JP2022113588A - Production plan generation device and production plan generation method - Google Patents

Abstract

To generate an optimum production plan for a plurality of products with different lead times.SOLUTION: A production control server 10 is a device which generates a production plan for producing a plurality of kinds of products at a plant. The production control server 10 includes a production sequence optimization part 122 which optimizes a production sequence of the products. The production sequence is indicated in an arranged order of a plurality of slots which is set for each process. The production sequence optimization part 122 acquires a first provisional sequence in which the production sequence is provisionally set, extracts those having additional lead time in the first provisional sequence, of the products, preferentially assigns the extracted product to the first slot according to the additional lead time and also assigns the other products to the second slot excluding the first slot so as to determine a second provisional sequence based on the first provisional sequence and determine a production sequence based on the second provisional sequence.SELECTED DRAWING: Figure 3

Description

The present invention relates to an apparatus and method for generating production plans for products.

Regarding the present invention, for example, a technique described in Patent Document 1 is known. Patent document 1 describes four schedulers that determine the processing order of six products for each of four processes, and control that instructs the schedulers to transfer data between the schedulers and to instruct the schedulers to execute processing. A scheduling apparatus is disclosed comprising: The CPU 12a1 of the scheduler calculates the production efficiency of the production schedule using the scheduled time calculator 12a12 that obtains the scheduled processing start time and the scheduled processing end time for each product, and the determined scheduled processing start time and processing end scheduled time for each product. Data for outputting the estimated processing end time information of each product obtained by the scheduled time calculation unit 12a12 to the evaluation unit 12a13 that evaluates, the schedule change unit 12a15 that changes the production schedule, and the scheduler of the process immediately after the own process. and an output unit 12a16.

JP-A-2005-18596

In the scheduling device described in Patent Document 1, the scheduled processing start time and the scheduled processing end time for each product are obtained using the scheduled processing end time information for each product in the immediately preceding process. Not enough consideration was given to time differences. Therefore, there is a problem that an optimum production plan cannot necessarily be obtained for a plurality of products with different lead times.

A production plan generation device according to the present invention is a device for generating a production plan when producing a plurality of types of products, and comprises a production order optimization unit for optimizing the production order of the products, wherein the production order is: The production order optimizing unit acquires a first provisional order in which the production order is provisionally set, and performs addition read in the first provisional order. extracting the product having time, preferentially assigning the extracted product to a first slot according to the added lead time, and assigning other products to a second slot other than the first slot; By assigning, a second provisional order based on the first provisional order is determined, and the production order is determined based on the second provisional order.
A production plan generation method according to the present invention is a method for optimizing the production order of a plurality of types of products to generate a production plan for the products, wherein the production order is the arrangement order of a plurality of slots set for each process. A computer acquires a first provisional order in which the production order is provisionally set, extracts the products having additional lead time in the first provisional order, and stores the extracted products as the additional lead A second provisional order based on the first provisional order by preferentially assigning to the first slot according to the time and assigning the other products to the second slots other than the first slot. is determined, and the production order is determined based on the second provisional order.

According to the present invention, an optimum production plan can be generated for multiple products with different lead times.

It is a figure showing composition of a production system concerning a 1st embodiment of the present invention. It is a figure which shows the outline|summary of a production line. It is a figure which shows the internal structure of a production control server. It is a figure which shows the structural example of the database memorize|stored in a production control server. It is a figure which shows the setting example of the production order for every process which concerns on the 1st Embodiment of this invention. It is a figure which shows the flow of the whole process of a production system. It is a flow chart which shows a flow of processing of a production order optimization part concerning a 1st embodiment of the present invention. It is a figure explaining the determination method of the production order for every production period. It is a figure which shows the example of a production information setting screen. FIG. 10 is a diagram showing an example of an option identifier setting screen; It is a figure which shows the example of a production control condition setting screen. FIG. 9 is a diagram showing an example of setting a production order for each process according to the second embodiment of the present invention; It is a flow chart which shows a flow of processing of a production order optimization part concerning a 2nd embodiment of the present invention.

Embodiments of the present invention will be described below with reference to the drawings. For clarity of explanation, the following descriptions and drawings are omitted and simplified as appropriate. The present invention is not limited to this embodiment, and all applications consistent with the idea of the present invention are included in the technical scope of the present invention. Unless otherwise specified, each component may be singular or plural.

In the following description, various types of information may be described in terms of, for example, "xxx table", but various types of information may be represented by data structures other than tables. The "xxx table" is sometimes referred to as "xxx information" to indicate that the various information does not depend on the data structure.

In addition, in the following description, when describing the same type of elements without distinguishing, reference symbols (or common parts in the reference symbols) are used, and when describing the same types of elements with distinction, the ID of the element (or element reference) may be used.

In the following description, processing may be described with the subject of "program" or its process, but the program is executed by a processor (for example, CPU (Central Processing Unit)) to perform a specified process. The subject of the processing may be a processor, as appropriate, using storage resources (eg, memory) and/or communication interface devices (eg, communication ports). A processor operates as a functional unit that implements a predetermined function by operating according to a program. Devices and systems that include processors are devices and systems that include these functional units.

(First embodiment)
FIG. 1 is a diagram showing the configuration of a production system according to the first embodiment of the present invention. The production system shown in FIG. 1 is intended for high-mix, low-volume production of multiple types of products with different specifications, such as automobiles. It is configured. The network 3 is configured using, for example, the Internet, a fixed telephone network, a mobile telephone network, etc., and relays information transmitted and received between the production control center 1 and the factory 2 .

