Cold-rolled strip steel cost accounting method, system and equipment based on multi-process division and medium
By refining the cold rolling process into independent sub-processes and using measuring instruments and production information systems to accurately collect data, the timeliness and accuracy of cost calculation in cold-rolled strip steel production have been solved, achieving refined management of costs across the entire process and reducing costs while increasing efficiency.
Patent Information
- Application Number
- CN202511674742.7
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-11-14
- Publication Date
- 2026-02-24
AI Technical Summary
In the production of cold-rolled strip steel, the traditional cost management model cannot accurately collect the specific production costs of each process, resulting in slow and inaccurate cost calculation, large errors in manual calculation, and affecting production organization and operating efficiency.
The cold rolling process is broken down into independent sub-processes. Dynamic consumption data is accurately collected through metering instruments, and fixed input data is allocated in combination with the production information system. The cost is calculated according to the process characteristics to generate the full process cost accounting result for each coil of steel.
This enables the generation of unit cost for each coil of steel as it comes off the production line at each stage, improving the accuracy of cost data, clearly statistically analyzing cost differences between different units and specifications, providing data support for differentiated production, and supporting refined management and cost reduction and efficiency improvement.
Smart Images
Figure CN121563585A_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of cold-rolled strip steel production technology, and in particular to a method, system, equipment and medium for calculating the cost of cold-rolled strip steel based on multi-process division. Background Technology
[0002] In recent years, the steel industry has been mired in multiple cost pressures and management dilemmas. On the raw material side, iron ore prices are often subject to short-term and significant fluctuations due to factors such as international supply and demand imbalances, geopolitical conflicts, and shipping cost fluctuations. Coking coal prices also fluctuate frequently with the cyclical adjustments in the coal market, resulting in an unstable raw material cost benchmark for cold-rolled strip steel production. In terms of energy consumption, electricity and gas account for a very high proportion in the cold rolling process, accounting for about 30% of the total cost. With increasingly stringent environmental policies, cold rolling mills need to continuously invest in upgrading and operating environmental protection facilities such as deep wastewater treatment, desulfurization and denitrification of waste gas, and resource utilization of solid waste. The profit margin of companies in the industry is generally less than 5%. The traditional cost management model that relies on manual summarization and extensive allocation can no longer meet the needs of refined management. It is urgent to break through the bottleneck through technological means and explore the space for cost reduction and efficiency improvement.
[0003] Because the cold rolling process involves a large number of units and production lines, the production consumption and cost data for each process are scattered, making it difficult to accurately collect data under the traditional model. This results in the inability to accurately calculate and analyze the specific production costs of each process. Cost statistics and analysis are also limited to the monthly level, unable to be further broken down to different grades and specifications of products. Furthermore, there is a lack of comparative data on cost differences between different units and production lines, which cannot provide effective support for differentiated production arrangements. The production costs of each process and product specification rely heavily on manual experience for calculation, which is prone to omissions and estimation errors during data collection, resulting in extremely low accuracy. This, in turn, misleads production organization and directly affects the overall operating efficiency of the enterprise. Summary of the Invention
[0004] In view of the aforementioned existing problems, the present invention is proposed.
[0005] Therefore, this invention provides a cost accounting method for cold-rolled strip steel based on multi-process division to solve the problems of slow timeliness, inaccuracy, and large errors in manual calculation of production process cost accounting.
[0006] To solve the above-mentioned technical problems, the present invention provides the following technical solution: In a first aspect, the present invention provides a method for cost accounting of cold-rolled strip steel based on multi-process division, including: Obtain the production process route for cold-rolled strip steel, perform data verification and demarcation of the route to obtain different independent sub-processes; Obtain production consumption and cost data for each sub-process, and divide the production consumption and cost data into dynamic consumption data and fixed input data; Dynamic consumption data is collected through metering instruments, and fixed input data is collected through production information systems. Dynamic consumption data is calculated based on the process characteristics of each sub-process, and fixed input data is allocated according to the proportion of production time. The calculation results of each sub-process are integrated to obtain the cost accounting result of cold-rolled strip steel.
[0007] As a preferred embodiment of the cold-rolled strip steel cost accounting method based on multi-process division described in this invention, the method includes: performing data accounting and demarcation of the route to obtain different independent sub-processes, including: Each sub-process is divided according to the sequence of cold-rolled strip steel production process and functional differences, and the production process, production consumption and cost data of each sub-process are capable of independent statistical accounting. The independent sub-processes include pickling, 20-roll rolling, degreasing, annealing, leveling, rewinding, and packaging.
