EP2174275A1 - Procédé et système pour établir un plan de production destiné à une installation de production - Google Patents

Procédé et système pour établir un plan de production destiné à une installation de production

Info

Publication number
EP2174275A1
EP2174275A1 EP08801502A EP08801502A EP2174275A1 EP 2174275 A1 EP2174275 A1 EP 2174275A1 EP 08801502 A EP08801502 A EP 08801502A EP 08801502 A EP08801502 A EP 08801502A EP 2174275 A1 EP2174275 A1 EP 2174275A1
Authority
EP
European Patent Office
Prior art keywords
production
components
plan
account
products
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
EP08801502A
Other languages
German (de)
English (en)
Inventor
Iiro Harjunkoski
Alexander Horch
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
ABB Research Ltd Switzerland
ABB Research Ltd Sweden
Original Assignee
ABB Research Ltd Switzerland
ABB Research Ltd Sweden
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by ABB Research Ltd Switzerland, ABB Research Ltd Sweden filed Critical ABB Research Ltd Switzerland
Publication of EP2174275A1 publication Critical patent/EP2174275A1/fr
Ceased legal-status Critical Current

Links

Classifications

    • G—PHYSICS
    • G06—COMPUTING; CALCULATING OR COUNTING
    • G06Q—INFORMATION AND COMMUNICATION TECHNOLOGY [ICT] SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES; SYSTEMS OR METHODS SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES, NOT OTHERWISE PROVIDED FOR
    • G06Q10/00—Administration; Management
    • G06Q10/06—Resources, workflows, human or project management; Enterprise or organisation planning; Enterprise or organisation modelling

