Flexible rebinding method after abnormal volume unbinding in industrial production

Abstract

The application discloses a flexible rebinding implementation method for abnormal rolls after debinding in industrial production and belongs to the technical field of intelligent manufacturing informatization. In view of the abnormal rolls in industrial production that are debound due to reasons such as material specification deviation, sales contract adjustment and production process fine adjustment, the method takes industrial full-link unique identification (plan number roll number) and cross-table association anchor point (contract hash value) as cores, constructs a complete business closed loop of 'flexible debinding-new contract batch binding-production plan flexible adaptation', and innovatively provides two flexible adaptation paths, i.e. binding an existing production plan and generating a new production plan and binding, and combines key technologies such as table value parameter batch processing, transaction safety control and process parameter automatic synchronization to realize rapid and accurate rebinding of abnormal rolls and seamless reentry of the production link. The application effectively solves the technical pain points in the traditional industrial system, such as the fragmentation of abnormal roll processing flow, the single rebinding path, the low material and production plan matching efficiency, the easy-to-mess data and the untraceable data, and has the advantages of simple operation and strong adaptability. The application can be seamlessly connected with the existing industrial MES / ERP system, significantly improves the material utilization rate and production flexibility. The technical scheme is not a theoretical model, but a mature technical scheme that has completed complete engineering landing, development and realization and stable operation in the MES / ERP integrated system of an actual industrial manufacturing enterprise, and has high practicability and popularization value.

Description

Technical Field

[0001] This invention relates to the field of production planning and material management technology in industrial production informatization and intelligent manufacturing MES systems. Specifically, it is a flexible implementation method for unbinding abnormal volumes, rebinding them to new contracts, and adapting them to production plans in industrial production. Background Technology

[0002] In industrial production, especially discrete manufacturing industries such as steel manufacturing, abnormal volumes often arise due to material specification deviations, sales contract adjustments, and minor adjustments to production processes. These abnormal volumes require first unbinding from the original contract and then re-matching with the new contract and production plan. Traditional industrial systems suffer from several pain points in handling abnormal volumes rebinding: First, the processing flow is fragmented; unbinding, binding to a new contract, and binding to a plan are independent operations, requiring multiple manual calls to different modules, resulting in extremely low efficiency. Second, the rebinding path is singular, only supporting binding to existing production plans; when no existing plan exists, it must be manually created and bound, making the operation cumbersome. Third, process parameter synchronization relies on manual input, which is prone to errors, leading to inconsistencies between production process quality inspection data and the production plan. Fourth, the lack of batch processing and transaction security controls makes it unsuitable for handling large volumes of abnormal volumes, and operation failures can easily generate dirty data. Fifth, some processing logic deletes the core identifier fields of the abnormal volume, making data untraceable after rebinding, affecting subsequent reconciliation and production management.

[0003] While existing technologies offer single methods for contract binding and production plan binding, they do not form a complete business loop for abnormal volume rebinding and cannot meet the actual production needs of "unbinding - binding a new contract - plan adaptation". Therefore, there is an urgent need for an integrated abnormal volume flexible rebinding method to solve the above-mentioned technical pain points. Summary of the Invention

[0004] This invention addresses the problems of fragmented, single-path, inefficient, and inconsistent data in existing abnormal volume rebinding processes. It proposes a flexible rebinding method for abnormal volumes in industrial production after unbinding. Based on the unique identifier of the plan number and volume number and the cross-table anchor point of the contract hash value, a complete business loop of **"unbinding - binding a new contract - production plan adaptation"** is constructed. This supports two flexible paths: binding existing production plans and generating new production plans and binding them. Combined with batch processing, transaction security control, and dual condition parameter synchronization technology, it achieves fast, accurate, and flexible rebinding of abnormal volumes, ensuring data consistency and traceability throughout the entire process, and improving material utilization and production flexibility.

