GB2248704A - Production order determining method - Google Patents

Production order determining method Download PDF

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Publication number
GB2248704A
GB2248704A GB9117410A GB9117410A GB2248704A GB 2248704 A GB2248704 A GB 2248704A GB 9117410 A GB9117410 A GB 9117410A GB 9117410 A GB9117410 A GB 9117410A GB 2248704 A GB2248704 A GB 2248704A
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production
day
produced
product
products
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GB9117410D0 (en
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Kuniya Kaneko
Harumichi Wakiyama
Tadashi Naito
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Toyota Motor Corp
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Toyota Motor Corp
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    • GPHYSICS
    • G06COMPUTING; CALCULATING OR COUNTING
    • G06QINFORMATION 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
    • G06Q10/00Administration; Management
    • G06Q10/06Resources, workflows, human or project management; Enterprise or organisation planning; Enterprise or organisation modelling
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02PCLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P90/00Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
    • Y02P90/02Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]

Abstract

A production order determining method includes steps of providing production information in the form of a specified production time period with respect to a plurality of product types, calculating 12 a production expectation value for each specified production time period, summing the production expectation values for each specified production time period for all the product types and then integer-processing the total number of product portions to be produced each day, providing each day with as many production orders as the integer-processed number of product portions to be produced on that day, and then determining by an average process 14 what product ape should be produced in each production order. <IMAGE>

Description

PRODUCTION ORDER DETERMINING METHOD The present invention relates to a production order determining method for determining a production order of a plurality of production types of products in a production line where a production information is given in the form of specified periods of time of production with respect to production types of products.
Japanese Patent Publication SHO 63-265791 discloses a method for determining a production order of different models or production types of engines, in an engine assembly line, which are to be supplied to different car assembly lines. In the prior art method, the production order of the different production types of engines at the engine assembly line is determined based on input requirements from the respective car assembly lines, which are given in the form of numbers of each production type of engine to be supplied per successive fixed production periods (e.g., per shift or per day) to each of the car assembly lines. More particularly, a production period portion P. for an engine of each production type i is calculated from the input requirements.After a fixed value of P. has been calculated for an engine of each production type i, a production expectation value Xii for each production order j of each engine type i is calculated by the following equations: Xi1 = Pi ~~~~~~~~~ ( 1 ) Xij = Xij-1 + Pi - Dij-1 ---------(2) where, Dij is a variable having the value 1 in a case where an engine of production type i is produced at production order j and taking the value 0 in other cases. In the prior art, a production order j is determined so as to produce an engine of the production type i having the highest value of Xij.
For example, in an engine assembly line which receives requests from an A car assembly line to supply two a-type engines a day, from a B car assembly factory to supply one b-type engine a day, and a C car assembly factory to supply one c-type engine, a production order of the a-, b-, and c-type engines is determined in the following way.
At first, a production period portion PA for the a-type engine is calculated by dividing the required number of a-type engines per production period (2 per day) by the sum of all a-, b-, and c-type engines required per production period: 2 / (2 + 1 + 1). The resulting value of PA is 0.5.
Similarly, a production rate PB of the b-type engine is 0.25, and a production rate PC of the c-type engine is 0.25.
Therefore, from equation (1), Xa1 is 0.5, Xbl is 0.25, and Xcl is 0.25. Because the highest of these values is X it is determined that the first type of engine to be produced each day is the a-type engine.
Then, Xa2, Xb2, and Xc2 are calculated in the following manner: Xa2 Xal + 0.5 - 1 = 0 Xb2 Xb1 + 0.25 - 0 = 0.5 Xc2 X Xci + 0.25 - 0 = 0.5 Because the highest of these values is Xb2 or Xc2, either or or X , for example, Xb2, is chosen and the second c2 c2 engine to be produced each day is the b-type engine.
