HF-MES-manual/en/business/equipment-warehouse.md

Equipment and Warehouse Management

1. Function Overview

This section covers two major modules: Equipment Management and Warehouse Logistics. It implements full lifecycle management of equipment and warehouse logistics management of materials to ensure smooth production processes.

Main Contents:

Chapter	Main Content
Equipment Management	Equipment ledger, inspection & maintenance, fault repair, OEE analysis
Warehouse Logistics	Receiving management, issuing management, inventory management

2. Equipment Management

2.1 Equipment Ledger

Equipment Information Management:

Function	Description
Equipment Registration	Basic equipment information entry
Equipment Query	Query equipment information by conditions
Equipment Change	Equipment information change management
Equipment Scrap	Equipment scrap process handling
Equipment Documents	Equipment document management

Equipment Lifecycle:

Equipment Procurement → Equipment Installation → Equipment Acceptance → Equipment Operation → Equipment Maintenance → Equipment Scrap

2.2 Equipment Inspection

Inspection Types:

Inspection Type	Execution Cycle	Executor	Main Content
Daily Inspection	Daily	Operator	Equipment running status check
Periodic Inspection	Weekly/Monthly	Maintenance Technician	Equipment performance check
Precision Inspection	Quarterly/Yearly	Engineer	Equipment accuracy check

Inspection Process:

Inspection Plan Generation → Inspection Task Assignment → Execute Inspection → Inspection Record → Abnormal Handling

Inspection Execution Steps:

1. Receive inspection task
2. Arrive at equipment location
3. Perform inspection item by item according to standards
4. Record inspection results
5. Submit inspection record
6. Trigger abnormal handling process if any abnormality found

Inspection Record Information:

Record Item	Description
Inspection Order No.	Unique identifier for inspection order
Equipment No.	Equipment being inspected
Inspection Type	Daily/Periodic/Precision
Inspector	Person performing inspection
Inspection Time	Inspection time
Inspection Items	Items being inspected
Inspection Result	Normal/Abnormal
Abnormal Description	Description of abnormality

2.3 Equipment Maintenance

Maintenance Types:

Maintenance Type	Cycle	Content	Man-hours
Daily Maintenance	Daily	Cleaning, lubrication, tightening	15-30min
Level 1 Maintenance	Weekly	Cleaning, lubrication, adjustment	2-4h
Level 2 Maintenance	Monthly	Cleaning, lubrication, tightening, replace wear parts	8h
Level 3 Maintenance	Quarterly	Comprehensive inspection, adjustment, replacement	1-2 days
Major Overhaul	Yearly	Complete disassembly and inspection	3-7 days

Maintenance Process:

Maintenance Plan → Maintenance Preparation → Maintenance Execution → Maintenance Record → Acceptance Confirmation

Maintenance Content:

Maintenance Item	Content	Required Materials
Cleaning	Equipment surface and internal cleaning	Cleaning agent, rags
Lubrication	Lubrication of moving parts	Lubricating oil
Tightening	Check and tighten loose parts	Wrenches and tools
Adjustment	Adjust equipment parameters	Adjustment tools
Replacement	Replace wear parts	Spare parts

2.4 Equipment Fault Management

Fault Classification:

Fault Category	Description	Repair Requirement
Minor Fault	No impact on production	Repair within 2 hours
General Fault	Partial function affected	Repair within 4 hours
Serious Fault	Equipment down	Repair within 8 hours
Emergency Fault	Equipment damaged	Immediate response

Fault Handling Process:

Fault Discovery → Fault Report → Fault Diagnosis → Repair Processing → Repair Acceptance → Fault Record

Fault Reporting Steps:

1. Discover equipment fault
2. Assess fault impact
3. Emergency shutdown (if needed)
4. Submit fault report
5. Maintenance technician receives work order
6. Fault diagnosis
7. Execute repair
8. Repair acceptance
9. Archive fault record

Fault Report Information:

Field	Description
Report No.	Unique identifier for fault report
Equipment No.	Faulty equipment
Fault Type	Type of fault
Fault Description	Description of fault
Fault Time	Time fault discovered
Reporter	Person reporting fault
Urgency Level	Emergency/General/Minor
Impact Scope	Impact on production

Maintenance Record Information:

Record Item	Description
Repair No.	Unique identifier for repair order
Repair Technician	Person performing repair
Repair Start Time	Start time of repair
Repair End Time	Completion time of repair
Fault Cause	Cause of fault
Repair Measures	Repair methods taken
Spare Parts Replaced	List of replaced parts
Repair Result	Repair effectiveness

2.5 Equipment OEE Analysis

OEE Concept:

OEE (Overall Equipment Effectiveness) is a ratio measuring the actual production capacity versus the theoretical production capacity of equipment.

