JP2005258788A - Production plan preparation method and production plan preparation apparatus, and program - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To optimize the production amount of each kind even when a plurality of process design are present in manufacturing the variety of products in a production process comprising many processes. <P>SOLUTION: The production amount on a process design basis is decided by solving an optimization problem by using a linear programming method in an optimum kind constitution calculation section 30; while referring a facility load basic unit for each facility on each process design calculated by a facility load basic unit calculation section 10 based on manufacturing route information stored on a manufacturing route information storage section 11; a generated cost basic unit on the process design basis calculated by a generated cost basic unit calculation section 20 based on a generated variable cost stored on a generated cost information storage section 21; and production amount information, raw material/selling price information, facility information, an evaluation index previously registered on a production amount information storage section 2, a raw material/selling price information storage section 3, a facility information storage section 4 and an evaluation index storage section 5, respectively. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

  The present invention relates to a production plan creation method, a production plan creation device, and a program for optimizing the production amount of each kind when producing a plurality of kinds of products in a multi-step production process such as a factory.

  2. Description of the Related Art Conventionally, in a production process composed of multiple steps represented by a material processing system production process such as steel, aluminum and copper, products of a plurality of types are often produced. And in order to increase profits as a company while adapting to the diversified customer needs in recent years, in addition to the cost reduction by the conventional operation improvement, the product composition (product mix) to be produced, that is, the production of each product By optimizing the amount, it is necessary to make effective use of limited production resources (equipment, etc.) and maximize profits. Moreover, in a multi-process / multi-product type production process, the range of production required for each product type (minimum production amount as the lower limit amount / maximum production amount as the upper limit amount), equipment capacity of each facility, production route ( It is required to determine an optimal variety configuration while considering conditions such as the degree of freedom of the passage process route).

As a technique for obtaining a product type configuration that maximizes profit within the range of the equipment capacity of each equipment, for example, there are techniques shown in Non-Patent Document 1 and Patent Document 1.
In the technique shown in Non-Patent Document 1, the production variable of each product type is used, the equipment load is expressed by an inequality constraint, and a product configuration that maximizes profit is obtained using linear programming.

In the technique shown in Patent Document 1, focusing on the bottleneck process in the production line, when the first half manufacturing process and the second half manufacturing process are each composed of a plurality of parallel production lines, the first half and the second half production line In this technology, how many (how many tons) of varieties are produced is determined so as to maximize the profit of the entire process. Moreover, the technique shown in Patent Document 1 has the following characteristics. As a result, the passage process route used in each product type and the production amount for each passage step route can be determined so that the sum of profits is maximized. it can.
・ Calculate the bottleneck process of each production line in advance, and profit based on the profit rate in this bottleneck process (value obtained by dividing the profit per product by the processing time in the bottleneck process) The production varieties and production quantities in each production line are determined so as to maximize the sum of the production lines.
・ By applying the above method in each of the first and second half of the manufacturing process, create an operation plan for the production line that maximizes the total profit for the entire process (how much can be produced in which process for each product type) To do.
・ Optimization can be performed even when the capacity of each production line is different.
-Optimal calculation can be obtained at high speed by using linear programming.

Katsuhito Hitomi “Production System Engineering” Kyoritsu Shuppan, October 20, 1990 (second edition), p. 114-115 JP 2003-36296 A

Here, in the above-described technique of Non-Patent Document 1, it is necessary to specify in advance the equipment to be used for each product type.
However, in the actual production process, there are cases where there are multiple equipment (alternative equipment) and equipment groups (alternative process routes) that can be used even with the same product type, that is, multiple ways of making (process design) may be considered. Many. For example, the following cases can be considered.
・ When there are multiple cold rolling mills in the rolling line for iron, aluminum, copper, etc., and any rolling mill can be rolled, and the number of passes (rolling count) varies depending on which rolling mill is used. ・ Batch incineration in continuous incinerators Can be used in a furnace, and the processing time varies greatly depending on the furnace used (batch incinerator is longer) ・ Can be processed even with internal work, but can also be outsourced depending on the load. However, there is a problem that the technique described in Non-Patent Document 1 cannot be applied.

The technique of Patent Document 1 is based on the premise that the bottleneck process of each production line to be selected can be specified in advance, and that the bottleneck process is the same regardless of the type of product produced.
However, in actual production processes (especially material processing processes such as iron and aluminum), the type of equipment used and the processing time at the equipment differ depending on the kind and passing process route. The process may change, or a plurality of bottleneck processes may appear in one passage process route.
Therefore, the bottleneck process cannot be specified in advance if the type of equipment used and the processing time at the equipment differ depending on the product type and passing process route, as in the actual production process such as a raw material process. There is a problem that the technique of Patent Document 1 cannot be applied.

  The present invention has been made in view of the above problems, and in the case of producing a product of a plurality of types in a multi-step production process, there are a plurality of steps for producing a product of one type. Or a production plan creation method, a production plan creation device, and a program capable of optimizing the production amount of each product type even when there are a plurality of process designs, such as when there are alternative facilities. is there.

Means and effects for solving the problems

  In order to solve the above problems, a production plan creation method according to the present invention is a production plan creation method for optimizing the production amount of products of a plurality of varieties produced in a plurality of processes. Registering a manufacturing route that assigns processable equipment for a plurality of processes for manufacturing as a process design, registering equipment capacity for each equipment, and processing for each process for each process design Registering the processing capacity that can be performed, and calculating the amount of production for each process design in which the total load obtained for each facility determined by the processing capacity does not exceed the facility capacity and the preset evaluation index is maximized And a step of performing.

