Digital workshop production management and mistake proofing system and method suitable for electronic component production

Abstract

The invention relates to the technical field of industrial intelligent manufacturing, in particular to a digital workshop production management and mistake proofing system suitable for electronic component production, which comprises a composite two-dimensional code generation module, a mobile terminal interaction module, a PDA (Personal Digital Assistant) equipment integration module, an inner package automatic mistake proofing module, a mantissa management module and a data interaction module, system integration is realized at low cost, and automatic data communication between a workshop execution system and an ERP system is realized without a deep development interface, so that an information closed loop is formed, and the system integration cost is reduced; quality accidents are intercepted from the source; a hard mistake proofing mechanism of'equipment automatic verification-instant shutdown alarm 'is adopted in the inner packaging process; full-process deep tracing is adopted: each step of operation of material circulation is recorded through code scanning, and when a product has a quality problem, a problem source can be accurately positioned; through mantissa management intelligence, the material utilization rate is increased; and the production efficiency is improved, the employees can complete various complex operations only by scanning codes, and the production efficiency is greatly improved.

Description

Technical Field

[0001] This invention relates to the field of industrial intelligent manufacturing technology, specifically to a digital workshop production management and error prevention system and method applicable to the production of electronic components. Background Technology

[0002] In the production of electronic components such as SMT connectors, products undergo multiple processes and are ultimately packaged in standardized inner packaging. Currently, there are several pain points in workshop management in this field:

[0003] 1. System information silos: The workshop execution system and the ERP system lack effective data interfaces. Information transmission relies on manual entry of paper documents, which is inefficient, error-prone, and unable to provide real-time feedback on production progress. Some work reporting systems only focus on business processes, and the synchronous management of material flow is lacking, which can easily lead to problems such as mixed materials and repeated scanning of barcodes for material reporting, resulting in chaotic production data and invalid traceability information.

[0004] 2. High quality risks in key processes: The manual affixing of product labels during the inner packaging process is prone to mislabeling or omissions, which can lead to batch quality incidents at the customer's site.

[0005] 3. Inefficient management of leftover items: The scattered leftover products generated during production rely on manual memory to find them, which is inefficient and lacks shelf-life monitoring, easily leading to material waste and quality risks.

[0006] 4. Difficulty in full-process traceability: Material flow cannot be accurately tracked down to the smallest physical unit. When product quality problems occur, it is difficult to quickly locate the entire chain of information, including production personnel, equipment, and material sources involved in the problematic batch, resulting in high traceability costs.

[0007] Therefore, there is an urgent need for a refined and traceable workshop management solution that can streamline the data flow from planning to execution to warehousing, enable automatic error prevention in key processes, and ensure that material unit operations are unique and data is accurate. Summary of the Invention

[0008] The purpose of this invention is to overcome the shortcomings of the prior art and provide a digital workshop production management and error prevention system and method suitable for electronic component manufacturing, so as to achieve seamless integration of workshop execution system and ERP data, error prevention at the source of inner packaging process, refined traceability of the whole process and intelligent management of the last digit.

[0009] The technical solution of the present invention is a digital workshop production management and error prevention system suitable for electronic component manufacturing, including a composite QR code generation module, a mobile terminal interaction module, a PDA device integration module, an inner packaging automatic error prevention module, a tail number management module, and a data interaction module.

[0010] The composite QR code generation module is used to generate composite QR codes with encoded information. The serial number is a unique identifier for the smallest independent material unit. The composite QR code is applied to production work orders, raw material labels, part labels, semi-finished product labels, inner labels of finished products, and outer labels of finished products.

[0011] The mobile terminal interaction module is used to support smartphones to scan composite QR codes, jump to the corresponding task page of the work reporting system, automatically parse the parameters after the URL address and pre-fill the form to complete the operations of material loading, work reporting, inspection, and last count query, and avoid data duplication through the anti-duplicate mechanism.

