1. A material demand calculation system based on a production plan, comprising:

the production information loading module is in signal connection with the industrial control system and is used for loading industrial production information required by material demand calculation in the industrial control system and issuing the loaded industrial production information;

the material demand calculation module is respectively in signal connection with the production information loading module and the industrial storage system, and is used for receiving the loaded industrial production information, obtaining a material demand result after analysis and calculation, and sending the obtained material demand result to the industrial storage system;

the industrial production information at least comprises planning work singular numbers of all production lines, daily planning product discharging lists of all production lines, in-process data in the industrial control system, inventory in-process data of all material bins, maximum packages in a material master file, minimum material throwing rate of materials, a material control blacklist and material putting control rules;

the material demand calculation module specifically comprises a material demand calculation module,

the information receiving and judging unit is in signal connection with the production information loading module and is used for receiving the loaded industrial production information, judging whether the required materials are in compliance according to the industrial production information, if the required materials are in compliance, forwarding the industrial production information, if the required materials are not in compliance, uploading an instruction to the production information loading module, and reloading the industrial production information,

the material demand calculation unit is in signal connection with the information receiving and judging unit and the industrial warehousing system, and is used for calculating a material demand result according to the industrial production information and sending the obtained material demand result to the industrial warehousing system;

the material demand result comprises the material demands of all production lines and all material bins and the HUB order demand.

2. The production plan-based material demand calculation system according to claim 1, wherein: the industrial control system is an MES system, and the industrial warehousing system comprises an SAP system and an INFOR system.

3. A production plan-based material demand calculation system using the production plan-based material demand calculation system according to any one of claims 1 or 2, comprising the steps of:

s1, loading production information, loading industrial production information required during calculation of the material loading requirement from the industrial control system, and issuing the loaded industrial production information;

and S2, calculating material demand, receiving the loaded industrial production information, obtaining a material demand result after analysis and calculation, and sending the obtained material demand result to an industrial storage system.

4. The production plan-based material demand calculation system according to claim 3, wherein the S1 specifically comprises the following steps:

the method comprises the steps of loading industrial production information required by calculation of material demand from an industrial control system, wherein the industrial control system is an MES system, the industrial production information at least comprises planning work singular numbers of all production lines, daily planning product discharge lists of all production lines, in-process data in the industrial control system, in-process stock data of all material bins, maximum packages in a material master file, minimum material throwing rate of materials, a material control blacklist and a material putting control rule, and then issuing the loaded industrial production information.

5. The production plan-based material demand calculation system according to claim 4, wherein the S2 specifically comprises the following steps:

s21, receiving the industrial production information, judging whether the required materials fall into a material control blacklist or not and whether the required materials accord with material putting control rules or not according to the industrial production information, if the required materials do not fall into the material control blacklist or accord with the material putting control rules, forwarding the industrial production information, and otherwise, returning to S1 and reloading the industrial production information;

s22, calculating the material requirements of the material bins corresponding to the production lines according to the planned labor number of the production lines and the daily planned product discharge list of the production lines;

s23, judging whether a product discharging list is established for a product in the demand according to the material demand of the material bin, if so, entering S24 in sequence, otherwise, returning to S1 and reloading industrial production information;

s24, respectively calculating the material requirements of each production line according to the industrial production information;

and S25, summarizing the material demands of the production lines and the material bins and the HUB order demands as material demand results, and sending the obtained material demand results to the industrial storage system, wherein the industrial storage system comprises an SAP system and an INFOR system, the SAP system automatically matches the quota problem of the materials, and the INFOR system generates a final material demand order according to the material demand results.

6. The production plan-based material demand calculation system according to claim 5, wherein the calculation formula of the material demand of each material bin in S22 is as follows: the material demand of the material bin = planned work number of the production line:dailyplanned product discharge number of the production line.

7. The system of claim 5, wherein the formula for calculating the material requirement of each production line in S24 is: the material requirements of the production lines = planned work of the production lines-daily planned product discharge of the production lines-minimum material throwing rate of the material in the master stock-in-process data in the industrial control system, and then the material requirements of the production lines are combined to generate the HUB order requirements.