Similarly, Xa3 = Xa2 + 0.5 - 0 = 0.5 Xb3 = Xb2 + 0.25 - 1 = -0.25 Xc3 = Xc2 + 0.25 - 0 = 0.75 Because the highest of these values is Xc3, the third engine to be produced each day is the c-type engine.
Similarly, Xa4 = Xa3 + 0.5 - 0 = 1 Xb4 = Xb3 + 0.25 - 0 = 0 Xc4 = Xc3 + 0.25 - 1 = 0 Because the highest of these values is Xa4, the fourth engine to be produced each day is another a-type engine.
Therefore, the engine production order for producing four engines a day is determined to be an order of a, b, c, and a.
With respect to the second day, Xa5 = Xa4 + 0.5 - 1 = 0.5 X = Xb4 + 0.25 - 0 = 0.25 Xc5 = Xc4 + 0.25 - 0 = 0.25 Because these values are equal to the values of Xa1, Xb1, and Xcl, respectively, the same order of engine production as that of the first day should be executed in the second day.
The reason why the above-described determination of a production order is possible is that P. can be calculated for the first day, and the same P. can be used for the second day, the third day, ... , and the n-th day without varying the P. value. More particularly, the above described determination of a production order is possible or effective only for a production line where input information is provided in the form of a number of products to be produced per fixed production period (e.g., each day) with respect to each production type, because the production period portion P. used in equations (1) and (2) is fixed.
However, in a production line, such as a complete knock down line (a packing line where parts are packed in a domestic country and are shipped to foreign countries), where input information for a production order schedule is given in the form of usually different specified periods of time of production (in the case of a packing line, specified periods of time of packing, that is, information about how many of what type of boxes should be packed within what periods of time), the prior art production order determining method cannot be used, because fixed values of Pi cannot be used in the above equations (1) and (2).
An object of the invention is to provide a method for determining a production order of production of different product types which is effective even in a production line where production inputs are given in the form of specified production time periods with respect to production of each production type, with the production time periods having different possible values, both for products of the same type and for products of different types.
The above-described object is attained by a method for determining a production order in accordance with the present invention. The method comprises steps of providing production information in the form of a specified production time period and a number of products to be produced in the specified period with respect to production of each of a plurality of product types; calculating a production expectation value for each specified production time period, the production expectation value being defined as a number of products to be produced a day with respect to each of the product types, by dividing the number of products to be produced in each specified production time period by the number of days included in each specified production time period; summing the production expectation values for all specified production time periods for all the production types with respect to each day to calculate a total number of products to be produced with respect to each day; then integer-processing the total number of products to be produced with respect to each day; providing a table having a number of columns for each day equal to the integer-processed number of products to be produced that day; and then average processing to determine what product type should be inserted in each of the columns, and thereby to determine a production order for all the product types.
In the above-described method, since a production expectation value for each day (which corresponds to the number of products to be produced for each day) is calculated by summing the production expectation values for all specified production time periods for all the product types with respect to each day and then integer-processing the total number of products to be produced with respect to each day, it is possible to determine a production order.
In this instance, the averaging process is necessary because the production period portions Pij change with respect to the production days, while the production period portions P.
in the prior art method have constant values because they are not functions of the production order j.
The above and other objects, features, and advantages of the present invention will become more apparent and will be more readily appreciated from the following detailed description of the preferred embodiment of the invention taken in conjunction with the accompanying drawings, in which: FIG. 1 is a diagram of a system for executing a production order determining method in accordance with one embodiment of the present invention; FIG. 2 is a table illustrating input information fed to a production schedule input file of the system of FIG. 1; FIG. 3 is a table illustrating production expectation values for respective specified periods of time of production calculated from the input information shown in the table of FIG. 2;; FIG. 4 is a table illustrating summed numbers of products to be produced each day calculated from the production expectation values shown in the table of FIG. 3 and the integer-processed values of the summed numbers of products to be produced each day; and FIG. 5 is a table illustrating the results of average processing based on the data shown in the tables of FIGS. 3 and 4 and a production order determined by the averaging process.
