Emergency production plan generation method and system for system or network burst failure

Abstract

This invention discloses a method and system for generating emergency production plans in the event of sudden system or network failures, belonging to the field of enterprise production planning management technology. It includes deploying an emergency system server, establishing an emergency plan system database, synchronizing data from the manufacturing system database to the emergency system, establishing an emergency plan compilation system, developing emergency plan import functions in work zones and unit L2 systems, and developing emergency plan import and production performance recovery functions for the manufacturing system. The entire invention employs database synchronization technology and independently deployed servers to achieve real-time synchronization of information between the manufacturing system and the emergency system. It can independently compile production plans for each unit. In the event of manufacturing system or network anomalies, emergency production plans can be compiled and transmitted to the secondary and tertiary systems of each field unit, achieving seamless online connection between the manufacturing system and the emergency system to ensure continuous, safe, and reliable production.

Description

Technical Field

[0001] This invention relates to the field of production planning and management technology, specifically to a method and system for generating emergency production plans in the event of sudden system or network failures. Background Technology

[0002] The production plans for all units within the factory are currently compiled through a manufacturing system deployed on a cloud platform. Since production plans require real-time compilation based on orders and materials, and must be distributed to second- and third-level systems via the network to ensure normal production organization, any anomalies in the cloud platform, manufacturing system, or network can lead to the paralysis of production plan compilation and issuance, seriously threatening production safety. Therefore, there is an urgent need to provide an emergency solution that can provide accurate emergency plans to the site in the event of the above-mentioned failures, in order to ensure safe production on site. Summary of the Invention

[0003] The purpose of this invention is to provide an emergency production plan generation method and system for sudden system or network failures. This method aims to improve response capabilities in abnormal situations, addressing sudden hardware or software failures in information systems or networks. By employing database synchronization technology, deploying independent servers, and developing relevant supporting functional modules, it achieves seamless online integration between the manufacturing system and the emergency system, ensuring continuous and reliable production, thereby overcoming the shortcomings of existing technologies.

[0004] To achieve the above objectives, the present invention provides the following technical solution:

[0005] A method for generating emergency production plans for sudden system or network failures includes the following steps:

[0006] S1: Deploy emergency system servers: Deploy multiple physical servers in locations other than the main data center that can access the production network, i.e., deploy multiple servers separately in different locations.

[0007] S2: Establish an emergency planning system database for the manufacturing system data architecture, including contract information tables, process tables for each process, material information tables for steelmaking, bar steel, hot rolling, and cold rolling, and production plans for each production line.

[0008] S3: Synchronize data from the manufacturing system database to the emergency system: Use CDC data synchronization software to achieve data synchronization between the production system and the emergency system;

[0009] S4: Establish an emergency plan preparation system: Develop client-side interfaces and corresponding server-side backend programs, including material query interface and backend, contract query interface and backend, material transfer interface and backend, plan preparation interface and backend, and plan export interface and backend;

[0010] S5: Develop an emergency plan import function in the work zone and unit L2 system, that is, adopt the method of exporting plan documents from the emergency system client;

[0011] S6: Develop emergency plan import and production performance recovery functions for the manufacturing system, including: emergency plan import, completion of raw material transfer and processing of production performance.

[0012] Furthermore, the contract information table in S2 is used to store contract information retrieved from the contract master table of the manufacturing system; the process table for each process is used to store the corresponding process parameters retrieved from the process table for each process in L4 of the manufacturing system; the material information tables for steelmaking, bar steel, hot rolling, and cold rolling are used to store material information from the material master files synchronized from the inventory module of L4 of the manufacturing system; and the production plan table for each production line is used to store the prepared plan information.

[0013] Furthermore, the material query screen and backend developed in S4 are used to query material information within the emergency system; the contract query screen and backend are used to query contract and process information within the emergency system; the material transfer screen and backend are for contracts for replaceable materials within the emergency system, limited to the emergency system and without interaction with the production system; the production planning screen and backend use material data, contract information, and process data from the emergency database to compile production plans, process data formats, and generate production orders for designated units; the production plan export screen and backend are used to export emergency production plans to documents according to the format requirements of each unit.