OEE Calculation Formula:

OEE = Availability × Performance × Quality

Where:
- Availability = Actual Operating Time / Planned Operating Time × 100%
- Performance = Actual Output / Theoretical Output × 100%
- Quality = Qualified Product Quantity / Total Output Quantity × 100%

OEE Standards:

OEE Value	Level	Description
≥85%	World Class	Excellent
70%-85%	Good	Meeting standard
60%-70%	Average	Needs improvement
<60%	Poor	Requires focused improvement

OEE Analysis Dimensions:

Analysis Dimension	Loss Type	Description
Availability	Fault Downtime	Downtime due to equipment failure
Availability	Changeover & Setup	Product changeover and setup time
Performance	Idle & Minor Stops	Short stops
Performance	Speed Loss	Running speed below theoretical speed
Quality	Scrap	Defective products
Quality	Rework	Products requiring rework

OEE Improvement Measures:

Loss Type	Improvement Measures
Fault Downtime	Strengthen preventive maintenance
Changeover & Setup	Optimize changeover process
Idle & Minor Stops	Optimize operation process
Speed Loss	Equipment upgrade and modification
Scrap & Rework	Strengthen quality control

3. Warehouse Logistics

3.1 Warehouse Layout

Warehouse Zone Planning:

Zone Type	Purpose	Characteristics
Inspection Zone	Pending inspection materials	Isolated storage
Raw Material Zone	Raw material storage	Zoned by category
Semi-finished Zone	Semi-finished product storage	Batch management
Finished Goods Zone	Finished product storage	FIFO
Return Zone	Returned materials	Separate management
Scrap Zone	Scrap storage	Safety isolation
Defective Zone	Defective product storage	Clear identification

Location Coding Rules:

Code Example	Meaning
A-01-001	Zone A, Row 01, Position 001
B-02-005	Zone B, Row 02, Position 005
C-03-010	Zone C, Row 03, Position 010

3.2 Receiving Management

Receiving Types:

Receiving Type	Description	Document Type
Purchase Receiving	Purchased materials arrival	Purchase Receipt
Production Receiving	Production finished goods	Production Receipt
Return Receiving	Sales return	Return Receipt
Transfer Receiving	Transfer from other warehouse	Transfer Order
Other Receiving	Other reasons	Other Receipt

Receiving Process:

┌──────────┐    ┌──────────┐    ┌──────────┐    ┌──────────┐
│  Arrival │───▶│ Document │───▶│   IQC    │───▶│ Inspection│
│  Receive │    │  Create  │    │  Trigger │    │  Execute │
└──────────┘    └──────────┘    └──────────┘    └──────────┘
                                                              │
                                                              ▼
┌──────────┐    ┌──────────┐    ┌──────────┐    ┌──────────┐
│Confirm   │◀───│Allocate  │◀───│Location  │◀───│ Qualified│ 
│Receiving │    │ Location │    │  Select  │    │  Decision│
└──────────┘    └──────────┘    └──────────┘    └──────────┘

Receiving Operation Steps:

1. Materials arrive, receive delivery note
2. Create receiving document
3. System automatically pushes IQC inspection task
4. Execute incoming inspection
5. After passing inspection, allocate location
6. Put materials onto designated location
7. Scan location to confirm
8. Complete receiving

Receiving Document Information:

Field	Description
Receipt No.	Unique identifier for receipt
Receiving Type	Purchase/Production/Return etc.
Supplier	Material supplier (for purchase)
Related Document	Purchase order/work order etc.
Receiving Date	Receiving date
Material Details	List of received materials
Warehouse	Receiving warehouse
Status	Pending inspection/Received etc.