Background

In industrial production, particularly in the electronics manufacturing industry, the calculation and management of material demand is a daily necessity for management personnel within an enterprise. In the actual application at the present stage, the calculation of the material demand is mainly performed by manual operation, and generally includes the following steps:

s1, manually establishing a report, setting maintenance basic information such as BOM (Bill of Material), Bill of materials, minimum package, beginning of manufacture and the like, and embedding a corresponding formula.

S2, producing products according to the daily plan, manually calculating the quantity of the required materials, wherein the calculation steps at least comprise: a. inputting the planned capacity of each production line and the BOM of the corresponding product; b. multiplying the planned capacity of each production line by the BOM of the product; c. adjusting the residual arrangement material receiving number of each production line; d. and adjusting the blacklist to control the materials.

S3, summarizing the quantity of the material demands, and splitting the material demands of each storage position (each production line and a transfer bin);

s4, checking whether the order material in the transfer bin has a corresponding quota manually, and then uploading the order to an SAP (System applications and products in data processing) system manually.

It can be seen from the above operation flow that there are many places in the prior art that need to be improved, which can be summarized as the following problems:

1. the manual calculation of the material requirement is time-consuming and labor-consuming, the calculation result is greatly influenced by subjective factors of operators, and the data accuracy is difficult to guarantee;

2. the condition that materials are easy to enter less or more is easily caused when some complex working conditions are involved, such as a double-station line body;

3. the blacklist materials in the operation process are completely used by manual intervention, so that the workload of management personnel in a production enterprise is increased;

4. because the conditions of material throwing and material moving in the production line cannot be monitored in real time, the accuracy of the material preparation of each production line is difficult to ensure;

5. the bin returning materials cannot be monitored in real time, so that the accuracy of a calculation result is further influenced.

In summary, a need exists in the art to provide a system and a method for calculating material demand based on a production plan in the electronic manufacturing industry to overcome the above-mentioned shortcomings in the prior art.

Disclosure of Invention

In view of the above-mentioned drawbacks of the prior art, the present invention provides a system and a method for calculating material demand based on production plan, which are as follows.

A production plan based material demand calculation system comprising:

the production information loading module is in signal connection with the industrial control system and is used for loading industrial production information required by material demand calculation in the industrial control system and issuing the loaded industrial production information;

the material demand calculation module is respectively in signal connection with the production information loading module and the industrial storage system, and is used for receiving the loaded industrial production information, obtaining a material demand result after analysis and calculation, and sending the obtained material demand result to the industrial storage system;

the industrial production information at least comprises planning work singular numbers of all production lines, daily planning product discharging lists of all production lines, in-process data in the industrial control system, inventory in-process data of all material bins, maximum packages in a material master file, minimum material throwing rate of materials, a material control blacklist and material putting control rules;

the material demand calculation module specifically comprises a material demand calculation module,

the information receiving and judging unit is in signal connection with the production information loading module and is used for receiving the loaded industrial production information, judging whether the required materials are in compliance according to the industrial production information, if the required materials are in compliance, forwarding the industrial production information, if the required materials are not in compliance, uploading an instruction to the production information loading module, and reloading the industrial production information,

the material demand calculation unit is in signal connection with the information receiving and judging unit and the industrial warehousing system, and is used for calculating a material demand result according to the industrial production information and sending the obtained material demand result to the industrial warehousing system;

the material demand result comprises the material demands of all production lines and all material bins and the HUB order demand.

Preferably, the industrial control system is an MES system, and the industrial warehousing system comprises an SAP system and an INFOR system.

A production plan based material demand calculation system using the production plan based material demand calculation system as described above, comprising the steps of:

s1, loading production information, loading industrial production information required during calculation of the material loading requirement from the industrial control system, and issuing the loaded industrial production information;

and S2, calculating material demand, receiving the loaded industrial production information, obtaining a material demand result after analysis and calculation, and sending the obtained material demand result to an industrial storage system.

Preferably, S1 specifically includes the following steps:

the method comprises the steps of loading industrial production information required by calculation of material demand from an industrial control system, wherein the industrial control system is an MES system, the industrial production information at least comprises planning work singular numbers of all production lines, daily planning product discharge lists of all production lines, in-process data in the industrial control system, in-process stock data of all material bins, maximum packages in a material master file, minimum material throwing rate of materials, a material control blacklist and a material putting control rule, and then issuing the loaded industrial production information.