Definitions

  • the invention relates to a method and a corresponding system for creating a production plan for a production plant, which has at least two production components.
  • production plants also comprise a plurality of different production components with which one or more predetermined production steps can be carried out or executed on the product to be produced.
  • the respective production components are connected to each other via a suitable transport and / or transfer system for semi-products or intermediates.
  • a production plan contains information about which production component or which resource is to perform or execute which partial production or process step on which product, taking into account or considering given boundary conditions.
  • a production plan can be optimized with consideration of given boundary conditions with regard to a predefinable target size, for example with regard to maximizing the number of manufactured products in a certain period of time, with respect to minimizing the energy consumption per product or minimizing the flow / process time per product.
  • the availability of an entire plant ie the ratio of the time within which a production plant actually produces, is assumed to be constant at the time when, if there is no failure of a production component or other disruption, it could produce on schedule.
  • the availability data are mostly based on many years of experience in the relevant or a comparable production plant and summarize the production-hindering disruption and / or downtime over a longer period of time.
  • At least information about the production target, the products to be produced in each case, the production plants and production components as well as operational and / or procedural boundary conditions must be provided for the production of a production plan.
  • the production goal includes planning data, such as the type of products to be produced and their quantity and / or quality. Of further importance in this context may be the period within which the respective product must be produced in order to be able to deliver it on time to the customer. Also, a priority order of the individual product types, which may result, for example, from the sales or profit to be realized with the product, may be significant.
  • the production target is always based on given boundary conditions, so that the demanded quantity does not exceed the theoretical maximum total capacity of the production facilities, taking into account holiday periods or unavoidable, long-term rebuilding or maintenance activities.
  • Information about the products to be produced are also important for the preparation of a production plan, for example, the indication of which individual production steps must be completed before a product has been completely manufactured or finished and / or finished a workpiece has been edited.
  • a production plan for example, the indication of which individual production steps must be completed before a product has been completely manufactured or finished and / or finished a workpiece has been edited.
  • the time interval between the passage through various production steps can be designed rather flexibly in other branches of industry, for example in the production of mechanical components or the assembly of individual mechanical components, and also with each other.
  • a production plant usually has several production components. Depending on the required production process, these production components can be sequentially interconnected, for example in the form of a production line, that is, the production components are successively processed according to the necessary production steps of the product being manufactured and / or processed, the end product of the preceding production step being the starting product of the production step subsequent production step forms and wherein no alternative production path is possible.
  • the production components can also be arranged in a conveyor technology parallel structure to each other, that is, there are several possible production paths for the production of the same product.
  • the conveying technology removal of a defective semi-finished product from the production process for rework and reintegration of the revised semi-finished product in the production process is a practicable for some products approach, as well as the use of intermediate or sorting storage, which are arranged conveyor technology between the production components.
  • Such memories are common, for example, in the painting of automobile bodies.
  • the order of the bodies is changed by the production plant in a color sorting memory such that a column of bodies, which in the same color to be painted, is formed to reduce the number of required color changes during the subsequent run through the paint shop in the form of a column.
  • the higher the parallel proportion of the conveying arrangement of the individual production components in a production plant the more flexible it can be used in the production process and the more potential for optimization exists in the preparation of the production plan.
  • the production components carry out the respective production steps on the product to be produced.
  • a production component may be fixed to or provided for a specific production step for a particular product, such as cutting a thread for a particular type of screw.
  • the production component is a robot
  • a much higher degree of flexibility can be achieved so that, for example, by automatically changing a tool, one and the same robot can perform both gluing and drilling operations on different types of products in a short time.
  • a production component can also have a degree of flexibility, which can be used in the production plan for its optimization.
  • Production components are subject to signs of wear and aging.
  • the quality of the production steps performed of a production component may depend on and / or be influenced by the degree of wear and the age of the production component. Similarly, the risk of short-term total loss of a production component increases with age or degree of wear.
  • Onskomponente A supplied via a suitable buffer production component B with semi-products which in turn provides a suitable buffer production component C with semi-products
  • production component A fills the buffer before production component B and production component C empties the buffer to production component B.
  • the capacities of the buffers are exhausted, production components A and C also have to stop production, causally because a single production component has failed.
  • buffer stores are usually kept as small as possible or are not present at all.
  • a short-term failure of one or more production components can thus lead to a disruption of production, production loss, quality reduction and thus also to increased expenses, especially in terms of time, material, costs.
  • maintenance work on the various production components are usually carried out in certain periods of time. In a simple case, this may include, for example, a cleaning of selected production-relevant components, also several times a day, and / or in a fixed time interval.
  • maintenance can also involve the replacement of particularly stressed components relevant to production, such as the replacement of a tool at the weekend. Due to the frequent implementation of such minor or low-quality maintenance, the necessary cycles within which such maintenance should be performed, usually well known within the company.
  • a maintenance plan in addition to the minor and / or low-quality maintenance work, in particular also extensive maintenance work, such as straightening a gripper tool for a robot or checking a robot gear, usually at longer time intervals, such as weeks or years to perform. These time intervals are usually fixed by the manufacturer of the corresponding production component or the production plant. Due to the high consequential damages As a result of subsequent outages, which may be associated with a failure of a production component, the maintenance intervals for more extensive maintenance work are usually conservative, ie short. That is, even under unfavorable conditions regarding the nature and duration of the use of the production component, the probability of their failure should always be below an accepted limit, which is achieved by sufficiently short maintenance intervals.
