Full-process production traceability method based on a single field of "plan number volume number"

Abstract

This invention discloses a full-process production traceability method based on a single field of "plan number and volume number," relating to the field of industrial production process control and data management technology. This invention uses the "plan number and volume number" as the unique core connecting field throughout the entire process, spanning raw materials, each production process, quality inspection, finished products, and delivery. It relies on a wide table to achieve unified collection of all-dimensional production data. Each process uses this identifier to collect and record relevant information such as production, process, quality, equipment, and personnel, forming a unique and complete production history for each material. This invention achieves forward and reverse traceability of materials, enabling rapid identification of anomalies and responsible links. It has advantages such as strong versatility, high traceability efficiency, complete data links, low management costs, and suitability for implementation in industrial settings across various industries. It effectively solves the common industry problems of chaotic identification, data silos, and difficult traceability in traditional production management. This invention has been fully implemented in a real industrial ERP system and can operate stably in real production environments for a long time, possessing mature engineering value and industrial promotion capabilities.

Description

Technical Field

[0001] This invention relates to the field of industrial production process control and data management technology, specifically to a universal method for tracing the entire production process of materials from raw material warehousing to finished product delivery based on a wide table, using the plan number and roll number as unified core fields. It is applicable to all continuous and process-oriented production scenarios, and is especially suitable for industries such as steel, metallurgy, textiles, and cables that produce roll / batch materials. Background Technology

[0002] In continuous and process-oriented production processes across various industries, materials need to go through multiple production steps and multiple management systems. Under the traditional production management model, each link and system uses independent identification rules and data recording methods, resulting in many common industry problems: inconsistent identification between systems and processes makes it impossible to effectively connect the entire production history of materials, leading to broken data links and extremely high costs for cross-link data verification; when quality problems or production anomalies occur, it is difficult to quickly locate the process, time period, equipment, and responsible personnel, resulting in extremely low investigation efficiency and delayed problem handling that can easily lead to large-scale losses; the correspondence between raw materials and finished products is chaotic, making it impossible to achieve forward and reverse bidirectional traceability of materials, and making quality traceability and responsibility determination difficult; data from multiple processes and systems are isolated, forming data silos that cannot be integrated and connected, resulting in insufficient refinement of production management.

[0003] Existing production traceability technologies lack a single, stable, and universally applicable core serial field that runs through the entire production process and has no unified data collection carrier. As a result, they cannot adapt to the end-to-end traceability needs of continuous production in various industries. Most traceability solutions can only achieve traceability of partial links and cannot cover the entire life cycle. Summary of the Invention

[0004] Purpose of the invention This invention connects the entire production process through a single core field, relying on a wide table to achieve unified data aggregation and completely break down data silos. The specific implementation plan is as follows: The production plan number and material roll number are merged to generate a unique and fixed "plan number roll number," which serves as the identifier for each piece / roll. Each roll of material has a unique, lifetime identifier that remains unchanged once generated. The "Plan Number / Roll Number" serves as the sole core key field throughout the entire production process, spanning from raw material storage to each production stage, quality inspection, finished product storage, and shipment, ensuring unified identification across the entire supply chain. During each production stage, the "Plan Number / Roll Number" forms the core, with all dimensions of data—including process parameters, equipment parameters, material specifications, production speed, operating temperature, operators, production time, quality inspection results, and anomaly information—being uniformly entered into the production table. All data from all production stages are bound to the "Plan Number / Roll Number" and uniformly aggregated into the production table in the database, using the "Plan Number / Roll Number" as the primary key to form a unique and complete production history for each piece / roll of material. When production anomalies occur or quality traceability is required, simply entering the "Plan Number / Roll Number" allows for a one-click query of relevant data and information for that material across all stages of the entire process from the production table, enabling rapid traceability.

[0005] Technical solution The production plan number and material roll number are merged to generate a unique and fixed "Plan Number Roll Number," which serves as a lifelong unique identifier for each piece / roll of material and will not be changed once generated. This "Plan Number Roll Number" is used as the unique core key field throughout the entire production process, spanning from raw material warehouse to each production process, finished product warehouse, and delivery, achieving unified identification across the entire chain. During each production process, the "Plan Number Roll Number" is used as the core to uniformly input all dimensions of data, including process parameters, equipment parameters, material specifications, production speed, operating temperature, operators, production time, quality inspection results, and anomaly information, into the large-scale production table. All data from all production stages are bound to the "Plan Number Roll Number" and uniformly collected in the large-scale production table of the database, using the "Plan Number Roll Number" as the primary key to form a unique and complete production history for each piece / roll of material. When production anomalies occur or quality traceability is required, simply entering the "Plan Number Roll Number" allows for a one-click query of relevant data and information for that material at all stages of the entire process from the large-scale table, enabling rapid traceability.

