CN113721549B - Method and system suitable for cutter cost management - Google Patents
Method and system suitable for cutter cost management Download PDFInfo
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- CN113721549B CN113721549B CN202111004081.9A CN202111004081A CN113721549B CN 113721549 B CN113721549 B CN 113721549B CN 202111004081 A CN202111004081 A CN 202111004081A CN 113721549 B CN113721549 B CN 113721549B
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B19/00—Programme-control systems
- G05B19/02—Programme-control systems electric
- G05B19/18—Numerical control [NC], i.e. automatically operating machines, in particular machine tools, e.g. in a manufacturing environment, so as to execute positioning, movement or co-ordinated operations by means of programme data in numerical form
- G05B19/406—Numerical control [NC], i.e. automatically operating machines, in particular machine tools, e.g. in a manufacturing environment, so as to execute positioning, movement or co-ordinated operations by means of programme data in numerical form characterised by monitoring or safety
- G05B19/4065—Monitoring tool breakage, life or condition
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B2219/00—Program-control systems
- G05B2219/30—Nc systems
- G05B2219/37—Measurements
- G05B2219/37616—Use same monitoring tools to monitor tool and workpiece
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
- Y02P90/30—Computing systems specially adapted for manufacturing
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Abstract
The invention provides a method and a system suitable for cutter cost management, wherein the method comprises the following steps: step 1: reading information of a cutter and a corresponding machined workpiece through a cutter cost management system, reading information of a cutter out of stock and price information through a cutter inventory management system, and writing the read information into a database respectively; step 2: checking all cutters written in the database and corresponding processed workpiece information, all cutters going out of the warehouse and price information; step 3: updating cutter and corresponding processed workpiece information, cutter delivery and price information in real time; step 4: calculating through a CPU algorithm, and updating cutter running cost data in real time; and acquiring cutter and workpiece information, cutter warehouse-out and price information from a database updated in real time through a programming algorithm, calculating a cutter CPU, and updating in real time. The beneficial effects of the invention are as follows: the CPU of the cutter is fully automatically operated, so that the labor cost investment and the accuracy can be saved.
Description
Technical Field
The invention relates to the field of cutter management, in particular to a method and a system suitable for cutter cost management.
Background
The engine is the heart of an internal combustion engine automobile and consists of a cylinder body, a cylinder cover, a crankshaft, a camshaft and a connecting rod 5. The required cutter of processing has covered kinds such as drill bit, screw tap, milling cutter, reamer, honing, emery wheel, brush, polishing area, roll and press the sword, needs thousands of cutters to process at the lathe during production, and cutter class is numerous and numerous, and cutter actual life (durability) is different, and according to the product variation actual consumption condition also unstable, has great challenges to statistics cutter use cost's timeliness and accuracy. At present, the industry commonly uses manual calculation of cutter consumption cost, obtains warehouse-out data through carding every month, correspondingly obtains warehouse-out amount from ERP, and calculates actual cost CPU of each product by combining actual yield data so as to support cutter management team to make decisions and optimize. The current solution has the following technical drawbacks in the tool pulling:
1. and human resources are wasted. The cutter management department needs special personnel to carry out cutter warehouse-in and warehouse-out data carding check, unit price inquiry check, yield data statistics check and other data collection processing work, and then carries out integration calculation, so that time and labor are wasted;
2. the cost of the cutter and the data output of the CPU are lagged. The statistical accounting is generally carried out by taking month as a unit, so that lean management is not facilitated, the abnormal process fluctuation cannot be mastered, and the cost management and optimization of the cutter cannot be effectively guided; 3. the data is not accurate enough. Errors are easy to occur in links such as yield statistics, ex-warehouse amount statistics, cutter variety use condition data collection and analysis, and errors are easy to occur in manual verification of various associated data, so that the data is not accurate enough;
4. the guidance is not enough in time. The month is taken as an analysis period, the dynamic process change of the CPU cannot be effectively monitored, and management personnel cannot be guided to adjust and optimize in time. And all data are displayed in a static report form, so that management personnel cannot easily acquire the data at any time and any place, and timeliness is poor.
