Method, computer program and system for planning material flow

Abstract

The invention relates to a method, a system and a computer program for planning a material flow. The method comprises the following steps: determining a shortage resource; determining an identifier allocated to the shortage resource; searching a database according to the identification allocated to the shortage resource; determining an alternative resource from a database according to the identifier allocated to the shortage resource, wherein the determined alternative resource replaces the shortage resource; and using the determined alternative resources in the material stream.

Description

TECHNICAL FIELD

[0001] The present invention relates to a method, a computer program and a system for planning a material flow. In particular, the present invention relates to a computer-implemented method for planning a material flow, wherein the computer-implemented method has the following steps: determining a short resource; determining an identification assigned to the short resource; searching a database according to the identification assigned to the short resource; determining a replacement resource from the database according to the identification assigned to the short resource, wherein the specific replacement resource replaces the short resource; and using the determined replacement resource in the material flow. Furthermore, the present invention relates to a computer program for planning a material flow according to the above-mentioned method. Furthermore, the present invention relates to a system for planning a material flow according to the above-mentioned method. BACKGROUND

[0002] Supply-Chain-Management (SCM) in enterprises is a term which aims at improving the long-term performance of single enterprises and of the whole supply chain, looking at the whole system within an enterprise and along the supply chain, at strategic coordination between and at tactical decisions within the traditional business functions.

[0003] Due to the trend of focusing on core competences (including by outsourcing) and reducing production depth, the division of labor in the supply chain is increasingly developed. Global market competition, short product introduction periods, short product life cycles and high customer expectations make the supply chain the center of decision-making.

[0004] Thus, instead of individual manufacturers vertically integrated, complex structured supply chains consisting of associated but independent enterprises compete on the respective target market. This system of decentralized organization gains competitive advantage through the market-oriented configuration of its structure and through the coordination and integration of autonomously controlled activities in the supply chain.

[0005] The present invention is particularly directed at the planning of a material flow in the scope of a supply chain and a SCM system. For illustration and without limitation, a scenario of a supply chain in the automotive industry is shown in the following. However, similar application cases are comprehensively covered by the present disclosure. Similar application cases can be roughly supply chains in the scope of individual components of an automobile. Furthermore, such similar application cases can include other industrial goods, such as airplanes, ships, motorcycles, etc.

[0006] In recent years, due to a shortage of resources, hereinafter referred to as short resources, such as semiconductors, the annual production of automobiles in the automotive industry has been reduced by approximately 20%. This corresponds to a loss of approximately 2.5 million automobiles per year in the automotive industry in Germany alone. Thus, the production plants of automobile manufacturers and suppliers at all levels, i.e. the supply chain or material flow, cannot be operated at full capacity.

[0007] In order to be able to keep the production plants of car manufacturers and suppliers fully loaded, car manufacturers and suppliers usually react with over-procurement. However, these reactions do not solve the problem of under-loaded production plants, but rather shift the scarce resources only within the material flow or supply chain.

[0008] The problem of shifting scarce resources within the material flow or supply chain described above does not only occur on a vertical level, i.e. between the original equipment manufacturer (i.e. OEM) and the suppliers of different tiers (in the following referred to as tiers). On the contrary, the problem described above occurs equally on a horizontal level, i.e. between suppliers of the same tier, e.g. between tier 1 suppliers, tier 2 suppliers,..., tier n suppliers.

[0009] US2020 / 006 5759A1 discloses a platform for managing engineering, production, supply chain and logistics operations, which can efficiently and effectively configure factors of product development, production, supply chain and logistics operations and can dynamically control these factors, supply chain and logistics in order to optimize performance. The platform also provides the feasibility of selectively and securely showing data about production factors, logistics and supply chain in order to be able to implement real-time monitoring to support sales, financial management or after-sales processes.

[0010] US2018 / 008 9604A1 discloses system, method and computer program product embodiments for performing real-time supply chain response planning. The described embodiments work by receiving a request from a client device, the request specifying an amount of a product required within a deadline. Then, a list of constraint variables related to the product is identified from a table of constraint variables. Each condition variable in the list is associated with a net available amount table stored in an in-memory database with column storage. Based on the table of constraint variables, a capacity required to satisfy the request is determined for each constraint variable in the list. To determine whether the capacity required for each constraint variable is met, the request is simulated within a current supply chain plan by aggregating the available capacity for each constraint variable using one or more columns of the associated net available amount table. The results based on the simulated request are sent to the client device.

