Data processing system and method for supply chain management

The data processing system has an online transactional processing (OLTP) system for receiving of reporting data from work centers of a production line. The production line is logically divided into shop areas. At the exits of each shop area where an intermediate product is completed one reporting point serves as exit point in order to report the completion of an intermediate production step. This data is stored in the OLTP system and retrieved at a later point of time in order to generate a table containing aggregated intermediate product quantities per shop area. This table is transferred to a financial data server for calculation of the value of work in progress.

FIELD

The present invention generally relates to the field of data processing, and more particularly without limitation, to online transactional processing.

BACKGROUND

Supply chain planning, which comprises the logistical plan of an in-house supply chain, is essential to the success of many of today's manufacturing firms. Most manufacturing firms rely on supply chain planning in some form to ensure the timely delivery of products in response to customer demands. Typically, supply chain planning is hierarchical in nature, extending from distribution and production planning driven by customer orders, to materials and capacity requirements planning, to shop floor scheduling, manufacturing execution, and deployment of products. Supply chain planning ensures the smooth functioning of different aspects of production, from the ready supply of components to meet production demands to the timely transportation of finished goods from the factory to the customer.

A modern supply chain often encompasses a vast array of data. The planning applications that create and dynamically revise plans in the supply chain in response to changing demands and capacity require rapid access to data concerning the flow of materials through the supply chain. The efficient operation of the supply chain depends upon the ability of the various plans to adjust to changes, and the way in which the required data is stored determines the ease with which it can be accessed.

Operations in a production line of a plant for producing a product are carried out at work centers. In supply chain planning tools work centers are represented by business objects that can e.g. represent the following real work centers: machines or machine groups; production lines; assembly work centers; and employees or groups of employees.

Together with bills of material and routings, business objects representing work centers belong to the master data in production planning and control systems. Business objects representing work centers are used in task list operations and work orders. Task lists are for example routings, maintenance task lists, inspection plans and standard networks. Work orders are created for production, quality assurance, plant maintenance and for the project system as networks.

Data in work centers is used for scheduling, costing, capacity planning, and simplifying operation maintenance. For the purpose of scheduling, operating times and formulas are entered in the business object representing the work center, so that the duration of an operation can be calculated. For the purpose of costing, formulas are entered in the business object representing the work center, so that the costs of the operation can be calculated. Usually a business object representing the work center is also assigned to a cost center.

The available capacity and formulas for calculating capacity requirements are entered into the business object representing a work center for capacity planning. Further, various default values for operations can be entered in the business object representing the work center for simplifying operation maintenance.

A business object representing a work center is created for a plant and is identified by a key. The work center category that can be defined in customising, determines which data can be maintained in the business object representing the work center.

Supply chain planning and management tools as the SAP R/3 system use routing. Routing is a description of which operations, e.g. process steps, have to be carried out and in which order to produce a product. In addition to information about the operations and the order in which they are carried out, routing also contains details about the work centers at which they are carried out as well as about the required production resources and tools. Standard values for the execution of individual operations are also saved in routings. Usually a bill of material (BOM) is assigned to routing. Individual components of the BOM are assigned to the routing operations.

SUMMARY

One embodiment consistent with the present invention provides for a data processing system comprising an online transactional processing (OLTP) system for receiving of reporting data from a set of reporting points of work centers of a production line for producing a product. The production line is logically divided into shop areas where each shop area comprises one or more work centers. Each shop area corresponds to an intermediate production step for producing an intermediate product. The intermediate production step of the shop area is completed at the exit point of the shop area. An exit point is a special reporting point that serves to report when an intermediate production step is completed.

The reporting data from the reporting points including the exit points is received by the OLTP system and stored in a database. For example, the reporting data is received in the form of documents, where each document contains data indicating a quantity of an intermediate product that has been completed in the corresponding intermediate production step and/or a scrap quantity. Scrap is reported when the intermediate product does not conform to quality standards.

On the basis of the reporting data stored in the database a table is generated that comprises aggregated quantities of intermediate products and/or scrap at the exit points. This way one aggregated quantity of intermediate product and/or scrap is obtained per shop area. The table is locally stored by the OLTP system.

The OLTP system is coupled to a server computer that has storage for a second table with value increments per shop area. Preferably, the server computer is a financial data server that can calculate the value increments of the individual shop areas based on master data stored in a master data server.

The server computer has a processor for running a program to calculate a total value of the work in process by means of the table comprising the aggregated quantities and by means of the table with the value increments per shop area. This way the total value of the intermediate products of the production line is valuated, such as for the purposes of accounting, asset management, book keeping, financial planning and/or company valuation and financial reporting.

The present invention may be particularly advantageous in that the OLTP system locally generates a table with the aggregated quantities of the intermediate products and/or scrap per shop area as reported from the exit points. This way a dramatic data compression is accomplished—comparing the resulting table size with the reporting data stored in the database. The table comprising the aggregated quantities is transferred from the OLTP system to the server computer when the total value of the work in process is to be calculated.