The production control center 1 is a facility for product production control, and has a production control server 10 , a production control operating terminal 11 and a system control operating terminal 12 . The factory 2 is a facility for producing products, and has a data collection device 20 and a production line 21 .

The production control server 10 is a computer device that functions as a production plan generation device that generates a production plan when the factory 2 produces products. The production control server 10 is connected to the data collection device 20 of the factory 2 via the network 3 and transmits the generated production plan to the data collection device 20 . It is also possible to receive information about the production status of products transmitted from the data collection device 20 and to manage the production of products based on this information. Details of the production control server 10 will be described later.

The production management operation terminal 11 and the system management operation terminal 12 are information devices for inputting necessary information when the production control server 10 generates a production plan. configured respectively. Production management operation terminal 11 is operated by a user to input production information, which is information relating to specifications and quantities of products to be produced in factory 2 . The system management operation terminal 12 is operated by a user to input production control condition information, which is information relating to the production order for producing products in the factory 2 and the constraint conditions of the production line 21 . A user who operates the production management operation terminal 11 is, for example, a person in charge of a production management department who performs work related to production management of products in the factory 2 . Also, the person in charge of operating the operating terminal 12 for system management is the person in charge of the system management department who performs work related to system management of the production line 21 in the factory 2 . These users may be the same person.

The production management operation terminal 11 and the system management operation terminal 12 are connected to the production control server 10 via a communication line such as a LAN, and transmit input production information and production control condition information to the production control server 10, respectively. Send. The production control server 10 stores the information transmitted from the production management operation terminal 11 and the system management operation terminal 12 in a database, and uses it when generating a production plan.

The production control server 10, the production management operation terminal 11, and the system management operation terminal 12 do not necessarily have to be physically installed in the same facility. That is, the production control center 1 is not only a physical facility configured by installing a plurality of information devices, but also a virtual facility configured by connecting a plurality of information devices to each other via the Internet or the like. may be Also, the production control server 10 may incorporate the functions of the production management operation terminal 11 and the system management operation terminal 12 .

The data collection device 20 receives the production plan transmitted from the production control server 10 and outputs this production plan to the production line 21 . The production line 21 has multiple production devices 22 . In the example of FIG. 1, the production line 21 has N production apparatuses 22, and the respective production apparatuses 22 are designated as production apparatuses 22-1, 22-2, . Although shown, the number of production devices 22 in the production line 21 is not limited to this. Each production device 22 carries out the work of each corresponding step in the overall product production process according to the production plan output from the data collection device 20 .

The data collection device 20 also acquires information on the production status of products from each production device 22 on the production line 21 and transmits the information to the production control server 10 via the network 3 . The production control server 10 grasps the production status of the product based on the information received from the data collection device 20 and reflects it in the production management of the product.

FIG. 2 is a diagram showing an outline of the production line 21. As shown in FIG. As shown in FIG. 2, the production line 21 is configured by combining a plurality of processes classified according to the type of work performed during product production, such as a welding line, a confluence line, a storage line, a coating line, and an assembly line. be done. For each process, a combination of constraints (constraint set) is set according to the performance, characteristics, operating conditions, etc. of the production equipment 22 to be used. In addition, like the welding lines 1 and 2 and the assembly lines 1 and 2 in FIG. 2, a plurality of individual lines may be set in parallel for the same process.

FIG. 3 is a diagram showing the internal configuration of the production control server 10. As shown in FIG. As shown in FIG. 3 , the production control server 10 is configured by connecting a network interface 101 , a control section 102 , an external storage device 103 and an internal storage device 104 via a bus 105 .

The network interface 101 performs predetermined interface processing for transmitting and receiving information between the production control server 10 and the data collection device 20 via the network 3 . Thereby, the production control server 10 and the data collection device 20 are connected via the network 3 . Furthermore, the production control server 10 is connected to the production management operation terminal 11 and the system management operation terminal 12, and the production information and the production control condition information input at the production management operation terminal 11 and the system management operation terminal 12 are transmitted. Processing for receiving may be performed in the network interface 101 .

The control unit 102 has a production management unit 121 and a production order optimization unit 122 as its functions. The control unit 102 is configured using, for example, a CPU, ROM, RAM, etc., and can realize each function of the production control unit 121 and the production sequence optimization unit 122 by executing a predetermined program. A GPU (Graphics Processing Unit), an FPGA (Field-Programmable Gate Array), or the like may be provided as the control unit 102, and each function of the production control unit 121 and the production sequence optimization unit 122 may be realized using these. .

The production order optimization unit 122 optimizes the production order of products and generates a production plan according to the production order. The production plan generated by the production sequence optimizing unit 122 is transmitted to the data collection device 20 via the network interface 101 and applied to the production of the product using the production line 21 in the factory 2 . Details of the processing performed by the production sequence optimization unit 122 will be described later.

The production control unit 121 performs product production control based on the production order optimized by the production order optimization unit 122 . At this time, the production management unit 121 grasps the production status of the product based on the information collected from the data collection device 20, for example, and compares it with the production plan generated by the production sequence optimization unit 122. FIG. By outputting this comparison result to the operation terminal 11 for production control, the information is presented to the person in charge of the production control department, and a review of the production plan is proposed as necessary. The above is an example of the production control method by the production control unit 121, and any other method can be used for product production control.

