A material whole-process intelligent scheduling method based on policy optimization

Abstract

The present application relates to the technical field of intelligent scheduling, in particular to a material whole-process intelligent scheduling method based on strategy optimization, which constructs a cross-line time sequence demand graph to uniformly describe the material demand of multiple production lines and the arrival deadline; based on the length information of the remaining material section, the expected available time stamp is combined with the demand time sequence for alignment matching to generate directional remaining material records; for uncovered demand, the replaceable remaining material is identified by using a specification degradation relationship table, and its feasibility is verified through comprehensive work time constraints such as logistics time and processing time to generate a replacement route or new material demand; at the same time, the feasibility of shortening absorption and parameter absorption is judged according to the process state to realize the dynamic utilization of products; finally, the time sequence coverage state is updated and the collaborative delivery constraint is verified to form a closed-loop scheduling optimization mechanism. The present application can significantly improve the utilization rate of remaining materials, reduce production costs, and improve the collaborative delivery capability of multiple production lines.

Description

Technical Field

[0001] This invention relates to the field of intelligent scheduling technology, specifically to an intelligent scheduling method for the entire material process based on strategy optimization. Background Technology

[0002] With the in-depth development of intelligent manufacturing technology, the material scheduling and management needs of discrete manufacturing enterprises are becoming increasingly complex. In the production and manufacturing scenarios of conveyor mechanical components, enterprises usually involve multiple parallel production lines, and the types, specifications and input sequences of raw materials required by each production line are significantly different, making the whole-process management of materials quite difficult.

[0003] In existing technologies, enterprises generally rely on Enterprise Resource Planning (ERP) systems or Manufacturing Execution Systems (MES) for planned material allocation. Their scheduling strategies are mostly based on static rules or preset priorities, and scheduling decisions depend on offline production plans, making it impossible to perceive real-time dynamic changes in the status of materials in the workshop. When processing surplus materials are generated during production, existing systems lack a mechanism to include these surplus materials in the schedulable resource pool and cannot dynamically assess their compatibility with the current work orders of other production lines. This results in surplus material resources being idle or discarded, leading to raw material waste.

[0004] Furthermore, when multiple production lines compete for the same type of material resources simultaneously, existing scheduling methods lack a dynamic priority decision-making strategy based on global production goals, making it difficult to coordinate the timing of material delivery across lines and leading to production rhythm imbalances. When customer orders change or production plans are adjusted, the existing system also cannot automatically trigger the rollback evaluation and rescheduling process for allocated materials, requiring manual intervention, resulting in delayed scheduling response and severely impacting production efficiency and on-time delivery rates.

[0005] To address this, a strategy-optimized intelligent scheduling method for the entire material supply chain is proposed. Summary of the Invention

[0006] The purpose of this invention is to provide a material end-to-end intelligent scheduling method based on strategy optimization. By constructing a cross-line time-series demand map, and combining surplus material time-series alignment, specification downgrading, and time constraints, it achieves efficient reuse of surplus materials and dynamic compensation for gaps, and performs absorption decisions and collaborative delivery verification based on process status.

[0007] To achieve the above objectives, the present invention provides the following technical solution: A strategy-optimized intelligent material scheduling method for the entire process includes: Summarize the demand times of raw materials of the same specification from each production line to form a cross-line time-series demand map; based on the cross-line time-series demand map, perform time-series alignment screening of feasible cutting schemes for surplus materials, and output targeted surplus material records containing surplus material specifications, available timestamps and target production line numbers; The available timestamps of the directional surplus material records are compared one by one with the material arrival deadlines of each production line to identify time gaps, and time gap records are output based on the gap amount. For non-directional surplus materials with larger specifications in the time gap record, the accessibility of the downgraded specification is confirmed by the specification downgrade relationship table, and the comprehensive working time constraint is used to check whether the deadline is met. If it is met, an alternative routing instruction is output; otherwise, it is confirmed as a new material replenishment requirement. Upon receiving the modification instruction, determine the feasibility of truncation absorption and / or parameter absorption based on the process status of each batch; for batches where absorption is not feasible, enter the specification downgrade route; update the timing coverage status and verify the collaborative delivery constraints.

[0008] Preferably, the formation of the cross-line time-series demand map includes: retrieving work orders from the work order database that are in the material-pending state for each production line within the current production cycle; extracting the raw material cross-sectional specifications, required length specifications, production line number, and required batch size for each work order; calculating the material arrival deadline for each production line based on the order delivery time and the total working hours required for all processes from material arrival to process completion; organizing and arranging the production line number, raw material specification parameters, required batch size, and material arrival deadline along a time axis using the material arrival deadline as the time node to form a cross-line time-series demand map; and forming time-series correlation constraints by reverse-deriving the material arrival deadlines of each supporting production line under the customer order in the cross-line time-series demand map through a unified delivery time.

[0009] Preferably, the process of obtaining the directional surplus material record includes: enumerating all feasible cutting schemes that meet the requirements of the main production line work order for the batch to be cut, and calculating the surplus material cross-sectional specifications and surplus material length generated by each scheme; retrieving the cross-line time sequence requirement map using the surplus material cross-sectional specifications and surplus material length as query conditions, identifying the target production line and corresponding time node whose surplus material length falls within the requirement length range of other production lines; for each matched target production line, calculating the expected available timestamp of the surplus material based on the real-time execution progress record of the work order, and verifying whether the timestamp is earlier than the material arrival deadline of the target production line; the real-time execution progress record of the work order is refreshed when each batch of cutting process starts, and the expected completion time is dynamically corrected based on the actual start time and the remaining cutting quantity, and the corrected expected completion time is the expected available timestamp of the surplus material; calculating the difference between the surplus material length and the required length of the target production line to determine the truncation amount; selecting the scheme with the smallest truncation amount from all schemes that meet the time sequence alignment conditions as the execution scheme, and outputting the directional surplus material record.

[0010] Preferably, the timing gap record output process includes: grouping all targeted surplus material records by target production line number; matching all demand batches for each production line with the coverable batches in the allocated targeted surplus material records; comparing the expected available timestamp of each targeted surplus material record with the material arrival deadline of the target production line: those with expected available timestamps earlier than the deadline are marked as surplus material timing coverage and removed from the list of demand items to be covered; those with expected available timestamps later than the deadline and / or no corresponding demand items for targeted surplus material records are marked as timing gaps; and using the difference between the total demand batches of the production line and the batches already covered by targeted surplus material as the gap amount to form a timing gap record.

[0011] Preferably, the process for confirming the accessibility of downgraded specifications includes: an offline pre-built specification downgrade relationship table, using each material specification as the query key, recording all smaller specifications that can be reached by truncation and the corresponding truncation amount for each path; the specification downgrade relationship table is updated synchronously with changes in the material specification system, and the update timestamp is recorded in the table header; For each time-series gap record, non-directional surplus materials with the same cross-sectional specifications and a length specification greater than the gap requirement length are retrieved from the non-directional surplus material pool based on the cross-sectional specifications. Using the current length specification of each selected surplus material as the query key, a list of achievable downgrade specifications is extracted from the specification downgrade relationship table. Each specification in the list of achievable downgrade specifications is matched one by one with the required length specification in the time-series gap record. For those that are successfully matched, the achievability of the downgrade specification of the gap corresponding to the surplus material is confirmed, and the corresponding truncation amount is extracted.

