JPH07182420A - Production planning device - Google Patents

Abstract

PURPOSE:To provide a production planning device which can maximize the total productivity of a production line within a range of capability of facilitates and also can satisfy the time limit of the delivery of the order. CONSTITUTION:A production planning device 0 consists of a calculating part 2 which calculates the lead time covering the neck process through the final process for each order and subtracts the lead time from the time limit of delivery set to the ordering to decide a schedules starting date of the neck process, an initial lot composing part 3 which gathers the orders received in a prescribed period of the neck process for each specification and initially composes a lot, a neck process load plan producing part 4 which continuously fetches the orders of the subsequent scheduled starting dates of the neck process into the lot to produce a load plan of the neck process, a total load plan producing part 6 which performs the FF/FB piling by means of the load plan and based on the neck process scheduled starting date within a range that satisfies the time limit of delivery to the order, etc. In such a constitution, the total productivity of a production line is maximized within a range of capability of facilities. Furthermore a production plan is obtained to satisfy the time limit of delivery to the order.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a production planning device,
More specifically, the present invention relates to a production planning apparatus for maximizing the productivity of a production line within the range of not exceeding the equipment load and making a production plan that satisfies an order delivery date.

[0002]

2. Description of the Related Art Conventionally, for example, Japanese Patent Laid-Open No. 4-233073 has been disclosed as a production planning method for making a production plan within a range not exceeding the facility load of a production line. In this conventional method, an order is expanded into work orders for each process, the orders are assigned to each process in order from the earliest delivery date, and if the load of the process exceeds the capacity, feedforward pile-up or feedback pile-up is performed to make a production plan. It is a way to create. The feedforward pile-up here means pile-up on a day-by-day basis for each process based on the scheduled start date of the work of the work order, and decides the date to start the process (scheduled start date of the work order).
When carrying out this feedforward stacking, the capacity of each process and the operating time zone are taken into consideration. For example, on the day when this capacity is exceeded, the stacking of work orders is stopped and the next working day is stacked. The feedback pile-up is to pile up work orders on a day-by-day basis for each process centered on the delivery date, and determine the date when the work is in process (scheduled start date of work order). When carrying out the feedback pile-up, the pile-up of the work order is stopped and the pile-up is carried out on the previous work day, taking into consideration the ability of each process and the operating time zone, for example, on the day when the ability is exceeded.

[0003]

The above-mentioned conventional production planning method has the following problems. In a normal production line, it is better to manufacture products of the same specification (size or product type) as a lot in batches because the setup change is less and the productivity is better. However, in the above-mentioned conventional method, since it is not considered that such orders having the same specifications are manufactured as a batch in a batch, the work orders are allocated from the earliest delivery date, so that the productivity of the entire production line is maximized. Difficult to do. In particular, the productivity of the production line usually varies, and the productivity of the entire production line cannot be maximized unless the productivity of the neck process, which has the lowest productivity, is maximized. In the above-mentioned conventional method, in order to carry out load pile-up without considering the productivity of the neck process, for example, when feed-forward pile-up is carried out, the plan is delayed and there is a possibility that the delivery date cannot be satisfied. The present invention has been made in view of the above circumstances, and an object thereof is to provide a production plan that maximizes the productivity of a production line within a range that does not exceed the facility load and that satisfies an order delivery date. It is to provide a production planning device that can make a plan.

[0004]

In order to achieve the above object, the present invention calculates a lead time from a neck process having the lowest productivity in a production line to a final process for each order handled in the production line, An estimated neck process start date calculating means for calculating the estimated neck process start date by subtracting the calculated lead time from the delivery date of the order, and an order in which the calculated neck process start date is within a predetermined period. Initial knitting preparation means for collectively knitting lots for each specification, and the scheduled start date will be delayed until the load of the neck process by the initially knitted lot exceeds the production capacity of the neck process within the predetermined period. The load plan creating means for creating a load plan for the neck process by incorporating the order into the lot, and the order using the load plan for the neck process created above Production comprising an overall load plan creation means for creating a load plan for the entire process by performing feedforward pile-up and / or feedback pile-up based on the scheduled start date of the neck process within a range that satisfies the delivery date It is configured as a planning device.

[0005]

According to the present invention, the lead time from the neck process having the lowest productivity in the production line to the final process is calculated for each order handled in the production line. The scheduled start date of the neck process is calculated by subtracting the calculated lead time from the delivery date of the order. The lots are initially organized by collecting the orders for which the calculated neck process start dates are within the predetermined period for each specification. Until the load of the neck process due to the initially organized lot exceeds the production capacity of the neck process within the above-mentioned predetermined period, the load of the neck process is created by incorporating subsequent orders into the lot with the scheduled start date. To be done. By using the created load schedule for the neck process and performing the feed forward pile and / or the feedback pile based on the scheduled start date of the neck process within the range where the delivery date of the order is satisfied, the load of the whole process is increased. A plan is created. In this way, by performing lot formation that collectively manufactures orders with the same specifications and maximizing the productivity of the neck process, which has the lowest productivity, the productivity of the entire production line can be maximized. As a result, it is possible to provide a production planning device for maximizing the productivity of the production line within a range not exceeding the facility load and for drafting a production plan that can satisfy the order delivery date.

