Material demand prediction and inventory dynamic replenishment management method for tea leaf packaging box production workshop

Abstract

The present application relates to the technical field of intelligent management of workshop materials, and discloses a material demand prediction and inventory dynamic replenishment management method for a tea packaging box production workshop, comprising the following steps: obtaining production orders, production line scheduling and a material list, generating a production material demand chain; correcting the production material demand chain in combination with the process progress of historical tasks and the actual material input and remaining situation, generating a corrected production material demand chain; collecting warehouse, line-side, locked and in-transit inventory, generating a batch supply chain; matching to form a complete supply unit set, and establishing candidate batch migration relationships and gap transmission relationships for uncovered tasks; screening out relationships that do not satisfy the consumption time, gap size, task cycle and delivery constraints, generating a monotone gap transmission graph and searching for a closable migration path; when the closable migration path cannot be closed, screening out blocking materials and generating a dynamic replenishment scheme. The present application uses gap transmission to realize material prediction and dynamic replenishment.

Description

Technical Field

[0001] This invention relates to the field of intelligent material management technology in production workshops, and in particular to a method for predicting material demand and managing dynamic inventory replenishment in a tea packaging box production workshop. Background Technology

[0002] Existing tea packaging box production workshops typically calculate material requirements based on production orders, production line schedules, and bills of materials, and then set replenishment quantities and times in conjunction with warehouse inventory. Some management systems can record temporary inventory on the production line, order-locked inventory, and in-transit inventory, and generate purchase prompts based on inventory quantities or safety stock thresholds.

[0003] Existing technologies typically handle material requirements and inventory quantities separately, failing to adjust demand quantities and demand periods based on actual material consumption in historical production tasks, and also failing to establish complete supply relationships according to the applicable production tasks and available production time of material batches. When a production task is short of materials, it is difficult to assess the material gap and depletion time caused by material batch migration to the source production task, and it is impossible to coordinate batch occupancy relationships through gap transmission paths, making it difficult to adjust replenishment quantities and replenishment timing in accordance with changes in production tasks.

[0004] Therefore, how to provide material demand forecasting and dynamic inventory replenishment management methods for tea packaging box production workshops is a problem that urgently needs to be solved by those skilled in the art. Summary of the Invention

[0005] One objective of this invention is to propose a method for material demand forecasting and dynamic inventory replenishment management in tea packaging box production workshops. This invention fully utilizes historical material consumption correction, material batch matching, batch occupation migration, gap transfer diagram construction, and migration path search methods to achieve production material demand forecasting, inventory collaborative allocation, and dynamic replenishment under material shortage conditions. It has the advantages of improving the accuracy of material demand forecasting, increasing inventory utilization, reducing production material shortages, and reducing the amount of ineffective replenishment.

[0006] The material demand forecasting and dynamic inventory replenishment management method for a tea packaging box production workshop according to an embodiment of the present invention includes the following steps:

[0007] Obtain tea packaging box production orders, production line schedules, and bills of materials to generate a production material demand chain;

[0008] Obtain the process progress, actual material input, and actual material remaining of historical production tasks, correct the production material demand chain, and generate a corrected production material demand chain.

[0009] Acquire warehouse inventory, production line temporary inventory, order-locked inventory, and in-transit inventory to generate a batch supply chain;

[0010] The corrected production material demand chain is matched with the batch material supply chain to determine the complete material supply unit and generate a complete material supply unit set.

[0011] Identify production tasks not covered by the complete material supply unit and generate candidate batch migration relationships;

[0012] For candidate batch migration relationships, determine the types of materials missing from the source production task after the material batch is transferred, the quantity of uncovered materials, and the material depletion time, and generate gap propagation relationships;

[0013] Based on the material depletion time, the quantity of uncovered materials, the types of missing materials, the repetition of production tasks, and the order delivery time, gap transmission relationships are filtered out to generate a monotonic gap transmission diagram.

[0014] Starting from the first gap node in the monotonic gap transit graph, search for migration paths and generate closable migration paths;

[0015] Adjust the material batch occupancy relationship according to the closable migration path. If no closable migration path is generated, filter the blocked materials and determine the corresponding replenishment quantity, and generate open-chain replenishment results and dynamic replenishment plan.

[0016] Optionally, obtaining the tea packaging box production order, production line schedule, and bill of materials, and generating the production material demand chain includes the following steps:

[0017] Match tea packaging box production orders with production line schedules to generate order schedule matching results;

[0018] Production tasks are divided according to production line number, process type, and execution time, and a task material basic dataset is generated.

[0019] Determine the required quantity and time period for each production task based on the planned production quantity and bill of materials, and generate a task material requirement record.

[0020] Arrange the task material requirement records according to the demand period and the order of process execution to generate a production material requirement chain.

[0021] Optionally, the step of obtaining the process progress, actual material input, and actual material remaining of historical production tasks, and correcting the production material demand chain to generate a corrected production material demand chain includes the following steps:

[0022] Match historical production tasks according to packaging box specifications, production line number, process type and material type, and generate corresponding results for historical tasks;

[0023] Calculate the actual material consumption of historical production tasks according to the process progress, and generate historical material consumption records;

[0024] Abnormal historical production tasks are screened out based on the actual material consumption per unit, and valid historical material consumption records are generated.

[0025] Adjust the required quantity based on valid historical material consumption records, and generate task material adjustment records;

[0026] Based on valid historical material consumption records, the demand period is adjusted to generate a corrected production material demand chain.

[0027] Optionally, the step of acquiring warehouse inventory, production line temporary inventory, order-locked inventory, and in-transit inventory to generate a batch supply chain includes the following steps:

[0028] Divide inventory into different categories according to material batch, inventory status and material location, and generate batch inventory segment records;

[0029] The available quantity is determined based on the inventory quantity recorded in each batch inventory segment, and a batch available quantity record is generated;

[0030] Match each material batch with the material testing data and packaging box specifications to determine the applicable production task;

[0031] Determine the material transfer process based on the location of the material and the location of the target production line, and generate a location transfer record;

[0032] The production time for each batch of materials is determined based on inventory status and material transfer process.

[0033] Arrange each batch of materials according to its production availability to generate a batch supply chain.

[0034] Optionally, the step of matching the corrected production material demand chain with the batch supply chain to determine the complete set of supply units and generate a complete set of supply units includes the following steps:

[0035] Collect all necessary materials according to the production task and generate a task-necessary material record.

[0036] Each necessary material is matched with an applicable material batch to generate a candidate batch record for necessary materials;

[0037] Generate necessary material batch groups by combining material batches according to the revised required quantity and minimum requisition quantity;

[0038] Cross-combining the necessary material batches to generate candidate complete material supply units;

[0039] Candidate material supply units are selected based on the batch quantity, the total remaining percentage of the batch, and the material supply time, and a set of material supply units is generated.

[0040] Optionally, determining the production tasks not covered by the complete material supply unit and generating candidate batch migration relationships includes the following steps:

[0041] Determine the target production tasks and their material shortages based on the coverage of the complete set of material supply units, and generate records of uncovered production tasks;

[0042] Select batches of the same material from the material batches occupied by other production tasks to generate migration batch screening results;

[0043] Determine the alternative material supply batches and alternative material supply times based on other available material batches from the source production task;

[0044] The quantity that must be retained is determined based on the cumulative material consumption prior to the replacement supply time.

[0045] The number of units that can be migrated is determined based on the locked available quantity, the quantity that must be retained, and the minimum quantity that can be issued.

[0046] Generate candidate batch migration relationships based on the total number of uncovered material combinations that can be migrated for the target production task.

[0047] Optionally, the step of determining the types of materials missing from the source production task after the material batch transfer, the quantity of uncovered materials, and the material depletion time, and generating the gap propagation relationship for the candidate batch migration relationship includes the following steps:

[0048] Simulate and adjust the material batch allocation quantity according to the candidate batch migration relationship, and generate batch migration simulation records;

[0049] Based on the cumulative material supply process of the source production tasks reorganized according to the available production time, a material supply time sequence after the source task migration is generated.