[0008] As a preferred embodiment of the multi-process-based cost accounting method for cold-rolled strip steel described in this invention, the method includes: acquiring production consumption and cost data for each sub-process, and dividing the production consumption and cost data into dynamic consumption data and fixed input data, including: Dynamic consumption data refers to the consumption data that changes dynamically with output or production time during the production process of each sub-process, including raw material loss, water consumption, electricity consumption, gas consumption, and consumption of special consumables for each sub-process. Fixed input data refers to the stable input data in each sub-process of production, including labor costs, equipment depreciation costs, maintenance costs, and auxiliary material costs.
[0009] As a preferred embodiment of the cold-rolled strip steel cost accounting method based on multi-process division described in this invention, the method includes: collecting dynamic consumption data through metering instruments, including: The dynamic consumption data of each sub-process is classified by type, and dynamic consumption data under different intense sun conditions is collected by different measuring instruments; The instrument integrates a real-time calibration device that automatically compares and calibrates with a standard metrological source. It also sets a data anomaly threshold and triggers a data review warning when the threshold is exceeded.
[0010] As a preferred embodiment of the cold-rolled strip steel cost accounting method based on multi-process division described in this invention, the method includes: collecting fixed input data through a production information system, including: The production information system pre-links the basic fixed input ledgers of each sub-process. The production information system assigns a unique identification code to each coil of steel. The identification code is used to automatically link the production time of the coil of steel in each sub-process, thereby matching the fixed input cost coefficient of the corresponding sub-process. The system records timestamps and operation logs throughout the process.
[0011] As a preferred embodiment of the cost accounting method for cold-rolled strip steel based on multi-process division described in this invention, the method includes: calculating dynamic consumption data according to the process characteristics of each sub-process, and allocating the fixed input data according to the proportion of production time, including: When calculating dynamic consumption data based on the process characteristics of each sub-process, the process functions of each process, such as pickling, 20-roll rolling, degreasing, annealing, leveling, rewinding, and packaging, are combined. The calculation logic for raw material loss, water, electricity and gas consumption, and special consumables for each process is adapted to the corresponding process. When allocating fixed input data according to the proportion of production time, the fixed input data of each sub-process is used as the benchmark, and the fixed input data is allocated to each coil of cold-rolled strip based on the proportion of actual production time of each coil of cold-rolled strip in the corresponding sub-process.
[0012] As a preferred embodiment of the multi-process-based cost accounting method for cold-rolled strip steel described in this invention, the method involves integrating the accounting results of each sub-process to obtain the cost accounting result for cold-rolled strip steel, including: The dynamic consumption accounting results of each sub-process of cold-rolled strip steel in pickling, 20-roll, degreasing, annealing, leveling, rewinding and packaging are summed with the allocated fixed input data to obtain the cost accounting results of each sub-process of each coil of steel. Summarize the accounting results of all sub-processes to generate the total cost accounting result for each coil of cold-rolled strip steel. The total result also synchronously links the key information of each coil of steel and the accounting basis for the process adaptation of each sub-process. Based on the overall accounting results of the entire process, the cost accounting differences of different sub-processes and different specifications of cold-rolled strip steel are statistically analyzed to generate a benchmarking basis between sub-processes and specifications.
[0013] Secondly, the present invention provides a cost accounting system for cold-rolled strip steel based on multi-process division, comprising: The process division module is used to obtain the production process route of cold-rolled strip steel, perform data verification and demarcation on the route to obtain different independent sub-processes; The data segmentation module is used to acquire production consumption and cost data for each sub-process and to divide the production consumption and cost data into dynamic consumption data and fixed input data. The data acquisition module is used to collect the dynamic consumption data through measuring instruments and the fixed input data through the production information system. The data accounting module is used to calculate the dynamic consumption data according to the process characteristics of each sub-process, allocate the fixed input data according to the production time ratio, and integrate the accounting results of each sub-process to obtain the cost accounting result of cold-rolled strip steel.
[0014] Thirdly, the present invention provides an electronic device, comprising: Memory and processor; The memory is used to store computer-executable instructions, and the processor is used to execute the computer-executable instructions. When the computer-executable instructions are executed by the processor, they implement the steps of the cold-rolled strip cost accounting method based on multi-process division.
[0015] Fourthly, the present invention provides a computer-readable storage medium storing computer-executable instructions that, when executed by a processor, implement the steps of the cold-rolled strip cost accounting method based on multi-process division.
