CN119990589A - Lean production management system for manufacturing industry based on circulation card reporting - Google Patents
Lean production management system for manufacturing industry based on circulation card reporting Download PDFInfo
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- CN119990589A CN119990589A CN202510008078.6A CN202510008078A CN119990589A CN 119990589 A CN119990589 A CN 119990589A CN 202510008078 A CN202510008078 A CN 202510008078A CN 119990589 A CN119990589 A CN 119990589A
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Abstract
The invention relates to the technical field of steam friction steam distribution and discloses a manufacturing industry lean production management system based on a circulation card newspaper worker, which comprises a data acquisition module, a production plan and circulation card configuration module, a production process tracking module and a quality inspection and batch tracing module, wherein the data acquisition module is used for acquiring production data in real time through a code scanning circulation card, the production plan and circulation card configuration module is used for making a production plan and generating a circulation card matched with the production plan, the production process tracking module is used for dynamically monitoring the production state and equipment use condition of the circulation card, and the quality inspection and batch tracing module is used for binding quality inspection data with the circulation card so as to realize tracing of quality problems. Through scanning the code circulation card, carry out the real-time collection of production data, with the state and the task progress real-time update to the system of every station in the production process, the manager can master the current state of production at any time, in time discovers potential problem and takes counter measures rapidly, has effectively promoted response speed and the production efficiency of sudden problem, promotes the production lean degree.
Description
Technical Field
The invention relates to the technical field of steam friction steam distribution, in particular to a manufacturing industry lean production management system based on circulation card newspaper industry.
Background
ERP and MES are widely applied to manufacturing industry production management and are excellent in performance on a full-automatic production line. However, in a non-fully automated production line, there are significant limitations to existing centralized code scanning reporting schemes and production data management approaches. The centralized code scanning generally requires a user to use a code scanning gun to scan the fixed codes printed in a centralized manner in batches in a fixed time period or to perform unified input through an industrial control integrated machine. Although the mode realizes the digitization of data to a certain extent, the real-time feedback effect of the mode on the production data is limited, and the management information is easy to be inaccurate due to delay or human factors.
Firstly, the centralized code scanning report mode requires users to input data uniformly after a longer time interval, and the mode leads to serious real-time lag of production data, so that a manager cannot accurately grasp the instant state of a production site, and misses the opportunity of timely finding and solving problems. Meanwhile, between two concentrated code scanning, a user depends on paper records in a large quantity, so that the workload of data input is increased, inaccuracy or omission of the records is easily caused, and the correctness of management decisions is further affected. In addition, the existing system lacks an effective error prevention and verification mechanism for the reliability of data input, and cannot timely find the conditions of human input errors, intentional concealing problems, data tampering and the like, so that uncertainty in production management is aggravated. For equipment monitoring and management, the prior art generally has difficulty in associating equipment operation information with production information, lacks a bridge for proving the association and matching degree of the equipment operation information and the production information, and generally has the problem that the monitoring association in the production process can not meet the requirement, so that small and medium-sized manufacturing enterprises have difficulty in quick response when facing temporary production task adjustment or equipment replacement, and the production efficiency is seriously affected. Meanwhile, the batch information in the existing centralized report mode is difficult to accurately record and track, so that the most accurate association between the production batch and the equipment operation and quality inspection results cannot be carried out, the production batch and the equipment operation and quality inspection results are all reserved in one large production batch, refinement cannot be carried out, and further quick tracing and management of defective products are not facilitated. In particular, in the case of sudden situations, such as equipment failure and production shutdown, the existing system cannot separate small batches (such as replacement of corresponding equipment on a production line) from the large batch process, so that the production flow is interrupted on the system level, and even a large amount of manual data supplement is required, thereby increasing the management cost of enterprises and reducing the reliability of the whole production.
Disclosure of Invention
Aiming at the defects of the prior art, the invention provides a manufacturing industry lean production management system based on circulation card newspaper industry, which solves the problems of production data lag, lack of data error prevention means, poor equipment management flexibility, insufficient quality traceability and weak emergency coping capability of the existing production management system.
