Production line feeding error-proofing control method and computer equipment
Technical Field
The invention relates to the technical field of production management in discrete manufacturing industry, in particular to a production line feeding error-proofing control method and computer equipment.
Background
The discrete manufacturing (Discrete Manufacturing) processes such as computer, automobile and industrial product manufacturing are complex processes composed of different part machining sub-processes or parallel or serial processes, and the focus of operation and management is materials and the change process thereof. Industrial products such as automobiles, ships, airplanes and the like are generally composed of thousands of parts, various parts are required to be installed and debugged on different production lines, stations and equipment, and whether the selected parts are correct or not is required to be identified in the actual operation process. Some product parts are various, small in size and similar in appearance (such as SMT paster industry), materials are frequently used in error, and if the errors cannot be avoided in advance, reworking or scrapping is caused, so that huge losses are brought to enterprises.
At present, many enterprises are exploring various material error-proofing measures, and the parts are prevented from being used by common methods or tools in the industries such as root breaking principle, insurance principle, conforming principle, sequence principle, isolation principle and the like. In practice, the method needs to manually identify the parts, records the part batch afterwards, and has the problems of low efficiency, large workload, easy error of recording results and the like.
Disclosure of Invention
The invention aims at: aiming at the current situations of multiple types of parts, large manual feeding error-proofing workload and easy error in the discrete manufacturing industry, the feeding error-proofing control method utilizing an automatic principle is provided, and the method performs matching verification on online materials and product MBOM (manufacturing bill of materials) through a bar code recognition technology, so that the application of an automatic tool can greatly improve the working efficiency and reduce the error rate of feeding error proofing. In addition, the material batch number is bound with the manufactured product by identifying the material batch information in the bar code, so that the industrial commonality problem about material batch tracing in the field of production and manufacturing can be solved.
According to one aspect of the invention, a method for controlling feeding error prevention of a production line is provided, which specifically comprises the following steps:
s01: constructing main material data information, printing a material bar code when a warehouse delivers goods, and pasting the material bar code on a material box or a material;
S02: establishing the association among production lines, stations and working procedures of a factory;
S03: the method comprises the steps of obtaining feeding procedure information of materials in a product MBOM, and defining a feeding procedure corresponding to the product materials produced by a factory;
S04: selecting a production line and a work order, executing a start instruction, and binding the current production line with the work order and the product;
S05: selecting a station before feeding, and acquiring production and feeding information of the current station;
s06: comparing the current station production and feeding information with the material information in the product MBOM, and generating a material changing operation instruction according to the comparison result;
S07: according to the operation indication of S06, aiming at reusable materials in the station, directly confirming that the materials and batch information are available, and entering step S12;
S08: according to the operation indication of S06, prompting to perform blanking operation for the materials which exist in the station but are not needed by the current product, deleting the materials in the production and feeding table, and entering step S12;
s09: according to the operation indication of S06, aiming at the materials which do not exist in the station but the current products need to be fed, entering a step S10 to carry out feeding and material verification operation;
S10: the material code and the batch number information are obtained by scanning a material bar code, the material code and the batch number information are compared with the product material code on line of the station, if the material does not exist in a station product bill of materials, the material is indicated to be wrong, and a feeding error prompt is directly given; if so, continuing to perform the next operation;
S11: aiming at the materials successfully verified in S10, locating the line where the product materials are located, and carrying the batch number information; continuing the S10 operation until all the new materials are successfully verified, and entering a step S12;
s12: according to the results of the S07, S08 and S11 steps, finishing the loading verification and confirmation, and updating the production loading information of the current station and the product;
S13: and binding the product material batch according to the production and feeding information of the station and the product.
Further, in step S01, the main data of the material is used to describe basic properties of the material, including: the material codes, the material names, the specification types and the batch numbers, and meanwhile, the material main data strictly adhere to one-object one-code rules, so that the unique material information can be identified by the code scanning.
Further, in step S02, the association among the production line, the stations and the working procedures is established according to the production process of the factory.
Further, in step S03, the feeding process information of the material in the product MBOM is used for guiding the material preparation and distribution in the production process, and the attribute values include: product number, product version number, material code, material name, number of applications and feeding process.
