JP2011076131A - Production plan creation method, production plan creation program, and production plan creation device - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To improve productivity while improving a delivery term achievement rate following the actual operation conditions of a factory in the case of manufacturing a product (especially, largely scaled single product). <P>SOLUTION: Information on an order instruction table, a product master, a process master, a resource master, a resource operation calendar, and a result information table is registered (S1), and initialization of a production plan date is executed (S2). An unallocated job list is created (S3), and an allocation possible calendar in an allocation level set in an order or job unit is created with respect to those jobs (S4). An allocation algorithm is applied to the job group of the unallocated job list, and the allocation of resources is executed under the consideration of the constraint of the resource operation calendar and the allocation possible calendar, and an allocation information table is updated (S5 to S9). On the basis of the allocation information table, whether or not the result of the production plan is satisfied is evaluated (S10), and when the result of the production plan is not satisfied (NG), the allocation level is changed in the order or job unit from the result of the production plan (S11), and when the result of the production plan is satisfied (OK), processing is ended. <P>COPYRIGHT: (C)2011,JPO&INPIT

Description

  The present invention relates to a production plan creation method, a production plan creation program, and a production plan creation apparatus that perform process management when manufacturing a product in a factory.

  Conventionally, when a product with an order is manufactured in a factory, a production plan is used to schedule and manage jobs, which are individual operations when each process is required for manufacturing the order. Has been created.

  Here, when a large single product is manufactured in a factory, it is usual that the number of processes is large and the working time of one process becomes long. For this reason, there are some production plans for large one-piece products that take more than one year due to the long manufacturing lead time. Therefore, when the production plan is created, if the estimation of the capacity of each resource is not correct, there is a possibility that a difference between the created production plan and the actual situation becomes large. In addition, the size of parts to be procured is large, and the time to obtain may be delayed from the production plan. In this way, when manufacturing large one-piece products at the factory, there are many factors that do not match the actual situation with respect to the production plan, so depending on the order, overtime etc. Special measures are taken.

  As a production plan for performing such a special response, for example, there is a technique disclosed in Patent Document 1. The technique shown in Patent Document 1 calculates overtime to achieve the delivery date for the purpose of increasing the productivity of the entire factory and keeping the production delivery date.

JP 2004-145814 A

  However, in the technique shown in Patent Document 1, it is possible to make adjustments in a factory that manufactures mass-produced products by a method that increases the productivity of the entire factory. However, in a factory that manufactures large single-product products, the delivery time is delayed. It is normal to handle overtime only for the work of orders that are currently in order, and it is not appropriate because it does not handle overtime work uniformly. In other words, in a factory that manufactures large single-item products, if you set the overtime hours uniformly and re-create the production plan, even for orders that can achieve the delivery date without dealing with overtime, etc. As a result, resources other than orders delayed in delivery are consumed, resulting in costly production plans and inconsistencies with the actual conditions of the factory.

  Also, in a factory that manufactures large one-item products, when working with overtime support, it is not necessary to set the overtime time uniformly, but if the work production time is completed within the set time, it is completed. It is common to be able to move on to the new work from the next day. In addition, when manufacturing large single-product products, there are processes that require continuous production for 24 hours, depending on the work. If a production plan is created with uniform operating hours and overtime hours, the production plan and factory will continue to increase. There is a high possibility that the actual situation will be different. In addition, regardless of a factory that manufactures a large single product, the same problem occurs in a factory that manufactures a product so that the number of processes is large and the working time of one process becomes long.

  Therefore, the problem to be solved by the present invention is that when producing products in a factory (especially a factory producing large one-piece products), the delivery rate achievement rate is improved in accordance with the actual operation of the factory. A production plan creation method, a production plan creation program, and a production plan creation device for improving productivity are provided.

  The production plan creation method according to the present invention creates a production plan by allocating allocatable resources to all jobs that are processes necessary for manufacturing one or more products in a computer. A production plan creation method, in which a process executed by a computing unit of a computer sets a resource operation calendar registration step for setting a resource operation time as a resource operation calendar, and is set in advance for each order or each job. Based on the assigned level, the assignable calendar creation step for creating the assignable calendar as a time that can be assigned to the job, and the unassigned jobs in the job to which the resources are not assigned are sequentially performed according to a predetermined assignment algorithm. Selected in consideration of the restrictions of the allocatable calendar and the resource movable calendar. A job allocation step of allocating the resource to an unallocated job, storing the allocated resource and period as a production plan, evaluating the production plan based on the delivery date of the order, and regarding the order not satisfying the delivery date, An evaluation step of changing the allocation level set for each order or for each job, updating the allocatable calendar, and executing the job allocation step again.

  The production plan creation program according to the present invention creates a production plan by allocating allocatable resources to all jobs that are processes necessary for producing one or more products of the order. It is a program, and it is possible to allocate the job based on a resource operation calendar registration step for setting the resource operation time as a resource operation calendar and an allocation level preset for each order or for each job. An allocatable calendar creation step for creating an allocatable time as an allocatable calendar, and an unallocated job that has not been allocated the resource in the job is sequentially selected by a predetermined allocation algorithm, and the allocatable calendar and the resource movable calendar are selected. Allocating the resource to the selected unallocated job in consideration of the constraints, A job allocation step for storing the attached resource and period as a production plan, and evaluating the production plan based on a delivery date of the order, and the order set for each order or each job with respect to the order that does not satisfy the delivery date. An evaluation step for changing the allocation level, updating the allocatable calendar, and executing the job allocation step again, and reading out by the calculation unit in the computer to execute the processing of each step To do.