[0014] Furthermore, in S4, where multiple emergency system servers are deployed, the developed client can select an available master server.

[0015] Furthermore, the specific methods in S5 include:

[0016] S501: Each production unit's work area is independent of the manufacturing system and is responsible for issuing production plans to the unit's L2 system. That is, the developed emergency plan import function imports emergency plan documents into the work area and issues them to the L2 system.

[0017] S502: In the event of a work zone failure, production can be organized according to an emergency plan. This means that the emergency plan can be directly imported into the L2 system of the relevant unit and then production can be organized.

[0018] Furthermore, in S6, after the manufacturing system recovers from a failure, the emergency plan is first imported, and relevant records are generated in the database. The raw material conversion is completed automatically in the manufacturing system according to the matching relationship between materials and contracts in the emergency plan, ensuring that the matching relationship between raw materials and contracts is correct. The production performance processing is that the production performance generated according to the emergency plan during the failure period can be automatically received by the manufacturing system or work area after the system is restored, and subsequent processing is completed according to the contract relationship.

[0019] This invention provides another technical solution: an emergency production plan generation system for system or network failures, comprising multiple separately deployed emergency system servers in different locations, an emergency system client interconnected with the emergency system servers, an independent emergency plan system database, an emergency plan compilation and export module, an emergency plan production import module, and a manufacturing system production performance recovery module; the emergency system servers are independently deployed outside the manufacturing system controlled by the cloud platform; the emergency plan system database uses CDC data synchronization technology to synchronously interconnect with the manufacturing system database, used to provide production plans for the site in case of emergencies; the emergency plan compilation and export module uses a CS system architecture to directly export plan documents from the emergency system client to the emergency plan production import module, which transmits the emergency plan production import module to the production site via network or USB flash drive, where production personnel import it into the L3 production operation system and then issue it to the unit's secondary execution; the manufacturing system production performance recovery module is used to import the production data generated during the failure into the restored manufacturing system.

[0020] Compared with the prior art, the beneficial effects of the present invention are:

[0021] The present invention provides an emergency production plan generation method and system for system or network failures. When an online manufacturing system experiences a sudden hardware or software failure that prevents access or a sudden interruption of network communication, and the system is unable to issue production plans to lower-level machines, it can provide accurate emergency plans to the field to ensure safe production. At the same time, after the manufacturing system is restored, production data can be quickly imported into the manufacturing system to complete automatic data matching, achieve consistent system data recovery, rapidly restore the system's production capacity, realize the effective preparation of production plans, and ensure continuous and stable production. Attached Figure Description

[0022] Figure 1 This is a logical framework diagram of the emergency production plan generation method of the present invention. Detailed Implementation

[0023] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0024] Please see Figure 1 The emergency production plan generation method for sudden system or network failures provided in this embodiment of the invention improves the response capability under abnormal conditions in the face of sudden hardware or software failures in information systems or networks. It includes the following steps:

[0025] S1: Deploy the emergency system server: The emergency system in this step adopts a client-server architecture. To avoid being affected by sudden failures of the cloud platform, manufacturing system or data center, the main server of the emergency system is deployed separately in a different location. That is, an independent physical server is used and deployed in a location other than the main data center that can access the production network. To improve the reliability of responding to abnormal situations, the emergency system can deploy multiple servers in different locations at the same time.

[0026] S2: Establish an emergency planning system database: Based on the manufacturing system data architecture, analyze and identify the data required to establish an emergency planning system database, including:

[0027] Establish a contract information table to store contract information retrieved from the manufacturing system's contract master table;

[0028] Establish process tables for each process to store the corresponding process parameters retrieved from the process tables of each process in the L4 manufacturing system;

[0029] Establish material information tables for steelmaking, bar steel, hot rolling, and cold rolling to store material information of each material master file synchronized from the L4 inventory module of the manufacturing system;

[0030] Establish production plan tables for each production line to store the prepared plan information.