[0050] Reorganize the cumulative consumption process of the source production tasks according to the revised demand period and historical material consumption process to generate the source task demand consumption time series;

[0051] By comparing the cumulative supply process and the cumulative consumption process, the types of materials missing and the quantity of uncovered materials from the source production task can be determined.

[0052] The material depletion time is determined based on the time and location of the first occurrence of the uncovered quantity in the phase.

[0053] Connect the material gap of the target production task to the source production task to generate a gap propagation relationship.

[0054] Optionally, the step of filtering out gap propagation relationships based on material depletion time, quantity of uncovered materials, types of missing materials, repetition of production tasks, and order delivery time to generate a monotonic gap propagation diagram includes the following steps:

[0055] Convert the gap propagation relationship into gap nodes and node connection relationships to generate the initial gap propagation graph;

[0056] Filter out node connections according to the direction of material depletion time;

[0057] Node connections are filtered out based on changes in the quantity of uncovered materials and the types of missing materials.

[0058] Based on the repetition of production tasks, eliminate node connections that form cycles;

[0059] Filter out node connections that cause orders to be overdue based on order delivery time;

[0060] Organize the filtered gap nodes and node connection relationships to generate a monotonic gap transmission diagram.

[0061] Optionally, the step of searching for migration paths and generating closable migration paths starting from the first gap node in the monotonic gap transit graph includes the following steps:

[0062] Determine the first gap node based on the material depletion time and establish the path status;

[0063] Expand the path state layer by layer along the node connection relationships;

[0064] Based on the material batch occupancy relationship in the path status, filter the remaining inventory and in-transit inventory, and determine the termination of the complete set of material supply units;

[0065] Connect the path states from the first path state to the terminating complete material supply unit to generate candidate closed migration paths;

[0066] Candidate closed migration paths are verified in the order from the end of the path to the first gap node, and path supply verification results are generated.

[0067] Candidate closed migration paths are selected based on the number of production tasks involved and the total duration of the gap, and closed migration paths are generated.

[0068] Optionally, the step of adjusting the material batch occupancy relationship according to a closable migration path, and when no closable migration path is generated, filtering blocked materials and determining the corresponding replenishment quantity, and generating open-chain replenishment results and dynamic replenishment plans, includes the following steps:

[0069] Adjust the material batch occupancy relationship according to the path status in the closable migration path;

[0070] Identify unclosed end gap nodes from the path states that have stopped expanding;

[0071] Based on the remaining supply quantity of the unclosed end gap node, filter the blocking materials and generate a blocking material record;

[0072] Determine the replenishment quantity and replenishment time corresponding to the blocked materials based on the packaging supply quantity and supply duration, and generate candidate replenishment records;

[0073] Connect the candidate replenishment records to the unclosed end gap node to generate candidate open chain results;

[0074] Candidate open-chain results are filtered based on the replenishment demand ratio and the remaining replenishment ratio, generating open-chain replenishment results and dynamic replenishment plans.

[0075] The beneficial effects of this invention are:

[0076] This invention combines tea packaging box production orders, production line scheduling, bill of materials, and actual material consumption data from historical production tasks to adjust the material demand quantity and demand period for each production task. This allows the material demand results to reflect changes in production progress, actual input, and actual surplus, reducing supply deviations caused by calculating material demand solely based on planned quantities.

[0077] This invention unifies the processing of warehouse inventory, production line temporary inventory, order-locked inventory, and in-transit inventory according to material batches, and constructs batch supply chains based on the applicable conditions, available quantities, location, and production time of the materials. By matching all necessary materials for the production task with complete sets of supply units, it helps to reduce the scattered occupation of material batches and improve the complete coverage of existing inventory for the production task.

[0078] When a production task is not covered by a complete set of material supply units, this invention performs migration analysis on material batches occupied by other production tasks, and calculates the number of uncovered materials and the material depletion time of the source production task after the material batch is transferred. This ensures that the adjustment of material batches is simultaneously constrained by the demand of the target production task and the supply status of the source production task, thereby reducing new production material shortages caused by material migration.

[0079] This invention coordinates and adjusts the material batch occupancy relationship between multiple production tasks by constructing a monotonic gap transfer graph and searching for closable migration paths. When the migration path cannot be closed, a dynamic replenishment plan is generated based on the quantity of materials to be replenished, the quantity supplied, and the supply time of the blocked materials. This helps to reduce the quantity of ineffective replenishment, shorten the duration of material gaps, and reduce the impact of material shortages on order delivery time. Attached Figure Description

[0080] The accompanying drawings are provided to further illustrate the invention and form part of the specification. They are used in conjunction with embodiments of the invention to explain the invention and do not constitute a limitation thereof. In the drawings:

[0081] Figure 1 This is a flowchart of the material demand forecasting and dynamic inventory replenishment management method for a tea packaging box production workshop proposed in this invention.

[0082] Figure 2 This is a schematic diagram illustrating the gap transmission relationship in the material demand forecasting and dynamic inventory replenishment management method for tea packaging box production workshops proposed in this invention.

[0083] Figure 3 This is a schematic diagram of the monotonic gap transmission method for the material demand forecasting and dynamic inventory replenishment management method in the tea packaging box production workshop proposed in this invention. Detailed Implementation

[0084] The present invention will now be described in further detail with reference to the accompanying drawings. These drawings are simplified schematic diagrams, illustrating only the basic structure of the invention, and therefore only show the components relevant to the invention.

[0085] refer to Figure 1 The material demand forecasting and dynamic inventory replenishment management method for tea packaging box production workshops includes the following steps:

[0086] Obtain tea packaging box production orders, production line schedules, and bills of materials to generate a production material demand chain;

[0087] Obtain the process progress, actual material input, and actual material remaining of historical production tasks, correct the production material demand chain, and generate a corrected production material demand chain.

[0088] Acquire warehouse inventory, production line temporary inventory, order-locked inventory, and in-transit inventory to generate a batch supply chain;

[0089] The corrected production material demand chain is matched with the batch material supply chain to determine the complete material supply unit and generate a complete material supply unit set.

[0090] Identify production tasks not covered by the complete material supply unit and generate candidate batch migration relationships;

[0091] For candidate batch migration relationships, determine the types of materials missing from the source production task after the material batch is transferred, the quantity of uncovered materials, and the material depletion time, and generate gap propagation relationships;

[0092] Based on the material depletion time, the quantity of uncovered materials, the types of missing materials, the repetition of production tasks, and the order delivery time, gap transmission relationships are filtered out to generate a monotonic gap transmission diagram.

[0093] Starting from the first gap node in the monotonic gap transit graph, search for migration paths and generate closable migration paths;

[0094] Adjust the material batch occupancy relationship according to the closable migration path. If no closable migration path is generated, filter the blocked materials and determine the corresponding replenishment quantity, and generate open-chain replenishment results and dynamic replenishment plan.

[0095] In this embodiment, obtaining tea packaging box production orders, production line schedules, and bills of materials to generate a production material demand chain includes the following steps:

[0096] Match tea packaging box production orders with production line schedules to generate order schedule matching results;

[0097] Specifically, this includes extracting the order number, packaging box specifications, order quantity, and order delivery time from tea packaging box production orders;

[0098] Extract the production line number, production line location, process type, planned start time, planned end time, planned production quantity, and task execution sequence from the production line schedule;

[0099] Write the production line schedule with the same order number and the same packaging box specifications into the corresponding tea packaging box production order;

[0100] Production tasks are divided according to production line number, process type, and execution time, and a task material basic dataset is generated.

[0101] Specifically, this includes: dividing scheduling records that are continuously executed on the same production line and have the same packaging box specifications into the same production task;

[0102] Divide scheduling records with different production line numbers, different packaging box specifications, or discontinuous execution times into different production tasks;

[0103] Extract the material number, material type, unit material usage, process loss ratio, line preparation time, minimum requisition quantity, inspection items, acceptance range and applicable process from the bill of materials.

[0104] Determine the required quantity and time period for each production task based on the planned production quantity and bill of materials, and generate a task material requirement record.

[0105] Specifically, this includes multiplying the planned production quantity by the unit material consumption to obtain the basic demand quantity;

[0106] Multiply the basic demand quantity by the process loss ratio to obtain the process loss quantity;

[0107] Add the basic demand quantity to the process loss quantity to obtain the demand quantity;

[0108] The start time of the demand period is determined by advancing the planned start time by the time of material preparation at the line.

