A production method and system based on order segmentation and material state dynamic scheduling

Abstract

This invention provides a production method and system based on order segmentation and dynamic scheduling of material status, comprising: receiving orders to be manufactured and dividing them into order task units with corresponding preset delivery sequences, and establishing production tasks by sequential numbering; establishing technical tasks for each unit, breaking them down into sheet metal and electrical design tasks, and generating corresponding component lists and drawings; determining procurement priorities based on component inventory, procurement needs, replacement status, supplier delivery and arrival time; dynamically releasing manufacturing tasks according to the actual arrival status of components, with tasks corresponding to those already delivered being executed first, and those not yet delivered remaining pending; allocating released tasks to three categories of tasks: sheet metal, electrical, and mechanical installation, with mechanical tasks handling tasks with material shortages, replacements, or abnormal pending tasks; performing segmented quality inspections on units that have completed manufacturing, shipping qualified items, and returning unqualified items to mechanical tasks for rework and re-inspection; each unit independently advances the entire process without waiting for all preceding steps to be completed, and can enter the manufacturing stage according to its own arrival status.

Description

Technical Field

[0001] This invention relates to the technical field of production scheduling for power distribution cabinets, and in particular to a production method and system based on order segmentation and dynamic scheduling of material status. Background Technology

[0002] In the existing mass production process, the production department usually formulates an overall production plan based on the total order quantity after receiving a customer order, and then hands the overall production plan over to the technical department for design. After the technical department completes the complete component list and related drawings, the purchasing department purchases all components in a unified manner. After the manufacturing department obtains all or the main production components, it manufactures according to the overall order. Quality inspection is usually carried out centrally after all products are completed.

[0003] When order quantities are large and delivery cycles are short, the above production method can easily cause some undelivered components in the order to become waiting factors for the entire production process. Even if other components required for certain products or certain order task units have arrived, the manufacturing process may still be unable to start in a timely manner because it is waiting for all components or for the previous batch to be completed.

[0004] Meanwhile, during the manufacturing process, if a component fails to arrive as planned, traditional production methods can easily put the entire manufacturing task related to that component in a waiting state, thus preventing other manufacturing tasks that are already ready for production from continuing. Furthermore, traditional methods typically involve centralized quality inspection after a large batch of products is completed. When quality problems are found, the corresponding products need to be returned to the manufacturing stage for rework, further extending the overall delivery time.

[0005] Therefore, without increasing production personnel and major production equipment, how to reduce the waiting time between different production stages of orders, enable manufacturing tasks that are already ready for production to enter production ahead of schedule, and enable completed order task units to undergo quality inspection and delivery in a timely manner has become a problem that needs to be solved. Summary of the Invention

[0006] The purpose of this invention is to provide a production method and system based on order segmentation and dynamic scheduling of material status, aiming to solve the problems of design waiting, procurement waiting, material waiting, manufacturing waiting, and centralized quality inspection waiting caused by the synchronous progress of the entire order when there are large-volume orders with short delivery cycles.

[0007] To achieve the above objectives, the technical solutions of the present invention are as follows: This invention provides a production method based on order segmentation and dynamic scheduling of material status, comprising: S10: Receive the order to be manufactured and divide the order to be manufactured into multiple order task units according to the delivery order corresponding to the order to be manufactured. Each order task unit corresponds to a preset delivery order. The order task units are numbered according to the delivery order required by the user, and corresponding production tasks are established in the order of numbering. S20: Establish technical tasks for each of the order task units, and divide the technical tasks into sheet metal design tasks and electrical design tasks, and form corresponding sheet metal component lists, cabinet installation drawings, electrical component lists and electrical wiring drawings respectively; S30: Based on the sheet metal component list and electrical component list corresponding to each order task unit, classify the components according to their inventory status, procurement needs, replacement status, supplier supply status, and expected delivery time, and determine the procurement priority of each component based on the classification results. S40: Based on the actual arrival status of each component, dynamically release the manufacturing tasks in each order task unit, so that the manufacturing tasks corresponding to the components that have arrived are given priority to enter the manufacturing process, while the manufacturing tasks corresponding to the components that have not yet arrived remain in the pending execution state. S50: The released manufacturing tasks are assigned to sheet metal installation tasks, electrical installation tasks and mechanical installation tasks respectively, wherein the mechanical installation tasks are used to handle pending tasks caused by component loss, component replacement or manufacturing abnormality. S60: Perform segmented quality inspection on the completed order task units, and put the qualified order task units into the delivery process according to their delivery sequence; for the unqualified order task units, return the corresponding unqualified task to the motor installation task for rework, and re-inspect the quality after the rework is completed. Each order task unit independently advances its design, procurement, manufacturing, and quality inspection according to its delivery sequence, so that subsequent order task units do not need to wait for the completion of all manufacturing tasks of the preceding order task units before they can enter the corresponding manufacturing stage based on the arrival status of their own components.

[0008] Compared with existing technologies, this invention divides large-volume orders into multiple order task units with independent delivery sequences, so that orders no longer have to be processed as a whole, thus prioritizing tasks with earlier delivery sequences. Furthermore, it links component procurement status with order task units, allowing components that have arrived and are ready for manufacturing to enter the manufacturing process first, without waiting for all components in the entire order to arrive. Additionally, it centrally handles material shortages, component replacements, and rework tasks outside of normal manufacturing tasks through mobile installation tasks, thereby reducing interference from abnormal tasks on normal manufacturing tasks. This improves the continuous utilization of existing production resources and shortens the overall manufacturing wait time for large-volume, short-delivery-cycle orders without simultaneously increasing the number of production personnel and major production equipment.

