In the deep penetration of Industry 4.0, the normalization of the digital transformation of the manufacturing industry, the production workshop high-value materials (covering precision tools, special consumables, core components, etc.) as the core support for industrial production, widely used in machinery manufacturing, automotive parts, aerospace, precision machining and other types of high-end production scenarios, and the level of its management is directly related to the continuity of production, product accuracy, operating costs and market Its management level is directly related to production continuity, product precision, operation cost and market competitiveness. High-value materials have a high unit price (single set / single piece from several thousand yuan to hundreds of thousands of yuan), precision specifications, easy to wear and tear, the need for accurate traceability, inventory control requirements of the core features of the traditional management model has been difficult to adapt to the modern workshop lean, digital management needs. At present, the majority of enterprises in the production workshop high-value materials management still rely on manual registration, ordinary shelf storage, Excel ledger records, there are cumbersome to receive, serious loss, inventory backlog, traceability difficulties, high capital occupation, weak security control and other pain points, not only consume a lot of manpower and material resources, but also due to improper material management leads to production delays, cost waste, product quality hidden danger. Intelligent tool material management cabinet as industrial Internet of Things and workshop high-value material management depth integration of intelligent equipment, relying on RFID radio frequency identification, Internet of Things, big data analysis and other core technologies, to achieve high-value materials “storage - receiving - traceability - inventory - control” of the whole process of digitalization, automation, precision control, and effectively break the traditional management bottlenecks, and become the best way to optimize production. It effectively breaks the traditional management bottleneck and becomes the core hand that optimizes the high-value material management system of production workshop and improves the cost control ability and operation efficiency. This paper combines the actual scenarios of high-value material management in production workshop, and comprehensively analyzes the application value of intelligent tool material management cabinet from two core dimensions of cost control and efficiency enhancement, combines the industry data and actual cases to provide practical reference for enterprises to optimize the high-value material management system and realize cost reduction and efficiency increase, and at the same time, strictly adheres to the rules of SEO and GEO, and highlights the workshop scenarios suitability, technical practicability and industry application value, focusing on the exclusive high-value material management system. At the same time, it strictly adheres to the rules of SEO and GEO, highlights the adaptability of workshop scenes, the practicality of technology and the value of industry application, and focuses on the exclusive management pain points and solutions of high value materials.

First, the production workshop high value materials traditional management status quo and cost efficiency pain points

Workshop high-value materials management is the core component of industrial production site management, through the material procurement, warehousing, storage, collocation, use, inventory, scrapping the whole process, its operational efficiency and cost control level, directly affecting the workshop production schedule, product quality, operating costs and corporate profitability. At present, the domestic industrial enterprises production workshop high-value materials management is still based on the traditional mode, especially small and medium-sized manufacturing enterprises, low degree of digitization, management process is not standardized, the core cost and efficiency pain points are concentrated in the following five aspects, which has become a constraint on the development of lean enterprise workshop, increasing the operational risk of the important bottleneck, but also with the modern high-value materials management system of the intelligent needs of a serious disconnect.

(i) High labor costs and management inefficiencies

In the traditional high-value materials management in the production workshop, receiving, returning, inventory, ledger registration, material scheduling and other aspects rely on manual operation, need to be equipped with full-time management personnel responsible for the receipt and issue of materials, inventory verification, data entry, loss statistics, etc., and because of the high requirements of high-value materials control, need to be equipped with additional supervisory personnel, high labor costs. According to industry research data show that medium-sized manufacturing enterprises production workshop (multiple production lines) on average need to be equipped with 4-6 high-value materials management personnel, large enterprises need more than 10 workshop, labor costs accounted for high-value materials management of the total cost of 50% above. At the same time, the manual operation process is cumbersome, workers need to manually fill out the receipt, check the material specifications, registration of the receipt of information, signature confirmation, the average time spent on each receipt of 8-15 minutes; inventory needs more than one management personnel to take 3-5 days to check the number of materials, the state of the material, the location of the storage, not only take up a lot of manpower, but also prone to registration errors, omissions, wrong inventory, ledger and the actual inventory It is also prone to registration errors, missing inventory, wrong inventory, discrepancies between the ledger and the actual inventory, etc., which leads to low management efficiency. In addition, the time cost for front-line workers to find suitable high-value materials is high. According to statistics, workers spend an average of 25-40 minutes per day on material searching and queuing up for use, which greatly occupies the effective production time and indirectly affects the production progress. Combined with the practice of high-value material management, the core of the traditional manual management inefficiency lies in the inability to achieve rapid identification of material information, real-time synchronization and accurate control, and the automation advantages of intelligent tool material management cabinets form a sharp contrast.

(ii) Serious material wastage and waste of direct costs

High-value materials are mostly precision equipment or consumables, the storage environment (temperature and humidity, dust-proof, moisture-proof, collision-proof), the use of specifications, storage requirements are extremely high, and the unit price is expensive, once the loss or damage, will cause huge direct economic losses. Under the traditional management mode, high-value materials are mostly stored in ordinary shelves and lockers, lacking clear zoning classification storage and professional protection measures, and the phenomenon of mixing materials of different specifications and uses is common. On the one hand, the materials are vulnerable to workshop oil, moisture, dust, collision and other environmental factors, resulting in damage to the edge of precision cutting tools, core components, precision degradation, aging and deterioration of consumables, can not be used normally, resulting in direct scrap losses; on the other hand, the lack of standardized control of material consumption, easy to wrong take, misappropriation, loss, private use and other issues, according to industry data show that under the traditional management mode, the annual loss rate of high-value materials in the workshop can be up to 5-12%, which is the same as the loss rate of the materials in the workshop. According to industry data, under the traditional management mode, the annual loss rate of high-value materials in production workshop can reach 5-12%, and the unnatural loss rate of wearable materials such as precision cutting tools is as high as 15-22%. In addition, part of the high-value materials, due to disordered storage and chaotic ledger, will be idle for a long time without being found, and eventually scrapped due to technological update and aging, which will further aggravate the wastage of materials, and push up the cost of material purchasing and replacing, and it's one of the most prominent cost pain points in the traditional high value material management system. This is also one of the most prominent cost pain points in traditional high-value material management system.