Preferably, S2 specifically includes the following steps:

s21, receiving the industrial production information, judging whether the required materials fall into a material control blacklist or not and whether the required materials accord with material putting control rules or not according to the industrial production information, if the required materials do not fall into the material control blacklist or accord with the material putting control rules, forwarding the industrial production information, and otherwise, returning to S1 and reloading the industrial production information;

s22, calculating the material requirements of the material bins corresponding to the production lines according to the planned labor number of the production lines and the daily planned product discharge list of the production lines;

s23, judging whether a product discharging list is established for a product in the demand according to the material demand of the material bin, if so, entering S24 in sequence, otherwise, returning to S1 and reloading industrial production information;

s24, respectively calculating the material requirements of each production line according to the industrial production information;

and S25, summarizing the material demands of the production lines and the material bins and the HUB order demands as material demand results, and sending the obtained material demand results to the industrial storage system, wherein the industrial storage system comprises an SAP system and an INFOR system, the SAP system automatically matches the quota problem of the materials, and the INFOR system generates a final material demand order according to the material demand results.

Preferably, the calculation formula of the material demand of each material bin in S22 is as follows: the material demand of the material bin = planned work number of the production line:dailyplanned product discharge number of the production line.

Preferably, the formula for calculating the material requirement of each production line in S24 is: the material requirements of the production lines = planned work of the production lines-daily planned product discharge of the production lines-minimum material throwing rate of the material in the master stock-in-process data in the industrial control system, and then the material requirements of the production lines are combined to generate the HUB order requirements.

Compared with the prior art, the invention has the advantages that:

the material demand calculation system based on the production plan fully utilizes the existing industrial control system in the production enterprise, and completes the calculation of the material demand in the production process in an automatic mode, thereby not only reducing the man-hour of manual operation and reducing the human input cost of the enterprise, but also avoiding data errors in the calculation process and remarkably improving the accuracy of the calculation result.

Corresponding to the system, the material demand calculation method based on the production plan further improves the intelligent application level of the industrial control system of the production enterprise, realizes the accurate monitoring of the production distribution in each production line and each stock, and ensures the initial accuracy of the material demand calculation.

The following detailed description of the embodiments of the present invention is provided in connection with the accompanying drawings for the purpose of facilitating understanding and understanding of the technical solutions of the present invention.

Drawings

FIG. 1 is a schematic process flow diagram of the system of the present invention.

Detailed Description

The invention provides a material demand calculation system and method based on a production plan, and the specific scheme is as follows.

A material demand calculation system based on a production plan comprises the following modules.

And the production information loading module is in signal connection with an industrial control system, the industrial control system is an MES system, and the production information loading module can be integrated in the MES system during actual setting. The production information loading module is used for loading industrial production information required by the material demand calculation from the industrial control system and issuing the loaded industrial production information.

And the material demand calculation module is respectively in signal connection with the production information loading module and the industrial warehousing system, the industrial warehousing system comprises an SAP system and an INFOR system, and similarly, when the material demand calculation module is actually arranged, the material demand calculation module can still be integrated in the MES system and only needs to be ensured to be in signal connection with the SAP system and the INFOR system. The material demand calculation module is used for receiving the loaded industrial production information, obtaining a material demand result after analysis and calculation, and sending the obtained material demand result to the industrial storage system; the industrial production information at least comprises planning work number of each production line, daily planning product discharging list of each production line, in-process data in the industrial control system, inventory in-process data of each material bin, maximum package in a material master file, minimum material throwing rate of materials, a material control blacklist and material putting control rules.

Wherein, the material demand calculation module specifically comprises:

and the information receiving and judging unit is in signal connection with the production information loading module and is used for receiving the loaded industrial production information, judging whether the required materials are in compliance according to the industrial production information, forwarding the industrial production information if the required materials are in compliance, and uploading an instruction to the production information loading module and reloading the industrial production information if the required materials are not in compliance.

The material demand calculation unit is in signal connection with the information receiving and judging unit and the industrial warehousing system, and is used for calculating a material demand result according to the industrial production information and sending the obtained material demand result to the industrial warehousing system; the material demand result comprises the material demands of all production lines and all material bins and the HUB order demands.