Further, in step S04, the production line and the work order are selected, a start instruction is executed, the work order, the product and the production line information are stored in the database through the operation, and the product information produced by each station in the production line is obtained through the database.
Further, in step S06, the indication of the reloading operation refers to comparing the actual production loading information queried in step S05 with the bill of materials to be loaded at the station for the current product, and automatically obtaining the indication of the reloading operation, so as to determine which materials can be reused, which materials need to be loaded, and which materials need to be reloaded.
Further, in step S10, the material bar code includes: material code, lot number, supplier, and order number.
Further, in step S12, the production and feeding information includes: work orders, products, stations, material codes, and lots.
Further, in step S13, the product material batch binding refers to obtaining product bar code information of a current product line passing through a product line collection point, and performing batch binding on the material information and the product bar code information in a product production feeding table, so as to implement a rapid product material tracing function.
According to another aspect of the present invention, a computer device is provided, where the computer device includes a memory and a processor, where the memory stores a computer program, and when the computer program is executed by the processor, the method for controlling feeding error prevention of a production line is executed.
The technical scheme provided by the invention has the following beneficial effects:
1) According to the invention, through standardizing and unifying the formats of the main material data, the product MBOM and the material bar code, the verification of the station and the required material of the product is realized rapidly by utilizing the technology of the Internet of things, the work efficiency and the accuracy of the feeding error prevention of the production line are improved greatly, and the method has great significance in ensuring the fast-paced production of the production line and reducing the cost;
2) According to the invention, according to the historical data and the current product information, a material changing operation instruction is automatically provided to guide an operator to perform material deletion, material multiplexing and material switching operation, so that the invention is a preliminary application of artificial intelligence, can reduce the error rate of the material receiving operation of workers, and solves the error proofing and foolproof commonality problem of the discrete manufacturing industry;
3) The invention can realize batch binding and tracing of products and materials through accumulation and application of production big data, and has positive demonstration effect on tracing product quality in discrete manufacturing industry.
Drawings
The specific effects of the present invention will be further described with reference to the accompanying drawings and examples, in which:
FIG. 1 is a diagram of a tray bar code sample of the present invention.
Detailed Description
For a clearer understanding of technical features, objects and effects of the present invention, a detailed description of embodiments of the present invention will be made with reference to the accompanying drawings.
The invention provides a production line feeding error-proofing control method, which comprises the following steps:
s01: defining main material data for describing basic properties of materials, including material coding, material name, specification model, material classification and other properties, please refer to table 1;
TABLE 1 Material Master data
Material coding |
Material name |
Specification of specification |
Material of material |
Material classification |
Material type |
Measuring unit |
70002 |
Micro-motor |
1020309 |
|
(10) Electronic type |
Raw materials |
Personal (S) |
30070191 |
Sponge cushion |
AM174-00-04 |
|
|
|
Personal (S) |
40080295 |
Single-row label paper |
40mm*20mm*2000PCS |
|
|
|
Roll-up |
10020057 |
Patch capacitor |
CC0805KRX7R9BB103 |
|
|
|
pcs |
WL202109101508 |
No-clean tin paste |
|
|
(40) Auxiliary materials |
Raw materials |
Personal (S) |
982257302 |
Circuit board paster assembly |
AM188-1 |
|
(10) Electronic type |
