JP2002351523A - Delivery date answering system - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a delivery date answering system capable of giving a delivery date answer and explaining a reason for delivery date answer calculation with emulation results by predicting an operation condition with a plant emulator constructed on a computer by using information acquired from an interface being the same as that of a real device, and performing virtual production by using the predicted operation condition. SOLUTION: This system for answering a delivery date in a manufacturing industry has an operation history collecting means for collecting operation history of the real, a real plant information transferring means for fetching information of the real device, an operation predicting means for predicting the operation condition of the real device from the operation history of the real device and real plant information, a scheduling means for performing scheduling preparation, the plant emulator for imitating the operation condition of the real device by using a virtual model on the computer and a delivery date calculating means for calculating a delivery date, performs virtual production on the computer and calculates a delivery date on the basis of virtual production results.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a delivery date answering system, and more particularly to calculating a delivery date using a method of emulating actual equipment in a factory.

[0002]

2. Description of the Related Art Conventionally, in order-to-order production in which expected production is not performed, when a delivery date is to be answered, the ordered items are scheduled based on the delivery date compliance rate, equipment operation rate, intermediate inventory amount, manufacturing cost, and the like. Scheduling is performed using a set of systems, a so-called scheduler, and a delivery date is answered from the obtained result.

In recent years when computer processing capability has been improved, a system for virtually simulating a factory or an emulator for imitating the operation of a device at the time of factory design or before factory operation (for example, Japanese Patent Laid-Open No. 7-3258).
No. 03 gazette), it is becoming possible to evaluate the operation state of the device without the actual device, such as the lead time, the tact time, and the timing of the intermediate distribution.

[0004]

Conventionally, when scheduling an ordered item, a scheduler uses a preset unit man-hour per product / machine as a production capacity to start each process and Calculate the completion time,
Determine the delivery date. For production capacity, use a constant value such as the average value of production performance information during a certain period during actual operation, or a probability distribution value such as a normal distribution, uniform distribution, Poisson distribution that can be confirmed by simulation before factory operation .

However, the conventional scheduling method is:
The time is accumulated based on the set value, but when moving from one position to another position because the three-dimensional position information of raw materials, semi-finished products, products, transport means, etc. in the actual factory is not considered, It is difficult to reflect in a scheduling a minute time, such as a shorter time on the same floor than a movement between different floors.

A system for performing a simulation, such as a line simulator, can reproduce the operation rate or the amount of stay of a logistics or production machine using parameters in which the operation and stop of the equipment are set in advance. To the extent that the load on the equipment is calculated.

Further, the line simulator performs operation setting of each device by inputting parameters.
Normally, since there is no interface with an external system, simulation must be performed multiple times to find better production conditions, or in order to perform simulation using actual information after factory operation, all parameters must be set again. It was necessary to input again, and it was difficult to use it after the actual device started operating.

[0008] Further, the production capacity using the average value of a certain period or the like is not changed until the timing for calculating the capacity for each period is reached.
Even when the equipment capacity is increased due to daily improvement, etc., there is a problem that the scheduling is performed using the production capacity that does not match the actual situation until the production capacity setting is changed artificially.

As a result, the delivery date calculated by the scheduler does not match the delivery date of the result of actual production.
Also, I can't explain why they don't fit,
No feedback could be given to subsequent scheduling.

Accordingly, the present invention predicts operating conditions on a factory emulator constructed on a computer by using information obtained from the same interface as an actual device.
An object of the present invention is to provide a delivery date answering system that performs virtual production using predicted operating conditions and can explain the delivery date answer and the reason for calculating the delivery date answer based on the result of emulation.

[0011]

In order to solve the above-mentioned problems, a first feature of the present invention is a system for responding to a delivery date of a manufacturing industry, and an operation history collection for collecting operation history of actual equipment. Means, actual factory information transfer means for capturing production results, progress information, and maintenance information of the actual equipment, operation prediction means for predicting the operation status of the actual equipment from the operation history of the actual equipment and actual factory information, and a production order. Scheduling means for creating, allocating equipment, and scheduling;
This is to provide a factory emulator that simulates the operating state of a real device in a factory using a virtual model on a computer, and a delivery date calculation unit that calculates a delivery date.

