JPH08106499A - Production schedule generating method - Google Patents

Abstract

PURPOSE: To provide the production schedule generating method which minimize loss when a production schedule is generated. CONSTITUTION: This method is applied to the production schedule generation system consisting of an input part 1, a processing part 2, a ROM part 3, a RAM part 4, and an output part 5, and one of combinations of raw materials is selected; a product groups is arranged in the order that the selected combination indicates to determine production order, and the loss generated as a result of arrangement for the production order is calculated. Then the processing part 2 calculates the losses due to arrangement for all the combinations and outputs the production order having the least loss.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a production plan making method for making a production plan for producing a wide variety of products.

[0002]

2. Description of the Related Art There are various types of apparatuses for producing a wide variety of products using one apparatus. Among them, there is a press device for producing a plate-shaped product by pasting a rolled-up decorative paper on a plate-shaped base material.

When producing a wide variety of products using this press machine, a base material corresponding to the product and a roll-shaped decorative paper are prepared. The press machine produces various products by changing the substrate and the decorative paper roll.

During this setup change, the setup process is minimized to save the labor of the operator. Such a technique is disclosed in Japanese Unexamined Patent Publication No. 5-253814.

[0005]

By the way, when the above-mentioned press machine is set up, a roll-shaped decorative paper causes a loss of about 10 [m]. Therefore, even if the setup process is minimized to save the labor of the operator, the loss due to the setup change may increase.

In such a case, the planner who creates the production plan manually calculates the combination of the production orders and calculates the loss. When asking for combinations, there is a part that depends on the experience and intuition of the planner, making it difficult to create a production plan that minimizes loss.

An object of the present invention is to eliminate the above drawbacks and to provide a production plan preparation method capable of minimizing the occurrence of loss when preparing a production plan.

[0008]

In order to achieve the object, the present invention is a production plan for using a plurality of raw materials and producing a product by using one of the raw materials. In addition, in the production plan creation method that creates the production plan in which the order of the raw materials to be exchanged is determined at the time of setup change for producing another product, each material of the raw material immediately before the last order is used. It is a group of products that includes the first treatment that selects one from the combination and the adjacent ranks in the combination that was selected in the first treatment, and among the products that use each material of the last raw material. , A second process for obtaining a group of products manufactured by using the same raw material as the last raw material, a third process for selecting one product group from the product groups obtained in the second process, and a product group already selected Second treatment except for products The third process repeated, and a fourth process of obtaining the respective products to the combination selected in the first processing, the order indicated combination selected in the first process,
The production order is determined based on the product group obtained in the fourth processing, and the fifth processing for calculating the losses caused by the setup change and the first processing except for the already determined combination with respect to the determined production order. A sixth process of performing a process of returning to the process, calculating a loss due to setup change for all combinations, and outputting a production order of the minimum loss.

[0009]

With the second to fourth processes of the present invention, the first process is performed.
The production order is determined by arranging the product groups in the order indicated by the combination selected in the process. And, for the decided production order,
Calculate the losses caused by the setup change.

After that, by returning the process to the first process, the losses due to the setup change for all the combinations are calculated, and the production order of the minimum losses is output.

As a result, by the first processing to the sixth processing,
The production order with the smallest loss can be automatically output.

[0012]

Embodiments of the present invention will now be described with reference to the drawings.

FIG. 3 shows a production planning system for implementing the present invention. This system creates a production plan for producing a wide variety of products using one press device. The pressing device is the same device as used in the prior art, and when the roll-shaped decorative paper is replaced, a loss of about 10 [m] is generated.

In the press machine, four kinds of base materials are used as each material of the raw material M. These item numbers are "A",
Represented by "D", "E", "F". Further, as each material of the raw material N, three types of roll-shaped decorative paper are used. These product numbers are represented by "152", "302", and "565".

