processing; by processing the data related to steel coil production, the accuracy and consistency of the data related to steel coil production are guaranteed.

[0020] Furthermore, the cost elements include fixed cost, raw material cost, variable cost, and auxiliary material cost, which respectively represent the labor cost, raw material cost, energy consumption cost, and auxiliary material cost required to produce a unit of product steel coil; the total steel coil cost is obtained by adding up the fixed cost, raw material cost, variable cost, and auxiliary material cost.

[0021] Furthermore, the cost element calculation rule for fixed costs is: fixed costs are the product of the average daily labor cost and the number of production days required to produce one ton of product steel coil; that is, they are directly allocated using the annual planned cost and production operation time. The fixed cost calculation formula for each ton of steel is:

[0022] In the above formula, is the annual planned fixed cost for the operating area, is the number of days in the year, is the total number of actual production days in the month, The actual production output of the month; The cost element calculation rule for raw material costs is to use the final cost of the previous process as the raw material cost of the subsequent process. The raw material cost of the initial process is the ratio of the raw material price of the steel coil to the actual yield rate of the steel coil. This calculation rule allows the steel coil cost to accumulate and compound like a snowball, thereby monitoring the actual production cost of each process. Assuming that the production process path of a steel coil is continuous annealing unit → rewinding unit, the actual unit cost of raw materials of the steel coil in the continuous annealing unit is calculated as follows:

[0023] in, is the raw material price of a certain brand of steel coil, is the actual yield rate of the steel coil; The raw material price calculation method for re-coiling the steel coil in the next process is: By calculating the fixed cost, raw material cost, variable cost and auxiliary material cost of the continuous annealing unit steel coil, the total unit cost of the continuous annealing unit steel coil is obtained as follows: , then according to the production process path, the next unit is the re-coiling unit, and the raw material cost of the steel coil in the re-coiling unit is , and then use this to calculate the other costs of the steel coil in the re-coiling unit, and finally get the actual total cost of the finished product; The cost element calculation rules for variable costs are as follows: Variable costs are obtained based on the historical data of the steel coil production line and the energy consumption data corresponding to the historical data of the steel coil production line. In other words, the cost is calculated using the activity-based costing (ABC method), and reasonable allocation is made based on the production time of the steel coil, energy consumption, and the actual situation of the steel strip on the production line. The difficulty in collecting energy consumption data (i.e., variable costs) for steel coils during production at each process unit lies in tracking the steel coil production process. This embodiment establishes statistical models for energy consumption of continuous and discontinuous production lines based on historical data collected from continuous and discontinuous production lines. For a continuous production line, considering that the energy consumption of the continuous production line is mainly concentrated in the core process section (such as the annealing furnace), and most of the energy consumption is concentrated in media such as gas, steam, and electricity, the statistical method of the continuous production line energy consumption statistical model in this embodiment includes: 1) Determine the energy statistics and measurement locations for steel coils: Based on the energy consumption characteristics of the continuous line, define the key energy consumption locations on the production line as the starting and ending points for energy consumption measurement; 2) Calculate the energy consumption data of the steel coil based on the start and end time of the steel coil energy consumption measurement location; There are k types of energy media defined as , define a certain medium as , the statistical location of energy consumption is defined as , the steel coil leads into The start time of the location is At this moment, the cumulative consumption value of a certain energy medium is ,,The tail of the steel coil leaves The location ends at , The cumulative consumption value of a certain energy medium at a moment is , then the steel coil is in ( – The energy consumption cost formula within the time period is:

[0024] in, For steel coils Energy consumption value of the location, is the price of the jth type of energy medium; For non-continuous production lines, considering that there is only one steel coil online at the same time (such as single-stand rolling mills and re-coiling units), the statistical rules for the energy and medium consumption cost of the steel coil are as follows: 1) Obtain real-time coil production data, uncoiler data, shearing data, coiler data, and energy medium metering data from the primary or secondary system of the unit production line.

[0025] 2) Use the coil loading and unloading time as the start and end time for the steel coil energy statistics collection, and automatically calculate the steel coil energy consumption data from the collected energy medium measurement data; There are k types of energy media defined as , define a certain medium as , assuming the coil winding time is , at this moment The cumulative consumption of energy is , the coil unwinding time is , at this moment The cumulative consumption of energy is , then the steel coil is in ( – The energy consumption cost formula within the time period is:

[0026] in, For steel coils Energy consumption value of the location, is the price of the jth type of energy medium.

