IT202300000276A1 - RESOURCE PLANNING SYSTEM, ORDER EXECUTION AND PRODUCTION AUTOMATION FOR THE MANUFACTURE OF CUSTOMIZED AND IDENTIFIABLE COMPONENTS FOR THE NAUTICAL INDUSTRY - Google Patents

Description

Description of the invention entitled:

?RESOURCE PLANNING SYSTEM, ORDER EXECUTION AND PRODUCTION AUTOMATION FOR THE MANUFACTURE OF CUSTOMIZED AND IDENTIFIABLE COMPONENTS FOR THE NAUTICAL INDUSTRY?

Description

Field of technique

The present invention operates in the field of hardware and software management systems in the naval industry. More specifically, the invention allows to plan the orders to be executed, automating the related production plan in order to create customized components, individually identifiable, intended to constitute vessels.

Known art

The Industry 4.0 model, to date, involves the adoption of a series of new generation technologies that progressively increase the level of industrial automation and improve the overall production control system.

At the same time, supply chain systems have spread, especially in the sectors of goods exchange and transport in general. These services usually concern the need for timely and efficient management of all flows of goods, from the supplier to the end customer, of Reverse Logistics and post-sales logistics. It is appropriate in the provision of these services to identify a balance between organization, reduction of delivery times and cost containment in order to find the optimal solutions for achieving the highest possible efficiency of logistics processes.

An example of the services offered to achieve these objectives is represented by the SOGEDIM company system which offers assistance in packaging, re-packaging, kit building, pick and pack, labelling and re-labelling, on-demand customisations.

More specifically, in recent years a widespread computerization mechanism has been developed in production processes, both for order management and for all production and processing phases.

The term ?automation? refers to the development of procedures to perform processes without direct human intervention. The advantages of correctly programmed and standardised production are enormous in any sector. The first of the advantages consists in optimising the resources available, both machinery and manpower. Process control is significantly more accurate and any errors or deviations from the programme can be corrected in real time thanks to the possibility of obtaining, even remotely via smartphone and tablet, a faithful photograph of the functioning of the production processes.

Existing solutions have proposed software frameworks for the management of production processes: for example, the MES system of ISI s.r.l. intervenes both on the machinery and on the management systems, interfacing them with each other so that they can communicate and circulate information in a fluid and effective manner.

Another example is the subject of patent application CN114782118A. The invention describes a method and system for modifying and transmitting sales information for ERP software and a method for controlling the supply account. The method includes the steps of first placing an order and then transmitting an access path, or first transmitting the access path and then placing the order. Such a system and method are easy to implement, the efficiency of invoicing and account control can be significantly improved, and data loss is avoided.

Another example is the subject of patent application CN114781958A. The invention discloses an order-based delivery method for an Enterprise Resource Planning (ERP) system and its associated system.

The method includes the following steps:

? phase 1, creating or modifying an order;

? phase 2, execution of the shipment;

? phase 3, direct delivery;

? Phase 4, invoicing and storage and generating a box label.

All order information is recorded on the label or body of each box.

None of the systems mentioned so far seem to apply the Enterprise Resource Planning model to production in the nautical sector. In fact, a large slice of the market remains uncovered, requiring accurate precision in the transition phases from distributors to assemblers. In most cases, in the nautical sector, in fact, the components ordered and produced before the assembly of a ship are unique and can be placed in a single destination. This uniqueness entails the risk of a high number of errors both in the recognisability of the pieces and in their placement.

There is no doubt, therefore, that the solutions mentioned so far do not address the aforementioned critical issues.

The purpose of this invention is to propose an operating system that solves the above-mentioned problems.

Even more advantageously, the system adopts hardware devices designed to simplify and make the operations used in the production process safer.

Description of the invention

According to the present invention, a system dedicated to the naval sector is created that effectively solves the above-mentioned problems. The present patent application has been created to provide new cutting-edge solutions compared to pre-existing systems.