  • Measured variables from which the state of a production component can be derived can be, for example, an electrical or mechanical power, a temperature and / or a flow rate.
  • characteristic data which can be used for condition evaluation of the production component. These may be, for example: average energy consumption, maximum energy consumption, number of production cycles, operating time since first commissioning, operating time since last maintenance or flow volume of a liquid medium since last maintenance. Based on these characteristic data, it is then possible to make statements about the state of the component which are evaluated by means of suitable condition evaluation methods, which indicate, for example, a probability of failure of the respective production component or the expected quality of the production step to be carried out by this component. These quantified state data are fed to the production planning method according to the invention as further input variables.
  • the boundary conditions described above and / or input variables for the preparation of a production plan reveal a flexibility or an optimization potential, that is, there are various possibilities for achieving a predetermined production target. Which of the various possibilities is the most suitable considering the given objectives can be specified by suitable objective functions. These may indicate, for example, that the entire system should produce as many products as possible in a given period of time and / or that the energy consumption in the production of products should be kept as low as possible and / or that maintenance must be kept to a minimum and / or that products in the produced to the highest possible quality.
  • the objective functions can contradict each other or contradict each other, for example the highest possible quality and / or minimal maintenance and / or minimum time expenditure, either only one objective function or several mutually prioritized objective functions can be specified.
  • the information for the objective function results from the requirements that are placed on the respective manufacturing company out of its environment. These can also change if the environment changes or changes, for example if low energy consumption gains in importance for reasons of image and / or ecological considerations.
  • the production plan drawn up with regard to the stated objective functions may contain information as to which production components are used in each case for the production of the respective products and / or in which time period. the respective products are to be produced and / or the period in which the respective products are to be produced.
  • the loss of production during a possible unscheduled maintenance can be further minimized by making use of the required production period for the various products during the maintenance period, only those products are manufactured for the production of the maintenance component in production is not needed. So it may be possible that even an unscheduled maintenance measure does not result in a loss of production.
  • a further advantageous embodiment variant of the method according to the invention includes incorporation or consideration of the quality which can be produced or achievable with the respective production component as a result of the state of production in production plan production or production planning and / or the respective production plan. This can vary and in particular decrease with increasing time interval from the last maintenance and depending on its use.
  • the method it is possible, in particular, for products which have low quality requirements for the respective production step to be produced as far as possible from those production components, which, due to signs of wear and tear, can no longer be expected to have the highest quality but a quality which lies within the product specifications.
  • high-quality or higher-quality product types are preferably produced by the production components which have the least risk of failure or can be expected to have the highest quality.
  • the possibility can be provided to modify the maintenance plan for the respective production components in accordance with the production requirements while maintaining the given boundary conditions when creating the production plan.
  • a condition evaluation procedure for the individual production components does not create a direct maintenance request, which is entered in the maintenance plan, provided that the boundary conditions are met, but instead provides data about the type and period of the maintenance requirement as an input to the production planning process.
  • the maintenance request in this case is carried out according to the method already in the preparation of the respective production plan, taking into account and / or incorporation of optimal / optimized production planning and the respective state of the production components and their individual default risk. If the requested maintenance period is within the given boundary conditions, the requested date is noted in the maintenance plan and the transmission of this data to the condition assessment procedure takes place. Based on this, this again determines the need for maintenance.
  • the object is achieved by a corresponding system for carrying out the aforementioned method for creating a production plan for a production plant with at least two production components.
  • the system comprises at least one data processing device with one or more means, with which in cooperation with at least one data and / or information source at least one input variable, which includes information on the nature and quantity of at least one product to be produced and / or nature and condition of the respective production plant and / or at least one of its production components, as well as at least one quantified state of one or more production components detectable and processable and As a result, a conditionally optimized production plan can be created.
  • the data sources may be data processing devices arranged in a distributed network and / or database and / or memory and / or management and / or MES systems.
  • the quantified state of a respective production component is the age of the production component and / or an imputed value of the production component and / or the previous period of use of the production component and / or its duration and / or the failures that have occurred so far or errors that have occurred so far Production component and their frequency considered and / or includes or includes.
  • At least one means is provided which utilizes additional information about the production plan and / or takes into account, which production components can be used and / or used for the production of respective products.
  • At least one means is provided which utilizes information on the production plan and / or takes into account the chronological sequence in which respective products can be produced with production components provided for this purpose.
  • At least one means can be provided which utilizes additional information about the production plan and / or takes into account the period during which the respective product can be produced with production components provided for this purpose.
  • at least one means which utilizes and / or takes into account when the production plan is drawn up when a particular production component is available for production or is available.
