JP2001147711A - Plan-updating method capable of minimizing the number of places to be changed - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a plan-updating method, capable of reducing the number of parts to be changed such as changes in a plan, changes in a processing instruction to a current state and the change of an answering period to a customer as much as possible. SOLUTION: At initial planning, a data-reading part 6 reads out master data, stock/work in process data, order data, and restricting conditions from latest data 11 of a production plan and develops the read data in a memory, a plan development part 7 generates lots by dividing them from respective master data and develops the plan backward in a direction going back the process procedure of master data on the basis of the process procedure of the master data in each lot, until the cancel of contravention in restriction to all orders and an end condition are satisfied. A plan-adjusting part 8 for canceling the contravention of the restriction evaluates the plan on the basis of the restriction condition registered as a master data, cancels the restriction contravention by moving a lot which generates the restriction contravention in the back and forth direction of a time base and stores the plan developed on the memory in an external storage device as the preceding plan data.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a production planning system which updates a production planning result while making a change, thereby reducing the number of changed parts from the previous plan as much as possible. How to update.

[0002]

2. Description of the Related Art In a factory production line, it is widely practiced to introduce a computer to control production. In this case, the input plan after drafting the production execution plan,
For example, Japanese Patent Application Laid-Open Publication No.
No. -100861. In the case of this publication, when the line stops for some reason or the equipment stops operating, the input plan and the process work plan are automatically reviewed even if the balance of the line is temporarily lost. , So that the balance between the work in progress and the waiting state can be regained.

Japanese Patent Application Laid-Open No. 06-168250 discloses a production plan, actual data of each affirmation, man-hours of each process, and a production operation date in order to automate and plan a production plan. Is input to the input unit and stored in the storage unit. When the production lot number and the input date of the product are specified and input at the time of inputting the production plan, based on the man-hours and operation day table for each process stored in the storage unit It is disclosed that a production plan for a lot number of the product is automatically determined by an arithmetic control unit in an interactive manner and displayed on an output display unit.

Japanese Patent Application Laid-Open No. 06-266725 discloses a cold rolling season planning system and the like in order to make it possible to formulate an efficient production plan in consideration of the delivery date of a unit product to be planned and the characteristics of each process. The product manufacturing process is divided into an upper process group, a lower process group, and a unit product to be planned into a product with fixed delivery date and a product with tentative delivery date, and the products with fixed delivery date and the product with tentative delivery date satisfy each process condition in the order of their delivery date. As
The daily production plan of the lower process group is formulated by arranging / provisionally arranging the products on a daily basis, and the unit products are tabulated by the assembly frame unit of the lower process group on a daily basis. By the day, the lot type of the upper process group is set for each day based on the position, and within the range of the predetermined period so as to satisfy the daily collective frame amount in the tentative delivery date of the lower process group based on the lot formation amount. It is disclosed to allocate and formulate daily production plans for Kamifong County.

Japanese Patent Application Laid-Open No. Hei 10-263994 discloses a method of creating a production plan that can efficiently perform lot production without stock-out while minimizing inventory. , Has been disclosed. Japanese Patent Application Laid-Open No. 10-307862 discloses that even if the number of production processes is large, a CPU is used to create a schedule in a short time.
Based on the processing information read from the processing information database, specifies a processing step that intersects all the processing paths of each part, and gives it to the reference processing step creation unit as a reference processing step. A production plan for the machining process is created and given to the backward section and the forward section, respectively.When the backward section is given the reference machining step plan, the machining plan is backwardly defined for each step upstream from the reference machining step. It is disclosed that the forward part prepares a processing plan by forward for each processing step downstream of the reference processing step.

[0006] However, none of these publications describes anything about making a plan with a minimum number of changes using a production plan made in the past of the production plan and the latest data. is there. By the way, in general, in a production planning system based on constraints,
Those that are in production are forward-developed based on the reference information,
For those not yet started, after the backward expansion, the plan is changed so that the minimum plan unit of a portion that violates a plurality of constraints such as load and material is moved forward and backward on the time axis to eliminate the plan. Conventionally, whether you are planning a plan for the first time or rebuilding the previous plan, the starting point of this backward development is the required delivery date (or target delivery date) of each order (hereinafter, order), and the required amount is set to an appropriate unit quantity. (Hereinafter referred to as a lot), and the plan is developed in a direction going back in time.