[0006] Core Innovation Points The system employs a single field, "Plan Number / Volume Number," spanning the entire production chain to achieve unique identification for each item / volume, fundamentally resolving the industry-wide problem of inconsistent identification across multiple stages and systems in traditional production. All process data is strongly bound to the "Plan Number / Volume Number" and centrally managed using a wide table, supporting forward and reverse bidirectional traceability of materials. This allows for rapid identification of production anomalies, significantly improving traceability efficiency. Each production process and management system uniformly uses the "Plan Number / Volume Number" as the key for data records, achieving seamless integration of data from multiple systems and processes, breaking down data silos, and ensuring clear and traceable production responsibilities. The system aggregates and manages all production data using a wide table, resulting in a unified data structure that eliminates the need for separate data storage systems for different stages, reducing production data management costs and improving data utilization.

[0007] Beneficial effects It enables rapid two-way traceability of materials from raw materials to finished products and from customers to raw materials, eliminating the need for cross-system and cross-process data verification and significantly improving the efficiency of troubleshooting production anomalies and quality issues. Through "plan number and volume number," it can accurately and quickly locate the specific process, time, equipment, and operator where anomalies occurred, enabling timely loss mitigation and effectively reducing production quality losses. Based on a wide table, it achieves unified storage and centralized management of production data throughout the entire process, completely solving the data fragmentation and data silos caused by multiple identifiers and systems. It is not limited by industry or production line and is applicable to all continuous and process-oriented production fields, requiring no separate adaptation or modification for different industries or production lines, making it highly versatile and ready for direct application. The entire production history is traceable and verifiable, clearly defining the responsibility boundaries of each production link, promoting standardized and transparent management of the production process, and improving the overall production management level of the enterprise. Detailed Implementation

[0008] Identifier Generation: When the production plan is issued and material processing begins (e.g., uncoiling, feeding, and line entry), the system automatically generates a "Plan Number / Roll Number" in the format "Production Plan Number + Material Roll / Serial Number". This field serves as a unique, lifelong ID for the material, flowing synchronously throughout the entire production process. Data Acquisition: At all production-related nodes, including the raw material warehouse, each processing step, quality inspection, finished product warehouse, and shipping, process parameters and equipment models / serial numbers are collected during operations. All dimensions of data, including operating parameters, operator information, production start and end times, quality inspection results, material specifications, abnormal events and handling results, are entered into a unified production big table in real time and accurately, using "plan number and volume number" as the key fields. Data storage: The production big table uses "plan number and volume number" as the primary key to uniformly store and centrally manage the production data collected throughout the entire process, ensuring that each piece of data can be uniquely linked to a specific material, forming a complete production history for that material. Traceability query: When quality problems, production anomalies, or routine traceability work are required, operators only need to enter "plan number and volume number" into the system, and the system can automatically retrieve the complete production history of the material from the big table, clearly displaying detailed parameters, anomaly records, operation information, equipment information, quality inspection results, etc. for each process. Two-way traceability: Supports forward traceability (raw materials → each production process → quality inspection → finished product → customer) and reverse traceability (customer feedback / complaint → finished product → quality inspection → each production process → raw materials), meeting the production traceability needs of enterprises in different scenarios such as quality control, customer inquiries, and responsibility definition, achieving full-chain traceability without blind spots.

Claims

1. A method for end-to-end production traceability based on a single field of "plan number and volume number", characterized in that, Includes the following steps: (1) Merge the production plan number and the material roll number to generate a unique and fixed "plan number roll number" as a lifetime unique identifier for each piece / roll of material; (2) Use “Plan Number and Volume Number” as a unified key field and apply it throughout the entire production process, from raw material warehouse to each production process, quality inspection, finished product warehouse, and delivery. (3) During the operation of each production-related node, the process parameters, equipment data, quality inspection results, production time, operators and other full-dimensional production data are recorded with the "plan number and volume number" as the core. (4) After binding all production data with "Plan Number and Volume Number", they are uniformly collected into a wide production table with "Plan Number and Volume Number" as the primary key to form a complete production history of the material; (5) By entering the “Plan Number Volume Number”, you can query the entire production history of the material with one click.

2. The method according to claim 1, characterized in that, The "Plan Number Volume Number" is generated in the format of "Production Plan Number + Material Volume / Serial Number". It is automatically generated by the system when the material starts processing and will not be changed once generated.

3. The method according to claim 1, characterized in that, The production data also includes one or more of the following: material specifications, production speed, operating temperature, abnormal information, and processing results.

4. The method according to claim 1, characterized in that, This method supports both forward and reverse traceability. The forward traceability path is: raw materials → each production process → quality inspection → finished product → customer. The reverse traceability path is: customer feedback / complaint → finished product → quality inspection → each production process → raw materials.

5. The method according to any one of claims 1 to 4, characterized in that, This method is applicable to all industrial sectors with continuous and process-oriented production, without the need for separate adaptations and modifications for different industries and production lines.