  The production plan creation device according to the present invention creates a production plan by allocating allocatable resources to all jobs that are processes necessary for manufacturing one or more products in a computer. In the production plan creation device, the calculation unit of the computer is based on a resource operation calendar registration unit that sets the resource operation time as a resource operation calendar, and an allocation level set in advance for each order or each job. An allocatable calendar creating unit that creates an allocatable calendar as an allocatable calendar, and an unallocated job that is not allocated the resource in the job is sequentially selected by a predetermined allocation algorithm, The resource is allocated to the selected unallocated job in consideration of the restrictions of the allocatable calendar and the resource movable calendar. Therefore, a job allocation unit that stores the allocated resource and period as a production plan, and evaluates the production plan based on the delivery date of the order, and for each order or job for each order that does not satisfy the delivery date. An evaluation unit that changes the set allocation level, updates the allocatable calendar, and executes the job allocation unit again.

  According to this, the production plan is created in consideration of the restrictions of the assignable calendar created based on the assignment level set for each order or each job. Therefore, the allocation level is changed only for orders or jobs that require overtime or holiday attendance, such as orders or jobs that are delayed in delivery, instead of uniformly handling overtime or holiday attendance. By doing so, it is possible to devise an effective lean production plan while optimizing costs such as unnecessary labor costs, and to properly eliminate the delay in delivery of the target. Also, because it matches the actual operation of factories (especially factories that produce large single-product products), the accuracy of production plans for products with a large number of jobs and long lead times that are characteristic of production plans for large single-product products Can be improved. The predetermined allocation algorithm means an allocation algorithm normally performed by those skilled in the art in the field of production planning and scheduling. For example, a priority is set for an order, and based on the priority by backward or forward. This shows the algorithm for assigning the extracted job to resources.

  Here, the production plan creation method, the production plan creation program, and the production plan creation device according to the present invention provide the allocation level of the operation time, the presence / absence of overtime and overtime, the presence / absence of shift work, and the correspondence of holidays. The presence / absence, holiday operation time, and presence / absence of 24-hour continuous operation may be set.

  According to this, by setting the restrictions on the availability of overtime, shift work, holidays, and 24 hour continuous operation as an assignment level for normal operation hours, an assignable calendar is created. It is possible to create a production plan that matches the actual operation. In addition, a holiday means the day which does not perform normal operation in a factory other than a weekend, a national holiday. The holiday operating time means a holiday operating time in the case of dealing with a holiday. In addition, shift work means whether to perform night shift by the operation time of the next day. Furthermore, the 24-hour continuous operation means that the operation is performed continuously for 24 hours, and it may be set so that the operation is continuously performed for 24 hours only on weekdays and the operation is not performed on holidays. May be set to perform continuous operation for 24 hours, or may be set to be limited to the day of the week, or may be set as appropriate.

  In addition, the production plan creation method and the production plan creation program according to the present invention consider the period of the job regarding the job that does not end within the operation time of the day among the orders that do not satisfy the delivery date in the evaluation step. When the end date and time of the job falls within a predetermined overtime after the operating hours of the day, the allocation calendar of the job is changed and the allocatable calendar is updated as the time over which the overtime can be allocated. You can do it.

  In the production plan creation device according to the present invention, in the evaluation unit, regarding the job that does not end within the operation time of the day among the orders that do not satisfy the delivery date, the end date / time of the job is determined in consideration of the period of the job. When it is within a predetermined overtime after the operation time of the day, the allocatable calendar may be updated by changing the assignment level of the job as the time over which the overtime can be assigned.

  According to this, when a job ends within a configurable overtime time, the overtime work is made only for the job and a production plan is created, so it is possible to uniformly handle overtime and holiday work. Therefore, it is possible to make a highly productive production plan while minimizing unnecessary labor costs.

  In addition, the production plan creation method and production plan creation program according to the present invention can allocate 24 hours in a continuous manner for orders or jobs that need to be worked continuously for 24 hours in the assignable calendar creation step. The assignable calendar may be created as an appropriate assignment level.

  In the production plan creation device according to the present invention, the assignable calendar creation unit sets the assignment level as an assignment level that can be assigned continuously for 24 hours for an order or job that needs to be worked continuously for 24 hours. You can create a possible calendar.

  According to this, for an order or job that needs to work continuously for 24 hours, a production plan is created by allocating continuously for 24 hours without using other constraints such as operating hours and overtime hours. Therefore, even if there are settings such as normal operating hours and overtime hours at the factory, it can be operated continuously for 24 hours regardless of these restrictions, and high-accuracy production that matches the actual operation of the factory I can make a plan.

  Further, the production plan creation method and the production plan creation program according to the present invention are configured such that, in the assignable calendar creation step, overtime is set for the assignment level for which overtime is set but no shift work is set. The allocatable calendar may be created by further adding a restriction to assign from the start time.

  Further, in the production plan creation device according to the present invention, in the allocatable calendar creation unit, overtime hours are set, but the assignment level is assigned from an operation start time on the next day to an assignment level in which shift work is not set. May be added to create the assignable calendar.

  According to this, in order to create a production plan that does not start new work within the prescribed overtime hours, it is in the actual operation of the factory, reducing labor costs and other costs, greatly increasing the accuracy of the production plan Can be improved.

  The production planning program according to the present invention can be distributed by being recorded on a removable recording medium such as a CD-ROM (Compact Disc Read Only Memory) or DVD (Digital Versatile Disk) or a fixed recording medium such as a hard disk. In addition, it can be distributed via a communication network such as the Internet by wired or wireless telecommunication means.

  The production plan creation method, the production plan creation program, and the production plan creation apparatus of the present invention are based on the actual operation of the factory when manufacturing the product in a factory (particularly, a factory that produces a large single product). The productivity can be improved while improving the delivery rate.

