JP2002023822A - Production control system for iron and steel industry and its method and recording medium with production control program recorded - Google Patents

Abstract

PROBLEM TO BE SOLVED: To improve yield without generating additional processes or generating increase in the total stock or increasing the defective rate. SOLUTION: A manufactured result obtained in each process of the production control system of producing equipment constituted of plural manufacturing processes and buffers is recognized by a rolling shape recognizing device 12. Whether or not product manufacture is valid in the next process is judged in the buffer of a cooling floor 13, and the correspondence of products with others is changed. Thus, it is possible to prevent any surplus stock of products or delay of delivery time by exchanging the orders of products in the same buffer even when any excess or insufficiency is generated due to the fluctuation of precision during manufacture.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a production management system, a production management method, and a recording medium for recording a production management program in the steel industry. It relates to a recorded recording medium.

[0002]

2. Description of the Related Art In many cases, production management in the iron and steel industry is basically made to order. This method is a method in which a production command according to the specification and a production start instruction are given in response to an order from a customer, and the production is completed by a predetermined delivery date. However, due to fluctuations in material weight and defective products occurring in each manufacturing process until a final product is obtained, products cannot be collected as planned in the final process, and remanufacturing is often performed. On the other hand, there is a surplus of products, and inventory increases. In such a case, not only the yield is reduced, but also it becomes difficult to complete the production by the delivery date.

To solve such a problem, Japanese Patent Application Laid-Open No.
Japanese Patent Publication No. 808 deals with the following. In other words, if there is an addition of a new order or an order related to re-invoicing (re-manufacturing), it will be possible to meet the additional delivery date from the material units in the advanced manufacturing process. Nevertheless, it searches for an order that has been assigned to the product without inconvenience and that the size of the product can satisfy the additional order. In this search, for example, information on the delivery date and the size of the product to be delivered included in the order information is used. Then, the correspondence between the product and the order is changed using the found one.

As described above, even if the remanufacturing occurs, if the delivery date of the product related to the order for which the remanufacturing has been imminent, the order is assigned to the preceding product. There is no delay in the delivery date. Also, when the correspondence is changed, it is possible to allocate an additional order fee to the surplus added to the preceding material unit.

[0005]

As described above, for example, by using information on the delivery date and the size of the product to be delivered included in the order information, material units added in the advanced manufacturing process are added. In a method of searching for a product that can satisfy the order and changing the correspondence, many of the changed products are often added to a process such as cutting to order dimensions again. In addition, if the method does not allow such additional processes, the amount of order change is drastically reduced, and the effect is affected by the manufacturing process and the production scale, and a sufficient effect cannot be obtained.

[0006] Further, even if it is possible to satisfy the order delivery date, if the delivery date of an extremely different order material is changed, an error occurs in the production plan at the start of the production and the inventory increases. However, there is a drawback that it causes a process disturbance. SUMMARY OF THE INVENTION The present invention has been made to solve the above-mentioned drawbacks of the related art, and has as its object to provide a string (ordering) between an ordered product and a product in a manufacturing process without causing an additional step or increasing inventory. The production management system, production management method, and production management program that can improve the yield without increasing the defect rate and prevent excessive product inventories and order delivery delays by changing The purpose of the present invention is to provide a recording medium.

[0007]

A production management system according to the present invention is a production management system for sequentially collecting products from a plurality of steel sheets in accordance with an order, comprising: a buffer for sequentially accumulating the plurality of steel sheets; Recognition means for recognizing the shape of the steel sheet material stored in this buffer, and the ordered product,
Determining means for determining whether or not it can be collected from the first steel sheet in the buffer recognized by the recognition means;
Control means for controlling so as to extract the ordered product from the second steel sheet in the buffer when it is determined that the ordered product cannot be collected by the determination means. Further, the control means changes the correspondence between the order and the first steel sheet to a correspondence between the order and the second steel sheet, thereby changing the product from the second steel sheet. It is characterized in that it is controlled to be collected.
The buffer is provided between a rolling step of manufacturing the steel sheet by a rolling process and a cutting step of cutting out the product from the steel sheet.