[0009] In one embodiment, the sheet metal component list and electrical component list in S20 are specifically as follows: The sheet metal component list includes at least standard sheet metal components, non-standard sheet metal components, customized sheet metal components, and replaceable sheet metal components; The list of electrical components includes at least standard electrical components, non-standard electrical components, custom electrical components, and replaceable electrical components.

[0010] In one embodiment, when classifying the procurement status of the components in S30, components that are not in the warehouse and have no replaceable inventory components are identified as components that need to be procured, components that have spare components in the warehouse are identified as components that do not need to be procured, and components that have replaceable inventory components are identified as components that can be replaced by inventory.

[0011] In one embodiment, in S40, the expected arrival time of the component is compared with the planned manufacturing time of the corresponding order task unit, and the component is divided into priority arrival components, normal arrival components, and components that cannot arrive as planned. For components that cannot arrive as planned, first look for the same or alternative components from other order task units that have already arrived, and then allocate them across order task units if the corresponding manufacturing task is met. When the same or a replacement component cannot be obtained, the manufacturing task corresponding to the component is set to a pending state, and other manufacturing tasks in the same order task unit that are ready for execution are allowed to continue to execute.

[0012] In one embodiment, in S40, when at least one component in the same order task unit has not yet arrived, the manufacturing tasks corresponding to other components that have arrived and meet the manufacturing conditions are prioritized for manufacturing, so that the same order task unit forms a segmented manufacturing process that is not completely synchronized.

[0013] In one embodiment, the sheet metal installation task, the electrical installation task, and the mechanical installation task in S50 specifically include: The sheet metal installation tasks include at least one of the following: cabinet frame installation, cabinet internal beam installation, cabinet panel installation, cabinet door installation, and top and bottom plate installation. The electrical installation task includes primary line installation and secondary line installation. The primary line installation includes at least one of horizontal row installation, vertical row installation, component overlap row installation and terminal block installation. The secondary line installation includes at least one of panel component wiring, cabinet component wiring and terminal component wiring. The mobile installation tasks include sheet metal mobile tasks and electrical mobile tasks, which are dynamically allocated based on the manufacturing tasks that are currently in a pending or rework state.

[0014] In one embodiment, in S60, the quality inspection is performed separately according to the sheet metal manufacturing results and the electrical manufacturing results, and sheet metal quality inspection results and electrical quality inspection results are formed respectively. When the sheet metal quality inspection result or the electrical quality inspection result is unqualified, the corresponding rework task is determined according to the unqualified item, and the rework task is sent to the mechanical installation task for processing; after the rework is completed, only the quality items corresponding to the rework task are re-inspected, without having other order task units that have passed inspection re-enter the manufacturing process.

[0015] In one embodiment, each order task unit has a corresponding task status during the design, procurement, manufacturing and quality inspection stages. The task status includes at least the pending status, the processing status, the material waiting status, the manufacturing completed status, the inspection waiting status, the rework status and the completed status.

[0016] In one embodiment, in S10, a large-volume order is divided into multiple order task units, and different order task units are made to form interleaved execution states in the design, procurement, manufacturing and quality inspection stages, so as to reduce the overall waiting time formed by waiting for all order materials to arrive before manufacturing.

[0017] The present invention also provides a production system applying the production method described above, comprising: The order segmentation module is used to receive orders to be manufactured and divide the orders to be manufactured into multiple order task units according to the delivery order corresponding to the orders to be manufactured, and to establish a corresponding delivery order for each order task unit. The technical task management module, which is connected to the order segmentation module, is used to create sheet metal design tasks and electrical design tasks for each order task unit, and generate corresponding sheet metal component lists, cabinet installation drawings, electrical component lists and electrical wiring drawings. The material status management module, which is connected to the technical task management module, is used to obtain the inventory status, procurement status, replacement status, supplier delivery status and actual arrival status of the components corresponding to each order task unit, and classify the components according to the obtained status information. The procurement scheduling module, which is connected to the material status management module, is used to determine the procurement priority of components based on the procurement status of the components, supplier prices, estimated delivery time, payment methods, and delivery order of order task units. The manufacturing task scheduling module is connected to the material status management module. It is used to determine whether the corresponding manufacturing task meets the execution conditions based on the actual arrival status of each component. When the execution conditions are met, the corresponding manufacturing task is released, so that the manufacturing task that has met the execution conditions can enter the manufacturing process, while the manufacturing task that does not meet the execution conditions remains in the pending execution state. The manufacturing execution module is connected to the manufacturing task scheduling module and is used to execute sheet metal installation tasks, electrical installation tasks and mechanical installation tasks. The mechanical installation tasks are used to handle pending tasks caused by missing components, component replacement, manufacturing abnormalities or quality inspection failures. The quality inspection module, which is connected to the manufacturing execution module, is used to perform quality inspection on the completed order task units and generate corresponding quality inspection results. The rework scheduling module is connected to the quality inspection module and the manufacturing execution module respectively. When the quality inspection result is unqualified, it generates a corresponding rework task based on the unqualified item, sends the rework task to the mobile installation task in the manufacturing execution module, and re-triggers the quality inspection module to perform quality inspection after the rework is completed. And a delivery management module, which is connected to the quality inspection module, is used to generate a delivery task according to the delivery order corresponding to each order task unit after the quality inspection of the order task unit is qualified; The order segmentation module, technical task management module, material status management module, procurement scheduling module, manufacturing task scheduling module, manufacturing execution module, quality inspection module, rework scheduling module, and delivery management module communicate with each other, enabling different order task units to advance the design, procurement, manufacturing, quality inspection, and delivery processes according to their respective task status and actual material arrival status, without waiting for all components of the entire order to be manufactured to arrive or for all manufacturing tasks to be completed. Attached Figure Description

[0018] The accompanying drawings, which are included to provide a further understanding of the invention and form part of this application, illustrate exemplary embodiments of the invention and, together with their description, serve to explain the invention and do not constitute an undue limitation thereof. In the drawings: Fig. 1 This is a flowchart illustrating a production method based on order segmentation and dynamic scheduling of material status, as described in this application. Fig. 2 This is a schematic diagram of a production system based on order segmentation and dynamic scheduling of material status, as described in this application. Detailed Implementation

[0019] To better illustrate the present invention, the invention will now be described in further detail with reference to the accompanying drawings.