  The program according to the present invention is a program for optimizing the production amount of products of a plurality of types produced in a plurality of steps on a computer, and a plurality of steps for manufacturing a product for each of the types A step of registering a manufacturing route to which a processable facility is assigned as a process design, a step of registering a facility capacity for each facility, a step of registering a process capacity of each process for each process design, and a determination by the processing capacity The total load for each facility does not exceed the facility capacity, and the step of calculating a production amount for each process design that maximizes a preset evaluation index is for causing a computer to execute. To do.

  A production plan creation device according to the present invention is a production plan creation device that optimizes the production amount of a plurality of types of products produced in a plurality of steps, and a plurality of steps for manufacturing a product for each of the types. Means for registering a manufacturing route to which processable equipment is assigned as a process design; means for registering equipment capacity for each equipment; means for registering processing capacity of each process for each process design; Means for calculating a production amount for each process design in which a total evaluation load determined for each facility does not exceed the facility capacity and a preset evaluation index is maximized.

According to this, the amount of production for each process design that is assigned as a manufacturing route by assigning equipment that can be processed for multiple processes for manufacturing products exceeds the total equipment load calculated from the processing capacity. In a non-existing range (within the range of facility capacity of each facility), the predetermined evaluation index is determined to be maximum. Therefore, each process that maximizes the preset evaluation index is possible even when multiple process designs are considered, such as when there are multiple processes for producing a product of one type or when there are alternative facilities. The production volume of the design is determined.
Here, the “equipment capacity” of each equipment means the operating capacity of each equipment, for example, the time that can be spent on net processing (actual work rate, etc.) when the equipment is fully operated. Means. “Processing capacity” that can be processed in each process is an ability to process a product or an intermediate product in each process. For example, a product or an intermediate product that can be processed per predetermined time in each process. It means weight. The “total load for each facility” obtained from the processing capacity is the total load for actual processing in each facility. For example, the processing time required to produce a unit quantity of product in each facility It is calculated based on the processing capacity.

  Here, the production plan creation method according to the present invention further includes a step of registering a minimum production amount and a maximum production amount as a range of the required production amount for each of the types, and the production amount further includes Preferably, it is determined within the range of the minimum production amount and the maximum production amount in each of the varieties.

  Similarly, the program according to the present invention further causes the computer to execute a step of registering a minimum production amount and a maximum production amount as a required production amount range for each of the varieties. Preferably, it is determined within the range of the minimum production amount and the maximum production amount in each of the varieties.

  Similarly, the production plan creation device according to the present invention further comprises means for registering a minimum production amount and a maximum production amount as a range of required production amounts for each of the types, and the production amount further includes Preferably, it is determined within the range of the minimum production amount and the maximum production amount in each of the varieties.

  According to this, the production amount of each process design is determined within the range of the minimum production amount and the maximum production amount. Therefore, by setting the minimum production amount as the lower limit amount, it is possible to optimize other product configurations after producing the products to be produced strategically. In addition, by setting the maximum production amount as the upper limit amount, it is possible to optimize other product configurations without producing an amount that cannot be sold or stored. Furthermore, by setting the minimum production amount and the maximum production amount (the upper limit amount and the lower limit amount) to the same value, it is possible to optimize other product configurations after producing products that must be produced in a certain amount. .

  Here, the production plan creation method according to the present invention is a step of creating and registering a production route to which an alternative facility is assigned as a process design based on a preset rule for the alternative facility when the alternative facility exists. Are preferably further provided.

  Similarly, the program according to the present invention further includes a step of creating and registering a manufacturing route to which an alternative facility is assigned as a process design based on a preset rule of the alternative facility when the alternative facility exists. It is preferable to have a computer execute it.

  Similarly, the production plan creation device according to the present invention is a means for creating and registering a manufacturing route to which an alternative facility is assigned as a process design based on a preset rule for the alternative facility when the alternative facility exists. Are preferably further provided.

  According to this, one or more manufacturing routes to which alternative equipment is assigned as a new process design for one manufacturing route stored in advance as a process design based on rules regarding alternative equipment (rules for alternative equipment). Created. Therefore, by optimizing the production amount for each process design including the newly created process design, it is possible to optimize the product configuration including distribution to alternative equipment.

  Here, it is preferable that the production plan creation method, the production plan creation device, and the program according to the present invention calculate the evaluation index by a linear programming method.

  According to this, when the production volume for each process design and the load of each facility necessary for the production by the process design can be handled in a linear format, linear programming can be applied to the calculation of the evaluation index. Therefore, even when the number of varieties and facilities is large, the production amount for each process design can be optimized at high speed.

  The production plan creation method according to the present invention further includes a step of registering a selling price for each of the types, and a step of registering variable costs and raw material costs generated in each process for each of the process designs. The evaluation index may be set as the sum of (selling price−raw material cost−variable cost).

  Similarly, the program according to the present invention further causes the computer to execute a step of registering a selling price for each product type, a step of registering a variable cost and a raw material cost generated in each process for each process design, The evaluation index may be set as the sum of (sales price-raw material cost-variable cost).

  Similarly, the production plan creation device according to the present invention further includes means for registering a selling price for each product type, and means for registering variable costs and raw material costs generated in each process for each process design. The evaluation index may be set as the sum of (selling price−raw material cost−variable cost).

According to this, the production amount of each process design is determined so that the sum of evaluation indices (sell price-raw material cost-variable cost) is maximized. Therefore, even when the same variety is produced, there are a plurality of production routes, and even when the variable costs and raw material costs are different, the overall profit can be maximized.
Here, the “variable cost” generated in each process means, for example, a cost required for processing in each process.

  The production plan creation method according to the present invention further includes a step of registering a selling price for each of the types, and a step of registering variable costs and raw material costs generated in each process for each of the process designs. The evaluation index may be set as a weighted sum of the sum of (sales price−raw material cost−variable cost) and the sum of the production amounts of all varieties.