It is a block diagram of a production plan creation device concerning this embodiment. It is a step figure showing the procedure of the production plan creation method concerning this embodiment. In the present embodiment, the result of the production plan is displayed in a Gantt chart according to the allocation information table in Table 10. In this embodiment, the result of the production plan that has been assigned at the assignment level changed based on the result of the production plan in FIG. 3 is displayed in a Gantt chart. In this embodiment, the result of the production plan that has been assigned at the assignment level changed based on the result of the production plan in FIG. 4 is displayed in a Gantt chart. In the present embodiment, the result of the production plan assigned at the assignment level changed when the delivery date of the order 4 is advanced with respect to the result of the production plan in FIG. 5 is displayed in a Gantt chart.

  Hereinafter, a form for carrying out a production plan creation method, a production plan creation program, and a production plan creation apparatus according to the present invention will be described based on a specific example with reference to the drawings. In addition, what is demonstrated below is only what was illustrated and does not show the application limit of the production plan creation method, the production plan creation program, and the production plan creation device according to the present invention. That is, the production plan creation method, the production plan creation program, and the production plan creation device according to the present invention are not limited to the following embodiments, and various modifications are possible as long as they are described in the claims. Is.

  In the present embodiment, a production line that is completed through a plurality of processes using resources such as a processing machine, an operator, and jigs and tools (jigs and tools) is an object. Here, the number of product processes varies depending on the type of product. Further, resources required in each process are determined in advance, and there are a plurality of substitutable resources depending on circumstances. The factory to which the present embodiment is applied assumes a factory that manufactures a large one-piece product, but is not limited to this, and the product is manufactured so that the number of processes is large and the working time of one process is also long. It can also be applied to factories that do.

  First, 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. The production plan creation apparatus 1 includes a calculation unit 10, a storage unit 20, an input unit, and an output unit, and is mounted on a computer. Here, each unit (calculation unit 10, storage unit 20, input unit, and output unit) of the production plan creation apparatus 1 shown in FIG. 1 is configured by a computer such as a general-purpose personal computer. Such a computer stores hardware such as a CPU, ROM, RAM, hard disk, and CD-ROM drive, and the hard disk stores a program (this program is recorded on a removable storage medium). Can be installed on a variety of computers). And the above-mentioned each part is constructed | assembled by combining these hardware and software.

  As shown in FIG. 1, the storage unit 20 includes an order instruction table 21, a product master 22, a process master 23, a resource master 24, a resource operation calendar 25, a performance information table 26, and an unassigned job list 27. And an assignable calendar 28 and an assignment information table 29.

  The order instruction table 21 is pre-registered with information related to the order instruction such as the quantity of products to be produced, the possible start date and time, and the delivery date based on the order instruction given from the outside.

  In the product master 22, information on a product name targeted by the production plan creation device 1 and a series of processes for completing the product is registered from the outside.

  The process master 23 is for registering each process information of the product from the outside. Here, the process information is information related to a series of processes performed to complete a certain processed product, and includes information such as resources used for each process, a ratio of resources used, and a time required for the process.

  In the resource master 24, information related to resources such as the resource name, resource code, and resource capability of the resource is registered from the outside.

  Here, in the order instruction table 21, the product master 22, the process master 23, and the resource master 24, information registered from the outside is input from an input unit (keyboard or the like) (not shown) or recorded in a removable storage medium. A storage device (auxiliary storage device) such as a ROM (Read Only Memory), a RAM (Random Access Memory), a hard disk, or the like provided by a wired or wireless telecommunication means via a communication network such as the Internet And so on.

  In the resource operation calendar 25, information related to the operation time, which is the time in which the resource can be operated, is registered from the resource operation calendar registration unit 11 described later. Here, the operation time indicates information including an operation day (day of the week), an operation time for the operation day, and the number of operations.

  The actual result information table 26 is used to register actually measured actual result information such as the start date / time, completion date / time, and progress rate of a job already executed according to the production plan. Here, the jobs already executed according to the production plan include jobs already in progress as well as jobs already executed. The actual information is read when the production plan is started, and the production plan is started by the production planning apparatus 1 with this as an initial state. Whenever the production line executes a job, the actual information is registered from the outside, and the actual information table 26 is updated. It is updated and results information increases. Note that in a completely initial state, the record information table 26 is empty. The job is a name for identifying a process of a product existing on the production line, and is developed based on the product master 22 and the process master 23.

  In the unallocated job list 27, when a production plan is newly started, an unallocated job whose production has not yet started on the production line is registered from the unallocated job list creation unit 12 described later.

  In the allocatable calendar 28, an allocatable calendar created based on an allocation level set in advance from the outside for each order or job is registered from the allocatable calendar creating unit 13 described later. Here, the allocation level is about the operating hours, whether overtime hours are supported and whether overtime hours are set, overtime hours, holiday hours, holiday hours, 24 hours continuous operation, shift work, etc. Is set. In addition, a holiday means the day which does not perform normal operation in a factory other than a weekend, a national holiday. The holiday operating time means a holiday operating time in the case of dealing with a holiday. In addition, shift work means whether to perform night shift by the operation time of the next day.

  In the allocation information table 29, resources allocated for each job (including the number of resources) and allocation information including a start date / time and an end date / time are registered from the resource allocation unit 14 described later. The allocation information table 29 is a production plan itself. The allocation information table can be read by an output device (display, printer, hard disk, etc.) external to the production planning device 1 via an output unit (output interface) (not shown). Here, the output interface is a program or hardware that performs data conversion and communication for output to the output device.

  The computing unit 10 includes a resource operation calendar registration unit 11, an unallocated job list creation unit 12, an allocatable calendar creation unit 13, a resource allocation unit (job allocation unit) 14, and an evaluation unit 15. .

  The resource operation calendar registration unit 11 registers an operation time, which is an operable time, for each resource corresponding to the resource registered in the resource master 24 and stores it in the resource operation calendar 25. Note that the resource operation calendar registration unit 11 performs resource operation on the premise that when overtime is possible, overtime is performed with the maximum overtime, and when continuous operation is possible for 24 hours, continuous operation is performed for 24 hours. Set the maximum time and amount possible.