[0012] The PDA device integration module is used to support industrial PDAs in scanning composite QR codes, performing anti-duplicate scanning and error code verification. If the verification passes, the packing operation is allowed; if the verification fails, a warning message will pop up. At the same time, the parsed product number, work order number, quantity and other data are written into the corresponding fields of the "Production Inbound Slip" in the ERP system.

[0013] The automatic error prevention module for inner packaging is integrated into the tape and reel equipment. It is used to automatically scan the composite QR code on the label inside the finished product, parse the product number and work order number and compare them with the current production task standard information. If the comparison is inconsistent or the label cannot be read, a stop command is sent and an on-site audible and visual alarm is triggered.

[0014] The tail quantity management module is used to receive tail quantity product entry registration information, record product number, location number, entry quantity, registrant, and registration time; support scanning the QR code of the new production work order to query tail quantity inventory; calculate the storage time based on the entry timestamp, and trigger an alert when the expiration date threshold is approaching;

[0015] The data interaction module is used to realize data interaction between the work reporting system and the ERP system, receive the "Production Task Order" from the ERP system, and send the production execution data back to the ERP system.

[0016] Preferably, the serial number is automatically generated by the system according to the sequence number or based on the current time.

[0017] A digital workshop production management and error prevention method applicable to electronic component manufacturing includes the following steps: task creation and driving, material flow and process execution, error prevention in inner packaging process, management of leftover products, and closed-loop warehousing of finished products.

[0018] Preferably, the task creation and driving includes the following steps: the work reporting system receives the "Production Task Order" issued by the ERP system, generates a corresponding composite QR code through the composite QR code generation module, and creates a "Production Work Order" containing the QR code and various material labels.

[0019] Preferably, the material flow and process execution include the following steps:

[0020] Step 1: Material requisition process: The warehouse generates a document in the ERP system based on the work order, and the workshop personnel scan the composite QR code on the "Production Work Order" to complete the material requisition and work confirmation.

[0021] Step 2: Process Execution: At the beginning or end of each production process, employees scan the QR code on the "Production Work Order" or the QR code on the process label. The system automatically triggers the printing of the process label, completing material loading, work reporting, quality confirmation and review.

[0022] Step 3: Packing and verification: The warehouse staff scans the QR code on the inner label of the finished product, and the system calculates and prints the outer box label; the industrial PDA is used to scan the QR codes on the outer box label and the inner label, and the PDA device integrated module performs anti-duplicate scanning and error code verification. If the verification is successful, the packing is completed.

[0023] Preferably, the error prevention process in the inner packaging includes the following steps:

[0024] Step 1: Trigger: Enter the tape-making process. The team leader scans the QR code on the "Production Work Order" and prints the inner label of the finished product containing the composite QR code.

[0025] Step 2: Affixing: The operator affixes the label from the finished product to the tape reel;

[0026] Step 3: Automatic identification and verification: The automatic barcode scanner integrated into the tape and reel equipment scans the label, parses the product number and work order number, and compares them with the current production task;

[0027] Step 4: Decision-making and linkage control: If the comparison is successful, the equipment will operate normally; if the comparison is inconsistent or the tag cannot be read, the system will send a shutdown command, trigger an on-site audible and visual alarm and display an error message; the operator will restart the equipment after correcting the error.

[0028] Preferably, the management of surplus products includes the following steps:

[0029] Step 1: End-of-line inventory storage: After the tape-making process reports the work, employees scan the QR code on the "Production Work Order", fill in the end-of-line quantity, store the physical goods according to the storage location number assigned by the system, and complete the inventory registration in the system.

[0030] Step 2: Remaining stock requisition: When a new production task enters the tape-making process, employees scan the QR code on the new "Production Work Order" and check the remaining stock inventory of the corresponding product through the remaining stock inventory query portal. After requisitioning, they complete the outbound registration and transfer the remaining stock to the new batch production line.