[0109] The planned end time is determined as the end time of the demand period;

[0110] Arrange task material requirement records according to demand time period and process execution sequence to generate production material requirement chain;

[0111] Specifically, this includes: arranging each production task from earliest to latest according to the start time of the demand period; arranging them according to the process execution order when the start time of the demand period is the same; and arranging them according to the task execution order when the process type is the same.

[0112] Record the order number, production task, production line number, production line location, process type, material type, required quantity, required time period, minimum requisition quantity, packaging box specifications, and order delivery time in sequence.

[0113] In this embodiment, obtaining the process progress, actual material input, and actual material remaining of historical production tasks, and correcting the production material demand chain to generate a corrected production material demand chain includes the following steps:

[0114] Match historical production tasks according to packaging box specifications, production line number, process type and material type, and generate corresponding results for historical tasks;

[0115] Specifically, this includes: obtaining the current collection time, and for each production task in the production material demand chain, selecting the 20 historical production tasks whose completion time is closest to the current collection time;

[0116] Collect the historical demand period start time, historical demand period end time, actual start time, actual end time, abnormal downtime duration, process progress, qualified completion quantity, actual material input, and actual material remaining quantity for each historical production task;

[0117] Calculate the actual material consumption of historical production tasks according to the process progress, and generate historical material consumption records;

[0118] Specifically, this includes: dividing each historical production task into 10 consecutive process progress intervals, and calculating the cumulative actual material input and actual material remaining at the end of each process progress interval;

[0119] The quantity after deducting the actual material surplus from the cumulative actual material input is determined as the actual material consumption at the corresponding process progress position.

[0120] The time when the actual material consumption first occurs is defined as the start time of actual demand.

[0121] The effective demand end time is determined by subtracting the abnormal downtime from the time when the actual material consumption stops increasing.

[0122] Abnormal historical production tasks are screened out based on the actual material consumption per unit, and valid historical material consumption records are generated.

[0123] Specifically, this includes dividing the actual material consumption at the end of each historical production task by the number of qualified completions to obtain the unit actual material consumption.

[0124] Arrange the 20 units of actual material consumption from smallest to largest, delete the first two units of actual material consumption and the last two units of actual material consumption, and determine the remaining 16 historical material consumption records corresponding to historical production tasks as valid historical material consumption records.

[0125] Adjust the required quantity based on valid historical material consumption records, and generate task material adjustment records;

[0126] Specifically, this includes dividing the actual material consumption at each process progress position of each valid historical production task by the actual material consumption at the end of that valid historical production task to obtain the cumulative consumption ratio.

[0127] Add up the 16 cumulative consumption ratios corresponding to the same process progress position and divide by 16 to obtain the corrected cumulative consumption ratio, and arrange them in order of process progress from earliest to latest to form a process cumulative consumption ratio sequence.

[0128] Add up the actual material consumption of 16 units and divide by 16 to get the corrected unit material consumption. Multiply the corrected unit material consumption by the planned production quantity of the current production task to get the corrected demand quantity.

[0129] Based on valid historical material consumption records, correct the demand period and generate a corrected production material demand chain;

[0130] Specifically, this includes: calculating the time difference between the actual demand start time and the historical demand period start time for each of the 16 effective historical production tasks, and the time difference between the effective demand end time and the historical demand period end time. The two sets of time differences are added together and divided by 16 to obtain the demand start correction duration and the demand end correction duration.

[0131] By using the demand start correction duration and demand end correction duration to shift the start and end times of the current production task's demand period, the corrected demand period is obtained;

[0132] Replace the corresponding demand quantity with the revised demand quantity, replace the corresponding demand period with the revised demand period, and rearrange each production task according to the start time of the revised demand period, the process execution order, and the task execution order.

[0133] In this embodiment, obtaining warehouse inventory, production line temporary inventory, order-locked inventory, and in-transit inventory to generate a batch supply chain includes the following steps:

[0134] Divide inventory into different categories according to material batch, inventory status and material location, and generate batch inventory segment records;

[0135] Specifically, this includes: extracting material batches, material types, inventory quantities, quantities to be shipped, quantities frozen for quality, storage locations, and inspection status from warehouse inventory;

[0136] Extract the material batch, material type, material requisition quantity, actual input quantity, confirmed return quantity, and production line from the temporary inventory on the production line.

[0137] Extract the material batch, locked quantity, occupied production task, location of locked material, and inventory release processing time from the order-locked inventory;

[0138] Extract material batches, material types, shipment quantities, received quantities, transportation loss quantities, and estimated arrival times from the inventory in transit;

[0139] The warehouse location, the production line location corresponding to the production line, and the location of the locked material are all converted into the material location, and the locked quantity is marked to the corresponding batch inventory segment record;

[0140] The available quantity is determined based on the inventory quantity recorded in each batch inventory segment, and a batch available quantity record is generated;

[0141] Specifically, this includes: for warehouse inventory that has passed inspection, subtracting the quantity to be shipped and the quantity frozen for quality from the inventory count to obtain the physical available quantity in the warehouse;

[0142] The quantity of materials temporarily stored on the production line is obtained by subtracting the actual quantity used and then adding the quantity of materials returned.

[0143] The quantity of goods already received and the quantity lost due to transportation will be deducted from the quantity of goods already shipped from the inventory in transit to obtain the quantity of goods available in transit.

[0144] The smaller of the physical available quantity in the warehouse or the physical available quantity temporarily stored on the production line and the locked quantity shall be determined as the locked available quantity;

[0145] The quantity remaining after deducting the locked available quantity from the corresponding physical available quantity is determined as the unlocked available quantity.

[0146] Match each material batch with the material testing data and packaging box specifications to determine the applicable production task;

[0147] Specifically, this includes: reading the testing items and acceptance ranges corresponding to each packaging box specification and material type from the bill of materials;

[0148] For face paper, ink, and laminating materials, compare the color test value, gloss test value, and thickness test value with the corresponding acceptance range;

[0149] For cardboard and lining materials, compare the measured values ​​of basis weight, thickness, moisture content, and compressive strength with the corresponding acceptance ranges.

[0150] For adhesive materials, the viscosity test value, solid content test value, drying time test value, and bond strength test value are compared with the corresponding acceptance range.

[0151] Establish a correlation between the batch inventory segment records where all test values ​​fall within the corresponding acceptance range and the corresponding production tasks;

[0152] Determine the material transfer process based on the location of the material and the location of the target production line, and generate a location transfer record;

[0153] Specifically, this includes: obtaining the path length from the material's location to each production line location, the material transfer speed, the loading time, and the unloading time; dividing the path length by the material transfer speed and then adding the loading time and unloading time sequentially to obtain the material transfer processing time; and recording the path length and material transfer processing time according to the material's location and the production line location.

[0154] The production time for each batch of materials is determined based on inventory status and material transfer process.

[0155] Specifically, this includes: obtaining the current collection time and determining the current collection time as the production time of the temporary inventory in the target production line;

[0156] The time after adding the corresponding material transfer and processing time to the current collection time is determined as the production time of warehouse inventory and production line temporary inventory located on other production lines.

[0157] The estimated arrival time is determined by adding unloading time, inspection time, and line-side delivery time to the estimated arrival time, and the time after that is determined as the production time of the in-transit inventory.

[0158] The later time between the end time of the correction demand period occupying the production task and the inventory release processing time, and the available production time corresponding to the location of the material, is determined as the available production time of the locked quantity relative to other applicable production tasks.

[0159] Arrange each batch of materials according to the production time available to generate a batch supply chain;

[0160] Specifically, this includes: establishing batch supply records for batch inventory segments formed by the same batch of materials under different inventory states or in different material locations, and recording the material batch, material type, inventory status, material location, unlocked available quantity, locked available quantity, occupied production task, available quantity in transit, applicable production task, material transfer processing time, and available time for production in sequence.

[0161] In this embodiment, matching the corrected production material demand chain with the batch supply chain to determine the complete set of supply units and generate a complete set of supply units includes the following steps:

[0162] Collect all necessary materials according to the production task and generate a task-necessary material record.