[0020] It should be understood that the described embodiments are merely some, not all, of the embodiments of this application. All other embodiments obtained by those skilled in the art based on the embodiments of this application without creative effort are within the scope of protection of the embodiments of this application.

[0021] The terminology used in the embodiments of this application is for the purpose of describing particular embodiments only and is not intended to limit the embodiments of this application. The singular forms “a,” “the,” and “the” used in the embodiments of this application and the appended claims are also intended to include the plural forms unless the context clearly indicates otherwise. It should also be understood that the term “and / or” as used herein refers to and includes any or all possible combinations of one or more of the associated listed items.

[0022] In the following description, when referring to the accompanying drawings, unless otherwise indicated, the same numbers in different drawings represent the same or similar elements. The embodiments described in the following exemplary embodiments do not represent all embodiments consistent with this application. Rather, they are merely examples of apparatuses and methods consistent with some aspects of this application as detailed in the appended claims. In the description of this application, it should be understood that the terms "first," "second," "third," etc., are used only to distinguish similar objects and are not necessarily used to describe a specific order or sequence, nor should they be construed as indicating or implying relative importance. Those skilled in the art can understand the specific meaning of the above terms in this application according to the specific circumstances.

[0023] Furthermore, in the description of this application, unless otherwise stated, "multiple" means two or more. "And / or" describes the relationship between related objects, indicating that three relationships can exist. For example, A and / or B can represent: A alone, A and B simultaneously, or B alone. The character " / " generally indicates that the preceding and following related objects have an "or" relationship.

[0024] This invention uses a large-volume order for low-voltage switchgear as an example. The applicant received an order from a domestic company for over 1,000 low-voltage switchgear units, requiring prompt delivery. However, similar low-voltage switchgear projects typically order around 100 units, making this large order significantly larger than usual. In traditional production methods, this large order would be planned as a whole. The production department would first develop an overall production plan based on all 1,000+ units. Then, the technical department would complete all technical designs, followed by the purchasing department procuring all components. The manufacturing workshop would then manufacture the entire product after receiving all or most of the components, and the quality inspection department would conduct a centralized inspection upon completion.

[0025] Combination Figs. 1-2 As shown, in order to solve the above problems, the present invention also provides a production system, which includes: The order segmentation module is used to receive orders to be manufactured and divide the orders to be manufactured into multiple order task units according to the delivery order corresponding to the orders to be manufactured, and to establish a corresponding delivery order for each order task unit. The technical task management module, which is connected to the order segmentation module, is used to create sheet metal design tasks and electrical design tasks for each order task unit, and generate corresponding sheet metal component lists, cabinet installation drawings, electrical component lists and electrical wiring drawings. The material status management module, which is connected to the technical task management module, is used to obtain the inventory status, procurement status, replacement status, supplier delivery status and actual arrival status of the components corresponding to each order task unit, and classify the components according to the obtained status information. The procurement scheduling module, which is connected to the material status management module, is used to determine the procurement priority of components based on the procurement status of the components, supplier prices, estimated delivery time, payment methods, and delivery order of order task units. The manufacturing task scheduling module is connected to the material status management module. It is used to determine whether the corresponding manufacturing task meets the execution conditions based on the actual arrival status of each component. When the execution conditions are met, the corresponding manufacturing task is released, so that the manufacturing task that has met the execution conditions can enter the manufacturing process, while the manufacturing task that does not meet the execution conditions remains in the pending execution state. The manufacturing execution module is connected to the manufacturing task scheduling module and is used to execute sheet metal installation tasks, electrical installation tasks and mechanical installation tasks. The mechanical installation tasks are used to handle pending tasks caused by missing components, component replacement, manufacturing abnormalities or quality inspection failures. The quality inspection module, which is connected to the manufacturing execution module, is used to perform quality inspection on the completed order task units and generate corresponding quality inspection results. The rework scheduling module is connected to the quality inspection module and the manufacturing execution module respectively. When the quality inspection result is unqualified, it generates a corresponding rework task based on the unqualified item, sends the rework task to the mobile installation task in the manufacturing execution module, and re-triggers the quality inspection module to perform quality inspection after the rework is completed. The system also includes a delivery management module, which is connected to the quality inspection module. This module generates a delivery task based on the delivery order of each order task unit after the quality inspection of the order task unit has passed. The order segmentation module, technical task management module, material status management module, procurement scheduling module, manufacturing task scheduling module, manufacturing execution module, quality inspection module, rework scheduling module, and delivery management module communicate with each other, enabling different order task units to advance the design, procurement, manufacturing, quality inspection, and delivery processes according to their respective task status and the actual arrival status of materials, without waiting for all components of the entire order to be manufactured to arrive or for all manufacturing tasks to be completed.

[0026] The modules mentioned above are linked through task data, so that different task units in an order can be in the design, procurement, manufacturing, inspection or rework state respectively, without the entire order having to wait synchronously.

