SunYF
05b0b8a909
1. 新增预警表添加工单号字段，支持按工单号检索预警 2. 添加工单过滤在制品/绩效报表/预警中心查询 3. 补全WMS台账字段口径与权限配置 4. 修复备料单与数量不符处理流程 5. 新增配送进度/库位联动/自动出库功能 6. 修复AGV配送状态更新逻辑 7. 优化退料与库存管理细节
465 lines
17 KiB
Go
465 lines
17 KiB
Go
package logic
|
||
|
||
import (
|
||
"context"
|
||
"errors"
|
||
"fmt"
|
||
"sort"
|
||
"strconv"
|
||
"time"
|
||
|
||
"bj_power_mes/ent"
|
||
"bj_power_mes/ent/materialrequest"
|
||
"bj_power_mes/ent/station"
|
||
"bj_power_mes/ent/workorder"
|
||
"bj_power_mes/internal/wmsclient"
|
||
)
|
||
|
||
// GenerateMaterialRequest 按日排产 + 今日工位派工(station_process) 自动算料，生成工位级备料单。
|
||
//
|
||
// 算法：
|
||
// - 路线来源：今日 station_process 派工（工位号→工序编号）。某工序(1~12)今日派工到哪些工位，
|
||
// 该工序的 BOM 物料就拆到这些工位各生成一行备料单（物料随工序上料）。
|
||
// - 数量：单工位量 = 该工位分配产量(日排产 stationPlanQty，未配置则日总量平均到各派工工位)
|
||
// × BOM 单台用量 ×(1+损耗率)；同工序多工位时日总量按分配/平均拆分，不重复放大。
|
||
// - 目标接驳台：取该派工工位的 station.dockCode（无接驳台则留空待仓管指定）。
|
||
// - processCode=0 的 BOM 物料（不参与工位绑定）：按日总量生成一行，工位/接驳台留空。
|
||
//
|
||
// 生成前校验：BOM 内所有物料编码须在 WMS 物料档案存在，有缺失返回 missing（不生成）；
|
||
// WMS 不可达/异常时降级为"全部存在"并记 eventlog，避免 WMS 抖动阻塞产线。
|
||
// 返回值：count=本次生成条数；missing=WMS 中不存在的物料编码（非空时 count=0）。
|
||
func (s *Service) GenerateMaterialRequest(ctx context.Context, planDate string, operator string) (int, []string, error) {
|
||
plans, err := s.ListDailyPlans(ctx, "", planDate)
|
||
if err != nil {
|
||
return 0, nil, err
|
||
}
|
||
if len(plans) == 0 {
|
||
return 0, nil, errors.New("该日期没有排产计划")
|
||
}
|
||
// 今日工位派工：工位号 → 工序编号
|
||
procMap, err := RouteStationProcessCodeMap(ctx, s.ctx.EntClient, TodayStr(), "")
|
||
if err != nil {
|
||
return 0, nil, err
|
||
}
|
||
if len(procMap) == 0 {
|
||
return 0, nil, errors.New("今日未配置工位派工(station_process)，无法生成备料单")
|
||
}
|
||
// 工序编号 → 工位号列表（反查，供 BOM 物料按工序拆到工位）
|
||
stationsByProcess := map[int][]int{}
|
||
stNos := make([]int, 0, len(procMap))
|
||
for stNo, pc := range procMap {
|
||
stationsByProcess[pc] = append(stationsByProcess[pc], stNo)
|
||
stNos = append(stNos, stNo)
|
||
}
|
||
// 工位号 → 接驳台编码
|
||
dockByStation := map[int]string{}
|
||
if sts, e := s.ctx.EntClient.Station.Query().Where(station.StationNoIn(stNos...)).All(ctx); e == nil {
|
||
for _, st := range sts {
|
||
dockByStation[st.StationNo] = st.DockCode
|
||
}
|
||
}
|
||
|
||
type planBom struct {
|
||
plan *ent.DailyPlan
|
||
wo *ent.WorkOrder
|
||
bom []*ent.BomItem
|
||
}
|
||
groups := make([]planBom, 0, len(plans))
|
||
codeSet := map[string]bool{}
|
||
for _, plan := range plans {
|
||
if plan.Status == "CANCELLED" || plan.Status == "DONE" {
|
||
continue // 已取消/已完成的排产不再算料
|
||
}
|
||
wo, err := s.ctx.EntClient.WorkOrder.Query().