[0163] Specifically, this includes: extracting the types of materials required for the same production task in the corresponding process from the corrected production material demand chain, identifying the extracted material types as all necessary materials, and recording the corrected demand quantity, corrected demand period, minimum requisition quantity and packaging box specifications for each necessary material.

[0164] The latest time among the start times of the modified demand periods corresponding to all necessary materials shall be determined as the start time of the complete set demand period.

[0165] The earliest time among the end times of the correction demand period corresponding to all necessary materials shall be determined as the end time of the complete set demand period.

[0166] Each necessary material is matched with an applicable material batch to generate a candidate batch record for necessary materials;

[0167] Specifically, this includes: screening batch supply records that are consistent in material type, suitable for the corresponding production task, and can be put into production no later than the start time of the complete set of requirements;

[0168] Add the unlocked available quantity to the locked available quantity locked to the current production task to obtain the current task's allocable quantity;

[0169] The quantity of in-transit available for production that can be put into production no later than the start time of the complete set demand period is defined as the quantity of in-transit tasks that can be allocated.

[0170] The existing allocable quantity of tasks or the allocable quantity of tasks in transit are determined as the initial allocable quantity of tasks in the corresponding batch of material supply records;

[0171] Generate necessary material batch groups by combining material batches according to the revised required quantity and minimum requisition quantity;

[0172] Specifically, this includes: dividing the revised demand quantity by the minimum requisition quantity and rounding up to obtain the requisition unit demand quantity;

[0173] Divide the initial number of tasks that can be allocated by the minimum number of units to be requisitioned, and then round down to obtain the number of available requisition units.

[0174] A batch of material supply records in which the number of available requisition units reaches the required number of requisition units is defined as a single batch of material batches.

[0175] A combination in which the total number of available requisition units from two or more batches of the same material supply records reaches the required number of requisition units is defined as a multi-batch material batch group.

[0176] According to the production time available, the necessary material batches are allocated requisition units from earliest to latest, and the number of allocated requisition units is multiplied by the minimum requisition quantity to obtain the material batch allocation quantity.

[0177] Cross-combining the necessary material batches to generate candidate complete material supply units;

[0178] Specifically, this includes: selecting one necessary material batch group from the necessary material batch groups corresponding to each necessary material, and combining the selected necessary material batch groups into candidate complete material supply units;

[0179] The latest time among the available production times of all batch feeding records included in the candidate complete feeding unit is determined as the complete feeding time.

[0180] Subtract the material batch allocation quantity from the initial task allocation quantity to obtain the remaining batch quantity;

[0181] Divide the remaining quantity of each batch by the initial number of tasks that can be allocated to obtain the remaining proportion of the batch. Then add up the remaining proportions of each batch to obtain the total remaining proportion of the batch.

[0182] Candidate material supply units are selected based on the batch quantity, the total remaining batch ratio, and the material supply time, and a set of material supply units is generated.

[0183] Specifically, this includes: retaining candidate complete material supply units where the cumulative batch allocation quantity of each necessary material reaches the corresponding corrected demand quantity and the complete material supply time is no later than the start time of the complete demand period;

[0184] For the same production task, the candidate complete material supply unit is selected in order of the minimum number of batches of materials used, the minimum total value of the remaining batch ratio, and the earliest complete material supply time.

[0185] The selected candidate material supply units are designated as complete material supply units, and the production task, all necessary materials, material batches, material batch allocation quantity, batch remaining quantity, complete set demand period, and complete set supply time are recorded.

[0186] In this embodiment, determining production tasks not covered by the complete material supply unit and generating candidate batch migration relationships includes the following steps:

[0187] Determine the target production tasks and their material shortages based on the coverage of the complete set of material supply units, and generate records of uncovered production tasks;

[0188] Specifically, this includes: mapping the production tasks in the corrected production material demand chain to the production tasks in the complete set of material supply units;

[0189] Production tasks not covered by complete material supply units are identified as target production tasks. The batch allocation quantities of each necessary material for the target production task are accumulated to obtain the quantity supplied to the target task.

[0190] The positive part of the revised demand quantity after deducting the quantity already supplied for the target task is determined as the quantity of uncovered materials.

[0191] Select batches of the same material from the material batches occupied by other production tasks to generate migration batch screening results;

[0192] Specifically, this includes: reading batch supply records from the batch supply chain that have the same material type as the uncovered material, are applicable to the target production task, can be put into production no later than the start time of the complete set demand period of the target production task, and have a available quantity greater than 0.

[0193] The production task occupying the corresponding material batch is identified as the source production task, and the smaller of the locked available quantity and the uncovered material quantity of the target production task is identified as the candidate migration upper limit.

[0194] Determine the alternative material supply batches and alternative material supply times based on other available material batches from the source production task;

[0195] Specifically, this includes: selecting from the batch supply chain records of the same batch that are applicable to the source production task, not written into the complete set of supply units, and not read by the current migration batch selection results;

[0196] The corresponding unlocked available quantity, the locked available quantity locked to the source production task, or the available quantity in transit are determined as the source task's allocable quantity, and the source task's allocable quantity is accumulated sequentially from earliest to latest according to the time when it can be put into production;

[0197] The batch supply records that participate in the accumulation are identified as alternative supply batches, and the production time corresponding to the alternative supply batch when the cumulative source task allocation quantity first reaches the candidate migration limit is identified as the alternative supply time.

[0198] The quantity that must be retained is determined based on the cumulative material consumption prior to the replacement supply time.

[0199] Specifically, this includes: selecting historical production tasks that are consistent with the packaging box specifications, production line number, process type and material type of the source production task, dividing the actual material consumption of each historical production task at different process progress positions by the actual material consumption at the end of the process to obtain the cumulative consumption ratio.

[0200] The cumulative consumption ratio at the same progress position of the process is averaged to form a sequence of cumulative consumption ratios of source tasks;

[0201] The schedule of the alternative material supply process is determined according to the position of the alternative material supply time within the period of adjusted demand for the source production task.

[0202] Multiply the revised demand quantity by the corresponding cumulative consumption ratio to obtain the cumulative demand consumption quantity before the replacement supply time;

[0203] The cumulative production task currently occupies the material batch allocation quantity, excluding the batch of materials to be migrated, and the production time is no later than the replacement material supply time, to obtain the reserved supply quantity of other batches;

[0204] The positive part of the cumulative demand consumption quantity after deducting the actual consumption quantity of the source task and the reserved supply quantity of other batches is determined as the quantity that must be retained.

[0205] The number of units that can be migrated is determined based on the locked available quantity, the quantity that must be retained, and the minimum quantity that can be issued.

[0206] Specifically, this includes: determining the positive portion of the locked available quantity after deducting the quantity that must be retained as the batch migration margin;

[0207] Divide the batch's transferable surplus by the minimum requisition quantity and round down to obtain the number of transferable requisition units.

[0208] Multiply the number of transferable units by the minimum transfer quantity to obtain the batch transferable quantity;

[0209] The smaller of the batch transferable quantity and the quantity of uncovered materials corresponding to the target production task is determined as the transferable quantity;

[0210] Generate candidate batch migration relationships based on the migrateable quantities of all uncovered material combinations for the target production task;

[0211] Specifically, this includes: for each type of uncovered material, selecting a single material batch whose migrateable quantity reaches the number of uncovered materials, or selecting multiple material batches whose cumulative migrateable quantity reaches the number of uncovered materials, to form a single migration batch group;

[0212] Cross-combine the individual migration batch groups corresponding to each uncovered material, retaining the sum of the quantity supplied for the target task and the cumulative migrationable quantity, so that all necessary materials for the target production task reach the corrected demand quantity respectively.

[0213] Record the target production task, source production task, material type, material batch, alternative supply batch, allocable quantity of source task, reserved supply quantity of other batches, required reserved quantity, alternative supply time, relocatable quantity, and material batch occupancy relationship before and after relocation.