[0016] Compared with existing technologies, the beneficial effects of this invention are as follows: By refining the cold rolling process into independent sub-processes, clarifying the cost structure classification, accurately collecting variable costs through measuring instruments, and allocating fixed costs according to production time through the production information system, and matching customized accounting logic to each sub-process, this invention achieves the generation of unit cost for each coil of steel as it comes off the production line at each process, solving the pain point of slow timeliness in traditional accounting; by summarizing the cost details of each sub-process, the cost differences of cold-rolled strip steel of different units, grades and specifications can be clearly statistically analyzed, providing data support for benchmarking and cost reduction between units and specifications, and making up for the shortcomings of the crude dimensions of traditional statistics; replacing manual calculation, it greatly improves the accuracy of cost data, avoids misleading production organization and sales pricing due to data deviations, and provides stable and reliable technical support for refined cost management and cost reduction and efficiency improvement in cold-rolled strip steel production. Attached Figure Description
[0017] To more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings used in the following description of the embodiments will be briefly introduced. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.
[0018] Figure 1 This is a schematic diagram of the overall process of a cost accounting method for cold-rolled strip steel based on multi-process division according to an embodiment of the present invention. Detailed Implementation
[0019] To make the above-mentioned objects, features, and advantages of the present invention more apparent and understandable, specific embodiments of the present invention will be described in detail below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of the present invention, and not all of them. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort should fall within the protection scope of the present invention.
[0020] Example 1, referring to Figure 1 Table 1 illustrates an embodiment of the present invention, providing a method for cost accounting of cold-rolled strip steel based on multi-process division, comprising: S1: Obtain the production process route of cold-rolled strip steel, perform data verification and demarcation of the route to obtain different independent sub-processes; Preferably, each sub-process is divided according to the sequence and functional differences of the cold-rolled strip steel production process, and the production process, production consumption and cost data of each sub-process are capable of independent statistical accounting; the independent sub-processes include pickling, 20-roll, degreasing, annealing, leveling, rewinding and packaging.
[0021] In some embodiments, based on the functional boundaries and data acquisition independence of key process equipment in the cold-rolled strip steel production process, the production route is divided into raw material uncoiling pretreatment process, continuous rolling shaping process, electrolytic cleaning and degreasing process, heat treatment process, leveling process, slitting and length setting process, and film coating and protective packaging process.
[0022] S2: Obtain production consumption and cost data for each sub-process, and divide the production consumption and cost data into dynamic consumption data and fixed input data; Preferably, the dynamic consumption data refers to the consumption data that changes dynamically with output or production time during the production process of each sub-process, including raw material loss, water consumption, electricity consumption, gas consumption, and consumption of special consumables for each sub-process; the fixed input data refers to the stable input data during the production process of each sub-process, including labor costs, equipment depreciation costs, maintenance costs, and auxiliary material costs.
[0023] In some embodiments, dynamic consumption data includes acid and rolling oil consumption in the pickling and rolling process, work roll wear and rolling oil consumption in the 20-roll process, alkali consumption in the degreasing process, coke oven gas and hydrogen consumption in the annealing process, leveling liquid and support roll wear in the leveling process, rust-preventive oil consumption in the rewinding process, stretch film and strapping consumption in the packaging process, as well as raw material cutting losses and yield losses generated during the production process of each process; fixed input data includes employee welfare expenses for production workers corresponding to each sub-process, workshop manufacturing costs, annual depreciation amortization expenses for equipment, the portion of the total auxiliary material costs approved in the previous year allocated according to output, and equipment periodic maintenance expenses within a fixed period.
[0024] S3: Collect dynamic consumption data through metering instruments and collect fixed input data through the production information system; Preferably, the dynamic consumption data of each sub-process is classified by type, and dynamic consumption data under different intense sunlight is collected by different measuring instruments; real-time calibration equipment is integrated at the measuring instrument end to automatically compare and calibrate with the standard measuring source, and a data abnormality threshold is set, triggering a data review warning when the threshold is exceeded.
[0025] In some embodiments, the measuring instrument may be a smart meter for collecting electricity consumption, a high-precision gas flow meter for collecting gas consumption, an acid pipeline flow meter for collecting acid consumption in the pickling and rolling process, an alkaline flow meter for collecting alkaline consumption in the degreasing process, a hydrogen flow meter for collecting hydrogen consumption in the annealing process, an anti-rust oil flow meter for collecting anti-rust oil consumption in the rewinding process, a smart coil weight meter for collecting the coil weight of raw materials in each process, a laser length meter for collecting strip length, an infrared width meter for collecting strip width, and a roll diameter measuring instrument for collecting roll consumption, etc.
[0026] Preferably, the production information system pre-links the basic fixed input ledgers of each sub-process, assigns a unique identification code to each coil of steel, and automatically links the production time of the coil of steel in each sub-process through the identification code, thereby matching the fixed input cost coefficient of the corresponding sub-process, and recording timestamps and operation logs throughout the process.