A production planning system for producing a production plan using these raw materials includes an input section 1, a processing section 2, and an RO.
M (Read Only Memory) unit 3 and RAM (Random Acces
s Memory) unit 4 and an output unit 5.

The ROM section 3 stores in advance processing procedures for creating a production plan based on the input data. The processing unit 2 creates a production plan based on the processing procedure stored in the ROM unit 3.

Data of raw materials M and N are added to the input section 1. At this time, as shown in the following table, the unit price of the roll-shaped decorative paper which is the raw material N is also added to the input unit 1.

[0018]

[Table 1] Further, as shown in the following table, the data of the product number of each product to be produced and the number j given to each product is added to the input unit 1.

[0019]

[Table 2] When these data are added to the input unit 1, the processing unit 2
As shown in FIGS. 1 and 2, the base material “A” of the raw material M,
A combination of "D", "E", and "F" is calculated (step S1). Since there are four types of base materials, the processing unit 2 has 4! = 4 × 3 × 2 × 1 = 24 combinations are calculated.

After that, the processing unit 2 selects, for example, "A → D → E → F" as the first combination of the base materials (step S2).

The processing unit 2 uses the selected combination "A → D".
→ E → F ”is initialized (step S3).
That is, the processing unit 2 uses the number i for each base material “A”, “D”, “E”, and “F” in the combination “A → D → E → F”.
(I = 1 to 4) is attached. After that, the processing unit 2 sets the number i of the base material to i = 1. Further, the processing unit 2 attaches a completion flag indicating whether or not the production order of each product is determined in Table 2 as shown in the following table.

[0022]

[Table 3] Furthermore, the processing unit 2 uses the combination of base materials “A → D → E →
The re-check level k using “F”, which indicates whether or not all the product production orders have been determined, is k = 0.

The processing section 2 selects the product number of the product using the same decorative paper from the substrates having the numbers i and i + 1, that is, the substrates having the numbers 1 and 2 as the base material (step S4). As a result, the processing unit 2 has the base material “A”.
Among the product numbers of (i = 1), “D” (i + 1 = 2) and the completion flag of which is “0”, products having the same decorative paper are grouped. In Table 3, the processing unit 2
152, D152), (A302, D302) pair (product group) is obtained.

There are multiple pairs and the recheck level k
Is "0" (step S5), the processing unit 2 sets the recheck level k to k = 1. Further, since k-1 = 0, the processing unit 2 determines that there is no rank determined (step S6).

When there are a plurality of pairs, the processing section 2 selects, for example, the first pair from the previously obtained two pairs,
This pair is referred to as pair 1 ... A152, D152. Then, the processing unit 2 changes the completion flags of the product numbers “A152” and “D152” to “1” as shown in the following table (step S7).

[0026]

[Table 4] The processing unit 2 checks whether or not the base material number i is equal to the base material type number "4" (step S8).

After that, the processing section 2 sets the number i of the base material to i = i + 1 (step S9).

The processing section 2 repeats steps S4 to S7 until the number i becomes i = 4 in step S8. That is,
As the base material, the product number of the product using the same decorative paper is selected from those having the numbers i + 1 and (i + 1) +1, here, those having the numbers 2 and 3. As a result, the processing unit 2 has the base materials “D” and “E” in Table 4.
To obtain the pair (D565, E565). Processing unit 2
Defines this pair as pair 2 ... D565, E565. After this, as shown in the following table, "D565",
The completion flag of "E565" is set to "1".

[0029]

[Table 5] The processing unit 2 similarly processes the number i of the base material as i = i + 2. That is, the processing unit 2 selects the product number that uses the same decorative paper from the base materials “E” and “F”. However, as is clear from Table 5, among the products whose completion flag is “0”, none of them use the same decorative paper.

