1、 Management status of existing tool room
1.1 tools and measuring tools management
1.1.1 management features of tools and measuring tools
1. The tool is frequently collected and returned, and the collection and return cannot be tracked and counted in real time.
2. There are many specifications of tools in the warehouse, with large consumption, which is difficult to count and count.
3. Multi person collection and return, no effective identification scheme, manual recording is difficult to control efficiently and timely, and it is difficult to trace and query.
4. Large tool consumption, high management value and high management cost.
5. Measuring tools are related to product quality and need to be calibrated and maintained regularly. Manual management is easy to forget, resulting in quality risk.
1.1.2 core problems of existing tool room management
1. Collection and return are frequent. Manual registration and collection form are used for warehouse in and warehouse out management. There are some problems, such as complex registration operation, workers are unwilling to register, registration time-consuming and so on.
2. It is difficult to make statistics of the collection form, so it is necessary to manually input the collection form into the computer excel table for the statistics of the incoming and outgoing records. Among them, a lot of manual and repetitive work is wasted, and there is an urgent need to improve efficiency.
3. It takes a long time to send excel reports regularly, which requires a lot of manual energy, and it is difficult to trace and manage them manually.
4. Weekly or monthly inventory checking requires manual account one-to-one corresponding search, which consumes a lot of energy, and the inventory errors are difficult to trace, resulting in losses.
5. The unreturned reminder needs to strengthen the functions such as tool whereabouts query, need to trace, and need to control the collection time according to the classification of tools and measuring tools, so as to prevent long-term loss or workers' private borrowing and circulation, which cannot be found.
6. The calibration of a large number of measuring tools needs management and adopts manual method, which is easy to be omitted and inconvenient to record the calibration cost, cycle, etc.
1.2 statistics of tools and measuring tools in tool room
There are five or six hundred kinds of cutting tools. There are both cutting tools with large consumption and cutting tools that are repeatedly collected and returned. The consumption is relatively small and the inventory is not large, but the time in the warehouse is very long. They have been polished and collected and returned for many times.
According to the preliminary statistics, the existing tools in the warehouse are divided into many types and quantities, with various sizes. The preliminary statistics are as follows:
Project | Number of species | Total in stock | Remarks |
Tool warehouse inventory | 697 | 5178 | July 2020 data |
Tools returned to warehouse | 115 | 241 |
1. Consumable large tool
There are mainly blades, milling cutters, taps, small drill clamps, etc. the consumption of such materials is relatively high, accounting for more than 80% of the total inventory.
This kind of tool is generally used for scrapping after being put on the machine. Due to the large consumption, it is important to manage the collection amount, return quantity, grinding quantity, scrapped quantity and cost of this kind of material.
2. Repeatedly receive returned cutting tools, sharpening tools and customized forming tools
This kind of tool has a long service life and needs to be collected, returned and repaired repeatedly. For this kind of tool, it needs to be managed separately one-on-one to distinguish the warehousing time, price, grinding times, service life, scrap cost, repeated collection management cost, etc. of different tools of the same model.
For such tools, material number coding alone can no longer meet the management requirements. The system needs to number them separately and generate QR code labels or laser QR codes for control.
QR code label information includes: name, specification, model, separate warehouse location, QR code and other information. When such tools are in and out of the warehouse, the QR code will be directly scanned and automatically recognized by the system.