[0027] S4: Calculate dynamic consumption data according to the process characteristics of each sub-process, allocate fixed input data according to the production time ratio, and integrate the calculation results of each sub-process to obtain the cost accounting result of cold-rolled strip steel. Preferably, when calculating dynamic consumption data according to the process characteristics of each sub-process, the calculation logic for raw material loss, water, electricity and gas consumption and special consumables for each process is adapted to the corresponding process, taking into account the differences in process functions of each process such as pickling, 20-roll, degreasing, annealing, leveling, rewinding and packaging. When allocating fixed input data according to the proportion of production time, the fixed input data of each sub-process is used as the benchmark, and the fixed input data is allocated to each coil of cold-rolled strip steel according to the proportion of actual production time of each coil of cold-rolled strip steel in the corresponding sub-process.
[0028] Preferably, the dynamic consumption calculation results of each sub-process of cold-rolled strip steel in pickling, 20-roll, degreasing, annealing, leveling, rewinding, and packaging are summed with the allocated fixed input data to obtain the cost accounting item results of each sub-process of each coil of steel. The cost accounting item results of all sub-processes are summarized to generate the total cost accounting result of each coil of cold-rolled strip steel, and the total result is synchronously linked to the key information of each coil of steel and the accounting basis for the process adaptation of each sub-process. Based on the total cost accounting result of the entire process, the cost accounting differences of different sub-processes and different specifications of cold-rolled strip steel are statistically analyzed to generate the benchmarking basis between sub-processes and between specifications.
[0029] For example, data accounting for each process includes: Unit cost calculation for pickling and rolling process: Raw materials ((entry coil weight / exit coil weight - 1) × raw material unit price - 0.0046 (fixed proportion of iron oxide red) × iron oxide red unit price - (entry coil weight / exit coil weight - 1 - 0.0046) × scrap steel unit price) + Electricity consumption (meter difference in electricity consumption during the start and end times of production of this coil in this unit × electricity unit price / exit coil weight) + Roll consumption (1.8 (unit cost of fixed support roll consumption) + 1.98 (unit cost of average work roll consumption) × h (exit thickness of this coil) / 1.6 (average thickness of the process)) + Acid solution (0.0235 kg / m2 (acid consumption per unit area)) () × Total surface area of the steel coil × Acid unit price / Export coil weight) + Rolling oil (fixed value per ton of steel) + Labor (based on the total wages of workers on this production line in the previous month / Number of days in the current month / 24 hours / 60 minutes / 60 seconds × Production time of the coil (seconds) / Export coil weight) + Depreciation (based on the depreciation expense of this production line in the previous month / Number of days in the current month / 24 hours / 60 minutes / 60 seconds × Production time (seconds) / Export coil weight) + Maintenance cost (Total maintenance cost of this production line in the previous year / Total output of this production line in the previous year × 50% + Total maintenance cost of this production line in the previous year × 50% / Total strip length of this production line in the previous year × Strip length of the coil / Export coil weight).
[0030] Unit cost calculation for the 20-roll process: Raw materials ((entry coil weight / exit coil weight - 1) × (raw material unit price - scrap steel unit price)) + Electricity consumption (electricity meter difference for the start and end times of production of this coil in this unit × electricity unit price / exit coil weight) + Roll consumption (total roll consumption cost of this production line in the previous year / total output of this production line in the previous year) + Rolling oil (total rolling oil consumption cost of this production line in the previous year / total output of this production line in the previous year) + Labor (based on the total wages of workers in this production line in the previous month / number of days in the current month / 24 hours / 60 minutes / 60 seconds × production time of this coil (seconds) / exit coil weight) + Depreciation (based on the depreciation expense of this production line in the previous month / number of days in the current month / 24 hours / 60 minutes / 60 seconds × production time (seconds) / exit coil weight) + Maintenance cost (total maintenance cost of this production line in the previous year / total output of this production line in the previous year) + Other materials and spare parts (total material and spare parts cost of this production line in the previous year / total output of this production line in the previous year).
[0031] Unit cost calculation for degreasing process: Raw materials ((inlet coil weight / outlet coil weight - 1) × (raw material unit price - scrap steel unit price)) + Electricity consumption (electricity meter difference for the start and end time of production of this coil in this unit × electricity unit price / outlet coil weight) + Alkali solution (0.0032kg / m2 (alkali consumption per unit area) × total surface area of the coil × alkali unit price / outlet coil weight) + Labor (based on the total wages of workers in this production line in the previous month / number of days in the current month / 24 hours / 60 minutes / 60 seconds × production time of this coil (seconds) / outlet coil weight) + Depreciation (based on the depreciation expense of this production line in the previous month / number of days in the current month / 24 hours / 60 minutes / 60 seconds × production time (seconds) / outlet coil weight) + Maintenance cost (total maintenance cost of this production line in the previous year / total output of this production line in the previous year × 50% + total maintenance cost of this production line in the previous year × 50% / total strip length of this production line in the previous year × strip length of this coil / outlet coil weight).