|
||
Where(workorder.WorkOrderNo(plan.OrderNo)).Only(ctx)
|
||
if err != nil {
|
||
continue
|
||
}
|
||
bom, err := s.ListBom(ctx, wo.ProductCode, bomNameOrDefault(""))
|
||
if err != nil {
|
||
continue
|
||
}
|
||
if len(bom) == 0 {
|
||
continue
|
||
}
|
||
for _, item := range bom {
|
||
if item.MaterialCode != "" {
|
||
codeSet[item.MaterialCode] = true
|
||
}
|
||
}
|
||
groups = append(groups, planBom{plan: plan, wo: wo, bom: bom})
|
||
}
|
||
if len(groups) == 0 {
|
||
return 0, nil, errors.New("该日期排产均无有效 BOM 物料，无法生成备料单")
|
||
}
|
||
// 阶段1：WMS 物料存在性校验（全部存在才生成）
|
||
codes := make([]string, 0, len(codeSet))
|
||
for c := range codeSet {
|
||
codes = append(codes, c)
|
||
}
|
||
missing, wmsErr := s.ctx.Wms.MaterialExists(ctx, codes)
|
||
if wmsErr != nil {
|
||
// 降级：WMS 不可达按"全部存在"放行，记日志供事后核查
|
||
s.ctx.EventLog.Write(ctx, "material.request.wms_skip", "", operator, "material_request", planDate,
|
||
"WMS 物料校验不可达，已降级放行", map[string]any{"planDate": planDate, "error": wmsErr.Error()})
|
||
} else if len(missing) > 0 {
|
||
return 0, missing, nil
|
||
}
|
||
// 阶段2：全部存在 → 按工位拆料生成
|
||
created := 0
|
||
tsBase := time.Now().Format("20060102150405")
|
||
seq := 1
|
||
for _, g := range groups {
|
||
// 工位产量分配（日排产层）：stationNo(字符串键) → 计划产量
|
||
stationQty := map[int]int{}
|
||
for k, v := range g.plan.StationPlanQty {
|
||
if n, e := strconv.Atoi(k); e == nil {
|
||
stationQty[n] = v
|
||
}
|
||
}
|
||
// 成品可作零部件：BOM 子项若为成品，递归展开到叶子（原材料/外购件）再算料
|
||
leaves := s.expandBomToLeaf(ctx, g.wo.ProductCode, bomNameOrDefault(""), 1, 0, map[string]bool{})
|
||
for _, item := range leaves {
|
||
pc := item.processCode // 该物料所属装配工序(1~12)，0=不参与工位绑定
|
||
if pc == 0 {
|
||
reqQty := float64(g.plan.PlanQty) * item.unitQty * (1 + item.lossRate/100)
|
||
if reqQty <= 0 {
|
||
continue
|
||
}
|
||
reqNo := fmt.Sprintf("MR%s%03d", tsBase, seq)
|
||
seq++
|
||
_ = s.ctx.EntClient.MaterialRequest.Create().
|
||
SetRequestNo(reqNo).SetOrderNo(g.plan.OrderNo).SetPlanDate(g.plan.PlanDate).
|
||
SetMaterialCode(item.materialCode).SetMaterialName(item.materialName).
|
||
SetUnit(item.unit).SetManageMode(item.manageMode).SetReqQty(reqQty).
|
||
SetStatus("PENDING").SetOperator(operator).Exec(ctx)
|
||
created++
|
||
continue
|
||
}
|
||
stations := stationsByProcess[pc]
|
||
if len(stations) == 0 {
|
||
// 该工序今日未派工到任何工位，本日无需上料（非缺料）
|
||
continue
|
||
}
|
||
qtys := splitQtyToStations(stations, g.plan.PlanQty, stationQty)
|
||
for i, stNo := range stations {
|
||
q := qtys[i]
|
||
if q <= 0 {
|
||
continue
|
||
}
|
||
reqQty := float64(q) * item.unitQty * (1 + item.lossRate/100)
|
||
if reqQty <= 0 {
|
||
continue
|
||
}
|
||
reqNo := fmt.Sprintf("MR%s%03d", tsBase, seq)
|
||
seq++
|
||
_ = s.ctx.EntClient.MaterialRequest.Create().