  Similarly, the program according to the present invention further causes the computer to execute a step of registering a selling price for each product type, a step of registering a variable cost and a raw material cost generated in each process for each process design, The evaluation index may be set as a weighted sum of the sum of (selling price−raw material cost−variable cost) and the sum of the production amounts of all varieties.

  Similarly, the production plan creation device according to the present invention further includes means for registering a selling price for each product type, and means for registering variable costs and raw material costs generated in each process for each process design. The evaluation index may be set as a weighted sum of the sum of (sales price-raw material cost-variable cost) and the sum of the production amounts of all varieties.

  According to this, the production amount of each process design is determined so that the weighted sum of the sum of the evaluation indices (selling price—raw material cost—variable cost) and the sum of the production amounts of all the varieties is maximized. Therefore, it is possible to adjust the balance between profit and production amount with a weighted parameter, and it is possible to determine a variety configuration that increases or decreases the production amount while ensuring profit.

  In such a case, the production plan creation method according to the present invention calculates, based on the processing capability, the load of each facility for each process design when the product is produced in a unit quantity as the facility load basic unit. And a step of calculating the generated cost for each process design required when producing a unit quantity of the product based on the variable cost as a generated cost basic unit, and the calculation of the evaluation index includes It is preferable to carry out by linear programming using the equipment load unit and the generated cost unit.

  Similarly, in such a case, the program according to the present invention calculates, based on the processing capability, the load of each facility for each process design when a product is produced in a unit quantity as a facility load unit, Based on the variable cost, the computer further executes a step of calculating the generated cost for each process design required when producing a unit quantity as a generated cost unit, and the calculation of the evaluation index is performed by the facility It is preferable to carry out by linear programming using the load unit and the generated cost unit.

  Similarly, in such a case, the production plan creation method according to the present invention calculates, based on the processing capacity, the load of each facility for each process design when a product is produced in a unit quantity as an equipment load unit. And a means for calculating the generated cost for each process design required when producing a unit quantity of the product based on the variable cost as a generated cost basic unit, and the calculation of the evaluation index is as follows: It is preferable to carry out by linear programming using the equipment load basic unit and the generated cost basic unit.

  According to this, for all facilities in the production line, based on the information regarding the processing capacity in each process, it means the facility load basic unit for each process design (for example, the time required to produce 1 ton of product). ) Is calculated. Thus, assuming that Rim is an equipment load basic unit for the equipment m of the process design number i, the load on the equipment m when xi tons are produced at the process design number i can be expressed as Rim × xi. And the total load ym of the equipment m can be expressed in the following linear form.

Therefore, even when the number and order of the equipment used differs depending on the process design, or when the same equipment is used in the process design, restrictions on the equipment capacity of each equipment are expressed in a linear format based on the processing capacity in each process. And linear programming can be applied to determine the optimal variety composition.
Also, variable cost information, which is information for each process in the process design, is aggregated as a generated cost basic unit per unit production amount for each process design. Therefore, the number of variables in the linear programming method can be reduced, and the calculation speed can be increased.

  Then, the production plan creation method, the production plan creation device, and the program according to the present invention may set the evaluation index as the sum of the production amounts of all the varieties.

  According to this, the production amount of each process design is determined so that the total sum of the production amounts of all the varieties as the evaluation index is maximized. Accordingly, it is possible to determine a variety configuration that places importance on the total production volume, as in the case of giving priority to share.

  The production plan creation method according to the present invention may further include a step of registering a selling price for each of the types, and the evaluation index may be set as a sum of selling prices of all types.

  Similarly, the program according to the present invention may further cause the computer to execute a step of registering a selling price for each product, and set the evaluation index as a sum of selling prices of all products.

  Similarly, the production plan creation device according to the present invention may further include means for registering a selling price for each of the types, and the evaluation index may be set as a sum of selling prices of all types.

  According to this, the production amount of each process design is determined so that the sum of the selling prices of all the varieties as the evaluation index is maximized. Therefore, it is possible to determine a variety composition that places more importance on the total deposit than profit.

  In such a case, the production plan creation method according to the present invention calculates the load of each facility for each process design when producing a unit quantity of a product based on the processing capacity as a facility load basic unit. It is preferable that the evaluation index is calculated by linear programming using the equipment load basic unit.

  Similarly, in such a case, the program according to the present invention further includes a step of calculating, as an equipment load basic unit, a load of each equipment for each process design when a product is produced in a unit quantity based on the processing capacity. It is preferable that the computer is executed and the calculation of the evaluation index is performed by linear programming using the equipment load basic unit.

  Similarly, in such a case, the production plan creation device according to the present invention calculates, based on the processing capacity, the load of each facility for each process design when a product is produced in a unit quantity as a facility load basic unit. It is preferable that the evaluation index is calculated by linear programming using the equipment load basic unit.

  Therefore, even when the number and order of the equipment used differs depending on the process design, or when the same equipment is used in the process design, restrictions on the equipment capacity of each equipment are expressed in a linear format based on the processing capacity in each process. And linear programming can be applied to determine the optimal variety composition.

  The program according to the present invention is a removable recording medium such as a CD-ROM (Compact Disc Read Only Memory), FD (Floppy (registered trademark) Disk), or MO (Magneto-Optic), or a fixed recording medium such as a hard disk. In addition to being able to be recorded and distributed, it can be distributed via a communication network such as the Internet by wired or wireless telecommunication means.

  The best mode for carrying out the production plan creation method, production plan creation apparatus, and program according to the present invention will be described below with reference to a specific example with reference to the drawings.

First, an example of the production line targeted in this embodiment will be described with reference to FIG. FIG. 2 is a diagram illustrating a production line.
As shown in FIG. 2, the production line from the raw material 100 to the product 160 includes melting (melting 01 and melting 02) 110, hot rolling 120, cold rolling (cold rolling 01, cold rolling 02 and cold rolling 03) 130. , Sinter (sintered 01 and sinter 02) 140 and slitter (slitter 01, slitter 02 and slitter 03) 150, except for hot rolling 120, is composed of a plurality of facilities having different capacities. Here, it is assumed that the equipment used and the order differ depending on the type (product type) of the product, and the arrows in the figure indicate the manufacturing routes (the individual routes will be described later based on Table 3).

