Paper roll preprinting production management system based on ERP and MES and management method thereof
The paper roll pre-printing production management system, which combines ERP and MES, solves the problems of resource constraints, process fragmentation, and imprecise material traceability in paper roll printing production. It achieves efficient and transparent production management and improves equipment utilization and production efficiency.
Patent Information
- Application Number
- CN202511348388.9
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-09-20
- Publication Date
- 2026-02-10
AI Technical Summary
In paper roll printing production, existing MES systems suffer from problems such as lack of dynamic coordination of resource constraints, fragmented production processes, lack of multi-functional modeling of equipment, and imprecise material traceability, resulting in low production efficiency and high error rates.
The paper roll pre-printing production management system, based on ERP and MES, is adopted. Through the core functional platform, mobile application and external integration system, it realizes resource-constrained scheduling, automated imposition, material tracking and automatic collection of equipment data, generates and prints QR code labels, and builds an information management process.
It improved production efficiency and equipment utilization, reduced downtime, enabled refined management and transparent control of the entire production process, and reduced human intervention and operational error rates.
Smart Images
Figure CN121503741A_ABST
Abstract
Description
Technical Field
[0001] This invention belongs to the field of intelligent manufacturing information management technology, specifically involving a paper roll pre-printing production management system and its management method based on ERP and MES. Background Technology
[0002] ERP (Enterprise Resource Planning) is a type of enterprise management software that primarily helps companies integrate finance, human resources, supply chain, manufacturing, procurement, sales, and performance data to achieve data flow and sharing between various business operations, ensuring a unified and accurate data source, thereby improving enterprise management and operational efficiency.
[0003] A Manufacturing Execution System (MES) is a management system used to monitor and control the manufacturing process. Its main functions include: Real-time monitoring: The MES system can track and record the production process from raw materials to finished products in real time, ensuring production efficiency and product quality; Data Acquisition: By capturing data from multiple sources, including machines, sensors, and operators, MES provides accurate and up-to-date information about the status of production activities; Optimize production: MES systems help companies identify and resolve problems in the production process in a timely manner, avoiding production delays and waste. Connecting to ERP Systems: MES acts as a bridge between Enterprise Resource Planning (ERP) systems and actual manufacturing operations, promoting efficient production management.
[0004] Integrating the MES system with the ERP system for paper roll printing production management enables information-based management of printing plates, sleeve molds, and bridge sleeve molds, thereby improving production efficiency. Analysis of current traditional printing industry MES systems reveals the following problems: Resource constraints are not dynamically coordinated: mold resources such as printing plates, rollers, and sleeves are disconnected from the production schedule, which can easily lead to downtime due to mold shortages.
[0005] The printing process is fragmented: the pre-printing and subsequent slitting processes lack automatic linkage and require manual intervention, resulting in low efficiency.
[0006] Lack of multi-functional modeling for equipment: The same equipment (such as a pre-printer that also functions as an inkjet printer) cannot have its resource usage managed uniformly in the scheduling process.
[0007] Material traceability is not precise: the correspondence between raw paper, semi-finished products, and finished products relies on manual recording, resulting in a high error rate. Summary of the Invention
[0008] In view of this, the present invention proposes a paper roll pre-printing production management system and its management method based on ERP and MES, which can solve the problems of production scheduling disconnect, production process fragmentation, and inability to manage uniformly in the current application of conventional EMS in the printing industry.
[0009] This invention is implemented as follows: This invention includes a paper roll pre-printing production management system based on ERP and MES. The production management system consists of three parts: a core functional platform, a mobile application, and an external integration system. The core functional platform, serving as the system's central hub, primarily comprises an Advanced Planning and Scheduling (APS) module and a Production Execution Management (MAM) module. The APS module receives instructions from higher levels and generates detailed production plans based on resource constraints and optimization algorithms. The MAM module executes these production plans. The mobile application mainly includes a first PDA application and a second PDA application; the first PDA application is used to handle the paper outbound, onboard, offboard, and return operations by scanning QR codes, and to synchronize data with the core functional platform; the second PDA application is used to handle the pre-printed semi-finished product outbound, onboard, offboard, and return operations and to trigger inventory updates. The external integration system mainly acts as the initiator of the upper-level instructions and the receiver of production result data; The production management system is centered on the core functional platform, connecting the upper-level ERP system with the lower-level production equipment, forming an interactive closed loop of three levels: decision-making, execution, and feedback.