(iii) Imbalanced inventory structure and high rate of capital utilization

Traditional high value material management in production workshop lacks accurate inventory control and data support, inventory counting relies on manual checking, data distortion, lag phenomenon is common, resulting in the lack of scientific basis for purchasing decisions, there is an imbalance in the inventory structure, which is the core of the waste of funds in the high value material management system. On the one hand, commonly used high-value materials (such as commonly used precision cutting tools, core consumables) due to inventory errors, data lag, there is a shortage of inventory, triggering stoppages, affecting the continuity of production, indirectly resulting in production losses; on the other hand, cold, niche specifications of high-value materials over-procurement, resulting in inventory backlogs, occupying a large amount of liquidity of the enterprise. According to statistics, under the traditional management mode, the inventory of high-value materials in the production workshop can occupy up to 10-20% of the enterprise's working capital, of which the proportion of stagnant materials is as high as 40% or more, and some enterprises even have a backlog of high-value materials in stock amounting to more than 50% of the total amount of the annual purchase, which seriously affects the efficiency of the enterprise's capital turnover and increases the cost of capital utilization. Especially in the background of high value material technology update faster, inventory backlog will also lead to material depreciation, further expanding the cost loss, and high value material management system “accurate control, efficient turnover” of the core demand is contrary.

(iv) Lack of process control, hidden costs and quality risks are prominent

The traditional production workshop high-value material management lacks a perfect process control mechanism, material receipt, return, use, traceability and other aspects of the process without a clear definition of responsibility and process specification, prone to shirking responsibilities, process disconnect and other issues, resulting in a large number of hidden costs. When there is a material shortage, damage, loss, can not quickly trace the flow of materials, the use of personnel and the cause of damage, it is difficult to investigate the root cause of the problem, resulting in inefficient processing of the problem, increasing the management of hidden costs. At the same time, the use of high-value materials lack of accurate control, some employees have irrational use, the phenomenon of illegal use of materials, and can not be detected and corrected in a timely manner; for the need for regular calibration, maintenance of precision cutting tools and other materials, the lack of effective expiration reminder mechanism, prone to overdue to use, which not only shortens the service life of the material, but also may be due to the material accuracy does not meet the standards of the product quality defects, increasing product rework, scrap cost This not only shortens the service life of materials, but also may lead to product quality defects due to substandard material precision, increasing product rework and scrap costs, and even affecting the brand reputation of enterprises. In addition, part of the enterprise due to material traceability is not in place, can not meet the industry compliance requirements, facing the risk of inspection and rectification, and further increase the hidden costs, restricting the standardization of high-value material management system upgrade.

(v) Low level of digitization and inefficient decision-making

Most enterprises still rely on manual ledgers and Excel forms to record material information for high-value material management, and the data cannot be updated and analyzed in real time, thus forming a data silo that cannot provide effective data support for high-value material management system. It is difficult for managers to grasp the real-time inventory status, usage frequency, loss pattern, and consumption situation of materials, and they cannot accurately judge the demand for materials. Purchasing plan and inventory quota adjustment are all based on experience, which can easily lead to wasteful purchasing, inventory backlogs, or material shortages. At the same time, the lack of multi-dimensional data report support, enterprise management can not quickly grasp the workshop high-value materials management cost and efficiency of the status quo, the lack of scientific basis for decision-making, and further constraints on the optimization and upgrading of high-value materials management system, and the digital transformation of the industry, the development of lean workshop management needs to be seriously out of step with the requirements of the modern high-value materials management system of digitalization requirements can not be satisfied.

Second, the core technology of the intelligent tool material management cabinet and the adaptability of high-value material management system

Intelligent tool material management cabinet is based on RFID radio frequency identification, Internet of Things (IoT), face recognition, big data analysis and other core technologies, designed specifically for the production workshop high-value material management design of intelligent equipment, its core value is to realize the high-value material of the whole process of digital, automation, precision control, and production workshop high-value materials “storage, collocation, traceability, The core value of the equipment is to realize the digitalization, automation and precise control of the whole process of high-value materials, which is highly suitable for the core management demand of ”storage, receiving, tracing, inventory, control" of high-value materials in production workshop, and can effectively make up for the shortcomings of the traditional management mode, and provide a solid technical support for cost control and efficiency improvement of high-value materials management system. Combined with the characteristics of high-value material management and industry application practice, the adaptability of its core technology and high-value material management system is as follows:

(i) Core technology support to build a solid foundation for digital management

Intelligent tool material management cabinet's core technology focuses on three major levels of intelligent identification, network transmission and data processing, which is accurately adapted to the management needs of high-value materials in the production workshop, and is also its core advantage in integrating into the high-value material management system. First, RFID radio frequency identification technology, through each piece of high-value materials on the paste anti-metal RFID tags (suitable for precision tools, metal parts and other material characteristics, strong anti-jamming, high temperature, waterproof, moisture, oil), the cabinet built-in RFID reader can quickly identify the material information (specifications, models, procurement date, consumption records, wear and tear, calibration cycle, service life, etc.), identification of the Accuracy ≥ 99.97%, to realize the automatic collection and entry of material information, instead of manual ledger, to completely solve the problem of cumbersome data entry, high error rate, which is also its integration into the high value material management system of the core technology to support; second is the Internet of Things technology, the cabinet can be accessed to the workshop LAN or cloud management platform, to achieve the high value of the material inventory data, consumption data, loss data, traceability data, real-time uploading and synchronization with the enterprise. Real-time uploading and synchronization, seamless docking with enterprise ERP (enterprise resource planning system), MES (manufacturing execution system), high-value material management system, breaking the data silo, and realizing the synergistic linkage of high-value material management and production planning, procurement management, production control; Third, big data analysis technology, the system automatically summarizes the data on the frequency of use of high-value materials, the rate of wear and tear, the inventory turnover rate, and the regularity of use, and generates multi-dimensional data through algorithmic analysis. Through algorithmic analysis to generate multi-dimensional data reports, for procurement plan optimization, inventory quota adjustment, cost control to provide scientific data support, help high-value material management system to achieve accurate control. In addition, some high-end models also integrate AI visual recognition and 5G+Wi-Fi 6E high-speed networking technology to further improve recognition efficiency and data transmission stability, which is suitable for the workshop's high-rhythm and high-precision high-value material management needs.