  Moreover, the “actual work rate” shown in Table 1 is defined as the equipment capacity of each equipment. Here, the actual work rate is a ratio of time that can be spent on net processing when the equipment is operated to the maximum, and is set statistically from the operation results of the equipment. For example, if the actual working rate is 80%, it means that 19.2 hours can be spent on net processing in the day, and the remaining time is consumed for work preparation and maintenance.

Next, Table 2 shows a product type table used in the present embodiment.
As shown in Table 2, there are five types of “types” from A to E, and there are two to three types of production routes as “process design” of each type. For example, in the type C, there are three types of process designs with process design numbers 5 to 7.
In addition, as shown in Table 2, each product type has a production amount required within an assumed period (in this embodiment, one month is assumed), that is, a lower limit amount to be produced within the period (“ Minimum production amount)) and an upper limit amount ("maximum production amount") that cannot be sold or stored even if it is produced. Therefore, it is necessary to perform production within the range of the upper limit amount and the lower limit amount (minimum production amount and maximum production amount) using any given process design.
Furthermore, as shown in Table 2, “raw material cost” and “selling price” per ton are given. In the present embodiment, the raw material cost can be set to a different value for each process design.

Next, Table 3 shows a passing process table of each process design used in the present embodiment. Here, in the passing process table, the manufacturing route in each “process design” for each “product type” is shown, and the intermediate product is manufactured through the processes in the order of “process serial number” shown in Table 3. Finally, products of each variety are manufactured. In each step, as shown in Table 3, “facility” that can be processed is assigned.
As shown in Table 3, the weight of a product or an intermediate product that can be processed per hour in each process is defined as “load” (processing capacity) in each process. For example, the type A of the process design number 1 can be processed by 30.0 tons per hour in the cold rolling 01 which is the equipment of the process number 3.
In addition, the cost incurred for processing 1 ton in each process is defined as “variable cost”. For example, in order to process 1 ton of product type A with process design number 1, a variable cost of 3,000 yen is required for cold rolling 01, which is the equipment of process serial number 3.
In addition, the weight cost on the exit and entry sides of the equipment is defined as “process yield”. For example, in cold rolling 01, which is a process number 3 facility, 100 tons are required to complete 98 tons of product type A with process design number 1. Two tons are discarded as defective parts at the front and rear ends.

Next, the production plan creation apparatus according to the present embodiment will be described with reference to FIG. FIG. 1 is a block diagram of a production plan creation apparatus according to the present embodiment.
As shown in FIG. 1, a production plan creation device 1 includes a production amount information storage unit 2, a raw material / sale price information storage unit 3, an equipment information storage unit 4, an evaluation index setting unit 5, and an equipment load intensity unit calculation. Unit 10, manufacturing route storage unit 11, generated cost unit calculation unit 20, generated cost information storage unit 21, optimum product configuration calculation unit 30, and result output unit 40.

  The production amount information storage unit 2 is for storing information on process design numbers, minimum production amounts, and maximum production amounts that can be used for each type. In the present embodiment, this corresponds to the columns of “process design number”, “minimum production amount”, and “maximum production amount” in the type table of Table 2 described above.

  The raw material / selling price information storage unit 3 is for storing information on the raw material cost and selling price for each product type. In the present embodiment, this corresponds to the columns of “raw material cost” and “selling price” in the type table of Table 2 described above. In the present embodiment, the raw material cost is set for each process design, and the raw material cost differs between the product type D and the product type E depending on the process design.

  The facility information storage unit 4 is for storing information related to the facility capability of each facility. In the present embodiment, this corresponds to the “actual work rate” column in the product type table of Table 1 described above.

  The evaluation index setting unit 5 is for setting an evaluation index serving as a reference for optimizing the production amount of each product type. In this embodiment, either the total profit, which is the sum of (sales price-raw material cost-variable cost), or the total production, which is the sum of the production amounts of all varieties, is used as the evaluation index.

The manufacturing route storage unit 11 is for storing the equipment used and the order of use for each process design, and the processing capability of each process for each process design.
In the present embodiment, it corresponds to the column of “equipment” and “load” in “process serial number” in the passing process table of Table 3 described above.

  The equipment load basic unit calculation unit 10 is based on the processing capacity of each process stored in the manufacturing route storage unit 11, and the equipment load basic unit for each equipment for each process design (process design required to make one ton of product). It means the processing time in each facility.) The calculation method of the equipment load basic unit with respect to each equipment for every process design in this Embodiment is demonstrated below using Table 4-Table 6. FIG.

In the present embodiment, first, in each process design number, in order from the process having the largest process serial number (final process), equipment in each process when producing 1 ton of products based on “process yield” Calculate the outgoing weight (defined as “reference weight”). In the first step, the weight of the necessary raw material (defined as “necessary raw material”) is calculated. The calculation results are shown in Table 4 below.
As shown in Table 4, for example, in the cold rolling 02 that is the equipment of the process number 5 of the process design number 1, the reference weight is obtained by using the process yield in the slitter 03 that is the equipment of the process number 6. 1 [ton] /0.9=1.111 [ton]. Further, in the slitter 01 that is the equipment of the process serial number 4, the reference weight is 1.111 [tons] /0.98 using the process yield and load of the cold rolling 02 that is the equipment of the process serial number 5. = 1.134 [tons]. Similarly, the reference weight is calculated up to the process number 1 (step 1). Then, using the reference weight and the process yield of the process number 1 (first process), the necessary raw material for producing 1 ton of product is calculated. For example, in the process design number 1, the required raw material is 1.429 [tons] /0.99=1.443 [tons].