In order to achieve the purpose, the invention is realized by the following technical scheme that the manufacturing industry lean production management system based on the circulation card newspaper industry comprises:
The data acquisition module is used for acquiring production data in real time through the code scanning of the circulation card;
The production plan and circulation card configuration module is used for making a production plan and generating circulation cards matched with the production plan and the circulation cards;
The production process tracking module is used for dynamically monitoring the production state and the equipment service condition of the circulation card;
The quality inspection and batch tracing module is used for binding the quality inspection data with the circulation card to realize tracing of quality problems;
the storage and logistics management module is used for managing material distribution and finished product storage based on the circulation card;
the data analysis and decision support module is used for analyzing the acquired data, generating a report and providing an optimization suggestion;
the emergency response module is used for processing the emergency caused by data entry errors, equipment faults, production downtime or quality problems in the production process and dynamically updating system data;
The data acquisition module takes the circulation card as the minimum data unit in the production process, the circulation card is scanned timely by a user in the production process, the circulation card is scanned, the code binding equipment and the quality inspection information are bound by the circulation card, and finally, the user finishes data input report work, and the data input report work is used for reflecting the production state in real time and improving the production lean management level.
Preferably, the data acquisition module includes:
The circulation card code scanning positioning unit is used for scanning and positioning through a mobile phone code scanning function and displaying all information of the current circulation card, all production, products, equipment, quality and the like bound with the current circulation card;
the circulation card code scanning matching unit is used for scanning codes for the second time in the circulation card, uniquely identifying code scanning equipment and carrying out matching binding on the circulation card;
the production data input and verification unit is used for inputting production data and can prevent data input errors, including production volume abnormal detection, finished product warehouse entry abnormal detection, equipment unbound alarm and quality inspection result missing prompt.
Preferably, the production plan and the circulation card configuration module make a production plan through the system, synchronize production targets through the circulation card and finally transmit the production targets to each production node, and meanwhile, the corresponding working procedures under the current production progress are automatically matched for the circulation card based on the production process flow, so that production equipment is not required to be bound in advance when the production plan is made, and temporary dynamic adjustment of the equipment is supported.
Preferably, the production process tracking module includes:
A circulation card state monitoring unit for recording the production state, throughput, operator and operation time of each circulation card at each production node;
and the equipment state monitoring unit is used for monitoring the production load, the use time and the abnormal state of the equipment.
Preferably, the quality inspection and batch tracing module includes:
The transfer card quality inspection data binding unit is used for recording quality inspection data of a batch corresponding to the transfer card in real time;
The quality problem tracing unit is used for rapidly positioning production batches and working procedures of defective products through quality inspection data and historical production records of the circulation cards.
Preferably, the warehouse and logistics management module includes:
the real-time inventory updating unit dynamically updates inventory data by warehousing based on the code scanning flow card;
And the warehouse-in and warehouse-out data tracking unit is used for realizing accurate management of product batches.
Preferably, the data analysis and decision support module includes:
the data statistics and report generation unit is used for generating statistics reports of production efficiency, equipment utilization rate and quality inspection results;
an exception handling and optimization suggestion unit for providing an optimization scheme when an exception is produced.
Preferably, the emergency response module includes:
The circulation card independent alarm unit is used for conveniently isolating the circulation card needing special treatment from other normal circulation cards under the emergency condition and marking the state of the circulation card for subsequent independent treatment;
and the dynamic task adjusting unit is used for adjusting the production task of the circulation card according to the emergency, and comprises the steps of suspending/resuming production, rebinding equipment and adjusting the production sequence.
The invention provides a manufacturing lean production management system based on a circulation card newspaper worker. The beneficial effects are as follows:
1. According to the invention, the production data are collected in real time through the code scanning circulation card, the state and task progress of each station in the production process are updated to the system in real time, a manager can master the production current situation at any time, discover potential problems in time and take countermeasures rapidly, and compared with the traditional centralized report mode, the system greatly shortens the time delay of data collection and feedback, and effectively improves the response speed and the production efficiency of sudden problems.
2. According to the invention, through the real-time inventory updating unit and the inventory entering and exiting tracking function based on the circulation card, inventory data are dynamically synchronized to the central database of the system, so that the real-time performance and accuracy of inventory states are ensured, inventory information can be shared in real time by the system among departments, information islands are eliminated, and product backlog and inventory waste caused by blind production or information lag are avoided, thereby optimizing the overall inventory management.