(ii) Exclusive structural design to meet the storage needs of high-value materials

Production workshop high-value material specifications are complicated, high precision requirements, from small precision tools, special consumables, to large core components, storage space, protection conditions, storage precision needs vary greatly, which requires intelligent tool material management cabinet must be highly adaptable with high-value material storage needs. Intelligent tooling material management cabinet adopts modularized grid design, the size of the grid can be flexibly adjusted according to the specifications of high-value materials, which is divided into small precision grid (suitable for precision cutting tools, small consumables), medium-sized grid (suitable for conventional high-value parts), large customized grid (suitable for large core materials, complete sets of precision cutting tools), to achieve the “one object, one grid The precise storage of ”one item, one compartment“ or ”one class, one compartment“ is highly compatible with the demand of high-value material classification management. Each compartment is equipped with an independent electronic lock, which can only be opened by authorized personnel, effectively preventing materials from being wrongly taken, lost or misappropriated; at the same time, the cabinet is equipped with constant temperature, humidity, dust, moisture, oil, collision, etc., which provides a stable and safe storage environment for high-value materials and reduces the loss of materials caused by the harsh environment in the workshop, which is a high degree of fit for the goal of maintenance and control of high-value materials. In addition, the modularized design supports the expansion mode of ”1 master cabinet + N slave cabinets", which can be flexibly expanded according to the growth of the number of production lines and the types and quantities of high-value materials in the workshop, and is suitable for the dynamic needs of the expansion of the workshop production scale and the upgrade of the high-value material management system.

(iii) Full-process automated control, suitable for high-value materials management of the whole process

Intelligent tool material management cabinet realizes the automated control of the whole process of high value material “warehousing - storage - claiming - returning - tracing - inventory - control”, which is deeply adapted to each link of high value material management with the production workshop, greatly reduces the manual intervention, and perfectly integrates into the high value material management system. First, intelligent warehousing, high-value materials into the warehouse, RFID reader automatically identify the material label information, entered into the inventory ledger and high-value material management system, without manual registration, warehousing efficiency to enhance 90% or more, completely solved the problem of cumbersome entry of high-value material information, prone to error; second, intelligent use and return, authorized personnel through face recognition, card, cell phone APP scanning code, etc. When the cabinet is opened and materials are claimed and returned, the system automatically records the information of claiming personnel, time, usage, material status, etc., and synchronously updates it to the high-value material management system, which shortens the time consumption of the claiming process from the traditional 8-15 minutes to less than 30 seconds, and significantly improves the claiming efficiency; thirdly, it is accurate traceability, and the system can query the track of the whole life cycle of each piece of high-value materials, including procurement, warehousing, claiming, returning, using, maintaining, calibrating, scrapping, and reporting, Use, maintenance, calibration, scrapping and all other links, once the material damage, loss or quality problems, can quickly locate the responsible person and the problem link, to solve the traditional management of the responsibility is difficult to define the pain point, for high-value material management system to provide strong support for the traceability control; Fourth, intelligent inventory, management personnel through the system to initiate inventory instructions, the cabinet automatically check the material information in the grid, generate inventory reports, synchronized to the high-value material management system, and then synchronize to the system. Synchronized to the high-value material management system, inventory accuracy rate of 99.9% or more, inventory time shortened by 80% or more, completely get rid of the tediousness of manual inventory; Fifth, the intelligent control reminder, the system according to the high-value material wear and tear pattern, calibration cycle, service life, automatic push maintenance, calibration, scrap reminder, to avoid the material overuse, extend the service life of the material, reduce the cost of loss, help the high-value material management system to trace and control the material. It helps the high-value material management system to realize fine control.

(D) Data-based control and remote operation to meet the needs of lean management of high-value materials

Intelligent tool material management cabinet is equipped with exclusive digital management system, which can summarize the whole process data of high-value material management in real time, and generate multi-dimensional reports such as inventory turnover rate, loss rate, frequency of use, maintenance records, etc., which can provide data support for cost analysis and efficiency optimization of high-value material management system in production workshop. Managers can remotely view material inventory status, usage records, and maintenance through computer and cell phone APP, and remotely initiate inventory, allocation, and maintenance commands, realizing “managing materials without leaving home”, significantly reducing managers“ on-site inspection time, and improving management efficiency. At the same time, the system supports inventory warning function, when the inventory of high-value materials is lower than the safety threshold or close to the service life, it will automatically push reminders to avoid stopping work and waiting for materials or waste of materials scrapping; it supports the mandatory mode of ”trade-in", which reduces irrational consumption and further optimizes cost control, and the lean management with the high-value materials management system, It is highly compatible with the lean management and safety management requirements of high-value material management system, and helps enterprises realize accurate control and efficient utilization of high-value materials.