[0031] S3: Synchronizing Data from the Manufacturing System Database to the Emergency System: Using CDC data synchronization software, data synchronization between the production system and the emergency system is achieved. CDC is a highly efficient database synchronization technology used to capture data changes (such as insertions, updates, and deletions) in the database and synchronize these changes to the target system in real time. Compared to traditional full synchronization, CDC significantly reduces latency and resource consumption, making it suitable for scenarios such as real-time data analysis and data warehouse synchronization. This invention, by using CDC technology, ensures real-time synchronization of data in designated data tables of the manufacturing system with data in the emergency system database, laying a data foundation for emergency system planning while not placing excessive load on the production system. If multiple emergency system servers are deployed, each needs to synchronize data with the manufacturing system.

[0032] S4: Establish an emergency planning system: Develop client-side interfaces and corresponding server-side programs. Due to the adoption of CDC database synchronization technology, the data in the emergency system is consistent with the data during sudden production system failures. To cope with sudden production system or network outages, this invention uses an independent system to provide emergency production plans, mainly including:

[0033] Develop a material query screen and backend for querying material information within the emergency system;

[0034] Develop a contract query screen and backend for querying contract and process information within the emergency system;

[0035] Develop a material transfer screen and backend, and use the contract for replaceable materials within the emergency system. This function is limited to the emergency system and has no interaction with the production and manufacturing system.

[0036] The development plan is created on the screen and backend. It uses material data, contract information, process data and other information from the emergency database to create production plans and process the data format to generate production orders for designated units. The plan creation is limited to the internal emergency system and has no interaction with the production and manufacturing system.

[0037] Export the development plan screen and backend, and export the emergency production plan to a document according to the format requirements of each unit;

[0038] In this step, if multiple emergency system servers are deployed, the client can select the available master server.

[0039] S5: Develop emergency plan import function in the work zone and unit L2 system: To avoid network interruptions causing emergency plans to fail to be issued over the network, this invention does not use the method of issuing via the network, but instead uses the method of exporting plan documents from the emergency system client, as detailed below:

[0040] (1) Each production unit's work area is independent of the manufacturing system and is responsible for issuing production plans to the unit's L2 system. Therefore, an emergency plan import function is developed in the work area to import emergency plan documents into the work area and issue them to the L2 system.

[0041] (2) Even in the event of a work zone failure, production can still be organized according to the emergency plan. An emergency plan import function can be developed in the relevant unit's L2 system, and the emergency plan can be directly imported and then production organized.

[0042] S6: Develop contingency plan import and production performance recovery functions for the manufacturing system. Since contingency plans are generated independently of the manufacturing system, the manufacturing system will not have contingency plan data after system failure recovery. Therefore, develop contingency plan and production performance processing functions for the manufacturing system, mainly including:

[0043] Emergency plan import: After the manufacturing system is restored, the emergency plan must be imported first, and relevant records must be generated in the database;

[0044] Complete the raw material conversion: Since the raw material conversion operation was performed in the emergency system, the matching relationship between raw materials and contracts changed. Therefore, a related function was developed to automatically complete the raw material conversion in the manufacturing system according to the matching relationship between materials and contracts in the emergency plan, so as to ensure the correct matching relationship between raw materials and contracts.

[0045] Processing production data: During the outage, the production data generated according to the emergency plan is stored at the second or third level or the third or fourth level interface. Therefore, it is necessary to develop relevant functions so that after the system is restored, the manufacturing system or work area can automatically receive the production data and complete the subsequent processing according to the contract relationship to ensure the accuracy of raw materials, output materials and contract data.

[0046] Specifically, the application scenarios for emergency plans can be as follows:

[0047] Scenario 1: Manufacturing system inaccessible, work area system normal, network normal: In this case, you can use the emergency system client to log in to the emergency system server, compile and export the production plan, send the plan file to the field personnel through communication software, import it into the work area system and then distribute it to the unit's secondary system to ensure continuous production.