The external storage device 103 and the internal storage device 104 are storage devices capable of reading and writing various data under the control of the control unit 102. For example, recording media such as HDDs (Hard Disk Drives) and SSDs (Solid State Drives) are used. configured using In the internal storage device 104, each program of a production control program 141 and a production order optimization program 142, a production information database 143, a factory layout information database 144, a production order information database 145, a production order basic model information database 146 and production constraints. Each database of the information database 147 (hereinafter the database may be abbreviated as "DB") is recorded. Each program is read from the internal storage device 104 and executed by the control unit 102, and each database is used when the control unit 102 executes these programs. Part or all of these programs and databases may be recorded in the external storage device 103 instead of the internal storage device 104 .

The production management program 141 and the production order optimization program 142 are programs for realizing the production management section 121 and the production order optimization section 122 in the control section 102, respectively. That is, the control unit 102 can function as the production management unit 121 by executing the production management program 141 and can function as the production sequence optimization unit 122 by executing the production sequence optimization program 142 .

The production information DB 143 is a database that stores production information regarding specifications, quantities, etc. of products produced in the factory 2 for each product.

The factory layout information DB 144 is a database storing information on each process of the production line 21 in the factory 2 .

The production order information DB 145 is a database that stores information on the production order of products optimized by the production order optimization unit 122 . The production sequence information DB 145 obtained by the production sequence optimization unit 122 is transmitted to the data collection device 20 via the network interface 101 as a production plan generated by the production control server 10 .

The production sequence basic model information DB 146 is a database that stores information on models that the production sequence optimization unit 122 uses when optimizing the production sequence of products.

The production constraint information DB 147 is a database that stores information on constraints when producing products in each process of the production line 21 .

FIG. 4 is a diagram showing a configuration example of a database stored in the production control server 10. As shown in FIG. As shown in FIG. 3, the internal storage device 104 of the production control server 10 stores a production information DB 143, a factory layout information DB 144, a production order information DB 145, a production order basic model information DB 146, and a production constraint information DB 147. . FIG. 4 shows a configuration example of these databases.

The production information DB 143 includes factory identifier 1431, product identifier 1432, product type 1433, production quantity 1434, and product option 1435 information. The production information DB 143 is configured by setting these pieces of information for each product.

The factory identifier 1431 represents a unique identifier given to the factory 2 where the product is produced. If there are a plurality of factories 2 that manufacture the product, the value of this factory identifier 1431 can identify which factory produces the product.

Product identifier 1432 represents a unique identifier assigned to the product. Each product can be individually identified by the value of this product identifier 1432 .

The product type 1433 represents the type of the product, and includes a product type identifier 14331, a constraint application condition 14332, a process 14333, and an additional lead time condition 14334.

The product type identifier 14331 represents a unique identifier given to the product type. In a high-mix, low-volume production factory 2 that produces a plurality of types of products with different specifications, the value of the product type identifier 14331 can distinguish each product according to the difference in specifications.

The constraint application condition 14332 represents a constraint application condition for the product type. As described above, in the production line 21 of the factory 2, a constraint set corresponding to the performance of the production equipment 22, operating conditions, etc. is set for each process. In this constraint set, the presence or absence of application is determined for each type of product. Therefore, based on the value of the constraint application condition 14332, it can be determined for each product type whether or not the constraint set is applied to the product when determining the production order of each product.

Step 14333 represents the steps required to produce the product. Based on the value of this process 14333, it is possible to determine for each product type through which process of the production line 21 each product is produced.

The additional lead time condition 14334 represents the condition of additional lead time required for production of the product. The lead time required for the production of each product differs from process to process, and depending on the product specifications, a longer lead time may be required than for other products. In such a case, the value of the additional lead time condition 14334 can be used to determine, for each product type, which process in the production line 21 requires a longer lead time than the other products. can.

The production quantity 1434 represents the production quantity of the product.

The product option 1435 represents information on additional specifications of the product, and includes an option identifier 14351, constraint application conditions 14352, process 14353, and additional lead time conditions 14354. The product option 1435 is set according to the number of additional specifications for the product. Therefore, as shown in FIG. 4, multiple product options 1435 may be set for one product.

The option identifier 14351 represents a unique identifier assigned to additional specifications of the product. By the value of this option identifier 14351, each product can be distinguished according to the difference in additional specifications in addition to its basic specifications.

Constraint application conditions 14352, process 14353, and additional lead time conditions 14354 are the same as the constraint application conditions 14332, process 14333, and additional lead time conditions 14334 of the product type 1433, respectively.

The factory layout information DB 144 includes factory identifier 1441 , production process identifier 1442 , production apparatus identifier 1443 , pre-process identifier 1444 , post-process identifier 1445 , and constraint identifier list 1446 . The factory layout information DB 144 is configured by setting such information for each process constituting the production line 21 .

Factory identifier 1441 is the same as factory identifier 1431 of production information DB 143 .

A production process identifier 1442 represents a unique identifier assigned to the process. Each process of the production line 21 can be individually specified by the value of this production process identifier 1442 .

The production equipment identifier 1443 represents a unique identifier given to the production equipment 22 used in the process. Which production device 22 is used in each process of the production line 21 can be specified by the value of this production device identifier 1443 .

A pre-process identifier 1444 and a post-process identifier 1445 represent unique identifiers given to processes that exist before and after the relevant process on the production line 21, respectively. The order of the processes in the production line 21 can be specified by the values of the pre-process identifier 1444 and post-process identifier 1445 .

A constraint identifier list 1446 represents a constraint set set for the process and is composed of a list of unique identifiers given to each constraint included in the constraint set. The value of each identifier in this constraint identifier list 1446 can specify a combination of constraints in the process.

The production order information DB 145 includes factory identifier 1451 , production process identifier 1452 , product identifier 1453 and production order 1454 . The production sequence information DB 145 is configured by setting these pieces of information for each product for each process that constitutes the production line 21 .