[0005] The core technical solution of this invention is based on three core data tables: the production process quality inspection record table, the production plan table, and the sales order details table. The plan number and volume number are unique identifiers across the entire supply chain, the contract hash value is the cross-table association anchor, and the finished product volume number is the unique identification field for abnormal volumes. Batch processing is achieved using table-valued parameters from an SQL Server database. Business logic is encapsulated through multiple dedicated unified stored procedures. The front end only needs to call a unified public function to complete the entire process, which includes the following four core steps, all of which follow the principles of "precise filtering, batch processing, transaction wrapping, and data traceability": Flexible termination of the original contract for abnormal volume For abnormal volumes that need to be rebound due to specification deviations, contract adjustments, or other reasons, the front end collects their finished volume numbers and calls a dedicated unbinding storage procedure for the abnormal volume. This procedure precisely filters the abnormal volume data in the production process quality inspection record table only by the finished volume number, clearing only contract-related information such as contract number, binding person, binding address, and contract binding time, while retaining core identifiers and basic data such as plan number, volume number, contract hash value, finished product weight, and material, providing data support for subsequent rebinding. The entire unbinding operation is wrapped in a transaction; if the operation fails, it is rolled back, and only the abnormal volume data is updated, without affecting the end-to-end data of other normal volumes.

[0006] Abnormal volumes are bulk-bound with new sales contracts. The front end collects the finished product roll number, newly matched sales contract number, new contract hash value, binding person, and binding address of the unbound abnormal roll. This information is encapsulated as table-valued parameters, and a dedicated stored procedure for binding the abnormal roll to the new contract is invoked. After a transaction is initiated, this procedure first batch updates the corresponding fields of the abnormal roll in the production process quality inspection record table with the new sales contract number, new contract hash value, binding person, binding address, and new binding time. Then, using the new contract hash value as the cross-table join anchor, it automatically joins the sales order details table, synchronously backfilling the salesperson, delivery deadline, unit price, and other production and settlement information for the new contract. Finally, it recalculates the cost data of the abnormal roll according to the formula: Total price of steel coil = Unit price × Finished product weight. If all operations succeed, the transaction is committed; otherwise, it is rolled back to ensure data consistency.

[0007] Flexible Adaptation and Binding of Production Planning Once the abnormal volume is bound to the new sales contract, two flexible adaptation paths are provided for the abnormal volume, depending on whether there is an existing compliant production plan on the production site. Both paths are wrapped by transaction safety mechanisms to achieve automatic synchronization of process parameters and production information without manual input. Path 1: Bind to existing production plan When an existing production plan exists that matches the specifications and requirements of the new sales contract, the front end collects the finished roll number of the abnormal roll and the corresponding existing plan number, encapsulates them as table-valued parameters, and calls the dedicated stored procedure BangDingZhiXianYouJiHua to bind the production plan. This process uses the plan number and finished roll number as dual filtering conditions to accurately locate the abnormal roll data in the production process quality inspection record table. First, it updates the plan number, plan compiler, and compilation address to the corresponding fields and automatically generates the plan compilation time. Then, using the plan number as the association key, it automatically synchronizes and backfills all process parameters (coating amount, yield strength, annealing temperature, etc.), production requirements (dimensional tolerances, packaging methods, etc.), and customer information from the production plan table to the production process quality inspection record table, ensuring that the quality inspection data is highly consistent with the production plan.

[0008] Path 2: Generate a new production plan and bind it. When there is no existing compliant production plan, the system automatically generates a new production plan based on the product specifications, delivery requirements, customer information, and settlement information of the new sales contract. A unique plan number is assigned to the new plan, and complete data such as the plan number, process parameters, production requirements, and customer information are written into the production plan table. After the new plan is completed, the system automatically binds the finished roll number of the abnormal roll to the new plan number, updates the new plan number to the production process quality inspection record table, and synchronously backfills the full amount of process parameters and production information of the new plan. This achieves seamless integration between the abnormal roll and the new production plan, and the new plan number is associated with the plan number and roll number of the abnormal roll, ensuring unified identification throughout the entire chain.

[0009] Results feedback and end-to-end data traceability Regardless of which production plan adaptation path is selected, after the operation is completed, the stored procedure returns the rebinding result (success / failure), the number of volumes processed, and specific operation information to the front end; if any step of the operation fails, the transaction will roll back all executed update operations to ensure that the production process quality inspection record table and production plan table have no dirty data and no intermediate state.