[0048] Scenario 2: Manufacturing system and work area system are inaccessible, but network is normal: In this case, you can use the emergency system client to log in to the emergency system server, compile a production plan, export it, and send the plan file to the field personnel through communication software. The plan can then be directly imported into the unit's secondary system to ensure continuous production.

[0049] Scenario 3: Network anomaly, both manufacturing system and work area system are inaccessible: In this case, go to the emergency server room, connect to the server in the server room to compile the plan, export it to a USB flash drive, and then manually send it to the work site. Depending on the situation on site, import it into the work area system or directly into the secondary system to ensure continuous production.

[0050] In the above scenario, when the manufacturing system, work area system and network return to normal, the emergency plan is first imported. After the system automatically completes the processing of production data during the failure period, the system can switch to normal operation.

[0051] To further illustrate the above embodiments, the present invention also provides: an emergency production plan generation system for system or network failures, comprising multiple separately deployed emergency system servers in different locations, an emergency system client interconnected with the emergency system servers, an independent emergency plan system database, an emergency plan compilation and export module, an emergency plan production import module, and a manufacturing system production performance recovery module. Wherein:

[0052] The emergency system server is deployed separately in a different location, that is, a separate physical server is used and deployed in a location other than the main server room that can access the production network. To improve the reliability of the emergency system, multiple emergency system servers can be deployed at different locations at the same time.

[0053] The emergency planning system database uses CDC data synchronization technology to synchronize with the manufacturing system database. Its primary function is to provide production plans to the site in case of emergencies. Therefore, it only needs to retrieve contract, material, process parameter, and planning data related to each unit's plan from the production system, without needing to extract all data from the entire production system. By using CDC database synchronization technology, it ensures real-time synchronization between designated data tables in the manufacturing system and the emergency system database, laying a data foundation for emergency system planning while minimizing the load on the production system database. If multiple emergency system servers are deployed, data synchronization between each server is required simultaneously.

[0054] The emergency plan preparation and export module adopts a client-server system architecture. It is necessary to develop material transfer and plan preparation and export functions for each production unit. In order to avoid the failure of emergency plans to be issued due to network interruption, this system does not use the method of distribution through the network, but instead uses the method of exporting the plan document from the emergency system client, that is, directly exporting the plan document to the emergency plan production import module.

[0055] The emergency production plan import module can be transmitted to the production site via network or USB flash drive. After being imported into the L3 production operation system by production personnel, it can be issued to the unit's secondary execution. In the event of a failure in the operation system, it can also be directly imported into the unit's secondary system to ensure the continuity and safety of production.

[0056] The manufacturing system production performance recovery module is used to import production data generated during a downtime into the restored manufacturing system. Specifically, after the manufacturing system is restored, to ensure continuous and stable production, it is necessary to quickly restore the production data generated during the downtime. Since the emergency plan is generated independently of the manufacturing system, and the manufacturing system recovery does not have relevant emergency plan data, the emergency plan and production performance processing functions are developed in the manufacturing system. These functions mainly include importing the emergency plan and completing the contract and raw material conversion matching according to the emergency plan, receiving the production performance of each unit uploaded by the work area, and completing subsequent calculations and input-output processing according to contract relationships to ensure the accuracy of raw materials, output materials, contracts, and other related data.

[0057] In summary, the emergency production plan generation method and system provided by this invention for system or network failures employs database synchronization technology and independently deployed servers to achieve real-time synchronization of information between the manufacturing system and the emergency system. It can also independently compile production plans for each unit. In the event of manufacturing system or network anomalies, emergency production plans can be compiled and transmitted to the secondary and tertiary systems of each on-site unit to ensure continuous safe production on-site.