  The unallocated job list creation unit 12 refers to the product master 22 and the process master 23 for jobs to be produced for products to be produced included in the order instruction table 21 when a new production plan is started. In addition, in the unassigned job list 27, the jobs that have already been produced by the production line and that exclude jobs registered in the performance information table 26 are regarded as unassigned jobs that have not yet been produced on the production line. It is for registration.

  The allocatable calendar creating unit 13 creates an allocatable calendar for each order or job based on an allocation level set in advance from the outside and registers it in the allocatable calendar 28. Here, in the assignable calendar, the operating hours, whether overtime hours are supported and whether overtime hours are set, whether overtime is available, holiday operating hours, holiday operating hours, whether 24-hour continuous operation is possible, whether there is shift work, etc. Is set for the day of the week and its time that can be assigned for each order or for each job based on a preset assignment level. The operating time is set in the assignable calendar as the initial assignment level. And based on the result of the evaluation part 15 mentioned later, an allocation level is changed and an allocatable calendar is updated. As an assignment level, it is possible to handle overtime in advance, and for orders or jobs that are set from the input section or the like that support overtime is required, the day of the week and the time of overtime are set as overtime. Add and set. Also, as the assignment level, holidays can be handled in advance, and the day of the week and the time of the holiday operation for the order or job set from the input unit etc. that the holiday needs to be handled is the holiday. Set as operating hours. Further, as an allocation level, a 24-hour continuous operation is possible in advance, and a day (24-hour continuous operation is possible for an order or job set from the input unit or the like that the 24-hour continuous operation is necessary. For days of the week, weekdays, and holidays), overtime and holiday settings are ignored and 24-hour continuous operation is set. Further, as the assignment level, the shift work is set in advance for an order or job that is set by the input unit or the like so that the shift work is possible and the shift work is necessary. Also, if the shift level is set as no shift work in advance, even if overtime support is set, a new job will not be allocated within the overtime hours, but will be allocated from the operation start time on the next day. Add some restrictions.

  The resource allocation unit (job allocation unit) 14 applies an allocation algorithm to the job group included in the unallocated job list 27 and considers the constraints of the resource operation calendar 25 and the allocatable calendar 28 based on the result information table 26. The resource is assigned to the job. Here, the allocation algorithm may be an allocation algorithm normally performed by those skilled in the field of production plan creation and scheduling.

  In the present embodiment, the allocation algorithm performs a priority plan based on the priority set in the order. Specifically, the allocation algorithm extracts jobs in the order of high priority from the unallocated job list, selects the target job sequentially by the specified allocation method (backward or forward), and selects the resource The assignment is performed in consideration of the restrictions of the operating calendar 25 and the assignable calendar 28. For the assignment, for example, for an order for starting a new production, the available date and time and the delivery date are acquired from the order instruction table 21. For orders that are under production, the scheduled completion date and time of the job in progress is calculated from the result information table 26, and the unassigned job that is executed next to the job that is in progress is calculated. The date and time that can be started. Based on these pieces of information, the earliest start date and time and the latest completion date and time of each job registered in the unassigned job list 27 are obtained. In the present embodiment, the earliest start date and time and the latest completion date and time of each job consider only the restrictions of the resource operation calendar 25 and the allocatable calendar 28, and do not consider the restrictions of resource sharing with other jobs. . The earliest start date and time is the date and time when the job can be started the earliest when there is no restriction on resource sharing with other jobs, and is the completion date and time when the job of the previous process is started with the earliest start date and time. The latest completion date and time is the completion date and time of each job that can strictly meet the delivery date of the order when there is no restriction on resource sharing with other jobs, and the job of the later process was executed with the latest completion date and time The start date and time of the case.

  When the designated allocation method is forward, the order of priority is the highest among the jobs that have not been extracted as allocation target jobs in the unallocated job list 27 (that is, allocation has not been completed). The job with the earliest completion date and time of a high job is extracted as the job to be assigned. In the case of the same date and time, it is possible to extract with an evaluation method according to the case, such as preferentially extracting jobs that have a long working time or jobs that have room for the completion date and time of the previous job as jobs to be assigned. Is possible. When the specified allocation method is backward, the job with the latest start date and time of the job with the highest order priority is extracted as the allocation target job.

  With reference to the allocation information table 29, the extracted allocation target job is allocated with resources and periods (start date and end date) that satisfy the constraints in consideration of the constraints of the resource operation calendar 25 and the allocatable calendar 28. . At the time of allocation, in addition to the restrictions on the resource operation calendar 25 based on the conventional allocation algorithm, the operation time set in the allocatable calendar 28, the presence / absence of correspondence of the overtime to the operation time, and the setting of overtime, Search for allocations of resources and periods that satisfy constraints such as availability of holidays, holidays operating hours, availability of continuous operation for 24 hours, presence of shift work, and the like. Thereby, it is possible to allocate based on the set allocation level without significantly changing the conventional allocation algorithm. In the restriction on the allocatable calendar 28, the correspondence of overtime is set, but when no shift work is set, a new job is not allocated within the overtime, but is allocated from the operation start time of the next day. In addition, when 24-hour continuous operation is set, regarding the days that can be operated continuously for 24 hours (limited to days of the week, weekdays, and holidays), the overtime setting and the holiday setting are ignored, and the 24-hour continuous operation is performed. To be assigned.

  As described above, the above-described allocation is performed until all jobs registered in the unallocated job list 27 are extracted as allocation target jobs. When resources and periods (start date / time and end date / time) are assigned to all jobs in the unassigned job list 27, the assignment information table 29 is saved, and the unassigned job list 27 is updated.