According to a second feature of the present invention, in the system according to the above-mentioned first feature, the delivery date calculation means calculates the production order created by the scheduling means and the operation prediction of the actual equipment calculated by the operation prediction means. Is input to the factory emulator, virtual production is performed on a computer, and the delivery date is calculated based on the result of the virtual production.

According to a third feature of the present invention, in the system according to the above-mentioned first feature or second feature, the delivery date reply means executes an emulation process for imitating the operation of a real device together with the delivery date reply. It is configured to include a delivery date calculation process display means for displaying.

According to a fourth feature of the present invention, in the system according to the first to third features described above, the operation predicting means determines the physical distribution time and the inter-process stagnation according to the location where the equipment is installed and the equipment. The point is that the prediction is performed in consideration of the distance that objects move between them.

According to a fifth feature of the present invention, in the system according to the above-described first to fourth features, each time a factory emulator performs emulation that simulates the operation of a real device, the operation history collecting means is provided. The operation history of the actual equipment collected in the above and the actual factory information obtained by the actual factory information transfer means are input to the operation prediction means, the operation state of the factory is predicted, and emulation is performed using the predicted operation state. This is the point configured as follows.

[0016]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described below based on an embodiment shown in the drawings. FIG. 1 is a block diagram showing a basic configuration of a delivery date reply system according to the present invention. The delivery date reply system includes an operation history collection unit 10, an actual factory information transfer unit 20, an operation prediction unit 30, and a scheduling unit 4.
0, a factory emulator 50, and a delivery time answering means 60, and has a function of calculating the delivery time of the ordered item.

FIG. 2 shows a delivery date answering system shown in FIG.
It is the flowchart which showed the procedure which gives a delivery date. The operation history collection means 10 (actually, a device incorporating software for collecting information in a computer and a device for transferring information via a communication line or a medium with a real device or a control device of the real device) includes: The operation signal of the real device is fetched at regular intervals, such as once every minute, and the operation history of the device is held (step S110).

The actual factory information transfer means 20 (actually, a device incorporating software and an interface for receiving information from the separately constructed production management system 70) is operated at regular intervals, such as once an hour. Every time, production information, progress information, and maintenance information of the factory are acquired, and the actual factory information is held (step S120).

The operation history collection means 10 holds the operation prediction means 30 (actually, a device in which software for predicting the operation state is installed in a computer) at regular intervals, such as once an hour. From the operating history and the actual factory information held by the actual factory information transfer means 20,
The actual operation value of an item with the same manufacturing specification or the current value of an item currently in production is used as the predicted value, and the subsequent operation status, more specifically, the production capacity per unit time, is considered for each device. Predict and hold the predicted value (step S130).

The scheduling means 40 (actually, a device in which a schedule assembly software is installed in a computer) creates a production order based on an order received from an order management system 80 separately constructed, and performs work. Allocate equipment, create scheduling,
The schedule information is held (step S140).

The factory emulator 50 (actually, an apparatus in which software for imitating actual equipment of a factory is incorporated in a computer) is provided with a delivery date answering means 60 (actually, software for giving a delivery date answer to a computer, a keyboard, In response to an instruction from an input / output device such as a mouse or a display, the schedule information held by the scheduling means 40 is received. Further, the factory emulator 50 receives the operation prediction of the device held by the operation prediction unit 30 (Step S150).

The factory emulator 50 imitates each item received from the scheduling means 40 as if each device in the factory produced, based on the operation prediction obtained from the operation prediction means 30, ie, a virtual model. Production is performed (step S160).

The result of the virtual production is set as the delivery date to be answered (step S170). Delivery time reply means 60
The result obtained in step S170 is answered (step S180).

The factory emulator 5 described in the present embodiment
0 will be described in more detail. The factory emulator 50 is disclosed in Japanese Patent Application Laid-Open No. 07-3258 as a known technology.
03 is used as an example.