[0031] Step 3: Intelligent Early Warning: The system calculates the storage time of the last item based on the entry timestamp. When the quantity approaches the preset shelf life threshold, a visual or message warning is triggered.

[0032] Preferably, the finished product warehousing closed loop is as follows: the warehouse worker uses an industrial PDA to scan the QR code on the outer box label or the inner label on the inner packaging tray, and the PDA device integration module writes the data into the ERP system to complete the finished product warehousing and realize the data closed loop.

[0033] Preferably, in the packing verification process, the specific logic of the anti-duplicate scanning and error code verification is as follows: the background verifies whether the scanned composite QR code has been recorded and whether the corresponding material is from the same batch; if it has not been recorded and is from the same batch, packing is allowed; if it has been recorded or the material is incorrect, a "material duplicate" or "material error" warning message will pop up.

[0034] Compared with existing technologies, this invention provides a digital workshop production management and error prevention method suitable for electronic component manufacturing, which has the following advantages:

[0035] 1. Low-cost system integration: Through the dual parsing mechanism of composite QR codes, automatic data exchange between the workshop execution system and the ERP system can be achieved without deep development interfaces, forming an information closed loop and reducing system integration costs.

[0036] 2. Preventing quality incidents at the source: The inner packaging process adopts a hard error prevention mechanism of "automatic equipment verification - immediate shutdown alarm", which transforms post-event inspection into in-process interception, fundamentally eliminating batch mixing incidents caused by mislabeling or missing labels.

[0037] 3. Deep traceability throughout the entire process: Every step of the material flow is recorded by scanning codes, forming a complete and tamper-proof digital traceability chain. When product quality problems occur, the source of the problem can be quickly and accurately located.

[0038] 4. Intelligent management of surplus products: Integrate surplus products into the digital management system to achieve accurate positioning, recycling and shelf-life warning, improve material utilization, and reduce warehousing costs and quality risks.

[0039] 5. Improve production efficiency: Employees can complete a variety of complex operations simply by scanning a code, reducing operational complexity and training costs, and significantly improving overall production efficiency. Attached Figure Description

[0040] The accompanying drawings, which are included to provide a further understanding of this application and form part of this application, illustrate exemplary embodiments and are used to explain this application, but do not constitute an undue limitation of this application. In the drawings:

[0041] Figure 1 This is a schematic diagram of the production module composition according to an embodiment of the present invention. Detailed Implementation

[0042] The technical solution of the present invention will now be clearly and completely described with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments.

[0043] The components of the embodiments of the invention described and shown in the accompanying drawings can typically be arranged and designed in a variety of different configurations. Therefore, the following detailed description of the embodiments of the invention provided in the drawings is not intended to limit the scope of the claimed invention, but merely to illustrate selected embodiments of the invention.

[0044] Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0045] In the description of this invention, it should be noted that the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing the invention and for simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the invention. Furthermore, the terms "first," "second," and "third" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0046] It should be noted that the terms "comprising," "including," or any other variations thereof are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. In this specification, illustrative expressions of the above terms do not necessarily refer to the same embodiments or examples. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.

[0047] A digital workshop production management and error prevention system suitable for electronic component manufacturing includes a composite QR code generation module, a mobile terminal interaction module, a PDA device integration module, an automatic error prevention module for inner packaging, a tail number management module, and a data interaction module.

[0048] The composite QR code generation module is used to generate composite QR codes with encoded information. The serial number is a unique identifier for the smallest independent material unit. The composite QR code is applied to production work orders, raw material labels, part labels, semi-finished product labels, inner labels of finished products, and outer labels of finished products. Low-cost system integration is achieved: through the dual parsing mechanism of the composite QR code, automatic data communication between the workshop execution system and the ERP system is realized without deep development interfaces, forming an information closed loop and reducing system integration costs.