[0027] This invention also provides a production method based on order segmentation and dynamic scheduling of material status, comprising: S10: Receive the order to be manufactured and divide the order to be manufactured into multiple order task units according to the delivery order corresponding to the order to be manufactured. Each order task unit corresponds to a preset delivery order. The order task units are numbered according to the delivery order required by the user, and corresponding production tasks are established in the order of numbering. Specifically, upon receiving the order, it is divided into multiple order task units based on the user's delivery sequence. For example, based on the actual delivery sequence of the user's power distribution rooms, the order is divided into delivery units for 10 power distribution rooms, subsequent power distribution rooms, etc. Each order task unit has a unique correspondence, recording: the order task unit number, the corresponding product quantity, the corresponding delivery object or power distribution room, the planned delivery time, and the delivery priority among all order task units. The low-voltage distribution cabinet corresponding to the first power distribution room requiring priority delivery is established as the first order task unit, and the low-voltage distribution cabinets corresponding to subsequent power distribution rooms are established as the second order task unit, the third order task unit, and so on. Thus, an order of over 1000 low-voltage distribution cabinets that originally needed to be processed as a whole is divided into multiple order task units that can be processed separately. It should be noted that the number of order task units is not limited to the above number, nor is it limited to division according to power distribution rooms; it can be divided according to delivery batches, product quantity, production sequence, or actual manufacturing organization method.

[0028] Furthermore, by dividing a large-volume order into multiple order task units and having different order task units form an interleaved execution state in the design, procurement, manufacturing, and quality inspection stages, the overall waiting time caused by waiting for all order materials to arrive before manufacturing can be reduced.

[0029] S20: Establish technical tasks for each of the order task units, and divide the technical tasks into sheet metal design tasks and electrical design tasks, and form corresponding sheet metal component lists, cabinet installation drawings, electrical component lists and electrical wiring drawings respectively; Specifically, after the order segmentation is completed, the order segmentation module sends each order task unit to the technical task management module. The technical task management module creates a technical task for each order task unit. Simultaneously, the technical task management module creates a material requirements set corresponding to the product set for each order task unit, and establishes a correspondence between each component in the material requirements set and the corresponding manufacturing task, thus forming a correspondence between manufacturing tasks and required components.

[0030] In this process, a manufacturing task can correspond to one or more required components, and a component can also correspond to one or more manufacturing tasks depending on its location in the product. By establishing this correspondence, the manufacturing task scheduling module can determine whether a manufacturing task is ready for execution based on the actual arrival status of the components corresponding to that specific manufacturing task, without needing to use the arrival status of all components in the entire order or the entire order task unit as the manufacturing start condition.

[0031] Each technical task includes at least two parts: sheet metal design and electrical design. 1. Sheet metal design task The sheet metal design task first compiles a list of sheet metal components based on the product quantity and product model of the corresponding order task unit. The sheet metal components are classified according to their usage and supply status, including: standard sheet metal components, non-standard sheet metal components, customized sheet metal components, and replaceable sheet metal components.

[0032] After generating the sheet metal component list, the technical task management module further creates corresponding cabinet installation drawings. These drawings can be categorized based on product structure into standard cabinet installation drawings, non-standard cabinet installation drawings, special cabinet installation drawings, and cabinet installation drawings that can be referenced from other projects. For cabinets with structures identical or similar to existing projects, relevant design data from those projects can be used as a reference; for cabinets with different structures, corresponding non-standard or special cabinet installation drawings are generated.

[0033] 2. Electrical Design Task Similar to sheet metal design tasks, electrical design tasks are established for each order task unit. The electrical design task first generates a list of electrical components, which are classified according to their usage and supply status, including: standard electrical components, non-standard electrical components, customized electrical components, and replaceable electrical components.

[0034] After completing the list of electrical components, corresponding electrical wiring diagrams are generated. These diagrams are categorized into standard, non-standard, and special wiring diagrams, or diagrams based on existing projects, depending on the actual product structure. This approach ensures that each order task unit has technical documentation corresponding to its product quantity and structure, rather than waiting for all technical documentation for an entire order of over 1000 units to be completed before proceeding to the next stage.

[0035] In this embodiment, the sheet metal component list and electrical component list in S20 specifically include: the sheet metal component list includes at least standard sheet metal components, non-standard sheet metal components, customized sheet metal components, and replaceable sheet metal components; the electrical component list includes at least standard electrical components, non-standard electrical components, customized electrical components, and replaceable electrical components. Replaceable sheet metal components and replaceable electrical components refer to alternative materials that, after evaluation and confirmation, can be used to replace the original design components, provided that they meet the requirements of functional, interface, and installation size compatibility.

[0036] S30: Based on the sheet metal component list and electrical component list corresponding to each order task unit, classify the components according to their inventory status, procurement needs, replacement status, supplier supply status, and expected delivery time, and determine the procurement priority of each component based on the classification results. Specifically, after completing the technical task, the technical task management module sends the corresponding sheet metal component list and electrical component list to the material status management module and the procurement scheduling module. The material status management module first checks the warehouse inventory status for each component.

[0037] For each component, at least the following checks should be performed: First, determine if the component exists in the warehouse. If the component does not exist, check if a replacement component exists in the warehouse. If neither the corresponding component nor a replacement component exists in the warehouse, mark the component as pending procurement. For example, if an order task unit requires component A: If component A is already in the warehouse, mark component A as available in stock. If component A is not in the warehouse, but a replacement component B that meets the design requirements is available, mark component A as replaceable. If neither component A nor a replacement component that meets the requirements exists in the warehouse, mark component A as pending procurement. This method avoids including components already in the warehouse in the procurement task.

[0038] For components identified as pending procurement, the procurement scheduling module creates corresponding procurement tasks. The module compares suppliers based on procurement information. For the same component to be procured, multiple suppliers' quotations and estimated delivery times can be obtained. In one embodiment, prices and delivery times can be compared between three or more suppliers. The price comparison results include at least: the lowest-priced supplier, the highest-priced supplier, and the supplier with the middle price. The delivery time comparison results include at least: suppliers that can meet the delivery requirements of the corresponding order task unit and suppliers that cannot meet the delivery requirements of the corresponding order task unit.