The system in question is equipped with advanced structural IT features and involves the interaction between a physical and/or virtual server that performs all IT operations, a database that stores the log files resulting from the system's IT processes and other useful information for the management of said company and a plurality of devices that are distributed to operators in the production phase to perform parts of the production process digitally. The entire process is focused on the production of customized components that are obtained from the processing of beams, profiles and sheet metal. The first of the advantages of the system in question is that it is equipped with 10 modules, specifically:

- a purchase order management module;

- a reception form;

- a registration form;

- a module dedicated to shipments;

- a processing module;

- a component management module;

- a roller conveyor module;

- a nest module;

- a cutting module;

- finally, in a further version, a sub-assembly module.

The production process starts with the automatic import of the purchase order received from each customer into the operating system by the aforementioned purchase order management module: the production process starts from the moment of import. The entry and registration of vehicles loaded with raw components in the production plant are saved digitally through the aforementioned reception module which records the type and weight of the components, as well as the railcar and trailer. Upon entry, the transport list is scanned and is subsequently saved by the aforementioned module, which attaches the digital data to an entry packing list and generates a check-in code necessary to carry out an entry unloading of said raw components within a warehouse park. Subsequently, the aforementioned entry/exit transport lists, together with the generated packing lists, are also stored and processed in a registration module which carries out a detailed management of the information contained in said documents from which it is possible to trace each of the incoming raw components, creating a dedicated detail area in which to access detailed information on said components and associating a purchase order number with the transport slips corresponding to the incoming components. At the same time, the same components are labeled by the competent operators using the devices provided that scan the check-in code.

Through the aforementioned shipping management module, new shipments are organized, previously created packing lists or individual components are aggregated, new transport documents are prepared and transfer orders are managed, including for customized components once they are ready for delivery to a customer.

After labeling the components, the aforementioned processing module translates the initially imported purchase orders into work orders, starting the production process of a given batch of a job.

Work orders are represented by the list of component types and corresponding requirements for the processing that takes place in a processing park and in this case consists of five activities all managed from the aforementioned processing module.

The first consists in assigning an operator to each job for the execution of each different process, then the management of the activities of picking the components prior to processing and the start of the sandblasting and priming process are foreseen; the module also records the cutting activities in real time including those performed manually and sequences said components to be loaded onto a cutting bench, for a specific processing flow.

The advantage of this module is that the various processing phases that a specific flow of a given batch must undergo, sandblasting and priming, machine cutting, manual cutting and shaping processes on semi-finished products, assembly into transportable subassemblies, can be performed by different factories; in any case, the module allows their assignment in order to monitor their execution.

A calendar shows for each day which batches need to be picked and the quantity of pieces required for each batch; therefore, the daily workload of the material park department is divided by reference construction site.

It is possible to anticipate and postpone the withdrawal by acting directly on the calendar which will then simulate the new workloads.

Advantageously, the operator in charge of the picking is given the number of the stall/platform where the material to be picked is stored. By scanning the QR code on the piece tag, the picking operation is recorded.

By scanning the QR code on the sheet metal tag, a series of information is sent to the PLC of the treatment line, such as:

- sheet metal dimensions;

- treatment to be performed;

- internal destination to the workshop.

The treatment to be performed is automatically defined based on the supply status of the sheet metal, whether with decayed primer or not, and in the case of re-transit whether to repair or completely re-treat.

It is also possible to monitor the sheets of metal present on the treatment line and in which area they are located.

The indication of which cutting pattern to create on the material collected and arrived in the cutting area is provided to the operators by scanning the QR code applied to the component being processed.

The operator sees a list of possible cutting patterns that he could create, with a preview of the naval design and the list of pieces that will be created.

By selecting the construction and the lot, the operator in charge of carrying out such work can view the list of components, the detail of the work, type of work, size involved as well as the naval drawings necessary for its execution. The documentation can be viewed and printed.

As mentioned, the module allows you to manage the sequencing of the sheets to be loaded onto the cutting bench, for a specific P-line processing flow: this, in addition to plasma cutting, requires them to be sorted into stacks according to a specific sequencing defined by the client shipyard.

The module indicates to the operator the order in which he must load the sheets onto the bench in order to obtain semi-finished products stacked in compliance with the required sequencing.

A component management module records step by step those still to be transformed and/or semi-finished products, classifying them based on type, size, quality of the composition material, testing body and/or by specific alphanumeric codes previously assigned. The main advantage is that of allowing a search for each individual component by providing identification coordinates, collection and/or any other useful information.

