Flexible manufacturing-based DPA component matching method

Abstract

The invention discloses a flexible manufacturing-based DPA component matching method, which comprises the following steps of: establishing a DPA component requirement catalog, establishing a management database, and creating catalog entries for each component needing DPA detection; the method comprises the following steps: establishing DPA components, and creating a corresponding DPA component for each basic component needing to execute DPA detection in enterprise product bill of material structure management; the method comprises the following steps: establishing a corresponding relation between a DPA component requirement directory and a component, establishing a mapping relation between a DPA requirement directory and a DPA component, triggering to generate or call a corresponding DPA component demand according to the mapping relation, and realizing automatic conversion from a detection requirement to a specific execution material; and establishing a matched operation system, and integrating the system into a manufacturing execution system or a material demand planning module of an enterprise resource plan. According to the method, automatic identification of DPA detection requirements, intelligent matching of detection materials and accurate accounting of related cost can be realized.

Description

Technical Field

[0001] This invention belongs to the field of intelligent manufacturing technology, and specifically relates to a supporting method for DPA components based on flexible manufacturing. Background Technology

[0002] Flexible manufacturing is a new production model that has emerged to address the demand for mass customization. It emphasizes the adaptability and flexibility of production systems. By adopting flexible production systems and advanced technologies such as the Industrial Internet and artificial intelligence, production systems can quickly respond to changes in market demand, product design updates, and manufacturing process variations, thereby efficiently meeting customized production needs.

[0003] Destructive Physical Analysis (DPA) is a method for verifying the process and control level of a component production batch. Its purpose is to obtain overall quality information for that batch of components by sampling from the production batch and employing a series of non-destructive and destructive inspection and analysis methods to verify whether the design, structure, materials, and manufacturing quality of the components meet relevant specifications or intended uses.

[0004] In existing smart manufacturing processes, different customers or products have varying requirements for DPA (Distribution and Approval) testing of components (such as testing items and sampling ratios). The main problems in the component assembly stage are as follows: 1. Difficulty in identifying testing requirements: Production plans or bills of materials (BOMs) cannot intuitively and automatically identify which components need to undergo DPA testing and the specific testing requirements.

[0005] 2. Low process efficiency: Due to the difficulty in identification, it often relies on manual judgment and coordination, which leads to a longer cycle of waiting for inspection instructions or materials on the production line.

[0006] 3. High delivery risk: It is easy to miss the DPA testing process or test report, resulting in incomplete documentation when the product leaves the warehouse, which affects delivery and compliance.

[0007] 4. Inaccurate cost accounting: The costs incurred by DPA testing (such as outsourced testing fees and sample costs) are difficult to accurately attribute to the cost of specific components or products.

[0008] Therefore, there is an urgent need for an automated DPA component matching method that can be integrated into a flexible manufacturing system to solve the above problems. Summary of the Invention

[0009] The technical problem this invention aims to solve is to address the shortcomings of existing technologies by providing a well-designed, highly efficient, and short-cycle method for matching DPA components based on flexible manufacturing. This method enables automatic identification of DPA testing requirements, intelligent matching of testing materials, and accurate calculation of related costs.

[0010] To achieve the above objectives, the present invention adopts the following technical solution: A supporting method for DPA components based on flexible manufacturing is characterized by the following steps: (1) Establish a DPA component requirements catalog Establish a management database to store and manage the DPA testing requirements for different components, create a catalog entry for each component that requires DPA testing, and enter detailed information.

[0011] (2) Establish DPA components In the enterprise's Bill of Materials (BOM) structure management, a corresponding "DPA component" is created for each "basic component" that requires DPA testing. The "DPA component" is a virtual or logical assembly, and its BOM contains two parts: one part is several basic components; the other part is the corresponding DPA test report. This report, as a virtual material or document deliverable, packages the above "basic components + DPA test report" into a complete unit that can be planned, procured, stocked, and matched. (3) Establish a DPA component requirement catalog and component correspondence. Establish a mapping relationship between the "DPA requirement catalog" and the "DPA component". When reading the product BOM, the corresponding DPA requirement catalog is automatically associated through the detailed information in step (1), and the corresponding "DPA component" requirement is triggered to be generated or called accordingly, so as to realize the automatic conversion of the test requirements to the specific execution materials. (4) Establish a supporting computing system The management database obtained in step (1), the DPA component in step (2), and the mapping relationship obtained in step (3) are used to construct a matching computing system through intelligent matching computing logic, and the matching computing system is integrated into the material requirements planning (MRP) module of the manufacturing execution system (MES) or enterprise resource planning (ERP).