|
||
SetRequestNo(reqNo).SetOrderNo(g.plan.OrderNo).SetPlanDate(g.plan.PlanDate).
|
||
SetMaterialCode(item.materialCode).SetMaterialName(item.materialName).
|
||
SetUnit(item.unit).SetManageMode(item.manageMode).SetReqQty(reqQty).
|
||
SetStatus("PENDING").SetOperator(operator).
|
||
SetStationNo(stNo).SetProcessCode(pc).SetTargetDock(dockByStation[stNo]).Exec(ctx)
|
||
created++
|
||
}
|
||
}
|
||
}
|
||
s.ctx.EventLog.Write(ctx, "material.request.generate", "", operator, "material_request", planDate, "按日排产+工位派工自动生成工位级备料单", map[string]any{"planDate": planDate, "count": created})
|
||
// 生成后立即自动出库（客户第1条：平时无需操作）。缺料/失败不阻塞生成，仅记预警等待补库存。
|
||
if _, short := s.AutoOutboundRequests(ctx, planDate, "", operator); len(short) > 0 {
|
||
s.ctx.EventLog.Write(ctx, "material.outbound.short", "", operator, "material_request", planDate,
|
||
"备料自动出库未齐套", map[string]any{"planDate": planDate, "short": strings.Join(short, "; ")})
|
||
}
|
||
s.notifyDashboard()
|
||
return created, nil, nil
|
||
}
|
||
|
||
// AutoOutboundRequests 工单备料自动出库（客户第1条：备料出库根据 MES 排产自动生成，平时无需操作）。
|
||
//
|
||
// 对指定排产日 / 工单下的备料单，按 FIFO 从 WMS「合格」在库库存自动领料：
|
||
// - 结构件(manageMode=1)：按批次号升序逐批出库，直到补足未出数量；
|
||
// - 电气件(manageMode=2)：按可用 SN 逐件出库。
|
||
//
|
||
// 幂等：只出「未出数量 = 需求量 − 已发数量」，重复调用不会超领。
|
||
// 库存不足的行已出部分照常计入 sentQty，差额维持待备料并触发「备料未齐套」预警，
|
||
// 库存补齐后再次调用即可补出（补出由 WMS 台账强约束兜底，不会超出工单 BOM 需求）。
|
||
// 返回：本次补足（出库总量达标）的备料单条数、未出齐的明细文案。
|
||
func (s *Service) AutoOutboundRequests(ctx context.Context, planDate, orderNo, operator string) (int, []string) {
|
||
list, err := s.ListMaterialRequests(ctx, MaterialRequestQuery{OrderNo: orderNo, PlanDate: planDate})
|
||
if err != nil {
|
||
return 0, []string{"查询备料单失败: " + err.Error()}
|
||
}
|
||
// 补料单(refill)优先于排产备料(plan)：先把补料发出，避免产线因缺料停线。
|
||
sort.SliceStable(list, func(i, j int) bool {
|
||
return list[i].Source == "REFILL" && list[j].Source != "REFILL"
|
||
})
|
||
done := 0
|
||
short := make([]string, 0)
|
||
for _, mr := range list {
|
||
need := int(mr.ReqQty - mr.SentQty + 0.5)
|
||
if need <= 0 {
|
||
continue
|
||
}
|
||
batches, sns, err := s.ctx.Wms.StockBatches(ctx, mr.MaterialCode)
|
||
if err != nil {
|
||
short = append(short, fmt.Sprintf("%s %s 查询 WMS 库存失败", mr.OrderNo, mr.MaterialCode))
|
||
continue
|
||
}
|
||
dock := mr.TargetDock
|
||
if dock == "" {
|
||
dock = "DOCK01"
|
||
}
|
||
remain := need
|
||
outboundNos := make([]string, 0, 4)
|
||
// 出库参数：补料(source=REFILL) 记为 refill 类型并默认叫车，且携带超领原因
|
||
// （补料常因损耗/报废超出 BOM 需求，WMS 侧有原因才放行）。
|
||
obType := "workorder"
|
||
if mr.Source == "REFILL" {
|
||
obType = "refill"