A production management method according to the present invention is a production management method for sequentially collecting products from a plurality of steel sheets according to an order. When the plurality of steel sheets are sequentially stored in the buffer, the products are stored in the buffer. A recognition step of recognizing the shape of the steel sheet to be processed, a determination step of determining whether or not the ordered product can be collected from the first steel sheet in the buffer recognized in the recognition step, and the determination step. And controlling the product to be sampled from the second steel sheet in the buffer when it is determined that the ordered product cannot be sampled.

A recording medium on which the production management program according to the present invention is recorded is a recording medium on which a production management program for causing a computer to perform production management for sequentially collecting products from a plurality of steel sheets according to an order is recorded. A step of recognizing a shape of the steel sheet material stored in the buffer when the plurality of steel sheet materials are sequentially stored in the buffer; and A determining step of determining whether or not the ordered product can be collected from the first steel sheet; and, if it is determined that the ordered product cannot be collected by the determining step, collecting the product from the second steel sheet in the buffer. And a control step of performing control as described above.

[0010] In short, in the present system, it is not necessary to judge whether the product is over or under based on the manufacturing result in a certain manufacturing process, and to change the order product and the product already manufactured in the process.
If it is determined that the product cannot be manufactured as planned in the next process production planning stage, from among other products waiting for the next process,
By exchanging the order information with a product that satisfies the order conditions, it is determined whether or not both ordered products can be manufactured, and if possible, the order information and the manufacturing instruction are changed.

According to the present system, the production result obtained in each process is recognized, it is determined whether or not the product can be produced in the next process, and the product is associated with the order based on the product history and the order information. As a result, if it is determined that the product cannot be manufactured as scheduled in the next process, it is determined whether or not both ordered products can be manufactured by satisfying the order conditions and replacing the order information for the product waiting for the next process. By changing the manufacturing instruction, if possible, the yield can be improved without adding a process or increasing the inventory and without increasing the defect rate.

[0012]

Next, an embodiment of the present invention will be described with reference to the drawings. In the drawings referred to in the following description, the same parts as those in the other drawings are denoted by the same reference numerals. Here, as an example of a production management system in the steel industry according to the present invention, an application example of the present system in a product sampling process of a thick steel plate will be described.

FIG. 1 is a diagram showing an outline of a product collecting process of a thick steel plate by a production management system according to one embodiment of the present invention. As shown in FIG. 1, the present system includes a rolling mill 11 that performs a rolling process of a predetermined thickness and a predetermined width, and a rolling shape recognition device that recognizes the shape of a large plate rolled by the rolling mill 11. 12, a cooling floor 13 serving as a buffer up to the cutting process, and a cutting machine 14 for cutting a large plate according to the order content (order) of the customer. The buffer realized by the cooling floor 13 is provided between a rolling step of manufacturing a steel sheet by a rolling process and a cutting step of cutting a product from the steel sheet. In the present system, since the steel sheets accumulated in the buffer realized by the cooling floor 13 are to be searched, there is no need to newly provide a buffer dedicated to search.

Incidentally, reference numeral 15 in the figure denotes a table line, and an arrow Y indicates the flow of the steel plate. In many cases, the production management of thick steel plates is a production management method generally called string production. This method is a method in which a production command according to the specification and a production start instruction are given in response to an order from a customer, and the production is completed by a predetermined delivery date. Therefore, although it is a multi-product small lot, the minimum unit of the production lot is a rolling unit called a large plate, and a plurality of products can be obtained by cutting the large plate.

The manufacturing process is as follows. First, a semi-finished product called a slab is manufactured by a continuous casting machine. Next, it is heated to a predetermined temperature in a heating furnace, and is rolled to a predetermined thickness and a predetermined width by a rolling mill 11 shown in FIG. In the cooling floor 13 shown in FIG. 1, dozens of large plates are cooled until they reach room temperature. Finally, in the product sampling process, the cutting board is used to divide the large plate into the desired product dimensions.