Finished product |
pcs |
8822458 |
Motor speed regulating module |
AM205YX |
|
(10) Electronic type |
Finished product |
pcs |
982258101 |
Circuit board assembly |
AM205YX-1 |
|
(10) Electronic type |
Finished product |
pcs |
8822532 |
Speed regulation module |
AM218SZ |
|
(10) Electronic type |
Finished product |
pcs |
982214103 |
Circuit board paster assembly |
AM22SZ |
|
(10) Electronic type |
Finished product |
pcs |
982214104 |
Socket assembly |
AM22SZ |
|
(10) Electronic type |
Finished product |
pcs |
8822430 |
Speed regulation module |
AM22SZCK |
|
(10) Electronic type |
Finished product |
pcs |
982214102 |
Circuit board assembly |
AM22SZ |
|
(10) Electronic type |
Finished product |
pcs |
982251902 |
Circuit board paster assembly |
AM227 |
|
(10) Electronic type |
Finished product |
pcs |
8822519 |
Speed regulation module |
AM227BYD |
|
(10) Electronic type |
Finished product |
pcs |
S02: the production line, station and process relation is defined, the production line, station and process information of the factory are related, the basic information of the processing center of the factory is generally not easy to change, and the production line, station and process information of the factory need to be defined according to the production process of the factory. One production line can correspond to a plurality of stations, and the relation between the stations and the working procedures is N: n, i.e. one station corresponds to a plurality of processes, or a plurality of stations corresponds to one process (each station executes one process step), please refer to table 2;
Table 2 production line, station, process association table
Shop name |
Line name |
Station code |
Station name |
Process coding |
Name of procedure |
SMT workshop |
SMT1 wire |
SMT01-01 |
Upper plate working position |
010 |
Upper plate |
SMT workshop |
SMT1 wire |
SMT01-02 |
Manual plug-in station |
020 |
Manual plug-in |
SMT workshop |
SMT1 wire |
SMT01-02 |
Patch station |
020-1 |
A-side patch |
SMT workshop |
SMT1 wire |
SMT01-02 |
Patch station |
020-2 |
B-side paster |
SMT workshop |
SMT1 wire |
SMT01-03 |
AOI detection station |
030 |
AOI detection |
S03: defining material feeding procedure information of materials in a product MBOM, wherein the material feeding procedure information is used for guiding material preparation and distribution in the production process, and attribute values comprise product numbers, product version numbers, material codes, material names, use numbers, material feeding procedures and the like, and refer to a table 3;
TABLE 3 MBOM information table for products
Product coding |
Product name |
Version number |
Material coding |
Material name |
Specification and model |
Number of uses |
Measuring unit |
Sub-component properties |
Feeding process |
8801202 |
Indoor temperature sensor |
V1.0 |
982232801 |
Circuit board assembly |
AM174 |
1 |
PCS |
Homemade |
250-Assembly |
8801202 |
Indoor temperature sensor |
V1.0 |
982232802 |
Patch circuit board assembly |
AM174 |
1 |
PCS |
Homemade |
050-Plug-in components |
8801202 |
Indoor temperature sensor |
V1.0 |
10090849 |
Circuit board |
AM174-A1.2 |
1 |
PCS |
Purchasing |
005-Upper plate |
8801202 |
Indoor temperature sensor |
V1.0 |
10060061 |
Integrated block |
LM2902QDRQ1 |
2 |
PCS |
Purchasing |
020-Hand insert |
8801202 |
Indoor temperature sensor |
V1.0 |
10020164 |
Patch capacitor |
0603B102K500NT |
5 |
PCS |
Purchasing |
020-Hand insert |
8801202 |
Indoor temperature sensor |
V1.0 |
10020290 |
Patch capacitor |
CT41-0603B564K500 |
2 |
PCS |
Purchasing |
020-Hand insert |
8801202 |
Indoor temperature sensor |
V1.0 |
10020162 |
Patch capacitor |
0603B103K500NT |
2 |
PCS |
Purchasing |
020-Hand insert |
8801202 |
Indoor temperature sensor |
V1.0 |
10020160 |
Patch capacitor |
0603B104K500NT |
3 |
PCS |
Purchasing |
020-Hand insert |
8801202 |
Indoor temperature sensor |
V1.0 |
10010964 |
Patch resistor-removing device |
RCML08W1003FT |
2 |
PCS |
Purchasing |
020-Hand insert |
8801202 |
Indoor temperature sensor |
V1.0 |
10010728 |
Chip resistor |
RC0603K2151FT |
4 |
PCS |
Purchasing |
020-Hand insert |
S04: executing a start command on the follow-up work order, binding the current production line with the work order and the product, and referring to Table 4; the table needs to be stored in a database or a cache, and the production line, the processing work order and the product information can be acquired at any time according to the selected stations in the subsequent steps.