  The evaluation unit 15 is for evaluating whether the result of the production plan is satisfied based on the allocation information table 29. Here, whether the result of the production plan is satisfied, for example, evaluates whether or not the delivery date of the order has been achieved. If the result of the production plan is satisfied, for example, the result of the allocation information table 29 is displayed on the output unit. On the other hand, if the result of the production plan is not satisfied, the assignment level is changed for each order or job based on the result of the production plan and is input to the assignable calendar creating unit 13 to update the assignable calendar 28. If the result of the production plan is not satisfied, an error display may be temporarily displayed on the output unit before the allocation level is changed and input to the allocatable calendar creation unit 13.

  The assignment level can be changed, for example, for over-order jobs that cannot be delivered, and when the end date and time of the job is within overtime, taking into account the job period, If the allocation level is set to support overtime, or if holiday support is possible, the allocation level of the order is set to support holiday. Note that the assignment level may be changed from the input unit based on an error display, or may be automatically performed based on a preset assignment level change rule. The allocation level change rule is a rule that extracts jobs of orders that do not achieve the delivery date, and sequentially handles overtime and holidays, and may be set in advance according to the production plan. Regardless of the result of the production plan, for example, if the assignment level needs to be changed, such as when an order is delivered earlier, the assignable calendar can be created by changing the assignment level via the input section. 13 and the assignable calendar 28 is updated. When the allocatable calendar 28 is updated, the updated allocatable calendar 28 is input to the resource allocation unit 14, and the resource allocation unit 14 again assigns an allocation algorithm to the job group included in the unallocated job list 27. And assigning resources to the job based on the result information table 26 in consideration of the constraints of the resource operating calendar 25 and the updated assignable calendar 28.

Next, the processing procedure of the production plan creation method according to the present embodiment will be described with reference to FIG. FIG. 2 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 production plan creation program in the computer as well. Further, the production plan creation program can be installed in storage devices of various computers by recording it in a removable storage medium.

  As shown in FIG. 2, in the computer, information related to the order instruction table, product master, process master, resource master, resource operation calendar, and result information table is input in advance from the input unit or recorded in a removable storage medium. Or provided via a communication network such as the Internet by wired or wireless telecommunication means and stored in the storage unit (step S1: resource operation calendar registration step). For details of this step, the resource operation calendar registration unit 11, the order instruction table 21, the product master 22, the process master 23, the resource master 24, the resource operation calendar 25, and the performance information table 26 of the production plan creation apparatus 1 described above. The description is the same as that described in FIG.

  Next, the production plan date and time is initialized (step S2). Specifically, the production plan date and time is set as the production plan start time.

  Next, based on the order instruction table, the name of the product to be produced is obtained and expanded from the product master and the process master to the job to be executed. Among the developed jobs, jobs that have already been executed by the results information table and jobs that are in progress are set in the assignment information table as the initial state of the production plan start. A job that does not exist in the record information table is registered in the unassigned job list (step S3). This is the initial state of the unallocated job list. The details of this step are the same as those described in the unallocated job list creation unit 12 and the unallocated job list 27 of the production plan creation apparatus 1 described above, and a description thereof will be omitted.

  For the jobs registered in the unassigned job list, an assignable calendar is created at an assignment level set for each order or job (step S4: assignable calendar creation step). Note that this step is the same as the description of the allocatable calendar creating unit 13 and allocatable calendar 28 of the production plan creating apparatus 1 described above, and a description thereof is omitted.

  Next, the allocation algorithm is applied to the job group included in the unallocated job list, and the allocation of resources to the job is executed based on the result information table in consideration of the constraints of the resource operation calendar and the allocatable calendar ( Steps S5 to S9: job allocation step). Note that this step is the same as the description of the resource allocation unit 14 described above, and a specific example in the present embodiment will be described below with reference to a flowchart.

  First, for an order for newly starting production, the available date and time and delivery date are obtained from the order instruction table. For orders that are under production, the scheduled completion date and time of the job in progress are calculated from the results information table, and the calculated completion date and time of the unassigned job to be executed next to the job in progress are calculated. Start date and time. Based on these pieces of information, the earliest start date and time and the latest completion date and time of each job registered in the unassigned job list are obtained (step S5). In the present embodiment, the earliest start date and time and the latest completion date and time of each job consider only the restrictions of the resource operation calendar and the allocatable calendar, and do not consider the restrictions of resource exchange with other jobs. The earliest start date and time is the date and time when the job can be started the earliest when there is no restriction on resource sharing with other jobs, and is the completion date and time when the job of the previous process is started with the earliest start date and time. The latest completion date and time is the completion date and time of each job that can strictly meet the delivery date of the order when there is no restriction on resource sharing with other jobs, and the job of the later process was executed with the latest completion date and time The start date and time of the case.

  If the specified allocation method is forward, the highest order priority is given to jobs that are not extracted as allocation target jobs (that is, allocation is not completed) in the unallocated job list. The job with the earliest completion date and time of the job is extracted as an assignment target job (step S6). In the case of the same date and time, it is possible to extract with an evaluation method according to the case, such as preferentially extracting jobs that have a long working time or jobs that have room for the completion date and time of the previous job as jobs to be assigned. Is possible. When the specified allocation method is backward, the job with the latest start date and time of the job with the highest order priority is extracted as the allocation target job.

  Next, it is determined whether there is an allocation target job, that is, whether all the jobs registered in the unallocated job list in step S6 have been extracted as allocation target jobs (step S7).