[0032] Unit cost calculation for annealing process: Coke oven gas (gas flow meter difference in a single cycle for each bell-type annealing furnace × gas unit price / furnace weight) + electricity consumption (electricity meter difference in a single cycle for each bell-type annealing furnace × electricity unit price / furnace weight) + hydrogen (total hydrogen cost of this production line in the previous year / total output of this production line in the previous year) + labor (based on total wages of workers in this area in the previous month / number of days in the current month / 181 (total number of furnaces in the area) / 24 hours / 60 minutes / 60 seconds × production time of the furnace (seconds) / furnace weight) + depreciation (based on depreciation cost of this production line in the previous month / number of days in the current month / 181 (total number of furnaces in the area) / 24 hours / 60 minutes / 60 seconds × production time of the furnace (seconds) / furnace weight) + maintenance cost (total maintenance cost of this production line in the previous year / total output of this production line in the previous year).
[0033] Unit cost calculation for leveling process: Raw materials ((inbound coil weight / outbound coil weight - 1) × (raw material unit price - scrap steel unit price)) + Electricity consumption (electricity meter difference for the start and end times of production of this coil in this unit × electricity unit price / outbound coil weight) + Leveling fluid (0.00204 kg / m2 (leveling fluid consumption per unit area) × total surface area of the coil × leveling fluid unit price / outbound coil weight) + Roller consumption (total roller consumption cost of this production line in the previous year / total output of this production line in the previous year) + Labor (based on the labor cost of this production line in the previous month) Total wages (number of days in the month / 24 hours / 60 minutes / 60 seconds × production time of the coil (seconds) / export coil weight) + Depreciation (depreciation cost of the production line in the previous month / number of days in the month / 24 hours / 60 minutes / 60 seconds × production time (seconds) / export coil weight) + Maintenance cost (total maintenance cost of the production line in the previous year / total output of the production line in the previous year × 50% + total maintenance cost of the production line in the previous year × 50% / total strip length of the production line in the previous year × strip length of the coil / export coil weight).
[0034] Unit cost calculation for rewinding process: Raw materials ((inbound coil weight / outbound coil weight - 1) × raw material unit price - mixed coil weight / outbound coil weight × mixed coil unit price - (inbound coil weight / outbound coil weight - 1 - mixed coil weight / outbound coil weight) × scrap steel unit price) + Electricity consumption (electricity meter difference for the start and end times of production of this coil in this unit × electricity unit price / outbound coil weight) + Rust-preventive oil (0.00131kg / m2 (leveling liquid consumption per unit area) × total surface area of the steel coil × rust-preventive oil unit price / outbound coil weight) + Labor (based on...) The formula is: (Total wages of workers on this production line last month / Number of days in the month / 24 hours / 60 minutes / 60 seconds × Production time of this coil (seconds) / Export coil weight) + Depreciation (Depreciation expense of this production line last month / Number of days in the month / 24 hours / 60 minutes / 60 seconds × Production time (seconds) / Export coil weight) + Maintenance cost (Total maintenance cost of this production line in the previous year / Total output of this production line in the previous year × 50% + Total maintenance cost of this production line in the previous year × 50% / Total strip length of this production line in the previous year × Strip length of this coil / Export coil weight).
[0035] Unit cost calculation for packaging process: As shown in Table 1, the unit cost of corresponding packaging materials is matched according to the width and weight of the steel coil. In addition, the packaging labor cost is 5 yuan / ton as per the contract.
[0036] Table 1 Unit Cost of Packaging Process
[0037] It should be noted that, according to the accounting method of this invention, the unit cost of each coil of steel is calculated immediately upon completion of each process. This invention consolidates the cost details of each coil of steel, calculates the total unit cost of the cold rolling process through statistical analysis, and performs statistical analysis based on the cost details, enabling cost reduction through benchmarking between different units and product specifications. Furthermore, according to the data accounting method of this invention, the unit cost of the cold rolling process can be determined after a small-scale trial production of new varieties, providing cost data support for sales operations and mass production, and accelerating the progress of product development.
[0038] This embodiment also provides a cost accounting system for cold-rolled strip steel based on multi-process division, including: The process division module is used to obtain the production process route of cold-rolled strip steel, perform data verification and demarcation of the route to obtain different independent sub-processes; The data segmentation module is used to obtain production consumption and cost data for each sub-process, and to divide the production consumption and cost data into dynamic consumption data and fixed input data. The data acquisition module is used to collect dynamic consumption data through metering instruments and fixed input data through the production information system. The data accounting module is used to calculate dynamic consumption data according to the process characteristics of each sub-process, allocate fixed input data according to the proportion of production time, and integrate the accounting results of each sub-process to obtain the cost accounting result of cold-rolled strip steel.