Table 4 production line start-up table
Current work order number |
Work center |
Product coding |
Material name |
Specification and model |
Version of |
Input quantity |
Measuring unit |
Production lot number |
Scheduled date of start-up |
Planned completion date |
GD20210723001 |
SMT01 wire |
8801202 |
Indoor temperature sensor |
KST17-57 |
V1.0 |
300 |
PCS |
20210701 |
2021-7-15 |
2021-8-15 |
S05: selecting a station before feeding, and acquiring feeding information produced by the current station, wherein the information is the result of last feeding error proofing verification and is reflected as the material information on line of the current station, and please refer to table 5;
Table 5 station production and feeding table
Station |
Material coding |
Material name |
Specification and model |
Number of uses |
Measuring unit |
Batch of materials |
Manual plug-in station |
10060061 |
Integrated block |
LM2902QDRQ1 |
2 |
PCS |
xxx-01 |
Manual plug-in station |
10020164 |
Patch capacitor |
0603B102K500NT |
5 |
PCS |
xxx-02 |
Manual plug-in station |
10020290 |
Patch capacitor |
CT41-0603B564K500 |
2 |
PCS |
XXX |
Manual plug-in station |
10020162 |
Patch capacitor |
0603B103K500NT |
2 |
PCS |
XXX |
Manual plug-in station |
10020160 |
Patch capacitor |
0603B104K500NT |
3 |
PCS |
XXX |
Manual plug-in station |
10010964 |
Patch resistor-removing device |
RCML08W1003FT |
2 |
PCS |
XXX |
Manual plug-in station |
10010728 |
Chip resistor |
RC0603K2151FT |
4 |
PCS |
XXX |
Manual plug-in station |
10010958 |
Chip resistor |
RC0603K6811FT |
2 |
PCS |
XXX |
S06: comparing the current station feeding information with the material information in the product MBOM, and generating a material changing operation instruction according to the comparison result, please refer to Table 6; the table identifies which materials can be reused, which materials need to be fed, and which materials need to be re-fed.
Table 6 indication of the reloading operation
Description of the invention |
Material coding |
Material name |
Specification and model |
Number of uses |
Measuring unit |
Verification identification |
Batch of materials |
To be deleted |
10090849 |
Circuit board |
AM174-A1.2 |
1 |
PCS |
Y |
xx |
To be deleted |
10060061 |
Integrated block |
LM2902QDRQ1 |
2 |
PCS |
Y |
xx |
Reusable |
10020164 |
Patch capacitor |
0603B102K500NT |
5 |
PCS |
Y |
2021-1 |
Reusable |
10020290 |
Patch capacitor |
CT41-0603B564K500 |
2 |
PCS |
Y |
2021-10 |
Whisker feeding |
10020162 |
Patch capacitor |
0603B103K500NT |
2 |
PCS |
Y |
|
Whisker feeding |
10020160 |
Patch capacitor |
0603B104K500NT |
3 |
PCS |
Y |
|
Whisker feeding |
10010964 |
Patch resistor-removing device |
RCML08W1003FT |
2 |
PCS |
Y |
|
Whisker feeding |
10010728 |
Chip resistor |
RC0603K2151FT |
4 |
PCS |
Y |
|
Whisker feeding |
10010958 |
Chip resistor |
RC0603K6811FT |
2 |
PCS |
N |
|
S07: according to the operation indication of S06, the material used in the previous product is also used in the current product, and the material can be directly used without changing the material (refer to the "reusable" line in table 6), and the batch information of the material is continuously reserved, and the process proceeds to step S12.
S08: according to the operation instruction of S06, for the material that exists in the production and feeding table but is not needed for the current product (refer to the "to be deleted" line in table 6), the blanking operation is prompted to be performed, and deletion is performed in the feeding table, so that the new production and feeding table does not contain the material, and the process proceeds to step S12.
S09: according to the operation instruction of S06, for the material that does not exist in the production and feeding table but needs to be fed (refer to the "material to be fed" line in table 6), the feeding and material verification operations are needed, and the process proceeds to step S09.
S10: aiming at the S09 condition, a handheld PDA is utilized to scan a material bar code, information such as the material code, the batch number and the like is obtained, the information is compared with the product material code on line of the station, if the material does not exist in the station product bill of materials, the material is indicated to be wrong, and a feeding error prompt is directly given; if so, continuing to perform the next operation; material bar code referring to figure 1, the bar code should include information such as material code, batch number, supplier, arrival order number, etc., and the bar code printing can be realized in the warehouse management system.
