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OEE重构完成

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86156
2026-03-19 18:17:08 +08:00
parent fbe2340423
commit ca14b88b18
11 changed files with 295 additions and 382 deletions
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24
klp-pocket/src/main/java/com/klp/pocket/acid/domain/vo/AcidOeeCoilInfoByDateVo.java Normal file
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@@ -0,0 +1,24 @@
package com.klp.pocket.acid.domain.vo;
import lombok.Data;
import java.math.BigDecimal;
/**
* 酸轧OEE按日钢卷信息（主库来源）。
*/
@Data
public class AcidOeeCoilInfoByDateVo {
/** 统计日期 yyyy-MM-dd */
private String statDate;
/** 当前钢卷号 */
private String coilNo;
/** 重量（吨） */
private BigDecimal weight;
/** 判级 */
private String qualityStatus;
}

22
klp-pocket/src/main/java/com/klp/pocket/acid/mapper/AcidOeeAcidMapper.java Normal file
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@@ -0,0 +1,22 @@
package com.klp.pocket.acid.mapper;
import com.baomidou.dynamic.datasource.annotation.DS;
import org.apache.ibatis.annotations.Mapper;
import org.apache.ibatis.annotations.Param;
import java.math.BigDecimal;
import java.util.List;
/**
* 酸轧线OEE酸轧库Mapper。
*/
@Mapper
@DS("acid")
public interface AcidOeeAcidMapper {
/**
* 查询卷级生产节拍（min/吨），用于理论节拍计算。
*/
List<BigDecimal> selectCoilCycleMinPerTon(@Param("startDate") String startDate,
@Param("endDate") String endDate);
}

65
klp-pocket/src/main/java/com/klp/pocket/acid/mapper/AcidOeeMapper.java
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@@ -1,65 +0,0 @@
package com.klp.pocket.acid.mapper;
import com.klp.pocket.acid.domain.vo.AcidOeeDailySummaryVo;
import org.apache.ibatis.annotations.Mapper;
import org.apache.ibatis.annotations.Param;
import java.util.List;
/**
* 酸轧线OEE Mapper接口
*
* @author klp
* @date 2026-01-30
*/
@Mapper
public interface AcidOeeMapper {
/**
* 查询OEE日汇总（按日期范围）
* 聚合产量（吨/卷）、停机时间等
*
* @param startDate 开始日期（yyyy-MM-dd）
* @param endDate 结束日期（yyyy-MM-dd）
* @return 日汇总列表
*/
List<AcidOeeDailySummaryVo> selectDailySummary(@Param("startDate") String startDate,
@Param("endDate") String endDate);
/**
* 查询每日的钢卷号和重量（用于良品/次品判定）
*
* @param startDate 开始日期（yyyy-MM-dd）
* @param endDate 结束日期（yyyy-MM-dd）
* @return Map列表，key为日期，value为卷号和重量信息
*/
List<CoilInfoByDate> selectCoilInfoByDate(@Param("startDate") String startDate,
@Param("endDate") String endDate);
/**
* 查询卷级生产节拍（min/吨），用于理论节拍计算。
*
* @param startDate 开始日期（yyyy-MM-dd）
* @param endDate 结束日期（yyyy-MM-dd）
* @return 每卷的生产节拍列表（min/吨）
*/
List<java.math.BigDecimal> selectCoilCycleMinPerTon(@Param("startDate") String startDate,
@Param("endDate") String endDate);
/**
* 卷号信息内部类（用于Mapper返回）
*/
class CoilInfoByDate {
private String statDate;
private String coilNo;
private java.math.BigDecimal weight;
public String getStatDate() { return statDate; }
public void setStatDate(String statDate) { this.statDate = statDate; }
public String getCoilNo() { return coilNo; }
public void setCoilNo(String coilNo) { this.coilNo = coilNo; }
public java.math.BigDecimal getWeight() { return weight; }
public void setWeight(java.math.BigDecimal weight) { this.weight = weight; }
}
}

32
klp-pocket/src/main/java/com/klp/pocket/acid/mapper/AcidOeeMasterMapper.java Normal file
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@@ -0,0 +1,32 @@
package com.klp.pocket.acid.mapper;