[0027] The cost per ton of steel coil is ,in is the weight of the steel coil; The cost element calculation rule for auxiliary material costs is to average the auxiliary material consumption data with the actual production performance data. This means that the auxiliary material costs are evenly divided based on the actual auxiliary material cost data consumed and the actual steel coil production output to obtain the cost of each auxiliary material consumption. For example, the auxiliary material items in the cold rolling process include refractory materials, spare parts, and packaging materials. Taking the packaging material cost as an example, the packaging price per ton of steel coil is

[0028] in, The actual packaging cost consumed by the operation area in a certain month, The weight of steel coils produced and packaged in a certain operation area; In this embodiment, the premise for calculating each cost element is to construct the cost base data configuration rules, which specifically include cost account definition, cost annual plan definition, raw material price definition, packaging price definition, process production path definition, and energy medium price definition.

[0029] Furthermore, the method includes: S3, analyzing the cost accounting report and proposing cost reduction optimization suggestions; by analyzing the cost accounting report, it is possible to identify links with high energy consumption and make optimization suggestions, such as improving equipment operating parameters, avoiding peak hours and optimizing production processes, etc., thereby achieving cost reduction.

[0030] Furthermore, the method includes: S4, visualizing costs based on the cost accounting report; the cost accounting report can be visualized in the form of charts to facilitate managers to intuitively understand the cost distribution. The production plan is adjusted based on the accounting results to optimize resource allocation and reduce production costs.

[0031] Furthermore, step S4 includes: multi-level cost visualization display of steel coil costs of different steel coils, brands, units, operating areas, and cold rolling mills; through detailed analysis of the production cost of a single steel coil, helping enterprises understand the cost structure of each steel coil; through cost analysis of steel coils of different brands, helping enterprises understand the production cost differences of different brands; through analysis of the production costs of different units, helping enterprises understand the cost performance of each unit; through analysis of the production costs of different operating areas, helping enterprises understand the cost performance of each operating area; through comprehensive analysis of the production costs of the entire cold rolling mill, helping enterprises to grasp the cost situation from a global perspective; through the establishment of multi-level visualization analysis functions such as steel coils, brands, units, operating areas and cold rolling mills, enterprises can better grasp the cost structure, identify cost drivers, optimize resource allocation, improve production efficiency, and ultimately achieve continuous cost reduction and enhanced competitiveness.

[0032] In summary, this embodiment provides a method for refined steel coil cost accounting for the cold rolling process. This method accurately calculates various costs in the cold rolling process by establishing mathematical models and cost models, thereby obtaining accurate steel coil cost data, providing strong support for the company's cost control and decision-making.

[0033] Example 2: This embodiment provides a computer device, such as a smartphone, tablet computer, laptop computer, desktop computer, rack-mounted server, blade server, tower server, or cabinet-mounted server (including a standalone server or a server cluster consisting of multiple servers), capable of executing programs. The computer device of this embodiment includes at least, but is not limited to, a memory and a processor that are interconnected via a system bus.

[0034] In this embodiment, the memory (i.e., readable storage medium) includes flash memory, hard disks, multimedia cards, card-type memories (e.g., SD or DX memories), random access memory (RAM), static random access memory (SRAM), read-only memory (ROM), electrically erasable programmable read-only memory (EEPROM), and programmable read-only memory (PROM). The memory may also be an external storage device of the computer device, such as a plug-in hard disk, a SmartMedia Card (SMC), a Secure Digital (SD) card, a flash memory card, etc. Of course, the memory may also include both the internal storage unit of the computer device and its external storage devices. In this embodiment, the memory is typically used to store the operating system and various application software installed on the computer device, such as the program code for the refined cost calculation method for cold rolling processes in Example 1. Furthermore, the memory may also be used to temporarily store various data that has been output or is about to be output.

[0035] In some embodiments, the processor can be a central processing unit (CPU), a controller, a microcontroller, a microprocessor, or other data processing chip. Such a processor is typically used to control the overall operation of a computer device. In this embodiment, the processor is used to execute program code stored in a memory or process data to implement the refined steel coil cost calculation method for the cold rolling process described in Example 1.