The processing section 2 uses the combination of base materials “A → D →
For E → F ”, the process of searching for a pair ends. At this time, the number i is i = 4 in step S8. After this, the processing unit 2 uses the combination of base materials “A →
Based on D → E → F ”and the searched pairs 1 and 2, the production order of the products is determined as shown in FIG. 4 (step S1.
0). Based on this production order, the processing unit 2 calculates the setup costs that occur at the time points a to f of changing the decorative paper.

[0031]

[Table 6] After that, the processing unit 2 calculates the total setup cost, and
It is stored in the AM unit 4 (step S11).

The processing section 2 checks whether or not the recheck level k is k = 0 (step S12), and checks whether or not the check has been completed for all combinations (step S13).

If the check is not completed in step S13, the processing section 2 sets the recheck level k to k = 1 (step S14). This shows that when the number i of the base material is i = 1, the production order of the products is not yet completely determined. Then, the processing unit 2 repeats steps S4 to S13.

That is, the processing unit 2 obtains a pair (A302, D302) of products using the same decorative paper among the products using the base material "A" and the base material "D". Further, among the products using the base material “D” and the base material “E”, a pair of products using the same decorative paper is obtained, but there is no symmetrical pair here. Further, among the products using the base material “E” and the base material “F”, a pair of products using the same decorative paper is obtained, but there is no symmetrical pair here.

After that, the processing unit 2 determines, based on the searched pair,
As shown in FIG. 5, the production order of the products is determined, the setup cost is calculated as shown in the following table, and the setup cost is stored in the RAM unit 4.

[0036]

[Table 7] When the processing unit 2 finishes the repetition of Steps S4 to S13 and finishes the processing for obtaining the production order and the setup cost for the first selected combination “A → D → E → F”, the processing unit 2 again performs the processing in Step S14. The check level k is reset to k = 0, and the following combinations are set. Steps S3 to S14 are repeated, and if all the checks are completed in step S13, the processing unit 2 ends the processing.

After that, the processing unit 2 selects the smallest one from all the setup costs and outputs it to the output unit 5 (step S15).

As described above, according to this embodiment, it is possible to automatically determine the production sequence that minimizes the total setup cost.

Although this embodiment was used to prepare a production plan for a press machine for producing a wide variety of products, it is not limited to this. The present invention can be applied to create production plans for various types of production equipment.

[0040]

As described above, according to the present invention, when the second process to the fourth process are performed, the product groups are arranged in the order indicated by the combination selected in the first process to determine the production order. Then, with respect to the determined production order, the loss caused by the setup change is calculated.

After that, by returning the process to the first process, the losses due to the setup change for all the combinations are calculated, and the production order of the minimum losses is output.

As a result, by the first to sixth processes,
The production order with the smallest loss can be automatically output.

[Brief description of drawings]

FIG. 1 is a flowchart according to the present invention.

FIG. 2 is a flowchart according to the present invention.

FIG. 3 is a block diagram of a production planning system for implementing the present invention.

FIG. 4 is a diagram showing a production order.

FIG. 5 is a diagram showing a production order.

[Explanation of symbols]

 1 input section 2 processing section 3 ROM section 4 RAM section 5 output section

Claims (1)

[Claims] 1. A production plan for producing a product using a plurality of raw materials and one raw material of each raw material, and exchanging at the time of setup change for producing another product. In a production plan creation method for creating a production plan in which the order of the raw materials to be processed is determined, a first process of selecting one from a combination using each material of the raw material immediately before the last order, A group of products including adjacent ranks in the combination selected in one process, and a group of products produced by using the same material as the last raw material among products using each material of the last raw material , A third process for selecting one product group from the product groups obtained in the second process, and a second process and a third process excluding the products of the already selected product group, Combination selected in the first process Each product and a fourth process of obtaining a group, the order indicated combination selected in the first processing for the fourth
The production order is determined based on the product group obtained in the process, and the 5th process for calculating the losses caused by the setup change is performed for the determined production order, and the 1st process is performed except for the already determined combination. And a sixth process for calculating the loss due to the setup change for all combinations and outputting the production order of the minimum loss.