[0010] Throughout the entire process, the unique identifier of the plan number and volume number is always retained. All operation records such as unbinding abnormal volumes, binding new contracts, and plan adaptation are associated with the plan number and volume number, realizing the traceability, penetration, and reconciliation of the entire data after the abnormal volume is rebound, providing complete data support for subsequent production, quality inspection, and settlement. Beneficial effects

[0011] Compared with the prior art, the present invention has the following significant advantages: Integrated business loop for high processing efficiency: Construct a complete business loop of "unbinding - binding new contract - production plan adaptation". All operations are carried out through unified public function calls on the front end, replacing traditional discrete manual operations and greatly improving the processing efficiency of abnormal volume binding. Flexible dual-path adaptation to meet actual production needs: Supports binding existing production plans and generating new production plans and binding them to two paths, adapting to different scenarios in industrial production with or without existing plans, solving the problem of traditional single path and improving production flexibility; Batch processing adapted to industrial needs: Abnormal volume information is encapsulated in batches using table-valued parameters, which can simultaneously process the rebinding operation of multiple abnormal volumes, adapting to the processing needs of large batches of abnormal volumes in industrial production, with efficiency far exceeding that of traditional single-volume processing methods. Automatic parameter synchronization, accurate and error-free: After the production plan is bound, all process parameters and production requirements are automatically synchronized and backfilled into the production process quality inspection record form, replacing manual entry and completely avoiding parameter errors caused by manual operation, ensuring that the quality inspection data is highly consistent with the production plan. Dual-condition matching ensures accurate data matching: When binding existing production plans, the dual filtering conditions of plan number + finished product roll number are used, which solves the data error problem that is easy to occur by traditional single plan number matching and ensures the accuracy of data matching. The entire transaction process is wrapped, ensuring high data consistency: All operations such as unbinding, binding to new contracts, and plan adaptation are wrapped by transaction safety mechanisms. If an operation fails, a full rollback will be performed to avoid dirty data and intermediate states, ensuring data consistency across all data tables. Core fields are retained and data is traceable: When flexibly terminating the original contract, only contract-related information is cleared, while core identification fields such as plan number and volume number are retained. The identification is consistent throughout the process, ensuring that the data is traceable, transparent, and reconcilable throughout the entire chain after abnormal volume duplication is bound. Significantly improved material utilization: Enables rapid rebinding and production link reentry of abnormal volumes, solving the problems of idle and difficult reuse of abnormal volumes in traditional systems, greatly improving the material utilization rate of industrial production and reducing production losses; Easy to integrate and maintain, and adaptable to existing systems: Business logic is uniformly encapsulated into a unified stored procedure, with no redundant SQL statements on the front end. It can seamlessly connect to existing industrial MES / ERP systems, and subsequent maintenance only requires handling the dedicated stored procedure, making maintenance easy. Detailed Implementation

[0012] The following describes in detail the specific implementation of the present invention in the context of a real-world production scenario of an MES system in the steel manufacturing industry.

[0013] The application platform in this embodiment is the MES system of a steel manufacturing enterprise. The core data tables are the production process quality inspection record table, the production plan table, and the sales order details table. The database uses SQL Server, and batch processing is achieved through table-valued parameters. The dedicated unified stored procedures include the abnormal volume unbinding process, the new contract binding process, and the existing plan binding process. The front end uses public functions written in VB.NET to implement parameter encapsulation and stored procedure calls.