[0214] In this embodiment, for candidate batch migration relationships, determining the types of materials missing from the source production task after the material batch transfer, the quantity of uncovered materials, and the material depletion time, and generating gap propagation relationships includes the following steps:

[0215] Simulate and adjust the material batch allocation quantity according to the candidate batch migration relationship, and generate batch migration simulation records;

[0216] Specifically, this includes: reading the target production task, source production task, material batch, transferable quantity, and material batch occupancy relationship before migration from the candidate batch migration relationship; without changing the actual record of the batch supply chain, deducting the transferable quantity from the material batch allocation quantity corresponding to the source production task and adding it to the material batch allocation quantity corresponding to the target production task to form the material batch occupancy relationship after migration.

[0217] Based on the cumulative material supply process of the source production tasks reorganized according to the available production time, a material supply time sequence after the source task migration is generated.

[0218] Specifically, this includes: subtracting the migrateable quantity from the material batch allocation quantity corresponding to the material batch to be migrated in the original production task to obtain the quantity to be retained after migration;

[0219] Select from the batch supply chain records of the same batch that are applicable to the source production task and have not been assigned to other production tasks;

[0220] Write the quantity retained after migration and the available quantity corresponding to each batch of material supply records into the corresponding production time position, and accumulate the supply quantity of each time position in order from earliest to latest time.

[0221] Reorganize the cumulative consumption process of the source production tasks according to the revised demand period and historical material consumption process to generate the source task demand consumption time series;

[0222] Specifically, this includes selecting historical production tasks that match the packaging box specifications, production line number, process type, and material type of the source production task.

[0223] The cumulative consumption ratio is obtained by dividing the actual material consumption of each historical production task at different process progress positions by the actual material consumption at the end.

[0224] The cumulative consumption ratio at the same progress position of the process is averaged to form a sequence of cumulative consumption ratios of source tasks;

[0225] The period of adjustment demand for source production tasks is divided into continuous time intervals corresponding to the cumulative consumption ratio sequence of source tasks.

[0226] The revised demand quantity is multiplied by the cumulative consumption ratio at each process progress position to obtain the cumulative demand consumption quantity at the end of each time interval.

[0227] By comparing the cumulative supply process and the cumulative consumption process, the types of materials missing and the quantity of uncovered materials from the source production task can be determined.

[0228] Specifically, this includes: reading the cumulative supply quantity and the corresponding cumulative demand consumption quantity at the end of each time interval, no later than that time position;

[0229] The positive part of the cumulative demand consumption quantity minus the cumulative supply quantity is determined as the quantity not covered in the stage;

[0230] The maximum value among the uncovered quantities for each time interval is determined as the uncovered material quantity, and the material types with uncovered material quantities greater than 0 are determined as the material types missing from the source production task;

[0231] The material depletion time is determined based on the time and location of the first occurrence of the uncovered quantity in the phase.

[0232] Specifically, this includes: reading the number of uncovered stages for each time interval from earliest to latest, and determining the time interval in which the number of uncovered stages first exceeds 0 as the exhaustion time interval;

[0233] Read the cumulative demand consumption and cumulative supply quantity at the start and end positions of the exhaustion time interval, and determine the material exhaustion time according to the position occupied by the cumulative supply quantity between the cumulative demand consumption quantity at the start and end positions;

[0234] When there are multiple missing material types, the earliest time among the material depletion times corresponding to each material type is determined as the material depletion time of the source production task;

[0235] Connect the material gap of the target production task to the source production task to generate a gap propagation relationship;

[0236] Specifically, this includes: sequentially recording the target production task, source production task, material batch, material type, migrateable quantity, material batch occupancy relationship after migration, material types missing from the source production task, quantity of uncovered materials, and material depletion time.

[0237] In this embodiment, the gap propagation relationship is filtered out according to the material depletion time, the quantity of uncovered materials, the type of missing materials, the repetition of production tasks, and the order delivery time to generate a monotonic gap propagation diagram. The steps include the following:

[0238] Convert the gap propagation relationship into gap nodes and node connection relationships to generate the initial gap propagation graph;

[0239] Specifically, this includes: identifying the target production task in each gap propagation relationship as the current gap node;

[0240] The corresponding source production task is identified as the new gap node;

[0241] The process of transferring material batches from the source production task to the target production task is defined as the node connection relationship from the current gap node to the new gap node;

[0242] Production tasks that are not covered by complete material supply units and are not source production tasks in other gap transmission relationships are identified as initial gap nodes;

[0243] Filter out node connections according to the direction of material depletion time;

[0244] Specifically, this includes: reading the material depletion time of the current gap node and the new gap node respectively, and deleting the node connection relationship where the material depletion time of the new gap node is not later than the material depletion time of the current gap node;

[0245] Node connections are filtered out based on changes in the quantity of uncovered materials and the types of missing materials.

[0246] Specifically, this includes: for the same type of material missing in the current gap node and the new gap node, deleting node connections where the number of uncovered materials in the new gap node is greater than the number of uncovered materials in the current gap node; and deleting the corresponding node connections when the new gap node is missing a type of material that is not included in the current gap node.

[0247] Based on the repetition of production tasks, eliminate node connections that form cycles;

[0248] Specifically, this includes: starting from each initial gap node, writing the production tasks that have passed through along the node connection direction in sequence, generating a path task identifier sequence, and deleting the node connection relationship pointing to the new gap node when the source production task corresponding to the new gap node to be written already exists in the path task identifier sequence.

[0249] Filter out node connections that cause orders to be overdue based on order delivery time;

[0250] Specifically, this includes: reading the location of materials and the material transfer processing time from the batch supply chain; adding the material transfer processing times in the same path sequentially to obtain the cumulative migration processing time; adding the cumulative migration processing time to the planned end time of the corresponding production task to obtain the adjusted planned end time; and deleting the node connection relationship in the same tea packaging box production order where the latest adjusted planned end time is later than the order delivery time.

[0251] Organize the filtered gap nodes and node connection relationships to generate a monotonic gap transmission diagram;

[0252] Specifically, this includes: retaining gap nodes that can be reached from the initial gap node along the node connection direction, deleting gap nodes that are not connected to any initial gap node, and sequentially recording the production task, missing material type, uncovered material quantity, and material depletion time corresponding to each gap node, as well as the material batch, migrateable quantity, material transfer processing time, cumulative migration processing time, and material batch occupancy relationship after migration corresponding to each node connection relationship.

[0253] In this embodiment, starting from the first gap node in the monotonic gap transmission graph, searching for migration paths and generating closable migration paths includes the following steps:

[0254] Determine the first gap node based on the material depletion time and establish the path status;

[0255] Specifically, this includes: reading each initial gap node from the monotonic gap transfer graph, determining the initial gap node with the earliest material depletion time as the first gap node, and establishing the first path status that records the current gap node, the production tasks that have been passed, the material batches that have been used, the material batch occupancy relationship copy, and the cumulative migration processing time;

[0256] Expand the path state layer by layer along the node connection relationships;

[0257] Specifically, this includes: reading all node connection relationships pointing to the new gap node from the current gap node; copying the current path state for each node connection relationship; writing the corresponding source production task into the production task that has already been passed; writing the corresponding material batch into the material batch that has already been used; deducting the migrateable quantity from the material batch allocation quantity corresponding to the source production task and adding it to the material batch allocation quantity corresponding to the target production task; updating the material batch occupancy relationship copy; adding the material transfer processing time to the cumulative migration processing time; and generating the next path state.

[0258] Based on the material batch occupancy relationship in the path status, filter the remaining inventory and in-transit inventory, and determine the termination of the complete set of material supply units;

[0259] Specifically, this includes: reading batch supply records from the batch supply chain that are applicable to the production task corresponding to the current gap node and have not been written into the material batches that have already been used;

[0260] The positive part of the unlocked available quantity after deducting the material batch allocation quantity already recorded in the material batch occupancy relationship copy is determined as the remaining inventory quantity in the path;

[0261] Read the available quantities in transit for materials that can be put into production no later than the start time of the corresponding complete set demand period, and accumulate the remaining inventory quantity and available quantities in transit for each missing material along the corresponding path.

[0262] When all missing materials reach the corresponding number of uncovered materials, the batch feeding records of the batches involved in the feeding will be combined to determine the terminated complete feeding unit.