III. Cost analysis of smart tool material management cabinets in high-value material management systems (cost reduction dimension)

One of the core values of intelligent tool material management cabinet in high value material management system of production workshop is to realize accurate control and significant reduction of high value material management cost through the whole process of intelligent control. Combined with industry data, intelligent management practices and actual application scenarios in the workshop, the cost reduction is mainly reflected in four dimensions: human cost, material loss cost, inventory capital cost, and hidden management cost, which are analyzed as follows to provide practical reference for the cost optimization of the high-value material management system:

(i) Reducing manpower costs and achieving “efficiency gains”

Intelligent tool material management cabinet through automation, digital management, replacing the traditional high-value material management in the manual registration, manual inventory, manual traceability, manual reminder and other cumbersome work, can significantly reduce the number of high-value material management personnel, reduce labor costs, which is also the most direct effect of its cost reduction in the high-value material management system. According to the industry practice data show that after the application of intelligent tool material management cabinet, the production workshop high-value material management personnel can be reduced by 65-85%, medium-sized enterprise workshop can be reduced from the original 4-6 management personnel to 1, and large-scale enterprise workshop can be reduced by more than 55% management personnel. Take medium-sized enterprise workshop as an example, assuming that the average monthly salary of high-value material management personnel is 7,000 yuan, after the application of intelligent tool material management cabinet, it can save 42-735,000 yuan of labor costs per year. At the same time, reduce the time of first-line workers looking for materials, queuing for receiving, so that workers focus on the production process, indirectly improve production efficiency, and further reduce the labor cost per unit of product sharing. In addition, the automated management reduces the manual operation errors, avoiding the loss of materials due to operation errors, inventory backlog and other cost losses, further optimizing the control of labor costs, and helping the high-value material management system to achieve the goal of “reducing manpower, improving quality and lowering costs”.

(ii) Reducing material wastage costs and minimizing wastage

Intelligent tool material management cabinet through accurate storage, standardized collocation, environmental protection, intelligent reminder and other functions, effectively reduce the loss and waste of high-value materials, reduce the cost of procurement and replacement of materials, which is the core of its high-value material management system in the cost reduction highlights. On the one hand, the modular grid opening design realizes “one item, one grid” precise storage, avoiding the collision and damage caused by the material mixing, and at the same time, the cabinet's functions of constant temperature, constant humidity, dustproof, moisture-proof, oil-proof, etc., reduce the material loss caused by the environmental factors in the workshop, and according to the statistics, the application of high-value materials after the non-normal wastage rate can be reduced by 80%. According to statistics, after application, the abnormal loss rate of high-value materials can be reduced by 80%, and the loss rate of high-value precision tools can be reduced to below 1%. Before the application of a precision machinery manufacturing enterprise workshop, the annual loss rate of high-value materials amounted to 18%, the annual cost of loss of 800,000 yuan, the application of intelligent tool material management cabinet, the loss rate fell to 2.5% below, saving 760,000 yuan in annual loss costs. On the other hand, the intelligent traceability and standardization of collocation function, to avoid material misuse, misappropriation, loss, while the “old for new” mode to reduce irrational collocation, reduce material waste; intelligent maintenance reminder function, to ensure that the precision cutting tools and other materials in a timely manner to maintain, calibrate, and extend the service life of the material, and further reduce the cost of wastage. From a comprehensive point of view, after the application of intelligent cutting tool material management cabinet, the cost of high-value material loss in the enterprise workshop can be reduced by 50-70%, significantly optimize the material procurement costs, and provide strong support for the cost control of high-value material management system.

(iii) Optimization of inventory structure and reduction of the cost of capital employed

Intelligent tool material management cabinet through digital inventory control and data report analysis, to help enterprises accurately grasp the inventory status of high-value materials and the use of the law, optimize the procurement plan, reduce inventory backlogs, reduce the cost of inventory capital occupancy, to alleviate the pressure of capital turnover in the management system of high-value materials. According to industry data, the application of intelligent tool material management cabinet, enterprise workshop high-value material inventory capital consumption can be reduced by 45-70%, the proportion of stagnant materials down to 5% below, capital turnover efficiency by 55% above. Before the application of an auto parts enterprise workshop, high-value materials inventory capital occupancy of 1.2 million yuan, the capital turnover cycle of 32 days, after the application, the inventory capital occupancy down to 420,000 yuan, the capital turnover cycle shortened to 10 days, according to the annual interest rate of 4.35% calculations, the annual cost of capital occupancy can be saved 35,280,000 yuan, and at the same time to reduce the loss of scrap of sluggish materials of about 150,000 yuan. In addition, the accurate inventory warning function avoids stoppage of work and waiting for materials due to insufficient inventory, reduces indirect cost losses caused by production delays, further optimizes the efficiency of capital use, and helps the high-value material management system to achieve efficient use of funds.

(iv) Reducing hidden costs and minimizing managerial internal consumption and quality risks

Intelligent tool material management cabinet reduces the hidden cost in traditional high value material management, reduces the internal consumption and quality risk, and further optimizes the cost structure of high value material management system through perfect process control, accurate traceability and intelligent reminder function. Firstly, the responsibility is clearly defined, and there is a clear record of materials' usage and return, so that the responsible person can be quickly located in case of problems, avoiding inter-departmental shirking of responsibilities, and reducing the processing time and management cost; secondly, it reduces the errors of manual operation, and avoids the problems of purchasing wastage and inventory backlogs caused by ledger errors and inventory errors, and reduces the cost of correcting errors; thirdly, it is the function of intelligent maintenance reminder, which can avoid product quality defects, equipment failures and product quality defects caused by material over-use, and reduce the cost of correcting errors. Third, the intelligent maintenance reminder function can avoid product quality defects and equipment failures caused by over-use of materials, reduce product rework, scrap costs, equipment maintenance costs, and reduce hidden losses caused by quality risks. After the application of an aerospace parts enterprise workshop, the product rework cost caused by improper management of high-value materials has been reduced from 250,000 yuan to 30,000 yuan per year, and the hidden cost has been reduced by more than 88% in total. In addition, the precise traceability function can meet the compliance requirements of the industry, avoid the cost loss caused by inspection and rectification, further optimize the hidden cost control, and help the high-value material management system to realize the optimization of the whole process cost.

