CN112862308A - Automatic scheduling system for realizing molding and vulcanization based on MES system - Google Patents
Automatic scheduling system for realizing molding and vulcanization based on MES system Download PDFInfo
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Abstract
The invention belongs to the field of tire manufacturing, and particularly relates to an automatic production scheduling system for realizing molding and vulcanization based on an MES (manufacturing execution system). A basic data module comprises molding machine main data, vulcanizing machine main data, tire blank process information, equipment productivity information, plan related information and available inventory information; the monthly plan module is used for realizing monthly plan scheduling according to the monthly plan scheduling logic; the weekly scheduling module is used for determining detailed weekly scheduling according to weekly scheduling logic and by combining an available inventory algorithm; the pulling module is a link between the upper and lower working procedures, and according to the tire requirements put forward by a supply chain, the tire materials are moved forward to vulcanization, molding, semi-parts and raw materials, so that all links of tire production are linked to form a complete pulling model; the invention establishes an automatic scheduling mode of the molding and vulcanizing links, optimizes the scheduling process, establishes a monitoring mechanism, and timely adjusts abnormal change information in production to form dynamic matching of all links of the whole chain of tire production.
Description
Technical Field
The invention belongs to the field of tire manufacturing, and particularly relates to an automatic production scheduling system for realizing molding and vulcanization based on an MES (manufacturing execution system).
Background
With the development of big data and artificial intelligence, the informatization and the intelligence of manufacture become the core direction of the revolution and the upgrade of the traditional manufacturing industry. The whole production cycle of the tire is that the raw materials are processed, formed and assembled into a tire blank through half parts, and vulcanized into a finished tire for sale by a sales department. The molding and vulcanizing procedures are used as key links for producing and manufacturing the tire, and the scheduling of the tire affects the arrangement of the whole production plan. At present, semi-steel related plans are mainly arranged by a production management department, firstly, a supply chain department provides net production requirements according to material requirements provided by a sales department and actual production of a factory, the production management department makes a next month plan, the plan granularity is accurate to the specifications of a forming machine and a tire, and a manufacturing department matches and splits the plan into the plan of a corresponding vulcanizing machine according to a forming daily plan. Because the specifications of the tires involved in planning are numerous and are influenced by multiple factors such as mould appliances, equipment and the like, the manual scheduling difficulty is high, the working intensity is high, the abnormal adjustment in the scheduling process depends on manual intervention, and the response is insensitive.
Disclosure of Invention
In order to solve the defects in the background art, the invention discloses an automatic scheduling system for realizing molding and vulcanization based on an MES system, which optimizes the scheduling process, improves the automation degree of scheduling, realizes timely and effective dynamic adjustment on the change in the tire production link, and realizes the development target of future intelligent and unmanned high-quality manufacturing industry.
In order to achieve the above purpose, the following technical solutions are provided:
an automatic scheduling system for realizing molding and vulcanization based on MES system comprises
The basic data module comprises forming machine main data, vulcanizing machine main data, green tire process information, equipment productivity information, plan related information and available inventory information;
the monthly plan module is used for realizing monthly plan scheduling according to the monthly plan scheduling logic;
the weekly scheduling module is used for determining detailed weekly scheduling according to weekly scheduling logic and by combining an available inventory algorithm;
the pulling module is a link between the upper and lower working procedures, and according to the tire requirements put forward by a supply chain, the tire materials are moved forward to vulcanization, molding, semi-parts and raw materials, so that all links of tire production are linked to form a complete pulling model;
the monthly plan scheduling process comprises the following steps:
step one, generating embryos corresponding to each net requirement, embryo specifications and required single mold days according to the positive vulcanization time of the embryos corresponding to the materials;
step two, obtaining the plan information of the reference point of the current scheduling production, wherein the plan information comprises the forming machine table corresponding to the current production material and the detail information of the used mold;