[0263] Connect the path states from the first path state to the terminating complete material supply unit to generate candidate closed migration paths;

[0264] Specifically, this includes: starting from the first path state, sequentially reading the source production task, material batch, transferable quantity, material transfer processing time, and updated material batch occupancy relationship copy added to each path state, and connecting the last path state with the terminated complete set of material supply unit;

[0265] Candidate closed migration paths are verified in the order from the end of the path to the first gap node, and path supply verification results are generated.

[0266] Specifically, this includes: allocating material batches in the terminated complete material supply unit to the production tasks corresponding to the gap nodes at the end of the path, then sequentially adjusting the material batch occupancy relationship in each path status, and for each production task that has passed through, recalculating the cumulative supply quantity and cumulative demand consumption quantity within the corrected demand period according to the adjusted material batch occupancy relationship, and retaining candidate closed migration paths where the cumulative supply quantity reaches the corresponding cumulative demand consumption quantity and the adjusted plan end time is not later than the order delivery time;

[0267] Candidate closed migration paths are selected based on the number of production tasks involved and the total duration of the gap, and closed migration paths are generated.

[0268] Specifically, this includes determining the latest time among the available production times for all batches of material supply records contained in the terminated complete material supply unit as the resumption time for the gap node at the end of the path;

[0269] Read the connection relationship of each node sequentially from the end of the path to the first gap node, and add the corresponding material transfer processing time to the recovery feeding time of the next gap node to obtain the recovery feeding time of the previous gap node.

[0270] The time difference between the resumption of material supply and the depletion of material is defined as the duration of the gap. The durations of the gaps in the same path are added together to obtain the total duration of the gap.

[0271] The number of non-repeating production tasks in the candidate closed migration path is determined as the number of production tasks involved. The candidate closed migration path with the fewest number of production tasks involved and the shortest total duration of the gap is selected.

[0272] In this embodiment, adjusting the material batch occupancy relationship according to a closable migration path, and when no closable migration path is generated, filtering out blocked materials and determining the corresponding replenishment quantity, and generating open-chain replenishment results and dynamic replenishment plans include the following steps:

[0273] Adjust the material batch occupancy relationship according to the path status in the closable migration path;

[0274] Specifically, this includes: when generating a closable migration path, allocating the material batches in the terminated complete feeding unit to the production task corresponding to the gap node at the end of the path, and sequentially deducting the migratable quantity from the material batch allocation quantity corresponding to the source production task and adding it to the material batch allocation quantity corresponding to the target production task in the order from the end of the path to the first gap node; and updating the batch feeding chain and complete feeding unit set using the material batch occupancy relationship copy in the last path state.

[0275] Identify unclosed end gap nodes from the path states that have stopped expanding;

[0276] Specifically, this includes: when no closable migration path is generated, reading the path status where there is no terminating complete material supply unit and no next node connection relationship, determining the corresponding current gap node as an unclosed end gap node, and reading the missing material type, uncovered material quantity, material depletion time, used material batches, and material batch occupancy relationship copy for the corresponding production task.

[0277] Based on the remaining supply quantity of the unclosed end gap node, filter the blocking materials and generate a blocking material record;

[0278] Specifically, this includes: reading batch supply records from the batch supply chain that are applicable to the corresponding production task and have not been written into the batches of materials that have already been used;

[0279] The positive part of the unlocked available quantity after deducting the material batch allocation quantity already recorded in the material batch occupancy relationship copy is determined as the remaining inventory quantity in the path, and the available quantity in transit that can be put into production no later than the material depletion time is read.

[0280] The positive part of the quantity of uncovered materials after deducting the remaining inventory quantity along the route and the available quantity in transit is determined as the quantity to be replenished, and the material types with a quantity to be replenished greater than 0 are determined as blocked materials.

[0281] Determine the replenishment quantity and replenishment time corresponding to the blocked materials based on the packaging supply quantity and supply duration, and generate candidate replenishment records;

[0282] Specifically, this includes: reading the single-package supply quantity, minimum order quantity, supply time, unloading time, inspection time, and line-side delivery time of the blocking materials from the bill of materials and supply data;

[0283] Divide the quantity to be replenished by the quantity supplied per single package, round up, and multiply the rounded result by the quantity supplied per single package to obtain the quantity of the package in multiples.

[0284] The larger of the package quantity and the minimum order quantity shall be determined as the replenishment quantity;

[0285] By sequentially adding the supply time, unloading time, inspection time, and line-side delivery time to the current collection time, the available time for replenishment to be put into production can be obtained.

[0286] Subtract the delivery time, inspection time, and unloading time from the material depletion time in sequence to obtain the material arrival time limit;

[0287] Subtract the delivery time from the material arrival time to obtain the replenishment initiation time;

[0288] Connect the candidate replenishment records to the unclosed end gap node to generate candidate open chain results;

[0289] Specifically, this includes: determining the replenishment quantity as the available quantity in transit, determining the replenishment time as the production time available, establishing a replenishment simulation batch, and writing the replenishment simulation batch into the batch supply chain copy;

[0290] For the same unclosed end gap node, the replenishment simulation batches corresponding to each blocked material are combined, and the quantity allocated to the corresponding production task is determined as the replenishment simulation batch allocation quantity. When the replenishment simulation batch allocation quantity of each blocked material reaches the corresponding replenishment quantity, the corresponding replenishment simulation batch combination is determined as the termination of the complete set of material supply unit. The material batch occupancy relationship copy in each path status is re-verified in the order from the end of the path to the first gap node.

[0291] Candidate open-chain results are filtered according to the replenishment demand ratio and the remaining replenishment ratio, and open-chain replenishment results and dynamic replenishment plans are generated.

[0292] Specifically, this includes dividing the replenishment quantity of each blocked material by the corresponding adjusted demand quantity to obtain the replenishment demand ratio;

[0293] The remaining replenishment ratio is obtained by dividing the replenishment quantity by the replenishment quantity after deducting the quantity allocated in the simulated replenishment batch.

[0294] Add up the replenishment demand ratios from the same candidate open-chain results to get the total replenishment demand ratio;

[0295] Add up the remaining replenishment ratios from the same candidate open-chain results to get the total remaining replenishment ratio;

[0296] The candidate open chain result with the smallest total replenishment demand ratio is selected. When the total replenishment demand ratios are the same, the candidate open chain results with the smallest remaining replenishment ratio, the fewest production tasks involved, and the shortest total duration of the gap are selected in sequence to generate an open chain replenishment result. The blocked materials, the quantity to be replenished, the replenishment quantity, the replenishment initiation time, the material arrival time limit, the replenishment time that can be put into production, the replenishment simulation batch, the replenishment simulation batch allocation quantity, the status of each path, and the adjustment order of the material batch occupancy relationship are recorded to generate a dynamic replenishment plan.

[0297] Example 1: To verify the feasibility of this invention in practice, it was applied to a material demand forecasting and inventory replenishment management scenario in a tea packaging box production workshop. (Reference) Figure 2 and Figure 3 The production workshop is equipped with printing, lamination, die-cutting, and forming production lines to produce three types of tea packaging boxes: Specification A, Specification B, and Specification C. The main materials used are face paper, grey board, ink, lamination materials, adhesive materials, and inner lining materials. During the implementation and verification period, 20 consecutive production days were recorded, involving a total of 72 production tasks, 12 tea packaging box production orders, and 46 material batches.

[0298] Figure 2 and Figure 3 In the diagram, target production task T1 represents the target production task with a material shortage. Source production tasks T2, T3, T4, and T5 represent the source production tasks that provide batches of materials to be migrated during the shortage transfer process or that generate new material shortages due to the migration of material batches. The task numbers in the diagram are only used to indicate different production tasks.

[0299] The original management method mainly calculated the required quantity based on the order quantity and the bill of materials, and issued a replenishment prompt when the available inventory was lower than the safety stock. When the production schedule changed, some material batches were locked by other orders, or the inventory in transit was delayed in arriving, the system could not determine whether each material batch could be put into production as a set within the required period. This resulted in situations where the paper sheet inventory was sufficient but the laminating material was not in place, duplicate replenishment of a single material, and material batches being occupied by production tasks.