The unprocessed and semi-processed sheets and profiles are classified according to the type of shape, dimensions, steel quality and testing body in Items, or identified by specific alphanumeric codes. The unprocessed materials, according to dimensional parameters and rotation indicators, are stored in pre-assigned pallets into which the physical warehouse is divided. It is possible to consult the list of pieces present in each stall, the vertical stacking order, as well as the specific level of stock for both sheets and profiles. The search by Item-material code provides information on the dimensional characteristics, on the stock pallet and on the number of pieces available in the warehouse.

The roller conveyor for transporting components is managed by the aforementioned roller conveyor management module, which is designed to regulate the treatment line of said components, allowing real-time monitoring on a sandblasting and priming treatment line and recording of each entry into the factory and warehouse.

The main advantage of this module is that it allows you to check the actual position of the sheets on the line and which of them have undergone the sandblasting and priming phase or not. This module allows the operators of the treatment department to report problems/defects of the components, monitor the temperatures of the combustors in progress and the system administrators to intervene in the event of communication errors between departments.

The aforementioned nest module then allows access to the unique identification code of each raw component from which the semi-finished components originated and thus traces back to the supply information and testing certificates. The work orders are translated into a cutting list, intended for a plasma and cutting department, by the aforementioned cutting module which also imports a basic list of the customized components to be produced, allowing the execution of the cutting activity of the raw and semi-finished components.

During the processing of the information, the module compares the detailed bill of materials with the design documents and with a cutting machine program: this reprocessing allows a comparison between technical documentation and said work orders by providing cutting instructions to be carried out. The cutting instructions are followed by assembly instructions of said semi-finished products to be obtained.

Finally, in a further advantageous version, a sub-assembly module that can be consulted based on the assembly activity in assembled and the reference batch. It is possible to consult the sub-assemblies to be made, the semi-finished products needed to perform the assembly and whether or not these have been delivered. If all the pieces to be assembled have been delivered, it is possible to start the assembly phase and the activity is recorded on the system. The correctly prepared sub-assemblies are available for shipping and those completed and shipped can be consulted on the aforementioned module which makes them available to the client.

The entire system, in further advantageous versions, is programmed for:

- evaluate document congruence and automatically intercept problems for which a correction is required in the production process, correct any problems and/or reload updated documents to be submitted for new processing to a designated module;

- operation also in offline mode to guarantee the local functions necessary for the establishment and associated with the normal running of operations;

- have a high standard of data protection by using direct communication through a TCP/IP communication module, and be prepared for the implementation of encryption systems such as password hashing;

- log in using any authentication method;

- automatic updates to ensure ever-better performance and functionality;

- allow the execution of advanced actions such as screen capture in a screenshot image format, the direct execution of actions through directly implemented DOS commands, the execution of functions and APIs even remotely.

In a more advantageous version, each of the devices supplied to the operators includes at least one hardware peripheral that implements a chip dedicated to communications security and that allows access to the system only after biometric authentication during the processing phases.

The advantages offered by the present invention are evident in light of the description set forth thus far and will be even clearer thanks to the attached figures and the relative detailed description.

Description of the figures

The invention will be described below in at least one preferred embodiment for explanatory and non-limiting purposes with the aid of the attached figures, in which:

- FIGURE 1 shows a general view of the operating system in question starting from a server 110 installed in a factory 102 and comprising a management module 1 that receives a purchase order 1.1 from the client 1.2; a receiving module 2 containing the list of incoming raw components 2.1 and the transport list 2.4 to be transferred to a registration module 3. A shipping module 4 and a processing module 5 that produces a work order 5.1 necessary for the processing park 400. A components module 6 necessary for cataloguing the raw materials 2.1 and the semi-finished products 2.2, a roller conveyor module 7 for managing the roller conveyor machinery 500 and a nest module 8. Finally, a cutting module 9 that produces a cutting document for the relative plasma department 600 and a sub-assembly module 10 for the conclusion of the processing.

- FIGURE 2 shows a view of the set of devices that communicate with said operating system installed in a factory 102 including: a server 110 equipped with a database 120 and in communication with a plurality of devices 200 supplied to operators 210.

Detailed description of the invention

The present invention will now be illustrated purely by way of example but not in a limiting or binding manner, using the figures which illustrate some embodiments relating to the present inventive concept.