[0012] Preferably, the comprehensive working time constraint is used to verify whether the deadline is met, including: for each remaining material and gap whose accessibility to the downgraded specification has been confirmed, the corresponding records are recorded, and three times are accumulated in sequence: the logistics time from the current storage location of the remaining material to the location where the shortening operation is performed, the working time of the shortening operation, and the logistics time from the material receiving location of the target production line after the shortening is completed; the estimated available timestamp of the remaining material is added to the sum of the three times to obtain the estimated time when the remaining material actually arrives at the target production line; Compare the expected arrival time with the material arrival deadline in the time gap record: for those whose expected arrival time is not later than the deadline, output an alternative route instruction and update the allocation status of the corresponding remaining material record in the material resource pool to directed route; for those whose expected arrival time is later than the deadline, confirm as new material replenishment needs.

[0013] Preferably, the feasibility of truncated absorption and / or parameter absorption is determined based on the process status of each batch, including: For batches whose process status is marked as cut but not yet entered into subsequent processes, the minimum feeding length required for the target specification to enter the subsequent process is extracted from the process specification parameter table. The minimum feeding length is the sum of the finished length of the target specification and the processing allowance of the subsequent process. If the cut length of the current batch is greater than the minimum feeding length, then cutting and absorption is feasible. The cutting amount is the difference between the cut length and the minimum feeding length, and the cutting operation time is included in the estimated actual arrival time of the batch material. If the cut length is not greater than the minimum feeding length, then cutting and absorption is not feasible. For batches whose process status is marked as having completed intermediate processes but not yet entered the final curing process, the maximum allowable parameter adjustment amount for intermediate processes is extracted from the process specification parameter adjustment tolerance table. The process specification parameter adjustment tolerance table is updated synchronously and the update timestamp is recorded when the process is changed. The difference between the actual effective processing length of the current batch and the modified target length is calculated as the length deviation. If the length deviation does not exceed the maximum parameter adjustment amount, parameter absorption is feasible, and subsequent processes continue after updating the processing parameters, with the expected actual arrival time of the material remaining unchanged. If the length deviation exceeds the maximum parameter adjustment amount, parameter absorption is not feasible.

[0014] Preferably, updating the timing coverage state and verifying collaborative delivery constraints includes: Summarize the processing results of each batch after the modification instruction: The estimated actual arrival time of the truncated absorption batch is the sum of the original estimated available timestamp and the truncated operation time; the estimated actual arrival time of the parameter absorption batch remains unchanged from the original estimated available timestamp; the absorption of infeasible batches is processed by specification downgrade routing, and the estimated arrival time in the alternative routing instruction is taken or a new material replenishment demand gap is formed; the estimated actual arrival time of each batch is written into the timing coverage record of the corresponding production line, replacing the timing coverage status before the modification, and the timing coverage status update is completed; The updated estimated actual arrival time of materials for each production line is compared with the material arrival deadline of each production line: if all production lines are no later than their respective deadlines, a collaborative delivery constraint satisfaction confirmation record is output; if any production line is later than its deadline, a new time-series gap record is formed based on the gap batch corresponding to the batch that exceeds the deadline, triggering the new material replenishment process.

[0015] Compared with the prior art, the beneficial effects of the present invention are as follows: 1. This invention constructs a cross-line time-series demand map, unifying the dispersed material demands of multiple production lines onto a single time axis. Using the material arrival deadline as the core constraint, it achieves global time-series correlation modeling on the demand side. Compared to existing scheduling methods based on single production lines or static demands, this invention significantly improves the completeness and foresight of demand perception, explicitly expressing potential collaborative relationships between different production lines, thus providing a reliable basis for cross-line reuse of surplus materials. Simultaneously, by reverse-engineering a unified delivery time to form a time-series constraint chain, it effectively avoids the overall delivery imbalance caused by local optima, improving the consistency and stability of multi-production-line collaborative delivery.

[0016] 2. This invention proposes a two-tiered optimization mechanism based on "time-sequence alignment of surplus materials + accessibility of specification downgrades" to achieve efficient utilization of surplus material resources. First, by matching the length of surplus materials with the target demand range and comparing the expected available timestamp with the deadline, precise matching of surplus materials in both time and space dimensions is achieved. Second, by pre-building a specification downgrade relationship table, the path and cost of converting surplus materials to various target specifications are systematically described, enabling non-directional surplus materials to be flexibly converted and used in various shortage scenarios. This invention improves the utilization rate of surplus materials, reduces the consumption of new materials, and simultaneously reduces inventory pressure and production costs.

[0017] 3. This invention achieves dynamic feasibility verification and closed-loop optimization of scheduling decisions by introducing a comprehensive time constraint and process state-driven absorption mechanism. During the replacement of surplus materials, logistics time, processing time, and process connections are comprehensively considered to ensure the time feasibility of the replacement scheme. Simultaneously, truncated absorption and parameter absorption strategies are designed for different process states, allowing work-in-process to be flexibly adjusted and utilized without interrupting the production process. Furthermore, through time-series coverage state updates and collaborative delivery constraint verification, a continuously iterative scheduling closed loop is formed. This invention improves the executability and robustness of the scheduling scheme. Attached Figure Description

[0018] Figure 1 A schematic diagram of the process of the intelligent material scheduling method based on strategy optimization provided by the present invention; Figure 2 This is a schematic diagram of the dynamic timing alignment logic flow for residual materials provided by the present invention; Figure 3 A schematic diagram of the process state-driven dynamic absorption logic provided by the present invention. Detailed Implementation

[0019] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are for illustrative purposes only and are not intended to limit the invention.

[0020] Example 1: This embodiment describes the technical solution in the context of conveyor component manufacturing. In conveyor component production, multiple production lines, such as idler roller lines, drum lines, and frame lines, share the same specification of steel pipe raw materials. Each production line has a different processing rhythm, and the same customer order requires all production lines to work collaboratively. This invention constructs an intelligent scheduling closed loop throughout the entire material flow by utilizing raw material cutting waste in a timely manner, verifying the specification downgrading of non-directional waste, and absorbing and judging process parameters to mitigate modification disturbances. This achieves the technical goal of maximizing the work-in-process utilization rate of waste materials and minimizing the triggering amount of new material replenishment under the constraint of multi-line collaborative delivery.

[0021] Please see Figure 1 This invention provides a method for intelligent scheduling of materials throughout the entire process based on strategy optimization. The technical solution is as follows: First, the demand times for raw materials of the same specification from each production line are aggregated to form a cross-line time-series demand map. Second, based on the cross-line time-series demand map, feasible cutting schemes are screened for surplus material time-series alignment, and directional surplus material records containing surplus material specifications, available timestamps, and target production line numbers are output. Third, the available timestamps of the directional surplus material records are compared one by one with the material arrival deadlines of each production line to identify time-series gaps, and time-series gap records are output based on the gap amount. Fourth, for time-series gap records, non-directional surplus materials with larger specifications are retrieved, and the accessibility of downgraded specifications is confirmed through a specification downgrade relationship table. The comprehensive working time constraint is used to verify whether the deadline is met. If it is met, an alternative routing instruction is output; otherwise, it is confirmed as a new material replenishment requirement. Fifth, after receiving modification instructions, the feasibility of truncation absorption and / or parameter absorption is judged according to the process status of each batch. Infeasible batches are absorbed into the specification downgrade route. Sixth, the time-series coverage status is updated and collaborative delivery constraints are verified.

