Intelligent point inspection method and device for production line change preparation

Abstract

The invention provides an intelligent point inspection method and device for line change preparation of a production line, and the method comprises the steps: S10, building a target SKU according to a production task, binding line change vehicles and line change pieces with the target SKU, binding a corresponding first line change vehicle RFID tag for each line change vehicle, and binding a corresponding first line change piece RFID tag for each line change piece; s20, establishing a standard wire changing piece list for the target SKU, the first wire changing vehicle RFID tag and the first wire changing piece RFID tag; importing the standard line changing piece list into a handheld terminal; s30, executing an inventory checking operation through the handheld terminal to obtain actual scanning data; s40, comparing the actual scanning data with the standard line changing piece list in real time to obtain a comparison result, and performing verification prompt on the handheld terminal according to the comparison result; and S50, adjusting the wire changing pieces according to the verification prompt, updating the information of each wire changing piece to a stocktaking synchronization interface, and generating an abnormal proportion chart.

Description

Technical Field

[0001] This invention relates to the field of intelligent inspection technology, and in particular to an intelligent inspection method and apparatus for production line changeover preparation. Background Technology

[0002] In industries such as wine bottling machines and packaging machines, production lines frequently need to switch SKUs, and each line change involves replacing a large number of specialized tooling, molds, and other changeover components. Currently, the industry generally relies on manual visual inspection and paper-based inventory management for line changeover preparation and inventory checks, which has significant drawbacks. 1. Low efficiency and prone to errors: Manually checking the character codes on parts is extremely easy to cause fatigue, leading to incorrect or missing parts, resulting in production line stoppages or quality accidents; Second, the process is not transparent and difficult to trace: the flow of replacement parts between the warehouse and the production line cannot be monitored in real time, and it is difficult to trace the responsible link when problems occur. Third, the management is extensive and lacks data support: it relies on experience and lacks accurate recording and analysis of key data such as the number of line changes and time consumption, which makes it impossible to provide a basis for decision-making for production optimization.

[0003] In recent years, although RFID technology has been widely used in general warehouse management, these general solutions only solve the static inventory management problem of "where the items are and how many there are," which is essentially a simple "goods-location" correspondence. For the dynamic and highly logical production error-proofing scenario of preparing a correct and complete set of dedicated tools for a specific production task (SKU), existing technologies lack deeply coupled business logic.

[0004] On production lines like those used for bottling machines, where SKUs frequently change, parts are numerous, and multiple parties need to be bound to the corresponding parts, the RFID technology used in warehouse management is clearly unable to meet the relationship binding of "production task - carrier tool - specific parts," and it is even more unable to perform task-driven real-time verification and error prevention during the execution process. Therefore, it is difficult to fundamentally solve the core pain points of the changeover process in the manufacturing industry. Summary of the Invention

[0005] The technical problem to be solved by the present invention is to provide an intelligent inspection method and device for production line changeover preparation, which can quickly and accurately ensure that the prepared changeover parts are fully matched with the current production task, thereby avoiding the technical problem of production line stoppage caused by manual mis-inspection or omission.

[0006] In a first aspect, the present invention provides an intelligent inspection method for production line changeover preparation, comprising: S10. Establish target SKUs according to production tasks, bind line change cars and line change parts to the target SKUs, bind a corresponding first line change car RFID tag to each line change car, and bind a corresponding first line change part RFID tag to each line change part. S20. Establish a standard replacement part list by combining the target SKU, the RFID tag of the first line change vehicle, and the RFID tag of the first line change part; import the standard replacement part list into the handheld terminal; S30. Perform a disk inventory operation through the handheld terminal to obtain the actual scanned data; S40. The actual scanned data is compared with the standard replacement parts list in real time to obtain the comparison result. Based on the comparison result, a verification prompt is given on the handheld terminal. S50. Adjust the replacement parts according to the verification prompts, update the information of each replacement part to the disk synchronization interface, and generate an anomaly percentage chart.