  If there is an allocation target job (step S7: Yes), referring to the allocation information table, the resource and period satisfying the constraints for the extracted allocation target job in consideration of the constraints of the resource operation calendar and the allocatable calendar (Start date / time and end date / time) are assigned (step S8). When assigning, in addition to the restrictions related to the resource operation calendar based on the conventional assignment algorithm, the operation time set in the allocatable calendar, whether overtime is supported for the operation time, setting of overtime, Search for allocation of resources and periods that satisfy constraints such as availability, holiday operating hours, availability of continuous operation for 24 hours, presence of shift work, etc. Thereby, it is possible to allocate based on the set allocation level without significantly changing the conventional allocation algorithm. In the restrictions on the allocatable calendar, when overtime support is set, but no shift work is set, a new job is not allocated within the overtime hours, but is allocated from the operation start time of the next day. In addition, when 24-hour continuous operation is set, regarding the days that can be operated continuously for 24 hours (limited to days of the week, weekdays, and holidays), the overtime setting and the holiday setting are ignored, and the 24-hour continuous operation is performed. To be assigned.

  The allocated resources and the period (start date / time and end date / time) are stored in the allocation information table, the unallocated job list is updated (step S9), and the process returns to step S6.

  If there is no job to be allocated (step S7: No), the result of the allocated resource and the period (start date and end date) for all jobs in the unallocated job list, that is, based on the allocation information table. Then, it is evaluated whether or not the result of the production plan is satisfied (step S10: evaluation step).

  If the result of the production plan is not satisfied (step S10: NG), the assignment level is changed for each order or job based on the result of the production plan (step S11: evaluation step), and the assignable calendar is updated ( Step S4). In addition, this step is the same as that described in the evaluation unit 15 of the production plan creation apparatus 1 described above, and a description thereof will be omitted.

  On the other hand, when the result of the production plan is satisfied (step S10: OK), the process of the production plan creation method is terminated.

  As described above, according to the production plan creation device, the production plan creation method, and the production plan creation program of this embodiment, the restrictions on the assignable calendar created based on the assignment level set for each order or for each job are taken into consideration. A production plan is created. Therefore, the allocation level is changed only for orders or jobs that require overtime or holiday attendance, such as orders or jobs that are delayed in delivery, instead of uniformly handling overtime or holiday attendance. By doing so, it is possible to devise an effective lean production plan while optimizing costs such as unnecessary labor costs, and to properly eliminate the delay in delivery of the target. Also, because it matches the actual operation of factories (especially factories that produce large single-product products), the accuracy of production plans for products with a large number of jobs and long lead times that are characteristic of production plans for large single-product products Can be improved.

  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, for an order that cannot meet the delivery date, the allocation level is changed so that overtime correspondence is set, but this is not a limitation. A holiday response may be set for changing the allocation level. In the above-described embodiment, when there is no shift work and overtime support is set, there is a restriction that a new job is not allocated within the overtime hours. A restriction may be attached so that a new job is allocated within the overtime hours without attaching a restriction.

  Next, a simple example will be described below in order to explain specific examples of the production plan creation device, the production plan creation method, and the production plan creation program of the present embodiment.

  In the present embodiment, a case is considered where there are four orders of products 1 to 3 including steps 1 to 4. Then, consider the case where the order instruction table, product master, process master, resource master, and resource operation calendar are as shown in Tables 1 to 5 below according to step S1 in the production plan creation method according to the present embodiment described above.

  The delivery date in the order instruction table of Table 1 is the production delivery date of the factory, and the scheduled date of the day. Also, the order of priority (in this embodiment, priority is set, and the higher the priority, the higher the priority) is assumed to be the same. Moreover, as shown in the process master of Table 3, process 1-3 shall be the process of manufacturing by 24-hour continuous operation (full operation). Each process can set a main resource and a plurality of sub-resources. Normally, a process that can be produced by a plurality of lines can register a combination of a main resource, a sub-resource, and a process time as a plurality of resource candidates. However, in this embodiment, one resource candidate is provided for simplicity. In this embodiment, the resource operation calendar shown in Table 5 registers the maximum number of resources that can handle overtime, shift work, and the like.

  Further, in this embodiment, for the sake of simplicity, it is assumed that there is no record at all, and the record information table is all blank. If there is a track record, the allocation table corresponding to it is initialized. Although not the result information table in the present embodiment, an example of the result information table is shown in Table 6 below.

  And according to step S2 in the production plan preparation method which concerns on this embodiment mentioned above, the production plan start date is set to April 1, 2009 0:00.

  From the above information, the unallocated job list shown in Table 7 below is created in accordance with step S3 in the production plan creation method according to the present embodiment described above.

  Here, according to step S4 in the production plan creation method according to the present embodiment described above, in this embodiment, the allocation level is set for each job, and the initial allocation level is Monday to Friday, weekdays, 8:00 to 16:00. Up to 8 hours working hours will be the operating hours, and holidays and overtime will not be handled. However, a job subject to full operation that operates continuously for 24 hours is not manufactured on a holiday, but is assigned at an allocation level for continuous operation for 24 hours on weekdays. Table 8 below shows the assignable calendars created in accordance with this assignment level.

  Here, according to steps S5 to S7 in the production plan creation method according to the present embodiment described above, the production plan start date and time is set to April 1, 2009, 0:00, the delivery date of the order, the resource operation calendar, and the assignable calendar Thus, the earliest start date and time and the latest end date and time of each job in the unassigned job list are calculated. Here, Table 9 in which the result of calculating the earliest start date and the latest end date is added to the unassigned job list is shown below. In this embodiment, for simplification, the job with the latest end date and time is assigned from the earliest to the job to be assigned. If the process time is the same, the job registered first is prioritized. The extraction order of assignment target jobs determined by this assignment algorithm is shown in Table 9 together. Actually, the assignment target job is determined by comprehensively evaluating the earliest start date and time, the latest end date and time, the process time, the margin of the assignable period, and the like.

  According to the steps S8 and S9 in the production plan creation method according to the present embodiment described above, the allocation target jobs are sequentially allocated according to the allocation order of the allocation target jobs shown in Table 9, and the result is added to the allocation information table. . The allocation information table is shown in Table 10 below.