|
||
}
|
||
opts := wmsclient.StockDeductOpts{
|
||
Qty: need, Operator: operator, TargetDock: dock,
|
||
OutboundType: obType, NeedAgv: mr.NeedAgv, OverReason: mr.OverReason,
|
||
}
|
||
if mr.ManageMode == "2" {
|
||
for _, sn := range sns {
|
||
if remain <= 0 {
|
||
break
|
||
}
|
||
opts.SnList = []string{sn}
|
||
opts.BatchNo = ""
|
||
opts.Qty = 1
|
||
no, _, e := s.ctx.Wms.StockDeduct(ctx, mr.OrderNo, mr.MaterialCode, opts)
|
||
if e != nil {
|
||
break
|
||
}
|
||
outboundNos = append(outboundNos, no)
|
||
remain--
|
||
}
|
||
} else {
|
||
for _, b := range batches {
|
||
if remain <= 0 {
|
||
break
|
||
}
|
||
take := b.Avail
|
||
if take > remain {
|
||
take = remain
|
||
}
|
||
if take <= 0 {
|
||
continue
|
||
}
|
||
opts.SnList = nil
|
||
opts.BatchNo = b.BatchNo
|
||
opts.Qty = take
|
||
opts.ZoneCode = b.ZoneCode
|
||
no, _, e := s.ctx.Wms.StockDeduct(ctx, mr.OrderNo, mr.MaterialCode, opts)
|
||
if e != nil {
|
||
break
|
||
}
|
||
outboundNos = append(outboundNos, no)
|
||
remain -= take
|
||
}
|
||
}
|
||
sent := need - remain
|
||
if sent > 0 {
|
||
upd := s.ctx.EntClient.MaterialRequest.UpdateOneID(mr.ID).AddSentQty(float64(sent))
|
||
if remain == 0 {
|
||
// 出库量已达标：备料完成，等 AGV 配送（WMS 下发后回写 DELIVERING）
|
||
upd = upd.SetStatus("LOCKED")
|
||
done++
|
||
}
|
||
if _, e := upd.Save(ctx); e == nil {
|
||
s.ctx.EventLog.Write(ctx, "material.outbound.auto", mr.OrderNo, operator, "material_request", mr.RequestNo,
|
||
"备料自动出库", map[string]any{"materialCode": mr.MaterialCode, "qty": sent, "outboundNos": strings.Join(outboundNos, ",")})
|
||
}
|
||
}
|
||
if remain > 0 {
|
||
short = append(short, fmt.Sprintf("%s %s 缺 %d", mr.OrderNo, mr.MaterialCode, remain))
|
||
s.Evaluate(ctx, "material_shortage", 1, "备料未齐套",
|
||
fmt.Sprintf("工单 %s 物料 %s 自动出库后仍缺 %d（已出 %d/%d）", mr.OrderNo, mr.MaterialCode, remain, sent, need),
|
||
"material_request", mr.RequestNo, mr.OrderNo)
|
||
}
|
||
}
|
||
if done > 0 {
|
||
s.notifyDashboard()
|
||
}
|
||
return done, short
|
||
}
|
||
|
||
// bomLeaf 递归展开后的叶子物料行（原材料/外购件）
|
||
type bomLeaf struct {
|
||
materialCode string
|
||
materialName string
|
||
unit string
|
||
manageMode string
|
||
unitQty float64 // 已折算父级倍率的单台用量
|
||
lossRate float64
|
||
processCode int
|
||
}
|
||
|
||
// expandBomToLeaf 递归展开产品物料清单到叶子（原材料/外购件），供备料算料。
|
||
//
|
||
// 业务口径：成品可以作为零部件被另一个成品再次加工（多级嵌套）。备料算料时必须把
|
||
// 成品子项按其自身的物料清单继续展开，直到原材料/外购件，否则产线会缺料。
|
||
// 用量按倍率相乘（父级单台用量 × 子级单台用量）。
|
||
//
|
||
// R1（2026-09-19）：递归骨架统一到 bom_expand.go 的 expandBomTree，与追溯侧
|
||
// （expandBindBom）共用同一份实现；下钻判定由 wmsFinishedResolver 注入，