3. According to the invention, through the emergency handling module, when the emergency such as equipment replacement, cutter or die damage, production shutdown or quality problem occurs, the circulation card needing special treatment can be rapidly isolated, the task state of the circulation card is singly marked, related tasks and process binding are dynamically adjusted, production tasks of other normal circulation cards can be continuously advanced, the interruption of the whole production flow caused by local problems is avoided, related data is automatically updated, manual supplementary recording operation is reduced, and the reliability and continuity of the system are improved.
4. The circulation card is strongly associated with each production node, can realize accurate tracing of warehouse-in and warehouse-out batch data and quality inspection results, provides more accurate statistical information of equipment utilization rate, load condition and operation time through equipment use data recorded by the system, and enables a manager to comprehensively analyze and optimize production processes and equipment resources by utilizing the data, thereby improving the overall resource utilization rate and realizing lean management.
Drawings
FIG. 1 is a schematic diagram of a system module of the present invention;
FIG. 2 is a schematic diagram of a data acquisition module according to the present invention;
FIG. 3 is a schematic diagram of a process tracking module according to the present invention;
FIG. 4 is a schematic diagram of a quality inspection and lot trace module according to the present invention;
FIG. 5 is a schematic diagram of a warehouse and logistics management module according to the present invention;
FIG. 6 is a schematic diagram of a data analysis and decision support module according to the present invention;
Fig. 7 is a schematic diagram of an emergency response module according to the present invention.
Detailed Description
The following description of the embodiments of the present invention will be made more apparent and fully hereinafter with reference to the accompanying drawings, in which some, but not all embodiments of the invention are shown. All other embodiments, which can be made by those skilled in the art based on the embodiments of the invention without making any inventive effort, are intended to be within the scope of the invention.
Referring to fig. 1, an embodiment of the present invention provides a manufacturing lean production management system based on a circulation card newspaper industry, including:
The data acquisition module is used for acquiring production data in real time through the code scanning of the circulation card;
The production plan and circulation card configuration module is used for making a production plan and generating circulation cards matched with the production plan and the circulation cards;
The production process tracking module is used for dynamically monitoring the production state and the equipment service condition of the circulation card;
The quality inspection and batch tracing module is used for binding the quality inspection data with the circulation card to realize tracing of quality problems;
the storage and logistics management module is used for managing material distribution and finished product storage based on the circulation card;
the data analysis and decision support module is used for analyzing the acquired data, generating a report and providing an optimization suggestion;
the emergency response module is used for processing the emergency caused by data entry errors, equipment faults, production downtime or quality problems in the production process and dynamically updating system data;
the data acquisition module takes the circulation card as the minimum data unit in the production process, timely scans the circulation card in the production process by a user, scans code binding equipment and quality inspection information by the circulation card, and finally completes data input report by the user, and is used for reflecting the production state in real time and improving the production lean management level.
Specifically, the manufacturing industry lean production management system based on the circulation card newspaper industry improves the production efficiency, management flexibility and data accuracy of the middle and small-sized manufacturing industry in a non-full-automatic production line environment through the cooperative work of a plurality of modules. The system takes the circulation card as a core data unit, and realizes the whole-flow lean management in the production process around the circulation card.
Firstly, the data acquisition module acquires production data in real time through a personnel code scanning flow card, ensures that the real-time state of a production site can be uploaded to a system without delay, avoids the problem of data lag in the traditional centralized report mode, and simultaneously provides basic support for follow-up tracking and analysis through binding equipment and quality inspection information.
The production plan and circulation card configuration module generates corresponding circulation cards for each production period by making a detailed production plan, a user can flexibly adjust the quantity of the circulation cards according to actual demands, support equipment dynamic binding and adjustment, ensure that the system can adapt to frequently changed production conditions, and print and output the circulation cards through bar codes so as to realize physical distribution and production starting of tasks.
The production process tracking module is used for realizing dynamic monitoring of each production link under the pushing of the transfer cards, and comprises the steps of recording the process progress, the equipment service condition, the operator and the operation duration of each transfer card in production, and providing comprehensive insight to the production state for a manager through real-time acquired accurate data.
The quality inspection and batch tracing module rapidly establishes the association between the quality problem and a specific production batch by binding the quality inspection data with the circulation card, realizes accurate tracing of defective products and tracing of process responsibility, effectively reduces the reworking cost and improves the quality management level of products.