  FIG. 3 shows the result of the production plan in the Gantt chart according to the allocation information table shown in Table 10. In the Gantt chart shown in FIG. 3, for the sake of simplicity, 0 to 8 o'clock is represented by 1 cell, 8 to 16:00 is represented by 1 cell, and 16:00 to 24:00 is represented by 1 cell. In addition, a job that suspends work on the current day and starts work from the next day is indicated by a horizontal line while the work is suspended. From the result of FIG. 3, it can be seen that the delivery date of the order is as shown in Table 11 below.

  From the results shown in Table 11, it can be seen that the order 1 can keep the delivery date, but the other orders 2 to 4 cannot keep the delivery date. It can be seen that in order to keep the delivery date of the order 2, it is necessary to start the final process from 12:00 on April 6, 2009 in consideration of the process time from at least the latest completion date and time of the final process. For this purpose, it is understood that the completion date and time of the job code “P2009-002-K13” needs to be completed 12 hours earlier so that the start date and time will be the previous start date and time from 24:00 on April 6, 2009.

  Therefore, according to steps S10, 11, and 4 in the production plan creation method according to the above-described embodiment, the job code “P2009-002-K13” is set to 12 on Saturday, April 4, 2009 via the input unit. The allocation level is changed so that production can be performed only for the time. Since this job is a full operation job, an allocatable calendar is created with an allocation level of “Monday-Friday: 00: 00-24: 00”. To this, “Sat: 00: 00-12: 00” is added to the assignable calendar and updated. FIG. 4 shows the result of executing steps S4 to S10 in the production plan creation method according to this embodiment described above based on the changed allocatable calendar.

  As shown in FIG. 4, it can be seen that the production plan is changed so that the delivery date of the order 2 can be kept by changing the allocation level. However, it can also be seen that the delivery date of Order 3 has not been kept. Since there is no timing when the equipment 3 used in the final process of the order 3 has a process time until the delivery date, the input is performed according to steps S10, 11, and 4 in the production plan creation method according to the above-described embodiment. Change the allocation level to handle overtime. That is, the allocation level of the job “P2009-003-K33” in the final process of order 3 is changed to overtime support (for example, 4 hours on weekdays is set as overtime hours), and the allocatable calendar is changed to “Monday-Friday: 8”. 0: 00-16: 00 "is changed to" Monday-Friday: 8: 00-20: 00 ". FIG. 5 shows the result of executing steps S4 to S10 in the production plan creation method according to the present embodiment described above based on the changed allocatable calendar.

  As shown in FIG. 5, it can be seen that the production plan has been changed so that the delivery date of the order 3 can be kept by changing the allocation level. Further, from the result of FIG. 5, it can be seen that the delivery date of the order is as shown in the following Table 12, and that the delivery date of all orders is kept. Therefore, the process ends according to step S10 in the production plan creation method according to the present embodiment described above.

  In this way, instead of uniformly dealing with overtime and holiday work, changing the assignment level only for the necessary jobs, while minimizing unnecessary labor costs and other costs, In addition, an effective production plan without waste can be made, and delays in delivery can be appropriately eliminated. Further, since it matches the actual operation of the factory, it is possible to improve the accuracy of production plans for products such as large one-product products with a large number of jobs and a long lead time.

  Next, in the above-described embodiment in which the production plan that can meet the delivery date of all orders shown in FIG. 5 is created, the delivery date of order 4 is from April 7, 2009 to April 6, 2009, depending on the convenience of the customer. Think about a case where you're too late. Considering the margin of the production equipment and the like, if the priority of order 4 is increased, the delivery date of other orders will be delayed, which is not a good idea. Therefore, in order to increase productivity by setting overtime hours for all jobs of order 4, the input unit is set according to steps S10, 11, and 4 in the production plan creation method according to this embodiment described above. The allocation level is changed so as to handle overtime. That is, the assignment level for all jobs of order 4 is changed to overtime support (for example, 8 hours on weekdays is set as overtime hours), and the assignable calendar is changed from “Monday-Friday: 8: 00-16: 00” to “ “Monday-Friday: 8: 00-24: 00”. In the present embodiment, when the assignment level is changed, a restriction that a new job is not assigned within the overtime hours is added to the assignable calendar on the assumption that there is no support for shift work. FIG. 6 shows the result of executing steps S4 to S10 in the production plan creation method according to the present embodiment described above based on the changed allocatable calendar.

  As shown in FIG. 6, by changing the allocation level, the job code “P2009-004-K32” of the second process of order 4 is changed to 2009/4/2 12:00:00 to 18:00 as a job corresponding to overtime. Assign. If the next process is a normal process, the next job should not be started during overtime, but should be started from the next day's operating hours (between 8:00 and 16:00 in this embodiment). Assigned to. Similarly, “P2009-004-K33” is assigned to 2009/4/3 14: 0 to 22:00 and completed. Further, from the result of FIG. 5, it can be seen that the delivery date of the order is as shown in the following Table 13, and that the production plan has been changed so that the delivery date of all orders including the order 4 with the earlier delivery date can be observed. I understand. Therefore, the process ends according to step S10 in the production plan creation method according to the present embodiment described above.

  In this way, instead of uniformly dealing with overtime and holiday work, changing the assignment level only for the necessary jobs, while minimizing unnecessary labor costs and other costs, In addition, an effective production plan without waste can be made, and delays in delivery can be appropriately eliminated. Further, since it matches the actual operation of the factory, it is possible to improve the accuracy of production plans for products such as large one-product products with a large number of jobs and a long lead time.