[0022] Furthermore, the formation of the cross-line time-series demand map includes: Retrieve work orders from the work order database that are in the pending material feeding state for each production line within the current production cycle, and extract the raw material cross-sectional specifications, required length specifications, production line number, and required batch size for each work order; Based on the unified delivery time of the same customer order, subtract the total working hours of all processes required for each production line from material arrival to process completion, and then reverse the calculation of the material arrival deadline for each production line. Using the material arrival deadline as the time node, the production line number, raw material specifications, required batch size and material arrival deadline are organized and arranged according to the time axis to form a cross-line time sequence demand map; In the cross-line time sequence demand map, the material arrival deadline of each supporting production line under the same customer order is derived by reverse deduction through the unified delivery time, forming the time sequence correlation constraint between each production line; The cross-line time-series demand map includes the following data: production line number, raw material cross-sectional specifications, required length specifications, required batch size, material arrival deadline, and time-series correlation constraints between production lines.

[0023] Specifically, at the start of each production cycle, the system retrieves all work orders in the "awaiting material input" status from the work order database. The "awaiting material input" status indicates that the work order has been assigned to the production line's process queue by the production scheduling system, but the corresponding materials have not yet been prepared and released from the warehouse. This status is automatically set by the production line's manufacturing execution system when the work order is assigned. For each retrieved work order, the system extracts four data items: raw material cross-sectional specifications (expressed as a pair of material and outer diameter × wall thickness parameters), required length specifications (expressed as discrete standard specification values), the production line number, and the required batch size. These four data items constitute the basic recording unit for the cross-line time-series demand map.

[0024] Based on the unified delivery time of the same customer order, backward calculations are performed for each supporting production line under the order: starting from the unified delivery time, the total processing time required for all processes from material arrival to completion of the process for that production line is subtracted sequentially. The resulting time is the material arrival deadline for that production line. The total processing time for all processes is taken from the standard processing time record of the corresponding product specification in the process specification parameter table. This record is periodically revised based on the average actual processing time of historical work orders of the same specification. The revision cycle is determined by the production process management department and recorded in the header of the time file. The meaning of the material arrival deadline is: if the material arrives after this time, the production line cannot complete processing before the unified delivery time, and the collaborative delivery constraint becomes invalid.

[0025] Using the timeline as the horizontal dimension, the material arrival deadlines for each production line are marked as time nodes. Each time node includes four data items: production line number, raw material cross-sectional specifications, required length specifications, and required batch size. These are arranged in chronological order to form a cross-line time-series demand map. The time nodes for each supporting production line under the same customer order are derived backward from the unified delivery time, thus establishing the time-series constraints between production lines—that is, the relative order relationship between the time nodes of each production line, reflecting the differences in the urgency of material arrival for each production line.

[0026] The cross-line timing demand map includes the following data fields: production line number, raw material cross-sectional specifications, required length specifications, required batch size, material arrival deadline, and timing constraint identifiers between production lines (i.e., the association markers for each supporting production line under the same order number). The map adds corresponding records in real time when each new work order enters the "awaiting material feeding" state, and automatically removes the corresponding records after the work order materials arrive, maintaining consistency between the map and the actual waiting-to-feed status.

[0027] Furthermore, based on the cross-line time-series demand map, feasible cutting schemes are screened for surplus material time-series alignment and directional surplus material records are output, referring to... Figure 2 ,include: For each cutting batch, enumerate all feasible cutting schemes that meet the requirements of the main production line work order, and calculate the cross-sectional specifications and length of the residual material generated by each scheme. Search the cross-line time sequence demand map using the scrap material cross-section specifications and scrap material length as query conditions, and identify the target production line and corresponding time node whose scrap material length falls into the demand length range of other production lines. For each matching target production line, the estimated available timestamp of the remaining material is calculated based on the real-time execution progress record of the work order, and it is verified whether the timestamp is earlier than the material arrival deadline of the target production line; the real-time execution progress record of the work order is refreshed when each batch of cutting process starts, and the estimated completion time is dynamically corrected based on the actual start time and the remaining cutting quantity, and the corrected estimated completion time is the estimated available timestamp of the remaining material. Calculate the difference between the remaining material length and the target production line required length to determine the cutting amount; From all the schemes that meet the timing alignment conditions, select the scheme with the smallest truncation amount as the execution scheme and output the directional surplus material record; The data included in the directional surplus material record are: surplus material identifier, surplus material cross-sectional specifications, surplus material actual length, estimated available timestamp, target production line number, target production line material arrival deadline, whether secondary shortening is required, and shortening amount. If no solution meets the timing alignment conditions, the surplus material is stored as non-directional surplus material, and no directional surplus material record is output.

[0028] Specifically, before initiating the material cutting process on the main production line, all feasible cutting schemes that meet the requirements of the main production line's work orders are enumerated for the raw material to be cut. The enumeration of feasible cutting schemes prioritizes meeting the required length specifications of the current work order on the main production line, using the standard length of the raw material as the boundary. The dimensions and length of the surplus material generated by each scheme are calculated. The dimensions of the surplus material's cross-section are the same as the raw material's cross-section (because shortening does not change the cross-sectional parameters). The surplus material's length is the standard length of the raw material minus the length required by the main production line and the cutting loss. The cutting loss is taken from the average single-cutting loss of the corresponding cutting equipment in the equipment's time record.

[0029] The system retrieves cross-line time-series demand maps using the scrap material cross-section specifications and scrap material length as query criteria, identifying target production lines whose scrap material length falls within the demand length range of other production lines, and their corresponding time nodes. "Falling within the demand length range" means that the scrap material length is not less than the target production line's demand length specification; that is, the scrap material can be shortened to meet that specification. For each matched target production line, the system verifies whether the estimated available timestamp of the scrap material is earlier than the target production line's material arrival deadline.

[0030] The estimated available timestamp for remaining material is based on the estimated completion time of the cutting batch. The system calculates this timestamp based on the real-time execution progress record of the work order: after each batch of cutting operations actually starts, the system reads the actual start time of the operation and the current amount of cutting completed from the production line manufacturing execution system, and dynamically calculates the estimated completion time based on the actual start time and the remaining cutting amount. Each time the production line execution progress is updated (the progress update is triggered by the production line manufacturing execution system after each cut is completed), the system corrects the estimated available timestamp with the latest actual progress data. The corrected timestamp overwrites the previous calculation result, ensuring that the time base on which the timing alignment judgment depends is consistent with the actual production status.

[0031] The difference between the remaining material length and the target production line's required length is calculated as the truncation amount: a truncation amount of zero indicates that the remaining material can directly meet the target production line's requirements without secondary truncation; a truncation amount greater than zero indicates that the remaining material requires secondary truncation to meet the requirements. The truncation operation is incorporated into the target production line's material receiving pre-processing step and is completed by the target production line before receiving the material. The truncation amount and corresponding time are recorded together in the directional remaining material record for subsequent comprehensive time constraint verification. From all solutions that meet the timing alignment conditions, the solution with the smallest truncation amount is selected as the execution solution to reduce material loss.

[0032] After the execution plan is confirmed, a directional surplus material record is output, containing the following data fields: surplus material identifier, surplus material cross-sectional specifications, actual surplus material length, estimated available timestamp (dynamically corrected value), target production line number, target production line material arrival deadline, whether secondary truncation is required, and truncation amount. The directional surplus material record is written to the material resource pool, and simultaneously triggers the "pre-allocation" status mark of the corresponding target production line record in the cross-line timing demand map to prevent the same demand from being repeatedly allocated. If no feasible cutting plan meets the timing alignment conditions, the surplus material is stored in the non-directional surplus material pool in a conventional manner, and no directional surplus material record is output.