The factory identifier 1451 and the production process identifier 1452 are the same as the factory identifier 1441 and the production process identifier 1442 of the factory layout information DB 144, respectively. Product identifier 1453 is the same as product identifier 1432 of production information DB 143 .

The production order 1454 represents the production order of the product in the process. The value of the production order 1454 can be used to identify the order in which each product is produced for each process.

The production sequence basic model information DB 146 includes each information of model identifier 1461 , model application condition 1462 , production sequence allocation unit 1463 , and production sequence control algorithm 1464 . The production order basic model information DB 146 is configured by setting these pieces of information for each model used when the production order optimization unit 122 in the production control server 10 optimizes the production order of products.

A model identifier 1461 represents a unique identifier assigned to the model. Each model used in the production sequence optimization unit 122 can be individually specified by the value of this model identifier 1461 .

The model application condition 1462 represents the application condition of the model. Based on the value of this model application condition 1462, it is possible to determine on what basis each model is applied when the production sequence optimization unit 122 optimizes the production sequence of products.

The production order allocation unit 1463 represents the production order allocation unit for the model. Based on the value of the production order allocation unit 1463, it can be determined whether the production order allocation by the model is per product or per product type.

The production order control algorithm 1464 represents the production order control algorithm employed by the model. Based on the value of this production sequence control algorithm 1464, it is possible to determine what kind of algorithm the model uses to optimize the production sequence.

The production constraint information DB 147 includes information on constraint identifiers 1471 , production process identifiers 1472 , constraint application conditions 1473 , production order allocation units 1474 , and constraint definition formulas 1475 . The production constraint information DB 147 is configured by setting these pieces of information for each constraint in the constraint set set for each process forming the production line 21 .

A constraint identifier 1471 represents a unique identifier assigned to the constraint and corresponds to each identifier listed in the constraint identifier list 1446 of the factory layout information DB 144 . By referring to the value of this constraint identifier 1471 , information corresponding to the constraint set indicated by the constraint identifier list 1446 can be searched in the production constraint information DB 147 .

The production process identifier 1472 is the same as the production process identifier 1442 of the factory layout information DB 144 .

The constraint application condition 1473 represents the application condition of the constraint. Based on the value of this constraint application condition 1473, it can be determined whether or not the constraint is applied when determining the production order of each product.

The production order allocation unit 1474 represents the production order allocation unit for the constraint. Based on the value of this production order allocation unit 1474, it can be determined whether the constraint is applied per product or per product type.

The constraint definition formula 1475 represents the definition formula of the constraint. The production order optimization unit 122 optimizes the production order of products so as to satisfy the constraints of the definitional expression represented by the constraint definitional expression 1475 .

The configuration of each database described above is merely an example, and other configurations may be used. In the production control server 10, any database configuration can be adopted as long as the production sequence optimizing unit 122 can acquire data necessary for optimizing the production sequence of products and generating a production plan.

FIG. 5 is a diagram showing a setting example of the production order for each process according to the first embodiment of the present invention. FIG. 5 shows an example of the production order optimized by the production order optimization unit 122 of the present embodiment for each process of production process 1, production process 2, and production process 3. As shown in FIG. The order of production in each of these processes is represented by the order of arrangement of a plurality of slots set for each process, and each slot corresponds to an individual product.

The production order of production process 2 is determined by production order optimization unit 122 based on the production order of production process 1 immediately before. At this time, the production order optimization unit 122 sets the production order of production process 1 as a provisional production order (provisional order) for production process 2 . In this provisional order, if there is a product with a longer lead time in production process 2 than other products (product 6 in the example of FIG. 5), a slot corresponding to the additional lead time (additional lead time) is allocated. Allocated preferentially to the product concerned. As a result, as shown in FIG. 5, the order of the product 6 has been moved down in the production order of the production process 2 .

Similarly, the production order of production process 3 is determined by production order optimization unit 122 based on the production order of production process 2 immediately before. At this time, the production order optimization unit 122 determines the optimum production order in the production process 3 by executing optimization processing using a model based on a predetermined algorithm. As a result, as shown in FIG. 5, in the production order of production process 3, the order of product 7 and product 8 is reversed.

In the above example, the production order is determined for the three consecutive processes in the production line 21, namely production process 1, production process 2, and production process 3, starting from the upstream process. The production order in the process can also be determined by a similar procedure. That is, the production order optimization unit 122 first determines a provisional order for each process, and if there is a product with additional lead time in the provisional order, Allocate the slot with priority and assign other products sequentially to the remaining slots. By executing optimization processing using a predetermined algorithm based on the provisionally determined production order, it is possible to determine the optimum production order. Details of the processing of the production order optimization unit 122 at this time will be described later.

Here, the production sequence optimizing unit 122 determines the production sequence for each process as described with reference to FIG. At this time, the user can use the production management operation terminal 11 to set an arbitrary production period, such as one day or one week, as a processing unit for creating the production order. Information on the production period set by the user is transmitted from the production management operation terminal 11 to the production control server 10 and reflected in the processing performed by the production sequence optimization unit 122 .

FIG. 6 is a diagram showing the flow of overall processing of the production system. In the production system of FIG. 1, first, based on the information input by the user at the operating terminal 12 for system management, the production control condition information regarding the production order when producing products in the factory 2 and the constraint conditions of the production line 21 is generated. , is transmitted from the system management operation terminal 12 to the production control server 10 (step S1).