[0039] Simultaneously, payment methods are categorized, including: prepayment required, no prepayment required, cash on delivery, installment payment, cash payment, and payment by acceptance bill. The procurement scheduling module determines the procurement priority of corresponding components based on the above procurement information. For example, for the first order task unit, if a component is a critical component necessary for delivery and its expected procurement cycle is long, then that component is set as a priority procurement component. If a component is already in stock in the warehouse, no new procurement task is created. If a component has replaceable stock, the system prioritizes determining whether the stock can be used to replace the component based on design requirements, thereby reducing procurement wait times.

[0040] In this embodiment, in step S40, the estimated arrival time of the component is compared with the planned manufacturing time of the corresponding order task unit, and the components are divided into priority arrival components, normal arrival components, and components that cannot arrive as planned. For components that cannot arrive as planned, the same component or a replacement component is first searched from other order task units that have already arrived, and cross-order task unit allocation is performed if the corresponding manufacturing task is met. When the same component or a replacement component cannot be obtained, the manufacturing task corresponding to the component is set to a pending state, and other manufacturing tasks in the same order task unit that have the conditions for execution are allowed to continue to be executed.

[0041] After a procurement task is established, the material status management module continuously acquires the actual arrival status of components. Based on the relationship between the expected or actual arrival time of the components and the manufacturing plan of the corresponding order task unit, the components are divided into: priority arrival components, normal arrival components, and components that cannot arrive as planned. Among them, priority arrival components are those that need to enter the production floor first to ensure that order task units with earlier delivery sequences can start manufacturing in a timely manner; normal arrival components are those that can meet the manufacturing requirements of the corresponding order task unit according to the normal procurement cycle; and components that cannot arrive as planned are those that cannot be obtained before the planned manufacturing time based on the current procurement status.

[0042] After receiving actual delivery information, the material status management module updates the status of the corresponding components. Following the component status update, the manufacturing task scheduling module determines the material availability status of each manufacturing task based on the correspondence between manufacturing tasks and components. For a given manufacturing task, if all necessary components are available, the task is determined to be in a material-sufficient state; if at least one necessary component is not yet delivered, the task is determined to be in a material-unsufficient state, and the task remains in a pending material status. The available status includes inventory in the warehouse, completed procurement and actual delivery, and the availability of replacement components that have been confirmed to meet technical requirements. For example, component A in a certain order task unit was originally in the state of pending purchase. After the purchase is completed and the component enters the warehouse, the material status is updated from pending purchase to delivered.

[0043] In addition, when the material status management module determines that a component cannot arrive as planned, it first checks whether the same component exists in other order task units that have already entered the manufacturing process or completed procurement. For example, the first order task unit needs component A, but component A has not yet arrived; while the second order task unit has already received multiple components A. Provided that the corresponding product technical requirements are met and the delivery of the second order task unit itself is not affected, the corresponding component can be reassigned from the order task units that have already received the component. If a component that meets the requirements can be obtained, the component is allocated to the current order task unit, and the material status of the current order task unit is updated. If the same component cannot be obtained, nor can a replacement component that meets the requirements be obtained, the manufacturing task corresponding to that component is set to a pending state.

[0044] At this point, other manufacturing tasks that are already ready to be executed will continue to be carried out.

[0045] For example, if an electrical component for a distribution cabinet has not yet arrived, the installation task corresponding to that component remains in a pending material status, while cabinet installation, panel installation, or other electrical installation tasks that are already ready continue. Thus, a single material shortage issue is confined to the scope of the corresponding manufacturing task, rather than directly causing the entire order task unit to halt.

[0046] In this embodiment, when classifying the procurement status of the components in S30, components that are not in the warehouse and have no replaceable inventory components are identified as components that need to be procured, components that have spare components in the warehouse are identified as components that do not need to be procured, and components that have replaceable inventory components are identified as components that can be replaced by inventory.

[0047] S40: Based on the actual arrival status of each component, dynamically release the manufacturing tasks in each order task unit, so that the manufacturing tasks corresponding to the components that have arrived are given priority to enter the manufacturing process, while the manufacturing tasks corresponding to the components that have not yet arrived remain in the pending execution state. Specifically, after receiving the actual arrival status of components, the manufacturing task scheduling module determines whether the manufacturing task meets the execution conditions based on the arrival status of the components required for the manufacturing task. For manufacturing tasks that meet the execution conditions, the manufacturing task scheduling module releases them to the manufacturing execution module. For manufacturing tasks that do not meet the execution conditions, they remain in a pending execution state or a pending material state. The absence of execution conditions for a certain manufacturing task within an order task unit does not cause all manufacturing tasks in that order task unit to stop. For example, the first order task unit requires cabinet frame installation, cabinet internal beam installation, electrical component installation, and wiring. If all the sheet metal components required for cabinet frame installation have arrived, but not all the electrical components have arrived, the manufacturing task scheduling module can first release the cabinet frame installation task and the cabinet internal installation task that has already met the conditions. The electrical installation tasks related to the electrical components that have not yet arrived remain in a pending material state. The corresponding electrical installation tasks are released only after the corresponding electrical components arrive. Therefore, different manufacturing tasks within an order task unit no longer need to start synchronously.

[0048] S50: The released manufacturing tasks are assigned to sheet metal installation tasks, electrical installation tasks and mechanical installation tasks respectively, wherein the mechanical installation tasks are used to handle pending tasks caused by component loss, component replacement or manufacturing abnormality. Specifically, the manufacturing execution module includes at least sheet metal installation tasks, electrical installation tasks, and mechanical installation tasks.