[0033] Furthermore, the available timestamps of the directional surplus material records are compared one by one with the material arrival deadlines of each production line to identify timing gaps. Timing gap records are then output based on the gap amount, including: Group all targeted surplus material records by target production line number, and match all demand batches of each production line with the coverable batches in the allocated targeted surplus material records one by one. Compare the estimated available timestamp of each targeted surplus material record with the material arrival deadline of the target production line: those with estimated available timestamps earlier than the deadline are marked as surplus material time-series coverage and removed from the list of requirements to be covered; those with estimated available timestamps later than the deadline or no corresponding requirement item for a targeted surplus material record are marked as time-series gaps. The gap is calculated by subtracting the batch size already covered by the directional surplus material from the total demand batch size of the production line, and a time-series gap record is formed. The timing gap record contains the following data: production line number, material cross-sectional specifications, required length specifications, gap batch, and material arrival deadline, which serve as input data for specification downgrade routing retrieval.

[0034] Specifically, all targeted surplus material records in the material resource pool are grouped by target production line number. For each production line, all required batches are read from the cross-line timing demand map and matched one by one with the coverable batches in all targeted surplus material records under that production line group. "Coverable batch" refers to the number of surplus material entries in the targeted surplus material record where the actual length of the surplus material is not less than the length specification required by the target production line.

[0035] For each corresponding item, the estimated available timestamp (dynamically adjusted value) of the targeted surplus material record is compared with the material arrival deadline of the target production line. If the estimated available timestamp is earlier than the deadline, the demand item is marked as "surplus material timeline coverage" and removed from the list of demands to be covered. This demand item does not require new material replenishment. If the estimated available timestamp is not earlier than the deadline, or if there are no entries in all targeted surplus material records pointing to this batch of demand for the production line, the demand item is marked as "timeline gap".

[0036] The gap is calculated by subtracting the number of batches that can be covered by directional surplus material of the same specification and whose timing is met from the total demand batches of the production line. The gap means that, under the current material resource pool status, the number of batches of materials that cannot be delivered before the deadline by directional surplus material is the quantity that needs to be filled through other means (specification downgrade routing or new material supplementation).

[0037] The timing gap record contains the following data fields: production line number, material cross-sectional specification, required length specification, gap batch, and material arrival deadline. The timing gap record serves as input data for specification degradation routing retrieval. If all required batches for a production line are covered by the directional surplus material timing record, then no timing gap record will be generated for that production line.

[0038] Furthermore, the accessibility of the downgraded specification is confirmed through the specification downgrade relationship table, including: An offline pre-built specification downgrade relationship table is used as the query key for each material specification. It records all smaller specifications that can be reached by truncation and the truncation amount for each path. The specification downgrade relationship table is updated synchronously with changes to the material specification system, and the update timestamp is recorded in the table header. For each time-series gap record, non-directional surplus material with the same cross-sectional specification and a length specification greater than the gap requirement is retrieved from the non-directional surplus material pool based on its cross-sectional specification. Using the current length specification of each screened surplus material as the query key, extract the list of achievable downgrade specifications from the specification downgrade relationship table, and match each specification in the list of achievable downgrade specifications with the required length specifications in the time gap record one by one. The successful matcher confirms the availability of the downgraded specification corresponding to the gap and extracts the corresponding cut-off amount. The output data after confirming the accessibility of the downgraded specification is: surplus material identifier, current length specification of surplus material, available gap length specification, and truncation amount, which serve as inputs for comprehensive time constraint verification.

[0039] Specifically, based on the material specification system of the conveyor industry (such as a discrete set of standard specifications for steel pipe length), an offline pre-built specification degradation relationship table is established. The specification degradation relationship table uses each material specification (a combination of cross-sectional and length specifications) as the query key, recording all smaller specifications reachable through truncation operations and the truncation amount corresponding to each degradation path. The truncation amount is calculated by subtracting the smaller specification length from the larger specification length and adding the cutting loss, which is taken from the average single-cutting loss of the corresponding cutting equipment in the equipment time record. The validity condition of the specification degradation relationship table is that the cross-sectional specifications are the same—specifications with different cross-sectional specifications do not have a degradation relationship and are not recorded in the table. The specification degradation relationship table is updated synchronously with changes in the material specification system, and the update timestamp is recorded in the table header. Before each degradation reachability query, the system verifies the update timestamp of the specification degradation relationship table. If the timestamp is later than the effective timestamp of the current process version of the system, the latest table data is used for the query.

[0040] The truncation amount in the specification downgrade relationship table is a deterministic calculation result, and there is no floating threshold that needs to be manually set. The average cutting loss is calculated from the actual cutting loss records of historical work orders: the system extracts the actual material loss data of the same cutting equipment when performing similar truncation operations in the past from the work order completion records, and uses the arithmetic mean of the loss amounts of each instance as the current average loss. The average is automatically triggered to update after a certain number of batches of historical data have been accumulated. The update batch threshold is set by the management rules of the equipment time file.

[0041] For each time-series gap record, using the cross-sectional specifications in the time-series gap record as the filtering condition, non-oriented surplus materials with the same cross-sectional specifications and a length specification greater than the gap requirement length are retrieved from the non-oriented surplus material pool. The non-oriented surplus material pool is a collection of surplus materials that are stored because they do not meet the time-series alignment conditions.

[0042] Using the current length specification of each selected surplus material as the query key, extract the list of achievable degradation specifications from the specification degradation relationship table. Match each specification in the list of achievable degradation specifications with the required length specifications in the time-series gap record one by one: for those that match successfully, confirm that the degradation specification of the surplus material for the gap is reachable, and extract the truncation amount of the degradation path as input for comprehensive time constraint verification; for those that do not match, record that the degradation path of the surplus material for the gap is unreachable, do not enter subsequent verification, and do not occupy subsequent calculation resources.

[0043] The output data fields are: surplus material identifier, current length specification of surplus material, achievable gap requirement length specification, and truncation amount, which serve as inputs for the comprehensive time constraint verification process.

[0044] Furthermore, the comprehensive time constraint is used to verify whether the deadline is met, including: For each remaining material and gap whose accessibility to the downgraded specifications has been confirmed, three time items are accumulated sequentially: the logistics time from the current storage location of the remaining material to the location where the trimming operation is performed (taken from the path time records between nodes in the logistics scheduling system), the trimming operation time (the trimming operation time consists of the sum of fixed preparation time and cutting time calculated based on the trimming amount; the fixed preparation time and the cutting time per unit trimming amount are taken from the historical averages in the equipment time archives), and the logistics time from the completion of trimming to the material receiving location of the target production line (path time records in the logistics scheduling system). Add the estimated available timestamp of the surplus material to the sum of the three timestamps to obtain the estimated time when the surplus material will actually arrive at the target production line; Compare the expected arrival time with the material arrival deadline in the time gap record: for those whose expected arrival time is not later than the deadline, output an alternative routing instruction and update the allocation status of the corresponding remaining material in the material resource pool to directed routing; for those whose expected arrival time is later than the deadline, confirm them as new material replenishment needs; The alternative routing instruction includes the following data: surplus material identifier, cut-off amount, cut-off operation execution time period, logistics path sequence, and target production line number; The data included in the new material replenishment requirement are: production line number, material specifications, shortage batch size, and material arrival deadline.

[0045] Specifically, for each remaining material and gap for which the availability of downgraded specifications has been confirmed, the following three time periods should be accumulated sequentially: The first item, logistics time (from surplus material to the cutting operation execution location): is taken from the node path time records maintained by the logistics scheduling system. The node path time records use each material node in the workshop (surplus material storage location, cutting equipment location, production line receiving location, etc.) as nodes, and the average historical actual transportation time of the transportation unit between nodes as the edge weight. A historical record is automatically added after each batch of material transportation is completed, and the average value of the node path time records is updated continuously. The "cutting operation execution location" is the location of the shared cutting equipment within the workshop that undertakes the cutting task; this location is fixed in the equipment ledger.