[0010] Furthermore, the Production Execution Management module includes a pre-printer-specific automatic version of MES and a post-printer-specific manual version of MES; The dedicated automatic version of MES for pre-printing machines is installed on the pre-printing machine. It automatically collects data such as paper feed length, machine speed, and output through the equipment data interface, realizing unmanned work reporting and material traceability. The dedicated manual version of the MES for downstream processes is installed on downstream equipment and provides an interface for manual input of material loading, output, and work reporting information.
[0011] Furthermore, the core functional platform also includes a material tracking module and a mold management module; The material tracking module is used to record the conversion and quantity relationships between raw paper, pre-printed semi-finished products, downstream semi-finished products and finished products through the automatic collection of the mobile application and MES. The mold management module is used to establish an electronic archive and real-time inventory status of printing plates, rollers, and sleeves, providing a key basis for resource constraint scheduling for the APS module.
[0012] Furthermore, the core functional platform also includes a label management and printing module, which is used to generate and print QR code labels containing structured data JSON for each roll of output. The QR code labels serve as a key medium connecting the physical world and the information world, providing information retrieval support.
[0013] This invention also provides a management method for a paper roll pre-printing production management system based on ERP and MES, the method specifically including the following steps: Step S1: Analyze resource requirements, receive and parse the production instructions issued by the ERP system, and extract the types and quantities of pre-printed plates, pre-printed rollers and pre-printed bridge sleeves required to complete the work order; Step S2: Dynamic estimation of mold availability. Based on the scheduling order and time, dynamically simulate and verify the available inventory of molds in the future period. The verification includes a horizontal check to see if the total demand in the same period exceeds the inventory, and a vertical check to see if the demand superposition caused by loading and unloading time of continuous work orders exceeds the inventory. Step S3: Conflict handling and decision-making. When a resource conflict is detected during verification, the operation of automatically adjusting the schedule, triggering an early warning, or suspending the schedule is executed. Step S4: Raw material and auxiliary material availability verification. After the mold verification is passed, the inventory of raw paper and auxiliary materials required for production is matched and verified according to the preset rules to ensure that they are sufficient. Step S5: Calculate the precise operation time. After satisfying all resource constraints, calculate the planned time of the process based on the planned production length, machine speed, and changeover optimization algorithm. Step S6: Output a feasible plan and lock resources, generate a scheduling plan and issue it, and at the same time reserve the mold, raw paper and auxiliary material resources used in the system.
[0014] Furthermore, the step of extracting the number of pre-printed bridge sleeves in step S1 includes: Based on the total number of colors in the work order, subtract the number of seamless sleeves to obtain the required number of pre-printing rollers; Subtract the number of mounting shafts to obtain the required number of pre-printed bridge sleeves.
[0015] Furthermore, the longitudinal inspection in step S2 specifically includes: Consider the loading and unloading time of the mold (N minutes), that is, after a mold is used up in the previous work order, it takes N minutes before it can enter the "usable" state; Verify whether the sum of the demand quantities for a certain type of mold in two consecutive work orders exceeds the total inventory of that mold.
[0016] Furthermore, the paper matching rules in step S4 include: Exact match: If the work order specifies a rating and / or environmental indicators, then the inventory will be searched strictly according to these criteria. Flexible matching: If the work order does not specify the grade and environmental protection indicators, only paper and print sizes will be matched, and inventory of any grade and environmental protection indicators will be considered available.
[0017] Furthermore, the preparation time calculation in step S5 employs a version-switching optimization algorithm, specifically as follows: Compare the plate sets of the current work order with those of the previous work order; The plate change time is calculated only for the plates with differences; the preparation time for the same plates is zero.
[0018] Furthermore, the specific steps for pre-allocating resources in step S6 include: Update the status of the mold to be used to "occupied" or "reserved"; Set the "estimated availability time" of the mold to the end time of this work order plus the loading and unloading time (N minutes); Reserve the required raw paper and auxiliary materials inventory in advance. Compared with existing technologies, the beneficial effects of the paper roll pre-printing production management system and its management method based on ERP and MES provided by this invention are: Improve production efficiency and equipment utilization; avoid downtime due to mold and raw material shortages through resource-constrained scheduling; reduce preparation and changeover time through automated panel layout and optimized changeover time. The system enables refined and transparent management of the entire production process. Through the system, the progress of work orders, equipment status, mold usage, material consumption and output can be monitored in real time, thus achieving refined and transparent management of the workshop production process. Reducing reliance on human experience and operational error rates, automated processes such as panelization process linkage and QR code data transmission reduce human intervention and decrease errors caused by insufficient human experience or negligence. Attached Figure Description
[0019] Figure 1 A system composition diagram; Figure 2 A diagram showing the internal structure and relationships of the ASP and MES systems; Figure 3 This is a flowchart of the method. Detailed Implementation
[0020] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to the accompanying drawings. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the invention.