A preferred embodiment of the present invention will now be explained with reference to the drawings.
As illustrated in FIG. 1, a production order determing method of the present invention includes step 11 of feeding production information into a production schedule input file, step 12 of calculating a production expectation value for each specified production time period, step 13 of summing the production expectation values and integer-processing the summed-up values, step 14 of applying an averaging process to determine a production order, and step 15 storing the determined production order in a production order output file.
More particularly, the input information is fed to the production schedule input file 11 from outside, either manually by an operator or via a communication network, and is stored in the production schedule input file 11.
As illustrated in FIG. 2, the input information is given in the form of a specified production time period, for example, a specified packing time period in a case where the production line is a packing line. Hereinafter, such packing line will be taken for an example; therefore, "production" may be replaced by "packing". FIG. 2 illustrates an example where three boxes of products of an A type (e.g., products to be shipped to a country A) are to be packed. The first box is to be packed in two days (the first and second days of a five-day period), the second box in four days (the first through fourth days of the same period), and the third box in two days (the fourth and fifth days of the period).Also, one box of products of a B product type (products to be shipped to a country B) is to be packed in five days (the first through fifth days of the same five-day period), and two boxes of products of a C product type (products to be shipped to a country C) are to be packed, the first C-type box in four days (the first through fourth days of the same period), and the second C-type box also in four days (the second through fifth days of the period).
At step 12 of FIG. 1, a production (packing) expectation value for each specified production (packing) time period is calculated. The production expectation value is defined as a number of product portions to be produced (packed) a-day with respect to each of a plurality of product (packing) types. This value is calculated by dividing the number of products to be produced (packed) in each specified production (packing) time period by the number of days in each specified production (packing) time period.
For example, as illustrated in FIG. 3, the requirement of one A-type box to be produced (packed) in the first and second days is divided into 0.5 box for the first day and 0.5 box for the second day; so that the production (packing) expectation value on the first day for this A-type box is 0.5, and the production (packing) expectation value for first box on the second day is 0.5. The requirement of a second A-type box for the first through fourth days is divided into 0.25 box for the first day, 0.25 box for the second day, 0.25 box for the third day, and 0.25 box for the fourth day; so that the production (packing) expectation value on each day of the first through fourth days for this second A-type box is 0.25.The requirement of a third A-type box for the fourth and fifth days is divided into 0.5 box for the fourth day and 0.5 box for the fifth day; so that the production (packing) expectation value for this third A-type box on each of the fourth and fifth days is 0.5. Similarly, the same calculation is applied to the single box of products of the B type; so that the production (packing) expectation value for the one B-type box on each of the first through fifth days is 0.2. Finally, the same calculation is applied to the two boxes of products of the C type; so that the production (packing) expectation value for the first C-type box on each of the first through fourth days is 0.25, and the production (packing) expectation value for the second C-type box on each of the second through fifth days is 0.25.
Then, at step 13 of FIG. 1, and as illustrated in FIG. 4, the production expectation values for specified production (packing) time periods are summed for all the product types with respect to each day to obtain a total number of product portions to be produced (partial boxes to be packed) on each day of the five-day period. For example, in the first column, all of the production (packing) expectation values 0.5, 0.25, 0.2, and 0.25 are summed to obtain the total number 1.2 of product portions to be produced in the first day. Similarly, the totaled numbers of 1.45 for the second day, 0.95 for the third day, 1.45 for the fourth day, and 0.95 for the fifth day are obtained.