[0058] 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 method for emergency production plan generation for system or network outages, characterized by, Includes the following steps: S1: Deploy emergency system servers: Deploy multiple physical servers in locations other than the main data center that can access the production network, i.e., deploy multiple servers separately in different locations. S2: Establish an emergency planning system database for the manufacturing system data architecture, including contract information tables, process tables for each process, material information tables for steelmaking, bar steel, hot rolling, and cold rolling, and production plans for each production line. S3: Synchronize data from the manufacturing system database to the emergency system: Use CDC data synchronization software to achieve data synchronization between the production system and the emergency system; S4: Establish an emergency plan preparation system: Develop client-side interfaces and corresponding server-side backend programs, including material query interface and backend, contract query interface and backend, material transfer interface and backend, plan preparation interface and backend, and plan export interface and backend; S5: Develop an emergency plan import function in the work zone and unit L2 system, that is, adopt the method of exporting plan documents from the emergency system client; S6: Develop emergency plan import and production performance recovery functions for the manufacturing system, including: emergency plan import, completion of raw material transfer and processing of production performance.

2. The contingency production plan generation method for system or network outages of claim 1, wherein: The contract information table in S2 is used to store contract information retrieved from the contract master table in the manufacturing system; the process table for each process is used to store the corresponding process parameters retrieved from the process table for each process in L4 of the manufacturing system; the material information tables for steelmaking, bar steel, hot rolling, and cold rolling are used to store material information from the material master files synchronized from the inventory module of L4 of the manufacturing system; and the production plan table for each production line is used to store the prepared plan information.

3. The contingency production plan generation method for system or network outages of claim 1, wherein: The material query screen and backend developed in S4 are used to query material information within the emergency system; the contract query screen and backend are used to query contract information and process information within the emergency system; the material transfer screen and backend are for contracts for replaceable materials within the emergency system, which is limited to the emergency system and has no interaction with the production system; the planning screen and backend use material data, contract information, and process data information from the emergency database to compile production plans, process data formats, and generate production orders for designated units. The export screen and backend are used to export emergency production plans to documents according to the format requirements of each unit.

4. The contingency production plan generation method for system or network outages of claim 1, wherein: In S4, where multiple emergency system servers are deployed, the developed client can select the available master server.

5. The contingency production plan generation method for system or network outages of claim 1, wherein: Specific methods in S5 include: S501: Each production unit's work area is independent of the manufacturing system and is responsible for issuing production plans to the unit's L2 system. That is, the developed emergency plan import function imports emergency plan documents into the work area and issues them to the L2 system. S502: In the event of a work zone failure, production can be organized according to an emergency plan. This means that the emergency plan can be directly imported into the L2 system of the relevant unit and then production can be organized.

6. The emergency production plan generation method for system or network sudden failures as described in claim 1, characterized in that: In S6, after a manufacturing system failure is resolved, the emergency plan is first imported, and relevant records are generated in the database. The raw material conversion is completed automatically in the manufacturing system according to the matching relationship between materials and contracts in the emergency plan, ensuring the correct matching relationship between raw materials and contracts. Production performance processing involves the production performance generated during the failure period according to the emergency plan. After the system is restored, the manufacturing system or work area can automatically receive the production performance and complete subsequent processing according to contractual relationships.

7. An emergency production plan generation system for sudden system or network failures, characterized in that: The system includes multiple separately deployed emergency system servers, an emergency system client interconnected with the emergency system servers, an independent emergency planning system database, an emergency plan creation and export module, an emergency plan production import module, and a manufacturing system production performance recovery module. The emergency system servers are independently deployed outside the manufacturing system controlled by the cloud platform. The emergency planning system database uses CDC data synchronization technology to synchronize and interconnect with the manufacturing system database, providing production plans for the site in case of emergencies. The emergency plan creation and export module uses a CS system architecture to directly export plan documents from the emergency system client to the emergency plan production import module. The emergency plan production import module transmits the data to the production site via network or USB flash drive, where production personnel import it into the L3 production operation system and then issue it to the unit's secondary execution level. The manufacturing system production performance recovery module is used to import the production data generated during the failure into the restored manufacturing system.

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