The warehouse and logistics management module manages the distribution of materials and the warehouse of finished products through the circulation card, realizes the dynamic update and real-time state display of the inventory, avoids the problem of material information lag in the traditional inventory management, and simultaneously combines the code scanning operation of the circulation card to ensure the accuracy and the tracking capability of the warehouse in-out data.
The data analysis and decision support module performs multidimensional analysis on production efficiency, equipment utilization rate, quality inspection results and the like by integrating all production data, generates a visual report, provides optimization suggestions based on abnormal conditions, supports a manager to rapidly decide and improves the overall production management level.
In addition, the emergency response module provides strong flexibility for the system, when the emergency such as equipment failure, process change, production shutdown or quality problem occurs, the system can isolate the affected circulation card in real time, ensure that other circulation cards and production processes can continue to operate, and meanwhile, the system can automatically update related data, avoid data deletion and work delay caused by manual supplementary recording, and greatly improve the adaptability of the system in complex production scenes.
In the whole, the system takes the circulation card as a driving core, through the synergistic effect of a plurality of modules, the system realizes the digitization, the lean and the intellectualization of the production flow from data acquisition to task execution, from state tracking to data analysis and then to flexible processing of emergency, and helps enterprises to more efficiently complete production tasks and cope with complex and changeable production environments.
Referring to fig. 2 to fig. 4, the data acquisition module includes:
The circulation card code scanning positioning unit is used for scanning and positioning through a mobile phone code scanning function and displaying all information of the current circulation card, all production, products, equipment, quality and the like bound with the current circulation card;
The circulation card code scanning matching unit is used for scanning codes for the second time in the circulation card, uniquely identifying code scanning equipment and carrying out matching binding on the circulation card;
the production data input and verification unit is used for inputting production data and can be used for preventing data input errors, including production volume abnormal detection, finished product warehouse entry abnormal detection, equipment unbound alarm and quality inspection result missing prompt;
The production plan and circulation card configuration module makes a production plan through the system, synchronizes production targets through the circulation card and finally transmits the production targets to each production node, and meanwhile, the circulation card is automatically matched with a corresponding procedure under the current production progress based on the production process flow, so that production equipment is not required to be bound in advance when the production plan is made, and temporary dynamic adjustment of the equipment is supported;
the production process tracking module comprises:
A circulation card state monitoring unit for recording the production state, throughput, operator and operation time of each circulation card at each production node;
an equipment state monitoring unit for monitoring production load, use time and abnormal state of the equipment;
The quality inspection and batch tracing module comprises:
The transfer card quality inspection data binding unit is used for recording quality inspection data of a batch corresponding to the transfer card in real time;
The quality problem tracing unit is used for rapidly positioning production batches and working procedures of defective products through quality inspection data and historical production records of the circulation cards.
Specifically, the code scanning and positioning unit of the circulation card in the data acquisition module performs code scanning operation of unique identification on each circulation card by using a mobile phone or other equipment with the code scanning function, and displays related information of the current circulation card in real time, including production tasks, product states, equipment information and quality data, so that the uniqueness and independence of the circulation card data are ensured. The circulation card scanning code matching unit can be uniquely matched with equipment and quality inspection data through a secondary scanning code, and the production capacity data input and verification unit of the circulation card scanning code matching unit is provided with a built-in error prevention mechanism comprising production capacity abnormality detection, equipment unbound alarm, quality inspection result missing prompt and finished product warehousing abnormality detection functions.
The production planning and circulation card configuration module realizes flexible setting of production targets through circulation cards and supports real-time synchronization of the production targets, so that each production node instantly acquires the latest task requirements; the module binds corresponding procedures for the transfer card based on the production process flow, abandons the limitation of binding of the traditional fixed equipment, and supports the dynamic adjustment of the equipment, thereby improving the flexibility and the efficiency of the system when coping with the temporary equipment change or the production task adjustment.
The production process tracking module comprises a circulation card state monitoring unit and an equipment state monitoring unit, wherein the circulation card state monitoring unit can record the operation state and specific operation time of each circulation card at each production node in real time, data support is provided for production efficiency analysis and process tracing, and the equipment state monitoring unit realizes the refinement of equipment management through monitoring the production load, the use time and the abnormal state of equipment, thereby helping enterprises optimize the equipment utilization rate and timely find potential problems.