Then, at step 13 of FIG. 1, and as illustrated in FIG. 4, integer-processing is applied to each total number of product portions to be produced on each day. The integer-processing is executed by selecting the closest integer to the sum of the totaled number for the instant day and a remainder from the previous day. For example, because the total number 1.2 of the first day is closer to integer 1 than to integer 2, integer 1 is selected for the first day; that is, one box is produced (packed) on the first day. A difference of +0.2 between the total number 1.2 and the selected integer 1 is carried over as a remainder for the next day. With respect to the second day, the total number 1.45 of the instant day (the second day) and the remainder +0.2 from the previous day (the first day) are summed to obtain a number 1.65.Because the number 1.65 is closer to integer 2 than to integer 1, the integer 2 is selected for the second day; that is, two boxes are produced (packed) on the second day. The difference of -0.35 between the total number 1.65 and the selected integer 2 is carried over to the next day. With respect to the third day, the total of 0.95 for the third day and the remainder -0.35 from the second day are summed to obtain a number 0.6. Because the number 0.6 is closest to integer 1, the integer 1 is selected for the third day; so that one box is produced (packed) on the third day. The difference of -0.4 (= 0.6 1) is carried over to the next day. With respect to the fourth day, the total of 1.45 for the fourth day and the remainder -0.4 from the third day are summed to obtain a number 1.05.Because the number 1.05 is closest to integer 1, the integer 1 is selected for the fourth day; so that one box is produced for the fourth day. The difference of 0.05 (= 1.05 - 1) is carried over to the next day. Similarly, with respect to the fifth day, the total number 0.95 for the fifth day and the remainder +0.05 from the fourth day are summed to obtain a number of 1.00, so that integer 1 is selected for the fifth day and one box is produced on the fifth day. In this way, the integer-processed numbers of products to be produced (packed) in the first, second, third, fourth, and fifth days are determined to be 1, 2, 1, 1, and 1, respectively.
Then, at step 14 of FIG. 1, and as illustrated in FIG. 5, an average process' (a process for making production intervals even) is applied to the integer-processed numbers of products so that a production order of a plurality of product types is determined.
More particularly, FIG. 5 is a table having as many vacant columns as all of the integer-processed number of products to be produced (packed) in first through fifth days, with each column representing a production order.
Thus, one column is allotted to each of the first day, the third day, the fourth day, and the fifth day, and two columns are allotted to the second day. The six columns are given production order numbers one through six. The first column number means the order of production (packing) of products to be produced (packed) in the first day.
Similarly, the second column number and the third column number mean the order of production of products to be produced in the second day. The fourth column number means the order of production of products to be produced in the third day, the fifth column number means the order of production of products to be produced in the fourth day, and the sixth column number means the order of production of products to be produced in the fifth day. The production (packing) expectation values of the A-, B-, and C-product (packing) types are inserted below the six column numbers.
Thus, in the example, the numbers 0.75, 0.2, and 0.25 below column number 1 are the respective production (packing) expectation values of the A-, B-, and C-types of boxes for the first day.
These production (packing) expectation values are obtained using the following equations: Xi1 = Pi1 ----------- (3) Xij = Xij-1 + Pij - Dij-1 ------------ (4) where, Xij is a production (packing) expectation value for production of product (packing) type i and production (packing) order j, Pij is the sum of all production (packing) expectation values for each specified production time period with respect to production (packing) of product type i in a day on which product (packing) type i is to be produced in production (packing) order j, and Dij is a variable that is equal to the total number of all product portions to be produced on the day that contains the production (packing) order j and the production (packing) of type i products, and that is equal to 0 when there is no production (packing) of i-type product.
For example, in accordance with equation (3) and as illustrated in FIG. 5, the production (packing) expectation values XA1, XB1, and Xcl in the case where the production (packing) order j is 1 are equal to PA1, PB1, and PCl. In this instance, PA1 is calculated to be 0.75, which is a summation of the production (packing) expectation values 0.5 and 0.25 (see FIG. 3) of the first day with respect to the production (packing) of the A-type of product.Similarly, PB1 is calculated to be 0.2, which is the production expectation value 0.2 of the first day with respect to production (packing) of the B-type of product, and PCl is calculated to be 0.25, which is the production expectation value 0.25 of the first day with respect to the C-type of product. Then, since the largest of these production (packing) expectation values is 0.75, it is determined that the A-type of product should be produced (packed) in the order j=l.