thirdly, sorting according to the plan of the previous day and the difference number of the production days in 20 days, comparing the residual amount of each material corresponding to the demand, if the residual amount is less, carrying out continuous production, otherwise, washing the mold, generating a priority, acquiring the number of replaceable machine stations every day, acquiring a certain number of mold changing according to the priority and temporarily storing the mold, and determining which mold is changed by a subsequent algorithm;
step four, for the successive production plan of the part which is not marked with the mould change in the previous day plan, generating the surplus of the current day net demand, and directly continuing for a plurality of days to 20 days;
fifthly, according to the specification of the tire blank before replacement, the replaced tire blank has the same specification, sorting is carried out according to the similarity of the specifications, the residual quantity of the requirement and the production stability of the mold, the specification with high priority is obtained, and the mold is replaced;
step six, acquiring feasibility of mold changing according to the mold standing book, verifying matching of the forming machine, only prompting when exceeding the condition, and repeating the previous step when the mold is insufficient;
step seven, judging whether the mold is lacked, and returning to the step five if the mold is lacked; if not, judging whether the month is the end of the month, and if not, returning to the step three; if the month is the end of the month, carrying out the step eight;
step eight, outputting and displaying the current month plan, the mold changing plan, the ratio of molding and vulcanization and the residual amount of the demand according to the scheduling storage result;
step nine, manually adjusting the confirmation plan, and if the verification is passed, forming a formal monthly plan; if the audit is not passed, manually adjusting again until the audit is passed;
the weekly planning and scheduling:
the method comprises the following steps of firstly, splitting a material plan to a vulcanizing machine according to a monthly plan, keeping a forward extension part unchanged, needing to be changed, and manually determining in an auxiliary manner;
step two, manually checking, wherein the manual checking does not pass the step one; after the manual examination is passed, performing the third step;
step three, generating the available inventory of the green tire on the first day of the week according to the formed and vulcanized plan and the occupation condition of the available inventory in the system;
step four, judging whether the ending specification and ending time exist according to the use of the blank every day in vulcanization;
fifthly, grouping according to the production specification of the forming machine, and confirming the specification replacement sequence;
step six, judging whether ending specifications exist, if so, arranging a certain number of the specification-changed tire blanks in the first order of each shift until finishing the scheduling, and then executing step eight; if not, executing the seventh step;
step seven, according to the specification replacement rule, determining the production quantity of each specification of each shift, and determining the order according to the priority;
step eight, updating the construction standard field in the corresponding plan according to the construction table coding information summarized by the molding process information;
step nine, for the specification changing node, checking the spare part satisfaction, and checking the productivity satisfaction by combining the process information, and marking;
step ten, judging whether the weekend is weekend or not, and if not, returning to the step five; if yes, outputting scheduled cycle molding, a vulcanization plan and manual adjustment;
and eleventh, checking and confirming the week plan, and finishing the week plan.
Further, the pulling module takes an ATP available inventory algorithm as pulling logic, and takes the current available inventory as a main measurement unit, so that the reasonable connection of the scheduling plans of the upper and lower working procedures and the dynamic adjustment under abnormal conditions are ensured; the triggering of the pull algorithm includes triggering of a core process, triggering of process plan validation, triggering of validation plan changes.
Further, in the third step, if the production days are less than 20 days and the net demand residual exists, the mold is marked as "continuous production", and the mold needs to be cleaned and replaced under other conditions and is marked as "to-be-replaced"; the specific judgment principle of the priority to be changed is that if the production days are more than 20 days and no net demand surplus exists, the high priority is defined; if the production days are more than 20 days and the net demand surplus exists, defining the production days as a medium priority; if the number of production days is less than 20 days and there is no net demand remaining, low priority is defined.
The invention has the beneficial effects that:
according to the invention, an automatic production scheduling mode of the forming and vulcanizing links is established, and the production scheduling process is optimized; establishing a linkage effect of the whole tire production and manufacturing link according to the pulling module, and forming a scheduling plan of each link of tire production from the tire to raw materials; and a monitoring mechanism is established for the production plan, the available inventory and the related state, and the abnormal change information in the production is adjusted in time to form dynamic matching of all links of the tire production whole chain.