Here, in the product sampling process, the product to be sampled cannot be obtained due to a variation in slab manufacturing or rolling accuracy, which is a previous process, or a product surplus called extra length occurs. FIG. 2 is a block diagram showing the configuration of the production management system according to one embodiment of the present invention. As shown in the figure, the present system is configured to include a rolling shape recognition device 12, a product collection possibility determination unit 21, an order information change processing unit 22, and an order information search processing unit 23. I have. The product collection possible determination unit 21 performs a simulation with reference to the product cutting plan 20 to determine whether a product can be collected from a large plate. Order information search processing unit 23
Performs order information search processing by referring to the contents of the result file 24a, plan file 24b, and instruction file 24c in the manufacturing management system 24. Product history information is stored in the result file 24a,
A product cutting plan is stored in the plan file 24b, and order information from the customer is stored in the command file 24c. The order information change processing unit 22 changes the order according to the result of the search processing performed with reference to the contents of these files.

In this system having such a configuration, the following processing is performed. First, the rolling shape is recognized by the rolling shape recognition device on the front of the cooling floor, and transmitted to the product sampling possibility determination unit. Then, after a simulation based on a plurality of cutting plans is performed, it is determined whether or not product sampling is possible. If product extraction is not possible, search for order candidates that meet customer specifications even if orders are exchanged within the same process (in all the large plates on the cooling floor), and roll the large plates containing the orders It is determined from the shape information, the order in which the product cannot be sampled, and the rolled shape information whether or not the product can be sampled even if the order is exchanged. If product sampling is possible even after the order is exchanged, the order exchange is performed, and accordingly, necessary files such as the production plan schedule, actual results, and instructions in the production management system are exchanged. In other words, in this system, by changing the correspondence between the order and a certain steel sheet to the correspondence between the order and another steel sheet, the product is controlled to be sampled from another steel sheet. .

FIG. 3 shows an example of replacement of products in the present system. 1A and 1B show a large plate A and a large plate B. A case where a product is collected from each of these large plates will be described. Note that the hatched portion in the figure is the remaining portion after the product is collected. FIG. 3A shows a case where a product a and a product b are collected from a large plate A, and a product c and a product d are collected from a large plate B. In this case, the product a and the product b can be collected from the large plate A without any problem. On the other hand, although the product d can be collected from the large plate B, the product c cannot be collected because the broken line portion H is insufficient.

Therefore, in this case, the large plate for collecting the product a and the large plate for collecting the product c may be exchanged. That is, the large plates to be collected are exchanged, and as shown in FIG. 3B, the products c and b are collected from the large plate A, and the products a and d are collected from the large plate B. I do. By performing the replacement in this manner, the product can be collected from the large plate without causing a shortage.
Therefore, even if there is a surplus or a shortage due to a variation in accuracy during manufacturing, by exchanging the order of the products in the same buffer, it is possible to prevent an excessive product inventory and a delay in order delivery.

FIG. 4 is a flowchart showing the operation of the present system. In this figure, the present system first recognizes a rolling shape (step S401).
Next, a simulation based on the cutting plan is performed (step S402). Thereafter, it is determined whether or not product collection is possible (step S403). If the product can be collected, a process according to a normal process is performed (step S403).
→ S408).

On the other hand, if the product cannot be collected in step S403, an order candidate that satisfies the customer specification even if the order is exchanged is searched in the same process (step S403 → S404). As a result of the search, if there is one whose order can be exchanged, the order in the instruction file is exchanged (step S405 → S406). Along with this, necessary files such as a production plan schedule and an actual result in the production management system are replaced (step S407). After that, the process according to the normal process is performed (step S40).
8).