  • condition-optimized production plan may include information and / or information about the chronological order at which the respective products are to be produced with which production components and / or the period in which the respective product is to be produced with the production components provided for it and / or in which quantity and / or quality to produce a particular product is ..
  • At least one means can be provided, which utilizes and / or takes into account when producing the production plan, that according to specifications and / or requirements identical products of one and the same product type can also be produced in a non-identical time sequence and / or with not the same production components.
  • a further development of the system provides at least one means which utilizes and / or takes into account when producing the production plan in that high-quality products are manufactured and / or processed with production components which have a low risk of failure and / or which one, in particular according to specification and / or According to the requirements, high quality of the respective partial production step can be expected and / or guaranteed.
  • At least one means can be provided which utilizes and / or takes into account when producing the production plan that products with low quality requirements are produced with those production components which, taking into account the predetermined quality parameters of the product to be produced, have a low expected quality of the respective partial production step.
  • system may comprise at least one means which, when the production plan is drawn up, determines or causes at a low expected utilization of the production facilities. agreed production components in production planning for a certain period of time are not taken into account and / or excluded.
  • Fig. 1 an exemplary trained system for carrying out the method according to the invention including the respective information flows in a modular implementation
  • an exemplary trained system for carrying out the method according to the invention including the respective information flows is shown in a modular implementation, according to the method for creating a production plan for a production plant, which has at least two production components, at least one input, which information about type and quantity producing products and / or nature and condition of the respective production plant and / or at least one of its production components, and at least one quantified state of one or more production components detected and processed and resulting in a condition-related optimized production plan is created.
  • the execution of the method is carried out on an exemplary trained system for creating a production plan for a production plant with at least two production components, which has a modular structure and at least one higher-level data processing device and means comprises, which at least one input variable, which information about type and quantity product to be produced and / or nature and condition of the respective production plant and / or at least one of its production components, as well as to capture and process at least one quantified state of one or more production components and as a result create a state-optimized production plan.
  • the individual modules can be different data and / or information sources, such as databases, state evaluation system, data storage, MES (Manufacturing Execution System), monitoring system and the like and / or the associated computer program products, each module, In particular, in a distributed network, for example, each associated with a data processing system and / or can be run on this. Several modules can also be assigned to the same data processing system and / or be executed on this. All system modules involved are appropriately linked with one another in order to be able to carry out a data and / or information exchange with one another. If several data processing systems or equipment are involved, these are also interconnected in a form suitable for data exchange.
  • MES Manufacturing Execution System
  • a first module 11 contains, in particular, data about the production target which, in cooperation with the other modules, are made available to a higher-level processing module 15 with the higher-level data processing device for process execution and / or conversion, as input variables, resulting in the creation of a state-optimized production plan
  • Another second module 12 provides the parent module 15, for example, data and / or information of the respective product specification as further input variables, a third module 17, the nominal data of the production plant and a fourth module 18 one or more target functions, based on which the strategy of the inventive method is determined for production planning.
  • a fifth module 13 contains, from a condition evaluation, evaluated data on the status of one or more production components, a sixth module 19 contains data / information about scheduling constraints of the production facility.
  • Both modules, the fifth and the sixth module, 13, 19 provide the respective data / information both a seventh module 16, which contains data / information on the maintenance plan, as well as the parent module 15.
  • the higher-level module 15 provides, as a result of the method, both the seventh module 16 maintenance data / information and an eighth module 14 data about the production for a future period.
  • the current production as described above, based on a production plan, which was previously created by the parent processing module 15, taking into account the defined in the first to third, in the fifth and sixth module 11 -13,17 and 19 boundary conditions. Disruptions to the system are not available.
  • the optimization criterion defined in the fourth module 18 previously by the scheduler of the plant is the preferred use of the highest efficiency production components.
  • the fifth module 13 which performs the condition evaluation of the individual production components, shows a sudden drop in the efficiency of a production component A from 99% to 65%. This rating remains almost constant over a period of time, for example 30 minutes.
  • the higher-level processing module 15 creates after this period on the basis of the changed boundary conditions an updated production plan, which is used from this moment for production. In this, the production component A is no longer preferably used. Furthermore, a maintenance requirement for production component A is determined and transferred to the seventh module 16 in terms of data.
  • the period within which an updated production plan can be created and used can be as short as a few minutes; for a multi-day efficiency drop, for example, the period can be 48 hours.
  • the current production is also based on a production plan, which was previously created by the parent processing module 15, taking into account the defined in the first to third, in the fifth and sixth module 11 - 13,17 and 19 boundary conditions. It is provided according to the filed in the seventh module 16 maintenance plan preventive and non-critical maintenance of a production component B, which is therefore scheduled in the production schedule in the scheduled maintenance period not for production. Due to an unexpected new order to be realized at short notice, the quantity of the products to be produced increases, as data-technically deposited in the first module 11.
  • the higher-level processing module 15 determines a new production plan and a new maintenance plan, which is characterized in particular by the fact that the necessary but not time-critical maintenance of the affected production component B is postponed by a certain period, for example 4 weeks.
  • the resulting unscheduled production capacity will be used to produce the products for the new order in a timely manner.
  • Another additional order may not be considered promptly when creating another production plan by the higher-level processing module 15 because the maintenance measure on production component B can no longer be postponed without justifiable risk.