With reference to Fig. 1, a general view of the operating system is shown that allows planning resources, executing orders and automating the production plan of a plant 102 in order to manage the entire production process of customized components 101 for the nautical sector and in particular for shipyards. As shown in Fig. 1, it provides for interaction with the following devices:

- at least one physical and/or virtual server 110 that allows the performance of IT operations, accessible via any authentication method and also functioning in offline mode to guarantee the local functions necessary for the establishment 102, associated with the normal performance of operations;

- at least one database 120 for storing log files resulting from the system's IT processes and other information useful for managing the production process;

- a plurality of devices 200 supplied to each operator 210 designed to ensure security, internal functions, external functions and to carry out the production process: each of them includes at least one hardware peripheral designed to implement a chip dedicated to communications security and designed to allow access to the system only after biometric authentication during the processing phases.

The system guarantees a high standard of data protection by using direct communication through a TCP/IP communication module and is also designed for the implementation of encryption systems such as password hashing.

Starting from Fig. 2 we can see the functioning of the system in question which includes a plurality of modules starting from a first management module 1, responsible for the automatic import of a purchase order 1.1 received from each client 1.2.

Once the import has taken place, a receiving module 2 allows the entry and registration of vehicles carrying raw components 2.1, indicated in the purchase order 1.1; said receiving module 2 saves information on the type and weight of the railcar and trailer, scans at least one transport list 2.4 and attaches said data digitally to an entry packing list, generating a check-in code necessary for the unloading of said incoming components 2.1 within a warehouse park 300.

The above mentioned transport lists 2.4 of the components that are incoming or outgoing are saved in a registration module 3, programmed to carry out their capillary management by being able to access and obtain from the above mentioned packing list the list of incoming raw components 2.1, create a dedicated detail area and obtain detailed information on them. The above mentioned module 3, consequently, associates a purchase order number 1.1 to the above mentioned transport lists 2.4 allowing the physical import of the above mentioned components 2.1 i.e. castings, plates supplied by the steel mill that ships individual products, sheets and raw profiles.

The operators 210 of the warehouse park 300, scanning through said devices 200 the aforementioned check-in code generated during the entry phase, start a labeling procedure for said components 2.1 awaiting processing. To support the monitoring of the large quantity of incoming components, a shipment management module 4 has been installed, specifically designed to: ? query the shipments created;

? create shipments;

? create packing lists from pallets or individual pieces;

? manage component transfer orders for other warehouses, factories and/or third parties;

? create free shipments, not tied to orders from the shipyard client;

? manage the list of vehicles and be able to query the history of trailer/tractor entry and exit.

Subsequently, a processing module 5 is planned, dedicated to the translation of the clients' 1.1 orders into 5.1 work orders and represented by a list of component types 2.1 and corresponding requirements, necessary for the production of a given batch of a 1.1 order.

The receipt of the aforementioned order 5.1 and the subsequent sending for processing allows the operators 210 of the processing park 400 to view what is needed to be collected, in terms of type of material and quantity. Subsequently, the work order 5.1 translates into cutting order 1.9 for the operators of the plasma and cutting department 600 of the semi-finished components 2.2 if they are rough pieces that need to undergo transformation.

In this section, in addition to being able to consult the various orders and their progress status, it is possible to consult the list of all the sheets and profiles taken and the progress status of production for each batch of a given order. The aforementioned module 5 performs:

? assignment of a 201 operator to each job;

? plans and manages the activities of picking 2.1 components prior to processing;

? starts the sandblasting and priming process of 2.1 components such as sheet metal, profiles, beams and monitors its progress;

? records real-time cutting activities of said 2.1 components such as sheets, beams and profiles including manually performed cutting activities; ? sequences said 2.1 components to be loaded onto a cutting bench, for specific machining operations.

At the same time, a component management module 6 proceeds to register the raw components 2.1 still to be transformed and/or the aforementioned semi-finished products 2.2, generating a classification based on type, dimensions, quality of a composition material, testing body and/or via specific alphanumeric codes previously assigned.

The aforementioned component management module 6 ultimately allows a search for a single component by providing coordinates for identification, collection and any other useful information.