Here, in step S404, a search is made for the preceding material in the buffer, and if there is no material that can be replaced with the preceding material, a search is made for the succeeding material. This search processing will be described with reference to FIG.
FIG. 2 shows a state where each lot L moves from the rolling mill 11 to the cutting machine 14. Each lot L has a rolling mill 1
When moving from 1 to the cutting machine 14 in the direction of arrow Y, it passes through the shape recognition device 12 and the cooling floor 13. Cooling floor 13
Have a function as a buffer of the same process.

In the same drawing, as shown in the above-mentioned large plate B in FIG.
For item 1, a search is first performed for the preceding material. As a result of this search, if there is a replaceable lot L2 in the preceding material, the process of replacing the lot L1 with the lot L2 is performed.
If no replaceable material is found for the preceding material, a search is made for the succeeding material. As a result of this search, if there is a replaceable lot L2 in the succeeding material, the lot L1 and the lot L
2 is replaced.

If the lot L1 moves to the vicinity of the cutting machine 14 and a replaceable material is not found even immediately before the cutting process, a different process is performed depending on whether there is enough time for delivery. If there is enough delivery time, within the order before the production start instruction, if there is an order that meets customer specifications even if the order is replaced, it will be replaced.If there is no spare time, within the cut order, Even if the order is exchanged, if there is an order that satisfies the customer specifications, the exchange is performed.

Referring back to FIG. 4, as a result of the search in step S404, if there is no order that can be exchanged even immediately before the cutting step, it is determined whether there is enough time for delivery of the product (step S405 → S409). If there is enough time for delivery of the product, an order candidate that satisfies the customer specifications even if the order is exchanged is searched in the order before the production start instruction (steps S409 → S410). As a result of the search, if the order can be exchanged, the order is exchanged (steps S411 → S412). If no candidate is found, the replacement is performed without performing replacement, for example, by performing remanufacturing (step S411 → S413 → end).
In this case, it is also possible to proceed to step S414 and search for a candidate from the disconnected order.

On the other hand, if there is no margin in the delivery date of the product, an order candidate that satisfies the customer specification even after the order is exchanged is searched for in the cut order (step S409 → S4).
14). As a result of the search, if there is any item whose order can be exchanged, the order is exchanged and disconnected again (step S41).
5 → S416). If the candidate is not found, the replacement is performed without performing replacement, and the countermeasure is performed (Step S
415 → S417 → end).

Since the present system operates as shown in the flowchart of FIG. 4, it is a production management method for sequentially collecting products from a plurality of steel sheets according to an order. A recognition step of recognizing the shape of the steel material to be stored in the buffer when storing in the buffer; and determining whether the ordered product can be collected from the first steel material in the buffer recognized in the recognition step. A production management method comprising: a determination step of performing a determination; and a control step of controlling the product to be collected from a second steel sheet in the buffer when it is determined that the ordered product cannot be collected by the determination step. Is realized by the present system. In the control step, the product is changed from the second steel sheet by changing the correspondence between the order and the first steel sheet to the correspondence between the order and the second steel sheet. It is controlled to collect.

As described above, by replacing the product information before the product cutting step, the defect rate can be reduced without generating an additional step such as re-cutting. Therefore,
As shown in FIG. 6, the present system can improve the product defect rate by about 20% as compared with the conventional system. As described above, this system recognizes the manufacturing results obtained in each process, determines whether the product can be manufactured in the next process, and associates the product with the order based on the product history and order information. If it is determined that the product cannot be manufactured as planned in the next process, the order information is replaced with the product that satisfies the order conditions from among the other products waiting for the next process, so that it is possible to manufacture both ordered products. This is determined, and if possible, the manufacturing instruction is changed, so that the yield can be improved without increasing the defect rate without adding a process or increasing inventory.

It is to be noted that if a recording medium on which a program for realizing the operation shown in FIG. 4 is recorded is prepared and the computer is controlled by the program recorded on the recording medium, the production management is performed in the same manner as described above. It is clear that actions can be taken. As this recording medium, various recording media other than the semiconductor memory, the magnetic disk, the optical disk, and the like not shown in FIG. 1 and the like can be used.