[0012] The technical problem to be solved by the present invention can also be achieved through the following technical solutions. The detailed information in step (1) includes, but is not limited to: material code, material name, specifications, applicable customers / products, specific testing requirements, testing ratio, and testing agency requirements. This directory serves as the authoritative data source for DPA testing requirements.

[0013] The technical problem to be solved by the present invention can also be achieved through the following technical solution: the intelligent matching operation logic process described in step (4) is as follows: 4.1 DPA Component Judgment: Based on the naming rules of "DPA Components", automatically scan and determine whether the BOM of the production order contains such components; 4.2 Requirements Summary: Summarize all identified DPA components to form a master requirements list; 4.3 Inventory Matching: Compare total demand with existing inventory, which includes inventory of completed DPA components; 4.4 Decision-making and execution: If inventory is sufficient: directly generate the corresponding instructions to prepare for shipment; If the inventory is insufficient: the system will automatically calculate the number of "basic components" that need to be replenished; Trigger Procurement: Generate a procurement instruction for components that need to be procured new. Trigger outsourced testing: For components that are already in stock but need to be sent for testing, automatically generate outsourced testing instructions containing specific testing requirements; 4.5 Warehousing and Closed Loop: After the purchased components are received into the warehouse, or after the outsourced testing is completed (test report uploaded to the system) and packaged as "DPA Components" for warehousing, the system updates the inventory status; 4.6 Matching Outbound: When all DPA components and other materials meet the requirements, the system generates the final matching instruction and completes the outbound process.

[0014] The technical problem to be solved by the present invention can also be achieved through the following technical solution: in step 4.1, the naming rule is to have "_DPA" as a suffix.

[0015] Compared with the prior art, the beneficial effects of the present invention are: (1) Improve efficiency and automation: The identification of DPA detection requirements and material matching are transformed from manual judgment to automatic calculation by the system, which significantly shortens the production line waiting time and the overall product delivery cycle.

[0016] (2) Clear management and easy identification: By creating a special “DPA component” and reflecting its characteristics in its name (such as the DPA suffix), all materials that need special testing can be quickly and accurately identified in the BOM, purchase list and supporting list, avoiding omissions.

[0017] (3) Accurate cost accounting: The direct costs of DPA testing (sample value, testing fee) are collected into the corresponding "DPA component", so that the cost of the component fully reflects "material cost + quality verification cost", which improves the accuracy of product cost accounting.

[0018] (4) Supports complex business scenarios: It can handle the need for MRP calculation of components with different batches and different testing requirements, and ensure that the test reports of each batch are traceable and matchable when used in mixed batches, making management more detailed. Attached Figure Description

[0019] Figure 1 This is a flowchart of the supporting method described in this invention; Figure 2 This is the flowchart of the operation of the supporting computing system described in step (4). Detailed Implementation

[0020] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments.

[0021] Reference Figure 1 A supporting method for DPA components based on flexible manufacturing includes the following steps: (1) Establish a DPA component requirement catalog. Establish a management database within the system to store and manage the DPA testing requirements for different components. Create a catalog entry for each component requiring DPA testing, and enter detailed information, including but not limited to: material code, material name, specifications, applicable customer / product, specific testing requirements (such as standards, items), testing ratio (sampling rate), and testing organization requirements. This catalog serves as the authoritative data source for DPA testing requirements.

[0022] (2) Establish DPA component parts. In the enterprise's product bill of materials (BOM) structure management, create a corresponding "DPA part" for each "basic component" that requires DPA testing. This "DPA part" is a virtual or logical assembly, and its BOM contains two parts: 1. A certain number of these "basic components" (the number is calculated based on the testing ratio and demand).