import com.baomidou.dynamic.datasource.annotation.DS;
import com.klp.pocket.acid.domain.vo.AcidOeeCoilInfoByDateVo;
import com.klp.pocket.acid.domain.vo.AcidOeeDailySummaryVo;
import org.apache.ibatis.annotations.Mapper;
import org.apache.ibatis.annotations.Param;
import java.util.List;
/**
* 酸轧线OEE主库Mapper。
*/
@Mapper
@DS("master")
public interface AcidOeeMasterMapper {
/**
* 查询OEE日汇总（总产量来自主库 wms_material_coil）。
*/
List<AcidOeeDailySummaryVo> selectDailySummary(@Param("startDate") String startDate,
@Param("endDate") String endDate,
@Param("createBy") String createBy);
/**
* 查询每日钢卷重量与判级（来自主库 wms_material_coil）。
*/
List<AcidOeeCoilInfoByDateVo> selectCoilInfoByDate(@Param("startDate") String startDate,
@Param("endDate") String endDate,
@Param("createBy") String createBy);
}

173
klp-pocket/src/main/java/com/klp/pocket/acid/service/impl/AcidOeeServiceImpl.java
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@@ -1,25 +1,34 @@
package com.klp.pocket.acid.service.impl;
import com.baomidou.dynamic.datasource.annotation.DS;
import com.klp.common.utils.StringUtils;
import com.klp.pocket.acid.domain.vo.AcidOeeCoilInfoByDateVo;
import com.klp.pocket.acid.domain.vo.AcidOeeDailySummaryVo;
import com.klp.pocket.acid.domain.vo.AcidOeeIdealCycleVo;
import com.klp.pocket.acid.domain.vo.AcidOeeLoss7Vo;
import com.klp.pocket.acid.domain.vo.Klptcm1ProStoppageVo;
import com.klp.pocket.acid.domain.bo.Klptcm1ProStoppageBo;
import com.klp.pocket.acid.mapper.AcidOeeMapper;
import com.klp.pocket.acid.mapper.AcidOeeMasterMapper;
import com.klp.pocket.acid.service.IAcidOeeService;
import com.klp.pocket.acid.service.IKlptcm1ProStoppageService;
import com.klp.pocket.common.service.ICoilQualityJudgeService;
import lombok.RequiredArgsConstructor;
import lombok.extern.slf4j.Slf4j;
import org.springframework.beans.factory.annotation.Value;
import org.springframework.stereotype.Service;
import java.math.BigDecimal;
import java.math.RoundingMode;
import java.text.SimpleDateFormat;
import java.util.*;
import java.util.ArrayList;
import java.util.Arrays;
import java.util.Calendar;
import java.util.Collections;
import java.util.Comparator;
import java.util.Date;
import java.util.HashMap;
import java.util.HashSet;
import java.util.List;
import java.util.Map;
import java.util.Set;
/**
* 酸轧线OEE Service实现类
@@ -29,53 +38,65 @@ import java.util.Calendar;
*/
@Slf4j
@RequiredArgsConstructor
@DS("acid")
@Service
public class AcidOeeServiceImpl implements IAcidOeeService {
/** 酸轧成品库库区ID */
private static final Long ACID_FINISHED_WAREHOUSE_ID = 1988150099140866050L;
/** 固定理论节拍（min/吨） */
private static final BigDecimal FIXED_IDEAL_CYCLE = BigDecimal.valueOf(0.47);
private final AcidOeeMapper acidOeeMapper;
/** 次品判级集合：命中这些 quality_status 判为次品 */
private static final Set<String> SCRAP_QUALITY_STATUS = new HashSet<>(
Arrays.asList("C+", "C", "C-", "D+", "D", "D-")
);
private final AcidOeeMasterMapper acidOeeMasterMapper;
private final IKlptcm1ProStoppageService stoppageService;
private final ICoilQualityJudgeService coilQualityJudgeService;
@Value("${oee.acid.coil-create-by}")
private String acidCreateName;
@Override
public List<AcidOeeDailySummaryVo> getDailySummary(String startDate, String endDate) {
// 1. 查询基础日汇总（产量、停机时间等）
List<AcidOeeDailySummaryVo> summaries = acidOeeMapper.selectDailySummary(startDate, endDate);