[0007] Secondly, the present invention provides an intelligent inspection device for production line changeover preparation, comprising: The binding management module establishes target SKUs based on production tasks, binds line change cars and line change parts to the target SKUs, and binds a corresponding first line change car RFID tag to each line change car and a corresponding first line change part RFID tag to each line change part. The task-driven module establishes a standard replacement part list by combining the target SKU, the RFID tag of the first line changer vehicle, and the RFID tag of the first line changer part; and imports the standard replacement part list into the handheld terminal. The inventory scanning module performs an inventory operation through the handheld terminal to obtain actual scan data; The comparison and verification module compares the actual scanned data with the standard replacement parts list in real time to obtain the comparison result, and provides a verification prompt on the handheld terminal based on the comparison result. The information query module adjusts the replacement parts according to the verification prompts, updates the information of each replacement part to the inventory synchronization interface, and generates an anomaly percentage chart.

[0008] One or more technical solutions provided in the embodiments of the present invention have at least the following technical effects or advantages: 1. Visualized location of replacement parts: The status (in stock or out of stock) and location (which car and which line) of all replacement parts are clearly visible. The replacement location of each replacement part is visualized, solving the pain points of difficulty in finding materials and unclear inventory, and realizing visualized asset management. 2. Changeover data visualization: Automatically performs quantitative analysis to generate percentage analysis reports, quantifies changeover anomaly data for different SKUs, transforms experience-based management into data-driven decision-making, and provides objective data basis for optimizing production scheduling, process improvement, and cost analysis; 3. Standardized Line Changeover Management: It features a process guide of "scanning the vehicle first, then scanning the parts," which conforms to operational logic, eliminates operational chaos, reduces reliance on operator experience, and improves operational standardization and first-time success rate. 4. RFID binding: RFID tags are deployed on each changeover part, and the tags are associated with the SKU changeover cart and SKU; RFID batch rapid identification replaces manual character code verification one by one, improving efficiency several times, greatly shortening changeover preparation time, and directly increasing the effective production time of the equipment; 5. Inbound and Outbound Management: The operator uses handheld terminals to scan labels for automatic inspection, quickly identifying wrong or missing parts. On-site scanning is compared in real time, and alarms are immediately triggered for wrong or missing parts to prevent them from entering the production line. This eliminates errors caused by manual visual inspection, avoiding line stoppages and quality risks, and ensuring production continuity. 6. SKU Information Query: Each operation is automatically recorded, forming a complete electronic record from the warehouse to the production line, which can be accurately traced and the responsible link can be quickly located when a problem occurs.

[0009] The above description is merely an overview of the technical solution of the present invention. In order to better understand the technical means of the present invention and to implement it in accordance with the contents of the specification, and in order to make the above and other objects, features and advantages of the present invention more apparent and understandable, specific embodiments of the present invention are described below. Attached Figure Description

[0010] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0011] Figure 1 This is a flowchart of the method of the present invention; Figure 2 This is a schematic diagram of the device. Detailed Implementation

[0012] This application provides an intelligent inspection method and device for production line changeover preparation. In the process of production line changeover preparation, it can quickly and accurately ensure that the prepared changeover parts are fully matched with the current production task, thereby avoiding the technical problem of production line stoppage caused by manual mis-inspection or omission. Example 1