[0021] like Figure 1The diagram shows the paper roll pre-printing production management system based on ERP and MES provided by this invention. The entire system is centered around the MES system, connecting the upper-level ERP and the lower-level production equipment. The interactions between the various modules of the system can be summarized into three levels: Decision-making level (SAP-APS): SAP issues instructions, and APS develops detailed plans based on resources and rules.
[0022] Execution layer (APS-MES-shop floor): APS dispatches plans to MES, MES drives automated equipment or manual execution, and accurately tracks materials through PDA applications.
[0023] Feedback Layer (Workshop-MES-SAP): Execution results are automatically collected and manually entered into the MES system, which then reports the results to SAP, forming a closed loop. QR code labels are a key medium bridging the physical and information worlds.
[0024] The management system consists of three parts: a core functional platform, a mobile application, and an external integration system.
[0025] The core functional platform specifically includes the following components: The APS Advanced Planning and Scheduling module, primarily acting as the management layer, is responsible for receiving work orders and resource data from SAP. Based on resource constraints (molds, raw materials, equipment), priority rules, and optimization algorithms, it generates feasible production plans for all processes, such as pre-printing, rewinding, and lamination.
[0026] The Production Execution Management module, as the execution layer of the entire system, is mainly responsible for executing the production plan generated by the APS Advanced Planning and Scheduling module.
[0027] The Production Execution Management module is divided into an automatic version of MES for pre-printing machines and a manual version of MES for post-printing machines. Among them, the dedicated automatic version of MES for pre-printing machines is installed on the pre-printing machine. It automatically collects data such as paper feed length, machine speed, and output through the equipment data interface, realizing unmanned work reporting and accurate material traceability. The manual version of the MES for downstream processes is installed on downstream equipment such as rewinding and slitting machines and laminating machines. It provides an interface for manual input of information such as material feeding, output, and work reporting to guide the operation.
[0028] The material tracking module, through two PDA applications, "PDA Paper Roll Loading and Unloading" and "PDA Pre-printed Semi-finished Product Loading and Unloading," as well as the automatic data collection by MES, records the conversion and quantity relationships of raw paper → pre-printed semi-finished product → downstream semi-finished product → finished product throughout the entire process.
[0029] The mold management module, as the key basis for APS to perform resource constraint scheduling, is mainly used to establish an electronic archive and real-time inventory status of printing plates, rollers, and sleeves, so that APS can easily query and retrieve data when performing resource constraint scheduling.
[0030] The label management and printing module generates and prints QR code labels containing structured JSON data for each roll of output (semi-finished or finished products).
[0031] The mobile applications include the "PDA Paper Roll Loading and Unloading" application and the "PDA Pre-printed Semi-finished Product Loading and Unloading" application.
[0032] The "PDA Paper Roll Loading and Unloading" application is specifically designed for use in raw paper warehouses and near pre-printing machines. By scanning the barcode of the raw paper roll, it handles the outbound, loading, unloading, and return operations of raw paper, and synchronizes the data with the MES system in real time. The "PDA Pre-printed Semi-finished Product Loading and Unloading" application is specifically designed for pre-printed semi-finished product warehouses and downstream equipment. By scanning the barcode of the semi-finished product, it handles the outbound, loading, unloading, and return operations of the semi-finished product, and automatically triggers inventory updates in the MES system.
[0033] External systems include SAP, which, as a group-level ERP, is the initiator of all master data and production instructions in this system, as well as the recipient of production result data.
[0034] The external system is primarily responsible for providing basic data, such as customer and material information. Issue production instructions, such as work orders, process plans, and material quantities; Provide resource status, such as raw material inventory and mold inventory; Receive execution results, such as work reports and defective product details; Parse the QR code of the finished product for warehousing.
[0035] The present invention also provides a management method for the management system, wherein the management method specifically includes: Step 1: Analyze resource requirements. The system receives and parses the "Pre-print Work Order Process Plan" issued by SAP and extracts key resource instructions.
[0036] Identify the preprint number and quantity required for the work order.
[0037] Determine the required roller type based on the "Compatible Roller Specifications" field in the preprint file: If it is "included", then this version is a seamless sleeve, and the subsequent roller / sleeve search will be skipped.
[0038] If a specific specification value is required, then this version requires a pre-printing roller of the corresponding specification.
[0039] Determine whether a bridge sleeve and its specifications are required based on the "Compatible Bridge Sleeve Specifications" field in the pre-printed roller file.