When the production control condition information transmitted from the system management operation terminal 12 is received, the production control server 10 sets a production control condition database in the internal storage device 104 based on the received production control condition information (step S2). ). Here, out of the production information DB 143, the factory layout information DB 144, the production order information DB 145, the production order basic model information DB 146, and the production constraint information DB 147, the factory layout information DB 144, the production order basic model information DB 146, and the production Each database of the constraint information DB 147 is set based on the production control condition information.

After that, the production control server 10 determines a provisional order for each process in consideration of the basic model and constraints of the production control conditions represented in the database set in step S2 (step S3). Here, for example, the provisional order is determined so that the total lead time for each product in each process is leveled.

After the provisional order is determined, the production control terminal 11 transmits production information related to the specifications and quantities of the products to be produced in the factory 2 based on the information input by the user through the production control terminal 11. It is transmitted to the server 10 (step S4).

The production control server 10 receives the production information transmitted from the production management operation terminal 11, thereby acquiring information on product production (step S5). Then, the acquired production information is stored in the production information DB 143 .

After acquiring the production information and setting the production information DB 143 in step S5, the production control server 10 refers to the production information DB 143 to extract products having additional lead time in the provisional order determined in step S3, and A production sequence is set according to the added lead time (step S6). Here, as described above, a product with an additional lead time is preferentially assigned a slot corresponding to the additional lead time, and other products are sequentially assigned to the remaining slots. Tentatively set the order.

After that, the production control server 10 performs an optimization process applying a predetermined multi-process batch individual vehicle allocation algorithm to the production sequence provisionally set in step S6 (step S7). Through this optimization process, an optimized production order can be obtained for each process of the production line 21 .

When the production order can be obtained in step S7, the production control server 10 generates a production plan representing the obtained production order, and transmits the production plan information to the data collection device 20 (step S8).

FIG. 7 is a flow chart showing the flow of processing of the production sequence optimization unit 122 according to the first embodiment of the present invention. The processing shown in this flowchart corresponds to steps S3 to S7 in FIG.

In step S<b>10 , the production order optimization unit 122 designates identifiers and quantities of products that the factory 2 produces on the production line 21 . Here, for example, the production information DB 143 is referred to, and based on the values set for the product identifier 1432, product type 1433, and production quantity 1434 in this production information DB 143, the target product whose production order is to be optimized is specified.

In step S20, the production sequence optimization unit 122 designates a basic model used for controlling the production sequence of the target product designated in step S10. Here, for example, the production sequence basic model information DB 146 is referred to, and based on the values respectively set in the production sequence basic model information DB 146 for the model identifier 1461, the model application condition 1462, the production sequence allocation unit 1463, and the production sequence control algorithm 1464. to specify the base model.

In step S30, the production order optimization unit 122 creates a provisional order for each process for the target product specified in step S10 based on the basic model specified in step S20. Here, for example, the provisional order is created by provisionally setting the production order of each product so that the total lead time of each product in each process is leveled. At this time, as described above, the production period designated by the user is used as a processing unit, and a provisional order is created for each production period. As a result, a provisional order for each process is created in step S30 for each production period, such as one day or one week.

As shown in FIG. 2, when the target product is produced in the production line 21 including a combination of a plurality of processes parallel to each other, in step S30, each product is produced through which process among these processes. It is preferable to create a provisional order for each process, taking into account whether the Specifically, for example, the product is selected for each process so that the constraint represented by the production constraint information DB 147 set for each process and the constraint represented by the production information DB 143 set for each product match each other. You can select it and create a tentative order in it. As a result, the production order optimizing unit 122 can create a provisional order so as to satisfy predetermined constraint conditions including combination conditions of product types and processes. As a result, it is possible to create a provisional order in an appropriate process for each product.

In step S40, the production order optimizing unit 122 determines whether or not there is a product for which an option identifier including additional lead time is set among the products in the tentative order created in step S30. Here, for example, in the production information DB 143, among the product options 1435 set for each product for which a provisional order is set, by referring to the value of the additional lead time condition 14354, the presence or absence of the additional lead time can be determined. Judge each. As a result, if there is at least one product for which an option identifier including the additional lead time is set, the product is extracted from the provisional order and the process proceeds to step S50; otherwise, the process proceeds to step S60.

In step S50, the production order optimizing unit 122 preferentially assigns the product set with the option identifier including the additional lead time extracted from the provisional order in step S40 to the slot corresponding to the additional lead time. Thereby, as illustrated in FIG. 5, the production order of the product can be moved down according to the added lead time.

If a plurality of products with option identifiers including additional lead times are extracted in step S40, the production order optimization unit 122 preferably assigns these products to interchangeable slots. The interchangeable slots referred to here are those in which the order of the slots is permitted to be interchanged only between the relevant slots and the interchange with other slots is restricted in the optimization process performed in step S80 described later.

In step S50, if all the products having additional lead times can be assigned to slots according to the additional lead time, the process proceeds to step S60.

In step S60, the production order optimizing unit 122 has already allocated in step S50 all the products that have not been extracted from the provisional order in step S40, i.e., the products for which option identifiers including additional lead time have not been set. Allocate sequentially to empty slots excluding the slots of As a result, the production order in consideration of the additional lead time is provisionally set based on the provisional order created in step S30.

In order to distinguish between the provisional order created in step S30 and the production order provisionally set in step S60, the former will be referred to as the "first provisional order" and the latter as the "second provisional order" in the following description. may be described as "order". That is, the production order optimizing unit 122 can determine the second provisional order based on the first provisional order by performing the processes of steps S40 to S60. However, if it is determined in step S40 that all the products included in the tentative order do not have additional lead time, then in step S60 the same first tentative order is determined as the second tentative order. be.