[0006]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Embodiments embodying the present invention will be described below with reference to the accompanying drawings for the understanding of the present invention. The following embodiments are examples of embodying the present invention and are not intended to limit the technical scope of the present invention. 1 is a block diagram showing a schematic configuration of a production planning apparatus 0 according to an embodiment of the present invention, FIG. 2 is a schematic diagram showing an example of a system to which the production planning apparatus 0 can be applied, and FIG. Fig. 4 is a flow chart showing the operation procedure of the system, Fig. 4 is a table showing the results of obtaining the scheduled start date of each order, Fig. 5 is a conceptual diagram when initial lot formation is performed, and Fig. 6 is a load plan of the neck process. It is a conceptual diagram at the time. As shown in FIG. 1, the production planning apparatus 0 according to the present embodiment has an initial data input unit 1 for inputting initial data, and a lead time from the neck process with the lowest productivity in the production line to the final process. Neck process expected date calculation unit 2 (Neck process expected date calculation unit that calculates the neck process expected date by calculating for each order handled by the production line included in the data and subtracting the calculated lead time from the order delivery date Equivalent to day calculation means)
And an initial lot formation unit 3 for initial formation of lots by grouping orders whose planned neck process start date calculated by the neck process start date calculation unit 2 is within a predetermined period according to specifications.
(Corresponding to the initial knitting forming means) and until the load of the neck process by the lot initially knitted by the initial lot knitting unit 3 exceeds the production capacity of the neck process within the predetermined period,
Created by the neck process load plan creation unit 4 (corresponding to load plan creation means) that creates a load plan for the neck process by incorporating an order whose scheduled start date is later into the lot, and created by the neck process load plan creation unit 4. By performing the feedforward pile-up and / or the feedback pile-up (FF / FB pile-up) based on the scheduled start date of the neck process within the range where the delivery date of the order is satisfied using the load plan of the neck process, It is composed of an overall load plan creation unit 5 (corresponding to the overall load plan creation means) that creates a load plan, and a production plan data output unit 6 that outputs lot organization data and load plan data as production plan data (Fig. The arrows inside indicate the flow of data).

FIG. 2 shows a system 7 for embodying such a production planning device 0. In the figure, 8 is an input device such as a display and a keyboard for inputting initial data by the initial data input unit 1, 9 is the neck process start date calculation unit 2, initial lot organization unit 3, neck process load plan preparation In the computer for executing the unit 4 and the overall load plan creation unit 5, various calculation algorithms and the like handled here are stored in the memory or the external storage device 10 as an executable program. Also, 1
Reference numeral 1 denotes an output device such as a printer for outputting the production plan data by the production plan data output unit 6. Therefore, the operator can input the necessary initial data from the input device 8 and operate the computer 9 to make a production plan, and obtain the result from the output device 11. However, in a production plan that requires a huge amount of data, data from a higher-level computer (not shown) is directly or indirectly input to the computer 9 as initial data and used. The specific operation procedure of the system 7 will be described below with reference to FIG.
The description will be added in the order of 1, S2, .... Here, first, initial data is input from a host computer (not shown) (S1). The lead time from the neck process to the final process is calculated for each order included in the initial data (S2). The lead time calculated in step S2 is subtracted from the delivery date of each order to calculate the scheduled start date of the neck process (S
3). FIG. 4 shows an example of the lead time and the scheduled start date of the neck process for each order obtained in steps S2 and S3. Subsequently, orders having the scheduled start date of the neck process within the predetermined period (the period designated by the operator) are grouped into a lot with the same specifications and initial formation is performed (S
4). FIG. 5 shows a conceptual diagram when the initial lot formation is performed in step S4.

The lot organization flag is set to 0 for all lots (S5). Period numbers are sequentially assigned from the earliest scheduled start period of the neck process (S6). The period of interest (T) = 1 is set (S7). The pre-take period (N) = 1 is set (S8). When the load of the neck process is removed after the period of interest T, the process ends (S9). If the load amount in the target period T exceeds the capacity, all the lot organization flags in the target period T are set to 1, the target period T = 1 is set, and the process returns to step S8 (S10, S10a). A lot having a lot organization flag of 0 in the period of interest T and having the earliest scheduled start of the neck process is selected. Then, the selected lot is designated as SL (S11). If the number of orders included in the lot SL> the maximum lot size, the lot organization flag of the lot SL is set to 1 and the process returns to step S8 (S12, S12).
a). If the preemption period N> N, the lot organization flag of the lot SL is set to 1 and the step S is executed.
It returns to 8 (S13, S13a). Lot S in period T + N
If there is no order with the same specifications as L, pre-emption period N = N
Set to +1 and return to step S9 (S14, S14
a). Of the orders having the same specifications as the lot SL, the order with the earliest scheduled neck process start date is added to the lot SL, the period T + N is removed from the load, and the process returns to step S9 (S1).
5). FIG. 6 shows a period T + N in the lot SL (lots of orders 1 and 2 in the figure) of the target period T = 1 in step S15.
(= 2) order (number 5 in the figure) is added.
After the above-described lot organization is completed, the load plan for the neck process is created by performing feedforward stacking (FF stacking) on the load plan for the neck process (S16). Specifically, the load schedule of the neck process is used to determine the date to start the process by stacking each process on a daily basis based on the scheduled start date of the neck process within a range that satisfies the order delivery date. When carrying out this feedforward stacking, the capacity of each process and the operating time zone are taken into consideration. For example, when the capacity is exceeded, the stacking of orders is stopped and the stacking is carried out for the next work day. However, if it is after the scheduled date of the order, it is not allowed from the viewpoint of punctual delivery.