[0300] In this scenario, the system acquires tea packaging box production orders, production line schedules, and bills of materials. It then divides production tasks according to production line number, process type, and execution time, and generates a material demand chain based on planned production quantity, unit material consumption, and process loss ratio. Taking a production task corresponding to a tea packaging box of specification B as an example, this task plans to produce 12,000 boxes. According to the bill of materials, the required quantity of face paper is 12,360 sheets, grey board is 12,180 sheets, laminating material is 2,860 square meters, ink is 138 kg, and adhesive material is 216 kg. The system further matches 20 historical production tasks with the same packaging box specifications, production line number, process type, and material type. Based on the process progress, actual material input, and actual material remaining of these historical production tasks, the system calculates the actual material consumption and filters out historical production tasks with actual material consumption at either end of the chain. After processing, the required quantities for correcting the face paper were 12,690 sheets, the required quantity for correcting the grey board was 12,340 sheets, the required quantity for correcting the laminating material was 2,975 square meters, the required quantity for correcting the ink was 146 kg, and the required quantity for correcting the adhesive material was 229 kg. The actual consumption quantities recorded after completing this production task were 12,640 sheets, 12,310 sheets, 2,958 square meters, 145 kg, and 227 kg, respectively. The average quantity deviation calculated using the corrected quantity requirements was 0.83%, while the average quantity deviation under the original management method was 4.92%.

[0301] The system adjusts the demand period based on the first occurrence and the cessation of actual material consumption in historical production tasks. This production task was originally planned to complete material preparation 60 minutes before production begins. Historical data shows that laminating materials for similar tasks typically need to enter the line-side temporary storage area 108 minutes before production starts. The system advances the start time of the demand period for laminating materials by 48 minutes and delays the end time by 36 minutes based on the actual process duration. The implementer recorded an average deviation of 31 minutes between the actual material input time and the corresponding demand period in the corrected production material demand chain, compared to an average deviation of 117 minutes when the demand period was determined according to the original production schedule. This indicates that the corrected production material demand chain more closely approximates the actual material input process.

[0302] The system acquires warehouse inventory, production line temporary inventory, order-locked inventory, and in-transit inventory, and categorizes inventory according to material batch, inventory status, and material location. During implementation verification, a total of 46 material batches were read: 21 warehouse inventory batches, 11 production line temporary inventory batches, 8 order-locked inventory batches, and 6 in-transit inventory batches. The system deducts quantities awaiting shipment, frozen quantities, actual input quantities, and transportation losses to determine the unlocked available quantity, locked available quantity, and in-transit available quantity for each material batch. This, combined with material inspection data, packaging specifications, material location, and material transfer processing time, determines the applicable production tasks and the available production time, forming a batch supply chain. After the system matches the corrected production material demand chain with the batch supply chain, 68 out of 72 production tasks formed complete material supply units, achieving a complete supply coverage rate of 94.44%. The original management method allocated inventory only based on total material quantity, and 52 production tasks completed all material preparation before the start of the plan, achieving a complete supply coverage rate of 72.22%.

[0303] For target production task A, which is not covered by the complete material supply unit, the system determines that it lacks 720 square meters of coating material, 460 sheets of grey board, and 18 kg of ink. The system filters 11 migration batches from other production tasks using the same material batches. The coating material batch used by source production task B has a locked available quantity of 980 square meters. Based on the cumulative material consumption before the alternative supply time, the system determines that source production task must retain 260 square meters, therefore the corresponding migrateable quantity is 720 square meters. After the material batch transfer, source production task B has 410 square meters of uncovered material within the original demand period, with the material depletion time occurring 6.3 hours after the migration execution. Another coating material batch used by source production task C has 420 square meters that can be migrated. After being migrated to source production task B, source production task C has 180 square meters of uncovered material, with the material depletion time occurring 9.1 hours after the migration execution. There is a 200-square-meter batch of coating material in transit in the batch supply chain. Its production time is 8.4 hours after the migration is executed. It can complete the supply before the material depletion time of source production task C, thus forming a closed migration path from target production task A, source production task B, source production task C to the batch of coating material in transit.

[0304] When constructing the monotonic gap transmission graph, the system filters node connections based on material depletion time, the quantity of uncovered materials, the type of missing materials, the repetition of production tasks, and the order delivery time. Of the 11 gap transmission relationships, 3 were filtered out because the material depletion time of the new gap node was earlier than expected; 2 were filtered out because the quantity of uncovered materials increased; 1 was filtered out because a new type of missing material was introduced; 1 was filtered out because the production task was repeated, forming a cycle; and 1 was filtered out because the adjusted plan end time was later than the order delivery time. Ultimately, 3 node connections were retained. The system expands the path states starting from the first gap node with the earliest material depletion time, forming 6 path states and 2 candidate closed migration paths. Based on the number of production tasks involved and the total duration of the gap, a closed migration path involving 3 production tasks and a total gap duration of 54 minutes is selected. After adjusting the material batch occupancy relationship according to this path, target production task A completes all material preparation before the start of the plan, and neither source production task B nor source production task C experiences any production line stoppages due to material shortages.

[0305] For another production task lacking adhesive material, no closable migration path was formed in the monotonic gap transfer graph. The system determined the replenishment quantity to be 64 kg based on the remaining supply quantity at the unclosed end gap node, and identified the adhesive material as the blocking material. The corresponding supply data showed a single-package supply quantity of 20 kg, a minimum order quantity of 80 kg, a supply time of 5.5 hours, an unloading time of 24 minutes, an inspection time of 38 minutes, and a line-side delivery time of 16 minutes. The system determined the replenishment quantity to be 80 kg, calculated that the replenishment could be put into production 6.8 hours after the replenishment was initiated, and connected the replenishment simulation batch to the unclosed end gap node for supply verification. This production task actually used 66 kg of replenishment material, leaving a remaining replenishment quantity of 14 kg; the original safety stock replenishment method replenished 120 kg according to a fixed replenishment batch, leaving 54 kg remaining after actual use. The dynamic replenishment scheme generated by this invention reduces the remaining quantity of the replenishment by 40 kg, while ensuring that the material enters the production line temporary storage area 22 minutes before the planned depletion.

[0306] The implementers summarized the operational data over 20 consecutive production days and used the existing management methods to process the same production orders, production line schedules, and initial inventory data as a comparison. The comparison results are shown in Table 1.

[0307] Table 1. Comparison of the Implementation Effects of Material Demand Forecasting, Batch Collaborative Supply, and Dynamic Replenishment Average Deviation of Material Requirement 7.36% 2.08% Decreased by 5.28 percentage points Average deviation of material demand period 126 minutes 37 minutes shortened by 89 minutes Complete set of material supply production task quantity 52 68 Add 16 Complete set of material supply coverage 72.22% 94.44% An increase of 22.22 percentage points. The proportion of actual inventory batches used to the total number of available batches 69.57% 84.78% An increase of 15.21 percentage points. The number of new production tasks with material shortages after batch migration 4 0 Reduce 4 Cumulative downtime of production line waiting for materials 286 minutes 64 minutes Shortened by 222 minutes Number of emergency restocks 9 times 3 times Reduce 6 times Average remaining percentage of replenishment materials 18.64% 6.27% Decreased by 12.37 percentage points Production tasks completed according to order delivery time 88.89% 98.61% An increase of 9.72 percentage points

[0308] As can be seen from the above implementation data, this invention corrects the production material demand chain by using historical material consumption data, making the material demand quantity and demand period closer to the actual production consumption process; it coordinates warehouse inventory, production line temporary inventory, order-locked inventory, and in-transit inventory through batch supply chain and complete supply unit set, improving the complete supply coverage of production tasks; it identifies gaps caused by material migration through candidate batch migration relationship, gap transmission relationship, and monotonic gap transmission diagram, and uses closable migration paths to adjust the material batch occupancy relationship, reducing new material shortages caused by batch migration; when the migration path cannot be closed, it determines the replenishment quantity and replenishment time by blocking materials, the quantity to be replenished, and the supply time, reducing the remaining replenishment quantity and the production line downtime waiting time for materials.

[0309] The above are merely preferred embodiments of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.