1.3 classification and statistics of cutting tools and measuring tools
Project | Number of models | Total in stock | Average inventory | Inventory proportion | classification |
Tools with inventory of 10 and above | 131 | 3407 | 26 | 66% | Consumable tool |
Tools with inventory less than 10 | 566 | 1771 | 3 | 34% | Repeated collection return type (borrowing type) |
Measuring tool | 340 | 710 | Repeated collection return type (borrowing type) |
1.4 tool refinement statistics and management instructions
project | Consumable tool | Repeatedly picking tool (borrowing type) | Measuring tool (borrowed type) |
Main types | Blade, milling cutter, tap, common drill bit | Returned to warehouse tools, drills, reamers, custom knives | Measuring tools, inspection tools and borrowed cutting tools and tooling |
management style | Manage the model and quantity, not the specific number | Number separately and print QR code labels | Number separately and print QR code labels |
Management focus | Consumption quantity, purchase cost, corresponding machine tool and work order processing cost | Storage time, grinding times, receiving times and basic service life records | Measuring tool search, traceability query, reminder of not yet returned, routine inspection and maintenance, quality traceability |
explain | The tool room and intelligent cabinet can store consumable tools, coding tools and measuring tools. The tool room is managed manually, and the intelligent cabinet is unattended and self-service management. Mainly consider the balance and optimization of input equipment cost and labor management cost. | ||
Tool room storage | Consumable tools are recommended to be put into the smart cabinet, but some tools can also be put into the shelf of the tool room due to the limitation of ruler | It is recommended to put it into the shelf of the tool room, and the location number corresponds to the QR code one by one. Manual distribution and recovery | On the shelves of the existing measuring tool room, the location number corresponds to the two-dimensional code one by one, and is distributed and recovered manually |
Intelligent cabinet storage | Intelligent tool cabinet storageUnattended | You can also consider putting it into the smart grid cabinet, putting various kinds together, scanning the code for confirmation and unattended | 智能格子柜，多種放一起，掃碼確認(rèn)，無人值守 |
Tool room storage | Personal recycling cell | Original storage location | Original storage location |
Collection method | Workers swipe their cards in the smart tool cabinet for self-service collection, and are unattended for 24 hours | The worker swipes the card, the technician directly scans the code through the system to issue the recovered tools, and the system automatically records the corresponding records and reports | The worker swipes the card, the technician directly scans the code through the system and issues the recovered measuring tools, and the system automatically records the corresponding records and statements |
Return method | Swipe your card to log in and return it to your own special recycling cell. Only you can open it | Return it to the tool room, scan the code and return it directly. It can be returned by yourself or others. It can be judged by identifying the QR code | Return it to the measuring tool room, scan the code and return it directly. You can return it yourself or others, and judge it by identifying the QR code |
1.5 introduction to technical scheme
The whole set of tool management is divided into two parts, one is deployed on the workbench in the tool room and the other is deployed outside the workshop and placed next to the machine tool to facilitate the production line to receive common tools.
All the data of the two points are unified in the background, and the account can be assigned in the LAN for login, viewing and management.
1.5.1 introduction to tool room deployment system
On the workbench at the door of the tool room, the system is deployed to a special computer, and is equipped with internal and external screens, which is convenient for the administrator and the receiver to view at the same time. The picking person does not enter the tool room, and the administrator carries out the picking and placing operation of picking and returning.
Considering the uneven quality of collecting personnel, some employees are always unwilling to fill in the registration, so they are equipped with card reader or account password, and directly swipe their card to log in when collecting and returning.
The configuration list is as follows: control computer, code scanning gun, card reader, display * 2, label printer, mouse and keyboard
All locations are numbered separately, and each location is placed with a separate tool, so that the tool material code and location number correspond one by one in the system.
1.5.2 field intelligent cabinet
According to the statistical requirements of common cutting tools, three smart cabinets are placed at the smart cabinet on the workshop site. According to the classification of cutting tools, different cabinet types are selected.
1. Tools with large consumption: intelligent vertical tool cabinet
Enter the model and quantity, and the corresponding number of tools will be automatically output. Whole process control, applicable to large quantities of consumable cutting tools. Return it to the on-site recycling cabinet and the administrator will count it.
2. The returned cutting tools or measuring tools can also be stored in the grid cabinet
Multiple models are adopted and placed in one cell picking mode, without automatic counting. The number entered by the employee in the system shall prevail, combined with camera control. After each collection, scan the code for secondary confirmation.
One drawer shall be placed in each cell, and multiple drawers shall be separated. Each separation shall be marked with the position and drawer position, and 2-3 infrequent knives shall be placed.
Enter the model, find the corresponding position, and automatically open the corresponding drawer. 10 models can be placed in each cell, and 200-300 models can be placed in each cabinet.
Features: more than one manageable model, low cost and high cost performance.
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