[0049] The mobile interaction module supports smartphones scanning composite QR codes to redirect to the corresponding task page of the work reporting system. It automatically parses the parameters after the URL address and pre-fills the form to complete operations such as material loading, process reporting, inspection, and quantity query. It also avoids duplicate data submission through an anti-duplicate mechanism. It intercepts quality accidents at the source: the inner packaging process adopts a hard error prevention mechanism of "automatic equipment verification - immediate shutdown alarm", which transforms post-event inspection into in-process interception, fundamentally eliminating batch mixing accidents caused by mislabeling or missing labels.

[0050] The PDA device integration module is used to support industrial PDAs in scanning composite QR codes, performing anti-duplicate scanning and error code verification. If the verification passes, the packing operation is allowed; if the verification fails, a warning message will pop up. At the same time, the parsed product number, work order number, quantity and other data are written into the corresponding fields of the "Production Inbound Slip" in the ERP system.

[0051] The automatic error prevention module for inner packaging is integrated into the tape-and-reel equipment. It is used to automatically scan the composite QR code on the label inside the finished product, parse the product number and work order number and compare them with the current production task standard information. If the comparison is inconsistent or the label cannot be read, a stop command is sent and an on-site audible and visual alarm is triggered. It uses full-process deep traceability: every step of the material flow is recorded by scanning the code, forming a complete and tamper-proof digital traceability chain. When a product has a quality problem, the source of the problem can be quickly and accurately located.

[0052] The tail count management module is used to receive tail count product entry registration information, record product number, location number, entry quantity, registrant, and registration time; support scanning the QR code of the new production work order to query tail count inventory; calculate the storage time based on the entry timestamp, and trigger an alert when the expiration date threshold is approaching; adopt intelligent tail count management: incorporate tail count products into the digital management system to achieve accurate positioning, recycling, and expiration date alerts, improve material utilization, and reduce warehousing costs and quality risks.

[0053] The data interaction module is used to realize data interaction between the work reporting system and the ERP system, receive the "Production Task Order" from the ERP system, and send the production execution data back to the ERP system.

[0054] The serial number is automatically generated by the system according to the sequence number or based on the current time.

[0055] A digital workshop production management and error prevention method applicable to electronic component manufacturing includes the following steps: task creation and driving, material flow and process execution, error prevention in inner packaging process, management of leftover products, and closed-loop warehousing of finished products.

[0056] The task creation and driving process includes the following steps: The work reporting system receives the "Production Task Order" issued by the ERP system, generates a corresponding composite QR code through the composite QR code generation module, and creates a "Production Accompanying Work Order" containing the QR code and various material labels.

[0057] The material flow and process execution include the following steps:

[0058] Step 1: Material requisition process: The warehouse generates a document in the ERP system based on the work order, and the workshop personnel scan the composite QR code on the "Production Work Order" to complete the material requisition and work confirmation.

[0059] Step 2: Process Execution: At the beginning or end of each production process, employees scan the QR code on the "Production Work Order" or the QR code on the process label. The system automatically triggers the printing of the process label, completing material loading, work reporting, quality confirmation and review.

[0060] Step 3: Packing and verification: The warehouse staff scans the QR code on the inner label of the finished product, and the system calculates and prints the outer box label; the industrial PDA is used to scan the QR codes on the outer box label and the inner label, and the PDA device integrated module performs anti-duplicate scanning and error code verification. If the verification is successful, the packing is completed.

[0061] The error prevention process for the inner packaging includes the following steps:

[0062] Step 1: Trigger: Enter the tape-making process. The team leader scans the QR code on the "Production Work Order" and prints the inner label of the finished product containing the composite QR code.

[0063] Step 2: Affixing: The operator affixes the label from the finished product to the tape reel;

[0064] Step 3: Automatic identification and verification: The automatic barcode scanner integrated into the tape and reel equipment scans the label, parses the product number and work order number, and compares them with the current production task;

[0065] Step 4: Decision-making and linkage control: If the comparison is successful, the equipment will operate normally; if the comparison is inconsistent or the tag cannot be read, the system will send a shutdown command, trigger an on-site audible and visual alarm and display an error message; the operator will restart the equipment after correcting the error.

