A method for production traceability of heavy-duty truck transmission assembly without accessories included in the gearbox

Abstract

This invention discloses a method and application for production traceability of non-in-box accessories in heavy-duty truck transmission assembly. It leverages existing enterprise production systems for collaborative expansion, without requiring a separate system. The core is based on ERP (Order / Production Planning), MES (Manufacturing Execution System), and TCM (Material Management Machine) systems, supplemented by a splitting, combining, and packaging system and a PDA scanning and binding system. These systems are interconnected and operate collaboratively. The PDA is only used for scanning and binding during the packaging process. Packaging tasks are based on the non-in-box accessory list in the BOM, including the production bill of materials, logistics quantities, and varieties. Work orders are split and combined to produce packaging boxes. After packaging, a shipping card is printed. The PDA scans the QR codes on the original packaging material card and the shipping card to bind the boxes. After binding, the packaging is sealed, and the shipping card is affixed to a designated location on the packaging box before loading and shipping. This invention makes shipments traceable and verifiable, preventing economic losses from over-shipments and re-shipments, and improving enterprise production management capabilities.

Description

Technical Field

[0001] This invention belongs to the field of automotive accessory packaging management technology, specifically relating to a method for tracing the production of accessories not included in the packaging of heavy-duty truck transmission assembly. Background Technology

[0002] With the continuous improvement of digitalization and intelligence, the entire AMT transmission production process, from material receiving to finished product delivery, has achieved digital management, making the production process transparent, controllable, and traceable. However, AMT and other intelligent products suffer from after-sales quality issues such as the over-shipment or omission of accessories not shipped with the packaging. These components are high-value purchased parts, and the process creates a "black hole," causing serious economic losses to enterprises. Patent CN108960707A discloses an automotive parts packaging management system that can ensure the integrity of information from warehouse to shipment. It can also measure the materials packaged in boxes, ensuring more detailed shipping information. Furthermore, the pallet numbers provided can improve the standardization and control capabilities of the packaging process.

[0003] The following are the main problems with not packaging accessories with the box and vehicle during the production process:

[0004] 1) During the production and shipment of commercial vehicle transmissions, there are large transmission components required for the final vehicle assembly. These components are generally optional. To ensure standardization of packaging or carriers during assembly shipment, these critical large components typically need to be packaged separately and shipped with the vehicle. These components are usually shipped according to the manufacturer's orders, not strictly according to the work order; their packaging is independent of the transmission itself. Since the transmission is packaged individually, each transmission package has a material card to facilitate online scanning and traceability by the OEM. To maximize transportation capacity, transmission assemblies are generally shipped according to the capacity of the logistics vehicle. However, this is different for non-packaged accessories. To save on packaging materials, a company's process regulations stipulate that if the quantity of such parts to be shipped equals the number of packages the part needs to be contained in, it is shipped as a whole package without repackaging. If it is less than the number of packages, it is sorted and mixed with other materials before shipment. This makes advance production scheduling and orderly production difficult, causing challenges in production management.

[0005] 2) Due to the randomness of the packaging and shipping of such parts, it is difficult to implement barcode tracking, making this link a "black hole" in the transmission production process.

[0006] This invention patent is based on a systematic review and study of the entire process of production, packaging, and shipment of non-accompanying accessories in the assembly and shipment of commercial vehicle transmissions for a certain enterprise. It develops a traceability method for the production of non-accompanying accessories in the assembly of heavy-duty truck transmissions, breaking the "black hole" in this process. The packaging and shipment process of parts such as pressure plates and driven plates is traceable and verifiable, eliminating economic losses caused by quality feedback, over-shipments, and re-shipments, and improving the enterprise's production management capabilities. Summary of the Invention

[0007] The purpose of this invention is to address the problem that when a transmission assembly is not shipped with accessories, if the quantity to be shipped is equal to the number of packages the part is included in the incoming material, it is shipped as a whole without changing the packaging; if it is less than the number of packages, it is sorted and shipped with a mixture of various materials, making it difficult to schedule production in advance and to ensure orderly production, which brings difficulties to production management. In order to address the problem that due to the randomness of the packaging and shipping of such parts, it is difficult to implement barcode traceability, making this link a "black hole" in the transmission production process, this invention provides a production traceability method for heavy truck transmission assembly without accessories included in the box.