In step S70, the production order optimization unit 122 sets constraints used for order control of each product in the optimization process of step S80. Here, for example, the factory layout information DB 144 and the production constraint information DB 147 are referred to, and the constraint for each process is set based on the information set in these databases.

In step S80, the production order optimization unit 122 performs optimization processing based on the second provisional order determined in step S60 and the constraints set in step S70. For example, among multiple production orders that satisfy the constraints set for the second provisional order, by treating it as an optimization problem to find the production order that minimizes the total lead time, a well-known calculation method can be used. It can be used to implement the optimization process in step S80. By executing such optimization processing in the production order optimization unit 122, it is possible to determine the optimum production order based on the second provisional order for each process. Any calculation method can be applied in step S80 as long as the optimum production order can be determined from the second provisional order.

Here, as described above, in step S30, the production period specified by the user is used as a processing unit, and a provisional order is created for each production period. Therefore, in the optimization process of step S80 as well, the optimum production order is determined for each process for each production period designated by the user. A specific example thereof will be described below with reference to FIG.

FIG. 8 is a diagram explaining a method of determining the production sequence for each production period. FIG. 6 shows an example in which the production order optimization unit 122 determines the optimum production order based on the second provisional order for a certain process in each of the first production period, the second production period, and the third production period. is shown.

As shown in FIG. 8, the production order in each production period is represented by the order of arrangement of a plurality of slots as in FIG. 5, and each slot corresponds to an individual product. Note that in the example of FIG. 8, the description of the type of each product is omitted.

In the optimization process of step S80, the production order optimizing unit 122 selects a predetermined number of slots adjacent to other production periods (example in FIG. 2 slots) is set as the connection area. The connection region is a range in which slots can be interchanged between production orders corresponding to two production periods adjacent to each other when determining the optimum production order based on the second provisional order. . Specifically, in the optimization process of step S80, between the connection area set in the last two slots of the first production period and the connection area set in the first two slots of the second production period, these It allows the exchange of slots included in the connection area. Similarly, between the connection area set in the last two slots of the second production period and the connection area set in the first two slots of the third production period, the slots included in these connection areas are exchanged. allow.

Furthermore, when the slot preferentially assigned to the product having the added lead time in step S50 is included in the connection area, in the optimization process in step S80, the production order optimization unit 122 Allows the slot to move between production sequences corresponding to two production periods. Specifically, of the connection areas set in the last two slots of the first production period, the last slot assigned to product 6 is allowed to move to the connection area of the next second production period. . Similarly, of the connection areas set in the last two slots of the second production period, the second to last slot assigned to product 17 is allowed to move to the connection area of the next third production period. do.

In the optimization process of step S80, the optimum production order is determined from the second provisional order after allowing slot replacement and movement between adjacent production periods as described above. This makes it possible to flexibly generate the optimum production plan for each production period.

In step S<b>90 , the production order optimization unit 122 determines whether or not there is a process whose production order has not been determined in the production line 21 . If the plurality of processes constituting the production line 21 includes a process for which the optimization process of step S80 has not yet been performed and therefore the production order has not yet been determined, return to step S30 and perform the above Continue processing. On the other hand, if the optimization process of step S80 has already been performed for all processes and therefore there is no process whose production order has not yet been determined, the process shown in the flowchart of FIG. 7 ends.

FIG. 9 is a diagram showing an example of a production information setting screen displayed when the user inputs production information on the production management operation terminal 11. As shown in FIG. FIG. 10 is a diagram showing an example of an option identifier setting screen called from the production information setting screen of FIG. The user can set the production information DB 143 by inputting various IDs assigned to the products produced in the factory 2, specifications and quantities of the products, details of additional specifications, etc. on these screens.

FIG. 11 is a diagram showing an example of a production control condition setting screen displayed when the user inputs production control condition information on the operating terminal 12 for system management. The user can set the factory layout information DB 144, the production order basic model information DB 146, and the production constraint information DB 147 by inputting the production order for producing the product in the factory 2 and the constraint conditions of the production line 21 on this screen. It can be performed.

According to the first embodiment of the present invention described above, the following effects are obtained.

(1) The production control server 10 is a device that generates a production plan for producing multiple types of products in the factory 2 . The production control server 10 includes a production order optimization unit 122 that optimizes the production order of products. The order of production is represented by the order in which a plurality of slots are arranged for each process. The production order optimizing unit 122 acquires the first provisional order in which the production order is provisionally set (step S30), extracts products having additional lead time in the first provisional order (step S40), and extracts A second provisional order based on the first provisional order is obtained by preferentially assigning the product to the first slot according to the added lead time and assigning other products to the second slot other than the first slot. The order is determined (steps S50, S60), and the production order is determined based on the second provisional order (step S80). By doing so, it is possible to generate the optimum production plan for a plurality of products with different lead times.

(2) When the production order optimizing unit 122 extracts a plurality of products having the same length of added lead time in the first provisional order in step S40, in step S50, the extracted products can be replaced with each other in the first order. It is preferable to assign each to one slot. In this way, an optimal production plan can be flexibly generated.

(3) In step S80, the production sequence optimization unit 122 determines the production sequence for each processing unit, using the production period specified by the user as the processing unit. Since this is done, an optimum production plan can be generated for each arbitrary production period.

(4) In step S80, the production order optimizing unit 122 sets some of the plurality of slots as connection areas. Then, when determining the production order based on the second provisional order, as shown in FIG. Allow replacement. Also, when the first slot is included in the connection area, the movement of the first slot between processing units is permitted. Since it did in this way, the optimal production plan can be produced|generated for every production period.