Drawings
FIG. 1 is a schematic diagram of an overall framework for implementing a molding and curing automatic scheduling system based on an MES system;
FIG. 2 is a logic diagram of a monthly scheduling module for implementing the automatic molding and curing scheduling system based on the MES system;
FIG. 3 is a logic diagram of a cycle scheduling module for implementing the automatic molding and vulcanization scheduling system based on the MES system.
Detailed Description
In order to make the technical solutions of the present invention more clear and definite for those skilled in the art, the technical solutions of the present invention will be described in detail below with reference to fig. 1 to 3, but the embodiments of the present invention are not limited thereto.
An automatic scheduling system for realizing molding and vulcanization based on MES system comprises
The basic data module comprises forming machine main data, vulcanizing machine main data, green tire process information, equipment productivity information, plan related information and available inventory information;
the main data of the forming machine mainly relates to a forming die and the forming machine, the data of the forming die comprises main data information such as BOM information and brand information of the forming die, key components realize numbering management to form component management information, and the data of the forming die also comprises die inventory management information which specifically comprises actual inventory operation and available inventory models. The BOM is mainly a set of forming parts which are combined into key parts required by an available forming machine, such as a machine head, a laminating drum, a belt, a PU ring and a transmission ring claw, and key information is related through cun-level and manufacturer. The forming machine mainly distinguishes manufacturers, forming modes, specifications (inch range), width range and variable information, each forming machine also has limitation on the width range of a formed tire blank, namely, when the forming machines are fixed, the width of a tire body of the produced tire blank is also in a certain range, and the forming machine can be specifically matched with tires with various specifications and models.
The main data of the vulcanizing machine mainly relates to a vulcanizing mold and a vulcanizing machine, the vulcanizing mold information comprises main data information such as BOM information and brand information of a forming mold, a key part realizes unique serial number, and the vulcanizing mold also comprises a mold inventory management model which specifically comprises actual inventory operation and an available inventory model. Besides, the system also comprises die standing book information and material die correspondence table information for recording the use condition of the die. The BOM of the vulcanizing mold mainly comprises a cavity, side plates, two half molds, segmented molds and pattern blocks, and information is managed and used by a whole set of the mold through company, trademark, pattern, size, specification, load index, speed grade, pattern name and mold sleeve size. In addition, the vulcanisation mould must be cleaned regularly in order to ensure the quality of the vulcanised tyre. The cleaning period of the semisteel vulcanization mold is generally 20 days, but the cleaning period can fluctuate under the influence of production scheduling, and the fluctuation range is between 6 days and 30 days. The vulcanizer mainly distinguishes inch grade, specification, vulcanization mode, and the size grade of the mold that the vulcanizer can match also has certain range restriction, and management is realized by the corresponding table information of the vulcanizer and the mold.
The tire blank process information mainly refers to the process construction table information of molding and vulcanization, the molding process construction table comprises half parts required by molding, key technical indexes involved in the molding construction process and the like, and the vulcanization process construction table mainly comprises temperature, time and pressure in the vulcanization process and key indexes required to be controlled in specific links.
The equipment productivity information is a measurement factor of plan arrangement, and mainly comprises molding productivity information accurate to machine grouping and specification, vulcanization productivity information and tyre blank positive vulcanization time, and in addition, the productivity information also relates to production scheduling rules, such as information limited by factors such as molding replacement specification, cycle range of washing and replacing molds, machine allocation habit of production scheduling and the like.
The plan related information mainly includes a net plan and an existing plan. The net plan is provided by a sales department, is determined after comprehensive measurement and evaluation of a supply chain, is accurate to the priority information of material numbers and demands, and individual important materials are required to be split to provide the demands at different time stages; the existing plan comprises a currently scheduled vulcanization system MES plan and a molding system MES plan, and specifically comprises confirmed molding and vulcanizing machine team plan information.
The available inventory information is used as a factor model of system scheduling by an available inventory algorithm of an ATP promise delivery model, and the available inventory of the upper and lower processes is calculated for checking the rationality of scheduling and assisting the scheduling of the schedule in the capacity range. The formula for the specific available inventory may be expressed as follows:
the available stock is the current real-time stock + planned production of the production process-planned consumption of the consumable process.