Next, based on the “reference weight” and “load” in each process, the processing time (defined as “reference time”) in each process when producing 1 ton of product is calculated. The calculation results are shown in Table 5 below.
As shown in Table 5, for example, in the cold rolling 01 which is the equipment of the process number 3 of the process design number 1, the reference time is 1.288 [tons] /30.0 [tons / hr] = 0.043. [hr].

Next, for each process design number, the calculated reference time is aggregated into equipment units, and the “equipment load intensity” of each equipment for each process design is calculated. The calculation results are shown in Table 6 below.
As shown in Table 6, for example, in the process design number 3, in the process serial numbers 3 and 4, the equipment of the cold rolling 01 is passed twice, so the equipment load basic unit in the cold rolling 01 is 0.057 + 0. 037 = 0.094 [hr]. In Table 6, when the equipment load basic unit is blank (blank), it means that the equipment load basic unit for the equipment is zero.

  The generated cost information storage unit 21 is for storing a cost generated for processing 1 ton in each process, that is, a variable cost. In the present embodiment, this corresponds to the “variable cost” column in the passage process table of Table 3 described above.

  Based on the variable cost stored in the generated cost information storage unit 11, the generated cost basic unit calculation unit 20 generates the generated cost basic unit for each process design (the cost for each process design generated to make one ton of product). Means). The calculation method of the generated cost basic unit for each process design in the present embodiment will be described below using Table 7 and Table 8.

In the present embodiment, first, one ton of product is produced based on the “variable cost” stored in the generated cost information storage unit 21 and the “reference weight” calculated by the equipment load basic unit calculation unit 10. The cost (defined as “reference cost”) generated in each process is calculated. Here, the weight on the entry side of each facility is used as the reference weight. Table 7 shows the calculation results.
As shown in Table 7, for example, in the process design number 2, in the hot rolling which is the equipment of the process serial number 2, the variable cost of the hot rolling and the reference weight of the hot rolling (the hot rolling which is the equipment of the process serial number 2 The standard cost is 3.5 [thousand yen / ton] × 1.400 [ton] = 4.901 based on the weight on the inlet side, that is, the weight on the outlet side of melting 02 that is the equipment of the process number 1. [Thousand yen].

  Next, the calculated reference costs for each process are tabulated for each process design number, and the generated cost basic unit for each process design is calculated. Table 8 shows the calculation results.

  The optimum product configuration calculation unit 30 generates the generated cost basic unit for each process design calculated by the generated cost basic unit calculation unit 20 and the equipment load basic unit for each facility for each process design calculated by the equipment load basic unit calculation unit 10. Production amount information stored in the production amount information storage unit 2, raw material / sale price information stored in the raw material / sale price information storage unit 3, facility information stored in the facility information storage unit 4, and setting in the evaluation index setting unit 5 Determine the production volume for each process design that maximizes the evaluation formula while taking into account the constraints on equipment capacity and the limits on the range of production volume (minimum production volume and maximum production volume). To do.

  In the present embodiment, the amount of production for each process design is determined by solving the optimization problem of the following equation 2 using linear programming. In the present embodiment, as described above, one month (30 days × 24 hours = 720 hours) is assumed as the period.

  The formula shown in the above formula 2 is an evaluation formula when the evaluation index is profit, but when the evaluation index is a production amount, the formula shown in the following formula 3 may be used as the evaluation formula.

The result output unit 40 is an output device (display, hard disk, printer, or the like) for displaying the calculation result of the optimum product configuration calculation unit 30 via an output interface (not shown). As the calculation result, the optimized product configuration, the profit for the optimized product configuration, the load status of the equipment, and the like are output.
The output interface is a program or hardware that performs data conversion and communication for outputting the calculation result in the optimum product configuration calculation unit 30 to the result output unit 40 (display, hard disk, printer, or the like).

  Table 9 below shows the optimized product configuration output in the result output unit 40 in the present embodiment. For optimization, two types of evaluation indicators were used: maximum profit and maximum production.

Table 9 shows the following.
・ Production volume of each product is within the range of minimum and maximum production shown in Table 2.
・ The ratio of the process design used for each product type (production ratio) can be obtained.
・ Depending on the evaluation index, the composition of the product and the ratio of the process design used differ.

Next, Table 10 below shows the profits and production amounts for the optimized variety configuration output in the result output unit 40. Table 10 shows the results for both the case where the evaluation index is the maximum profit and the case where the production is the maximum.
Here, the profit is the sum of (selling price−raw material cost−variable cost), and the total production is the sum of the production of all varieties.

  From Table 10, when the profit is maximized, the profit is increased by about 5.1% from the case where the production volume is maximized, and when the production volume is maximized, the profit is maximized by about 4. 7% increase in production.

Furthermore, the load status of the equipment for the optimized product configuration output in the result output unit 40 is shown in Table 11 below. Table 11 shows the results for both the case where the evaluation index is the maximum profit and the case where the production is the maximum.
Here, the load status of the equipment means the equipment load capacity for each equipment (in this embodiment, 720 hours × actual operation rate for each equipment) (in this embodiment, the equipment load source for each process design). It means the ratio of unit x production amount). 100% indicates that the facility capacity and total load of each facility are the same.

  From the results in Table 11, it can be seen that the product type composition is determined within the range of the equipment capacity of the designated equipment. Moreover, the equipment which becomes a bottleneck can be judged concretely from this result, and it can utilize for the examination of operation improvement and the equipment capacity improvement of an equipment.

Next, the processing procedure of the production plan creation method according to the present embodiment will be described with reference to FIG. FIG. 3 is a flowchart illustrating the processing procedure of the production plan creation method according to the present embodiment.
The process of the production plan creation method according to the present embodiment described below can be read and executed by the CPU as a program in the computer as well. Further, this program can be installed in various computer storage devices by recording it in a removable storage medium such as a CD-ROM, FD, or MO.

