HF-MES-manual/en/device_management/equipment_consumables_management.md

Equipment Consumables Management

1. Function Overview

The Equipment Consumables Management module is used for full lifecycle management of various consumables (such as cutters, jigs, carriers, etc.) in production equipment, achieving clear classification, controllable lifespan, traceable usage, and predictable anomalies.

Core Features:

• Equipment Consumables Category Management: Uniformly maintain consumables categories and standardize data structure
• Equipment Consumables Item Management: Establish complete consumables basic information and lifespan parameters
• Equipment Consumables Lifespan Management: Record usage times and lifespan consumption in real-time, manage replacement processes, and ensure stable equipment operation
• Equipment Consumables Replacement Log: Complete record of historical replacement records for traceability analysis

Feature Screenshots:

Figure 1: Equipment Consumables Management Function Page

Figure 2: Equipment Consumables Category Function Page

Figure 3: Equipment Consumables Item Management Function Page

Figure 4: Equipment Consumables Lifespan Management Function Page

Figure 5: Equipment Consumables Replacement Log Function Page

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2. Term Definitions

2.1 Consumables Related Terms

Term	Definition	Description
Consumables	Functional components with limited service life that require lifecycle management and regular replacement during production equipment operation	Such as: cutters, nozzles, filters, jigs, etc.
Consumables Category	Classification by usage characteristics or lifecycle management method	Such as: count-based (cutters), time-based (filters), fixed-period replacement (lubrication parts)
Consumables Item	Specific consumables instance registered in the system for lifecycle management and equipment binding	Such as: cutter (Φ3 drill bit), mounter nozzle, reflow oven filter, etc.
Standard Lifespan	Maximum theoretical usable lifespan of consumables	Can be defined by count or time
Warning Lifespan	Lifespan threshold for early warning trigger	Usually less than standard lifespan
Lifespan Unit	Unit of measurement for consumables lifespan	Such as count, hours, days
Used Lifespan	Accumulated usage count/duration of current consumables	Used for lifespan calculation
Replacement Record	Historical record generated when consumables are replaced	Used for traceability and analysis

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3. Equipment Consumables Function Description

3.1 Equipment Consumables Category Management

Equipment consumables categories are used for hierarchical classification management of consumables, facilitating unified maintenance and quick retrieval.

Typical Usage Scenarios:

• When the system is first launched, all consumables categories need to be sorted out and entered to establish a basic classification system
• When expanding business or introducing new equipment, add new consumables categories according to actual needs

Field Description:

Field	Description	Required
Consumables Category Code	Unique identifier for consumables category	✓
Consumables Category Name	Name of consumables category	✓
Creation Time	Automatically generated after addition	-
Update Time	Automatically generated after editing	-
Remarks	Supplementary description	-

Operation Steps:

1. Navigate to [Equipment Management] → [Equipment Consumables Management] → [Equipment Consumables Category]
2. Click [Add] button
3. Fill in category information
4. Click [Confirm] to complete creation

Feature Screenshot:

Figure 1: Equipment Consumables Category Management Add Function Page

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3.2 Equipment Consumables Item Management

Consumables item management is used to maintain basic information and lifespan parameters of all specific consumables.

Core Features:

• Maintain consumables basic archives
• Bind consumables categories with equipment categories
• Configure standard lifespan and warning lifespan
• Support multiple lifespan units (count/time)

Typical Usage Scenarios:

• During asset planning or system initial launch, sort out and enter all consumables categories involved in equipment to establish a basic classification system
• When importing new equipment or expanding production lines, add corresponding consumables items according to equipment structure
• When introducing new wearing parts to equipment, add corresponding consumables items for management

Field Description:

Field	Description	Required
Consumables Item Code	Unique identifier	✓
Consumables Item Name	Name description	✓
Consumables Category	Associated category	✓
Equipment Category	Applicable equipment type	✓
Standard Lifespan	Maximum usable lifespan	✓
Warning Lifespan	Early warning threshold	✓
Lifespan Unit	Count/Hours/Days	✓
Creation Time	System automatically records	-
Update Time	System automatically records	-
Remarks	Supplementary information	-

Operation Steps:

• Single Addition

  1. Navigate to [Equipment Management] → [Equipment Consumables Management] → [Equipment Consumables Item Management]
  2. Click [Add] button
  3. Fill in consumables information
  4. Click [Confirm] to complete creation

• Batch Addition

  1. Navigate to [Equipment Management] → [Equipment Consumables Management] → [Equipment Consumables Item Management]
  2. Click [Import] button
  3. Click [Download Template] button
  4. Fill in relevant content according to the template
  5. Click [Select File] and select the filled template file
  6. Preview information to confirm no issues
  7. Click [Confirm] button

[Tip] It is recommended to set the warning lifespan to 80%~90% of the standard lifespan to ensure advance preparation for replacement.

Feature Screenshot:

Figure 1: Equipment Consumables Item Management Add Function Page

Figure 2: Equipment Consumables Item Management Batch Import Function Page

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3.3 Equipment Consumables Lifespan Management

This function is used to bind specific consumables to equipment and manage their usage and lifespan status in real-time.

Core Features:

• Bind consumables to equipment
• Record usage count or time in real-time
• Automatically calculate remaining lifespan
• Support manual lifespan adjustment
• Support consumables replacement operation

Business Description:

Each equipment can be bound with multiple consumables. The system automatically accumulates consumables usage based on equipment operation data and performs lifespan calculation.