When the production process plans, after confirmation, the system records the plan increasing items of the available stock independently, and generates the rated plan consumption according to the rating of the process before consumption. When the production is being executed, after the warehousing is confirmed, the system automatically reduces the increase of the available inventory plan, reduces the quota consumption, increases the actual quantity of the synchronous inventory and reduces the inventory action of consuming the actual quota quantity by the previous procedure. The planning and the planning execution of the subsequent processes also execute the same logic, so that the available inventory information of tires with various specifications at various time points in various production links can be established.
The monthly plan module is used for realizing monthly plan scheduling according to the monthly plan scheduling logic;
the weekly scheduling module is used for determining detailed weekly scheduling according to weekly scheduling logic and by combining an available inventory algorithm;
the pulling module is a link between the upper and lower working procedures, and according to the tire requirements put forward by a supply chain, the tire materials are moved forward to vulcanization, molding, semi-parts and raw materials, so that all links of tire production are linked to form a complete pulling model; specifically, the module takes an ATP available inventory algorithm as pulling logic, takes the current available inventory as a main measurement unit, and ensures the reasonable connection of the scheduling plans of the upper and lower working procedures and the dynamic adjustment under abnormal conditions.
Pull production practices may be embodied as kanban plans or pull plans. The billboard not only reflects the current inventory and the safety inventory, but also needs to reflect the output of the arranged plan, the consumption of the arranged plan, the actual output and the actual consumption, and the change information of the normal plan, so that the production information can be conveniently and comprehensively known by people. On one hand, the pulling module combines the future requirement, the current plan and the current available inventory of the materials, calculates the inventory satisfaction, and if the requirement is not met, the working procedure is required to make a corresponding production plan to increase the available inventory, so that the pulling plan of other working procedures is initiated, and finally the corresponding scheduling plan of each working procedure is generated. On the other hand, when production is abnormal or production demand changes, production adjustment of each process needs to be triggered in time according to abnormal change information.
Specifically, the triggering of the pull algorithm can be divided into the following aspects:
(1) triggering of core procedures
The core process here refers to a weekly schedule confirmation trigger of the molding process. After the molding week plan is confirmed, the system automatically pulls and generates corresponding suggested week plans of all the procedures according to the ATP available inventory algorithm concept, the safety inventory of the procedures and the confirmed molding plan and the minimum production batch information of the system, and determines the scheduling plan of the whole tire production system.
(2) Triggering of process plan validation
Every day or each shift, the process or the responsible person of the shift should re-confirm the actual planned number of the machine in the shift according to the actual execution condition of the system, and in this case, if there is information change, the pull plan will be triggered. At the moment, the system sends out warning information to related personnel, after the personnel confirm, the system provides the system suggested plan quantity again by utilizing an ATP algorithm according to the changing range, and generates a system formal confirmation plan after the personnel confirm.
(3) Validating triggering of a scheduled change
In the production process, the change of the confirmed plan is triggered by the abnormality of equipment and the change of production demand, the system automatically searches and lists the plan information of the upper and lower processes possibly influenced by the change, proposes a suggested adjustment scheme, and forms a new adjustment confirmation plan after manual confirmation and adjustment. In addition, because the adjustment change involves the time delay, the system calculates the influence on the post-process according to the time delayed by the change, if the production of the post-process has negative available stock, the marking is carried out to prompt the user to adjust the production, the influence on the pre-process is only prompted, the user determines whether to adjust the production, and the changed part of the system after the adjustment carries out availability verification.