[0013] This embodiment provides an intelligent inspection method for production line changeover preparation, such as... Figure 1 As shown, it includes the following steps: S10. Establish target SKUs according to production tasks, bind line change cars and line change parts to the target SKUs, bind a corresponding first line change car RFID tag to each line change car, and bind a corresponding first line change part RFID tag to each line change part. S20. Establish a standard replacement part list by combining the target SKU, the RFID tag of the first line change vehicle, and the RFID tag of the first line change part; import the standard replacement part list into the handheld terminal; S30. Perform a disk inventory operation through the handheld terminal to obtain the actual scanned data; The inventory check operation is specifically as follows: S31. Use a handheld terminal to scan the RFID tag on the line-changing vehicle for verification; S32. After the RFID tag of the line changing vehicle is verified, use a handheld terminal to scan the RFID tag of the line changing component on the line changing vehicle. S33. Record the actual scan data as the RFID tags of the line changing components actually installed on the line changing vehicle; the actual scan data includes the RFID tags of the second line changing vehicle and the RFID tags of the second line changing components. S40. The actual scanned data is compared with the standard replacement parts list in real time to obtain the comparison result. Based on the comparison result, a verification prompt is given on the handheld terminal. The verification prompt is specifically as follows: If a second replacement part RFID tag exists in the standard replacement part list and is scanned, it is marked in green on the handheld terminal interface. If a second replacement part's RFID tag is not present in the standard replacement part list but is scanned, it will be marked in red on the handheld terminal interface and a message indicating that it is an incorrect part will be displayed. If the RFID tag of the first replacement part recorded in the standard replacement part list is not in the actual scan data, it will be marked in red on the handheld terminal interface and indicated as a missing part. S50. Adjust the replacement parts according to the verification prompts, update the information of each replacement part to the inventory synchronization interface, and generate an abnormal percentage chart. The inventory synchronization interface includes: line change component information, line change component pairing status, line change vehicle information, line change vehicle pairing status, target SKU, and inbound / outbound information; The anomaly percentage chart shows the percentage of RFID tags marked in red on the replacement parts in the total number of replacement parts. The anomaly percentage chart supports filtering and analysis by production line and year of production task.

[0014] Based on the same inventive concept, this application also provides an apparatus corresponding to the method in Embodiment 1, as detailed in Embodiment 2. Example 2

[0015] This embodiment provides an intelligent inspection device for production line changeover preparation, such as... Figure 2 As shown, it includes the following modules: The binding management module establishes target SKUs based on production tasks, binds line change cars and line change parts to the target SKUs, and binds a corresponding first line change car RFID tag to each line change car and a corresponding first line change part RFID tag to each line change part. The task-driven module establishes a standard replacement part list by combining the target SKU, the RFID tag of the first line changer vehicle, and the RFID tag of the first line changer part; and imports the standard replacement part list into the handheld terminal. The inventory scanning module performs an inventory operation through the handheld terminal to obtain actual scan data; The inventory operation specifically includes: The line changer unit uses a handheld terminal to scan the RFID tag on the line changer for verification. After the RFID tag of the line changing unit on the line changing vehicle is verified, use a handheld terminal to scan the RFID tag of the line changing unit on the line changing vehicle. The result recording unit records the actual scan data of the RFID tags of the line changing components actually installed on the line changing vehicle; the actual scan data includes the RFID tag of the second line changing vehicle and the RFID tag of the second line changing component. The comparison and verification module compares the actual scanned data with the standard replacement parts list in real time to obtain the comparison result, and provides a verification prompt on the handheld terminal based on the comparison result. The verification prompts specifically include: If a second replacement part RFID tag exists in the standard replacement part list and is scanned, it is marked in green on the handheld terminal interface. If a second replacement part's RFID tag is not present in the standard replacement part list but is scanned, it will be marked in red on the handheld terminal interface and a message indicating that it is an incorrect part will be displayed. If the RFID tag of the first replacement part recorded in the standard replacement part list is not in the actual scan data, it will be marked in red on the handheld terminal interface and indicated as a missing part. The information query module adjusts the replacement parts according to the verification prompts, updates the information of each replacement part to the inventory synchronization interface, and generates an anomaly percentage chart. The inventory synchronization interface includes: line change component information, line change component pairing status, line change vehicle information, line change vehicle pairing status, target SKU, and inbound / outbound information; The anomaly percentage chart shows the percentage of RFID tags marked in red on the replacement parts in the total number of replacement parts. The anomaly percentage chart supports filtering and analysis by production line and year of production task.