[0046] The second item, truncation operation time: Truncation operation time consists of two parts: fixed preparation time and cutting time calculated based on the truncation amount. Fixed preparation time refers to the time required for preparatory operations such as clamping and positioning, and equipment parameter input, which are unrelated to the truncation amount, in each truncation operation. It is taken from the historical average fixed preparation time of the corresponding cutting equipment in the equipment time file. Cutting time calculated based on the truncation amount refers to the time during the cutting execution phase. It is calculated by multiplying the historical average cutting time per unit truncation amount for this type of cutting equipment in the equipment time file by the current truncation amount. The methods for obtaining the average fixed preparation time and the average cutting time per unit truncation amount are the same as those for obtaining the average cutting loss, both derived from the actual time records of historical work orders.

[0047] The third item, logistics time (shortened operation execution location to target production line material receiving location): is taken from the path time records between nodes in the logistics scheduling system, and the value is obtained in the same way as the first item.

[0048] Add the estimated available timestamp of the surplus material (dynamically corrected) to the sum of the three timestamps to obtain the estimated time when the surplus material will actually arrive at the target production line.

[0049] The estimated arrival time is compared with the material arrival deadline in the time gap record: if the estimated arrival time is not later than the deadline, it is determined that the deadline is met, an alternative route instruction is output, and the allocation status of the corresponding surplus material in the material resource pool is updated to "directed route" to prevent the same surplus material from being allocated repeatedly; if the estimated arrival time is later than the deadline, it is determined that the deadline is not met, the alternative path of the surplus material to the gap is marked as infeasible, and the corresponding gap is finally confirmed as a new material replenishment requirement.

[0050] The alternative routing instruction includes the following data fields: surplus material identifier, truncation amount, truncation operation execution period (the start time is the estimated available timestamp of the surplus material, and the end time is the sum of the start time, the first logistics time, and the truncation operation time), logistics path sequence (a description of the order of surplus material storage location → truncation equipment location → target production line receiving location), and target production line number.

[0051] The data fields included in the new material replenishment requirement are: production line number, material specification parameters (cross-sectional specifications, required length specifications), gap batch, and material arrival deadline.

[0052] When multiple feasible alternative paths exist for the same surplus material, all satisfying the comprehensive time constraints (i.e., the surplus material, after truncation, can simultaneously meet the time-series gap requirements of multiple production lines), the system prioritizes allocation based on the material arrival deadline of each target production line (i.e., the deadline is shortest from the current time), outputting alternative route instructions to the production line with the most urgent time sequence. After allocation, the system updates the time-series gap list, marking gaps filled by feasible alternative paths as surplus material route coverage, and ultimately confirming unfilled gaps as new material replenishment requirements to minimize the new material procurement trigger.

[0053] Furthermore, the feasibility of truncated absorption and / or parameter absorption is determined based on the process status of each batch, referring to... Figure 3 ,include: For batches whose process status is marked as cut but not yet entered into subsequent processes, extract the minimum feeding length required for the target specification to enter the subsequent process from the process specification parameter table. The minimum feeding length is the sum of the finished length of the target specification and the processing allowance of the subsequent process. If the cut length of the current batch is greater than the minimum feeding length, then cutting and absorption is feasible. The cutting amount is the difference between the cut length and the minimum feeding length, and the cutting operation time is included in the estimated actual arrival time of the batch of materials. If the cut length is not greater than the minimum feeding length, then cutting and absorption is not feasible. For batches whose process status is marked as having completed intermediate processes but not yet entered the final curing process, the maximum allowable parameter adjustment amount for that intermediate process is extracted from the process specification parameter adjustment tolerance table. The process specification parameter adjustment tolerance table is updated synchronously when the process is changed, and the update timestamp is recorded. The difference between the actual effective processing length of the current batch and the modified target length is calculated as the length deviation. If the length deviation does not exceed the maximum parameter adjustment amount, parameter absorption is feasible, and subsequent processes continue after updating the processing parameters, with the expected actual arrival time of the material remaining unchanged. If the length deviation exceeds the maximum parameter adjustment amount, parameter absorption is not feasible. Those batches for which both truncation and parameter absorption are infeasible are designated as infeasible batches, and their current actual specification parameters are used as the starting specification input for the specification degradation routing process. The data involved in the judgment process are: batch identifier, process status identifier, cut length or actual effective processing length, target specification finished product length, processing allowance for subsequent processes, maximum parameter adjustment amount for intermediate processes, shortening amount, shortening operation time, and estimated actual arrival time.

[0054] Specifically, upon receiving a modification instruction (which includes the original specifications, the modified specifications, and the affected work order identifier), the system queries the manufacturing execution system (MES) for the process completion status identifiers of each affected batch of materials. The MES automatically sets the process completion status identifiers upon completion of each process, with values ​​including: "cut and not yet in subsequent processes," "intermediate processes completed and not yet in the final curing process," and "into the final curing process." The setting condition for each status identifier is triggered by the completion confirmation signal of the corresponding process.

[0055] For batches with a process status marked as "cut but not yet proceeding to subsequent processes," the minimum material feed length required for the target specification to proceed to the subsequent process is extracted from the process specification parameter table. The minimum material feed length refers to the shortest initial length of material required to ensure the product meets the target specification dimensions after the process (such as chamfering) is completed. The minimum material feed length is calculated as the sum of the target specification finished product length and the processing allowance for the subsequent process. The processing allowance for the subsequent process is taken from the standard processing allowance record for the corresponding process in the process specification parameter table. This record is determined and maintained by the process management department during the process design phase and is updated synchronously with process version changes.

[0056] If the current batch's cut length is greater than the minimum feeding length, then truncation absorption is feasible, and the truncation amount is the difference between the cut length and the minimum feeding length. If the current batch's cut length is not greater than the minimum feeding length, then truncation absorption is not feasible. When truncation absorption is feasible, the truncation operation time is determined according to the calculation method for truncation operation time (the sum of fixed preparation time and cutting time converted according to the truncation amount), and is included in the estimated actual arrival time of the batch of materials. The estimated actual arrival time is the current moment plus the truncation operation time.

[0057] For batches with a process status marked as "intermediate process completed but not yet in final curing process," the maximum allowable parameter adjustment for that intermediate process is extracted from the process specification parameter adjustment tolerance table. The maximum parameter adjustment amount means the upper limit of length deviation that can be accommodated by adjusting the processing parameters of subsequent processes without compromising the quality of the material in the completed process. The maximum parameter adjustment amount is taken from the process specification parameter adjustment tolerance table, which is determined by the process management department during the process design phase based on process processing accuracy requirements and material characteristics, and is updated synchronously when the process changes. The update timestamp is recorded in the table header. The system verifies the update timestamp of the tolerance table before each parameter absorption feasibility assessment to ensure that the assessment basis is consistent with the current process version.

[0058] Calculate the difference between the actual effective processing length of the current batch and the target length of the modification, i.e., the length deviation: if the length deviation does not exceed the maximum parameter adjustment amount, then parameter absorption is feasible, and the processing parameters of this batch are directly updated before continuing the subsequent processes, and the expected actual arrival time of the material remains unchanged; if the length deviation exceeds the maximum parameter adjustment amount, then parameter absorption is not feasible.

[0059] Those batches where both truncation absorption and parameter absorption are infeasible are identified as batches where absorption is infeasible, and their current actual specification parameters (cross-sectional specifications and existing effective length) are used as the starting specification input for the specification degradation routing process.