Disclosure of Invention
The invention provides a method suitable for cutter cost management, which comprises the following steps:
step 1: and reading cutter and corresponding processing workpiece information through a cutter and tool information database, reading cutter ex-warehouse information and price information through a cutter cost database, and writing the read information into the database respectively.
Step 2: checking all the cutters and corresponding processed workpiece information and all the cutter ex-warehouse and price information written into the database, if the data is checked correctly, entering the next step, otherwise returning to the step 1, and re-reading the cutter information and the corresponding processed workpiece information or the cutter ex-warehouse information and price information.
Step 3: and updating the cutter and corresponding processed workpiece information, and delivering the cutter to a warehouse and price information in real time.
Step 4: calculating through a CPU algorithm, and updating cutter running cost data in real time; and acquiring cutter and workpiece information, cutter warehouse-out and price information from a database updated in real time through a programming algorithm, calculating a cutter CPU, and updating in real time.
As a further improvement of the present invention, in the step 1, the tool information and the corresponding processed workpiece information include, but are not limited to, a tool number, a tool lifetime set value, a current lifetime value and a remaining lifetime value, a tool state, a processed workpiece number, and model data.
As a further improvement of the present invention, in the step 1, the cutter delivery information and price information include a cutter number, a goods code, a delivery time, a corresponding price, a delivery amount, and a stock position.
As a further improvement of the invention, after said step 4, the following steps are performed:
a data presentation step: and developing a CPU display board UI according to the workshop site layout, and clearly displaying the dynamic CPU data and the processing workpiece data of each line/each device/each cutter.
As a further improvement of the present invention, in the data presentation step, the overall trend of each line/each modular cutter CPU can also be presented simultaneously.
As a further improvement of the invention, in the data presentation step, an early warning area, an integral stock and change condition display area and an abnormal consumption condition display area are also arranged.
As a further improvement of the invention, the method further comprises the step of:
information pushing and early warning steps: and when the value of the CPU of the cutter exceeds the monitoring setting range or the data fluctuation is abnormal, informing the management related personnel to perform early warning in an email/instant communication mode.
As a further improvement of the invention, after said step 4, the following steps are performed:
the steps of consulting and using: the tool is convenient for manager of each level to look up and use at any time and any place through PC client and mobile client.
As a further improvement of the invention, after said step 4, the following steps are performed:
and (3) cost lean management: all CPU data are derived through cutter numbers, OP stations, production lines and time screening, cutter processing characteristics, cutter history test replacement records and purchase batch number manufacturer data are associated, engineers are helped to analyze and judge the data, and cutter cost lean management is carried out.
The invention also discloses a system suitable for cutter cost management, which comprises: a memory, a processor and a computer program stored on said memory, said computer program being configured to implement the steps of the method of the invention when called by said processor.
The beneficial effects of the invention are as follows: 1. the CPU of the cutter is fully automatically operated, so that the labor cost investment and accuracy can be saved, data assets are formed, the data can be further analyzed, refined and displayed according to the requirements of cutter management personnel at each level, and the related personnel are helped to carry out lean cutter management work; 2. the cutter CPU monitors the real-time active management from the monthly response, and effectively improves the cost control capability of cutter management; 3. the cost data of the cutter is accurate, so that the cost optimization management and control of the cutter is truly and effectively guided, and the problem point of accurate positioning is solved; 4. the cost of the cutter is visually managed, the CPU is precisely distributed, and management staff is helped to pay attention to the problem of site machining abnormality in time, so that cost loss is reduced in time; 5. the related information of the cutter cost is automatically pushed and pre-warned in time, so that engineers can be helped to lock abnormal stations in time to conduct attack-closure analysis, and response efficiency is improved; 6. the cutter cost management system has the mobile office attribute, is convenient for management personnel to review and use at any time, and improves convenience; 7. the cost information of the cutter is improved in a paperless way, all data are stored in a database, and can be led out for use or archiving management as required to become a data asset.
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FIG. 1 is a schematic block diagram of the method of the present invention;
fig. 2 is a flow chart of the method of the present invention.