[0040] Calculate the required quantity: Based on the total number of colors in the work order, deduct the number of seamless sleeves to obtain the required number of pre-printing rollers; then deduct the number of mounting shafts (considered as rollers) to obtain the required number of pre-printing bridge sleeves.
[0041] Step 2: Dynamic estimation of mold availability. Based on the scheduling order and time, dynamically simulate and verify the available inventory of molds in future periods.
[0042] The inspection is divided into horizontal inspection and vertical inspection.
[0043] The horizontal inspection specifically involves checking whether the total demand for a certain type of mold from all machines within the same planned time period exceeds the total inventory of that mold. For example, if machine A needs 8 X-type rollers and machine B needs 4, but the total inventory of X-type rollers is 10, then there is a conflict, and the plan is not feasible.
[0044] The vertical verification specifically involves checking whether the sum of the demand for a certain type of mold in two consecutive work orders exceeds the total inventory. For example, work order 1 requires 8 molds, work order 2 requires 4 molds, and the total inventory is 10 molds. If it takes N minutes for the molds to be unloaded and usable after work order 1 is completed, then at the start of work order 2, the machine tool will still need to occupy these 8 molds, resulting in a total demand of 12 > 10, which is a conflict.
[0045] Considering the loading and unloading time of the mold, that is, after a mold is used up, it takes N minutes before it can enter the "usable" state for the next work order.
[0046] Step 3, Conflict handling and decision-making: When resource conflicts are detected in Step 2, the system adopts a response strategy.
[0047] Automatic adjustment: APS automatically attempts to adjust the scheduling order of work orders to avoid resource conflicts, provided that delivery time and other rules are met.
[0048] Trigger prompt: If the conflict cannot be resolved automatically, a conflict warning will be sent to the planner, specifying which type of resource, when, and how much is in short supply.
[0049] Pause scheduling: Mark the work order or the entire layout group as "awaiting resources" until resources become available.
[0050] Step four: Raw material and auxiliary material availability verification. After the mold verification is passed, further verification is made to ensure that there are enough raw paper and auxiliary materials required for production.
[0051] Paper matching: Match the paper with the paper inventory details provided by SAP based on the "paper code, width, grade, and environmental indicators" specified in the process plan.
[0052] Exact match: If the work order specifies a grade / environmental indicator, the inventory will be searched strictly according to this.
[0053] Flexible matching: If the work order does not specify a grade / environmental indicator, only paper and print sizes will be matched, and inventory of any grade / environmental indicator will be considered available.
[0054] Accessory matching: If SAP specifies accessory requirements in "Work Order Process Materials", then the corresponding accessory inventory should also be checked for sufficiency. Step 5: Calculate the precise operation time. After all resource constraints are met, calculate the precise planned time for the operation.
[0055] Running time = planned production meters / machine speed.
[0056] Priority of machine speed values: Work order specified value > APS rule set value > Machine tool default value.
[0057] Preparation time: The plate change optimization algorithm is adopted, which only compares the differences with the plate set of the previous work order and calculates the plate change time only for the differences. The preparation time for the same plate is zero.
[0058] Total time = preparation time + running time + removal time.
[0059] Step 6: Output feasible plans and lock resources, generate the final scheduling plan, and reserve the required resources in the system.
[0060] The scheduling plan is sent to the MES execution terminal.
[0061] In the mold inventory, update the status of the planned mold to "occupied" or "pre-occupied" and set its "estimated available time" to the end time of this work order plus loading and unloading time of N minutes to prevent it from being mistakenly occupied by other work orders. Similarly, pre-occupy the required raw and auxiliary material inventory.
Claims
1. A paper roll pre-printing production management system based on ERP and MES, characterized in that, The production management system consists of three parts: a core functional platform, a mobile application, and an external integration system. The core functional platform, serving as the system's central hub, primarily comprises an Advanced Planning and Scheduling (APS) module and a Production Execution Management (MAM) module. The APS module receives instructions from higher levels and generates detailed production plans based on resource constraints and optimization algorithms. The MAM module executes these production plans. The mobile application mainly includes a first PDA application and a second PDA application; the first PDA application is used to handle the paper outbound, onboard, offboard, and return operations by scanning QR codes, and to synchronize data with the core functional platform; the second PDA application is used to handle the pre-printed semi-finished product outbound, onboard, offboard, and return operations and to trigger inventory updates. The external integration system mainly acts as the initiator of the upper-level instructions and the receiver of production result data; The production management system is centered on the core functional platform, connecting the upper-level ERP system with the lower-level production equipment, forming an interactive closed loop of three levels: decision-making, execution, and feedback.