Next, a load plan before the neck process is created by feedback-loading (FB stacking) the load plans of the neck process (S17). Specifically, using the load schedule of the neck process, the orders are piled up on a day-by-day basis based on the scheduled start date of the neck process, and the date to finish the process is determined. When carrying out this feedback stacking, the stacking capacity of each process is taken into consideration, and, for example, the stacking of orders is stopped on the day when the capacity is exceeded, and the stacking is carried out on the previous work day.
However, if the work date is before the plan creation date, it is not possible to realize it, so the previous work days are not piled up. In this way, a production plan for the entire line is created by carrying out load planning for the entire process. As described above, according to the present embodiment, the productivity of the whole production line is maximized by performing the lot organization that collectively manufactures orders with the same specifications and maximizing the productivity of the neck process having the lowest productivity. Can be As a result, it is possible to provide a production planning device for maximizing the productivity of the production line within a range not exceeding the facility load and for drafting a production plan that can satisfy the order delivery date. Incidentally, in the above-mentioned embodiment, the feed-forward pile is carried out in step S16, and the feedback pile is carried out in step S17.
In actual use, steps S16 and S17 may be executed in reverse order or at the same time. In the case of simultaneous execution, there is a possibility that the calculation time can be further shortened. In the above embodiment, it is possible to deal with the case where a new order is placed after the plan is created. For example, it is possible to obtain the scheduled start date of the neck process for the order, cancel the lot formation after the period including the scheduled date, and set the period to period number 1 to redo the lot formation. The production plan after the neck process may be obtained by performing a simulation based on the lot organization plan. The device 0 of the above embodiment
Then, the neck process scheduled date calculation unit 2, the initial lot organization unit 3, the neck process load plan creation unit 4, and the overall load plan creation unit 5 are used as the respective processes of the software built in the computer 9 of the system 7 or the like. Although it is assumed, in actual use, part or all of it may be replaced with the hardware configuration.

[0010]

Since the production planning apparatus according to the present invention is configured as described above, it performs lot organization for collectively manufacturing orders of the same specifications and also achieves the productivity of the neck process having the lowest productivity. By maximizing, the productivity of the entire production line can be maximized. as a result,
The production planning apparatus can maximize the productivity of the production line within the range of not exceeding the facility load and can make a production plan that can satisfy the order delivery date.

[Brief description of drawings]

FIG. 1 is a block diagram showing a schematic configuration of a production planning device 0 according to an embodiment of the present invention.

FIG. 2 is a schematic diagram showing an example of a system to which the production planning apparatus 0 can be applied.

FIG. 3 is a flowchart showing an operation procedure of the system.

FIG. 4 is a chart showing a result of obtaining a lead time of each order and a scheduled start date of a neck process.

FIG. 5 is a conceptual diagram when initial lot formation is performed.

FIG. 6 is a conceptual diagram when load planning of a neck process is performed.

[Explanation of symbols]

1 ... Initial data input unit 2 ... Neck process start date calculation unit (corresponding to neck process start date calculating unit) 3 ... Initial lot formation unit (corresponding to initial formation preparation unit) 4 ... Neck process load plan formation unit (load) 5 ... Overall load plan creation unit (corresponding to overall load plan creation unit) 6 ... Production plan data output unit

Claims (1)

[Claims] 1. A lead time from a neck process having the lowest productivity to a final process in a production line is calculated for each order handled in the production line, and the calculated lead time is subtracted from a delivery date of the order. A neck process scheduled start date calculating means for calculating the scheduled neck process start date by means of the above, and an initial knitting forming means for collecting the orders for which the calculated neck process scheduled start date is within a predetermined period for each specification into an initial lot. ， Until the load of the neck process by the initially organized lot exceeds the production capacity of the neck process within the above-mentioned predetermined period, the load schedule of the neck process is created by incorporating the orders whose start date is later into the lot. Using the load plan creating means and the load plan of the neck process created above, the planned start date of the neck process is set within the range that satisfies the delivery date of the order. By performing the reference feed-forward pile and / or the feedback pile,
A production planning apparatus comprising: an overall load plan creating means for creating a load plan for the entire process.