IV. Analysis of the efficiency improvement of intelligent tool material management cabinets in high-value material management systems (efficiency dimension)

Intelligent tool material management cabinet can not only effectively reduce the production workshop high-value material management costs, but also significantly improve management efficiency, optimize the operational efficiency of high-value material management system, to promote the workshop production of the whole process of synergistic efficiency enhancement, combined with the industry application practice, specifically embodied in the inventory management efficiency, the use of restitution efficiency, the efficiency of traceability control, maintenance management efficiency, decision-making efficiency of five dimensions, combined with the shop floor of the actual Application scenarios are analyzed in detail as follows:

(i) Improvement of inventory management efficiency and realization of accurate control

In the traditional inventory management of high-value materials in production workshop, inventory is time-consuming and labor-intensive, with low accuracy rate and outstanding data distortion, which seriously affects the operation efficiency of high-value materials management system. Intelligent tool material management cabinet can realize real-time updating and automatic checking of inventory data through the intelligent inventory function, relying on the fast recognition advantage of RFID read-write, and greatly improve the efficiency of inventory management. Management personnel through the system to initiate inventory instructions, the cabinet can be completed within one hour of all high-value materials inventory work, generate accurate inventory reports, synchronized to the high-value materials management system, while the traditional manual inventory takes 3-5 days, the efficiency of 95% or more, inventory accuracy from the traditional 70% or so to 99.9% or more, to completely solve the problem of inventory data malfunction. The problem of inventory data distortion is completely solved. At the same time, the system real-time update of material inventory status, use, maintenance records, managers can view at any time, without manual reconciliation of the ledger, significantly saving inventory management time. In addition, through the analysis of data reports, it can accurately grasp the pattern of material use, optimize the inventory quota, realize the accurate control of inventory, avoid inventory backlog and shortage, improve the efficiency of inventory turnover, and help the high-value material management system to realize efficient inventory control.

(ii) Enhancement of the efficiency of claim restitution to ensure production continuity

Workshop production is fast-paced, high-value materials receiving efficiency directly affects the production schedule, but also one of the core efficiency indicators of high-value material management system. Intelligent tool material management cabinet greatly improves material flow efficiency by automating the process of receiving and returning. Under the traditional mode, workers need to fill out the claim form, manual checking, signing confirmation to claim high-value materials, and each claim takes an average of 8-15 minutes, while the intelligent tool material management cabinet through the authorization of identification, automatic recording, each claim time is shortened to less than 30 seconds, the claiming efficiency to improve the 90% or more. For the batch receiving scenario, the efficiency improvement is even more obvious, can realize multiple pieces of material receiving at the same time, automatic recording, greatly saving the workers receiving time, so that the workers focus on the production process. At the same time, when the material is returned, the system automatically recognizes the material information, detects the material status, and updates the inventory data and high-value material management system without manual registration, which further improves the flow efficiency. In addition, the inventory warning function can remind the shortage of materials in time, make procurement preparations in advance, avoid stopping work and waiting for materials, protect the continuity of production, and help the high-value material management system and the production process to work together efficiently.

(iii) Enhancing the efficiency of traceability control and reducing quality and management risks

The traceability of high-value materials is directly related to product quality, operational safety and management risk, and is one of the core requirements of high-value material management system. Relying on the full life cycle traceability advantage of RFID technology, the intelligent tool material management cabinet realizes the accurate traceability of the whole process of high-value materials, and significantly improves the traceability control efficiency. Under the traditional mode, the material traceability need to manually check the ledger, time-consuming and labor-intensive and prone to traceability faults, while the intelligent tool material management cabinet through the system to quickly query the procurement of each piece of material, warehousing, collation, return, use, maintenance, calibration, scrapping and other full-process records, the traceability of the time-consuming from the traditional hours to a few minutes to shorten the efficiency of the enhancement of 90% or more. When there is material failure, damage, loss or product quality problems, you can quickly trace the flow of materials, the use of personnel and the cause of damage, investigate the root cause of the problem, and take timely corrective measures to reduce quality losses, safety risks and management costs. Especially in aerospace, automobile manufacturing and other industries with strict requirements on material management, the intelligent traceability function can meet the compliance requirements of the industry, enhance the standardized level of workshop management, and help high-value material management system to realize the whole process of traceability control.

(iv) Enhancing maintenance management efficiency and extending material service life

Regular maintenance and calibration of high-value materials (especially precision tools) is the key to prolonging service life and reducing wastage, and is also an important part of high-value material management system. Under the traditional management mode, the maintenance plan is based on manual memorization, which is prone to problems such as omission and overdue, and maintenance efficiency is low. Intelligent tool material management cabinet through the system automatically records the material use time, maintenance cycle, calibration time, automatically push the maintenance, calibration reminders, managers can make maintenance plans according to the reminders, reasonable arrangement of maintenance personnel and time, to avoid material overdue use. At the same time, the system can record the material maintenance records, easy to trace the maintenance situation, optimize the maintenance program, improve the maintenance efficiency and maintenance quality. According to statistics, after the application of intelligent tool material management cabinet, the maintenance efficiency of high-value materials will be improved by more than 75%, the maintenance cost will be reduced by more than 35%, and the service life of the materials will be extended by an average of 30-40%, which further reduces the cost of material replacement, and helps the high-value material management system to realize the refinement of the maintenance management and control.