[0007]

Problems to be solved by this method are as follows.
If the required quantity of the order is large, the number of lots will be multiple, and those lots may be moved in the front and back direction (past and future directions) due to adjustment when resolving constraint violations,
Replanning means that there is no guarantee that it will be at the same time as the previous time.

SUMMARY OF THE INVENTION The present invention has been made to solve the above-mentioned conventional problems, and has been developed under the circumstances in which the latest devices and stocks are kept in a state where it is easy to violate predetermined constraints such as a load exceeding capacity. When making a plan repeatedly, the change from the previous plan can be made as small as possible, and the change of the work instruction to the current situation and the change of the delivery date to the customer can be reduced. The purpose is to provide a plan update method.

[0009]

In order to achieve the above object, the present invention provides a plan updating method for minimizing the number of changed parts by a data reading unit from a previous plan data of a production plan drafting stored in a storage device. In addition to reading master data and order data, read inventory / work-in-progress data, master data, order data, and constraints from the latest data for production planning, reflect the latest master data in the previous master data, and A first step of reflecting the latest order data in data and developing the data in a memory, and, based on the data developed in the memory, a plan developing unit completes the information of each lot of the previous plan data with the completion of each lot. A second step of performing backward development by going back through the process procedure for each lot based on the date and time; A plan adjustment unit for resolving the constraint violation based on the matter, evaluating the plan, and moving the lot where the constraint is violated in the front-back direction on the time axis to eliminate the constraint violation; And a fourth step of storing the plan developed on the memory as the previous plan data in the storage device.

[0010] Therefore, the master data and order data are read from the previous planning data of the production plan stored in the storage device by the data reading unit, and the stock / work-in-progress data, the master data, and the order data are read from the latest data of the production planning. The data and the constraint conditions are read out, the latest master data is reflected on the previous master data, and the latest order data is reflected on the previous order data, and the data is expanded in the memory. Next, based on the data developed on the memory by the planning and development unit, the information for each lot of the previous planning data is backward developed by going back through the process procedure for each lot based on the completion date and time of each lot. Then, the plan coordinator evaluates the plan based on the constraint conditions to eliminate the constraint violation, and moves the lot where the constraint violation occurs in the front-back direction on the time axis to eliminate the constraint, and Since the plan developed above is saved in the storage device as the previous plan data, in the situation where it is easy to violate predetermined constraints such as the load exceeding the capacity, the latest When making a plan repeatedly by reflecting the situation, the change from the previous plan can be made as small as possible, and the change of the work instruction to the current situation and the change of the delivery date to the customer can be reduced.

[0011]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Next, an embodiment of a plan updating method for minimizing the number of changed parts according to the present invention will be described with reference to the drawings. FIG. 1 is a functional block diagram showing a configuration of a plan updating apparatus applied to the first embodiment of the present invention. In FIG. 1, the plan updating device includes:
Last plan data 5, data readout unit 6, plan development unit 7, plan adjustment unit 8 for violation elimination, data storage unit 9,
A plan 10 and the latest data 11 developed on the memory are included.

The previous plan data 5 includes, for example, master data 12 and order data 13 as shown in FIG. 3, and is stored in a storage device such as a hard disk.
The details of the master data 12 and the order data 13 are composed of information 15 of the quantity and completion date and time of all lots for each order 14. As shown in FIG. 4, the latest data 11 is information such as inventory and work-in-progress data (hereinafter referred to as stock / work-in-progress data) 16, master data 17, order data 18, and constraint conditions 19 that change with time. is there.

The data reading unit 6 stores the previous plan data 5
From the master data 12 and the order data 13, and the latest data 11 to read inventory / work in progress and master data,
Expand on memory. When a plan is first created, the previous plan data 5 is empty, so the data reading unit 6 reads the stock / process data 16, the master data 17, the order data 18, and the constraint conditions 19 from the latest data 11.

The plan developing unit 7 reads the data read out by the data reading unit 6 based on various data developed on the memory.
A lot is generated, and the plan is developed backward in the direction going back through the process procedure. The plan adjustment unit 8 for eliminating constraint violations evaluates the plan 10 based on the constraint conditions registered in advance as master data, and moves the lot where the constraint violation occurs in the longitudinal direction on the time axis. To resolve constraint violations. The data storage unit 9 stores the plan 1 in the memory.
From 0, necessary information is stored as the previous plan 5 in the form of FIG.