The monthly plan scheduling process comprises the following steps:
step one, generating embryos corresponding to each net requirement, embryo specifications and required single mold days according to the positive vulcanization time of the embryos corresponding to the materials;
step two, obtaining the plan information of the reference point of the current scheduling production, wherein the plan information comprises the forming machine table corresponding to the current production material and the detail information of the used mold;
thirdly, sorting according to the plan of the previous day and the difference number of the production days in 20 days, comparing the residual amount of each material corresponding to the demand, if the residual amount is less, carrying out continuous production, otherwise, washing the mold, generating a priority, acquiring the number of replaceable machine stations every day, acquiring a certain number of mold changing according to the priority and temporarily storing the mold, and determining which mold is changed by a subsequent algorithm; if the production days are less than 20 days and the net demand surplus exists, the mold is marked as 'smooth production', and the mold needs to be cleaned and replaced under other conditions and is marked as 'mold to be replaced'; the specific judgment principle of the priority to be changed is that if the production days are more than 20 days and no net demand surplus exists, the high priority is defined; if the production days are more than 20 days and the net demand surplus exists, defining the production days as a medium priority; if the number of production days is less than 20 days and there is no net demand remaining, low priority is defined.
Step four, for the successive production plan of the part which is not marked with the mould change in the previous day plan, generating the surplus of the current day net demand, and directly continuing for a plurality of days to 20 days;
fifthly, according to the specification of the tire blank before replacement, the replaced tire blank has the same specification, sorting is carried out according to the similarity of the specifications, the residual quantity of the requirement and the production stability of the mold, the specification with high priority is obtained, and the mold is replaced;
step six, acquiring feasibility of mold changing according to the mold standing book, verifying matching of the forming machine, only prompting when exceeding the condition, and repeating the previous step when the mold is insufficient;
step seven, judging whether the mold is lacked, and returning to the step five if the mold is lacked; if not, judging whether the month is the end of the month, and if not, returning to the step three; if the month is the end of the month, carrying out the step eight;
step eight, outputting and displaying the current month plan, the mold changing plan, the ratio of molding and vulcanization and the residual amount of the demand according to the scheduling storage result;
step nine, manually adjusting the confirmation plan, and if the verification is passed, forming a formal monthly plan; if the audit is not passed, manually adjusting again until the audit is passed;
the weekly planning and scheduling:
the method comprises the following steps of firstly, splitting a material plan to a vulcanizing machine according to a monthly plan, keeping a forward extension part unchanged, needing to be changed, and manually determining in an auxiliary manner;
step two, manually checking, wherein the manual checking does not pass the step one; after the manual examination is passed, performing the third step;
step three, generating the available inventory of the green tire on the first day of the week according to the formed and vulcanized plan and the occupation condition of the available inventory in the system;
step four, judging whether the ending specification and ending time exist according to the use of the blank every day in vulcanization;
fifthly, grouping according to the production specification of the forming machine, and confirming the specification replacement sequence;
step six, judging whether ending specifications exist, if so, arranging a certain number of the specification-changed tire blanks in the first order of each shift until finishing the scheduling, and then executing step eight; if not, executing the seventh step;
step seven, according to the specification replacement rule, determining the production quantity of each specification of each shift, and determining the order according to the priority;
step eight, updating the construction standard field in the corresponding plan according to the construction table coding information summarized by the molding process information;
step nine, for the specification changing node, checking the spare part satisfaction, and checking the productivity satisfaction by combining the process information, and marking;
step ten, judging whether the weekend is weekend or not, and if not, returning to the step five; if yes, outputting scheduled cycle molding, a vulcanization plan and manual adjustment;
and eleventh, checking and confirming the week plan, and finishing the week plan.
While the invention has been described with respect to the preferred embodiments, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the spirit and scope of the invention as defined by the appended claims.