3.3 Issuing Management

Issuing Types:

Issuing Type	Description	Document Type
Production Issue	Materials for production	Issue Order
Sales Issue	Sales delivery	Sales Issue Order
Return Issue	Return to supplier	Return Order
Transfer Issue	Transfer to other warehouse	Transfer Order
Other Issue	Other reasons	Other Issue Order

Issuing Process:

┌──────────┐    ┌──────────┐    ┌──────────┐    ┌──────────┐
│ Material │───▶│ Document │───▶│ Picking  │───▶│ Approval │
│ Request  │    │  Create  │    │  Prepare │    │  Pass    │
└──────────┘    └──────────┘    └──────────┘    └──────────┘
                                                              │
                                                              ▼
┌──────────┐    ┌──────────┐
│Confirm   │◀───│ Scan     │
│ Issuing  │    │  Issue   │
└──────────┘    └──────────┘

Issuing Operation Steps:

1. Create issue order based on work order or manually
2. Select required materials
3. System checks inventory status
4. Approve issue order
5. Warehouse personnel prepare and pick materials
6. Scan materials and locations
7. Confirm issuing
8. Deliver materials to using department

Issue Order Information:

Field	Description
Issue No.	Unique identifier for issue order
Issue Type	Production issue/Other
Related Work Order	Work order related to issue
Issue Department	Department requesting materials
Issuer	Person issuing materials
Issue Date	Issue date
Material Details	List of issued materials
Warehouse	Issuing warehouse
Status	Pending approval/Issued etc.

3.4 Inventory Management

Inventory Query:

Query Dimension	Query Content
By Material	Inventory status of a material
By Warehouse	Inventory status of a warehouse
By Location	Inventory status of a location
By Batch	Inventory status of a batch
By Status	Inventory quantity distribution

Inventory Data:

Data Item	Description
Material Code	Material number
Material Name	Material name
Warehouse	Warehouse location
Location	Storage location
Batch	Material batch
Quantity	Inventory quantity
Unit	Unit of measurement
Inventory Status	Normal/Frozen/Pending inspection

Inventory Accounting:

Account Type	Description
Opening Inventory	Inventory at period start
Current Receipt	Quantity added this period
Current Issue	Quantity removed this period
Closing Inventory	Inventory at period end

Inventory Calculation Formula:

Closing Inventory = Opening Inventory + Current Receipt - Current Issue

3.5 Batch Management

Batch Traceability:

Traceability Dimension	Traceability Content
Forward Traceability	Raw Material → Finished Product
Reverse Traceability	Finished Product → Raw Material

Batch Information:

Information Item	Description
Batch No.	Unique batch identifier
Material Batch	Material batch
Supplier Batch	Supplier provided batch
Production Batch	Production batch
Receiving Date	Receiving time
Expiry Date	Shelf life
Inspection Status	Qualified/Unqualified

First In First Out (FIFO):

Principle	Description
First in, first out	Earlier received materials issued first
Shelf life management	Near expiry materials issued first
Clear batch identification	Clear traceable batch identification

3.6 Inventory Alert

Alert Types:

Alert Type	Trigger Condition	Alert Content
Safety Stock Alert	Inventory ≤ Safety Stock	Low inventory alert
Expiry Alert	Near expiry date	Expiry approaching alert
Slow-moving Alert	Long-term unused	Material slow-moving alert
Maximum Stock Alert	Inventory ≥ Maximum Stock	High inventory alert

Inventory Control Strategies:

Strategy	Description	Application Scenario
Safety Stock	Minimum inventory guarantee	Regular materials
Maximum Stock	Inventory upper limit control	Avoid overstock
Reorder Point	Replenish when inventory reaches reorder point	Fixed quantity procurement
Periodic Order	Regular inventory check and replenishment	Periodic procurement

3.7 Inventory Count

Count Types:

Count Type	Description	Frequency
Full Count	Count all materials	Year-end
Partial Count	Count selected materials	Monthly/Weekly
Cycle Count	Planned cyclic counting	Daily
Dynamic Count	Real-time counting	Continuous

Count Process:

Count Plan → Count Preparation → Initial Count → Recount → Variance Review → Accounting Adjustment

Count Steps:

1. Create count document
2. Select warehouse and materials
3. Execute initial count (first count)
4. Execute recount (verification)
5. Reconcile with system records
6. Analyze count variances
7. Approve variances
8. Execute accounting adjustment

Count Records:

Record Item	Description
Count No.	Unique count document identifier
Count Type	Full/Partial/Cycle
Count Warehouse	Warehouse being counted
Count Date	Count date
Book Quantity	System recorded quantity
Actual Quantity	Physically counted quantity
Variance Quantity	Quantity difference
Variance Reason	Reason for variance
Approval Status	Pending approval/Approved

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End of Equipment and Warehouse Management