List<AcidOeeDailySummaryVo> summaries = acidOeeMasterMapper.selectDailySummary(
startDate,
endDate,
acidCreateName
);
if (summaries == null || summaries.isEmpty()) {
return Collections.emptyList();
}
// 2. 查询停机事件，按日期聚合停机时间
Map<String, Long> downtimeByDate = aggregateDowntimeByDate(startDate, endDate);
// 3. 查询产量明细，用于良品/次品判定
Map<String, List<CoilInfo>> coilInfoByDate = getCoilNosByDate(startDate, endDate);
// 4. 理论节拍：使用固定值0.47
BigDecimal idealCycleTon = FIXED_IDEAL_CYCLE;
// 5. 填充每个日汇总的完整数据
// 4. 先按天计算 dailyCycle = runTime/totalOutputTon，再取中位数作为理论节拍
List<BigDecimal> dailyCycles = new ArrayList<>();
for (AcidOeeDailySummaryVo summary : summaries) {
String statDate = summary.getStatDate();
summary.setLineId("SY");
summary.setLineName("酸轧线");
// 填充停机时间
Long downtime = downtimeByDate.getOrDefault(statDate, 0L);
summary.setDowntimeMin(downtime);
// 计算运转时间
Long loadingTime = summary.getLoadingTimeMin() != null ? summary.getLoadingTimeMin() : 0L;
Long runTime = Math.max(0, loadingTime - downtime);
summary.setRunTimeMin(runTime);
// 理论节拍：若尚未填充，则统一使用“优良日统计”得到的节拍
if (summary.getIdealCycleTimeMinPerTon() == null && idealCycleTon != null) {
BigDecimal totalOutputTon = summary.getTotalOutputTon();
if (runTime > 0 && totalOutputTon != null && totalOutputTon.compareTo(BigDecimal.ZERO) > 0) {
BigDecimal dailyCycle = BigDecimal.valueOf(runTime)
.divide(totalOutputTon, 6, RoundingMode.HALF_UP);
dailyCycles.add(dailyCycle);
}
}
dailyCycles.sort(BigDecimal::compareTo);
BigDecimal idealCycleTon = applyEightyPercent(median(dailyCycles));
// 5. 回填理论节拍、良品次品并计算派生指标
for (AcidOeeDailySummaryVo summary : summaries) {
String statDate = summary.getStatDate();
if (idealCycleTon != null) {
summary.setIdealCycleTimeMinPerTon(idealCycleTon);
}
@@ -91,11 +112,6 @@ public class AcidOeeServiceImpl implements IAcidOeeService {
summary.setDefectOutputCoil(0L);
}
// 填充理论节拍（从回归数据或缓存获取，这里暂时留空，由调用方填充）
// summary.setIdealCycleTimeMinPerTon(...);
// summary.setIdealCycleTimeMinPerCoil(...);
// 计算派生指标
calculateDerivedMetrics(summary);
}
@@ -127,7 +143,11 @@ public class AcidOeeServiceImpl implements IAcidOeeService {
@Override
public AcidOeeIdealCycleVo getIdealCycle(String startDate, String endDate) {
// 1) 取基础日汇总（产量、负荷时间等）
List<AcidOeeDailySummaryVo> daily = acidOeeMapper.selectDailySummary(startDate, endDate);
List<AcidOeeDailySummaryVo> daily = acidOeeMasterMapper.selectDailySummary(
startDate,
endDate,
acidCreateName
);
AcidOeeIdealCycleVo rsp = new AcidOeeIdealCycleVo();
rsp.setLineId("SY");
rsp.setLineName("酸轧线");
@@ -151,23 +171,31 @@ public class AcidOeeServiceImpl implements IAcidOeeService {
d.setRunTimeMin(Math.max(0, loading - downtime));
}
// 3) 卷级节拍 = (END_DATE - START_DATE)/出口重量，计算中位数（用于展示，不用于OEE计算）
List<BigDecimal> coilCycles = acidOeeMapper.selectCoilCycleMinPerTon(startDate, endDate);
coilCycles.removeIf(c -> c == null || c.compareTo(BigDecimal.ZERO) <= 0);
coilCycles.sort(BigDecimal::compareTo);
BigDecimal medianCycle = median(coilCycles);
// 理论节拍使用固定值0.47（用于OEE计算）
rsp.setIdealCycleTimeMinPerTon(FIXED_IDEAL_CYCLE);
// 中位数理论节拍（用于展示）
// 3) 理论节拍按“天维度”：每天(运转时间/总吨)，再按日样本统计中位数用于展示
List<BigDecimal> dailyCycles = new ArrayList<>();
for (AcidOeeDailySummaryVo d : daily) {
Long run = d.getRunTimeMin();
BigDecimal ton = d.getTotalOutputTon();
if (run == null || run <= 0 || ton == null || ton.compareTo(BigDecimal.ZERO) <= 0) {
continue;
}