S11: aiming at the materials successfully verified in S10, locating the line where the product materials are located, and carrying the batch number information; continuing the S10 operation until all the new materials are successfully verified, and entering a step S12;
S12: and finishing the loading verification and confirmation according to the operation results of the steps S08, S09, S10 and S11, and updating the production loading information of the product to form a new station production loading table, please refer to table 5.
S13: product information of the current production line passing point is obtained, material batch binding is carried out according to the product production and feeding information, a product material traceability table is generated, and reference is made to table 7. The function can realize complete product line material tracing, and helps customers to perfect product files.
TABLE 7 product Material traceability Table
Product coding |
Product name |
PCB bar code |
Time to point of crossing |
Material number |
Material name |
Specification and model |
Number of uses |
Measuring unit |
Batch of materials |
Feeding station |
8801202 |
Indoor temperature sensor |
xxxxxxx1 |
2022-1-216:00 |
10060061 |
Integrated block |
LM2902QDRQ1 |
2 |
PCS |
xxx-01 |
Manual plug-in station |
8801202 |
Indoor temperature sensor |
xxxxxxx1 |
2022-1-216:00 |
10020164 |
Patch capacitor |
0603B102K500NT |
5 |
PCS |
xxx-02 |
Manual plug-in station |
8801202 |
Indoor temperature sensor |
xxxxxxx1 |
2022-1-216:00 |
10020290 |
Patch capacitor |
CT41-0603B564K500 |
2 |
PCS |
xxx |
Manual plug-in station |
8801202 |
Indoor temperature sensor |
xxxxxxx1 |
2022-1-216:00 |
10020162 |
Patch capacitor |
0603B103K500NT |
2 |
PCS |
xxx |
Manual plug-in station |
8801202 |
Indoor temperature sensor |
xxxxxxx1 |
2022-1-216:00 |
10020160 |
Patch capacitor |
0603B104K500NT |
3 |
PCS |
xxx |
Manual plug-in station |
8801202 |
Indoor temperature sensor |
xxxxxxx1 |
2022-1-216:00 |
10010964 |
Patch resistor-removing device |
RCML08W1003FT |
2 |
PCS |
xxx |
Manual plug-in station |
As an optional implementation manner, the present embodiment provides a computer device, where the computer device includes a memory and a processor, and the memory stores a computer program, and when the computer program is executed by the processor, each process of the foregoing embodiment of the error proofing method for a product line material is executed, and the process can achieve the same technical effect, so that repetition is avoided, and no further description is given here.
The embodiment of the invention discloses a production line feeding error-proofing control method and computer equipment, which comprises the steps of defining main material data, a product MBOM, a working center and process information as a basis for station feeding verification; work orders are started, and an association relation between a production line and a product is established; before loading verification, a station is selected to acquire current production loading information, and the current production loading information is compared with a product MBOM to automatically generate a reloading operation instruction; respectively carrying out material multiplexing, discharging and feeding confirmation according to the operation instruction, wherein the feeding confirmation needs to scan a material bar code for information verification; after the feeding is finished, new production feeding information is generated, and product material batch binding can be performed during operation report. The embodiment directly verifies the material matching property of the online material and the MBOM through a bar code recognition technology, simplifies operation, improves efficiency, and solves the industry commonality problem about material batch tracing in the field of production and manufacturing.
It should be noted that, in this document, the terms "comprises," "comprising," or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or system that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or system. Without further limitation, an element defined by the phrase "comprising one does not exclude the presence of other like elements in a process, method, article, or system that comprises the element.
The foregoing embodiment numbers of the present invention are merely for the purpose of description, and do not represent the advantages or disadvantages of the embodiments. In the unit claims enumerating several means, several of these means may be embodied by one and the same item of hardware. The use of the terms first, second, third, etc. do not denote any order, but rather the terms first, second, third, etc. are used to interpret the terms as labels.
The foregoing description is only of the preferred embodiments of the present invention, and is not intended to limit the scope of the invention, but rather is intended to cover any equivalents of the structures or equivalent processes disclosed herein or in the alternative, which may be employed directly or indirectly in other related arts.