[0011] US 2011 / 0320805 Al discloses an implementation of a method for collectively using data in a supply chain, wherein the data corresponds to an object associated with a tag, comprising generating data corresponding to the object, generating a data reference, encrypting the data with an encryption key to provide encrypted data, communicating the encrypted data via a network for storage in a database based on the data reference, writing the data reference and the encryption key onto the tag, and communicating the object to a successor in the supply chain. Belonging to the implementation are calling the information stored on the tag electronically, wherein the information comprises the data reference and the encryption key, communicating a data request via the network to call the encrypted data from the database, wherein the data request comprises the data reference, receiving the encrypted data from the database and decrypting the encrypted data with the encryption key to provide decrypted data.

[0012] US 2006 / 0155593 Al discloses a method, system and computer-implemented architecture for performing supply chain planning. In one implementation a system is provided, the system comprising: a database configured such that it stores master data, the master data describing elements of a supply chain; a model generator coupled to the database and configured such that it derives a core model based on the master data, the core model illustrating a problem of supply chain planning; and a solver configured such that it translates the core model into a mathematical model and determines a solution for the mathematical model. Further, the system can comprise a pre-processor configured such that it pre-processes the core model in a manner that the pre-processor subjects the core model to a set of rules in order to derive a pre-processed core model, wherein the solver creates the mathematical model from the pre-processed core model. By applying a set of pre-processing rules to the core model that also captures the business logic of the problem of supplier planning, the solving process of the planning problem is improved and the performance of the solver is increased. Further, the customer can be informed of a compelling result from the pre-processing.

[0013] Catena-X is a collaborative open data ecosystem for the automotive industry. It connects global participants into a coherent value chain. The goal is a standardized global data exchange. The party providing the data retains control and decides for itself who, how, when, where and under which conditions participates in the data exchange.

[0014] However, a disadvantage of all the above-described disclosures is that determining a replacement resource is a computer-technically consuming operation due to the large amount of resources required for complex products. Therefore, it is not possible in computer technology to quickly determine a replacement resource for a determined short resource.

[0015] It is therefore an object of the present invention to at least partially solve and / or improve the disadvantages of the prior art. SUMMARY

[0016] The objects on which the application is based are achieved by the features of the independent claims. Advantageous design solutions of the application are defined in the dependent claims.

[0017] In a first embodiment, a method for planning a material flow is provided. Here, the computer-implemented method has the steps of determining a short resource, determining an identification assigned to the short resource, searching a database according to the identification assigned to the short resource, determining a replacement resource from the database according to the identification assigned to the short resource, wherein the determined replacement resource replaces the short resource, and using the determined short resource in the material flow.

[0018] According to the first embodiment, the short resource is replaced by the replacement resource according to the identification. Replacing the short resource by the replacement resource by means of the identification provides a high-performance data format here, on the basis of which the database can determine a replacement resource for the short resource in a high-performance manner.

[0019] In a preferred embodiment, the database has a plurality of databases, wherein the plurality of databases is held on different computers.

[0020] In another preferred embodiment, the searching the database has searching a plurality of databases on different computers.

[0021] In another preferred embodiment, the plurality of databases on different computers is respectively assigned to a different level in a hierarchy of the computers.

[0022] In another preferred embodiment, each level has a plurality of databases. Here, each level corresponds to a level of the planned material flow.

[0023] In another preferred embodiment, each database of the databases of the same level is assigned to a different computer of the manufacturers of the short resources.

[0024] In another preferred embodiment, the determining the replacement resource from the database has the short resource within one level being replaced by another manufacturer of the same level.

[0025] In another preferred embodiment, the identification is constructed from an industry code and a material manufacturer code. In another preferred embodiment, the identification can be a supply chain transparency (SCT) identification, in the following referred to as SCT-ID.

[0026] In another preferred embodiment, determining the short supply resource has the steps of determining a required number of the short supply resource; determining a stock of the short supply resource in an inventory of the short supply resource; and determining that the stock of the short supply resource in the inventory of the short supply resource is less than the required number of the short supply resource.

[0027] In another preferred embodiment, the substitute resource is equivalent to the short supply resource.

[0028] In another embodiment, a computer program is provided. Here, the computer program has instructions which, when executed by a computer, cause the computer to perform a method according to one of the above embodiments.

[0029] In another embodiment, a system for planning a material flow is provided. The system has: means for determining a short supply resource; means for determining an identification assigned to the short supply resource; means for searching a database according to the identification assigned to the short supply resource; means for determining a substitute resource from the database according to the identification assigned to the short supply resource, wherein the determined substitute resource replaces the short supply resource; and means for using the specific substitute resource in the material flow. BRIEF DESCRIPTION OF DRAWINGS

[0030] Preferred embodiments of the present application are explained in detail below with reference to the accompanying drawings. The drawings show:

[0031] Figure 1 a method for planning a material flow according to one embodiment of the present application is shown;

[0032] Figure 2 a method for planning a material flow according to another embodiment of the present application is shown; and

[0033] Figure 3 a schema for building a database with identifications according to another embodiment of the present application is shown. DETAILED DESCRIPTION

[0034] Preferred embodiments for planning a material flow are shown below.