In the first embodiment, as an example, as shown in FIG. 2, for example, as a result of the previous planning, three lots are planned to satisfy a certain order, and If the “Lot 1 completion date and time 2”, “Lot 2 completion date and time 3”, and “Lot 3 completion date and time 4” are shifted from the requested delivery date 1, When developing a plan, each lot is expanded backwards starting from the completion date and time of each lot, and the lot is moved to eliminate constraint violations, so that changes from the previous plan can be minimized. .

Next, the operation of the first embodiment will be described in detail with reference to the drawings. First, the operation when making a plan for the first time will be described. The data reading unit 6 of FIG. 1 converts the latest data 11 into the master data 1 shown in FIG.
7. The stock / in-process data 16, the order data 18, and the constraint conditions 19 are read and expanded on the memory.

Next, the plan developing unit 7 develops a plan from the data developed in the memory. For example,
As shown in FIG. 5, the required quantity of the order is divided into lots, which are units of work, from the requested delivery date 20 of the order, and for each lot, “process 4” is performed according to the master data process procedure →
The work time for each process is determined retroactively in the order of “process 3” → “process 2” → “process 1”. At this time, equipment to be used in each process is also determined at the same time from the manufacturing conditions of the master data. The plan developing unit 7 performs all the process developing processes for the order. When the required quantity of an order is large, one order is divided into a plurality of lots.

Next, the plan adjustment unit 8 for solving constraint violations shown in FIG. 1 executes the process of each lot for the portion of the plan developed in the above process where the constraint is violated in the front-back direction on the time axis. It is resolved by moving it to. in this case,
For example, if the load on the equipment at a certain time exceeds the capacity of the equipment, an attempt is made to move any of the lots processed simultaneously at that time in the past direction or the future direction on the time axis to try to eliminate it.

The plan adjustment unit 8 for eliminating constraint violations until all constraint violations are eliminated or until some termination condition (such as termination of adjustment in a fixed time) is satisfied.
Repeat the adjustment process. As a result, as shown in FIG. 2, the completion dates and times of a plurality of lots of the same order whose completion dates and times match before adjustment may be different times. Lastly, the data storage unit 9 stores the plan 10 developed on the memory as the previous plan data 5 in, for example, an external storage device. At this time, the quantity and completion date and time of each lot are stored for all orders as shown in FIG.

Next, as a second embodiment of the present invention, a plan updating method for minimizing the number of changed parts by planning as little as possible using a plan made in the past and the latest data will be described. In this case, FIG.
The data reading unit 6 reads the master data 12 and the order data 13 from the previous plan data 5 as shown in FIG. In addition, the latest data 11
As shown in FIG. 4, the stock / in-process data 16, the master data 17, the order data 18, and the constraint conditions 19 are read and expanded on the memory.

At this time, the latest master data 17 is reflected on the previous master data 12. In this case, for example, the content is such that a process procedure is added or equipment used in a certain process is changed. Further, the latest order data 18 is reflected on the previous order data 13.
In this case, for example, the order quantity of the order and the required delivery date change. In particular, when the order quantity is changed, the quantity of an appropriate lot is increased or decreased from the lot group belonging to the order. Next, planning and development section 7
Develops a plan based on the data developed in the memory.

The method of developing the plan at this time is different from the first plan development, in that the information 15 for each lot of the previous plan data is used as a starting point based on the completion date and time of each lot as shown in FIG. Perform backward expansion retroactively. When backward development is completed for all orders, a lot plan that minimizes the difference from the previous plan can be developed. Subsequently, the plan adjustment unit 8 for eliminating the constraint violation removes the constraint violation by moving the lot back and forth, as in the case of drafting the plan for the first time.

Since there is already little difference from the previous plan, if there is no change in the constraint conditions 19, the number of lots and the amount of movement to be moved to eliminate the constraint violation will be small. This will be described with reference to FIG. 6, as shown in FIG. 6A, "backward expansion 22 starting from the requested delivery date of the order". Is moved, the result is as shown in "Result 23 of adjustment for eliminating constraint violation" shown in FIG. 6B.
When the backward expansion is performed each time starting from the requested delivery date of the order, the loads of all the lots overlap, so that many lots are moved, and each time, the “adjustment is made to eliminate the constraint violation” shown in FIG. There is no guarantee that the plan of "Result 23" will be obtained, and there is a possibility that the plan will be completely different.