(5) In the factory 2, products are produced by a production line 21 including a combination of multiple processes parallel to each other. In step S30, the production order optimizing unit 122 preferably creates the first provisional order so as to satisfy predetermined constraint conditions including combination conditions of product types and processes. In this way, the first provisional order can be created in an appropriate process for each product.

(Second embodiment)
Next, a second embodiment of the invention will be described. In this embodiment, an example will be described in which the second provisional order is determined by allocating slots for each type of product, and the production order is determined for each product based on this second provisional order.

The configurations of the production system and the production control server according to this embodiment are the same as the configurations of FIGS. 1 and 3 described in the first embodiment. Also, the configuration of the database stored in the production control server is the same as that shown in FIG. 4 described in the first embodiment. Therefore, the operation of this embodiment will be described below using these configurations in the first embodiment.

FIG. 12 is a diagram showing a setting example of the production order for each process according to the second embodiment of the present invention. FIG. 12 shows an example of the production order optimized by the production order optimization unit 122 of the present embodiment for each process of production process 1, production process 2, and production process 3. As shown in FIG. The order of production in each of these processes is represented by the order of arrangement of a plurality of slots set for each process, similar to FIG. 5 described in the first embodiment, and each slot corresponds to an individual product. there is However, in the example of FIG. 12, except for the production process 3, only the product type corresponding to each slot is displayed.

The production order of production process 2 is determined by production order optimization unit 122 based on the production order of production process 1 immediately before. At this time, the production order optimization unit 122 sets the production order of production process 1 as a provisional production order (provisional order) for production process 2 . In this temporary order, if there is a product type (type B in the example of FIG. 5) with a longer lead time in production process 2 than other product types, the additional lead time (additional lead time) Allocate slots preferentially to the product type. As a result, as shown in FIG. 12, the order of the type B is moved down in the production order of the production process 2 respectively.

Similarly, the production order of production process 3 is determined by production order optimization unit 122 based on the production order of production process 2 immediately before. At this time, the production order optimization unit 122 determines the optimum production order for each product type in the production process 3 by executing optimization processing using a model based on a predetermined algorithm for each product type. As a result, as shown in FIG. 12, in the production order of production process 3, the order of type A and type C is partly changed.

After determining the production order for each product type in the production process 3, the production order optimization unit 122 allocates each product to the corresponding slot according to the production order for each product type. As a result, as shown in FIG. 12, the order of production for each product in production process 3 is determined.

In the above example, the production order is determined for the three consecutive processes in the production line 21, namely production process 1, production process 2, and production process 3, starting from the upstream process. As in Embodiment 1, the order of production in each step can be determined by the same procedure. That is, the production order optimizing unit 122 first determines a provisional order for each process, and if there is a product type having an additional lead time in the provisional order, the additional lead time is calculated for the product type. The slot corresponding to the product type is preferentially assigned, and other product types are assigned sequentially to the remaining slots. By executing optimization processing using a predetermined algorithm based on the provisionally determined production order, it is possible to determine the optimum production order.

FIG. 13 is a flow chart showing the processing flow of the production sequence optimization unit 122 according to the second embodiment of the present invention. The processing shown in this flowchart corresponds to steps S3 to S7 in FIG. 6 described in the first embodiment, and is realized by executing the production sequence optimization program 142 in the control unit 102. FIG.

In steps S10 to S30, processes similar to those in the flowchart of FIG. 7 described in the first embodiment are performed.

In step S40A, the production order optimizing unit 122 determines whether or not there is a product type including the added lead time among the products in the tentative order created in step S30. Here, for example, in the production information DB 143, among the product types 1433 set for each product for which a provisional order is set, by referring to the value of the additional lead time condition 14334, the presence or absence of the additional lead time can be determined. Judge for each type. As a result, if even one product type including the additional lead time exists, the product type is extracted from the tentative order and the process proceeds to step S50A. If none exists, the process proceeds to step S60A.

In step S50A, the production order optimizing unit 122 preferentially assigns the product type including the additional lead time extracted from the provisional order in step S40A to the slot corresponding to the additional lead time. Thereby, as illustrated in FIG. 12, the production order of the product type can be moved down according to the added lead time.

Note that when a plurality of product types including the added lead time are extracted in step S40A, the production order optimization unit 122 allocates each of these product types to interchangeable slots, as in the first embodiment. is preferred.

In step S50A, if all product types having additional lead times can be assigned to slots according to the additional lead time, the process proceeds to step S60A.

In step S60A, the production order optimizing unit 122 extracts all the product types that have not been extracted from the tentative order in step S40A, that is, the product types that do not include the additional lead time, excluding the slots already assigned in step S50A. Allocate to empty slots sequentially. As a result, the second provisional order in consideration of the additional lead time is determined for each product type based on the first provisional order created in step S30.

In steps S70 to S90, processes similar to those in the flowchart of FIG. 7 described in the first embodiment are performed. As a result, the optimum production order is determined for each product type based on the second provisional order for each product type determined in step S60A. If it is determined in step S90 that the optimization process of step S80 has already been performed for all processes and therefore there is no process whose production order has not been determined, the process proceeds to step S100.

In step S100, the production order optimization unit 122 allocates arbitrary products corresponding to each product type with respect to the optimum production order determined for each product type by the processing up to step S90. This makes it possible to determine the optimum production order for each process for each product. After executing step S100, the process shown in the flowchart of FIG. 13 ends.