Detailed Description
As shown in fig. 1-2, the present invention discloses a method suitable for tool cost management, comprising the steps of:
step 1: reading cutter and corresponding processing workpiece information through a cutter and tool information database, reading cutter ex-warehouse information and price information through a cutter cost database, and writing the read information into the database respectively; the method comprises the following steps:
collecting cutter and processing workpiece data:
all machine tool equipment containing the cutters are linked in the same local area network, the data in each machine tool equipment PLC/PMC is accessed in a programming mode, the cutter and workpiece information in the machine tool is traversed in real time, and the data including, but not limited to, the work sequence number, the cutter service life set value, the current service life value, the residual service life value, the cutter state, the number of machined workpieces, the machine type and the like are obtained, so that data acquisition is completed.
Writing cutter and processing workpiece information into a database:
and programming the collected cutter and workpiece information data, calculating through specific processing, and writing the calculated cutter and workpiece information data into a database.
And (3) collecting cutter warehouse-out information and price information:
and acquiring the cost related information corresponding to the field-used cutter by reading the cutter and the delivery data (including but not limited to cutter number, commodity code, delivery time, corresponding price, delivery amount, library position and the like) in the tool information database in real time, and completing data acquisition.
Cutter ex-warehouse and price information are written into a database:
and programming the collected tool ex-warehouse data, calculating through specific processing, and writing the calculated tool ex-warehouse data into a database.
Step 2: checking all the cutters and corresponding processed workpiece information and all the cutter ex-warehouse and price information written into the database, if the data is checked correctly, entering the next step, otherwise returning to the step 1, and re-reading the cutter information and the corresponding processed workpiece information or the cutter ex-warehouse information and price information.
When the cutter information in the database is updated, checking is performed piece by piece, and the data integrity and effectiveness are ensured.
When the cutter ex-warehouse and price information in the database is updated, the cutter ex-warehouse and price information is checked piece by piece according to a specified format, so that the data is ensured to be effective.
Step 3: and updating the cutter and corresponding processed workpiece information, and delivering the cutter to a warehouse and price information in real time.
And reading the information of the cutter and the machined workpiece in the machine tool once every traversing, and updating and writing the information into corresponding information in the database to complete the real-time updating of the database.
And (3) updating and writing the cutter ex-warehouse and price information in the cost management software database into the built database once every time, and completing the real-time updating of the database.
Step 4: calculating through a CPU (single-piece cutter cost) algorithm, and updating cutter running cost data in real time; and acquiring cutter and workpiece information, cutter warehouse-out and price information from a database updated in real time through a programming algorithm, calculating a cutter CPU, and updating in real time.
After the step 4, the method further comprises the following steps:
a data presentation step: developing a CPU display board UI according to workshop site layout, and clearly displaying the dynamic CPU data of each cutter of each device of each line, the quantity and model of the processing tool books and the like; simultaneously showing the overall trend of each line/each module cutter CPU; and is provided with an early warning area (abnormal data can be displayed and flash reminding), an integral stock and change condition display area, an abnormal consumption condition display area and the like.
And the display modes can be reserved according to different requirements of different stages of cutter management personnel, so that the relevant conditions of the cutter CPU can be displayed as comprehensively and three-dimensionally as possible, and the management personnel can be supported to timely and accurately master the service conditions of the cutter.
And setting a monitoring range according to the actual requirements of cutter management, and carrying out special display early warning when the CPU value reaches a threshold value to remind a manager of paying attention to solving.
After the step 4, the method further comprises the following steps:
information pushing and early warning steps: and when the value of the CPU of the cutter exceeds the monitoring setting range or the data fluctuation is abnormal, informing the management related personnel to perform early warning in an email/instant communication mode.
After the step 4, the method further comprises the following steps:
the steps of consulting and using: the tool is convenient for manager of each level to look up and use at any time and any place through PC client and mobile client.
After the step 4, the method further comprises the following steps:
and (3) cost lean management: all CPU data are derived through cutter numbers, OP stations, production lines and time screening, cutter processing characteristics, cutter history test replacement records and purchase batch number manufacturer data are associated, engineers are helped to analyze and judge the data, and cutter cost lean management is carried out.