Typical Usage Scenarios:

• When new equipment is put into production or consumables are first bound, initialize the corresponding consumables and their used lifespan for the equipment
• During equipment operation, automatically or manually report accumulated consumables usage lifespan to achieve real-time lifespan tracking
• When consumables reach warning lifespan, remind maintenance personnel to prepare for replacement in advance
• When consumables reach or exceed standard lifespan, perform replacement operation and reset the lifespan cycle
• For scenarios where usage data cannot be automatically collected, supplement lifespan data through manual reporting

Field Description (Add Consumables Item):

Field	Description	Required
Consumables Item	Selected consumables item	✓
Belonging Equipment	Select equipment to which the consumables item belongs	✓
Standard Lifespan	Automatically loaded after selecting consumables item	-
Warning Lifespan	Automatically loaded after selecting consumables item	-
Used Lifespan	How much lifespan has been used at creation	✓
Remarks	Remarks content	-

Feature Screenshot:

Figure 1: Consumables Lifespan Management Add

Field Description (Replace Consumables Item):

Field	Description	Required
Consumables Item	Selected consumables item	-
Belonging Equipment	Select equipment to which the consumables item belongs	-
Standard Lifespan	Automatically loaded after selecting consumables item	-
Warning Lifespan	Automatically loaded after selecting consumables item	-
Replacement Personnel	Replacement operator	✓
Replacement Time	Replacement time	✓
Replacement Reason	Dropdown selection (Abnormal Consumption/Normal Consumption/Exceed Standard Lifespan)	✓
Replacement Duration	Time taken for replacement process	✓
Remarks	Abnormal consumption information	-

Replacement Reason Status Determination Rules:

Status	Determination Condition
Abnormal Consumption	Usage < Warning Lifespan (may be damaged due to special reasons, e.g., cutter impact wear, need to describe in remarks)
Normal Consumption	Usage ≥ Warning Lifespan and < Standard Lifespan
Exceed Standard Lifespan	Usage ≥ Standard Lifespan

Lifespan Status Determination Rules:

Status	Determination Condition
Normal	Usage < Warning Lifespan
Near Standard Lifespan	Usage ≥ Warning Lifespan and < Standard Lifespan
Exceed Standard Lifespan	Usage ≥ Standard Lifespan

Figure 1: Equipment Consumables Lifespan Management Status

Operation Steps (Replace Consumables):

1. Navigate to [Equipment Management] → [Consumables Management] → [Equipment Consumables Lifespan Management]
2. Select target equipment and consumables
3. Click [Replace] button
4. Fill in replacement information
5. Click [Confirm] to complete replacement

Feature Screenshot:

Figure 1: Consumables Lifespan Management Replace

Operation Steps (Manual Report Lifespan):

1. Navigate to [Equipment Management] → [Consumables Management] → [Equipment Consumables Lifespan Management]
2. Select target equipment and consumables
3. Click [Report Lifespan] button
4. Fill in current used lifespan
5. Click [Confirm] to complete reporting

[Important] Consumables exceeding lifespan should be prohibited from continued production or require mandatory confirmation before continued use.

Feature Screenshot:

Figure 1: Consumables Lifespan Management Report

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3.4 Equipment Consumables Replacement Log

Used to record all consumables replacement history, achieving full-process traceability and data analysis.

Core Features:

• Record detailed information for each replacement
• Support query by equipment/consumables/replacement time/creation time
• Support replacement reason analysis
• Support replacement duration statistics

Query Conditions:

Query Condition	Description
Equipment Code	Query specified equipment
Consumables Item Code	Query specified consumables item
Consumables Item Name	Query specified consumables item
Replacement Time Range	Filter time interval
Creation Time Range	Filter time interval

Replacement Record Field Description:

Field	Description
Belonging Equipment	Equipment name
Consumables Item Code	Replaced consumables item code
Consumables Item Name	Replaced consumables item name
Standard Lifespan	Standard lifespan value
Warning Lifespan	Warning lifespan value
Used Lifespan	Usage before replacement
Replacement Reason	Normal replacement/abnormal damage, etc.
Replacement Time	Actual replacement time
Replacement Personnel	Operator
Replacement Duration	Time taken for replacement
Remarks	Abnormal consumption remarks

[Tip] The replacement log can be used to analyze the difference between actual lifespan and theoretical lifespan of consumables for optimizing maintenance strategies.

Feature Screenshot:

Figure 1: Equipment Consumables Replacement Log Function Page

Figure 2: Equipment Consumables Replacement Log Export Function

Figure 3: Equipment Consumables Replacement Log Export File Download

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4. Data Management Standards

4.1 Data Integrity Requirements

[Important] To ensure the effectiveness of consumables management, it is necessary to ensure:

• All consumables must have standard archives established
• All critical consumables for equipment must be bound and managed
• All replacement operations must be logged
• Usage data must be collected in real-time or near real-time

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4.2 Management Rules

Rule	Description
Uniqueness	Consumables item code is globally unique
Relevance	Consumables items must be associated with equipment categories
Real-time	Usage data must be updated timely
Traceability	All replacement records must be queryable

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5. Common Issues and Handling

5.1 Common Issues

Issue Phenomenon	Possible Cause	Handling Method
Lifespan not updated	Data not collected	Check equipment data interface
Premature damage	Abnormal usage	Analyze process or operation issues
Warning not triggered	Incorrect warning configuration	Check lifespan parameter settings
No replacement record	Replacement process not executed	Force standardized operation process

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5.2 Optimization Suggestions

• It is recommended to automatically collect usage count based on equipment operation data
• Establish mandatory replacement mechanism for critical consumables
• Regularly analyze consumables lifespan and costs

[Tip] For high-value or critical consumables, it is recommended to implement linkage control with equipment status management.