[0008] To achieve the above objectives, the technical solution provided by this invention is as follows:

[0009] A method for tracing the production of heavy-duty truck transmission assembly without accessories is proposed. This method utilizes information technology software to achieve online management of planned production, and includes the following steps:

[0010] Step 1: The workshop production execution system (MES, etc.) receives the production plan information and BOM information from the ERP system and begins production of the transmission;

[0011] Step 2: After the transmission assembly is produced, determine the number of units (n) shipped by Manufacturer A for this logistics vehicle transportation based on factors such as the main equipment manufacturer, the level of order activity, and the capacity of the logistics vehicles.

[0012] Step 3: Select the transmission plan list of Manufacturer A from the plans where the transmissions have been completed but not yet packaged, and select the production and packaging task according to the shipment quantity n.

[0013] Furthermore, the packaging task generates a bill of materials based on the list of non-box accessories in the BOM, and then, based on the logistics quantity and variety in the bill of materials, and in accordance with the rules and the principle of minimizing packaging materials, the work order is split and combined to produce packaging boxes.

[0014] Furthermore, after generating the packaging box, a shipping card is printed. The shipping card contains a QR code for the packaged item. Workers sort and pack the materials on the shipping card according to the shipping card. They also use a PDA to scan the material card on the original packaging and the QR code on the shipping card to bind them together. After binding, the packaging is sealed, and the shipping card is affixed to the designated position on the packaging box before loading and shipping.

[0015] Compared with the prior art, the present invention has the following beneficial technical effects:

[0016] 1. This invention analyzes and studies the entire process of production, packaging, and shipment of non-accompanying accessories in the assembly and shipment of commercial vehicle transmissions for a certain enterprise. It develops a traceability method for the production of non-accompanying accessories in the assembly of heavy-duty truck transmissions, breaking the "black hole" in this process. The packaging and shipment process of parts such as pressure plates and driven plates is traceable and verifiable, eliminating economic losses caused by quality feedback, over-shipments, and re-shipments, and improving the enterprise's production management capabilities.

[0017] 2. This invention leverages existing enterprise production systems for collaborative expansion, without relying on independent systems. Its core is based on ERP (Enterprise Resource Planning), MES (Manufacturing Execution System), and TCM (Material Management Machine) systems, supplemented by a splitting, combining, and packaging system and a PDA scanning and binding system. These systems enable data interoperability and collaborative operation. Regarding handheld device applications, the PDA is only used for scanning and binding during the packaging process, providing a high level of traceability. Attached Figure Description

[0018] Figure 1 This is a list of completed but unpackaged production plans, representing an embodiment of a method for tracing the production of non-boxed accessories in heavy-duty truck transmission assembly according to the present invention.

[0019] Figure 2 This is a business process diagram in an embodiment of the method for tracing the production of heavy-duty truck transmission assembly without accessories.

[0020] Figure 3 This is a list of materials with an agreement number after confirming a manufacturer's packaging task in an embodiment of the present invention.

[0021] Figure 4 This is a bill of materials in an embodiment of the present invention.

[0022] Figure 5 This is a material scanning and binding method used in this embodiment of the invention.

[0023] Figure 6 This refers to production work order information in this embodiment of the invention.

[0024] Figure 7 This is a flowchart of the solution in an embodiment of the present invention.

[0025] Figure 8 This is the interface of the split packaging system in an embodiment of the present invention.

[0026] Figure 9 This is page one of the packaging system for non-packaged accessories in this embodiment of the invention.

[0027] Figure 10 This is page two of the packaging system for non-included accessories in this embodiment of the invention.