[0036] Example 3: The present application also provides a computer-readable storage medium, such as a flash memory, a hard disk, a multimedia card, a card-type memory (e.g., SD or DX memory), a random access memory (RAM), a static random access memory (SRAM), a read-only memory (ROM), an electrically erasable programmable read-only memory (EEPROM), a programmable read-only memory (PROM), a magnetic memory, a disk, an optical disk, a server, an app store, etc., storing a computer program that, when executed by a processor, implements a corresponding function. The computer-readable storage medium of this embodiment is used to store program code for a method for refining steel coil cost calculation for a cold rolling process. When executed by a processor, the method for refining steel coil cost calculation for a cold rolling process according to the first embodiment is implemented.

[0037] It should be pointed out that, according to the needs of implementation, the various steps / components described in this application can be split into more steps / components, or two or more steps / components or partial operations of steps / components can be combined into new steps / components to achieve the purpose of the present invention.

[0038] It will be easily understood by those skilled in the art that the above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included in the scope of protection of the present invention.

Claims

1. A method for calculating the cost of steel coils in a cold rolling process, characterized in that: The following steps are involved: S1. Collecting data related to steel coil production in the cold rolling process and processing the data related to steel coil production; S2. Calculate the steel coil production related data according to the set cost elements and cost element calculation rules to obtain the steel coil cost and cost accounting report.

2. The method for calculating the cost of steel coils in a cold rolling process according to claim 1, characterized in that: Steel coil production-related data includes production raw material data, production performance data, steel coil production line history data, energy consumption data, and auxiliary material consumption data; Production raw material data, production performance data, and auxiliary material consumption data are obtained through the unit's raw material table, performance table, and auxiliary material data table; Energy consumption data is obtained by reading the unit controller information; The historical data of steel coil production lines are divided into continuous production lines and non-continuous production lines according to the production process of cold rolling production lines; For continuous production lines, the historical data of steel coil production lines is obtained by tracking the welds of steel coils on the production line and calculating the time period when the steel coils pass through the set energy metering position; for non-continuous production lines, it is obtained by tracking the time points when the steel coils pass through the positions of each unit.

3. The method for calculating the cost of steel coils in a cold rolling process according to claim 2, characterized in that: Data processing includes data cleaning, format conversion, and outlier processing.

4. The method for calculating the cost of steel coils in a cold rolling process according to claim 2, characterized in that: Cost elements include fixed cost, raw material cost, variable cost, and auxiliary material cost, which respectively represent the labor cost, raw material cost, energy consumption cost, and auxiliary material cost required to produce a unit of steel coil.

5. The method for calculating the cost of steel coils in a cold rolling process according to claim 4, characterized in that: The cost element calculation rules for fixed costs are as follows: fixed costs are the product of the average daily labor cost and the number of production days required for each ton of product steel coil; The cost element calculation rule for raw material cost is: the final cost of the previous process is used as the raw material cost of the subsequent process. The raw material cost of the initial process is the ratio of the raw material price of the steel coil to the actual yield rate of the steel coil. The cost element calculation rule for variable cost is as follows: obtain variable cost based on the historical data of the steel coil production line and the energy consumption data corresponding to the historical data of the steel coil production line; The cost element calculation rule for auxiliary material costs is: average the auxiliary material consumption data with the production performance data.

6. The method for calculating the cost of steel coils in a cold rolling process according to claim 1, characterized in that: The method includes: S3, analyzing the cost accounting report and proposing cost reduction optimization suggestions.

7. The method for calculating the cost of steel coils in a cold rolling process according to claim 1, characterized in that: The method includes: S4, performing cost visualization according to the cost accounting report.

8. The method for calculating the cost of steel coils in a cold rolling process according to claim 7, characterized in that: Step S4 includes: performing multi-level cost visualization display of steel coil costs of different steel coils, brands, mills, operating areas, and cold rolling mills.

9. A computer comprising a memory, a processor, and a computer program stored in the memory and executable on the processor, wherein: When the processor executes the computer program, the steps of the method for refined calculation of steel coil costs for cold rolling processes according to any one of claims 1 to 8 are implemented.

10. A computer storage medium having a computer program stored thereon, characterized in that: When the computer program is executed by a processor, the steps of the method for refined calculation of steel coil costs for cold rolling processes according to any one of claims 1 to 8 are implemented.

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