[0014] Example 1: Binding an abnormal volume to an existing production plan A steel production company has 5 abnormal coils (finished coil numbers J202603001-J202603005). Due to material deviation, the binding relationship with the original sales contract was terminated. After the binding was terminated, core data such as the plan number, coil number, and finished product weight were retained. For these 5 abnormal coils, a new sales contract number XS202603002 is re-matched, with a contract hash value HD202603002001, a binding person of Zhang San, and a binding address of the production department's quality inspection workshop. The front end encapsulates the above information into table-value parameters, calls the new contract binding process, completes the binding of the abnormal coils with the new contracts, and synchronizes the new contract's salesperson Li Si, delivery deadline 2026-04-15, unit price of 5100 yuan / ton, and recalculates the total price of the steel coils. There is an existing compliant production plan number JH202603002 on the production site, which matches the specifications and requirements of the new contract; the front end encapsulates the finished roll numbers of 5 abnormal rolls and the plan number JH202603002 into table-valued parameters and calls the existing plan binding process; The process initiates a transaction, using the plan number and finished roll number as dual conditions, and updates the plan number, compiler, and compilation address to the production process quality inspection record table, automatically generating the compilation time 2026-03-12 16:00:00; then, it synchronously backfills the full amount of process parameters (coating amount 25g / m², yield strength 320MPa, annealing temperature 720℃, etc.) and production requirements (thickness tolerance ±0.03mm, fine packaging, etc.) in the production plan table; All operations were executed successfully, the transaction was committed, and the front end returned "Rebinding successful, 5 volumes processed". The 5 abnormal volumes were successfully bound to the existing production plan JH202603002, and the data was traceable throughout the entire chain.

[0015] Example 2: Generating and binding a new production plan for an abnormal volume A steel production company has 3 abnormal coils (finished coil numbers J202603006-J202603008). Due to the adjustment of the original contract, the binding was terminated, and the core identification data was retained after the binding was terminated. Re-match the three abnormal volumes with the new sales contract number XS202603003 and the contract hash value HD202603003001. The front end completes the batch binding of the abnormal volumes with the new contracts and synchronizes the product specifications, customer information, unit price and other data of the new contracts. Since there was no existing compliant production plan on-site, the system automatically generated a new production plan number JH202603003 based on the information from the new sales contract, and wrote the plan number, process parameters (coating amount 20g / m², yield strength 300MPa, etc.), production requirements, and customer information into the production plan table. The system automatically binds the three abnormal volumes to the new production plan JH202603003, updates the new plan number to the production process quality inspection record table, and synchronously backfills the full amount of process parameters and production information of the new plan. The operation was executed successfully, and the front end returned "Rebinding successful, 3 volumes processed, new production plan JH202603003 generated". The 3 abnormal volumes successfully re-entered the production link.

[0016] This embodiment is only a preferred embodiment of the present invention and is not intended to limit the scope of the present invention. All equivalent modifications made based on the technical solutions of the present invention fall within the protection scope of the present invention.

Claims

1. A method for flexible rebinding after abnormal volume unbinding in industrial production, characterized in that, Based on the unique identifier of the plan number and volume number and the cross-table association anchor of the contract hash value, a complete business closed loop is constructed, which includes flexible unbinding, batch binding of new contracts, dual-path production plan adaptation, and result feedback traceability. The dual-path adaptation process is controlled by transaction security mechanisms, and the unique identifier is retained for traceability throughout the entire process.

2. The method according to claim 1, characterized in that, The flexible unbinding process calls a dedicated unified storage procedure, which precisely filters abnormal volume data only by the finished volume number, clears the associated contract information and retains the core production data. The operation is wrapped by a transaction and does not affect normal volume data.

3. The method according to claim 1, characterized in that, The batch binding of new contracts uses a stored procedure to encapsulate table-valued parameters for batch processing. It automatically links the sales order details table to synchronize settlement, delivery information, and recalculate the total price of steel coils. If the processing fails, the entire transaction is rolled back.

4. The method according to claim 1, characterized in that, When binding existing plans, a dual screening mechanism of plan number + finished product roll number is used to match data based on the full range of process parameters and production requirements to avoid data confusion.

5. The method according to claim 4, characterized in that, After a successful double-screening match, all business parameters of the new contract are automatically synchronized to the existing production plan.

6. The method according to claim 1, characterized in that, When generating a new plan, complete production plan data is automatically generated based on the new contract information, and the new plan number is consistent with the abnormal volume identifier to ensure the integrity of the data link.

7. The method according to claim 1, characterized in that, The entire process only updates intermediate business tables such as quality inspection forms and planning forms, while retaining original data such as sales / purchase order forms to ensure the uniqueness and integrity of core data.