[0028] The annotations in the attached figures are explained as follows:

[0029] 1-Plan Number, 2-Work Order Number, 3-Agreement Number, 4-Order Quantity (NAI), 5-Production Schedule Date, 6-Manufacturer Code, 7-ERP System, 8-MES System, 9-Gearbox Production, 10-Logistics Transportation Vehicle, 11-Customer Order Urgency, 12-Determine if the MBOM contains parts that need not be packaged with the box, 13-Generate Parts Quantity List, 14-Incoming Material Quantity (N) as an integer multiple of M, 15-Quantity to be individually packaged after unpacking, 16-Picking and Packaging, 17-Produce Packaging Boxes and Print Shipping Cards, 18-Determine if the Material Number on the Material Card is associated with the Material Number on the Packaging Box QR Code. Whether they match, 19- Bind the material batch information in the incoming material card to the work order information in the packaging box, 20- Affix the shipping card to the designated packaging box, 29- Generate button, 30- Work order quantity, 31- Work order setting, 32- Packaging task, 33- List details of work orders to be packaged, 34- Agreement number for generating packaging task, 35- Part quantity, 36- Part setting, 37- Generate packaging box button, 38- Submit button, 39- Packaging box code, 40- Print material card button, 41- Scan code traceability area, 42- Product order and MBOM information, 43- Generate packaging task button. Detailed Implementation

[0030] To make the objectives, advantages, and features of the present invention clearer, the present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments. Those skilled in the art should understand that these embodiments are merely used to explain the technical principles of the present invention and are not intended to limit the scope of protection of the present invention.

[0031] like Figures 1 to 5 As shown, this embodiment provides a method for production traceability of heavy-duty truck transmission assembly without accompanying accessories. It utilizes information technology software to achieve online management of planned production, including the following steps:

[0032] Step 1: The workshop production execution system (MES, etc.) receives the production plan information and BOM information from the ERP system and begins production of the transmission;

[0033] Step 2: After the transmission assembly is produced, determine the number of units (n) shipped by Manufacturer A for this logistics vehicle transportation based on factors such as the main equipment manufacturer, the level of order activity, and the capacity of the logistics vehicles.

[0034] Step 3: Select the transmission plan list of Manufacturer A in the plan where the transmission has been completed but not yet packaged, and generate packaging task 32 by selecting work order quantity 30 according to the shipment quantity n.

[0035] Furthermore, packaging task 32 produces a bill of materials based on the list of non-box accessories in the BOM, and then, based on the logistics quantity and variety in the bill of materials, and in accordance with the rules and the principle of minimizing packaging materials, splits and combines the work order to produce packaging boxes.

[0036] Furthermore, after generating the packaging box, a shipping card is printed. The shipping card contains a QR code for the packaged item. Workers sort and pack the materials on the shipping card according to the shipping card. They also use a PDA to scan the material card on the original packaging and the QR code on the shipping card to bind them together. After binding, the packaging is sealed, and the shipping card is affixed to the designated position on the packaging box before loading and shipping.

[0037] like Figures 6 to 10 As shown, the application of a production traceability method for heavy-duty truck transmission assembly without accompanying accessories includes the following steps:

[0038] Step 1: In the ERP system, maintain order information and receive product orders and MBOM information 42, including plan number 1, work order number 2, agreement number 3, order quantity nai 4, production schedule date 5, and manufacturer code 6;

[0039] Step 2: In MES system 8, receive order information and arrange transmission production 9. After production is completed, the work order is completed in MES system 8. Logistics personnel contact logistics transportation vehicles 10. Based on the urgency of the customer order 11 and the capacity of logistics transportation vehicles 10, determine the number of transmission assemblies to be loaded by a certain manufacturer (represented by manufacturer A) as n.

[0040] Step 3: Determine the list of work order agreement numbers 3 for this loading by Company A, including agreement numbers a1, a2, a3, etc. Based on the product order and the part information of this workstation in MBOM information 42, determine whether the MBOM contains parts 12 that need not be packaged with the box, and form a parts list 13: L1(a1), L2(a1), ..., L1(a2), L2(a2), ..., including driven plates, pressure plates, etc. that are not packaged with the box but are shipped with the vehicle, represented by L1, L2, L3, ...

[0041] Step 4: Click the "Generate Packaging Task" button 43 on the system page. Based on the number of work orders 30, set the work order 31 by multiple M times the number of incoming materials (N) 14 and the number of materials to be packaged separately after unpacking 15. After completing the work order setting 31 and splitting, click the "Generate" button 29 to generate a detailed list of work orders to be packaged 33. The number of gearboxes in each protocol number 3 is nai, where n = ∑nai. After the splitting is completed, the system automatically calculates the remaining work orders for this work order. Click the "Generate" button 29 to generate the packaging task 32.