[0016] Since the apparatus described in Embodiment 2 of the present invention is an apparatus used to implement the method of Embodiment 1 of the present invention, those skilled in the art can understand the specific structure and variations of the apparatus based on the method described in Embodiment 1 of the present invention, and therefore will not be described again here. All apparatuses used in the method of Embodiment 1 of the present invention fall within the scope of protection of the present invention. Example 3

[0017] In practical use, this invention is mainly divided into two parts: on-site operation via a handheld terminal APP and comprehensive management via a Web management backend, which together form a complete business closed loop.

[0018] I. System Initialization and Binding Information entry: Administrators can pre-create production task (SKU) information, changeover car numbers, and detailed information of all changeover parts through the web management backend.

[0019] RFID Binding: Operators use the RFID card binding function of the line changeover parts in the handheld terminal APP. Scan the RFID tag on the line changeover part, and then select or enter the precise model number of the part in the APP interface (which must match the part nameplate) to complete the binding; the status of each bound line changeover part will turn green with a checkmark, and vice versa; similarly, the binding operation is performed for each line changeover vehicle; the system automatically establishes and stores a three-level logical association of "SKU - line changeover vehicle - line changeover part" in the background.

[0020] The status of a single line switch can be edited individually on the handheld terminal. Clicking the edit button next to the line switch will bring up a window for binding operations of the single line switch.

[0021] Once the line changing vehicle and line changing components are bound together, you can use the APP function to perform inventory checks.

[0022] II. Inventory Operation of Replacement Components Task Initiation and List Retrieval: When the production line needs to switch SKUs, the operator accesses the inventory function on the handheld terminal APP and selects the "target SKU" to be switched from the list. The system then automatically retrieves the list of standard changeover parts associated with that SKU and displays the corresponding changeover vehicle.

[0023] Perform intelligent inventory management: 1. The operator clicks the "Start Inventory Inventory" button on the APP, and the button changes to "Stop Inventory Inventory"; 2. Press and hold the handle button of the barcode scanner (handheld terminal) to start scanning. Inventory check requires first identifying the RFID tag of the line change vehicle, and then scanning the RFID tags of all line change parts on the line change vehicle in sequence. If the line change vehicle is not identified, the subsequent inventory check of line change parts cannot be performed. 3. The inventory process is a real-time scanning process. Operators can visually view which parts have not been identified using a handheld device, and receive data feedback for real-time error prevention and prompts. If the scanned replacement part is in the standard list, a "green checkmark" will be displayed next to it. If a replacement part not in the list is scanned (wrong part), or if a part in the list is never scanned (missing part), the corresponding item will be highlighted as a red anomaly, and the handheld terminal will emit a prompt sound. Operators can then locate, replace, or replenish parts on-site based on the prompts. Complete and synchronize status: After verifying that all parts are correct, click "Complete Inventory Check". Once the inventory check is complete, outbound and inbound operations can be performed. Target locations need to be selected for subsequent line changeover vehicle location management. The system then drives a background data update: The status of all line changeover parts involved in this operation is updated synchronously, the location information is updated to the target production line, and a complete record containing SKU, line changeover vehicle, operator, and timestamp is generated.

[0024] III. Web Operation Process of One-Click Inspection and Replacement Management System Administrators can log in to the management backend to conduct comprehensive monitoring and decision-making: The inventory synchronization interface allows you to view the real-time inventory status and anomaly information of all line-changing vehicles and components.

[0025] On the warehouse location query interface, you can query the information of the replacement parts that have been put into the warehouse and their pairing status.

[0026] The information query interface allows users to view the binding details and pairing status of all line-changing vehicles.

[0027] The inbound and outbound record interface allows you to track all material inbound and outbound information.