[0039] This embodiment also provides an electronic device applicable to the cost accounting of cold-rolled strip steel based on multi-process division, including: a memory and a processor; the memory is used to store computer-executable instructions, and the processor is used to execute the computer-executable instructions to realize the cost accounting method of cold-rolled strip steel based on multi-process division as proposed in the above embodiment.
[0040] This embodiment also provides a storage medium storing a computer program that, when executed by a processor, implements the cost accounting method for cold-rolled strip steel based on multi-process division as proposed in the above embodiments.
[0041] The storage medium proposed in this embodiment and the method for calculating the cost of cold-rolled strip steel based on multi-process division proposed in the above embodiments belong to the same inventive concept. Technical details not described in detail in this embodiment can be found in the above embodiments, and this embodiment has the same beneficial effects as the above embodiments.
[0042] Based on the above description of the implementation methods, those skilled in the art can clearly understand that the present invention can be implemented using software and necessary general-purpose hardware, and of course, it can also be implemented using hardware. Based on this understanding, the technical solution of the present invention, or the part that contributes to the prior art, can be embodied in the form of a software product. This computer software product can be stored in a computer-readable storage medium, such as a computer floppy disk, read-only memory (ROM), random access memory (RAM), flash memory, hard disk, or optical disk, etc., including several instructions to cause a computer device (which may be a personal computer, server, or network device, etc.) to execute the methods of the various embodiments of the present invention.
[0043] Example 2, based on the previous example, provides a cost accounting method for cold-rolled strip steel based on multi-process division. To verify the effectiveness of the invention, this example is scientifically demonstrated through experiments.
[0044] Taking the production of a 0.25mm×1250mm DC01 coil as an example, the production process route of this coil of steel is: pickling → twenty rolls → degreasing → annealing → leveling → rewinding → packaging.
[0045] Among them, the weight of the pickled steel coil at the inlet is 24.5t, the thickness at the outlet is 0.7mm, and the weight is 24.3t; the weight of the 20-roll steel coil at the inlet is 0.7mm, the thickness is 0.7mm, and the weight is 24.3t; the weight of the steel coil at the outlet is 0.25mm, and the weight is 24t; the weight of the steel coil at the inlet is 0.25mm, the thickness is 0.25mm, and the weight is 23.9 ... outlet is 0.25mm, the thickness is 0.25mm, and the weight is 23.8t; the weight of the steel coil at the inlet is 0.25mm, the thickness is 0.25mm, and the weight is 23.8t; and the weight of the steel coil at the outlet is 0.25mm, the thickness is 0.25mm, and the weight is 23t. The weight of the mixed steel is 0.4t.
[0046] Other experimental conditions include: Pickling and rolling process: Raw material unit price 3500 yuan / ton, iron oxide red unit price 1400 yuan / ton, scrap steel 2500 yuan / ton, electricity consumption difference for producing this coil 1700 kWh, electricity unit price 0.6 yuan / kWh, total surface area of this coil 3000 m2, acid unit price 0.05 yuan / kg, rolling oil fixed at 5 yuan / ton, total working days last month 30 days, total labor wages 1 million yuan, depreciation expenses 1.5 million yuan, production time of this coil 480 seconds, total maintenance cost of this production line last year 15 million yuan, total output 1.5 million tons, total strip length 160,000 km, strip length of this coil 3.6 km.
[0047] 20-roll process: Raw material unit price = pickling and rolling raw material unit price + pickling and rolling process unit cost. Scrap steel is 2500 yuan / ton. The electricity consumption difference for producing this coil is 2400 kWh, with an electricity unit price of 0.6 yuan / kWh. Last year, the total roll consumption cost of this production line was 3 million yuan, and the total output was 120,000 tons. Last year, the total rolling oil cost of this production line was 1.2 million yuan. The production time for this coil is 4800 seconds. Last month, there were 30 days. Last month, the total wages of workers on this production line were 150,000 yuan, and the depreciation expense was 200,000 yuan. Last month, the output of this production line was 10,000 tons. Last year, the total maintenance cost of this production line was 1.2 million yuan. Last year, the total material and spare parts cost of this production line was 500,000 yuan.
[0048] Degreasing process: Raw material unit price = 20-roller raw material unit price + 20-roller process unit cost, scrap steel 2500 yuan / ton, electricity difference for producing this coil 300kwh, electricity unit price 0.6 yuan / kwh, total steel area of this coil 12500m2, alkali unit price 5 yuan / kg, production time of this coil 3600s, total 30 days last month, total wages of workers on this production line last month 40,000 yuan, depreciation expenses 50,000 yuan, total maintenance cost of this production line last year 120,000 yuan, total output 96,000 tons, total strip length 10300km, strip length of this coil 9.8km.