A roller conveyor management module 7 is then programmed to monitor and regulate a roller conveyor machine 400 that transports from one area of the plant 102 to another and manages a treatment line for components 2.1, 2.2 during the production process. This module 7 allows real-time monitoring of the raw components 2.1 and semi-finished products 2.2 and the recording of each entry into the plant 102 and into the stock area following treatment. A nest module 8 is then programmed to execute a list of semi-finished components 2.2 obtained from the cutting operations and allows access to the unique identification code of the raw components 2.1 from which the semi-finished products 2.2 originated and to trace supply information and test certificates. For each piece, the dimensional information, the cutting pattern from which that piece was generated and which sheet metal or raw profile was used are specified. By clicking on the unique identifier of the piece from which the semi-finished product was generated, the system can be accessed. has been made? It is possible to trace the supply information, as well as the material testing certificates.

A cutting module 9 as mentioned provides for the translation of work order 5.1 into cutting order 1.9.

The cutting documentation and the basic list of pieces to be produced by cutting sheet metal and profiles is provided by the customer 1.2 and reworked by the system. The documents provided are files in xls format, in pdf format and in dxf and iso formats for the execution of automatic cutting on plasma machines. The documents in xls format provide the list of semi-finished products 2.2 that will be produced by cutting raw material, while the documents in pdf format are design documents, graphic representation of the cutting.

The cut 9 module in question provides the possibility of correcting problems and/or reloading updated documents to be processed again by the system.

The cutting instructions are also followed by the assembly instructions of the semi-finished products 2.2 obtained in assemblies: they are called sub-assemblies and consist of the aforementioned customized components 101.

Thus, depending on the assembly activity in assembled units, the construction and the reference batch, it is possible to consult a sub-assembly module 10, in which the semi-finished products 2.2 necessary to carry out the assembly are indexed.

Once all the parts to be assembled have been delivered, you can start the assembly by registering them internally in the system. Once completed, the 101 customized components are available for shipping and can be consulted once shipped.

The aforementioned system is able to evaluate the document congruence and automatically intercept the problems for which correction is required during the entire production process.

Finally, it is clear that modifications, additions or variations obvious to a person skilled in the art may be made to the invention described herein, without thereby departing from the scope of protection provided by the attached claims.

Claims (9)