[0060] The data fields involved in this embodiment are: batch identifier, process status identifier, cut length or actual effective processing length, target specification finished product length, processing allowance for subsequent processes, maximum parameter adjustment amount for intermediate processes, truncation amount, truncation operation time, and estimated actual arrival time.

[0061] Furthermore, update the timing coverage state and verify the collaborative delivery constraints, including: Summarize the handling results of each batch after the modification instruction: The estimated actual arrival time of the shortened absorption batch is the sum of the original estimated available timestamp and the shortened operation time; the estimated actual arrival time of the parameter absorption batch remains unchanged from the original estimated available timestamp; the absorption of infeasible batches is processed by specification downgrade routing and the estimated arrival time in the alternative routing instruction is taken or a new material replenishment demand gap is formed. Write the estimated actual arrival time of each batch into the timing coverage record of the corresponding production line, replace the timing coverage status before the modification, and complete the timing coverage status update. The updated estimated actual arrival time of materials for each production line is compared with the material arrival deadline of each production line: if all production lines are no later than their respective deadlines, a collaborative delivery constraint satisfaction confirmation record is output; if any production line is later than the deadline, a new time-series gap record is formed based on the gap batch corresponding to the batch that exceeds the deadline, triggering the new material replenishment process. The data involved in the update and verification process includes: batch disposal type identifier, estimated actual arrival time, production line material arrival deadline, time sequence coverage status identifier, collaborative delivery constraint satisfaction identifier, and new time sequence gap records. Specifically, after the modification instruction is processed, the final disposal results of each batch of materials and the corresponding estimated actual arrival time are summarized: the estimated actual arrival time of the truncated absorption batch is the sum of the original estimated available timestamp (derived from the dynamic correction value) and the truncated operation time; the estimated actual arrival time of the parameter absorption batch remains unchanged from the original estimated available timestamp; for the batches in the infeasible absorption batches, the batches that have been downgraded in specification and output alternative routing instructions have their estimated actual arrival time taken from the estimated arrival time recorded in the alternative routing instructions; the gap batch record corresponding to the batches that are still not covered is the quantity base of the new material replenishment requirement.

[0062] Write the estimated actual arrival time of each batch into the timing coverage record of the corresponding production line, replacing the timing coverage status before the modification, and complete the timing coverage status update. The timing coverage record is indexed by the production line number and records the estimated arrival status and corresponding time of the current materials on each production line.

[0063] Based on the updated estimated actual arrival time of materials for each production line, each material arrival time is compared with its corresponding deadline (derived from the cross-line timing demand map). The collaborative delivery constraint refers to the overall constraint that the material arrival time of all supporting production lines under the same customer order is no later than their respective material arrival deadlines. If the estimated actual arrival time of materials for all production lines is no later than their respective deadlines, a collaborative delivery constraint satisfaction confirmation record is output, and the scheduling loop is completed. If the estimated actual arrival time of materials for any production line is later than its material arrival deadline, a new timing gap record is formed based on the uncovered gap batch corresponding to the batch exceeding the deadline, and the process returns to perform specification downgrade routing retrieval. If specification downgrade routing also has no feasible alternative path, a new material replenishment process is triggered until the collaborative delivery constraints of all production lines are satisfied.

[0064] The data fields involved in this embodiment are: batch disposal type identifier (four types: truncation absorption, parameter absorption, downgraded routing, and new material replenishment), estimated actual arrival time, production line material arrival deadline, time sequence coverage status identifier, collaborative delivery constraint satisfaction identifier, and newly added time sequence gap record.

[0065] Example 2: Based on Example 1 (which has completed the timing alignment screening of surplus materials, the identification of timing gaps, and the comprehensive time verification of the correspondence between each surplus material and the gap, and has completed the feasibility judgment of the absorption of the modified batch), this example continues the above results. For situations where there are multiple surplus materials competing for the same gap or the same surplus material can satisfy the gaps of multiple production lines, multi-factor comprehensive scoring and conflict resolution are performed. When the collaborative delivery constraint fails locally, graded early warning and priority remedy are performed.

[0066] When multiple batches of surplus materials can satisfy the same time-series gap through comprehensive time constraint verification, or when the same surplus material can satisfy the time-series gaps of multiple production lines, a multi-factor comprehensive score is performed on the correspondence between each surplus material and the gap, including: The timing margin is obtained by subtracting the estimated time when the remaining material actually arrives at the target production line from the material arrival deadline recorded in the timing gap record. The larger the timing margin, the more lenient the corresponding relationship is in terms of timing, and the higher the factor score. The amount of material cut off at the notch in the specification downgrade relationship table is used as the loss factor. The smaller the amount of material cut off, the less material loss, and the higher the score of this factor. The path complexity factor is the number of nodes along the route from the location of surplus material storage to the material receiving location of the target production line, as recorded in the path time record of the logistics scheduling system. The fewer the nodes, the lower the difficulty of scheduling and coordination, and the higher the score of this factor. The three factor scores mentioned above are weighted according to the statistical proportion of each factor's influence on the delivery result in the historical scheduling records of the material resource pool. The weighted sum is then used to obtain the comprehensive score of the relationship between the surplus material and the shortage. The weight of each factor is updated by the system at the end of each production cycle, using the actual execution results of all replacement routing instructions in this cycle (the deviation distribution between the arrival time and the deadline) as a sample to statistically update the correlation between each factor and the delivery achievement rate. The updated weights are written into the material resource pool scheduling parameter table for use in the next production cycle scheduling. Based on the comprehensive score, all remaining materials and gap correspondences are sorted from high to low and allocated sequentially: for the correspondence with the highest comprehensive score, an alternative route instruction is output, and the allocation status of the remaining material is updated to directed route; after the remaining material has been allocated, the remaining correspondences related to that remaining material are removed from the score queue, and the corresponding gap returns to the pending allocation status; for gaps that are no longer involved after allocation, the next highest comprehensive score correspondence is searched among the remaining unallocated remaining materials, and the above process is repeated until all remaining materials are allocated or all gaps are covered; The data involved in the multi-factor comprehensive scoring process are: surplus material identifier, time-series surplus, truncation amount, number of path nodes, weight of each factor, comprehensive score value, scheduling parameter table update timestamp, and alternative routing instructions.

[0067] Specifically, after the comprehensive working time constraint verification is completed, there are several candidate sets of correspondences between surplus materials and gaps that have passed the verification in the material resource pool. When there is a many-to-many mapping in the candidate set (multiple batches of surplus material candidates for the same gap, or multiple gaps for the same surplus material candidate), the system calculates a comprehensive score for each candidate correspondence.

[0068] Timing margin factor: This is calculated by subtracting the estimated actual arrival time of the remaining material at the target production line from the material arrival deadline recorded in the timing gap record. The timing margin reflects the leeway in material arrival time; the larger the margin, the more buffer space there is to cope with subsequent disturbances, and the higher the individual score of this factor.

[0069] Material loss factor: The loss is quantified by the amount of material cut off required to reach the required specification in the specification degradation relationship table. The smaller the cut-off amount, the higher the raw material utilization rate, and the higher the individual score of this factor.

[0070] Path complexity factor: This is a quantified value based on the total number of path nodes traversed from the location of surplus material storage to the target production line receiving location, as recorded in the path time logs between nodes in the logistics scheduling system. Fewer nodes mean fewer scheduling instructions required for logistics coordination, higher execution stability, and a higher score for this factor.