[0049] 1. Sheet metal installation task Sheet metal installation tasks include cabinet installation tasks and door panel installation tasks. Cabinet installation tasks include: cabinet frame installation, internal beam installation, and cabinet panel installation. Door panel installation tasks include: cabinet door installation, top panel installation, and bottom panel installation. The manufacturing task scheduling module releases tasks that are ready for execution sequentially based on the material arrival status.

[0050] 2. Electrical installation tasks Electrical installation tasks include primary wiring installation and secondary wiring installation. Primary wiring installation includes: horizontal wiring installation, vertical wiring installation, component overlap wiring installation, primary component installation, secondary component installation, and terminal block installation. Secondary wiring installation includes: panel component wiring, cabinet component wiring, and terminal component wiring. Electrical installation tasks are also dynamically released based on the actual arrival status of the corresponding components.

[0051] 3. Mobile installation task Mechanical installation tasks include sheet metal mechanical tasks and electrical mechanical tasks. Mechanical installation tasks are primarily used to handle abnormal tasks outside of normal manufacturing processes. For example, when a component cannot arrive as planned, the corresponding task enters a pending state; when a component replacement task arises, the corresponding task enters the mechanical installation task; when manufacturing defects are discovered during quality inspection, a rework task is created and enters the mechanical installation task. Therefore, mechanical installation tasks do not wait for a fixed production process, but are dynamically acquired based on abnormal tasks generated throughout the production process.

[0052] When at least one component in the same order task unit has not yet arrived, the manufacturing tasks corresponding to other components that have arrived and meet the manufacturing conditions are prioritized for manufacturing, thus creating a segmented manufacturing process within the same order task unit that is not fully synchronized. Manufacturing tasks are released according to the actual arrival status of the components. For components that have arrived and meet the manufacturing conditions, their corresponding manufacturing tasks are executed first. For components that arrive later, their corresponding manufacturing tasks are released after arrival. For example, the first order task unit includes manufacturing tasks M1, M2, M3, and M4. Among them, all components required for M1 have arrived, all components required for M2 have arrived, M3 is missing one component, and M4 is missing two components. The manufacturing task scheduling module first releases M1 and M2, while M3 and M4 remain in a pending material status. When the missing component for M3 arrives, M3 is released and enters manufacturing; when the missing component for M4 arrives, M4 is released and enters manufacturing. Therefore, the manufacturing process does not operate in a "unified start after all materials in the entire order are complete" manner, but rather proceeds item by item according to the actual material arrival status.

[0053] Because the component procurement schedules differ across order task units, each order task unit can be at different manufacturing stages. For example, the first order task unit might be in the quality inspection stage, the second in the electrical installation stage, the third in the sheet metal installation stage, the fourth in the procurement stage, and the fifth in the technical design stage; these different stages can coexist. Therefore, the entire order no longer represents a single linear production process, but rather a production process where multiple order task units intertwine.

[0054] In this embodiment, each order task unit has a corresponding task status in the design, procurement, manufacturing and quality inspection stages. The task status includes at least the pending status, the processing status, the material waiting status, the manufacturing completed status, the inspection pending status, the rework status and the completed status.

[0055] S60: Perform segmented quality inspection on the completed order task units, and put the qualified order task units into the delivery process according to their delivery sequence; for the unqualified order task units, return the corresponding unqualified task to the motor installation task for rework, and re-inspect the quality after the rework is completed. Specifically, once a task unit for an order is manufactured, it is sent to the quality inspection module. The quality inspection module creates sheet metal inspection tasks and electrical inspection tasks. The sheet metal inspection task is used to check the sheet metal installation results, and the electrical inspection task is used to check the electrical installation and wiring results. If both the sheet metal and electrical inspections are qualified, the corresponding task unit for the order is considered qualified.

[0056] After receiving a qualified status, the delivery management module arranges shipment according to the delivery order of that order task unit among all order task units. In this embodiment, quality inspection does not need to wait for the completion of manufacturing of all 1000+ products. Quality inspection can begin as soon as a particular order task unit has completed its corresponding manufacturing task.

[0057] If the quality inspection module finds a quality problem in a task unit of an order, it generates a non-conforming result. The rework scheduling module determines the corresponding rework task based on the non-conforming item. For example, if there is a problem with the cabinet installation, a sheet metal rework task is generated; if there is a problem with the electrical wiring, an electrical rework task is generated. The rework task is then sent to the mechanical installation task in the manufacturing execution module.

[0058] After the mobile installation task completes the corresponding problem handling, the rework completion status is sent to the quality inspection module, which then inspects the corresponding item again. If the inspection is qualified, the order task unit enters the qualified state; if it fails again, a rework task is generated again, forming a closed loop.

[0059] The quality inspection is conducted separately according to the sheet metal manufacturing results and the electrical manufacturing results, and sheet metal quality inspection results and electrical quality inspection results are generated separately. When the sheet metal quality inspection result or the electrical quality inspection result is unqualified, the corresponding rework task is determined according to the unqualified item, and the rework task is sent to the mechanical installation task for processing. After the rework is completed, only the quality items corresponding to the rework task are re-inspected, without having to re-enter the manufacturing process of other order task units that have passed inspection.

[0060] Each order task unit independently advances its design, procurement, manufacturing, and quality inspection according to its delivery sequence, so that subsequent order task units do not need to wait for the completion of all manufacturing tasks of the preceding order task units before they can enter the corresponding manufacturing stage based on the arrival status of their own components.

[0061] Compared with existing technologies, this invention divides large-volume orders into multiple order task units with independent delivery sequences, so that orders no longer have to be processed as a whole, thus prioritizing tasks with earlier delivery sequences. Furthermore, it links component procurement status with order task units, allowing components that have arrived and are ready for manufacturing to enter the manufacturing process first, without waiting for all components in the entire order to arrive. Additionally, it centrally handles material shortages, component replacements, and rework tasks outside of normal manufacturing tasks through mobile installation tasks, thereby reducing interference from abnormal tasks on normal manufacturing tasks. This improves the continuous utilization of existing production resources and shortens the overall manufacturing wait time for large-volume, short-delivery-cycle orders without simultaneously increasing the number of production personnel and major production equipment.