Claims 1. Resource planning, order execution and production automation system for at least one plant (102), capable of managing the production process of customized (101) and identifiable components intended for the nautical sector; said system having advanced structural IT features and being characterized by the fact that it includes: - at least one physical and/or virtual server (110) capable of enabling IT operations to be carried out; - at least one database (120) suitable for storing the log files resulting from the computer processes of the system and other information useful for the management of said establishment (102); - a plurality of devices (200) supplied to each operator (210) designed to ensure safety, internal functions, external functions and to carry out the production process; - at least one management module (1) of purchase orders (1.1) capable of allowing the automatic import of said purchase order (1.1) received from each client (1.2); - at least one receiving module (2) suitable for allowing an initial entry and registration of each vehicle containing raw components (2.1) including sheet metal, beams and profiles to be processed in said factory (102); said receiving module (2) being suitable for recording information on the type and weight of the railcar and trailer, scanning at least one transport list (2.4) and attaching said data digitally to an entry packing list; said module (2) being suitable for generating a check-in code suitable for unloading said raw components (2.1) entering a warehouse park (300); - at least one registration module (3) of said incoming/outgoing transport lists (2.4) capable of accessing and extracting from said packing list each of said incoming raw components (2.1), creating a dedicated detail area and obtaining detailed information on said components; said module (3) associating a purchase order number (3.2) to said transport lists (2.4) corresponding to said incoming components (2.1); each device (200) supplied to operators (210) of said warehouse park (300) being capable of scanning said check-in code starting the labelling of said components (2.1); - a shipment management module (4) designed to create/organize a shipment, aggregate multiple previously created packing lists or individual components (2.1), prepare new transport documents (2.4), manage transfer orders; - a processing module (5) dedicated to the translation of orders (1.1) into work orders (5.1) represented by a list of component types (2.1) and corresponding requirements, necessary for the production of a given batch of a job order; said processing taking place in a processing park (400); said processing module (5) being able to: ? assign an operator (201) to each job for the execution of each processing phase; ? plan and manage component picking activities (2.1) prior to processing; ? start the sandblasting and priming process of components (2.1) such as sheet metal, profiles, beams and monitor its progress; ? record real-time cutting activities of said components (2.1) such as sheets, beams and profiles including manually performed cutting activities; ? sequence said components (2.1) to be loaded onto a cutting bench; - a component management module (6) capable of recording said components (2.1) still to be transformed and/or semi-finished components (2.2), generating a classification based on type, dimensions, quality of a composition material, testing body and/or via specific alphanumeric codes previously assigned; said component management module (6) allowing the search for single components (2.1) providing coordinates for identification, collection and/or any other useful information; - a roller conveyor management module (7) capable of monitoring and regulating a roller conveyor machine (500) capable of managing a treatment line for said raw components (2.1) such as sheet metal, beams, profiles; said roller conveyor management module (7) allowing real-time monitoring of said components (2.1) on a sandblasting and priming treatment line and the recording of each entry into said factory (102) and into said warehouse park (300); - a nest module (8) comprising a list of semi-finished components (2.2) obtained from said cutting operations; said module (8) allowing access to the unique identification code of each raw component (2.1) from which said semi-finished component (2.2) originated and to trace supply information and testing certificates; - a cutting module (9) suitable for translating said work order (5.1) into a cutting list (1.9) intended for a plasma and cutting department (600); said module (9) also importing a basic list (1.4) of the customized components (101) to be produced by performing said cutting activity of said raw components (2.1); said module (9) being suitable for receiving information necessary for said cutting list (1.9) and said basic list (1.4) from a client and reprocessing information to be inserted in said documents; during said reprocessing, said module (9) carrying out a comparison of said detailed basic list (1.4) with design documents (1.6) and with a machine program; said reprocessing of said cutting list (1.9) being suitable for allowing a comparison between technical documentation and work orders (1.1) by providing cutting instructions to be carried out on said raw components (2.1); the said cutting instructions are followed by assembly instructions for the said semi-finished products (2.2) to be obtained and/or already obtained. 2. System according to the previous claim 1, characterized in that said documents provided are files in xls format, in pdf format and in dxf and iso formats and are suitable for carrying out automatic cutting operations on plasma machines; said documents in xls format providing a list of semi-finished products (2.2) produced by said cutting of raw components (2.1), while the documents in pdf format are design documents (1.6) and graphic representation of said cutting operation; through an upload of said documents internally to said server (110), a re-elaboration takes place suitable for reconstructing said basic list (1.4) and importing a plurality of information useful for said production of customized components (101). 3. System according to any of the preceding claims 1 or 2, characterized in that it is capable of evaluating the document congruence and automatically intercepting problems for which a correction is required in the production process; said system being capable of correcting any problems and/or reloading updated documents to be subjected to new processing in a designated module. 4. System according to any of the preceding claims, characterised in that it comprises a sub-assembly module (10) suitable for containing an assembly document (1.5) of said sub-assemblies to be made, indicating said semi-finished components (2.2) necessary to carry out said assembly of sub-assemblies and indicating, by means of a check mark, the delivery of semi-finished (2.2) and raw (2.1) components to be used in said assembly; said module (8) being suitable for starting an assembly of said sub-assemblies and recording said activity; at the conclusion of an assembly, said sub-assemblies are available to be shipped and consulted before and after shipment. 5. System according to any of the preceding claims, characterised by the fact that it is capable of operating also in offline mode to guarantee the local functions necessary for said establishment (102) associated with the normal performance of operations. 6. System according to any of the preceding claims, characterized in that it uses direct communication through a TCP/IP communication module, and is designed for the implementation of cryptographic systems such as password hashing. 7. System according to any of the preceding claims, characterized in that each of said devices (200) comprises at least one hardware peripheral capable of implementing a chip dedicated to communications security and capable of allowing access to the system only after biometric authentication during processing; said server (110) being subsequently accessible via any authentication method. 8. System according to any of the preceding claims, characterised by providing for the automatic updating of the software included in the system. 9. System according to any of the preceding claims, characterized by allowing: the execution of advanced actions such as screen capture in an image format (screenshot); the direct execution of actions through directly implemented DOS commands; the execution of functions and APIs even remotely.