(v) Improving decision-making efficiency and facilitating lean management of high-value materials

Intelligent tool material management cabinet through the digital management system, automatic summary of high-value material management of the whole process data, generate multi-dimensional data reports (inventory turnover rate report, loss rate report, receiving frequency report, maintenance records report, etc.), for enterprise management, workshop management personnel to provide a scientific basis for decision-making, significantly improve the efficiency of decision-making, and promote the high-value material management system to the lean upgrading. Under the traditional mode, managers need to spend a lot of time to organize the ledger, analyze the data, the decision-making cycle is long and prone to bias, while the intelligent system can generate real-time data reports, clearly presenting the status quo of the cost and efficiency of the management of high-value materials, and the managers can quickly grasp the pattern of use of the materials, the inventory structure, the maintenance of the situation in a timely manner to optimize the procurement plan, adjust the inventory quota, improve the management process, optimize the maintenance program. For example, by analyzing the report on the frequency of requisition, the system can accurately determine the commonly used material models, optimize the procurement plan, and avoid blind procurement; by analyzing the report on the rate of loss, the system can find out the reasons for the high loss of materials and formulate improvement measures to improve the management efficiency. At the same time, the system seamlessly connects with ERP and MES systems, realizing the synergy between high-value material management, production planning, procurement management and equipment maintenance, which further improves the overall decision-making efficiency of the enterprise and the lean management level of the workshop, and helps the high-value material management system to realize the intelligent control of the whole process.

V. Practical application case analysis (cost efficiency landing validation)

In order to further verify the cost efficiency enhancement effect of intelligent tool material management cabinet in the high-value material management system of production workshop, combined with the industry application practice, this paper selects two actual application cases of different industries and scales of enterprise workshop, from the application background, implementation process, cost efficiency enhancement effect of the three dimensions, to analyze its application value, and to optimize the high-value material management system for other enterprises to provide reference.

(i) Case 1: Workshop of a medium-sized precision machinery manufacturing enterprise (types of high-value materials: precision tools, special consumables, core components)

1. Application background: The enterprise has 15 production lines, and the commonly used high-value materials in the workshop include more than 230 kinds of precision tools, special consumables, core components, etc., of which the proportion of high-value precision tools (such as CNC tools, diamond tools) is about 40%, and the unit price of a single set of tools reaches up to 50,000 yuan. Traditional high-value materials management, equipped with five managers, there are material storage chaos, low collocation efficiency, serious inventory backlog, high attrition rate, quality risk, etc., annual high-value material loss costs amounted to 800,000 yuan, inventory capital consumption of 1.2 million yuan, manpower costs of 420,000 yuan, due to improper management of materials caused by the stoppage of waiting for the material, product rework, equipment maintenance losses of about 280,000 yuan per year, high-value materials management total costs remain high, the total cost of high-value materials management. The total cost of high value material management remains high, inefficient, and unable to meet the requirements of industry compliance inspection, high value material management system is virtually useless.

2. Implementation process: The enterprise introduces 8 intelligent tool material management cabinets, which are divided into small precision compartments, medium-sized compartments and large customized compartments according to the specifications and precision requirements of high-value materials, and affixes anti-metallic RFID tags for each piece of high-value materials, and enters the information of the materials (specifications, models, procurement date, maintenance cycle, authority to use, precision standards, etc.). Build an intelligent management platform to realize seamless docking of cabinets with enterprise ERP, MES system and high-value material management system, and realize real-time synchronization of material data with production plan, procurement data and maintenance data. Formulate the authorization management rules, assign different receiving and operating privileges for first-line workers, management personnel and maintenance personnel, enable the “trade-in” mode, and standardize the material receiving process; use the system's inventory warning and maintenance reminder function to set the material safety stock and maintenance cycle, optimize the procurement plan and maintenance plan, and give full play to the intelligent management and control advantages, and perfect the high-value material management system. management and control advantages, and improve the high-value material management system.

3. Cost and efficiency improvement effect: after implementation, the cost and efficiency of high-value material management in the workshop of the enterprise have been significantly optimized, and the high-value material management system has been upgraded intelligently. Firstly, in terms of cost, the number of high-value material management personnel is reduced to 1, which saves 336,000 yuan of labor cost per year; the material loss rate is reduced from 18% to 2.5%, which saves 760,000 yuan of loss cost per year; the inventory capital consumption is reduced to 420,000 yuan, which saves 35,280,000 yuan of capital consumption cost per year, and the hidden cost (stoppage of materials, product rework, and loss of equipment maintenance) is reduced to 30,000 yuan, which saves 1,612,800 yuan of cost per year. Total annual cost savings of 1,116,128,000 yuan. Secondly, in terms of efficiency, the efficiency of material requisitioning has been improved by 92%, and the time for workers to requisition materials has been shortened from 40 minutes to 3.2 minutes per day; the time for inventory counting has been shortened from 4 days to 45 minutes, and the accuracy rate of inventory counting has reached 99.9%; the efficiency of traceability has been improved by 96%, and the time for problem investigation has been shortened from several hours to 3 minutes; the efficiency of maintenance has been improved by 78%, and the average service life of materials has been extended by 35%. Maintenance efficiency has been improved by 78%, and the average service life of materials has been extended by 35%. Inventory turnover efficiency has been improved by 60%, and the proportion of defective materials has been reduced to less than 3%, which effectively guarantees the continuity of production, and the overall productivity of the workshop has been improved by 20%, and at the same time meets the requirements of the industry's compliance inspections, and reduces the risk of quality and management.

(ii) Case 2: workshop of a large automotive parts enterprise (types of high-value materials: precision tools, core components, special consumables)

1. Application background: the enterprise has 30 production lines, workshop commonly used high-value materials, including precision cutting tools, core components, special consumables, such as more than 450 kinds of high-value precision cutting tools, core components accounted for about 48%, a single piece of the core components of the unit price of up to 120,000 yuan. Traditional high-value materials management, equipped with 12 managers, there are inventory data distortion, material backlog, cumbersome process of collocation, traceability difficulties, maintenance of untimely, etc., annual high-value materials inventory capital consumption of 1.8 million yuan, material loss cost of 1.1 million yuan, labor costs of 1.008 million yuan, due to improper management of materials resulting in loss of quality, equipment failures, safety accidents loss of about 400,000 yuan per year, seriously affecting the profitability of the enterprise and the workshop, and the company has a significant impact on the quality and efficiency of the company's business. The loss of quality, equipment failure and safety accidents caused by improper material management is about 400,000 yuan per year, which seriously affects the profitability of the enterprise and the safety production of the workshop.

