Material distribution method based on workstation group division

A material distribution method based on workstation group division, the method comprising:

• step 1:
• setting a radio frequency identification (RFID) scanner at the first workstation where a production line starts, performing statistics on the number and models of online products, and taking the number of the online products as an indicator of a production process;
• step 2:
• obtaining material requirements of each product according to a bill of materials (BOM) of the product, mapping the required materials to each workstation, and accordingly calculating material consumption at each material consumption workstation when an i-th product is produced;
• step 3:
• checking specific information on each type of material and transportation means according to the BOM, establishing a mathematical model according to the specific information and the number of materials consumed, planning material distribution, and distributing materials for a workstation group Zj composed of the material consumption workstations when the i-th product is produced, wherein the specific information on each type of material and transportation means comprises information on material storage containers, types and sizes of material boxes, modes of combination of the material boxes, the number of stored materials and transportation capacity of the transportation means;
• step 4:
• planning a distribution route of each workstation group according to the workstation group division, wherein
• the workstation group division specifically comprises:
• calculating a material demand lackin of an n-th material consumption workstation for the production of an i-th product through the quantity of materials consumed for products, planning according to information on a material demand Con of an n-th type of material for a unit product, a quantity Can of materials in a unit material box, a material box volume Vn and a maximum carrying capacity Q of transportation means;
• when the number of material lacking boxes is equal to or greater than the maximum carrying capacity Q of the transportation means, distributing materials;
• wherein at this time, transportation workstations form a transportation workstation group;
• updating the material lacking quantity after the distribution is completed, and enabling one round of material lacking workstations to fall into one workstation group;
• and a maximum inventory Maxn and a minimum inventory Minn of line side materials are set, and the line side inventory shall not exceed the maximum inventory;
• and when the line side inventory is the minimum inventory, distribution tasks are arranged even if a loading rate of a vehicle is low;
• step 5:
• obtaining a distribution frequency of each type of material according to the workstation group division, and establishing a mathematical model according to material attribute analysis, pick frequency analysis, inter-material correlation and a material storage mode to optimize a storage location of a warehouse;
• taking a temporary material storage area as the center, and reasonably planning the distribution route of each workstation group according to the divided workstation groups and existing distribution channels of a factory;
• wherein:
• according to the material pick frequency analysis, formula (1) denotes minimizing the total picking distance of all materials in a fixed period,
• min Σn=1NΣa=1AΣb=1Bxnabdabfn (1)
• dab is a travel distance from a b-th goods shelf in an a-th area to a picking working table, fn is an average pick frequency of a material n in a fixed period, s.t:
• ∀n, Σa=1Axnab=1, xnab=1 means that an n-th type of parts are placed on the b-th goods shelf in an a-th area, otherwise it is 0, which means that one type of material can only be placed in one storage location;
• the mathematical model established according to the material attribute analysis, the pick frequency analysis, the inter-material correlation and the material storage mode is shown in formula (2),
• min Σn=1NΣa=1AΣb=1BxnabdabFn (2)
• wherein s.t:
• Fn=fn/Rn, ∀n, Σa=1Axnab=1, and xnab=1 means that the n-th type of parts are placed on the b-th shelf in the a-th area, otherwise, it is 0;
• and
• according to the inter-material correlation and the divided workstation groups, when two types of materials are in the same workstation group for more times, the correlation is greater, the materials with correlation are clustered, and a material correlation coefficient is defined as formula (3),
• r
• mn
• =
• p
• mn
• Maxp
• mn
• (
• 3
• )
• wherein Pmn denotes the number of times that materials m and n are in the same workstation group, rmn denotes the inter-material correlation, rnm∈[0,1], a new parameter is defined as a pick frequency Fn, Fn=fn/Rn, Rn=Σn=1Nrmn after correction of each type of material, and fn is an average pick frequency of the materials n in a fixed period;
• and
• step 6:
• dividing staff into warehouse material preparation personnel and distribution personnel, and distributing materials according to a work flow.