|
||
// WMS 不可达时按叶子处理，不阻塞备料生成。
|
||
func (s *Service) expandBomToLeaf(ctx context.Context, productCode, bomName string, mult float64, depth int, path map[string]bool) []bomLeaf {
|
||
return bomTreeToLeaf(s.expandBomTree(ctx, productCode, bomName, mult, depth, path, s.wmsFinishedResolver))
|
||
}
|
||
|
||
// splitQtyToStations 把日总量 dayQty 拆分到 stations 各工位：
|
||
// 优先使用 stationQty 显式分配（其和>0 时直接采用）；否则平均分配（余数补到前面工位）。
|
||
func splitQtyToStations(stations []int, dayQty int, stationQty map[int]int) []int {
|
||
n := len(stations)
|
||
out := make([]int, n)
|
||
usePlan := true
|
||
sum := 0
|
||
for _, st := range stations {
|
||
v, ok := stationQty[st]
|
||
if !ok {
|
||
usePlan = false
|
||
break
|
||
}
|
||
sum += v
|
||
}
|
||
if usePlan && sum > 0 {
|
||
for i, st := range stations {
|
||
out[i] = stationQty[st]
|
||
}
|
||
return out
|
||
}
|
||
if n == 0 {
|
||
return out
|
||
}
|
||
base := dayQty / n
|
||
for i := 0; i < n; i++ {
|
||
out[i] = base
|
||
}
|
||
for i := 0; i < dayQty-base*n; i++ {
|
||
out[i]++
|
||
}
|
||
return out
|
||
}
|
||
|
||
// MaterialRequestQuery 备料单查询条件（零值=不过滤）。
|
||
// 统一入口：原 ListMaterialRequests / ListMaterialRequestsFiltered 两套位置参数合并到本结构，
|
||
// 避免参数越加越长、调用点易错。
|
||
type MaterialRequestQuery struct {
|
||
OrderNo string
|
||
PlanDate string
|
||
Status string
|
||
MaterialCode string
|
||
MaterialName string
|
||
TargetDock string
|
||
StationNo string
|
||
Source string // PLAN / REFILL
|
||
Keyword string // 兜底匹配 备料单号/工单号/物料编码
|
||
}
|
||
|
||
// ListMaterialRequests 备料单查询（大小写不敏感）。
|
||
func (s *Service) ListMaterialRequests(ctx context.Context, o MaterialRequestQuery) ([]*ent.MaterialRequest, error) {
|
||
q := s.ctx.EntClient.MaterialRequest.Query()
|
||
if o.OrderNo != "" {
|
||
q = q.Where(materialrequest.OrderNoEqualFold(o.OrderNo))
|
||
}
|
||
if o.PlanDate != "" {
|
||
q = q.Where(materialrequest.PlanDate(o.PlanDate))
|
||
}
|
||
if o.Status != "" {
|
||
q = q.Where(materialrequest.Status(o.Status))
|
||
}
|
||
if o.MaterialCode != "" {
|
||
q = q.Where(materialrequest.MaterialCodeContainsFold(o.MaterialCode))
|
||
}
|
||
if o.MaterialName != "" {
|
||
q = q.Where(materialrequest.MaterialNameContainsFold(o.MaterialName))
|
||
}
|
||
if o.TargetDock != "" {
|
||
q = q.Where(materialrequest.TargetDockEqualFold(o.TargetDock))
|
||
}
|
||
if o.Source != "" {
|
||
q = q.Where(materialrequest.Source(o.Source))
|
||
}
|
||
if o.Keyword != "" {
|
||
q = q.Where(materialrequest.Or(
|
||
materialrequest.RequestNoContainsFold(o.Keyword),
|
||
materialrequest.OrderNoContainsFold(o.Keyword),