[0028] Data Analysis and Optimization: In the line changeover ratio analysis interface, the system automatically calculates and displays the ratio of abnormal line changeover parts to the total number of line changeover parts for different production lines and different SKUs based on historical operation history, providing accurate data support for optimizing production scheduling and reducing line changeover time.

[0029] Through the above implementation methods, this invention transforms the traditional cumbersome process that relies on manual experience and paper lists into a data-driven, real-time error-proof, and fully traceable intelligent operation, fundamentally ensuring the accuracy and production efficiency of line changeover preparation.

[0030] The technical solutions provided in this application embodiment have at least the following technical effects or advantages: The intelligent inspection method and device for production line changeover preparation provided in this application embodiment goes beyond the scope of traditional RFID being used only for "identification" and "inventory". Through the deep coupling of technology and business, a brand-new solution with intelligent error prevention, closed-loop management and data-driven approach is constructed.

[0031] Those skilled in the art will understand that embodiments of the present invention can be provided as methods, systems, or computer program products. Therefore, the present invention can take the form of a completely hardware embodiment, a completely software embodiment, or an embodiment combining software and hardware aspects. Furthermore, the present invention can take the form of a computer program product embodied on one or more computer-usable storage media (including, but not limited to, disk storage, CD-ROM, optical storage, etc.) containing computer-usable program code.

[0032] This invention is described with reference to flowchart illustrations and / or block diagrams of methods, apparatus (systems), and computer program products according to embodiments of the invention. It will be understood that each block of the flowchart illustrations and / or block diagrams, and combinations of blocks in the flowchart illustrations and / or block diagrams, can be implemented by computer program instructions. These computer program instructions can be provided to a processor of a general-purpose computer, special-purpose computer, embedded processor, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing apparatus, generate instructions for implementing the flowchart illustrations and / or block diagrams. Figure 1 One or more processes and / or boxes Figure 1 A device that provides the functions specified in one or more boxes.

[0033] These computer program instructions may also be stored in a computer-readable storage medium that can direct a computer or other programmable data processing device to function in a particular manner, such that the instructions stored in the computer-readable storage medium produce an article of manufacture including instruction means, which are implemented in a process Figure 1 One or more processes and / or boxes Figure 1 The function specified in one or more boxes.

[0034] These computer program instructions may also be loaded onto a computer or other programmable data processing equipment to cause a series of operational steps to be performed on the computer or other programmable equipment to produce a computer-implemented process, thereby providing instructions that execute on the computer or other programmable equipment for implementing the process. Figure 1 One or more processes and / or boxes Figure 1 The steps of the function specified in one or more boxes.

[0035] While specific embodiments of the present invention have been described above, those skilled in the art should understand that the specific embodiments described are merely illustrative and not intended to limit the scope of the present invention. Equivalent modifications and variations made by those skilled in the art in accordance with the spirit of the present invention should be covered within the scope of protection of the claims of the present invention.

Claims

1. An intelligent inspection method for production line changeover preparation, characterized in that, include: S10. Establish target SKUs according to production tasks, bind line change cars and line change parts to the target SKUs, bind a corresponding first line change car RFID tag to each line change car, and bind a corresponding first line change part RFID tag to each line change part. S20. Establish a standard line changer list by combining the target SKU, the first line changer RFID tag, and the first line changer RFID tag; Import the standard replacement parts list into the handheld terminal; S30. Perform a disk inventory operation through the handheld terminal to obtain the actual scanned data; S40. The actual scanned data is compared with the standard replacement parts list in real time to obtain the comparison result. Based on the comparison result, a verification prompt is given on the handheld terminal. S50. Adjust the replacement parts according to the verification prompts, update the information of each replacement part to the disk synchronization interface, and generate an anomaly percentage chart.