[0049] Annealing process: The furnace where the coil is located weighs 98t, the gas flow rate difference during the production cycle is about 3500 Nm3, the gas unit price is 1.3 yuan / Nm3, the electricity consumption difference during the production cycle is about 1600 kWh, the electricity unit price is 0.6 yuan / kWh, the furnace production time is 144000s, the total hydrogen cost of this production line in the previous year was 9.3 million yuan, the last month had 30 days, the total wages of workers on this production line in the previous month were 1 million yuan, the depreciation cost was 1.8 million yuan, the output of this production line in the previous month was 300,000 tons, the total maintenance cost of this production line in the previous year was 14 million yuan, and the total output was 3.3 million tons.
[0050] Leveling process: Raw material unit price = degreasing raw material unit price + degreasing process unit cost + annealing process unit cost. Scrap steel is 2500 yuan / ton. The electricity consumption difference for producing this coil is 300 kWh, and the electricity unit price is 0.6 yuan / kWh. The total surface area of this coil is 12200 m2, and the leveling liquid unit price is 8 yuan / kg. Last year, the total roller consumption cost of this production line was 800,000 yuan, and the total output was 1.1 million tons. Last month had 30 days, total labor wages were 200,000 yuan, and depreciation expenses were 300,000 yuan. The production time for this coil is 1800 seconds. Last year, the total maintenance cost of this production line was 4 million yuan, the total strip length was 112,000 km, and the strip length of this coil was 9.7 km.
[0051] Rewinding process: Raw material unit price = leveling raw material unit price + leveling process unit cost. General raw materials: 3300 yuan / ton; scrap steel: 2500 yuan / ton. Electricity consumption difference for this coil: 280 kWh; electricity unit price: 0.6 yuan / kWh; total surface area of this coil: 11900 m²; rust-preventive oil unit price: 12 yuan / kg; last month: 30 days; total labor wages: 150,000 yuan; depreciation expenses: 180,000 yuan; production time for this coil: 4500 seconds; last year: total maintenance cost for this production line: 2 million yuan; total output: 500,000 tons; total strip length: 54,000 km; strip length for this coil: 9.5 km. Packaging process: 23 tons per roll, 1250mm in width.
[0052] By substituting the above conditions and data into the data accounting method of this invention, the unit cost of the steel coil produced in each process can be directly obtained.
[0053] The cost of pickling and rolling is 94.07 yuan / ton; the cost of 20-roll rolling is 149.85 yuan / ton.
[0054] The degreasing process costs 29.35 yuan / ton; the annealing process costs 72.06 yuan / ton; the leveling process costs 45.99 yuan / ton; the rewinding process costs 84.48 yuan / ton; and the packaging process costs 19.34 yuan / ton.
[0055] Therefore, using the cold rolling process cost calculation model, the unit cost of producing 0.25mm×1250mm DC01 can be calculated as: 94.07+149.85+29.35+72.06+45.99+84.48+19.34=495.14 yuan / ton.
[0056] Therefore, it can be seen that by accurately calculating the unit cost of the entire process and the detailed cost of each process of the 0.25mm×1250mm DC01 through process-by-process calculation, the problem of low accuracy of traditional manual calculation is solved, avoiding misleading production organization and sales; the unit cost can be output immediately after each process is completed, breaking the time lag of traditional monthly statistics; the cost details can support cost reduction benchmarking between different units and product specifications, and the cost of new products can be calculated with only a small amount of trial production data, providing a basis for mass production decisions, effectively accelerating the progress of product development, and fully adapting to the steel industry's needs for refined cost reduction and efficient production.
[0057] It should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and not to limit it. Although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solutions of the present invention without departing from the spirit and scope of the technical solutions of the present invention, and all such modifications or substitutions should be covered within the scope of the claims of the present invention.
Claims
1. A cost accounting method for cold-rolled strip steel based on multi-process division, characterized in that, include: Obtain the production process route for cold-rolled strip steel, perform data verification and demarcation of the route to obtain different independent sub-processes; Obtain production consumption and cost data for each sub-process, and divide the production consumption and cost data into dynamic consumption data and fixed input data; Dynamic consumption data is collected through metering instruments, and fixed input data is collected through production information systems. Dynamic consumption data is calculated based on the process characteristics of each sub-process, and fixed input data is allocated according to the proportion of production time. The calculation results of each sub-process are integrated to obtain the cost accounting result of cold-rolled strip steel.