Claims (3)
1. The utility model provides a realize shaping, vulcanize automatic scheduling system based on MES system which characterized in that: comprises that
The basic data module comprises forming machine main data, vulcanizing machine main data, green tire process information, equipment productivity information, plan related information and available inventory information;
the monthly plan module is used for realizing monthly plan scheduling according to the monthly plan scheduling logic;
the weekly scheduling module is used for determining detailed weekly scheduling according to weekly scheduling logic and by combining an available inventory algorithm;
the pulling module is a link between the upper and lower working procedures, and according to the tire requirements put forward by a supply chain, the tire materials are moved forward to vulcanization, molding, semi-parts and raw materials, so that all links of tire production are linked to form a complete pulling model;
the monthly plan scheduling process comprises the following steps:
step one, generating embryos corresponding to each net requirement, embryo specifications and required single mold days according to the positive vulcanization time of the embryos corresponding to the materials;
step two, obtaining the plan information of the reference point of the current scheduling production, wherein the plan information comprises the forming machine table corresponding to the current production material and the detail information of the used mold;
thirdly, sorting according to the plan of the previous day and the difference number of the production days in 20 days, comparing the residual amount of each material corresponding to the demand, if the residual amount is less, carrying out continuous production, otherwise, washing the mold, generating a priority, acquiring the number of replaceable machine stations every day, acquiring a certain number of mold changing according to the priority and temporarily storing the mold, and determining which mold is changed by a subsequent algorithm;
step four, for the successive production plan of the part which is not marked with the mould change in the previous day plan, generating the surplus of the current day net demand, and directly continuing for a plurality of days to 20 days;
fifthly, according to the specification of the tire blank before replacement, the replaced tire blank has the same specification, sorting is carried out according to the similarity of the specifications, the residual quantity of the requirement and the production stability of the mold, the specification with high priority is obtained, and the mold is replaced;
step six, acquiring feasibility of mold changing according to the mold standing book, verifying matching of the forming machine, only prompting when exceeding the condition, and repeating the previous step when the mold is insufficient;
step seven, judging whether the mold is lacked, and returning to the step five if the mold is lacked; if not, judging whether the month is the end of the month, and if not, returning to the step three; if the month is the end of the month, carrying out the step eight;
step eight, outputting and displaying the current month plan, the mold changing plan, the ratio of molding and vulcanization and the residual amount of the demand according to the scheduling storage result;
step nine, manually adjusting the confirmation plan, and if the verification is passed, forming a formal monthly plan; if the audit is not passed, manually adjusting again until the audit is passed;
the weekly planning and scheduling:
the method comprises the following steps of firstly, splitting a material plan to a vulcanizing machine according to a monthly plan, keeping a forward extension part unchanged, needing to be changed, and manually determining in an auxiliary manner;
step two, manually checking, wherein the manual checking does not pass the step one; after the manual examination is passed, performing the third step;
step three, generating the available inventory of the green tire on the first day of the week according to the formed and vulcanized plan and the occupation condition of the available inventory in the system;
step four, judging whether the ending specification and ending time exist according to the use of the blank every day in vulcanization;
fifthly, grouping according to the production specification of the forming machine, and confirming the specification replacement sequence;
step six, judging whether ending specifications exist, if so, arranging a certain number of the specification-changed tire blanks in the first order of each shift until finishing the scheduling, and then executing step eight; if not, executing the seventh step;
step seven, according to the specification replacement rule, determining the production quantity of each specification of each shift, and determining the order according to the priority;
step eight, updating the construction standard field in the corresponding plan according to the construction table coding information summarized by the molding process information;
step nine, for the specification changing node, checking the spare part satisfaction, and checking the productivity satisfaction by combining the process information, and marking;
step ten, judging whether the weekend is weekend or not, and if not, returning to the step five; if yes, outputting scheduled cycle molding, a vulcanization plan and manual adjustment;
and eleventh, checking and confirming the week plan, and finishing the week plan.
2. The MES-based automatic scheduling system for molding and vulcanizing, according to claim 1, wherein: the pulling module takes an ATP available inventory algorithm as pulling logic and takes the current available inventory as a main measurement unit to ensure the reasonable connection of the scheduling plans of the upper and lower working procedures and the dynamic adjustment under abnormal conditions; the triggering of the pull algorithm includes triggering of a core process, triggering of process plan validation, triggering of validation plan changes.
3. The MES-based automatic scheduling system for molding and vulcanizing, according to claim 1, wherein: in the third step, if the production days are less than 20 days and the net demand surplus exists, the mold is marked as 'smooth production', and in other cases, the mold needs to be cleaned and replaced and is marked as 'to-be-replaced'; the specific judgment principle of the priority to be changed is that if the production days are more than 20 days and no net demand surplus exists, the high priority is defined; if the production days are more than 20 days and the net demand surplus exists, defining the production days as a medium priority; if the number of production days is less than 20 days and there is no net demand remaining, low priority is defined.
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