[0042] Step 5: After generating the packaging task 32, click on the work order details 33 in the packaging task to display the work order list for the task, which includes the protocol number 34 information that requires the packaging task to be generated; in the packaging BOM list, according to the packaging calculation logic in step 3, based on the number of parts 35, split and set the packaging part settings 36, after setting, click the Generate Packaging Box button 37 to produce the packaging box, manually check the packaging box details and then click the Submit button 38 to submit the packaging box code 39;

[0043] Step 6: To reduce costs, the packaging process follows the rule that the quantity of a certain part is an integer multiple of its incoming material containment number (N) by M times. 14. The quantity of parts packaged separately after unpacking is (nM*N) / 3=k...p and formulas 1 and 2 are used to calculate whether to unpack and the number of wooden crates to be packaged. In the MES system 8, maintain the part setting 36, the quantity of part Li in a package in this packaging box code 39, the system automatically calculates the remaining quantity, and then generates the next packaging box according to the same steps. Use the print material card button 40 to generate the shipping card for the packaging box, and affix the shipping card to the designated position on the packaging box 20.

[0044]

[0045]

[0046] In the formula: Ns represents the number of parts that can be packaged without being disassembled; Ns represents the number of protocol numbers 34 that generate the packaging task; n represents the number of transmissions that the logistics workshop can reserve for manufacturer A at this time. The number of transmissions shipped for each Agreement No. 3; The quantity of a certain part in the selected protocol number 3BOM; The containment number when a certain part is received; The number of boxes containing a specific part packaged separately; The number of parts to be bundled together with the remaining parts.

[0047] Step 7: In the work order list, split and combine parts according to the quantity of 35, produce packaging boxes and print shipping cards 17. The operator prepares K packaging boxes according to the contents of the shipping card, and packs the pressure plate, driven plate and other parts respectively. The remaining p pressure plates and driven plates are packed into one packaging box for picking and packing 16. Then, the operator uses a handheld PDA barcode scanning system to scan the QR code information on the incoming material card, extracts the material part code, and sends it to the MES system 8. The MES system 8 extracts the material code from the product order and MBOM information 42 and compares it. It judges whether the material number on the material card is consistent with the material number associated with the QR code on the packaging box 18. If they are consistent, the comparison is successful. Then, the operator binds the material batch information in the incoming material card with the work order information in the packaging box 19 and sends the scanning completion information to the PDA. Alternatively, the operator can use a barcode scanner connected to a PC to scan the QR code information on the material card. The traceability code of the product will be displayed in the scanning traceability area 41, indicating that the scanning is complete and traceability is possible. After the operator completes the packing, For parts that can be packaged without being disassembled, the shipping card shall be affixed to the packaging as specified.

[0048] Step 8: The production traceability process for a heavy-duty truck transmission assembly without accompanying accessories is completed.

[0049] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and are not intended to limit them. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features therein. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the present invention.

Claims

1. A method for production traceability of heavy-duty truck transmission assembly without accompanying accessories, characterized by the use of information technology software to achieve online information management of planned production, wherein... Includes the following steps: Step 1: The workshop production execution system (MES) receives production plan information and BOM information from the ERP system and begins production of the transmission. Step 2: After the transmission assembly is completed, determine the number of units shipped by Manufacturer A for this logistics vehicle to be n units based on factors such as the main equipment manufacturer, the level of order activity, and the capacity of the logistics vehicle. Step 3: Select the transmission plan list of Manufacturer A from the plans where the transmissions have been completed but not yet packaged, and select the production and packaging task according to the shipment quantity n.

2. The method for tracing the production of heavy-duty truck transmission assembly without accompanying accessories as described in claim 1, characterized in that, The packaging task generates a bill of materials (BOM) based on the list of non-packaged accessories in the BOM. Then, based on the logistics quantities and varieties in the BOM, and in accordance with the rules and the principle of minimizing packaging materials, the work order is split and combined to produce packaging boxes.

3. A method for tracing the production of heavy-duty truck transmission assembly without accompanying accessories, as described in claim 2, is characterized in that... After generating the packaging box, a shipping card is printed. The shipping card contains a QR code for the packaged item. Workers sort and pack the materials according to the shipping card. They also use a PDA to scan the QR code on the original packaging material card and the shipping card to bind them together. After binding, the packaged item is sealed, and the shipping card is affixed to the designated position on the packaging box before loading and shipping.