[0071] The method for obtaining factor weights: Initial weights for the three factors are determined by the process management department based on the priority of the three indicators—timeliness, material utilization, and logistics stability—during the initial system deployment. These initial ratios are then written into the material resource pool scheduling parameter table. Subsequently, at the end of each production cycle, the system extracts the deviation between the actual arrival time and the deadline from the completion records of all executed alternative routing instructions for that cycle. The correlation strength between the individual scores of the three factors and the delivery achievement results is calculated, and the weights of the three factors are updated according to the ratio of these correlation strengths. The updated results are written back to the scheduling parameter table, and an update timestamp is recorded. The minimum sample batch threshold required for weight updates is taken from the preset "Weight Update Trigger Batch Count" field in the scheduling parameter table. This field is determined by the process management department during system deployment based on the production cycle time (i.e., the historical average of the daily number of alternative routing instructions), ensuring that the sample size for each weight update is no less than the lower limit of the number of batches required to generate statistical stability. When the actual number of alternative routing instructions executed in the current cycle does not reach this trigger threshold, the weights remain unchanged from the previous cycle. After weighted summation, the system sorts all candidate correspondences from high to low according to the comprehensive score and outputs the sorted queue.

[0072] After the comprehensive scoring and ranking allocation is completed, the scoring and ranking results corresponding to all surplus materials and gaps are verified for conflict resolution, including: Identifying conflict correspondences: In the scoring and ranking results, if the same scrap material appears in multiple candidate correspondences of gaps in the ranking queue, it constitutes a scrap material competition conflict; if the same gap has multiple candidate correspondences of scrap material in the ranking queue, it constitutes a gap competition conflict. For conflicts in the competition of surplus materials, the corresponding relationship with the highest comprehensive score of the surplus material is retained as the final allocation result, and the other corresponding relationships are removed from the queue. The gaps corresponding to the removed corresponding relationships are re-entered into the waiting allocation state, and new candidate corresponding relationships are retrieved from the remaining unallocated surplus materials. For gap competition conflicts, the correspondence with the highest comprehensive score of the gap is retained as the final allocation result, and the remaining correspondences are removed from the queue. The remaining materials corresponding to the removed correspondences are remarked as allocable and participate in the candidate search of other gaps. The conflict resolution process is executed iteratively until there are no more conflicts of competition for surplus materials or for gaps in the queue of all surplus material and gap correspondence. After the iteration ends, the final set of alternative routing instructions and the remaining uncovered time-series gap records are output. The uncovered time-series gap records are confirmed as new material replenishment requirements. The data involved in the conflict resolution verification includes: conflict type identifier, set of surplus material identifiers involved in the conflict, set of gap production line numbers involved in the conflict, scoring queue status of each iteration, set of final alternative routing instructions, and time-series gap records confirmed as new material replenishment needs.

[0073] Specifically, the comprehensive score ranking queue is scanned line by line to identify two types of conflicts: Conflict in competition for surplus material: If the same surplus material identifier appears in two or more candidate correspondences, it indicates that the surplus material is being competed for by multiple gaps simultaneously. The system retains the correspondence with the highest comprehensive score for the surplus material, removes the remaining correspondences from the queue, and re-marks the gaps pointed to by the removed correspondences as pending coverage, entering the next round of candidate retrieval.

[0074] Gap Competition Conflict: When the same gap (identified by the production line number and required length specification) appears in two or more candidate correspondences, it indicates that multiple batches of surplus materials are simultaneously vying to cover the gap. The system retains the correspondence with the highest comprehensive score, removes the other correspondences, and the surplus materials in the removed correspondences are remarked as available for allocation.

[0075] The two types of conflict identification and resolution are executed iteratively, with the queue status updated after each iteration until no more conflicts remain in the queue. During the iteration process, the material resource pool updates the status identifier (allocated, allocable, covered, to be covered) of each remaining material and each gap in real time to ensure that the candidate retrieval in subsequent rounds is based on the latest status.

[0076] After the iteration ends, the final alternative routing instruction set is output for all confirmed correspondences, and the gaps that are still in the uncovered state are confirmed as new material replenishment needs, triggering the procurement or allocation process.

[0077] If, after verification of collaborative delivery constraints, any production line material still fails to arrive before the deadline, and the new material replenishment process has been triggered but all time gaps cannot be eliminated, tiered warnings and priority remediation will be implemented for the remaining unmet production lines, including: The downstream dependency of each production line in the supporting order is read from the process route dependency table. The downstream dependency is defined as the number of other supporting production lines that require the output material of this production line as a necessary assembly input. The process route dependency table is maintained by the process management department in sync with the process specifications when the order is placed, and records the correspondence between each production line and the downstream assembly process. All remaining unmet production lines are sorted from highest to lowest downstream dependency. For those with the same downstream dependency, they are sorted from nearest to furthest material arrival deadline to form a priority queue for remediation. According to the priority queue for remediation, the currently available new material replenishment resources are preferentially allocated to the production lines at the front of the queue. After each allocation is completed, the remaining amount of available resources is updated, and the timing coverage status of the production line is re-verified. For remaining production lines that still cannot meet the deadline after priority remediation, a graded early warning record is generated. The graded early warning record is divided into two levels according to the downstream dependency: a first-level early warning record is generated for downstream dependencies not lower than the preset dependency threshold, and a second-level early warning record is generated for downstream dependencies lower than the preset dependency threshold. The preset dependency threshold is taken from the median of the downstream dependencies of all production lines in the process route dependency table and is updated synchronously after each update of the process route dependency table. The tiered early warning record contains the following data: production line number, downstream dependence, early warning level, shortage batch, expected delay duration, and a list of affected downstream production line numbers. The tiered early warning record is transmitted to the production scheduling system, which triggers the generation process of corresponding downstream process delay adjustment or alternative assembly schemes based on the early warning level.

[0078] Specifically, once the collaborative delivery constraint verification is completed and the new material replenishment process has been triggered, if there are still production lines whose expected material arrival time is later than the material arrival deadline for that production line, the system reads the process route dependency table to obtain the downstream dependency of each remaining unmet production line.

[0079] Maintenance of the process route dependency table: This table is entered by the process management department when each new order is placed, based on the assembly process route diagram of that order, to record the correspondence between the output materials of each production line and the downstream assembly processes. The downstream dependency field is recorded as an integer. The table is updated synchronously when the order or process is changed.

[0080] Acquisition of preset dependency threshold: After each update of the process route dependency table, the system sorts the downstream dependency values ​​of all production lines in the table and takes the median. The median is then written into the "dependency classification threshold" field of the scheduling parameter table for use in the current round and subsequent classification judgments.

[0081] Formation and execution of the remedy priority queue: The system sorts the remaining unmet production lines according to their downstream dependencies from high to low. For those with the same dependency, they are ordered by their deadlines from most recent to furthest, forming a remedy priority queue. Available new material replenishment resources are allocated sequentially according to the queue order. After each allocation, the available resource balance is updated and the timing coverage status of the production line is re-verified.

[0082] Generation of tiered early warning records: For production lines that still cannot meet the deadline after remedial priority allocation, a Level 1 early warning record is generated if the downstream dependency is not lower than the dependency tier threshold, and a Level 2 early warning record is generated if the downstream dependency is lower than the threshold. The tiered early warning record includes the production line number, early warning level, shortfall batch, expected delay duration, and a list of affected downstream production line numbers, and is transmitted to the production scheduling system.