FIG. 3 is a block diagram showing a basic configuration of the factory emulator 50. The factory emulator 50 includes a factory layout 51 on a computer and a physical distribution equipment model 52 that simulates the operation of physical distribution equipment such as an automatic warehouse and transport equipment.
And a production equipment model 53 that mimics the operation of production equipment,
It has an interface 54 that imitates the same input and output as the operation control interface of the real device, and is further connected between the device models or an external instruction system simulator or an external system such as a real system via the interface 54. ing.

The factory emulator 50 inputs an instruction of the external system from an operation control interface 54 connected to the external system, and operates the physical equipment model 52 and the production equipment model 53 on the factory layout 51 to operate the actual equipment. Imitate. The result of the imitation is configured to be transferred between each device model or to an external system through the operation control interface 54 to imitate the entire factory.

Since the factory layout 51 is provided, it is possible to calculate the time in consideration of the positional relationship between the respective device models. Further, the interface 54 of the actual device is provided to exchange information between the respective devices. By doing
It is possible to dynamically change the physical distribution time and the amount of stagnation between processes and reproduce the output equivalent to that of an actual factory.

The factory emulator 50 not only exchanges work instructions and operation control information for controlling logistics equipment and production equipment at all times, but also receives manufacturing condition parameters for each lot, and receives trace information of products. To an external system, management of manufacturing information similar to the actual factory,
Mimic progress management.

By performing the imitation at a speed higher than that of the actual device, the factory emulator 50 can obtain a manufacturing result on a time axis shorter than that of the actual factory when the emulation is completed. From a human perspective, this result is prediction information at a future time.

In the embodiment shown in the flowchart of FIG. 2, the operation history, the actual factory information, the operation prediction, and the schedule information are stored in the operation history collection means 10, the actual factory information transfer means 20, the operation prediction means 30, and the scheduling, respectively. Although the mode is held by the means 40, it is needless to say that a mode in which the information is recorded in an external storage device using a database system or the like is also possible.

At the time of emulation, in addition to receiving the operation prediction from the operation prediction means 30, the operation prediction is transferred to the factory emulator 50 at regular intervals and the factory emulator 50 holds or manages the operation prediction. A form using factory information and operation prediction is also possible.

Further, by recording the process of emulation in the virtual production in step S160 in FIG. 2, the state of the virtual production is shown by animation together with the delivery date as shown in a display example in FIG. 4A. 4B, it is possible to display a scenario expressing the operation status of each device together with the delivery date as shown in a display example in FIG. 4B, and it is possible to explain the calculation of the delivery date. In this case, as shown in FIG. 5, the delivery date calculation process display means 90 is added to the basic configuration of FIG.

Further, in the operation prediction in step S130, the operation prediction means 30 determines the distribution time, the inter-process stagnation, and the equipment stop, which change according to the operation state of the equipment, based on the actual factory information. When it is created and passed to the factory emulator 50, the delivery date obtained as a result of the emulation can be accurately calculated.

Further, in the processing procedure of FIG. 2, the actual factory information is obtained at regular intervals or the operation is predicted. However, every time emulation is performed, the operation history and the actual factory information are obtained and acquired. When the operation is predicted using the operation history and actual factory information, the emulation is performed using the actual equipment status and operation prediction immediately before emulation is performed, so that the factory operation status can be more accurately emulated. Will be possible. With reference to FIG. 6, a description will be given of a processing procedure in a case where actual factory information is acquired every time emulation is performed and operation prediction is further performed.

First, the operation history collection means 10 captures the operation signal of the actual device at regular intervals, such as once a minute, and holds the operation history of the device (step S210).

The factory emulator 50 is a
According to the instruction of 0, the operation prediction unit 30 and the scheduling unit 40 are requested to obtain operation prediction and scheduling information for performing emulation (step S220).

The operation predicting means 30 is provided in the factory emulator 5
Based on the request of No. 0, the actual factory information held by the production management system 70 is acquired by using the actual factory information transfer means 20. Further, the operation history of the real device held by the operation history collection means 10 is acquired. Using the acquired actual factory information and the operation history, the operation prediction of the actual equipment is performed and passed to the factory emulator 50 (step S230).

The scheduling means 40 creates schedule information from the order received from the order management system 80 or the like based on the request from the factory emulator 50, and passes it to the factory emulator 50 (step S24).
0).