Claims

1. A method for material demand forecasting and dynamic inventory replenishment management in a tea packaging box production workshop, characterized in that, Includes the following steps: Obtain tea packaging box production orders, production line schedules, and bills of materials to generate a production material demand chain; Obtain the process progress, actual material input, and actual material remaining of historical production tasks, correct the production material demand chain, and generate a corrected production material demand chain. Acquire warehouse inventory, production line temporary inventory, order-locked inventory, and in-transit inventory to generate a batch supply chain; The corrected production material demand chain is matched with the batch material supply chain to determine the complete material supply unit and generate a complete material supply unit set. Identify production tasks not covered by the complete material supply unit and generate candidate batch migration relationships; For candidate batch migration relationships, determine the types of materials missing from the source production task after the material batch is transferred, the quantity of uncovered materials, and the material depletion time, and generate gap propagation relationships; Based on the material depletion time, the quantity of uncovered materials, the types of missing materials, the repetition of production tasks, and the order delivery time, gap transmission relationships are filtered out to generate a monotonic gap transmission diagram. Starting from the first gap node in the monotonic gap transit graph, search for migration paths and generate closable migration paths; Adjust the material batch occupancy relationship according to the closable migration path. If no closable migration path is generated, filter the blocked materials and determine the corresponding replenishment quantity, and generate open-chain replenishment results and dynamic replenishment plan.

2. The method for material demand forecasting and dynamic inventory replenishment management in a tea packaging box production workshop according to claim 1, characterized in that, The process of obtaining tea packaging box production orders, production line schedules, and bills of materials to generate a production material demand chain includes the following steps: Match tea packaging box production orders with production line schedules to generate order schedule matching results; Production tasks are divided according to production line number, process type, and execution time, and a task material basic dataset is generated. Determine the required quantity and time period for each production task based on the planned production quantity and bill of materials, and generate a task material requirement record. Arrange the task material requirement records according to the demand period and the order of process execution to generate a production material requirement chain.

3. The method for material demand forecasting and dynamic inventory replenishment management in a tea packaging box production workshop according to claim 1, characterized in that, The process of obtaining the historical production task's process progress, actual material input, and actual material remaining quantity, and then correcting the production material demand chain to generate a corrected production material demand chain, includes the following steps: Match historical production tasks according to packaging box specifications, production line number, process type and material type, and generate corresponding results for historical tasks; Calculate the actual material consumption of historical production tasks according to the process progress, and generate historical material consumption records; Abnormal historical production tasks are screened out based on the actual material consumption per unit, and valid historical material consumption records are generated. Adjust the required quantity based on valid historical material consumption records, and generate task material adjustment records; Based on valid historical material consumption records, the demand period is adjusted to generate a corrected production material demand chain.

4. The method for material demand forecasting and dynamic inventory replenishment management in a tea packaging box production workshop according to claim 1, characterized in that, The process of acquiring warehouse inventory, production line temporary inventory, order-locked inventory, and in-transit inventory to generate a batch supply chain includes the following steps: Divide inventory into different categories according to material batch, inventory status and material location, and generate batch inventory segment records; The available quantity is determined based on the inventory quantity recorded in each batch inventory segment, and a batch available quantity record is generated; Match each material batch with the material testing data and packaging box specifications to determine the applicable production task; Determine the material transfer process based on the location of the material and the location of the target production line, and generate a location transfer record; The production time for each batch of materials is determined based on inventory status and material transfer process. Arrange each batch of materials according to its production availability to generate a batch supply chain.

5. The method for material demand forecasting and dynamic inventory replenishment management in a tea packaging box production workshop according to claim 1, characterized in that, The process of matching the corrected production material demand chain with the batch supply chain to determine complete sets of supply units and generate complete sets of supply units includes the following steps: Collect all necessary materials according to the production task and generate a task-necessary material record. Each necessary material is matched with an applicable material batch to generate a candidate batch record for necessary materials; Generate necessary material batch groups by combining material batches according to the revised required quantity and minimum requisition quantity; Cross-combining the necessary material batches to generate candidate complete material supply units; Candidate material supply units are selected based on the batch quantity, the total remaining percentage of the batch, and the material supply time, and a set of material supply units is generated.

6. The method for material demand forecasting and dynamic inventory replenishment management in a tea packaging box production workshop according to claim 1, characterized in that, The process of identifying production tasks not covered by the complete material supply unit and generating candidate batch migration relationships includes the following steps: Determine the target production tasks and their material shortages based on the coverage of the complete set of material supply units, and generate records of uncovered production tasks; Select batches of the same material from the material batches occupied by other production tasks to generate migration batch screening results; Determine the alternative material supply batches and alternative material supply times based on other available material batches from the source production task; The quantity that must be retained is determined based on the cumulative material consumption prior to the replacement supply time. The number of units that can be migrated is determined based on the locked available quantity, the quantity that must be retained, and the minimum quantity that can be issued. Generate candidate batch migration relationships based on the total number of uncovered material combinations that can be migrated for the target production task.

7. The method for material demand forecasting and dynamic inventory replenishment management in a tea packaging box production workshop according to claim 1, characterized in that, The process of determining the types of materials missing from the source production task after the material batch transfer, the quantity of uncovered materials, and the material depletion time for generating gap propagation relationships based on candidate batch migration relationships includes the following steps: Simulate and adjust the material batch allocation quantity according to the candidate batch migration relationship, and generate batch migration simulation records; Based on the cumulative material supply process of the source production tasks reorganized according to the available production time, a material supply time sequence after the source task migration is generated. Reorganize the cumulative consumption process of the source production tasks according to the revised demand period and historical material consumption process to generate the source task demand consumption time series; By comparing the cumulative supply process and the cumulative consumption process, the types of materials missing and the quantity of uncovered materials from the source production task can be determined. The material depletion time is determined based on the time and location of the first occurrence of the uncovered quantity in the phase. Connect the material gap of the target production task to the source production task to generate a gap propagation relationship.

8. The method for material demand forecasting and dynamic inventory replenishment management in a tea packaging box production workshop according to claim 1, characterized in that, The process of filtering out gap propagation relationships based on material depletion time, quantity of uncovered materials, types of missing materials, repetition of production tasks, and order delivery time to generate a monotonic gap propagation diagram includes the following steps: Convert the gap propagation relationship into gap nodes and node connection relationships to generate the initial gap propagation graph; Filter out node connections according to the direction of material depletion time; Node connections are filtered out based on changes in the quantity of uncovered materials and the types of missing materials. Based on the repetition of production tasks, eliminate node connections that form cycles; Filter out node connections that cause orders to be overdue based on order delivery time; Organize the filtered gap nodes and node connection relationships to generate a monotonic gap transmission diagram.

9. The method for material demand forecasting and dynamic inventory replenishment management in a tea packaging box production workshop according to claim 1, characterized in that, The process of searching for migration paths and generating closable migration paths, starting from the first gap node in the monotonic gap transit graph, includes the following steps: Determine the first gap node based on the material depletion time and establish the path status; Expand the path state layer by layer along the node connection relationships; Based on the material batch occupancy relationship in the path status, filter the remaining inventory and in-transit inventory, and determine the termination of the complete set of material supply units; Connect the path states from the first path state to the terminating complete material supply unit to generate candidate closed migration paths; Candidate closed migration paths are verified in the order from the end of the path to the first gap node, and path supply verification results are generated. Candidate closed migration paths are selected based on the number of production tasks involved and the total duration of the gap, and closed migration paths are generated.

10. The method for material demand forecasting and dynamic inventory replenishment management in a tea packaging box production workshop according to claim 1, characterized in that, The process of adjusting material batch occupancy relationships according to closable migration paths, and when no closable migration path is generated, filtering blocked materials and determining the corresponding replenishment quantity, and generating open-chain replenishment results and dynamic replenishment plans includes the following steps: Adjust the material batch occupancy relationship according to the path status in the closable migration path; Identify unclosed end gap nodes from the path states that have stopped expanding; Based on the remaining supply quantity of the unclosed end gap node, filter the blocking materials and generate a blocking material record; Determine the replenishment quantity and replenishment time corresponding to the blocked materials based on the packaging supply quantity and supply duration, and generate candidate replenishment records; Connect the candidate replenishment records to the unclosed end gap node to generate candidate open chain results; Candidate open-chain results are filtered based on the replenishment demand ratio and the remaining replenishment ratio, generating open-chain replenishment results and dynamic replenishment plans.

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