[0083] Those skilled in the art will readily understand that the above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A method for intelligent scheduling of materials throughout the entire process based on strategy optimization, characterized in that, include: Summarize the demand times of raw materials of the same specification from each production line to form a cross-line time-series demand map; based on the cross-line time-series demand map, perform time-series alignment screening of feasible cutting schemes for surplus materials, and output targeted surplus material records containing surplus material specifications, available timestamps and target production line numbers; The available timestamps of the directional surplus material records are compared one by one with the material arrival deadlines of each production line to identify time gaps, and time gap records are output based on the gap amount. For non-directional surplus materials with larger specifications in the time gap record, the accessibility of the downgraded specification is confirmed by the specification downgrade relationship table, and the comprehensive working time constraint is used to check whether the deadline is met. If it is met, an alternative routing instruction is output; otherwise, it is confirmed as a new material replenishment requirement. Upon receiving the modification instruction, determine the feasibility of truncation absorption and / or parameter absorption based on the process status of each batch; for batches where absorption is not feasible, enter the specification downgrade route; update the timing coverage status and verify the collaborative delivery constraints.

2. The intelligent material scheduling method based on strategy optimization according to claim 1, characterized in that: The formation of the cross-line time-series demand map includes: retrieving work orders from the work order database that are in the material-pending state for each production line within the current production cycle; extracting the raw material cross-sectional specifications, required length specifications, production line number, and required batch size for each work order; calculating the material arrival deadline for each production line based on the order delivery time and the total time required for all processes from material arrival to process completion; organizing and arranging the production line number, raw material specification parameters, required batch size, and material arrival deadline along a time axis using the material arrival deadline as the time node to form the cross-line time-series demand map; and forming time-series correlation constraints by reverse-deriving the material arrival deadlines for each supporting production line under the customer order in the cross-line time-series demand map through a unified delivery time.

3. The intelligent material scheduling method based on strategy optimization according to claim 2, characterized in that: The process of acquiring directional surplus material records includes: enumerating all feasible cutting schemes that meet the main production line's work order requirements for the batch to be cut, and calculating the surplus material cross-sectional specifications and length generated by each scheme; retrieving the cross-line timing demand map using the surplus material cross-sectional specifications and length as query conditions, identifying the target production line and corresponding time node whose surplus material length falls within the demand length range of other production lines; for each matched target production line, calculating the estimated available timestamp of the surplus material based on the real-time execution progress record of the work order, and verifying whether the timestamp is earlier than the material arrival deadline of the target production line; the real-time execution progress record of the work order is refreshed when each batch of cutting processes starts, and the estimated completion time is dynamically corrected based on the actual start time and the remaining cutting quantity, and the corrected estimated completion time is the estimated available timestamp of the surplus material; calculating the difference between the surplus material length and the target production line's required length to determine the truncation amount; selecting the scheme with the smallest truncation amount from all schemes that meet the timing alignment conditions as the execution scheme, and outputting the directional surplus material record.

4. The intelligent material scheduling method based on strategy optimization according to claim 3, characterized in that: The timing gap record output process includes: grouping all targeted surplus material records by target production line number; matching all demand batches for each production line with the coverable batches in the allocated targeted surplus material records; comparing the expected available timestamp of each targeted surplus material record with the material arrival deadline of the target production line: those with expected available timestamps earlier than the deadline are marked as surplus material timing coverage and removed from the list of demand items to be covered; those with expected available timestamps later than the deadline and / or no corresponding demand items for targeted surplus material records are marked as timing gaps; and using the difference between the total demand batches of the production line and the batches already covered by targeted surplus material as the gap amount to form a timing gap record.

5. The intelligent material scheduling method based on strategy optimization according to claim 4, characterized in that: The process of confirming the accessibility of downgraded specifications includes: an offline pre-built specification downgrade relationship table, using each material specification as the query key, recording all the smaller specifications that can be reached by truncation and the corresponding truncation amount for each path; the specification downgrade relationship table is updated synchronously with changes in the material specification system, and the update timestamp is recorded in the table header. For each time-series gap record, non-directional surplus materials with the same cross-sectional specifications and a length specification greater than the gap requirement length are retrieved from the non-directional surplus material pool based on the cross-sectional specifications. Using the current length specification of each selected surplus material as the query key, a list of achievable downgrade specifications is extracted from the specification downgrade relationship table. Each specification in the list of achievable downgrade specifications is matched one by one with the required length specification in the time-series gap record. For those that are successfully matched, the achievability of the downgrade specification of the gap corresponding to the surplus material is confirmed, and the corresponding truncation amount is extracted.

6. The intelligent material scheduling method based on strategy optimization according to claim 5, characterized in that: The comprehensive working time constraint is used to verify whether the deadline is met, including: for each remaining material and gap whose accessibility to the downgraded specification has been confirmed, the corresponding records are recorded, and three times are accumulated in sequence: the logistics time from the current storage location of the remaining material to the location where the shortening operation is performed, the working time of the shortening operation, and the logistics time from the material receiving location of the target production line after the shortening is completed; the estimated available timestamp of the remaining material is added to the sum of the three times to obtain the estimated time when the remaining material actually arrives at the target production line; Compare the expected arrival time with the material arrival deadline in the time gap record: for those whose expected arrival time is not later than the deadline, output an alternative route instruction and update the allocation status of the corresponding remaining material record in the material resource pool to directed route; for those whose expected arrival time is later than the deadline, confirm as new material replenishment needs.

7. The intelligent material scheduling method based on strategy optimization according to claim 1, characterized in that: The feasibility of truncated absorption and / or parameter absorption is determined based on the process status of each batch, including: For batches whose process status is marked as cut but not yet entered into subsequent processes, the minimum feeding length required for the target specification to enter the subsequent process is extracted from the process specification parameter table. The minimum feeding length is the sum of the finished length of the target specification and the processing allowance of the subsequent process. If the cut length of the current batch is greater than the minimum feeding length, then cutting and absorption is feasible. The cutting amount is the difference between the cut length and the minimum feeding length, and the cutting operation time is included in the estimated actual arrival time of the batch material. If the cut length is not greater than the minimum feeding length, then cutting and absorption is not feasible. For batches whose process status is marked as having completed intermediate processes but not yet entered the final curing process, the maximum allowable parameter adjustment amount for intermediate processes is extracted from the process specification parameter adjustment tolerance table. The process specification parameter adjustment tolerance table is updated synchronously and the update timestamp is recorded when the process is changed. The difference between the actual effective processing length of the current batch and the modified target length is calculated as the length deviation. If the length deviation does not exceed the maximum parameter adjustment amount, parameter absorption is feasible, and subsequent processes continue after updating the processing parameters, with the expected actual arrival time of the material remaining unchanged. If the length deviation exceeds the maximum parameter adjustment amount, parameter absorption is not feasible.

8. The intelligent material scheduling method based on strategy optimization according to claim 7, characterized in that: Update the timing coverage status and verify the collaborative delivery constraints, including: Summarize the processing results of each batch after the modification instruction: The estimated actual arrival time of the truncated absorption batch is the sum of the original estimated available timestamp and the truncated operation time; the estimated actual arrival time of the parameter absorption batch remains unchanged from the original estimated available timestamp; the absorption of infeasible batches is processed by specification downgrade routing, and the estimated arrival time in the alternative routing instruction is taken or a new material replenishment demand gap is formed; the estimated actual arrival time of each batch is written into the timing coverage record of the corresponding production line, replacing the timing coverage status before the modification, and the timing coverage status update is completed; The updated estimated actual arrival time of materials for each production line is compared with the material arrival deadline of each production line: if all production lines are no later than their respective deadlines, a collaborative delivery constraint satisfaction confirmation record is output; if any production line is later than its deadline, a new time-series gap record is formed based on the gap batch corresponding to the batch that exceeds the deadline, triggering the new material replenishment process.

Images