dailyCycles.add(BigDecimal.valueOf(run).divide(ton, 6, RoundingMode.HALF_UP));
}
dailyCycles.sort(BigDecimal::compareTo);
BigDecimal medianCycle = median(dailyCycles);
// 理论节拍：按“当天运转时间/当天总吨”逐日计算，接口返回前乘以80%
BigDecimal idealCycle = applyEightyPercent(medianCycle);
rsp.setIdealCycleTimeMinPerTon(idealCycle);
// 展示字段保持为中位数
rsp.setMedianCycleTimeMinPerTon(medianCycle);
// 样本天数：当前查询区间内有产量的自然日数量（与传入的日期范围一一对应）
rsp.setSampleDays(daily.size());
// 4) 日粒度对比数据：理论耗时 vs 实际运转时间（用于前端展示"有效性"）
// 使用固定值0.47计算理论耗时
// 使用“中间50%样本平均理论节拍”计算理论耗时
List<AcidOeeIdealCycleVo.DailyComparePointVo> compare = new ArrayList<>();
if (FIXED_IDEAL_CYCLE != null) {
if (idealCycle != null) {
for (AcidOeeDailySummaryVo d : daily) {
BigDecimal ton = d.getTotalOutputTon();
Long run = d.getRunTimeMin();
@@ -175,7 +203,7 @@ public class AcidOeeServiceImpl implements IAcidOeeService {
AcidOeeIdealCycleVo.DailyComparePointVo p = new AcidOeeIdealCycleVo.DailyComparePointVo();
p.setStatDate(d.getStatDate());
p.setActualRunTimeMin(run);
p.setTheoreticalTimeMin(FIXED_IDEAL_CYCLE.multiply(ton));
p.setTheoreticalTimeMin(idealCycle.multiply(ton));
compare.add(p);
}
}
@@ -270,25 +298,25 @@ public class AcidOeeServiceImpl implements IAcidOeeService {
SimpleDateFormat dateFormat = new SimpleDateFormat("yyyy-MM-dd");
Calendar cal = Calendar.getInstance();
for (Klptcm1ProStoppageVo event : events) {
if (event.getStartDate() == null || event.getDuration() == null || event.getDuration() <= 0) {
continue;
}
Date eventStart = event.getStartDate();
long durationSec = event.getDuration();
long durationMin = (durationSec + 59) / 60; // 向上取整，避免丢失秒数
// 计算停机结束时间
cal.setTime(eventStart);
cal.add(Calendar.SECOND, (int) durationSec);
Date eventEnd = cal.getTime();
// 如果停机事件在同一天，直接累加
String startDateStr = dateFormat.format(eventStart);
String endDateStr = dateFormat.format(eventEnd);
if (startDateStr.equals(endDateStr)) {
// 同一天，直接累加
downtimeMap.merge(startDateStr, durationMin, Long::sum);
@@ -300,23 +328,23 @@ public class AcidOeeServiceImpl implements IAcidOeeService {
cal.set(Calendar.SECOND, 0);
cal.set(Calendar.MILLISECOND, 0);
Date dayStart = cal.getTime();
Date currentDayStart = dayStart;
while (currentDayStart.before(eventEnd)) {
cal.setTime(currentDayStart);
cal.add(Calendar.DAY_OF_MONTH, 1);
Date nextDayStart = cal.getTime();
// 计算当前天的停机分钟数
Date dayEnd = nextDayStart.before(eventEnd) ? nextDayStart : eventEnd;
long dayMinutes = Math.max(0, (dayEnd.getTime() - Math.max(currentDayStart.getTime(), eventStart.getTime())) / (1000 * 60));
if (dayMinutes > 0) {
String dateKey = dateFormat.format(currentDayStart);
downtimeMap.merge(dateKey, dayMinutes, Long::sum);
}
currentDayStart = nextDayStart;
}
}
@@ -329,13 +357,18 @@ public class AcidOeeServiceImpl implements IAcidOeeService {
* 获取每日的钢卷号和重量（用于良品/次品判定）
*/
private Map<String, List<CoilInfo>> getCoilNosByDate(String startDate, String endDate) {
List<AcidOeeMapper.CoilInfoByDate> coilInfoList = acidOeeMapper.selectCoilInfoByDate(startDate, endDate);
List<AcidOeeCoilInfoByDateVo> coilInfoList = acidOeeMasterMapper.selectCoilInfoByDate(
startDate,
endDate,
acidCreateName
);
Map<String, List<CoilInfo>> result = new HashMap<>();
for (AcidOeeMapper.CoilInfoByDate info : coilInfoList) {
for (AcidOeeCoilInfoByDateVo info : coilInfoList) {
String date = info.getStatDate();
result.computeIfAbsent(date, k -> new ArrayList<>())