2. Implementation process: the enterprise introduces 15 intelligent tool material management cabinets, adopting the mode of “1 master cabinet + N slave cabinets”, flexibly dividing the compartments according to the specifications of high-value materials, usage and precision requirements, equipped with constant temperature and humidity control system to provide a constant temperature, dust-proof, humidity-proof and oil-proof storage environment for the precision cutting tools and core components; and customized metal-resistant RFID tags are affixed to each piece of material to ensure that accurate identification can still be realized under the complex environment of the workshop. Customized metal-resistant RFID tags are pasted on each piece of material to ensure that accurate identification can still be achieved in the complex environment of the workshop. Build intelligent data analysis platform, docking enterprise ERP, MES system, high value material management system, realizing real-time summary and analysis of the whole process data of high value materials; enable remote control function, management personnel can remotely view the material inventory, initiate inventory, allocation, maintenance instructions through cell phone APP; set up the material wear and tear early warning, maintenance expiration reminder function, optimize the material maintenance and replacement plan, and improve the intelligent management of high value material management system. Intelligent control capability of high value material management system.

3. Cost and efficiency enhancement effect: after implementation, the enterprise's workshop high-value material management has realized the double breakthrough of “cost reduction and efficiency enhancement”, and the high-value material management system has realized refined and intelligent control. Firstly, in terms of cost, the number of high-value material management personnel is reduced to 5, saving 588,000 yuan of labor cost per year; the material loss rate is reduced from 16% to 1.8%, saving 994,000 yuan of loss cost per year; the inventory capital consumption is reduced to 540,000 yuan, saving 55,440,000 yuan of capital occupation cost per year, and the implicit cost is reduced to 40,000 yuan, saving 1,677,444 yuan of cost per year in total. The total annual cost saving is 1,677,440,000 yuan, and the payback period is only 7 months. Secondly, in terms of efficiency, the efficiency of material requisitioning is improved by 93%, and the time consuming for batch requisitioning is shortened by 88%; the efficiency of inventory counting is improved by 97%, and the inventory counting time is saved by 120 hours per year; the efficiency of traceability is improved by 98%, and the whole life cycle track of materials can be located quickly to satisfy the stringent requirements of the automotive industry; the efficiency of maintenance is improved by 82%, and the average service life of materials is extended by 40%. Maintenance efficiency has been improved by 82%, the average life span of materials has been extended by 40%; inventory turnover efficiency has been improved by 62%, the loss of obsolete materials scrapped has been reduced by 92%, the continuity of production has been effectively guaranteed, the production cycle of the unit product has been shortened by 15%, the level of workshop safety has been significantly improved, and the overall competitiveness of the enterprise has been further strengthened.

Sixth, intelligent tool material management cabinet application considerations and industry development trends

Intelligent tool material management cabinet in the production workshop high-value material management system has significant cost efficiency enhancement value, combined with the characteristics of high-value material management and industry application practice, enterprises in the application process, need to pay attention to the following matters, in order to give full play to its role in perfecting the high-value material management system; at the same time, combined with the industry development trend, the reasonable planning of the application of the strategy, to help the enterprise shop floor of the long-term lean and digitalized development.

(i) Application considerations

1. Adaptation to the characteristics of workshop high-value materials: Enterprises should reasonably choose the model, compartment size and function module of intelligent tool material management cabinet according to the specifications, types, quantities, usage frequency, storage environment and precision requirements of their own workshop high-value materials, so as to avoid the waste of resources or insufficient functions. For example, precision machining workshop can focus on the choice of constant temperature and humidity, small precision grid mouth cabinet, machinery manufacturing workshop can focus on the choice of anti-oil, anti-collision, large-scale grid mouth cabinet; at the same time, the choice of anti-metal RFID tags to match the workshop environment, to ensure the accuracy of identification, optimize the labeling method, to avoid affecting the accuracy of the material.

2. Standardize the entry of material information: the accuracy of material information is the foundation of intelligent management and the premise of efficient operation of high-value material management system. Enterprises in the entry of high-value material information, need to ensure that the specifications, models, procurement date, maintenance cycle, calibration time, receipt of authority, accuracy standards and other information is accurate, and regularly update the material information (such as material maintenance, repair, scrapping, and timely update of the system data), to avoid management loopholes due to the error of the information, and to ensure that the RFID labeling information is consistent with the data of the high-value material management system.

3. Strengthen personnel training: the operation of intelligent tool material management cabinet, RFID label maintenance, the use of the system requires a certain degree of professional knowledge, the enterprise should strengthen the workshop management personnel, front-line workers, maintenance personnel training, to ensure that they are proficient in the operation of the cabinet, the system to use the skills of the maintenance of RFID labels, to avoid improper operation of the equipment failure, data errors or damage to the label; at the same time. Establish a perfect management system to standardize the process of material requisition, return, inventory, maintenance, etc., to ensure that the management work is standardized to ensure the orderly operation of the high-value material management system.

4. Do a good job of equipment maintenance and after-sales service: Intelligent tool material management cabinet as intelligent equipment, the need for regular maintenance and maintenance, such as cleaning the cabinet, check the RFID reader, maintenance of electronic locks, backup system data, check the integrity of the label, calibration of constant temperature and humidity system, etc., to ensure that the equipment operates normally; choose a professional equipment supplier to ensure the quality of the equipment and after-sales service, and timely solution to the problem of RFID recognition failures, system jams and other problems in the course of the operation of the equipment. Choose professional equipment suppliers to ensure equipment quality and after-sales service, solve RFID recognition failure, system jamming and other problems during the operation of the equipment in a timely manner, and ensure the continuous development of high-value materials management.

5. Promote system synergy and docking: when introducing intelligent tool material management cabinet, enterprises should give priority to choose products that can be seamlessly docked with existing ERP, MES and other systems and high-value material management systems, so as to break the data silos, realize the synergy between high-value material management and production planning, procurement management, equipment maintenance, safety production and other links, enhance the overall management efficiency of enterprises and avoid management disconnection caused by system incompatibility. Disconnect.