[0062] It should be noted that traditional production methods typically proceed in the following manner: overall order, overall design, overall procurement, overall material kitting, overall manufacturing, overall quality inspection, and overall shipment. This embodiment, however, proceeds in the following manner: order segmentation, independent design of task units, material status classification, release of manufacturing tasks based on actual arrival status, segmented manufacturing, segmented quality inspection, rework of non-conforming tasks, and delivery of conforming tasks. Therefore, multiple order task units at different stages of production can exist simultaneously.

[0063] When a component in an order is out of stock, only the manufacturing task corresponding to that missing component enters the pending execution state, while other tasks that have already met the execution conditions can continue. When a component in an order completes manufacturing, it can proceed to quality inspection without waiting for other components to complete. This reduces the waiting time caused by "waiting for all components to arrive" and "waiting for all products to be completed before unified quality inspection."

[0064] When organizing the production of an order for more than 1,000 low-voltage distribution cabinets using the above method, the overall order is divided into multiple order task units, and the design, procurement, manufacturing and quality inspection processes can be carried out alternately between different order task units. Therefore, tasks that are ready for production can be given priority to enter the manufacturing process.

[0065] The above embodiments demonstrate that by segmenting order tasks into units, classifying material status, implementing first-come-first-served production, allowing partial waiting for tasks with material shortages, handling flexible tasks, and conducting segmented quality inspections, the overall waiting time between different production stages in large-volume orders can be reduced.

[0066] In this embodiment, the modules do not operate independently, but rather are associated with each other based on order task units. After the order segmentation module generates an order task unit, it sends the order task unit to the technical task management module. The technical task management module establishes a material requirement set, a manufacturing task set, and a correspondence between manufacturing tasks and required components based on the order task units. The material status management module obtains the actual arrival status of each component in the material requirement set and sends the material status to the manufacturing task scheduling module. The manufacturing task scheduling module determines whether a manufacturing task meets the execution conditions based on the process prerequisites between manufacturing tasks and sends the manufacturing tasks that meet the conditions to the manufacturing execution module.

[0067] When a manufacturing task is in a pending material status due to a lack of components, the material status management module can retrieve available components from other order task units and determine whether to perform material allocation based on the impact of the allocation on the manufacturing task and delivery requirements of the allocated order task unit. After the material allocation is completed, the material status management module updates the material status of the relevant order task unit, and the manufacturing task scheduling module re-evaluates whether the manufacturing task meets the execution conditions based on the updated material status.

[0068] After the manufacturing execution module completes the manufacturing task, it sends the manufacturing completion status to the quality inspection module. The quality inspection module generates a pass or fail result. For a fail result, the rework scheduling module generates a corresponding rework task and resends it to the manufacturing execution module. For a pass result, the delivery management module generates a corresponding delivery task according to the delivery order of the order task units.

[0069] This invention is not limited to the above-described embodiments. If any modifications or variations to this invention do not depart from the spirit and scope of this invention, and if such modifications and variations fall within the scope of the claims and equivalent technologies of this invention, then this invention also intends to include such modifications and variations.

Claims

1. A production method based on order segmentation and dynamic scheduling of material status, characterized in that, include: S10: Receive the order to be manufactured and divide the order to be manufactured into multiple order task units according to the delivery order corresponding to the order to be manufactured. Each order task unit corresponds to a preset delivery order. The order task units are numbered according to the delivery order required by the user, and corresponding production tasks are established in the order of numbering. S20: Establish technical tasks for each of the order task units, and divide the technical tasks into sheet metal design tasks and electrical design tasks, and form corresponding sheet metal component lists, cabinet installation drawings, electrical component lists and electrical wiring drawings respectively; S30: Based on the sheet metal component list and electrical component list corresponding to each order task unit, classify the components according to their inventory status, procurement needs, replacement status, supplier supply status, and expected delivery time, and determine the procurement priority of each component based on the classification results. S40: Based on the actual arrival status of each component, dynamically release the manufacturing tasks in each order task unit, so that the manufacturing tasks corresponding to the components that have arrived are given priority to enter the manufacturing process, while the manufacturing tasks corresponding to the components that have not yet arrived remain in the pending execution state. S50: The released manufacturing tasks are assigned to sheet metal installation tasks, electrical installation tasks and mechanical installation tasks respectively, wherein the mechanical installation tasks are used to handle pending tasks caused by component loss, component replacement or manufacturing abnormality. S60: Perform segmented quality inspection on the completed order task units, and put the qualified order task units into the delivery process according to their delivery sequence; for the unqualified order task units, return the corresponding unqualified task to the motor installation task for rework, and re-inspect the quality after the rework is completed. Each order task unit independently advances its design, procurement, manufacturing, and quality inspection according to its delivery sequence, so that subsequent order task units do not need to wait for the completion of all manufacturing tasks of the preceding order task units before they can enter the corresponding manufacturing stage based on the arrival status of their own components.

2. The production method based on order segmentation and dynamic scheduling of material status according to claim 1, characterized in that, The sheet metal component list and electrical component list in S20 are specifically as follows: The sheet metal component list includes at least standard sheet metal components, non-standard sheet metal components, customized sheet metal components, and replaceable sheet metal components; The list of electrical components includes at least standard electrical components, non-standard electrical components, custom electrical components, and replaceable electrical components.