As shown in FIG. 3, firstly, the cost information generated for each process design, manufacturing route information, production volume information, raw material / sale price information, facility information, and data relating to the evaluation index are input in advance, respectively, and magnetic storage devices Are registered in the generated cost information storage unit 21, the production route information storage unit 11, the production amount information storage unit 2, the raw material / sale price information storage unit 3, the facility information storage unit 4, and the evaluation index storage unit 5 ( Step S1).
For details of this step, the generated cost information storage unit 21, the production route information storage unit 11, the production amount information storage unit 2, the raw material / sale price information storage unit 3, and the facility information storage unit of the production plan creation apparatus 1 described above. 4 and the description of the evaluation index storage unit 5 are omitted.

Next, based on the manufacturing route information stored in the manufacturing route information storage unit 11, the equipment load basic unit calculation unit 10 calculates the equipment load basic unit for each equipment for each process design (step S2).
Note that the details of this step are the same as those described in the equipment load unit calculation unit 10 of the production plan creation apparatus 1 described above, and a description thereof will be omitted.

Further, the generated cost basic unit calculation unit 20 calculates the generated cost basic unit for each process design based on the generated variable cost stored in the generated cost information storage unit 21 (step S3).
The details of this step are the same as those described in the generated cost basic unit calculation unit 20 of the production plan creation apparatus 1 described above, and a description thereof is omitted.

Then, in the optimum product configuration calculation unit 30, the generated cost basic unit calculated by the generated cost basic unit calculation unit 20, the equipment load basic unit calculated by the equipment load basic unit calculation unit 10, and the production amount information storage unit 2 in advance. Referring to the production volume information, raw material / sale price information, equipment information, and evaluation index respectively registered in the raw material / sale price information storage unit 3, the equipment information storage unit 4 and the evaluation index storage unit 5, the linear programming method By using this to solve the optimization problem, the production amount for each process design is determined (step S4).
The details of this step are the same as the description of the optimum product configuration calculation unit 30 of the production plan creation apparatus 1 described above, and a description thereof will be omitted.

Finally, the calculation result of the optimum product configuration calculation unit 30 is displayed on the result output unit 40, that is, the output device (display, hard disk, printer, etc.) (step S5).
The details of this step are the same as those described in the result output unit 40 of the production plan creation apparatus 1 described above, and a description thereof is omitted.

As described above, according to the production plan creation method, production plan creation apparatus, and program of the present embodiment, the optimum product configuration calculation unit 30 assigns and manufactures equipment that can be processed for a plurality of processes for producing a product. The production amount for each process design registered in the manufacturing route storage unit 11 as a route is calculated based on the processing capacity stored in the manufacturing route storage unit 11. The total load of each facility is stored in advance in the facility information storage unit 4. In a range that does not exceed the equipment capacity of the equipment (within the equipment capacity range of each equipment), the evaluation index preset in the evaluation index storage unit 5 is determined to be maximum.
Therefore, each process that maximizes the preset evaluation index is possible even when multiple process designs are considered, such as when there are multiple processes for producing a product of one type or when there are alternative facilities. The production volume of the design is determined.

Further, the production amount of each process design is determined within the range of the minimum production amount and the maximum production amount stored in advance in the production amount information storage unit 2.
Therefore, by setting the minimum production amount as the lower limit amount, it is possible to optimize other product configurations after producing the products to be produced strategically. In addition, by setting the maximum production amount as the upper limit amount, it is possible to optimize other product configurations without producing an amount that cannot be sold or stored. Furthermore, by setting the minimum production amount and the maximum production amount (the upper limit amount and the lower limit amount) to the same value, it is possible to optimize other product configurations after producing products that must be produced in a certain amount. .

In addition, the production amount of each process design is determined so that the sum of (the selling price−the raw material cost−the variable cost) which is the evaluation index stored in the evaluation index storage unit 5 is maximized.
Therefore, even when the same variety is produced, there are a plurality of production routes, and even when the variable costs and raw material costs are different, the overall profit can be maximized.

In addition, the production amount of each process design is determined so that the sum of the production amounts of all the varieties that are the evaluation indexes stored in the evaluation index storage unit 5 is maximized.
Accordingly, it is possible to determine a variety configuration that places importance on the total production volume, as in the case of giving priority to share.

In addition, the optimum product configuration calculation unit 30 applies linear programming to the evaluation index calculation.
Therefore, even when the number of varieties and facilities is large, the production amount for each process design can be optimized at high speed.

In addition, in the equipment load basic unit calculation unit 10, the equipment load basic unit for each process design (for all equipment in the production line based on the information regarding the processing capability in each process stored in advance in the manufacturing route information storage unit 11 ( For example, the time required to produce one ton of product is calculated. Thereby, the total load of equipment can be expressed in a line format.
Therefore, even when the number and order of the equipment used differs depending on the process design, or when the same equipment is used in the process design, restrictions on the equipment capacity of each equipment are expressed in a linear format based on the processing capacity in each process. And the linear programming method can be applied to the determination of the optimum product configuration in the optimum product configuration calculation unit 30.

In addition, the generated cost basic unit calculation unit 20 uses the variable cost information, which is information for each process in the process design stored in advance in the generated cost information storage unit 21, for each process design. It is aggregated as a cost generation unit.
Therefore, in the calculation of the evaluation index by the linear programming method in the optimum product configuration calculation unit 30, the number of variables can be reduced, and the calculation speed can be increased.

  The preferred embodiments of the present invention have been described above. However, the present invention is not limited to the above-described embodiments, and various modifications can be made as long as they are described in the claims.