2. The cost accounting method for cold-rolled strip steel based on multi-process division as described in claim 1, characterized in that, The route is divided and demarcated using data verification to obtain different independent sub-processes, including: Each sub-process is divided according to the sequence of cold-rolled strip steel production process and functional differences, and the production process, production consumption and cost data of each sub-process are capable of independent statistical accounting. The independent sub-processes include pickling, 20-roll rolling, degreasing, annealing, leveling, rewinding, and packaging.
3. The method for cost accounting of cold-rolled strip steel based on multi-process division as described in claim 2, characterized in that, Obtain production consumption and cost data for each sub-process, and divide the production consumption and cost data into dynamic consumption data and fixed input data, including: Dynamic consumption data refers to the consumption data that changes dynamically with output or production time during the production process of each sub-process, including raw material loss, water consumption, electricity consumption, gas consumption, and consumption of special consumables for each sub-process. Fixed input data refers to the stable input data in each sub-process of production, including labor costs, equipment depreciation costs, maintenance costs, and auxiliary material costs.
4. The cost accounting method for cold-rolled strip steel based on multi-process division as described in claim 3, characterized in that, Dynamic consumption data is collected through measuring instruments, including: The dynamic consumption data of each sub-process is classified by type, and dynamic consumption data under different intense sun conditions is collected by different measuring instruments; The instrument integrates a real-time calibration device that automatically compares and calibrates with a standard metrological source. It also sets a data anomaly threshold and triggers a data review warning when the threshold is exceeded.
5. The cost accounting method for cold-rolled strip steel based on multi-process division as described in claim 4, characterized in that, Data on fixed inputs is collected through the production information system, including: The production information system pre-links the basic fixed input ledgers of each sub-process. The production information system assigns a unique identification code to each coil of steel. The identification code is used to automatically link the production time of the coil of steel in each sub-process, thereby matching the fixed input cost coefficient of the corresponding sub-process. The system records timestamps and operation logs throughout the process.
6. The method for cost accounting of cold-rolled strip steel based on multi-process division as described in claim 5, characterized in that, Dynamic consumption data is calculated based on the technological characteristics of each sub-process, and fixed input data is allocated according to the proportion of production time, including: When calculating dynamic consumption data based on the process characteristics of each sub-process, the process functions of each process, such as pickling, 20-roll rolling, degreasing, annealing, leveling, rewinding, and packaging, are combined. The calculation logic for raw material loss, water, electricity and gas consumption, and special consumables for each process is adapted to the corresponding process. When allocating fixed input data according to the proportion of production time, the fixed input data of each sub-process is used as the benchmark, and the fixed input data is allocated to each coil of cold-rolled strip based on the proportion of actual production time of each coil of cold-rolled strip in the corresponding sub-process.
7. The method for cost accounting of cold-rolled strip steel based on multi-process division as described in claim 6, characterized in that, The accounting results of each sub-process are integrated to obtain the cost accounting results for cold-rolled strip steel, including: The dynamic consumption accounting results of each sub-process of cold-rolled strip steel in pickling, 20-roll, degreasing, annealing, leveling, rewinding and packaging are summed with the allocated fixed input data to obtain the cost accounting results of each sub-process of each coil of steel. Summarize the accounting results of all sub-processes to generate the total cost accounting result for each coil of cold-rolled strip steel. The total result also synchronously links the key information of each coil of steel and the accounting basis for the process adaptation of each sub-process. Based on the overall accounting results of the entire process, the cost accounting differences of different sub-processes and different specifications of cold-rolled strip steel are statistically analyzed to generate a benchmarking basis between sub-processes and specifications.
8. A cost accounting system for cold-rolled strip steel based on multi-process division, using the method described in any one of claims 1-7, characterized in that, include: The process division module is used to obtain the production process route of cold-rolled strip steel, perform data verification and demarcation on the route to obtain different independent sub-processes; The data segmentation module is used to acquire production consumption and cost data for each sub-process and to divide the production consumption and cost data into dynamic consumption data and fixed input data. The data acquisition module is used to collect the dynamic consumption data through measuring instruments and the fixed input data through the production information system. The data accounting module is used to calculate the dynamic consumption data according to the process characteristics of each sub-process, allocate the fixed input data according to the production time ratio, and integrate the accounting results of each sub-process to obtain the cost accounting result of cold-rolled strip steel.
9. An electronic device, characterized in that, include: A memory and a processor; the memory is used to store computer-executable instructions, and the processor is used to execute the computer-executable instructions, which, when executed by the processor, implement the steps of the cold-rolled strip cost accounting method based on multi-process division as described in any one of claims 1 to 7.
10. A computer-readable storage medium, characterized in that, It stores computer-executable instructions, which, when executed by a processor, implement the steps of the cold-rolled strip cost accounting method based on multi-process division as described in any one of claims 1 to 7.