3. The production method based on order segmentation and dynamic scheduling of material status according to claim 1, characterized in that: When classifying the procurement status of the components in S30, components that are not in the warehouse and have no replaceable inventory components are identified as components that need to be procured, components that have spare components in the warehouse are identified as components that do not need to be procured, and components that have replaceable inventory components are identified as components that can be replaced by inventory.

4. The production method based on order segmentation and dynamic scheduling of material status according to claim 1, characterized in that: In S40, the estimated arrival time of the components is compared with the planned manufacturing time of the corresponding order task unit, and the components are divided into priority arrival components, normal arrival components, and components that cannot arrive as planned. For components that cannot arrive as planned, first look for the same or alternative components from other order task units that have already arrived, and then allocate them across order task units if the corresponding manufacturing task is met. When the same or a replacement component cannot be obtained, the manufacturing task corresponding to the component is set to a pending state, and other manufacturing tasks in the same order task unit that are ready for execution are allowed to continue to execute.

5. The production method based on order segmentation and dynamic scheduling of material status according to claim 1, characterized in that: In S40, when at least one component in the same order task unit has not yet arrived, the manufacturing tasks corresponding to other components that have arrived and meet the manufacturing conditions are prioritized for manufacturing, so that the same order task unit forms a segmented manufacturing process that is not completely synchronous.

6. The production method based on order segmentation and dynamic material status scheduling according to claim 1, characterized in that, The sheet metal installation task, the electrical installation task, and the mechanical installation task in S50 are specifically as follows: The sheet metal installation tasks include at least one of the following: cabinet frame installation, cabinet internal beam installation, cabinet panel installation, cabinet door installation, and top and bottom plate installation. The electrical installation task includes primary line installation and secondary line installation. The primary line installation includes at least one of horizontal row installation, vertical row installation, component overlap row installation and terminal block installation. The secondary line installation includes at least one of panel component wiring, cabinet component wiring and terminal component wiring. The mobile installation tasks include sheet metal mobile tasks and electrical mobile tasks, which are dynamically allocated based on the manufacturing tasks that are currently in a pending or rework state.

7. The production method based on order segmentation and dynamic scheduling of material status according to claim 1, characterized in that: In S60, the quality inspection is carried out separately according to the sheet metal manufacturing results and the electrical manufacturing results, and sheet metal quality inspection results and electrical quality inspection results are generated separately. When the sheet metal quality inspection result or the electrical quality inspection result is unqualified, the corresponding rework task is determined according to the unqualified item, and the rework task is sent to the mechanical installation task for processing; After rework is completed, only the quality items corresponding to the rework task are re-inspected, without having to re-enter the manufacturing process for other order task units that have already passed inspection.

8. The production method based on order segmentation and dynamic scheduling of material status according to claim 1, characterized in that: Each order task unit has a corresponding task status in the design, procurement, manufacturing and quality inspection stages. The task status includes at least the pending status, the processing status, the material waiting status, the manufacturing completed status, the inspection pending status, the rework status and the completed status.

9. The production method based on order segmentation and dynamic scheduling of material status according to claim 1, characterized in that: In S10, by dividing a large-volume order into multiple order task units and making different order task units form an interleaved execution state in the design, procurement, manufacturing and quality inspection stages, the overall waiting time formed by waiting for all order materials to arrive before manufacturing can be reduced.

10. A production system applying the production method as described in any one of claims 1 to 9, characterized in that, include: The order segmentation module is used to receive orders to be manufactured and divide the orders to be manufactured into multiple order task units according to the delivery order corresponding to the orders to be manufactured, and to establish a corresponding delivery order for each order task unit. The technical task management module, which is connected to the order segmentation module, is used to create sheet metal design tasks and electrical design tasks for each order task unit, and generate corresponding sheet metal component lists, cabinet installation drawings, electrical component lists and electrical wiring drawings. The material status management module, which is connected to the technical task management module, is used to obtain the inventory status, procurement status, replacement status, supplier delivery status and actual arrival status of the components corresponding to each order task unit, and classify the components according to the obtained status information. The procurement scheduling module, which is connected to the material status management module, is used to determine the procurement priority of components based on the procurement status of the components, supplier prices, estimated delivery time, payment methods, and delivery order of order task units. The manufacturing task scheduling module is connected to the material status management module. It is used to determine whether the corresponding manufacturing task meets the execution conditions based on the actual arrival status of each component. When the execution conditions are met, the corresponding manufacturing task is released, so that the manufacturing task that has met the execution conditions can enter the manufacturing process, while the manufacturing task that does not meet the execution conditions remains in the pending execution state. The manufacturing execution module is connected to the manufacturing task scheduling module and is used to execute sheet metal installation tasks, electrical installation tasks and mechanical installation tasks. The mechanical installation tasks are used to handle pending tasks caused by missing components, component replacement, manufacturing abnormalities or quality inspection failures. The quality inspection module, which is connected to the manufacturing execution module, is used to perform quality inspection on the completed order task units and generate corresponding quality inspection results. The rework scheduling module is connected to the quality inspection module and the manufacturing execution module respectively. When the quality inspection result is unqualified, it generates a corresponding rework task based on the unqualified item, sends the rework task to the mobile installation task in the manufacturing execution module, and re-triggers the quality inspection module to perform quality inspection after the rework is completed. And a delivery management module, which is connected to the quality inspection module, is used to generate a delivery task according to the delivery order corresponding to each order task unit after the quality inspection of the order task unit is qualified; The order segmentation module, technical task management module, material status management module, procurement scheduling module, manufacturing task scheduling module, manufacturing execution module, quality inspection module, rework scheduling module, and delivery management module communicate with each other, enabling different order task units to advance the design, procurement, manufacturing, quality inspection, and delivery processes according to their respective task status and actual material arrival status, without waiting for all components of the entire order to be manufactured to arrive or for all manufacturing tasks to be completed.

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