It is to be noted that only the table comprising the aggregated quantities may need to be transmitted to the server computer in order to calculate this total value but not the complete reporting data stored in the database. This has the advantage that the transfer of the aggregated reporting data required to calculate the total value only minimally loads the network.

Another advantage is that only a small portion of the capacity of the server computer's processor is required to perform the calculation of the total value. This is due to the fact that the table comprising the value increments is only calculated once and then stored for future reference. This is further due to the fact that only a limited number of calculations needs to be performed to obtain the total value of the work in process based on the table comprising the aggregated quantities and the table comprising the value increments.

The present invention may also be particularly advantageous as it facilitates to calculate the total value of work in process even when the routing is changed. In a real life plant the routing is changed quite frequently. This is reflected in the routing data stored in the master data server. When the routing data and/or the bill of materials is changed the financial data server recalculates the table comprising the value increment per shop area. Other than that, no change is required as the processing logic is not affected by the modification of the master data.

In accordance with a further embodiment consistent with the present invention, the calculation of the value of the work in process is initiated by a push-service of the OLTP system. For example, the OLTP system has a timer; each time the timer expires the OLTP system triggers the push-service in order to transfer the table with the aggregated quantities to the financial data server. This transfer triggers the calculation of the total value of the work in process by the financial data server.

Alternatively the calculation of the total value of the work in process is implemented as a pull-service, i.e. the financial data server pulls the table comprising the aggregated quantities from the OLTP system at regular and/or pre-scheduled times or time intervals and/or on a user's request.

DESCRIPTION OF THE EMBODIMENTS

FIG. 1shows plant100that has at least one production line for producing product102. The production line is constituted by a number of work centers W. Each work center W has a reporting point104coupled to network106. This way reporting points104are coupled to computer system108.

The reporting points104serve for the purpose of plant data collection. A reporting point104can be implemented as a sensor, e.g. a bar code reader, or it can be a personal computer for manually entering reporting data.

The production line is logically divided into shop areas1,2, . . . N. Each one of the shop areas1,2, . . . N corresponds to an intermediate production step, i.e. at the exit of a shop area an intermediate product is obtained. When the intermediate product does not meet quality standards scrap is obtained instead.

Each one of the shop areas1,2, . . . N comprises at least one work center W. For example shop area1has a number of n work centers W11, W12, W13, . . . W1n. In the work center W1nthe intermediate production step performed in shop area1is completed. Hence reporting point104of work center W1nis defined as the exit point for reporting quantities of the intermediate products completed in shop area1. Likewise scrap produced in shop area1is reported from the exit point implemented by reporting point104of work center W1n.

A plurality of other shop areas may subsequently follow after shop area2in the production line. The last shop area N of the production line has a number of o work centers, i.e. work centers WN1, WN2, . . . , WNo.

In operation reporting data is acquired at the reporting points104in order to reflect the status of the ongoing production. Corresponding report documents110are sent from the reporting points104, including the exit points at the boundaries of the shop areas, to computer system108via network106.

OLTP system112has at least one processor118for running computer program120and timer122.

Storage124of OLTP system112serves to store table126. As the size of table126is quite limited in comparison to the amount of data contained in the report documents110it can either be held in the working memory of OLTP system112as an alternative to storage on a primary storage device, such as a hard disk.

Table126has two entries for each one of the shop areas1,2, . . . N. One entry is for the aggregated quantity of the intermediate products completed in the respective shop area and the other entry is for the scrap reported from that shop area at its exit point. For example table126has entry PQ1for the aggregated quantity of intermediate product produced in shop area1and reported from the exit point of shop area1. Likewise entry SQ1shows the aggregated scrap quantity reported from the exit point of shop area1.

In general terms table126has entries PQiand SQifor the aggregated intermediate product quantity and the aggregated scrap quantity reported from the exit point of shop area i. Further, table126may contain an entry CQ for indicating the aggregated quantity of completed product102(cf.FIG. 1) that has left the production line. Usually the aggregated completed product quantity CQ is identical to the aggregated quantity PQNreported from the last exit point of the last shop area N of the production line.

OLTP system112is coupled to master data server128, financial data server130and material management server132.

OLTP system112, master data server128, financial data server130and/or material management server132can be implemented on separate server computers being interconnected by a network. Alternatively OLTP system112, master data server128, financial data server130and/or material management server132are implemented as separate logical servers on a common physical unit, such as a parallel processing computer system or a blade computer system.

Master data server128has storage134for storing of master data, such as bill of materials (BOM)136, routing data138, and work center objects140, i.e. business objects representing the work centers W of the production line of plant100(cf.FIG. 1). Further master data server128stores master data in order to define shop areas1,2, . . . N (cf.FIG. 1). Shop areas can be defined by storing a table listing all work centers belonging to a given shop area or by other suitable shop area objects142.

Financial data server130has at least one processor144for running program modules146,148, and150. Program module146serves to calculate the value increments per shop area on the basis of the master data stored by master data server128. The resulting table152containing the value increments Viper shop area i is stored in storage154of financial data server130.