[0035] Figure 1An exemplary flow of a method for planning a material flow according to one embodiment of the present application is shown. The method starts in step 1 in which an OEM, here OEM A, defines a bottleneck relating to a certain component. The certain component is in this embodiment a short supply resource. The defined bottleneck is stored in a database. In step 2 a first tier manufacturer, here called Tier 1 A, defines the short supply resource more precisely. The more precisely determined short supply resource is stored in the database. In step 3 a second tier manufacturer, here a semiconductor manufacturer, names the same short supply resource that the first tier manufacturer, here Tier 1 B, has already provided. Step 3 is also implemented on the basis of the database. In step 4 the first tier manufacturer Tier 1 B confirms that it has assembled the short supply resource into a component. Furthermore, the first tier manufacturer Tier 1 B checks which further OEM has obtained the component with the short supply resource from the first tier manufacturer 1 B. Step 4 is also implemented on the basis of the database. In step 5 the OEM B checks the availability of the component with the short supply resource. The step is also implemented on the basis of the database. Furthermore, in step 5 the OEM B can define the short supply resource that it obtains in exchange. The definition can be checked automatically in the background on the basis of the database and the software built thereon. It can furthermore be checked whether the short supply resource that the OEM B obtains in exchange is used by other OEMs, for example OEM A, and is available for exchange. As described above, on the basis of the database check, the short supply resource of OEM A can be exchanged with the short supply resource of OEM B in the same amount and in the same time period. In step 6 an agreement is concluded between OEM A and OEM B via exchange.

[0036] Figure 2An exemplary system for planning a material flow according to the present application is shown. The system is based on a personalized programming software (in the following: SCT software), which is partially supported by artificial intelligence, i.e. AI. The core is a database (here: SCT database based on SQL) and a computer-supported allocation (here: SCT-ID) of the identification of the scarce resources. The SCT software and the SCT database have an interface via which data associated with the scarce resources can be exchanged with different OEMs and 1-n level manufacturers. The interface is constituted by a homepage and / or a dedicated software module (here: SCT-APP). The database and the interface are here subject to an access rights control. The access rights control can allow a virtual private network (VPN) access and / or a universal serial bus, i.e. USB stick, access. The individual data sets can be entered manually in a first construction phase via a secure access homepage by individual staff of the OEM, 1-n level manufacturer and semiconductor manufacturer. In a subsequent construction phase, the data exchange takes place in a digital, i.e. automatic, manner in bottleneck / shortage situations according to the resource planning (EPR), IT system (usually SAP or Oracle) of the respective involved and network-connected enterprises.

[0037] Figure 3 An exemplary architecture for constructing a database with an identification according to another embodiment of the present application is shown. Here, the identification can be a supply chain transparency-ID, i.e. SCT-ID. In step 1, an OEM can determine a scarce resource. In step 2, an identification assigned to the scarce resource can be determined. Here, the determined identification can be the SCT-ID. In step 3, the database can be searched according to the SCT-ID assigned to the scarce resource. Here, the database can be the SCT database. In step 4, a replacement resource can be determined with the SCT database according to the SCT-ID assigned to the scarce resource. Here, the resource determined in the described manner can replace the scarce resource, in the following referred to as replacement resource. In step 5, the previously determined replacement resource can be used in a material flow. In step 6, each of the above-mentioned steps 1 to 5 can be tracked in a further database. Here, the further database can be the SCT database or another database.

[0038] The embodiments and examples described above can be regarded as a first stage, wherein the overall process comprises three stages. Therefore, stage two and stage three are shown below.

[0039] Phase 2: Artificial intelligence tools, i.e. AI tools, can help developers to find the right components (e.g. semiconductors) in supply chain transparency combined components, i.e. SCT combined components. The SCT-ID of the short supply resource can together with the AI software in the second step be used to build up step by step with the first tier manufacturer and the manufacturer of the short supply resource to an SCT standard combined component. The SCT standard combined component helps the developer to select the right short supply resource for the OEM or for the supply of the first tier manufacturer in the scope of the AI supported SCT selection tool (according to defined parameters, e.g.: industry, temperature of the field of use, function of the semiconductor) to reduce the variety of used short supply resources. The goal is to reduce application specific integrated circuits (ASICs) or custom chips in the product development iteration. Thereby more standardized short supply resources (e.g. the above mentioned standard semiconductors) are used, which in turn increases the resilience of the supply chain.