When a software user moves to each machine tool by using a pointer (a mouse or finger touch, etc.), the data information of all the cutter CPUs in the machine tool can be automatically displayed; clicking again can enter the CPU information base of the single cutter, can consult the history information, the associated use information, the supplier information, the batch information and the like, is convenient for engineers to analyze, and prompts lean management capability.
Remarks: 1. the cutter cost database refers to a part of the cutter inventory management system SAP/ERP and stores a cost data unit module; 2. the cutter and information database refers to the relevant information of all cutters in the real-time reading equipment, and is a cutter use data storage unit module; 3. the cutter and tool information database and the cutter cost database are data storage units distributed under two subsystems, and finally, the cutter cost management system of the invention comprehensively reads and calculates the data to use, thereby being a data source.
The invention also discloses a system suitable for tool cost management, comprising a memory, a processor and a computer program stored on the memory, wherein the computer program is configured to realize the steps of the method when being called by the processor.
The invention relates to a system suitable for managing cutter cost, which comprises the following hardware: a computer for running the cutter cost management system software, a computer for running the cutter inventory management system, a large screen display for displaying cutter CPU information and a mobile terminal of a user; the software includes autonomously developed tool cost management system software and tool inventory management system software.
The system suitable for tool cost management is installed and applied to a client and a mobile terminal, after real-time dynamic data are obtained, the tool cost CPU data dynamic information is presented through a setting algorithm, a fluctuation range and an early warning threshold value are set, timely early warning can be performed, information can be pushed and presented to tool management staff, meanwhile, accurate prediction can be performed according to linear trend, and tool management staff can conveniently know the tool cost condition at any time and any place; according to the CPU change curve, the engineer team is guided to conduct management optimization, the CPU consumed by each cutter or each product can be independently subjected to homonymy or cyclic analysis, information exceeding the range of a set fluctuation value is automatically pushed, the cutter management team is helped to find differences and problems in time, and the efficiency and the guidance are greatly improved.
The system is suitable for managing cutter cost, reads all cutter information (including but not limited to data such as a work sequence number, a cutter service life set value, a current service life value, a residual service life value, a cutter state and the like, which are specifically dependent on user intention and software and hardware environment) and corresponding processing workpiece information (information such as processing quantity, machine type and the like) in each machine tool PLC/PMC in a workshop in real time through an autonomously developed cutter cost management system, and writes cutter and corresponding processing workpiece information data into a database; meanwhile, a database of the tool inventory management system is opened, information such as tool numbers, quantity, unit price, suppliers and the like consumed by real-time dynamic ex-warehouse of tools in SAP/ERP is read, calculation and analysis are carried out according to a specific algorithm, and the result is displayed in a mode meeting the requirements of management staff (both a client and a mobile terminal can be used). All basic data acquisition is fully automated, and the problem of time and labor consumption of manual basic data statistics is solved.
The system suitable for tool cost management reads the related data of the tool cost and the data of the tool inventory management system in the machine tool in real time, realizes the visual display of the CPU data through an algorithm, achieves real-time update, and can solve the problem of CPU output lag.
The system for managing the cost of the cutter, disclosed by the invention, has the advantages that the acquired data are all from data exchange of machine tool equipment, the cutter, a computer database and the like, no artificial participation exists, and accurate original data can be obtained.
The invention has the technical innovation points that:
1. automatic acquisition of cutter data: and the data processing such as reading, checking, writing, recording, operation and the like of the service life information of all cutters, the processing data of each machine tool, the purchasing price and other related information is completely automatically operated through software.
CPU real-time dynamic operation: and calculating the cost data of the cutter in real time according to a CPU algorithm and dynamically updating.
CPU visual management: visual development can be performed according to field device distribution, all tool CPUs are decomposed to each device, and management decisions are clearly guided.
4. Information automatic pushing and early warning: the CPU floating range of each cutter, each equipment and each production line can be set according to the management requirement, the system is monitored in real time, and communication functions such as WeChat, mail and the like can be used for early warning once the CPU floating range is out of range.