Similarly, with respect to the order j=2, A2 = XAl + 0.75 - 1.2 = 0.3 XB2 = XB1 + 0.2 - 0 = 0.4 XC2 = XCl + 0.5 - 0 = 0.75 Since the largest value is 0.75, it is determined that the C-type of product should be produced (packed) in the order J=2. In this instance, the 0.75 in the equation for XA2 is a summation of the production expectation values 0.5 and 0.25 (See FIG. 3) of the A-type of product with respect to the second day, and the 1.2 in the equation for XA2 is the total number of products to be produced on the first day (see FIG. 4) and has to be subtracted in the equation for XA2 because A-type product was produced (packed) in the first day. Similarly, in the equation for XB2, the 0.2 is the production expectation value of the B-type of product with respect to the second day (see FIG. 3), and the 0 means that Dij is zero. In the equation for Xc2, the 0.5 is a summation of the 0.25 and 0.25 of production expectation values of the C-product type (see FIG. 3), and the 0 means that D. is zero.
Similarly, with respect to the order j=3, XA3 = XA2 + 0.75 - 0 = 1.05 XB3 = XB2 + 0.2 - 0 = 0.6 XC3 = XC2 + 0.5 - 1.45 = -0.2 Since the largest of these expectation values is XA3, the A-type of product is produced (packed) in the order j=3.
Similarly, with respect to the order j=4, XA4 = XA3 + 0.25 - 1.45 = -0.15 XB4 = XB3 + 0.2 - 0 = 0.8 XC4 XC3 + 0.5 - 0 = 0.3 Since the largest of these expectation values is XB4, the B-product type is produced (packed) in the order j=4.
Similarly, with respect to the order j=5, XAS XA4 + 0.75 - 0 = 0.6 XBS = XB4 + 0.2 - 0.95 = 0.05 XCS XC4 + 0.5 - 0 = 0.8 Since the largest of these expectation values is XC5, the C-type of product is produced (packed) in the order j=5.
Finally, with respect to the order j=6, A6 = XAS + 0.5 - 0 = 1.1 XB6 = XB5 + 0.2 - 0 = 0.25 XC6 = XC5 + 0.25 - 1.45 = -0.4 Since the largest of these expectation values is XA6, the A-product type is produced (packed) in the order j=6.
In this way, a production (packing) order is determined so that the A-type product is produced (packed) in the first day (j = 1), the C-type product and then the A-type product are produced in the second day (j = 2, 3), the B-type product is produced in the third day (j = 4), the C-type product is produced in the fourth day (j = 5), and the A-type product is produced in the fifth day (j = 6).
The above-described process for making production intervals as even as possible is called an averaging process.
In this averaging process, it is possible to calculate Pij because it is determined as a summation of production expectation values of the day that contains the order j. In this instance, Pij varies in accordance with the order j, while P. of the described prior art method is constant (i.e., is independent of the order j).
In accordance with the present invention, the following advantages are obtained.
First, a production order determining method which can satisfy both (a) production of products within a production time limit and (b) average processing (making production intervals as even as possible) is obtained, though the two production conditions are not compatible in the prior art.
Second, due to the above-described production condition (a), a required stock of products at a given production (packing) line is greatly decreased and a shutdown of a subsequent assembly line due to lack of supply of products is effectively prevented.
Third, due to the above-described production condition (b), a required stock of parts at a previous line is greatly decreased and a shutdown of the instant line due to lack of supply of parts is effectively prevented.

Claims (6)

CLAIMS:
1. A production order determining method comprising steps of: providing production information in the form of a specified production time period and a number of products to be produced in the specified production time period with respect to each of a plurality of product types; calculating a production expectation value for each specified production time period, said value being defined as a number of product portions to be produced a day with respect to each of the product types, by dividing the number of products to be produced in each specified production time period by a number of days included in the respective specified production time period;; summing the production expectation values in each specified production time period for all the product types with respect to each day to calculate a total number of products to be produced each day, and then integer-processing the total number of products to be produced each day; and providing a production order sequence having as many production orders for each day as the integer-processed number of products to be produced on that day, and then average processing the summed production expectation values to determine what product type should be produced in each production order.