The quality inspection and batch tracing module comprises a transfer card quality inspection data binding unit and a quality problem tracing unit, wherein the transfer card quality inspection data binding unit records the association information of the transfer card and the quality inspection result in real time in the quality inspection link, thereby laying a foundation for quality management of products, and the quality problem tracing unit rapidly positions production batches and problem procedures corresponding to defective products through the quality inspection data and the historical production records of the transfer card, thereby realizing accurate tracing, effectively reducing the reworking cost and improving the quality management efficiency. The above-mentioned each module unit cooperates the operation in the system, can promote the real-time, accuracy and traceability of the production data comprehensively, show production efficiency and the administrative ability of optimizing the enterprise, reduce the extra cost because of human error and equipment problem bring simultaneously.
Referring to fig. 5-7, the warehouse and logistics management module includes:
the real-time inventory updating unit dynamically updates inventory data by warehousing based on the code scanning flow card;
the warehouse-in and warehouse-out data tracking unit is used for realizing accurate management of product batches;
the data analysis and decision support module comprises:
the data statistics and report generation unit is used for generating statistics reports of production efficiency, equipment utilization rate and quality inspection results;
an abnormality processing and optimizing advice unit for providing an optimization scheme when an abnormality is produced;
the emergency response module comprises:
The circulation card independent alarm unit is used for conveniently isolating the circulation card needing special treatment from other normal circulation cards under the emergency condition and marking the state of the circulation card for subsequent independent treatment;
and the dynamic task adjusting unit is used for adjusting the production task of the circulation card according to the emergency, and comprises the steps of suspending/resuming production, rebinding equipment and adjusting the production sequence.
Specifically, the warehouse and logistics management module comprises a real-time inventory updating unit and a warehouse in and warehouse out data tracking unit. The real-time inventory updating unit dynamically records the warehouse-in and warehouse-out states of materials and finished products through the code scanning operation of the user on the circulation card, and synchronizes inventory data to a central database of the system in real time to ensure the accuracy and timeliness of inventory information. The warehouse-in and warehouse-out data tracking unit is used for recording the warehouse-in and warehouse-out information of each batch of products in detail through the circulation card identification and the code scanning operation of the user, refining batch management to the circulation card layer, and providing accurate data support for subsequent quality tracing, shipment dispatching and inventory optimization.
The data analysis and decision support module comprises a data statistics and report generation unit and an exception handling and optimization suggestion unit. The data statistics and report generation unit generates a multidimensional statistics report and visual data by integrating key index data such as production efficiency, equipment utilization rate and quality inspection results, and provides an intuitive production process panoramic view for a manager. When the production abnormality occurs, the abnormality processing and optimizing suggestion unit generates an optimizing scheme, such as optimizing circulation card task allocation or optimizing equipment utilization, by automatically analyzing abnormal data and combining historical data with the current production state, so that a manager is supported to quickly decide and promote the overall production management level, the production efficiency is improved, and the waste is reduced.
The emergency response module comprises a circulation card independent alarm unit and a dynamic task adjustment unit. The circulation card independent alarm unit isolates the circulation card needing special treatment from other normal circulation cards and marks the state of the circulation card under the emergency of equipment failure, process change, quality problem or data input error, and the like, and simultaneously supports the suspension or recovery of the production task of the related circulation card to prevent the problem from further spreading, and the function ensures that the influence of the sudden problem is limited in a small range and reduces the interference on the whole production line. The dynamic task adjusting unit adjusts the production tasks of the circulation cards in real time according to emergency conditions, including suspending or restoring the production of the specific circulation cards, rebinding proper procedures and equipment or suspending some tasks temporarily, ensuring the normal propulsion of the production tasks of other circulation cards, and improving the flexibility and the strain capacity of the system. The cooperative operation of the module units ensures the sustainability, reliability and high efficiency of the system under the abnormal production condition, and provides comprehensive support for enterprises to cope with complex and changeable production scenes.
Although embodiments of the present invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made therein without departing from the principles and spirit of the invention, the scope of which is defined in the appended claims and their equivalents.
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| Publication number | Priority date | Publication date | Assignee | Title |
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| CN120851551A (en) * | 2025-09-23 | 2025-10-28 | 杭州科强信息技术有限公司 | Multi-process task tracking management method and system |
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Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN120851551A (en) * | 2025-09-23 | 2025-10-28 | 杭州科强信息技术有限公司 | Multi-process task tracking management method and system |
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