Compared with the prior art, the system of the invention has the following advantages:

1. the man-hour of manual operation can be reduced;

2. the material requirements on the production line can be calculated more accurately;

3. the system can monitor the production distribution of each production line and each stock more accurately, and ensure the initial accuracy of the system for calculating the material demand;

4. the material throwing and moving conditions of the production line can be better monitored, and the investment and use conditions of blacklist materials can be better monitored;

in summary, the material demand calculation system based on the production plan provided by the invention fully utilizes the existing industrial control system in the production enterprise, and completes the calculation of the material demand in the production process in an automatic manner, thereby not only reducing the man-hour of manual operation and reducing the human input cost of the enterprise, but also avoiding data errors in the calculation process and remarkably improving the accuracy of the calculation result.

As shown in fig. 1, the present invention further provides a material demand calculation system based on a production plan, which uses the material demand calculation system based on a production plan as described above, and is characterized by comprising the following steps:

and S1, loading production information, loading industrial production information required during the calculation of the material demand from the industrial control system, and issuing the loaded industrial production information.

The step is specifically that industrial production information required during calculation of material demand is loaded from an industrial control system, the industrial control system is an MES system, the industrial production information at least comprises planning labor number of each production line, daily planning product discharge list of each production line, in-process data in the industrial control system, in-process stock data of each material bin (automatically disassembled into virtual PPID in-process data by the MES system), maximum package in a material master file, minimum material throwing rate of materials, a material control blacklist and a material throwing control rule, and the loaded industrial production information is issued.

And S2, calculating material demand, receiving the loaded industrial production information, obtaining a material demand result after analysis and calculation, and sending the obtained material demand result to an industrial storage system.

The method specifically comprises the following steps:

and S21, receiving the industrial production information, judging whether the required materials fall into a material control blacklist or not and whether the required materials accord with material putting control rules or not according to the industrial production information, if the required materials do not fall into the material control blacklist or accord with the material putting control rules, forwarding the industrial production information, and otherwise, returning to S1 and reloading the industrial production information.

S22, calculating the material requirements of the material bins corresponding to the production lines according to the planned labor number of the production lines and the daily planned product discharge list of the production lines, wherein the calculation formula is as follows: the material demand of the material bin = planned work number of the production line:dailyplanned product discharge number of the production line.

And S23, judging whether a product discharging list is established for the product in the demand according to the material demand of the material bin, if so, entering S24 in sequence, otherwise, returning to S1 and reloading industrial production information.

S24, respectively calculating the material requirements of each production line according to the industrial production information, wherein the calculation formula is as follows: the material requirements of the production lines = planned work of the production lines-daily planned product discharge of the production lines-minimum material throwing rate of the material in the master stock-in-process data in the industrial control system, and then the material requirements of the production lines are combined to generate the HUB order requirements.

And S25, summarizing the material demands of the production lines and the material bins and the HUB order demands to serve as material demand results, and sending the obtained material demand results to the industrial warehousing system. The industrial storage system comprises an SAP system and an INFOR system, the SAP system automatically matches the quota problem of the materials, and the INFOR system generates a final material demand order according to a material demand result.

Corresponding to the system, the material demand calculation method based on the production plan provided by the invention has the core that the production materials and the stock in-process states are controlled by using the PPID, so that the intelligent application level of a production enterprise to an industrial control system is further improved, the accurate monitoring of the in-process distribution in each production line and each stock is realized, and the initial accuracy of material demand calculation is ensured.

In addition, the method can also be used as a reference basis for solving related approximate problems in the same field, and can widen the application range of the scheme by optimizing and defining the scheme, thereby further enriching the application scenes of the scheme.

It will be evident to those skilled in the art that the invention is not limited to the details of the foregoing illustrative embodiments, and that the present invention may be embodied in other specific forms without departing from the spirit or essential attributes thereof. The present embodiments are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein, and any reference signs in the claims are not intended to be construed as limiting the claim concerned.

Finally, it should be understood that although the present description refers to embodiments, not every embodiment contains only a single technical solution, and such description is for clarity only, and those skilled in the art should integrate the description, and the technical solutions in the embodiments can be appropriately combined to form other embodiments understood by those skilled in the art.