[0040] The SCT database helps the semiconductor manufacturers to classify their standard semiconductors by SCT-ID and to provide them transparently to the purchasers. Here, the SCT selection tool selects the standard short supply resources (e.g. the standard semiconductors) for the specific application purpose of the purchaser in an AI supported way. Ideally, multiple manufacturers provide interchangeable short supply resources (semiconductors), which turns the often used "single source" strategy in the automotive industry before the corona pandemic into a "dual source" or "multi source" strategy. This way, the market's dependency on individually manufactured short supply resources (semiconductors) is reduced. The market thereby becomes more transparent step by step.

[0041] Phase 3: Providing SCT software modules. Each user of phase 1 and 2 discloses information about their supply chain during the transaction, which is saved in a structured way in the SCT database in accordance with the data protection basic regulation (DSGVO). For example:

[0042] Phase 1: The value chain section of the components from the OEM via the manufacturer to their suppliers has a quantity specification per week;

[0043] Phase 2: The SCT-ID correlates the individual supplier components with each other.

[0044] All this information is centrally available as data in the SCT database in accordance with the DSGVO. In parallel to phases 1 to 2, the SCT develops software modules that are interdependent and correlate with each other. All modules serve the purpose of making the supply chain more transparent and more resilient. Here, the SCT database provides a basis from the start for software modules such as:

[0045] • SCT-SM (Short-Management) module;

[0046] • SCT-DC (Demand / Capacity Management) module;

[0047] • SCT-VCT (Value Chain Transparency) module;

[0048] • SCT-DP (Demand Prognose) module;

[0049] • SCT-SERP (Simulation-Enterprise-Resource-Planning) module;

[0050] • SCT-OCC (Operations Control Center).

[0051] Here, the advantage of the SCT software is that it combines the data of the SCT-database with future expected applications. Thus, the users of the SCT phases one to three are supported technically comprehensively and throughout, so that their supply chain is more resilient.

[0052] The above description is merely preferred implementations of the present application. The description should not be considered to be restrictive in any way. Rather, other modifications, enhancements, variations, improvements, and the like are possible in light of the above teachings. Thus, the scope of the present application should not be limited to the implementations described herein but should be given the broadest interpretation of the appended claims to their fullest scope permissible under the laws.

Claims

1. A computer-implemented method for planning a material flow, wherein the computer-implemented method has the steps of: - determining a short resource; - determining an identification assigned to the short resource; - searching a database according to the identification assigned to the short resource; - determining a replacement resource from the database according to the identification assigned to the short resource, wherein the determined replacement resource replaces the short resource; and - using the determined replacement resource in the material flow.

2. The computer-implemented method according to claim 1, wherein the database has a plurality of databases, and wherein the plurality of databases is held on different computers.

3. The computer-implemented method according to any of the preceding claims, wherein searching the database comprises searching the plurality of databases on different computers.

4. The computer-implemented method according to any of the preceding claims, wherein the plurality of databases on different computers is respectively assigned to a different level in a hierarchy of computers.

5. The computer-implemented method according to any of the preceding claims, wherein each level has a plurality of databases, and wherein each level corresponds to a level of the planned material flow.

6. The computer-implemented method according to any of the preceding claims, wherein each database of the databases of the same level is assigned to a different computer of a manufacturer of the short resource.

7. The computer-implemented method according to any of the preceding claims, wherein determining a replacement resource from the database comprises a short resource within one level being replaced by another manufacturer of the same level.

8. The computer-implemented method according to any of the preceding claims, wherein the identification consists of an industry code and a material manufacturer code.

9. The computer-implemented method according to any of the preceding claims, wherein determining a short resource has the steps of: - determining a required number of the short resource; - determining a stock number of the short resource in a stock of the short resource; and - determining that the stock number of the short resource in the stock of the short resource is less than the required number of the short resource.

10. The computer-implemented method according to claim 9, wherein the computer-implemented method further comprises: - comparing to a planned production program of an original equipment manufacturer, i.e. OEM, a first tier supplier and a consignor of the short resource, wherein the planned production program has an amount per unit of time, in particular daily or weekly.

11. The computer-implemented method according to any of the preceding claims, wherein the replacement resource is equivalent to the short resource.

12. A computer program having instructions which, when executed by a computer, cause the computer to carry out the method according to any of claims 1 to 11.

13. A system for planning a material flow, having: - means for determining a short resource; - means for determining an identification assigned to the short resource; - means for searching a database according to the identification assigned to the short resource; - means for determining a replacement resource from the database according to the identification assigned to the short resource, wherein the determined replacement resource replaces the short resource; and - means for using the determined replacement resource in the material flow. - means for determining a substitute resource from the database according to an identification assigned to the short resource, wherein the determined substitute resource replaces the short resource; and - means for using the determined substitute resource in the material flow.

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