4. A method for tracing the production of heavy-duty truck transmissions without the inclusion of accessories in the transmission assembly, characterized in that, Includes the following steps: Step 1: Maintain order information and receive product orders and MBOM information in the ERP system, including plan number, work order number, agreement number, order quantity NAI, production schedule date, and manufacturer code; Step 2: In the MES system, receive order information and arrange transmission production. After production is completed, the work order is completed in the MES system. Logistics personnel contact logistics transportation vehicles. Based on the urgency of the customer order and the capacity of the logistics transportation vehicles, determine the number of transmission assemblies that Manufacturer A will load this time as n. Step 3: Determine the list of work order agreement numbers for this loading by Company A, including agreement numbers a1, a2, a3... Based on the product order and the part information for this workstation in the MBOM information, determine whether the MBOM contains parts that need to be shipped without being packed in the box, and form a parts list: L1(a1), L2(a1)..., L1(a2), L2(a2)... This includes parts such as driven pallets and pressure plates that are not packed in the box but are shipped with the vehicle, represented by L1, L2, L3... Step 4: On the system page, click the "Generate Packaging Task" button. Based on the work order quantity, set the work order splitting by multiples of the incoming material containment number N by M, and the quantity of materials to be packaged separately after unpacking. After completing the work order splitting, click the "Generate" button to generate a detailed list of work orders to be packaged. The quantity of gearboxes in each protocol number is nai, where n = ∑nai. After the splitting is completed, the system automatically calculates the remaining work orders for that work order. Click the "Generate" button to generate the packaging task. Step 5: After generating the packaging task, click on the work order details in the packaging task to display the work order list for the task, which includes the protocol number information for generating the packaging task; in the packaging BOM list, according to the packaging calculation logic in step 3 and the number of parts, split and set the packaging parts settings by splitting; after setting, click the Generate Packaging Box button to produce the packaging box; manually check the packaging box details and click the Submit button to submit the packaging box code. Step 6: To reduce costs, the packaging process follows the rules of whether the quantity of a certain part is an integer multiple of its incoming material containment number N by M, the quantity of separately packaged parts after unpacking is (nM*N) / 3=k...p, and formulas 1 and 2 to calculate whether to unpack and the number of wooden crates to pack; maintain the part settings in the MES system, the quantity of part Li in a package in this packaging box code, the system automatically calculates the remaining quantity, and then generates the next packaging box according to the same steps, uses the print material card button to generate the shipping card for the packaging box, and affixes the shipping card to the designated packaging box; ； ； In the formula: Ns represents the number of packages for a certain type of part that can be packaged without being disassembled; n represents the number of protocol numbers that generate the packaging task; and n represents the number of transmissions that the logistics workshop can reserve for manufacturer A at this time. The number of transmissions shipped for each agreement number; The quantity of a certain part in the selected protocol number BOM; The containment number when a certain part is received; The number of boxes containing a specific part packaged separately; The number of parts to be bundled together with the remaining parts; Step 7: In the work order list, split and combine parts according to quantity, produce packaging boxes and print shipping cards. The operator prepares K packaging boxes according to the contents of the shipping card, and packs them with pressure plates, driven plates, and other parts respectively. The remaining p pressure plates and driven plates are combined into one packaging box. Picking and packing are then performed. Then, the operator uses a handheld PDA scanning system to scan the QR code information on the incoming material card, extracts the material part code, and sends it to the MES system. The MES system extracts the material code from the product order and MBOM information for comparison. It judges whether the material number on the material card matches the material number associated with the QR code on the packaging box. If they match, the comparison passes. Then, the operator binds the material batch information in the incoming material card with the work order information in the packaging box and sends the scanning completion information to the PDA. Alternatively, a scanner connected to a PC can be used to scan the QR code information on the material card. The traceability code of the product will be displayed in the scanning traceability area, indicating that the scanning is complete and traceability is possible. After the operator completes the packing, For parts that can be packaged without being disassembled, the shipping card shall be affixed to the packaging until the specified quantity is reached; Step 8: The production traceability process for a heavy-duty truck transmission assembly without accompanying accessories is completed.

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