2. The paper roll pre-printing production management system based on ERP and MES as described in claim 1, characterized in that, The Production Execution Management module includes an automatic version of MES for pre-printing machines and a manual version of MES for post-printing machines. The dedicated automatic version of MES for pre-printing machines is installed on the pre-printing machine. It automatically collects data such as paper feed length, machine speed, and output through the equipment data interface, realizing unmanned work reporting and material traceability. The dedicated manual version of the MES for downstream processes is installed on downstream equipment and provides an interface for manual input of material loading, output, and work reporting information.
3. The paper roll pre-printing production management system based on ERP and MES as described in claim 1 or 2, characterized in that, The core functional platform also includes a material tracking module and a mold management module; The material tracking module is used to record the conversion and quantity relationships between raw paper, pre-printed semi-finished products, downstream semi-finished products and finished products through the automatic collection of the mobile application and MES. The mold management module is used to establish an electronic archive and real-time inventory status of printing plates, rollers, and sleeves, providing a key basis for resource constraint scheduling for the APS module.
4. The paper roll pre-printing production management system based on ERP and MES as described in claim 1, characterized in that, The core functional platform also includes a label management and printing module, which is used to generate and print QR code labels containing structured data JSON for each roll of output. The QR code labels serve as a key medium connecting the physical world and the information world, providing information retrieval support.
5. A production management method for a paper roll pre-printing production management system based on ERP and MES, characterized in that, The method is applied to the ERP and MES-based paper roll pre-printing production management system as described in any one of claims 1-4, and the method specifically includes the following steps: Step S1: Analyze resource requirements, receive and parse the production instructions issued by the ERP system, and extract the types and quantities of pre-printed plates, pre-printed rollers and pre-printed bridge sleeves required to complete the work order; Step S2: Dynamic estimation of mold availability. Based on the scheduling order and time, dynamically simulate and verify the available inventory of molds in the future period. The verification includes a horizontal check to see if the total demand in the same period exceeds the inventory, and a vertical check to see if the demand superposition caused by loading and unloading time of continuous work orders exceeds the inventory. Step S3: Conflict handling and decision-making. When a resource conflict is detected during verification, the operation of automatically adjusting the schedule, triggering an early warning, or suspending the schedule is executed. Step S4: Raw material and auxiliary material availability verification. After the mold verification is passed, the inventory of raw paper and auxiliary materials required for production is matched and verified according to the preset rules to ensure that they are sufficient. Step S5: Calculate the precise operation time. After satisfying all resource constraints, calculate the planned time of the process based on the planned production length, machine speed, and changeover optimization algorithm. Step S6: Output a feasible plan and lock resources, generate a scheduling plan and issue it, and at the same time reserve the mold, raw paper and auxiliary material resources used in the system.
6. The production management method of the paper roll pre-printing production management system based on ERP and MES as described in claim 5, characterized in that, The step of extracting the number of pre-printed bridge sleeves in step S1 includes: Based on the total number of colors in the work order, subtract the number of seamless sleeves to obtain the required number of pre-printing rollers; Subtract the number of mounting shafts to obtain the required number of pre-printed bridge sleeves.
7. The production management method of the paper roll pre-printing production management system based on ERP and MES as described in claim 5, characterized in that, The longitudinal inspection in step S2 specifically involves: Consider the loading and unloading time of the mold (N minutes), that is, after a mold is used up in the previous work order, it takes N minutes before it can enter the "usable" state; Verify whether the sum of the demand quantities for a certain type of mold in two consecutive work orders exceeds the total inventory of that mold.
8. The production management method of the paper roll pre-printing production management system based on ERP and MES as described in claim 5, characterized in that, The paper matching rules in step S4 include: Exact match: If the work order specifies a rating and / or environmental indicators, then the inventory will be searched strictly according to these criteria. Flexible matching: If the work order does not specify the grade and environmental protection indicators, only paper and print sizes will be matched, and inventory of any grade and environmental protection indicators will be considered available.
9. The production management method of the paper roll pre-printing production management system based on ERP and MES as described in claim 5, characterized in that, The preparation time calculation in step S5 uses a version-switching optimization algorithm, specifically: Compare the plate sets of the current work order with those of the previous work order; The plate change time is calculated only for the plates with differences; the preparation time for the same plates is zero.
10. The production management method of the paper roll pre-printing production management system based on ERP and MES as described in claim 5, characterized in that, The specific steps for pre-allocating resources in step S6 include: Update the status of the mold to be used to "occupied" or "reserved"; Set the "estimated availability time" of the mold to the end time of this work order plus the loading and unloading time (N minutes); Reserve the required raw paper and auxiliary materials inventory in advance.