[0023] 2. The corresponding "DPA test report" (as a virtual material or document deliverable). Through this "component-based" management, "components + testing services" are packaged into a complete unit that can be planned, procured, stocked, and matched.

[0024] (3) Establish the DPA component requirement catalog and component correspondence, and establish the mapping relationship between the "DPA requirement catalog" and "DPA component" in the system. When the system reads the product BOM, it can automatically associate with the corresponding DPA requirement catalog through information such as material code, and trigger the generation or call of the corresponding "DPA component" requirements accordingly, so as to realize the automatic conversion of the test requirements to the specific execution materials.

[0025] (4) Establish a supporting computing system based on DPA components, construct an intelligent supporting computing logic, and integrate it into the Material Requirements Planning (MRP) module of the Manufacturing Execution System (MES) or Enterprise Resource Planning (ERP). See also Figure 2 The system operation process is as follows: 4.1 DPA Component Judgment: The system automatically scans and determines whether the production order's BOM contains such components based on the naming rules for "DPA components" (such as those with the suffix "_DPA").

[0026] 4.2 Requirements Summary: Summarize all identified DPA components to form a total requirements list.

[0027] 4.3 Inventory Matching: Compare total demand with existing inventory (including inventory of completed DPA parts).

[0028] 4.4 Decision-making and Implementation: (1) If the inventory is sufficient: directly generate the corresponding instructions to prepare for shipment.

[0029] (2) If the inventory is insufficient: the system automatically calculates the number of "basic components" that need to be replenished.

[0030] ① Trigger Procurement: Generate a procurement instruction for components that need to be procured.

[0031] ② Trigger outsourced testing: For components that are already in stock but need to be sent for testing, automatically generate outsourced testing instructions containing specific testing requirements.

[0032] 4.5 Warehousing and Closed Loop: After the purchased components are received into the warehouse, or after the outsourced testing is completed (test report uploaded to the system) and packaged as "DPA Components" for warehousing, the system updates the inventory status.

[0033] 4.6 Matching Outbound: When all DPA components and other materials meet the requirements, the system generates the final matching instruction and completes the outbound process.

[0034] Example 1: Taking a high-end communication equipment manufacturing company as an example, its products require the use of a specific type of capacitor (material code: CAP-001). Customer A's contract requires DPA testing of the capacitor, with a sampling rate of 5%, and the testing items include internal structure analysis and component testing.

[0035] (1) Create a DPA requirements directory and add a new record to the system's "DPA Requirements Directory Library": Material code: CAP-001 • Client / Project: Client A-XX Project • Testing requirements: Conduct internal structure analysis and elemental composition analysis in accordance with GJB4027A-XXXX standard.

[0036] • Detection rate: 5% • Report requirements: A formal report must be issued by a CNAS accredited laboratory.

[0037] (2) Create a DPA component. In the BOM library, create a new component named "CAP-001_DPA_CLIENTA". The BOM structure of this component is defined as follows: Sub-item 1: Capacitor CAP-001, quantity = production requirement * (1 + 5%) Sub-item 2: DPA test report (document material), quantity = 1 (3) Establish a correspondence In the system backend, associate the “DPA requirements of CAP-001 for customer A-XX project” in the directory with the component “CAP-001_DPA_CLIENTA”.

[0038] (4) The supporting computing system executes 4.1 When a production order for "Customer A-XX Project" is received, the system parses its product BOM.

[0039] 4.2 The system recognizes that the BOM contains the "CAP-001_DPA_CLIENTA" component, and based on the mapping relationship, it knows that DPA needs to be performed.

[0040] 4.3 Assume the order requires the assembly of 1000 of these capacitors. The system calculates the demand for this DPA component as: 1000*(1+5%)=1050 basic materials of CAP-001, and 1 report.

[0041] 4.4 System Inventory Query: Scenario 1: If there is already a finished product inventory of "CAP-001_DPA_CLIENTA" ≥1000, then mark the material as compatible.

[0042] Scenario 2: If the inventory is insufficient, the system calculates that 1050 CAP-001 raw materials need to be prepared.

[0043] If the raw material inventory is sufficient, an "Outsourced Testing Instruction Form" will be automatically generated, specifying that 1050 CAP-001 samples will be sent to the cooperating laboratory for testing according to Customer A's requirements, and the report will be tracked and returned.