|
||
materialrequest.MaterialCodeContainsFold(o.Keyword),
|
||
))
|
||
}
|
||
if o.StationNo != "" {
|
||
if n, e := strconv.Atoi(o.StationNo); e == nil {
|
||
q = q.Where(materialrequest.StationNo(n))
|
||
}
|
||
}
|
||
return q.Order(ent.Desc(materialrequest.FieldCreatedAt), ent.Desc(materialrequest.FieldID)).All(ctx)
|
||
}
|
||
|
||
// ReceiveMaterialRequest 接料确认（两个入口共用：工位终端扫码接料 / MES 备料页人工点「已接料」）。
|
||
//
|
||
// 字段口径（2026-09-19 定稿）：写 receivedQty（已接料），**不再累加 sentQty**。
|
||
// sentQty 已发出量 [写者：自动出库] —— 幂等基准「还需发多少 = reqQty − sentQty」
|
||
// receivedQty 已接料量 [写者：本方法] —— 在途 = sentQty − receivedQty
|
||
//
|
||
// 上限 = 已发出量（工位只能接到仓库已发出来的料），不超接。
|
||
// qty<=0 表示「确认本批全部剩余」，适合扫码/一键接料；>0 为本次实收批次量。
|
||
// 累计接到 sentQty 且已发齐 reqQty → 状态置 DONE（送达并与接料双完结）。
|
||
func (s *Service) ReceiveMaterialRequest(ctx context.Context, requestNo string, qty int, operator string) error {
|
||
mr, err := s.ctx.EntClient.MaterialRequest.Query().
|
||
Where(materialrequest.RequestNo(requestNo)).Only(ctx)
|
||
if err != nil {
|
||
return errors.New("备料单不存在")
|
||
}
|
||
sent := int(mr.SentQty)
|
||
already := int(mr.ReceivedQty)
|
||
pending := sent - already // 已发出但尚未接料（在途）
|
||
if pending < 0 {
|
||
pending = 0
|
||
}
|
||
add := qty
|
||
if add <= 0 {
|
||
add = pending // 确认本批全部剩余
|
||
}
|
||
if add > pending {
|
||
add = pending // 不超接：上限是仓库已发出的量
|
||
}
|
||
if add < 0 {
|
||
add = 0
|
||
}
|
||
newReceived := already + add
|
||
upd := s.ctx.EntClient.MaterialRequest.UpdateOneID(mr.ID).
|
||
SetReceivedQty(float64(newReceived)).
|
||
SetReceivedAt(time.Now().Unix()).
|
||
SetReceiveBy(operator)
|
||
if mr.Status != "DONE" && sent >= int(mr.ReqQty) && newReceived >= sent {
|
||
upd.SetStatus("DONE")
|
||
}
|
||
if _, err = upd.Save(ctx); err != nil {
|
||
return err
|
||
}
|
||
s.ctx.EventLog.Write(ctx, "material.request.receive", requestNo, operator, "material_request", requestNo,
|
||
"接料确认", map[string]any{"add": add, "receivedQty": newReceived, "sentQty": sent,
|
||
"reqQty": int(mr.ReqQty), "awaiting": sent - newReceived})
|
||
s.notifyDashboard()
|
||
return nil
|
||
}
|
||
|
||
|
||
// SetMaterialRequestStatus 推进备料单状态（WMS 下发 AGV DELIVERING / 到位 DONE）
|
||
func (s *Service) SetMaterialRequestStatus(ctx context.Context, requestNo, status string) error {
|
||
n, err := s.ctx.EntClient.MaterialRequest.Update().
|
||
Where(materialrequest.RequestNo(requestNo)).
|
||
SetStatus(status).
|
||
Save(ctx)
|
||
if err != nil {
|
||
return err
|
||
}
|
||
if n == 0 {
|
||
return errors.New("备料单不存在")
|
||
}
|
||
s.notifyDashboard()
|
||
return nil
|
||
}
|