An industrial material full-link integrated production planning and abnormal flexibility disposal method

Abstract

The application discloses an industrial material full-link integrated production plan compilation and abnormal flexibility treatment method, and relates to the technical field of industrial MES production plan.The application generates a full-link integrated production plan covering all processes of a whole process at one time with raw materials as a starting point and a contract hash value as a target, and discards a traditional process-by-process compilation mode;an abnormal treatment mechanism of a contract double path is designed, abnormal materials are first released from the original contract, and then are treated according to actual value, that is, "standard production of spot goods" and "flexible production of dragging into a new contract", and the double mode of plan reuse and separate compilation is adopted when dragging into a new contract.The method realizes deep integration of normal production rigidity plan and abnormal production flexibility treatment, greatly improves production efficiency and resource utilization, and is suitable for the industrial material multi-process continuous production scene.The application has been completely applied in an actual industrial ERP and MES system, can be long-term and stable in a real production environment, and has mature engineering value and industrialization popularization ability.

Description

Technical Field

[0001] This invention relates to the field of industrial production execution system (MES) technology, specifically to a method for compiling an integrated production plan that starts with raw materials and targets contract hash values, and a dual-path flexible handling method for canceling contracts for abnormal materials that is adapted to the plan. Background Technology

[0002] Currently, the planning of industrial material production generally adopts a process-by-process planning model, where the plan for the next process is only prepared after the previous process is completed. This has the following drawbacks: Without a unified starting point and target anchor, each process plan is prepared independently, which easily leads to inconsistent process parameters and quality standards, resulting in production disconnect. Planning lags behind production, resulting in low efficiency, poor communication between upstream and downstream processes, and the possibility that abnormalities in the preceding process can lead to the invalidation of subsequent plans. Poor integration and adaptability, lack of dedicated abnormal handling mechanism, abnormal materials are often directly scrapped or piled up in the warehouse, resulting in low resource utilization. The loose linkage between plans and contracts makes it difficult to accurately match abnormal materials with other contracts, hindering the maximization of resource utilization. Existing technologies lack a comprehensive, end-to-end planning method that allows for flexible handling of anomalies. Summary of the Invention

[0003] Purpose of the invention This paper presents a method for integrated production planning and flexible handling of anomalies across the entire industrial material supply chain. Starting with raw materials and using contract hash values ​​as the production target, it generates a full-process production plan in one go. It is equipped with a dual-path anomaly handling mechanism for contract termination, achieving "one-line rigid planning for normal production and flexible handling of anomalies to avoid waste," forming a complete closed loop. Technical solution (I) End-to-End Integrated Production Planning Method

[0004] Anchoring the origin and target of planning: Taking the raw materials to be produced as the starting point of planning, binding the finished product contract hash value (contract number + material attribute MD5 hash value) that the raw materials need to be delivered to the finished product contract as the production target, and clarifying the final finished product delivery requirements; One-time generation of full-process plan: Based on the finished product requirements corresponding to the contract hash value, reverse the process parameters, quality standards and production constraints of all production processes, and generate a full-chain integrated production plan covering all processes in one go; Plan binding and distribution: The plan is uniquely bound to the raw materials, contract hash value, plan number and material number, and distributed synchronously to all relevant production processes, and each process executes production according to the plan; Full-process data traceability and binding: Production data, process parameters, and quality inspection results of all processes are bound to the plan, contract hash value, plan number, and material number, realizing full-process data traceability. (II) Flexible Two-Path Disposal Method for Terminating Contracts for Abnormal Materials

[0005] Termination of original contract (preliminary action): When a material fails to meet the original contract delivery standard due to an abnormality in any process of production, the material is formally terminated from all binding relationships with the original contract, and the binding relationship with the original production execution plan is removed, and the material is put into the abnormal material disposal pool. Path 1: Continue production according to spot standards: Abnormal materials still have processing value but cannot be matched with any existing contracts. Complete the remaining processes according to the company's general spot process standards, and sell the finished products separately at prices according to actual specifications. There are no new contracts tied to them. Path Two: Flexible Production by Dragging Into a New Contract: When the actual quality / parameters of abnormal materials meet the delivery standards of another existing contract, they are tied to the target new contract, and the remaining process plans are prepared according to the following two modes: Plan reuse mode: If the target new contract already has an existing end-to-end plan, the material can be directly dragged into that plan and production can be completed following the existing plan; Separate planning mode: If there is no existing plan for the target new contract, a full-chain plan covering all remaining processes will be prepared at once, with the delivery standards of the new contract as the target. New contract settlement and delivery: After the finished product is off the production line, delivery will be completed according to the pricing and settlement rules of the target new contract.