Program module148serves to calculate the value VCPof the completed product102(cf.FIG. 1). The value VCPobtained from program module148is also stored in storage154.

Program module150serves to calculate the total value V of the work in progress, i.e. the accumulated values of the completed intermediate products being processed in the production line of plant100(cf.FIG. 1). This calculation also considers scrap and subtracts the value of the completed product as completed products is no longer work in process by definition. The corresponding formula is given below

N is the total number of shop areas,

PQiis the aggregated quantity of intermediate product reported from the exit point of shop area i,

Viis the value increment of the production step performed in shop area i,

SQiis the aggregated quantity of scrap reported from shop area i,

CQ is the quantity of completed product that leaves the production line, and

VCPis the value of the completed product

The value V of the work in progress which is thus obtained from program module150can be posted in ledger156stored in storage154. The value VCof the completed product obtained from program module148is stored on storage location158of storage154.

Personal computer160is coupled to master data server128for entering and updating of master data stored in storage134.

Material management server132can be implemented as the SAP R/3 component materials management (MM) for managing the supply of materials to the production line plant100(cf.FIG. 1).

In operation computer system108receives report documents110from plant100that reflect the ongoing production. The data contained in the report documents110is stored in relational database116. When timer122expires computer program120is triggered. Computer program120has instructions for reading of master data from master data server128, including shop area objects142.

Further computer program120has instructions for performing a database query of database116in order to retrieve report documents110that originate from exit points. On this basis computer program120calculates the entries PQiand SQifor each shop area i. This way table126is generated and stored in storage124.

Next table126is transferred from OLTP system112to financial data server130. Program module146reads master data from master data server128, in particular bill of materials136, routing data138, work center objects140and shop area objects142in order to calculate the value increment at the various intermediate production steps corresponding to the shop areas. For example, the value increment an intermediate product experiences going through a particular shop area is calculated by determining the production costs of the production steps performed in the shop area considered, i.e. the cost of materials, components, energy costs, etc. This way table152is obtained and stored in storage154. On this basis, program module148calculates the value VCPand stores it in storage location158.

When financial data server130receives table126from OLTP system112this invokes program module150. On the basis of the data contained in table126and table152program150calculates the value V of work in progress. The value V is then posted in ledger156.

FIG. 3shows the steps performed by the financial data server in order to generate table152and to calculate VCP. In step300the financial data server reads the required master data, e.g. bill of materials, routing data and shop area objects. In step302the financial data server calculates the value increment per shop area on the basis of the master data obtained in step300. The resulting table (cf. table152ofFIG. 2) with the value increments per shop area is stored in step304. In step306the financial data server calculates the value VCPof the completed product by calculating the total of all value increments.

FIG. 4shows the method performed by the OLTP system. In step400the OLTP system receives and stores report documents in its database. After a user defined period of time a database query is performed in order to retrieve the reports obtained from the exit points from the database (step402). In step404table126(cf.FIG. 2) with the aggregated quantity data is generated on the basis of the retrieved report documents. In step406the table which is thus obtained in step404is pushed to the financial data server in order to trigger the calculation of the value V of work in progress. This procedure can be performed repetitively.

Alternatively table126is pulled from financial data server. In this case timer122is implemented in financial data server in order to trigger the pull of table126.

FIG. 5illustrates the method performed by the financial data server in order to calculate value V of work in progress and to update the electronic ledger. In step500the financial data server receives table126from OLTP system; this may be implemented as “push” or “pull”. In step502the financial data server reads table152with the value increments per shop area and the total of the value increments VCP. In step504the financial data server calculates the value V of the work in progress on the basis of tables126,152and value VCP. In step506the value V of work in progress is posted in the electronic ledger of the financial data server (step506). Again this procedure can be performed repeatedly.

FIG. 6shows another example for an manufacturing plant. Elements ofFIG. 6that correspond to elements ofFIGS. 1 and 2are designated by the same reference numerals.

On the left sideFIG. 6shows a detailed level logistics view of plant100. Plant100has a number of work centers that are logically grouped into shop areas. For ease of explanation the last three shop areas N−b2, N−1 and N of the total of N shop areas is shown inFIGS. 6. Like in the embodiment ofFIG. 1each one of the shop areas has an exit point at its boundary, i.e. a special reporting point for reporting of data relating to the completion of an intermediate production step to be performed in a particular shop area.

On the right side,FIG. 6shows a logical level view of plant100. In the logical view each one of the shop areas may be reduced to its respective exit point from where the data is reported to the computer system.

FIG. 7shows plant100ofFIG. 6after a parallel logistic branch of work centers has been added to the shop area N−1. As illustrated inFIG. 7this does not affect the logical level view of production plant100. This has the advantage that the logistics of plant100can be modified without affecting the logical view. Thus the data processing load for performing evaluation remains substantially unchanged when changes are made to the logistical structure as complex loops or parallel logistical structures do not need to be resolved for the purpose of valuation.