According to the second embodiment of the present invention described above, the production order optimizing unit 122 determines the second provisional order for each product type (steps S50A and S60A), and determines the second provisional order for each product type. Based on the obtained second provisional order, the production order is determined for each product (steps S80, S100). Since this is done, the optimization process can be executed for each product type, which makes it possible to reduce the amount of calculation. As a result, it is possible to quickly create an optimal production plan for a plurality of products with different lead times.

In each of the above embodiments, the control unit 102 of the production control server 10 is caused to function as the production order optimization unit 122, and the production order optimization unit 122 executes the processes of steps S10 to S30. An example of creating a tentative order of 1 has been described. However, the production control server 10 acquires the first provisional order created at a location other than the production control server 10, and the production order optimization unit 122 uses this first provisional order to , or the processes after step S40A in FIG. 13, the production order of each product may be determined and a production plan may be created. Alternatively, the production order input by the user using the production management operation terminal 11 may be used as the first provisional order. Besides this, it is possible to create a production plan based on the first provisional order acquired by any method.

Moreover, the production system described in each of the above embodiments is suitable for creating a production plan when producing automobiles, but it can also be applied to other products. If a plurality of types of products are produced and some of them include products with different lead times from other products, the present invention can be applied to the production plan of any product.

The embodiments and various modifications described above are merely examples, and the present invention is not limited to these contents as long as the features of the invention are not impaired. Moreover, although various embodiments and modifications have been described above, the present invention is not limited to these contents. Other aspects conceivable within the scope of the technical idea of the present invention are also included in the scope of the present invention.

1: production control center, 2: factory, 3: network, 10: production control server, 11: operation terminal for production control, 12: operation terminal for system control, 20: data collection device, 21: production line, 22: production Device 101: Network interface 102: Control unit 103: External storage device 104: Internal storage device 105: Bus 121: Production control unit 122: Production order optimization unit 141: Production control program 142: Production sequence optimization program 143: Production information database 144: Factory layout information database 145: Production sequence information database 146: Production sequence basic model information database 147: Production constraint information database

Claims (14)

A device for generating a production plan when producing multiple types of products,
a production order optimization unit that optimizes the production order of the products;
The production order is represented by the order of arrangement of a plurality of slots set for each process,
The production order optimization unit
Acquiring a first provisional order in which the production order is provisionally set;
extracting the products with added lead time in the first tentative order;
By preferentially allocating the extracted product to a first slot corresponding to the added lead time and allocating the other product to a second slot other than the first slot, the first temporary determine a second tentative order based on the order;
A production plan generating device that determines the production order based on the second provisional order. In the production plan generation device according to claim 1,
The production order optimizing unit, when extracting a plurality of the products having the same length of the added lead time in the first provisional order, assigns each of the extracted products to the mutually interchangeable first slots. Production plan generator. In the production plan generation device according to claim 1,
The production sequence optimizing unit determines the production sequence for each processing unit, with a production period specified by a user as a processing unit. In the production plan generation device according to claim 3,
The production order optimization unit
setting a part of the plurality of slots as a connection area;
when determining the production order based on the second provisional order, switching the slots included in the connection area between the plurality of slots respectively corresponding to the two processing units adjacent to each other; Allowable production plan generator. In the production plan generation device according to claim 4,
When the production order is determined based on the second provisional order, the production order optimization unit, when the first slot is included in the connection area, determines the number of processing units between the processing units of the first slot. A production plan generator that allows movement in In the production plan generation device according to claim 1,
The product is produced by a production line including a combination of a plurality of the processes parallel to each other,
The production order optimizing unit is a production plan generation device that creates the first provisional order so as to satisfy a predetermined constraint condition including a combination condition of the product type and the process. In the production plan generation device according to claim 1,
The production order optimization unit determines the second provisional order for each product type,
A production plan generating device for determining the production sequence for each product based on the second provisional sequence determined for each product type. A method for optimizing the production order of multiple types of products and generating a production plan for the products, comprising:
The production order is represented by the order of arrangement of a plurality of slots set for each process,
by computer
Acquiring a first provisional order in which the production order is provisionally set;
extracting the products with added lead time in the first tentative order;
By preferentially allocating the extracted product to a first slot corresponding to the added lead time and allocating the other product to a second slot other than the first slot, the first temporary determine a second tentative order based on the order;
A production plan generation method for determining the production order based on the second provisional order. In the production plan generation method according to claim 8,
A method of generating a production plan, wherein, when a plurality of the products having the same length of the added lead time are extracted in the first provisional order, each of the extracted products is assigned to the first slots that can be replaced with each other. In the production plan generation method according to claim 8,
A production plan generation method for determining the production sequence for each processing unit, with a production period designated by a user as the processing unit. In the production plan generation method according to claim 10,
setting a part of the plurality of slots as a connection area;
when determining the production order based on the second provisional order, switching the slots included in the connection area between the plurality of slots respectively corresponding to the two processing units adjacent to each other; Allowed production plan generation methods. In the production plan generation method according to claim 11,
A production plan that allows movement of the first slot between the processing units when the first slot is included in the connection area when the production order is determined based on the second provisional order. generation method. In the production plan generation method according to claim 8,
The product is produced by a production line including a combination of a plurality of the processes parallel to each other,
A production plan generation method for generating the first provisional order so as to satisfy predetermined constraint conditions including combination conditions of the product type and the process. In the production plan generation method according to claim 8,
determining the second provisional order for each type of the product;
A production plan generating method for determining the production sequence for each product based on the second provisional sequence determined for each type of the product.

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