Regarding the description of the claims, the present invention can further adopt the following aspects. (1) In the control step, by changing the correspondence between the order and the first steel sheet to the correspondence between the order and the second steel sheet, the product is changed to the second steel sheet. 5. The production management method according to claim 4, wherein control is performed so as to extract the material.

(2) The buffer is provided between a rolling step of manufacturing the steel sheet by a rolling process and a cutting step of cutting the product from the steel sheet. Production management method. (3) In the control step, by changing a correspondence between the order and the first steel sheet to a correspondence between the order and the second steel sheet, the product is changed to the second steel sheet. The recording medium according to claim 5, wherein the recording medium is controlled to be collected from a material.

(4) The buffer is provided between a rolling step of manufacturing the steel sheet by a rolling process and a cutting step of cutting the product from the steel sheet. Recording medium.

[0033]

As described above, according to the present invention, means for recognizing the manufacturing result obtained in each step, means for determining whether or not a product can be manufactured in the next step, and product history and order information are stored. If it is determined that the product cannot be manufactured as scheduled in the next process by having a means to associate the means with the product and the order, replace the order information with the product that satisfies the order conditions from other products waiting for the next process Therefore, it was decided whether or not both products could be manufactured, and if possible, the manufacturing instruction was changed.Therefore, it was possible to improve the yield without increasing the defect rate without adding processes or increasing inventory. There is an effect that can be done.

[Brief description of the drawings]

FIG. 1 is a diagram showing an outline of a product collecting process of a thick steel plate by a production management system according to an embodiment of the present invention.

FIG. 2 is a block diagram showing a configuration of a production management system according to one embodiment of the present invention.

3A and 3B are diagrams illustrating an example of product replacement in the present system, in which FIG. 3A illustrates a state before replacement and FIG. 3B illustrates a state after replacement.

FIG. 4 is a flowchart showing the operation of the present system.

FIG. 5 is a diagram showing a search process for a preceding material and a following material in the present system.

FIG. 6 is a diagram showing a product defect rate between the present system and a conventional system.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 11 Rolling machine 12 Rolling shape recognition apparatus 13 Cooling floor 14 Cutting machine 15 Table line

Claims (5)

[Claims] 1. A production management system for sequentially collecting products from a plurality of steel plates in accordance with an order, comprising: a buffer for sequentially storing the plurality of steel plates; and a shape of the steel plate stored in the buffer. Recognizing means, a determining means for determining whether or not the ordered product can be collected from the first steel sheet material in the buffer recognized by the recognizing means, and a product ordered by the determining means cannot be collected. Control means for controlling the product to be taken from the second steel sheet in the buffer when it is determined that 2. The control unit changes the correspondence between the order and the first steel sheet to the correspondence between the order and the second steel sheet, thereby changing the product to the second steel sheet. 2. The production management system according to claim 1, wherein the control is performed so as to extract from a steel plate. 3. The buffer according to claim 1, wherein the buffer is provided between a rolling step of manufacturing the steel sheet by a rolling process and a cutting step of cutting the product from the steel sheet. The production management system described. 4. A production management method for sequentially collecting products from a plurality of steel sheets according to an order, wherein when sequentially storing the plurality of steel sheets in a buffer, the shape of the steel sheet material stored in the buffer is determined. A recognition step for recognizing, a determination step for determining whether or not the ordered product can be collected from the first steel sheet material in the buffer recognized in the recognition step, and a product ordered by the determination step being collected. Controlling the product to be taken from the second steel sheet in the buffer when it is determined that the product cannot be obtained. 5. A recording medium recording a production management program for causing a computer to perform production management for sequentially collecting products from a plurality of steel sheets in accordance with an order, said program comprising: A recognition step of recognizing the shape of the steel material accumulated in the buffer when sequentially accumulating in the buffer, and whether an ordered product can be sampled from the first steel material in the buffer recognized in the recognition step A determining step of determining whether or not the ordered product cannot be collected by the determining step, and a controlling step of controlling the product to be collected from the second steel sheet in the buffer. Characteristic recording medium.