2. The intelligent inspection method for production line changeover preparation according to claim 1, characterized in that, The inventory operation of S30 is as follows: S31. Use a handheld terminal to scan the RFID tag on the line-changing vehicle for verification; S32. After the RFID tag of the line changing vehicle is verified, use a handheld terminal to scan the RFID tag of the line changing component on the line changing vehicle. S33. Record the actual scan data as the RFID tags of the line changing components actually installed on the line changing vehicle; the actual scan data includes the RFID tags of the second line changing vehicle and the RFID tags of the second line changing components.

3. The intelligent inspection method for production line changeover preparation according to claim 2, characterized in that, The verification prompt in S40 is specifically as follows: If a second replacement part RFID tag exists in the standard replacement part list and is scanned, it is marked in green on the handheld terminal interface. If a second replacement part's RFID tag is not present in the standard replacement part list but is scanned, it will be marked in red on the handheld terminal interface and a message indicating that it is an incorrect part will be displayed. If the RFID tag of the first replacement part recorded in the standard replacement part list is not in the actual scan data, it will be marked in red on the handheld terminal interface and indicated as a missing part.

4. The intelligent inspection method for production line changeover preparation according to claim 1, characterized in that, The inventory synchronization interface in S50 includes: line changer information, line changer pairing status, line changer vehicle information, line changer vehicle pairing status, target SKU, and inbound / outbound information.

5. The intelligent inspection method for production line changeover preparation according to claim 3, characterized in that, The anomaly percentage chart in S50 represents the percentage of RFID tags marked in red on the line changeover parts in the total number of line changeover parts. The anomaly percentage chart supports filtering and analysis by production line and year of production task.

6. An intelligent inspection device for production line changeover preparation, characterized in that, include: The binding management module establishes target SKUs based on production tasks, binds line change cars and line change parts to the target SKUs, and binds a corresponding first line change car RFID tag to each line change car and a corresponding first line change part RFID tag to each line change part. The task-driven module establishes a standard replacement part list by combining the target SKU, the RFID tag of the first line changer vehicle, and the RFID tag of the first line changer part; and imports the standard replacement part list into the handheld terminal. The inventory scanning module performs an inventory operation through the handheld terminal to obtain actual scan data; The comparison and verification module compares the actual scanned data with the standard replacement parts list in real time to obtain the comparison result, and provides a verification prompt on the handheld terminal based on the comparison result. The information query module adjusts the replacement parts according to the verification prompts, updates the information of each replacement part to the inventory synchronization interface, and generates an anomaly percentage chart.

7. The intelligent inspection device for production line changeover preparation according to claim 6, characterized in that, The inventory operation specifically includes: The line changer unit uses a handheld terminal to scan the RFID tag on the line changer for verification. After the RFID tag of the line changing unit on the line changing vehicle is verified, use a handheld terminal to scan the RFID tag of the line changing unit on the line changing vehicle. The result recording unit records the actual scan data of the RFID tags of the line changing components actually installed on the line changing vehicle; the actual scan data includes the RFID tag of the second line changing vehicle and the RFID tag of the second line changing component.

8. The intelligent inspection device for production line changeover preparation according to claim 7, characterized in that, The verification prompts specifically include: If a second replacement part RFID tag exists in the standard replacement part list and is scanned, it is marked in green on the handheld terminal interface. If a second replacement part's RFID tag is not present in the standard replacement part list but is scanned, it will be marked in red on the handheld terminal interface and a message indicating that it is an incorrect part will be displayed. If the RFID tag of the first replacement part recorded in the standard replacement part list is not in the actual scan data, it will be marked in red on the handheld terminal interface and indicated as a missing part.

9. The intelligent inspection device for production line changeover preparation according to claim 6, characterized in that, The inventory synchronization interface includes: line change component information, line change component pairing status, line change vehicle information, line change vehicle pairing status, target SKU, and inbound / outbound information.

10. The intelligent inspection device for production line changeover preparation according to claim 8, characterized in that... The anomaly percentage chart shows the percentage of RFID tags marked in red on the replacement parts in the total number of replacement parts. The anomaly percentage chart supports filtering and analysis by production line and year of production task.

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