[0044] If the raw material inventory is insufficient, a "CAP-001 purchase order" and an "outsourced testing instruction order" will be generated simultaneously.

[0045] 4.5 After the outsourced testing is completed, the laboratory will package the 1000 qualified capacitors and 50 consumed samples (or remaining samples) and send them back to the system along with the electronic test report. The warehouse manager will then receive the goods and "assemble" 1050 CAP-001 raw materials and 1 report into the system as a "CAP-001_DPA_CLIENTA" component, with a quantity of 1000 sets.

[0046] 4.6 Once all materials are complete, the system generates a final matching list to guide the warehouse outbound shipment. This list includes 1,000 sets of the “CAP-001_DPA_CLIENTA” component, ensuring that the outbound materials are accompanied by a valid DPA report.

[0047] Through the above process, the automatic identification of DPA testing requirements, the precise matching of materials, the closed-loop management of the testing process, and the accurate collection of costs are achieved.

[0048] The above description is only a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.

Claims

1. A supporting method for DPA components based on flexible manufacturing, characterized in that, The method includes the following steps: (1) Establish a DPA component requirements catalog Establish a management database to store and manage DPA testing requirements for different components. Create catalog entries for each "basic component" requiring DPA testing and enter detailed information. (2) Establish DPA components In the enterprise's Bill of Materials (BOM) structure management, a corresponding "DPA component" is created for each "basic component" that requires DPA testing. This "DPA component" is a virtual or logical assembly, and its BOM contains two parts: one part consists of several basic components; the other part consists of the corresponding DPA test report. This report, as a virtual material or document deliverable, packages the above "basic components + DPA test report" into a complete unit that can be planned, procured, stocked, and matched. (3) Establish a DPA component requirement catalog and component correspondence. Establish a mapping relationship between "DPA requirement catalog" and "DPA component". When reading the product BOM, the corresponding DPA requirement catalog is automatically associated through the detailed information in step (1), and the corresponding "DPA component" requirement is triggered to generate or call, so as to realize the automatic conversion of the test requirements to the specific execution materials. (4) Establish a supporting computing system The management database obtained in step (1), the DPA component in step (2), and the mapping relationship obtained in step (3) are used to construct a matching computing system through intelligent matching computing logic, and the matching computing system is integrated into the material requirements planning (MRP) module of the manufacturing execution system (MES) or enterprise resource planning (ERP).

2. The supporting method for DPA components based on flexible manufacturing according to claim 1, characterized in that, The detailed information in step (1) includes, but is not limited to: material code, material name, specifications, applicable customers / products, specific testing requirements, testing ratio, and testing institution requirements. This directory serves as the authoritative data source for DPA testing requirements.

3. The supporting method for DPA components based on flexible manufacturing according to claim 1, characterized in that, The intelligent matching operation logic process described in step (4) is as follows: 4.1 DPA Component Judgment: Based on the naming rules of "DPA Component", automatically scan and determine whether the BOM of the production order contains such components; 4.2 Requirements Summary: Summarize all identified DPA components to form a master requirements list; 4.3 Inventory Matching: Compare total demand with existing inventory, which includes inventory of completed DPA components; 4.4 Decision-making and execution: If inventory is sufficient: directly generate the corresponding instructions to prepare for shipment; If the inventory is insufficient: the system will automatically calculate the number of "basic components" that need to be replenished; Trigger Procurement: Generate a procurement instruction for components that need to be procured new. Trigger outsourced testing: For components that are already in stock but need to be sent for testing, automatically generate outsourced testing instructions containing specific testing requirements; 4.5 Warehousing and Closed Loop: After the purchased components are received into the warehouse, or after the outsourced testing is completed, the test report is uploaded to the system and packaged as "DPA Components" for warehousing. The system then updates the inventory status. 4.6 Matching Outbound: When all DPA components and other materials meet the requirements, the system generates the final matching instruction and completes the outbound process.

4. The supporting method for DPA components based on flexible manufacturing according to claim 3, characterized in that, In step 4.1, the naming rule is to include the "_DPA" suffix.

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