DESCRIPTION OF SYMBOLS 1 Production plan creation apparatus 11 Resource operation calendar registration part 12 Unallocated job list creation part 13 Assignable calendar creation part 14 Resource allocation part (job allocation part)
15 Evaluation Unit 25 Resource Operation Calendar 27 Unassigned Job List 28 Allocatable Calendar S1 Resource Operation Calendar Registration Step S4 Allocatable Calendar Creation Steps S5 to S9 Job Assignment Steps S10 and 11 Evaluation Step

Claims (15)

In a computer, a production plan creation method for creating a production plan by allocating allocatable resources to all jobs that are processes required to produce one or more orders of products,
The processing executed by the computing unit of the computer is
A resource operation calendar registration step for setting the resource operation time as a resource operation calendar;
An allocatable calendar creating step for creating an allocatable calendar as an allocatable calendar based on an allocation level preset for each order or for each job;
The unallocated jobs that do not allocate the resources in the job are selected in order by a predetermined allocation algorithm, and the resources to the selected unallocated jobs are selected in consideration of the constraints of the allocatable calendar and the resource movable calendar. And a job allocation step for storing the allocated resource and period as a production plan,
The production plan is evaluated based on the delivery date of the order, and for the order that does not satisfy the delivery date, the assignment level set for each order or each job is changed, the assignable calendar is updated, and again, An evaluation step for executing the processing of the job assignment step;
A production plan creation method characterized by comprising: The allocation level is
The production plan according to claim 1, wherein operation time, presence / absence of overtime and overtime, presence / absence of shift work, presence / absence of holiday and holiday operation time, presence / absence of continuous operation for 24 hours are set. How to make. In the evaluation step,
Of the orders that do not meet the delivery date, regarding jobs that do not end within the operation time of the day, considering the period of the job, if the end date and time of the job falls within a predetermined overtime after the operation time of the day, 3. The production plan creation method according to claim 2, wherein the assignable calendar is updated by changing an assignment level of the job as a time in which the overtime hours can be assigned. In the assignable calendar creation step,
4. The assignable calendar is created as an assignment level that can be assigned continuously for 24 hours for an order or job that needs to be worked continuously for 24 hours. Production plan creation method. In the assignable calendar creation step,
The assignable calendar is created by further adding a restriction to assign from the operation start time of the next day to an assignment level in which overtime is set but shift work is not set. The production plan preparation method as described in any one of 2-4. A production plan creation program for creating a production plan by allocating allocatable resources to all jobs that are processes required to manufacture one or more orders of products,
A resource operation calendar registration step for setting the resource operation time as a resource operation calendar;
An allocatable calendar creating step for creating an allocatable calendar as an allocatable calendar based on an allocation level preset for each order or for each job;
The unallocated jobs that do not allocate the resources in the job are selected in order by a predetermined allocation algorithm, and the resources to the selected unallocated jobs are selected in consideration of the constraints of the allocatable calendar and the resource movable calendar. And a job allocation step for storing the allocated resource and period as a production plan,
The production plan is evaluated based on the delivery date of the order, and for the order that does not satisfy the delivery date, the assignment level set for each order or each job is changed, the assignable calendar is updated, and again, An evaluation step for executing the job assignment step processing;
A production plan creation program characterized by having a computer read out by a calculation unit and causing each step to be executed. The allocation level is
The production plan according to claim 6, wherein operation time, presence / absence of overtime and overtime, presence / absence of shift work, presence / absence of holiday and holiday operation time, availability of continuous operation for 24 hours are set. Creation program. In the evaluation step,
Of the orders that do not meet the delivery date, regarding jobs that do not end within the operation time of the day, considering the period of the job, if the end date and time of the job falls within a predetermined overtime after the operation time of the day, 8. The production plan creation program according to claim 7, wherein the assignable calendar is updated by changing an assignment level of the job as a time in which the overtime can be assigned. In the assignable calendar creation step,
9. The assignable calendar is created as an assignment level that can be assigned continuously for 24 hours for an order or job that needs to be worked continuously for 24 hours. Production planning program. In the assignable calendar creation step,
The assignable calendar is created by further adding a restriction to assign from the operation start time of the next day to an assignment level in which overtime is set but shift work is not set. The production plan creation program according to any one of 7 to 9. In a computer, a production plan creation device that creates a production plan by allocating allocatable resources to all jobs that are processes required to produce one or more orders of products,
The computing unit of the computer is
A resource operation calendar registration unit for setting a resource operation time as a resource operation calendar;
An allocatable calendar creating unit that creates an allocatable calendar as an allocatable calendar based on an allocation level preset for each order or each job;
The unallocated jobs that do not allocate the resources in the job are selected in order by a predetermined allocation algorithm, and the resources to the selected unallocated jobs are selected in consideration of the constraints of the allocatable calendar and the resource movable calendar. A job allocation unit that stores the allocated resource and period as a production plan,
The production plan is evaluated based on the delivery date of the order, and for the order that does not satisfy the delivery date, the assignment level set for each order or each job is changed, the assignable calendar is updated, and again, An evaluation unit that executes a job allocation unit;
A production plan creation device characterized by comprising: The allocation level is
The production plan according to claim 11, wherein operation time, presence / absence of overtime and overtime, presence / absence of shift work, presence / absence of holiday and holiday operation time, presence / absence of continuous operation for 24 hours are set. Creation device. In the evaluation unit,
Of the orders that do not meet the delivery date, regarding jobs that do not end within the operation time of the day, considering the period of the job, if the end date and time of the job falls within a predetermined overtime after the operation time of the day, 13. The production plan creation apparatus according to claim 12, wherein the assignable calendar is updated by changing an assignment level of the job as a time in which the overtime hours can be assigned. In the assignable calendar creation unit,
14. The assignable calendar is created as an assignment level that can be assigned continuously for 24 hours for orders or jobs that need to be worked continuously for 24 hours. Production plan creation device. In the assignable calendar creation unit,
The assignable calendar is created by further adding a restriction to assign from the operation start time of the next day to an assignment level in which overtime is set but shift work is not set. The production plan creation device according to any one of 12 to 14.

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