(ii) Trends in industry development

1. Intelligent level continues to improve: with the iteration of artificial intelligence, big data, edge computing and other technologies, intelligent tool material management cabinet will achieve a higher level of intelligence, such as AI algorithms to predict the state of wear and tear of high-value materials, the use of demand, automatic optimization of the procurement plan and maintenance plan, to further reduce the manual intervention; combined with digital twin technology, to achieve high-value material management of virtual simulation and real-time monitoring to help the workshop to achieve the whole process of intelligent management; at the same time, RFID tags will be developed to a more compact, high interference resistance, long life, high precision direction to adapt to more complex workshop environment and high precision material management needs. At the same time, RFID tags will be developed in the direction of miniaturization, high anti-interference, long life and high precision to meet the needs of more complex workshop environments and high-precision material management, and to further improve the intelligent level of high-value material management system.

2. Increasing degree of integration: in the future, the intelligent tool material management cabinet will be deeply integrated with workshop industrial robots, AGV carts, intelligent monitoring equipment, etc., to realize automatic warehousing, automatic requisitioning, automatic transportation and automatic maintenance of high-value materials, build a high-value material management system of full-process automation, further enhance the efficiency of production coordination, promote the deep integration of high-value material management system and production links, and realize “unmanned” management. Realize "unmanned" management.

3. The demand for customization is becoming more and more prominent: different industries, different scale of enterprise workshop, the type of high-value materials, specifications, precision requirements, management needs vary greatly, in the future, the intelligent tool material management cabinet will be developed in the direction of customization, the supplier will be based on the specific needs of the enterprise, the design of personalized layout of the compartment, functional modules and management system, to adapt to the management characteristics of the workshop in different industries, such as for aerospace For example, for the aerospace workshop to design high precision traceability, high protection of customized cabinets, for small and medium-sized enterprises workshop design cost-effective, easy to operate cabinets, to meet the personalized needs of different enterprises high-value material management system.

4. Green and energy-saving development: led by the goal of “dual-carbon”, the intelligent tool material management cabinet will adopt energy-saving components and environmentally friendly materials to reduce energy consumption of equipment; at the same time, by optimizing inventory management, extending the service life of materials, reducing material waste, realizing green and lean management, and promoting the low-carbon development of enterprise workshops. In addition, the head enterprise will establish a high-value material recycling and refurbishment system, combined with RFID traceability, to realize the green management of the whole life cycle of the material, further reduce costs, promote the industry to the evolution of the circular economy model, and help the high-value material management system to achieve green upgrading.

5. Market scale continues to expand: with the acceleration of industrial digital transformation, more and more enterprises are aware of the importance of intelligent management of high-value materials in the workshop, the market demand for intelligent tool material management cabinet will continue to grow. According to industry forecasts, in 2026 China's intelligent material management equipment market size is expected to reach 4 billion yuan, of which the intelligent tool material management cabinet will account for more than 70%, 2022-2026 period of compound annual growth rate of up to 55%, the share of domestic substitution continues to expand, the industry concentration continues to improve, and its application in the high-value material management system will be more widely used.

VII. Conclusion

Under the background of digitalization of industrial production and lean transformation of workshop, cost control and efficiency improvement of high-value material management in production workshop has become the key to enhance core competitiveness of enterprises, guarantee product quality and optimize capital use efficiency. The traditional high-value material management mode exists in the high labor cost, material loss, inventory backlog, low efficiency, quality risk and other pain points, has been unable to meet the modern high-value material management system of intelligent, refined demand. Intelligent tool material management cabinet by virtue of RFID radio frequency identification, Internet of Things, big data analysis and other core technologies, and production workshop high-value material management depth of adaptation, by reducing labor costs, material loss costs, inventory capital costs, hidden costs, improve inventory management, restitution, traceability control, maintenance management, decision-making and other process efficiency, to achieve high-value material management system of the It realizes the double breakthrough of “cost reduction and efficiency increase” of high value material management system, effectively solves the core pain points of traditional management mode, and promotes the transformation of high value material management from traditional manual management to digital and intelligent management.

From the actual application cases, whether it is a medium-sized precision machinery manufacturing enterprise workshop or a large auto parts enterprise workshop, the introduction of intelligent tool material management cabinet, have achieved a significant reduction in cost, efficiency significantly improve the return on investment is significant, can effectively help enterprises optimize the high-value material management system, improve high-value material management system, enhance the workshop lean, digital management level, to ensure safe production It can help enterprises optimize the high-value material management system, improve the high-value material management system, enhance the lean and digital management level of workshops, guarantee safe production, and meet the requirements of industry compliance. With the continuous iteration of technology and the continuous growth of industry demand, the intelligent tool material management cabinet will develop in the direction of higher intelligence, integration, customization and greening, and become the core equipment for upgrading the high-value material management system of the production workshop, and promote enterprises to achieve high-quality development in the wave of industrial digital transformation.

For industrial enterprises, should be combined with their own workshop production scale, high-value material characteristics and management needs, the reasonable introduction of intelligent tool material management cabinet, standardize the application process, strengthen personnel training and equipment maintenance, give full play to its cost-efficiency advantages, improve the high-value material management system; at the same time, follow the development trend of the industry, promote the high-value material management and the depth of the integration of the industrial Internet, artificial intelligence and other technologies, to achieve the whole process of intelligent, lean management of the workshop to reduce operating costs, improve production efficiency and product quality, enhance the core competitiveness of enterprises. At the same time, following the development trend of the industry, promoting the deep integration of high-value material management with industrial Internet, artificial intelligence and other technologies, realizing the intelligent and lean management of the whole process of high-value materials in the workshop, reducing the operation cost, improving the production efficiency and product quality, and enhancing the core competitiveness of enterprises.