After acquiring the schedule information and the operation prediction, the factory emulator 50 imitates each item of the scheduling information on the basis of the obtained operation prediction as if each device of the factory produced, that is, a virtual model. Production is performed (step S250).

The result of the virtual production is set as the delivery date to be answered (step S260). Delivery time reply means 60
The result obtained in step S260 is answered (step 270).

In the embodiment shown in the flowchart of FIG. 6, the schedule and the operation history are stored in the operation history collection means 10 and the scheduling means 40, respectively.
The recording in the external storage device is possible in the same manner as the configuration shown in FIG.

In the embodiment shown in FIGS. 2 and 6,
Emulation is performed once and for one item, and the result is used as a delivery date response.In actual operation, multiple items are delivered at the same time, or production efficiency, delivery date compliance, production cost, etc. For example, emulation of a plurality of indices may be performed, and a delivery date response may be made from various perspectives.

[0043]

As described above, when the delivery date reply system according to the present invention is used, on the factory emulator constructed on the computer, based on the operation prediction using the information obtained from the same interface as the real device of the device model, It is possible to realize a delivery date answering system that can perform a virtual production and explain the delivery date answer and the reason for calculating the delivery date answer based on the result of the emulation.

[Brief description of the drawings]

FIG. 1 is a block diagram showing a basic configuration of a delivery date reply system according to the present invention.

FIG. 2 is a flowchart showing a procedure for performing a delivery date reply according to the present invention.

FIG. 3 is a block diagram showing a basic configuration of a factory emulator according to the present invention.

FIG. 4 is an example of a screen for simultaneously displaying a delivery date answer and a delivery date calculation reason according to the present invention.

FIG. 5 is a block diagram showing a basic configuration of the present invention when a delivery date answer and a delivery date calculation reason are simultaneously displayed.

FIG. 6 is a flowchart illustrating a procedure of an embodiment of performing an operation prediction each time of emulation according to the present invention.

[Explanation of symbols]

 REFERENCE SIGNS LIST 10 operation history collection means 20 actual factory information transfer means 30 operation prediction means 40 scheduling means 50 factory emulator 51 factory layout 52 logistics equipment model 53 production equipment model 54 interface 60 delivery date reply means 70 production management system 80 order management system 90 delivery date calculation process Display means

──────────────────────────────────────────────────続 き Continued on the front page (51) Int.Cl. ⁷ Identification symbol FI Theme coat ゛ (Reference)

Claims (5)

[Claims] 1. A system for responding to a delivery date of a manufacturing industry, comprising: an operation history collection unit for collecting operation history of an actual device;
Means for transferring actual factory information, which captures production results, progress information, and maintenance information of actual equipment; operation prediction means for predicting the operation status of actual equipment from the operation history of actual equipment and actual factory information; Scheduling means for allocating equipment and creating a schedule plan, a factory emulator for imitating the operation state of actual equipment in a factory using a virtual model on a computer, and delivery date answering means for answering a delivery date Delivery time response system characterized by. 2. The delivery time reply system according to claim 1, wherein the delivery time reply means sends the production order created by the scheduling means and the operation prediction of the actual equipment calculated by the operation prediction means to the factory emulator. A delivery date answering system characterized by inputting, performing virtual production on a computer, and calculating a delivery date based on the result of the virtual production. 3. The delivery date answering system according to claim 1, wherein said delivery date answering means includes a delivery date calculation process display means for displaying an emulation process for imitating the operation of an actual device together with the delivery date answer. , A delivery date answering system characterized by that. 4. The delivery date answering system according to claim 1, wherein the operation prediction means considers the physical distribution time, the inter-process stagnation, and the distance that the equipment moves between the place where the equipment is installed and the equipment. A delivery date answering system, which makes predictions. 5. The delivery date answering system according to claim 1, wherein the factory emulator stores the operation history of the actual device collected by the operation history collection unit and the actual factory information acquired by the actual factory information transfer unit. Each time an emulation is performed, the operation is input to the operation prediction means to predict a factory operation state, and emulation is performed using the predicted operation state.