[0066] The management of remaining products includes the following steps:

[0067] Step 1: End-of-line inventory storage: After the tape-making process reports the work, employees scan the QR code on the "Production Work Order", fill in the end-of-line quantity, store the physical goods according to the storage location number assigned by the system, and complete the inventory registration in the system.

[0068] Step 2: Remaining stock requisition: When a new production task enters the tape-making process, employees scan the QR code on the new "Production Work Order" and check the remaining stock inventory of the corresponding product through the remaining stock inventory query portal. After requisitioning, they complete the outbound registration and transfer the remaining stock to the new batch production line.

[0069] Step 3: Intelligent Early Warning: The system calculates the storage time of the last item based on the entry timestamp. When the quantity approaches the preset shelf life threshold, a visual or message warning is triggered.

[0070] The finished product warehousing closed loop works as follows: Warehouse staff use an industrial PDA to scan the QR code on the outer box label or the inner label on the inner packaging tray. The PDA device's integrated module writes the data into the ERP system, completing the finished product warehousing and achieving a data closed loop. Employees only need to scan the code to complete a variety of complex operations, reducing operational complexity and training costs, and significantly improving overall production efficiency.

[0071] In the packing verification process, the specific logic of the anti-duplicate scanning and error code verification is as follows: the background verifies whether the scanned composite QR code has been recorded and whether the corresponding material is from the same batch; if it has not been recorded and is from the same batch, packing is allowed; if it has been recorded or the material is incorrect, a "material duplicate" or "material error" warning message will pop up.

[0072] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

Claims

1. A digital workshop production management and error prevention system suitable for electronic component manufacturing, characterized in that: It includes a composite QR code generation module, a mobile terminal interaction module, a PDA device integration module, an automatic error prevention module for inner packaging, a tail quantity management module, and a data interaction module; The composite QR code generation module is used to generate composite QR codes with encoded information. The serial number is a unique identifier for the smallest independent material unit. The composite QR code is applied to production work orders, raw material labels, part labels, semi-finished product labels, inner labels of finished products, and outer labels of finished products. The mobile terminal interaction module is used to support smartphones to scan composite QR codes, jump to the corresponding task page of the work reporting system, automatically parse the parameters after the URL address and pre-fill the form to complete the operations of material loading, work reporting, inspection, and last count query, and avoid data duplication through the anti-duplicate mechanism. The PDA device integration module is used to support industrial PDAs in scanning composite QR codes, performing anti-duplicate scanning and error code verification. If the verification passes, the packing operation is allowed; if the verification fails, a warning message will pop up. At the same time, the parsed product number, work order number, quantity and other data are written into the corresponding fields of the "Production Inbound Slip" in the ERP system. The automatic error prevention module for inner packaging is integrated into the tape and reel equipment. It is used to automatically scan the composite QR code on the label inside the finished product, parse the product number and work order number and compare them with the current production task standard information. If the comparison is inconsistent or the label cannot be read, a stop command is sent and an on-site audible and visual alarm is triggered. The tail quantity management module is used to receive tail quantity product entry registration information and record product number, location number, entry quantity, registrant, and registration time; Supports scanning the QR code accompanying the new production order to check the remaining inventory; calculates the inventory duration based on the inbound timestamp and triggers an alert when the expiration date threshold is approaching. The data interaction module is used to realize data interaction between the work reporting system and the ERP system, receive the "Production Task Order" from the ERP system, and send the production execution data back to the ERP system.

2. The digital workshop production management and error prevention system for electronic component manufacturing according to claim 1, characterized in that: The serial number is automatically generated by the system according to the sequence number or based on the current time.