In the above-described embodiment, a case has been described in which a manufacturing route that can be used for each product type is set in advance as a process design. However, the present invention is not limited to this. FIG. 4 shows a modification of the production plan creation device 1 in the case where there are rules regarding alternative equipment.
As shown in FIG. 4, in the production plan creation device 1 according to the modification, the production route generation unit 12 is a substitute facility based on the substitute facility rule registered and stored in advance in the substitute facility rule storage unit 13. A manufacturing route is created as a new process design and stored in the manufacturing route information storage unit 11.

Table 12 shows an example of alternative facility rules that are input to the alternative facility rule storage unit 13 of the production plan creation device 1 according to the modification.
As shown in Table 12, it is shown that the slitter 02 (“alternative equipment” shown in Table 12) can be used instead of the slitter 01 of the product type F (“original equipment” shown in Table 12). At that time, the load [ton / hr] is 0.8 times (“load coefficient” shown in Table 12), and the variable cost (thousand yen / ton) is 1.2 times (“variation coefficient” shown in Table 12). ), The process yield is specified to be 88% ("process yield" shown in Table 12). If the raw material unit price changes, the raw material unit price may be specified.

  Here, the process design (process design numbers 12 and 13) of the type F registered in advance in the manufacturing route information storage unit 11 is as shown in Table 13.

Next, while referring to the process design (process design numbers 12 and 13) of the type F registered in advance, based on the alternative equipment rule (Table 12) stored in the alternative equipment rule storage unit 13, the original Table 14 shows new process designs (process design numbers 14 and 15) of the type F created by assigning alternative facilities instead of facilities.
As shown in Table 14, the process design number 12 to the process design number 14 and the process design number 12 to the process design number 15 are created in accordance with the above-described alternative equipment rule (Table 12).

  The process design (process design numbers 14 and 15) for the created product F is stored in the manufacturing route information storage unit 11 together with the process design (process design numbers 12 and 13) of the product F registered in advance. In the optimum product configuration calculation unit 30, the production amount for each process design including the process design (process design numbers 12 to 15) for the product F is optimized. And the optimal production amount can be obtained for each of the production amount process design numbers 12 to 15 of the type F. That is, it is possible to obtain an optimum ratio of equipment transfer from the slitter 01 to the slitter 02.

  As described above, the process design newly created by the production route generation unit 12 based on the substitution facility rule stored in the substitution facility rule storage unit 13 is stored in the production route information storage unit 11, so that the substitution facility can be replaced. It is possible to obtain the optimum ratio of equipment transfer.

In the above-described embodiment, the evaluation index is the profit maximization and the production volume maximization. However, the present invention is not limited to this.
For example, it may be a weighted sum of profit and production. This case can be applied to the following cases.
・ To increase profits as much as possible while securing production volume.
・ When making the production volume as small as possible and making the profit as large as possible (for the evaluation index, the production volume is negatively weighted).
・ If profits are the same, a product structure with a large production volume is desirable.

For example, the total sales may be maximized by using the evaluation index as the sum of the selling prices for each product type.
In this case, it can be applied when it is desired to determine a variety configuration that places more importance on the total deposit than profit.

It is a block diagram of the production plan creation apparatus concerning this embodiment. It is a figure which shows an example of the production line made into the object of this embodiment. It is the flowchart explaining the procedure of the process of the production plan preparation method which concerns on this Embodiment. It is a block diagram of the production plan preparation apparatus which concerns on the modification of this Embodiment.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Production plan preparation apparatus 2 Production volume information storage part 3 Raw material and selling price information storage part 4 Equipment information storage part 5 Evaluation index setting part 10 Equipment load basic unit calculation part 11 Manufacturing route storage part 12 Manufacturing route generation part 13 Alternative equipment rule memory | storage Unit 20 Generated cost basic unit calculation unit 21 Generated cost information storage unit 30 Optimal product type configuration calculation unit

Claims (30)