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  • Engineering & Computer Science (AREA)
  • Business, Economics & Management (AREA)
  • Human Resources & Organizations (AREA)
  • Strategic Management (AREA)
  • Economics (AREA)
  • Entrepreneurship & Innovation (AREA)
  • Educational Administration (AREA)
  • Game Theory and Decision Science (AREA)
  • Development Economics (AREA)
  • Marketing (AREA)
  • Operations Research (AREA)
  • Quality & Reliability (AREA)
  • Tourism & Hospitality (AREA)
  • Physics & Mathematics (AREA)
  • General Business, Economics & Management (AREA)
  • General Physics & Mathematics (AREA)
  • Theoretical Computer Science (AREA)
  • Management, Administration, Business Operations System, And Electronic Commerce (AREA)
  • General Factory Administration (AREA)

Abstract

L'invention concerne un procédé et un système pour établir un plan de production destiné à une installation de production qui comprend au moins deux éléments de production. Selon l'invention, au moins une grandeur d'entrée, présentant des indications sur le type et la quantité de produits à fabriquer et/ou sur le type et la structure de l'installation de production et/ou d'au moins un de ses éléments de production, ainsi qu'au moins un état quantifiable d'un ou de plusieurs éléments de production sont détectés et traités, puis un plan de production optimisé en fonction de l'état est établi.
EP08801502A 2007-07-31 2008-07-31 Procédé et système pour établir un plan de production destiné à une installation de production Ceased EP2174275A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE102007036325A DE102007036325A1 (de) 2007-07-31 2007-07-31 Verfahren und System zur Erstellung eines Produktionsplans für eine Produktionsanlage
PCT/EP2008/006299 WO2009015885A1 (fr) 2007-07-31 2008-07-31 Procédé et système pour établir un plan de production destiné à une installation de production

Publications (1)

Publication Number Publication Date
EP2174275A1 true EP2174275A1 (fr) 2010-04-14

Family

ID=39967265

Family Applications (1)

Application Number Title Priority Date Filing Date
EP08801502A Ceased EP2174275A1 (fr) 2007-07-31 2008-07-31 Procédé et système pour établir un plan de production destiné à une installation de production

Country Status (3)

Country Link
EP (1) EP2174275A1 (fr)
DE (1) DE102007036325A1 (fr)
WO (2) WO2009016485A2 (fr)

Families Citing this family (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102010010551B4 (de) * 2010-03-05 2014-03-13 Abb Ag Verfahren und Vorrichtung zum Koordinieren von zwei aufeinanderfolgenden Herstellungsstufen eines Produktionsprozesses
DE102010015001A1 (de) * 2010-04-14 2011-10-20 Abb Ag Verfahren und Vorrichtung zum Erstellen eines Produktionsablaufplans
WO2018050252A1 (fr) * 2016-09-19 2018-03-22 Siemens Aktiengesellschaft Procédé et dispositif de planification d'un processus de production à partir d'une spécification et de fonctions de base
EP3358431A1 (fr) * 2017-02-07 2018-08-08 Primetals Technologies Austria GmbH Planification intégrée des plans de la production et / ou les plans de service
DE102021201887A1 (de) 2021-03-01 2022-09-01 Sms Group Gmbh System, Verfahren und Computerprogramm zur betriebswirtschaftlichen Optimierung eines Prozesses in einer Produktionsanlage, insbesondere einer Produktionsanlage der metallerzeugenden Industrie, der nicht-Eisen- oder Stahlindustrie oder der Vorlegierungsherstellung
CN117974069B (zh) * 2024-03-28 2024-06-07 山东国泰民安玻璃科技有限公司 一种注射剂瓶生产数据采集方案制定方法、设备及介质

Family Cites Families (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5280425A (en) * 1990-07-26 1994-01-18 Texas Instruments Incorporated Apparatus and method for production planning

Non-Patent Citations (2)

* Cited by examiner, † Cited by third party
Title
None *
See also references of WO2009015885A1 *

Also Published As

Publication number Publication date
WO2009015885A1 (fr) 2009-02-05
WO2009016485A2 (fr) 2009-02-05
DE102007036325A1 (de) 2009-02-05

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