.add(new CoilInfo(info.getCoilNo(), info.getWeight()));
.add(new CoilInfo(info.getCoilNo(), info.getWeight(), info.getQualityStatus()));
}
return result;
@@ -347,10 +380,12 @@ public class AcidOeeServiceImpl implements IAcidOeeService {
private static class CoilInfo {
final String coilNo;
final BigDecimal weight;
final String qualityStatus;
CoilInfo(String coilNo, BigDecimal weight) {
CoilInfo(String coilNo, BigDecimal weight, String qualityStatus) {
this.coilNo = coilNo;
this.weight = weight;
this.qualityStatus = qualityStatus;
}
}
@@ -362,19 +397,18 @@ public class AcidOeeServiceImpl implements IAcidOeeService {
long goodCoil = 0L;
BigDecimal defectTon = BigDecimal.ZERO;
long defectCoil = 0L;
for (CoilInfo coilInfo : coilInfos) {
String coilNo = coilInfo.coilNo;
BigDecimal coilWeight = coilInfo.weight != null ? coilInfo.weight : BigDecimal.ZERO;
String qualityStatus = StringUtils.trim(coilInfo.qualityStatus);
// 通过WMS判定良品/次品
Boolean isScrap = coilQualityJudgeService.isScrap(ACID_FINISHED_WAREHOUSE_ID, coilNo);
if (isScrap == null) {
// 匹配不到，忽略不计
// 没有判级时按良品处理（避免再次跨库匹配导致错配）
if (StringUtils.isBlank(qualityStatus)) {
goodTon = goodTon.add(coilWeight);
goodCoil++;
continue;
}
if (Boolean.TRUE.equals(isScrap)) {
if (SCRAP_QUALITY_STATUS.contains(qualityStatus)) {
// 次品
defectTon = defectTon.add(coilWeight);
defectCoil++;
@@ -406,6 +440,7 @@ public class AcidOeeServiceImpl implements IAcidOeeService {
}
// 性能稼动率（吨维度）
// 口径：理论节拍单位为 min/吨 时，性能稼动率 = (理论节拍 × 实际产量) / 实际运转时间 × 100
Long runTime = summary.getRunTimeMin() != null ? summary.getRunTimeMin() : 0L;
BigDecimal idealCycleTon = summary.getIdealCycleTimeMinPerTon();
BigDecimal totalOutputTon = summary.getTotalOutputTon();
@@ -415,12 +450,14 @@ public class AcidOeeServiceImpl implements IAcidOeeService {
&& totalOutputTon != null
&& totalOutputTon.compareTo(BigDecimal.ZERO) > 0) {
BigDecimal idealTime = idealCycleTon.multiply(totalOutputTon);
BigDecimal performanceTon = idealTime.divide(BigDecimal.valueOf(runTime), 4, RoundingMode.HALF_UP)
BigDecimal performanceTon = idealTime
.divide(BigDecimal.valueOf(runTime), 4, RoundingMode.HALF_UP)
.multiply(BigDecimal.valueOf(100));
summary.setPerformanceTon(performanceTon);
}
// 性能稼动率（卷维度）
// 口径：理论节拍单位为 min/卷 时，性能稼动率 = (理论节拍 × 实际产量) / 实际运转时间 × 100
Long totalOutputCoil = summary.getTotalOutputCoil() != null ? summary.getTotalOutputCoil() : 0L;
BigDecimal idealCycleCoil = summary.getIdealCycleTimeMinPerCoil();
if (runTime > 0
@@ -428,7 +465,8 @@ public class AcidOeeServiceImpl implements IAcidOeeService {
&& idealCycleCoil.compareTo(BigDecimal.ZERO) > 0
&& totalOutputCoil > 0) {
BigDecimal idealTime = idealCycleCoil.multiply(BigDecimal.valueOf(totalOutputCoil));
BigDecimal performanceCoil = idealTime.divide(BigDecimal.valueOf(runTime), 4, RoundingMode.HALF_UP)
BigDecimal performanceCoil = idealTime
.divide(BigDecimal.valueOf(runTime), 4, RoundingMode.HALF_UP)
.multiply(BigDecimal.valueOf(100));
summary.setPerformanceCoil(performanceCoil);
}
@@ -463,6 +501,15 @@ public class AcidOeeServiceImpl implements IAcidOeeService {
return a.add(b).divide(BigDecimal.valueOf(2), 6, RoundingMode.HALF_UP);
}
/** 理论节拍返回前按业务口径乘以70% */
private BigDecimal applyEightyPercent(BigDecimal cycle) {
if (cycle == null) {
return null;
}
return cycle.multiply(BigDecimal.valueOf(0.7)).setScale(6, RoundingMode.HALF_UP);
}
/**
* 解析日期字符串为Date对象
*/