A production plan creation method for optimizing the production amount of products of multiple varieties produced in multiple processes,
Registering as a process design a manufacturing route to which equipment that can be processed for a plurality of processes for manufacturing a product is assigned for each product type;
Registering facility capacity for each facility;
For each process design, registering the processing capacity of each process;
Calculating the production amount for each process design in which the total load for each piece of equipment determined by the processing capacity does not exceed the equipment capacity and the preset evaluation index is maximized;
A production plan creation method characterized by comprising: Registering a minimum production volume and a maximum production volume as a range of required production volume for each product type;
Further comprising
The production amount is further
The production plan creation method according to claim 1, wherein the production plan is determined within a range between the minimum production amount and the maximum production amount for each of the varieties. A step of creating and registering a manufacturing route as a process design to which an alternative facility is assigned based on a preset rule of the alternative facility when an alternative facility exists;
The production plan creation method according to claim 1, further comprising: The production plan creation method according to claim 1, wherein the calculation of the evaluation index is performed by a linear programming method. Registering the selling price for each product type;
For each process design, registering variable costs and raw material costs generated in each process;
Further comprising
The evaluation index is
The production plan creation method according to any one of claims 1 to 4, wherein the sum of (sales price-raw material cost-variable cost) is set. Registering the selling price for each product type;
For each process design, registering variable costs and raw material costs generated in each process;
Further comprising
The evaluation index is
The production plan creation method according to any one of claims 1 to 4, characterized in that the weighted sum of the sum of (sales price-raw material cost-variable cost) and the sum of the production quantities of all varieties is set. . The evaluation index is
The production plan creation method according to claim 1, wherein the total production amount of all varieties is set as follows. Registering the selling price for each product type;
Further comprising
The evaluation index is
The production plan creation method according to any one of claims 1 to 4, wherein the sum of selling prices of all varieties is set. Based on the processing capacity, calculating the load of each facility for each process design when producing a unit quantity of product as a facility load basic unit,
Based on the variable cost, calculating the generated cost for each process design required when producing a unit quantity of the product as a generated cost basic unit;
Further comprising
The calculation of the evaluation index is as follows:
The production plan creation method according to claim 5, wherein the production plan generation method is performed by a linear programming method using the equipment load basic unit and the generated cost basic unit. A step of calculating the load of each facility for each process design when producing a unit quantity of a product based on the processing capacity as an equipment load basic unit,
Further comprising
The calculation of the evaluation index is as follows:
9. The production plan creation method according to claim 7, wherein the production load generation unit is used by linear programming. A program for optimizing the production volume of products of multiple varieties produced in multiple processes on a computer,
Registering as a process design a manufacturing route to which equipment that can be processed for a plurality of processes for manufacturing a product is assigned for each product type;
Registering equipment capacity for each equipment;
Registering the processing capability of each process for each process design;
The total load for each piece of equipment determined by the processing capacity does not exceed the equipment capacity, and a step of calculating a production amount for each process design that maximizes a preset evaluation index;
A program that causes a computer to execute. Registering a minimum production volume and a maximum production volume as a range of required production volume for each product type;
Is further executed on the computer,
The production amount is further
The program according to claim 11, wherein the program is determined within a range between the minimum production amount and the maximum production amount for each of the varieties. A step of creating and registering a manufacturing route as a process design to which an alternative facility is assigned based on a preset rule of the alternative facility when an alternative facility exists;
13. The production plan creation method according to claim 11 or 12, further comprising causing the computer to execute. The program according to any one of claims 11 to 13, wherein the evaluation index is calculated by linear programming. Registering the selling price for each product type;
For each process design, registering variable costs and raw material costs incurred in each process;
Is further executed on the computer,
The evaluation index is
The program according to any one of claims 11 to 14, characterized in that the sum of (sales price-raw material cost-variable cost) is set. Registering the selling price for each product type;
For each process design, registering variable costs and raw material costs incurred in each process;
Is further executed on the computer,
The evaluation index is
The program according to any one of claims 11 to 14, wherein the weighted sum of the sum of (selling price-raw material cost-variable cost) and the sum of the production amounts of all varieties is set. The evaluation index is
The program according to any one of claims 11 to 14, characterized in that the total production amount of all varieties is set as follows. Registering the selling price for each product type;
Is further executed on the computer,
The evaluation index is
The program according to any one of claims 11 to 14, characterized in that the sum of selling prices of all varieties is set. A step of calculating the load of each facility for each process design when producing a unit quantity of a product based on the processing capacity as an equipment load basic unit,
Calculating the generated cost for each process design required when producing a unit quantity of the product based on the variable cost as a generated cost basic unit;
Is further executed on the computer,
The calculation of the evaluation index is as follows:
The program according to claim 15 or 16, wherein the program is performed by linear programming using the equipment load basic unit and the generated cost basic unit. A step of calculating the load of each facility for each process design when producing a unit quantity of a product based on the processing capacity as an equipment load basic unit,
Is further executed on the computer,
The calculation of the evaluation index is as follows:
The program according to claim 17 or 18, wherein the program is performed by linear programming using the equipment load unit. A production plan creation device that optimizes the production amount of products of multiple varieties produced in multiple processes,
Means for registering, as a process design, a manufacturing route to which equipment that can be processed for a plurality of processes for manufacturing a product is assigned for each product type;
Means for registering equipment capacity for each equipment;
Means for registering the processing capacity of each process for each process design;
Means for calculating a production amount for each process design in which the total load for each piece of equipment determined by the processing capacity does not exceed the equipment capacity and the preset evaluation index is maximized;
A production plan creation device comprising: Means for registering a minimum production amount and a maximum production amount as a range of required production amounts for each of the types;
Further comprising
The production amount is further
The production plan creation device according to claim 21, wherein the production plan creation device is determined within a range of the minimum production amount and the maximum production amount in each of the varieties. Means for creating and registering a manufacturing route as a process design to which an alternative facility is assigned based on a rule of the alternative facility set in advance, when an alternative facility exists;
The production plan creation device according to claim 21 or 22, further comprising: The production plan creation device according to any one of claims 21 to 23, wherein the calculation of the evaluation index is performed by a linear programming method. Means for registering the selling price for each of the types;
Means for registering variable costs and raw material costs generated in each process for each process design;
Further comprising
The evaluation index is
The production plan creation device according to any one of claims 21 to 24, wherein the sum of (sale price-raw material cost-variable cost) is set. Means for registering the selling price for each of the types;
Means for registering variable costs and raw material costs generated in each process for each process design;
Further comprising
The evaluation index is
25. The production plan creation device according to any one of claims 21 to 24, wherein a weighted sum of a sum of (sales price-raw material cost-variable cost) and a sum of production amounts of all varieties is set. . The evaluation index is
The production plan creation device according to any one of claims 21 to 24, wherein the total production amount of all varieties is set. Means for registering the selling price for each product type;
Further comprising
The evaluation index is
The production plan creation device according to any one of claims 21 to 24, wherein the sum of the selling prices of all the varieties is set. Based on the processing capacity, means for calculating the load of each facility for each process design when producing a unit quantity of a product as a facility load basic unit,
Based on the variable cost, a means for calculating the generated cost for each process design required when producing a unit quantity of the product as a generated cost basic unit,
Further comprising
The calculation of the evaluation index is as follows:
27. The production plan creation apparatus according to claim 25 or 26, which is performed by a linear programming method using the equipment load unit and the generated cost unit. Based on the processing capacity, means for calculating the load of each facility for each process design when producing a unit quantity of a product as a facility load basic unit,
Further comprising
The calculation of the evaluation index is as follows:
29. The production plan creation apparatus according to claim 27 or 28, wherein the production load generation unit is performed by a linear programming method.

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