[0006] It pioneered a whole-chain integrated planning logic with "raw materials as the origin and contract hash value as the target", generating a full-process plan at once, solving the problems of lag and disconnect in traditional segmented planning; Design a dual-path abnormal handling mechanism for contract termination, with the termination of the original contract as a prerequisite, and separate the handling of spot production and dragging into the new contract to achieve accurate bottom-line protection of abnormal materials; The new contract adopts a dual model of planned reuse and separate preparation, which takes into account both production efficiency and resource utilization, and minimizes the scrapping of abnormal materials. The entire process uses contract hash value, plan number, and material number as core binding identifiers to ensure data consistency and traceability. Beneficial effects

[0007] Planning efficiency has been improved by 80%, and plans for each process are unified and smoothly connected, avoiding parameter deviations and production disconnects from the source. Rigid planning and flexible handling are deeply integrated, ensuring uniform standards for normal production and precise backup for abnormal production, so as to avoid wasting resources. Abnormal materials are reused across contracts, reducing the scrap rate by more than 10%, and significantly improving resource utilization and corporate economic benefits; The entire process is data-closed and traceable, with no issues of data confusion or material mismatch. It aligns with the realities of continuous multi-process production of industrial materials, and both planning and anomaly handling are easy to implement. Detailed Implementation

[0008] Production planning: The system collects raw material information (material Q235, thickness 1.0mm) and the corresponding finished product contract hash value (HT20240507_8f3d21). Based on the delivery requirements corresponding to the hash value, it generates a one-time integrated production plan covering the pickling, rolling, galvanizing, and leveling processes. The plan is then bound to the raw materials, contract hash value, plan number, and material number (JH20240507001) and distributed to each process. Normal production: Each process is executed according to plan, and production data is bound to the plan and contract hash value in real time. The system monitors the production progress and parameters throughout the process. Anomaly detection: The rolling mill process detected that the thickness of the material was locally out of tolerance and could not meet the original contract requirements. The system triggered the anomaly handling procedure. Abnormal Handling: Terminate original contract: The system removes the binding relationship between the material and the original contract and plan, and enters the exception handling pool; Path selection: After verification, the actual parameters of the material meet the delivery standards of another existing contract (hash value HT20240508_6e2a93). Path two is selected to drag the new contract in. Planning: The target new contract already has an existing full-chain plan. Using the plan reuse model, the material is dragged into the plan and follows the existing plan to complete the subsequent galvanizing and leveling processes. Settlement and Delivery: After the finished product is off the production line, delivery is completed according to the pricing and settlement rules of the target new contract. The system records all operations (planning, contract cancellation, dragging in new contracts) and supports one-click query of the entire process history by contract hash value, plan number, and material number.

Claims

1. A method for integrated production planning and flexible handling of anomalies across the entire industrial material supply chain, characterized in that, This includes a whole-chain integrated production planning method and a dual-path flexible handling method for canceling contracts for abnormal materials. The specific steps are as follows: (1) Full-chain integrated production planning: Starting with the raw materials to be produced, the finished product contract hash value is bound to the production target. Based on the delivery requirements corresponding to the contract hash value, a full-chain integrated production plan covering all production processes is generated at once. The plan is then uniquely bound to the raw materials, contract hash value, plan number and material number and then distributed to each process. (2) Termination of original contract for abnormal materials: When a material is abnormal in any process of production and fails to meet the delivery standards of the original contract, the binding relationship between the material and the original contract is terminated, and the binding relationship between the material and the production execution of the original full-chain plan is simultaneously unbound. (3) Dual-path handling of abnormal materials: After the original contract is terminated, the abnormal materials are handled according to two options based on their actual process value: ① Production according to spot standards: If there is no new contract to match, the remaining production is completed according to the company's general spot process standards, and the finished products are sold separately at spot prices; ② Flexible production under a new contract: If the materials meet the delivery standards of another existing contract, the materials are bound to the target new contract, and the full-chain production plan for the remaining processes is prepared according to the planned reuse mode or the separate preparation mode, and the finished products are settled and delivered according to the new contract.

2. The method according to claim 1, characterized in that, The contract hash value is a unique identifier formed by concatenating the contract number as a prefix with the MD5 hash value of the material attribute. The material attribute includes material, thickness, width, process parameters, surface grade, and physical properties.

3. The method according to claim 1, characterized in that, The plan reuse mode involves directly dragging abnormal materials into the existing full-chain plan of the target new contract, while the separate compilation mode involves compiling a full-chain production plan covering all remaining processes at once.

4. The method according to claim 1, characterized in that, Terminating the original contract is a necessary prerequisite for handling all anomalies, and any abnormal materials dragged into the new contract must fully comply with the target new contract delivery standards.

5. The method according to claim 1, characterized in that, All operations are bound to contract hash values, plan numbers, and material numbers, enabling full-process data traceability. All database operations use standard SQL basic syntax and are compatible with SQL Server and GaussDB platforms.