2. A production order determining method according to claim 1, wherein the integer-processing is executed by selecting an integer closest to a sum of the total number of product portions to be produced on a given day and a remainder from the previous day which is defined as the difference between the selected integer of the previous day and the number of product portions to be produced on the previous day.
3. A production order determining method according to claim 1, wherein the averaging process comprises: (a) calculating production expectation values using the following equations: Xii P ii X.. = X..1 + P.. - D..
13 ij-l 13 L where, Xij is a production expectation value for production of product type i and production order j, Pij is the sum of all production expectation values for each specified production time period with respect to production of product type i in a production day which includes the production of product type in the production order j, and Dij is a variable that is equal to a total number of product portions to be produced on the day that contains the production order j and the production of i-type products and is equal to 0 when there is no production of i-type products; and (b) selecting the largest Xij among the Xijs having the same production order number j to determine the product type i to be produced in the production order j.
4. A production order determining method according to claim 1, wherein the production process is packing.
5. A production order determining method according to claim 1, wherein the production process is packing in a complete knock down engine assembly line.
6. A method for controlling a production line, substantially as hereinbefore described with reference to the accompanying drawings.
6. A production order determining method substantially as hereinbefore described with reference to the accompanying drawings.
AMENDMENTS TO THE CLAIMS HAVE BEEN FILED AS FOLLOWS.
1. A method for controlling a production line for the production of a plurality of product types in respective specified periods of time comprising determining a production order for the respective product types by: providing production information in the form of a specified production time period and a number of products to be produced in the specified production time period with respect to each of said plurality of product types; calculating a production expectation value for each specified production time period, said value being defined as a number of product portions to be produced a day with respect to each of the product types, by dividing the number of products to be produced in each specified production time period by a number of days included in the respective specified production time period;; summing the production expectation values in each specified production time period for all the product types with respect to each day to calculate a total number of products to be produced each day, and then integer-processing the total number of products to be produced each day; providing a production order sequence having as many production orders for each day as the integer-processed number of products to be produced on that day, and then average processing the summed production expectation values to determine what product type should be produced in each production order; and producing said plurality of product types in accordance with said production order sequence.
2. A method according to Claim 1, wherein the integer-processing is executed by selecting an integer closest to a sum of the total number of product portions to be produced on a given day and a remainder from the previous day which is defined as the difference between the selected integer of the previous day and the number of product portions to be produced on the previous day.
3. A method according to Claim 1, wherein the averaging process comprises: (a) calculating production expectation values using the following equations: Xil = Pil X3 = Xijl + Pjj - Dij- where, Xij is a production expectation value for production of product type i and production order j, Pij is the sum of all production expectation values for each specified production time period with respect to production of product type i in a production day which includes the production of product type in the production order j, and Djj is a variable that is equal to a total number of product portions to be produced on the day that contains the production order j and the production of i-type products and is equal to 0 when there is no production of i-type products; and (b) selecting the largest Xij among the Xüs having the same production order number j to determine the product type i to be produced in the production order j.
4. A method according to Claim 1, wherein the production process is packing.
5. A method according to Claim 1, wherein the production process is packing in a complete knock down engine assembly line.
GB9117410A 1990-08-23 1991-08-12 Production order determining method Withdrawn GB2248704A (en)

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GB2289963B (en) * 1994-05-25 1999-05-12 Matsushita Electric Ind Co Ltd Production line controller operated in accordance with generated production plans
US5841659A (en) * 1994-05-26 1998-11-24 Matsushita Electric Industrial Co., Ltd. Production plan generating method and apparatus

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JPH04105855A (en) 1992-04-07
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