On the other hand, when backward development is performed starting from the completion date and time of the previous lot, as shown in FIG. 6C, "backward development 24 starts from the completion date and time of the lot". On the other hand, when the constraint violation is eliminated, FIG.
As shown in (d), the “result 25 adjusted to eliminate the constraint violation” reflects the previous plan in which the constraint violation has been eliminated to some extent in advance, so that a large lot does not move. Therefore, the number of changes from the previous plan is reduced.

[0025]

As described above, according to the present invention, master data and order data are read from the previous plan data of the production plan stored in the storage device by the data readout unit, and the latest data of the production plan is prepared. Read inventory / work-in-progress data, master data, order data, and constraints from, apply the latest master data to the previous master data, apply the latest order data to the previous order data, and load the data into memory. Based on the data expanded in the memory by the expansion unit, backward development of the information of each lot of the previous plan data by retroactively going back the process procedure for each lot based on the completion date and time of each lot, and violating constraints The plan coordinator evaluates the plan based on the constraints and resolves the lot where the constraint is violated on the time axis. Moved in the front-back direction to eliminate the constraints and save the plan developed in the memory as the previous plan data in the storage device, so the predetermined constraints such as the load exceeding the capacity In situations where it is easy to violate, when making a plan repeatedly by reflecting the latest device and inventory status, changes from the previous plan can be minimized as much as possible, Changes can be reduced.

[Brief description of the drawings]

FIG. 1 is a functional block diagram showing a configuration of a plan updating apparatus applied to a first embodiment of a plan updating method for minimizing changed portions according to the present invention.

FIG. 2 is an explanatory diagram of a time-to-lot process processing procedure for explaining the operation of the first embodiment of the plan updating method for minimizing the number of changed parts according to the present invention;

FIG. 3 is an explanatory diagram of plan data in the plan updating device of FIG. 1;

FIG. 4 is an explanatory diagram of the latest data in the plan updating device of FIG. 1;

FIG. 5 is an explanatory diagram of a time-to-lot process processing procedure for explaining the operation of the first embodiment of the plan updating method for minimizing the number of changed parts according to the present invention;

FIG. 6 is an explanatory diagram when a lot plan is developed in the first embodiment of the plan updating method for minimizing the number of changed parts according to the present invention.

[Explanation of symbols]

1, 20, 21 ... Order request delivery date, 2 ... Lot 1 completion date and time, 3 ... Lot 2 completion date and time, 4 ... Lot 3 completion date and time, 5 ... Previous plan data, 6 ... Data readout unit, 7 ... Plan development unit, 8 Plan adjustment unit for eliminating constraint violations, 9 Data storage unit, 10 Plan, 11
... latest data, 12, 17 ... master data, 13, 1
8: Order data, 14: Order 1, 15: Information for each lot of previous plan data, 16: Stock / work in progress data, 19: Constraints, 22: Requested delivery date of order backed Word expansion, 23: Result of adjustment to eliminate constraint violation, 24: Result of backward expansion starting from lot completion date and time, 25: Result of adjustment to eliminate constraint violation.

Claims (3)

[Claims] 1. A data reading unit reads master data and order data from the previous plan data of a production plan stored in a storage device, and reads inventory / process data, master data, and master data from the latest data of the production plan.
A first step of reading the order data and the constraint conditions and reflecting the latest master data on the previous master data, and reflecting the latest order data on the previous order data and developing the data in a memory; A second step of performing backward development of the information for each lot of the previous planning data by the planning and developing unit based on the completion date and time of each lot and going backwards through the process procedure for each lot based on the data described above; A third step of evaluating the plan based on the conditions by a plan adjustment unit for eliminating the constraint violation, moving the lot where the constraint is violated in the longitudinal direction on the time axis to eliminate the constraint violation; And a fourth step of saving the plan developed on the memory as the previous plan data in the storage device. How to update the plan 2. The data reading unit according to claim 1, wherein the data reading unit increases or decreases the quantity of an appropriate lot from a group of lots belonging to the order when the previous order data changes the order quantity. How to update the plan with as few changes as possible. 3. The plan updating method according to claim 1, wherein the data reading unit reflects the change in the requested delivery date in the previous order data.