5. And mobile management is realized, so that management staff at each level can check and monitor at any time and any place.
6. Data asset application: and the data with different formats can be exported according to the requirements of cutter management personnel to conduct further relation analysis, so as to guide engineers to conduct optimization promotion.
The invention has the beneficial effects that: 1. the cutter CPU is fully automatically operated, so that the labor cost investment and accuracy can be saved, data assets are formed, the data can be further refined and displayed according to the requirements of cutter management personnel at each level, and the related personnel are helped to carry out lean cutter management work; 2. the cutter CPU monitors the real-time active management from the monthly response, and effectively improves the cost control capability of cutter management; 3. the cost data of the cutter is accurate, so that the cost optimization management and control of the cutter is truly and effectively guided, and the problem point of accurate positioning is solved; 4. the cost of the cutter is visually managed, the CPU is precisely distributed, and management staff is helped to pay attention to the problem of site machining abnormality in time, so that cost loss is reduced in time; 5. the related information of the cutter cost is automatically pushed and pre-warned in time, so that engineers can be helped to lock abnormal stations in time to conduct attack-closure analysis, and response efficiency is improved; 6. the cutter cost management system has the mobile office attribute, is convenient for management personnel to review and use at any time, and improves convenience; 7. the cost information of the cutter is improved in a paperless way, all data are stored in a database, and can be led out for use or archiving management as required to become a data asset.
The foregoing is a further detailed description of the invention in connection with the preferred embodiments, and it is not intended that the invention be limited to the specific embodiments described. It will be apparent to those skilled in the art that several simple deductions or substitutions may be made without departing from the spirit of the invention, and these should be considered to be within the scope of the invention.
Claims (5)
1. A method for tool cost management comprising the steps of:
step 1: reading cutter and corresponding processing workpiece information through a cutter and tool information database, reading cutter ex-warehouse information and price information through a cutter cost database, and writing the read information into the database respectively;
step 2: checking all the cutters and corresponding processed workpiece information and all the cutter ex-warehouse and price information written into the database, if the data is checked correctly, entering the next step, otherwise, returning to the step 1, and re-reading the cutter information and the corresponding processed workpiece information or the cutter ex-warehouse information and price information;
step 3: updating cutter and corresponding processed workpiece information, cutter delivery and price information in real time;
step 4: calculating through a CPU algorithm, and updating cutter running cost data in real time; acquiring cutter and workpiece information, cutter warehouse-out and price information from a database updated in real time through a programming algorithm, calculating a cutter CPU, and updating in real time; in the step 1, the tool information and the corresponding processing workpiece information comprise a tool number, a tool life set value, a current service life value, a residual life value, a tool state, the number of processing workpieces and model data;
after the step 4, the method further comprises the following steps:
a data presentation step: developing a CPU display board UI according to workshop site layout, and clearly displaying dynamic CPU data and processing workpiece data of each line/each device/each cutter;
information pushing and early warning steps: when the CPU value of the cutter exceeds the monitoring setting range or the data fluctuation is abnormal, informing management related personnel to perform early warning automatically through a mail/instant communication mode;
the steps of consulting and using: the PC client and the mobile client facilitate the manager of each level to review and use the cutter at any time and any place;
and (3) cost lean management: all CPU data are derived through cutter numbers, OP stations, production lines and time screening, cutter processing characteristics, cutter history test replacement records and purchase batch number manufacturer data are associated, engineers are helped to analyze and judge the data, and cutter cost lean management is carried out.
2. The method according to claim 1, wherein in the step 1, the tool delivery information and price information include a tool number, a product code, a delivery time, a corresponding price, a delivery amount, and a stock position.
3. The method according to claim 1, characterized in that in the data presentation step, the overall trend per line/per modular cutter CPU is also presented simultaneously.
4. The method of claim 1, wherein in the data presentation step, an early warning area, an overall inventory and change situation display area, and an abnormal consumption situation display area are further provided.
5. A system for tool cost management, comprising: a memory, a processor and a computer program stored on the memory, the computer program being configured to implement the steps of the method of any one of claims 1-4 when called by the processor.
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