3. A digital workshop production management and error prevention method suitable for electronic component manufacturing, implemented based on the system described in any one of claims 1-2, characterized in that: Includes the following steps: Task creation and driving, material flow and process execution, error prevention in inner packaging process, management of leftover products, and closed-loop warehousing of finished products.

4. The digital workshop production management and error prevention method for electronic component manufacturing according to claim 3, characterized in that: The task creation and driving process includes the following steps: the work reporting system receives the "Production Task Order" issued by the ERP system, generates a corresponding composite QR code through the composite QR code generation module, and creates a "Production Accompanying Work Order" containing the QR code and various material labels.

5. The digital workshop production management and error prevention method for electronic component manufacturing according to claim 3, characterized in that: The material flow and process execution include the following steps: Step 1: Material requisition process: The warehouse generates a document in the ERP system based on the work order, and the workshop personnel scan the composite QR code on the "Production Work Order" to complete the material requisition and work confirmation. Step 2: Process Execution: At the beginning or end of each production process, employees scan the QR code on the "Production Work Order" or the QR code on the process label. The system automatically triggers the printing of the process label, completing material loading, work reporting, quality confirmation and review. Step 3: Packing and verification process: The warehouse staff scans the QR code on the inner label of the finished product, and the system calculates and prints the outer box label; the industrial PDA is used to scan the QR codes on the outer box label and the inner label, and the PDA device integrated module performs anti-duplicate scanning and error code verification. If the verification is successful, the packing is completed.

6. The digital workshop production management and error prevention method for electronic component manufacturing according to claim 3, characterized in that: The error prevention process for the inner packaging includes the following steps: Step 1: Trigger: Enter the tape-making process. The team leader scans the QR code on the "Production Work Order" and prints the inner label of the finished product containing the composite QR code. Step 2: Affixing: The operator affixes the label from the finished product to the tape reel; Step 3: Automatic identification and verification: The automatic barcode scanner integrated into the tape and reel equipment scans the label, parses the product number and work order number, and compares them with the current production task; Step 4: Decision-making and linkage control: If the comparison is successful, the equipment will operate normally; if the comparison is inconsistent or the tag cannot be read, the system will send a shutdown command, trigger an on-site audible and visual alarm and display an error message; the operator will restart the equipment after correcting the error.

7. The digital workshop production management and error prevention method for electronic component manufacturing according to claim 3, characterized in that: The management of remaining products includes the following steps: Step 1: End-of-line inventory storage: After the tape-making process reports the work, employees scan the QR code on the "Production Work Order", fill in the end-of-line quantity, store the physical goods according to the storage location number assigned by the system, and complete the inventory registration in the system. Step 2: Remaining stock requisition: When a new production task enters the tape-making process, employees scan the QR code on the new "Production Work Order" and check the remaining stock inventory of the corresponding product through the remaining stock inventory query portal. After requisitioning, they complete the outbound registration and transfer the remaining stock to the new batch production line. Step 3: Intelligent Early Warning: The system calculates the storage time of the last item based on the entry timestamp. When the storage time approaches the preset shelf life threshold, a visual or message warning is triggered.

8. The digital workshop production management and error prevention method for electronic component manufacturing according to claim 3, characterized in that: The finished product warehousing closed loop is as follows: the warehouse staff uses an industrial PDA to scan the QR code on the outer box label or the inner label on the inner packaging tray. The PDA device integration module writes the data into the ERP system, completing the finished product warehousing and realizing the data closed loop.

9. A digital workshop production management and error prevention method for electronic component manufacturing according to claim 5, characterized in that: In the packing verification process, the specific logic of the anti-duplicate scanning and error code verification is as follows: the background verifies whether the scanned composite QR code has been recorded and whether the corresponding material is from the same batch; if it has not been recorded and is from the same batch, packing is allowed; if it has been recorded or the material is incorrect, a "material duplicate" or "material error" warning message will pop up.

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