JP2003162313A - Method and device for production system planning - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method for planning a production system which can exactly extract problems concerning the production system planning based on a versatile and reasonable standard, solve the problems thus extracted and efficiently plan a production system which is optimized in cost and ability to solve the problems which conventional technique has, and also to provide a device therefor. <P>SOLUTION: The production system planning comprises a process plan, an equipment positioning plan based on the process plan, a personnel placement plan based on the process plan and equipment placement plan and a production plan based on the process plan, equipment placement plan and personnel positioning plan. In addition, the simulation of production activity is made by a production line model prepared in each plan mentioned above and then an evaluation reference value is prepared. Judgement for whether the plans each are right or not is made based on the reference value, and then the planning are amended based on the judgement. <P>COPYRIGHT: (C)2003,JPO

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a production system planning method and a production system planning apparatus. More specifically, the present invention relates to a production system planning method and a production system planning apparatus that save labor and efficiency in creating each plan related to a production system plan such as a process plan, an equipment layout plan, a staffing plan, and a production plan.

[0002]

2. Description of the Related Art In recent years, as the needs of consumers have diversified, the production pattern in various manufacturing fields has shifted from a small variety mass production type to a large variety small production type, and the production process of various products has become complicated and diversified. ing. In addition, the life cycle of products is generally shortened, and new products are often introduced to factories. As a result, there are increasing opportunities for new factories or equipment changes.

When a new factory or equipment is changed, it is necessary to plan a production system that is optimized to reduce production costs and production pitches. It is also required to have a flexible system that can handle production disturbances.

However, in the planning of this production system, it is necessary to prepare various plans such as a process plan, an equipment layout plan, a staffing plan and a production plan. Therefore, conventionally, many support methods and support devices have been proposed for supporting the preparation of each plan related to such a production system plan.

Among such support methods and support devices, for example, the support method described in Japanese Patent Laid-Open No. 2000-237937 assumes that the order of steps is known when a production line of a factory is constructed, and is assigned to each step. The simulation is carried out while operating the capacity of the produced production resources (equipment, personnel) as a parameter, and the optimal resource allocation is examined based on the results. More specifically, various factors related to the evaluation reference value of the plan, such as the number of facilities arranged in each process and the installation area of the facilities, are set as parameters, and a plurality of factors are automatically changed. It is assumed that simulation conditions are generated, simulation is performed under each condition, each simulation result is ranked based on the evaluation reference value, and presented to the planner.

The factory planning apparatus described in Japanese Patent Laid-Open No. 2000-39905 determines the characteristics of the transfer system such as the amount of work transferred and the capacity of transfer equipment between the facilities of a production line, particularly a job shop type production line. Considering this, the production system should be planned to optimize the transportation system such as the arrangement of equipment and the number of transportation devices.

In the process design system described in Japanese Patent Laid-Open No. 9-138830, the number of equipments and the number of workers are determined based on the production speed required on the assumption that the process sequence is known, and the correspondence of each worker. By referring to the list of possible work, the number of workers that can be dealt with is small, and therefore, workers are preferentially allocated from the process that is critical for worker allocation.

The production line planning method described in Japanese Patent Laid-Open No. 8-229779 plans a line configuration based on required production speed, process sequence information and facility information so as to support the planning of a flow shop type production line. , The planned results will be evaluated by simulation.

All of these conventionally proposed methods / apparatuses analyze each planning result regarding the planning of the production system,
If that is unsatisfactory, the planner should repeatedly carry out the procedure such as changing the constraints created for planning and recreating the plan, and formulating an optimal plan. To be taken. In this way, when the planner manually analyzes the plan result and changes the constraint conditions, the following problems occur.

(1) It takes a lot of time and labor to analyze the plan result, extract the problem, and correct the constraint condition of the plan. In particular, this problem becomes serious when it is necessary to create a large number of plans by trial and error to some extent so as to optimize a plurality of evaluation criteria (eg, production cost, production pitch).

(2) The prolongation of the planning time makes it impossible to promptly start up or modify the production system, and it becomes difficult to plan the production system by promptly coping with changes in production requirements. As a result, it is not possible to formulate an appropriate plan in advance, and the allocation and operation method of the production resources (equipment, personnel) will be examined by trial and error at the site. Therefore, the start-up of the production system may be delayed, and the equipment may need to be relocated, resulting in unnecessary expenses.

Therefore, as a proposal for solving such a problem, the plan support method described in Japanese Patent Laid-Open No. 11-85852 implements a process plan and a facility layout plan based on given production conditions. When the production cost in the production system according to each plan exceeds the target production cost, the plan result is fed back and the plan is executed again. Here, the feedback of the plan result is to change the equipment layout, process rearrangement, processing method /
The method of changing the tool / cutting condition and the method of changing the material / product shape are registered in advance, and the plan is corrected in this priority order.

However, this plan support method, when feeding back the plan result, is supposed to make corrections such as reducing the number of machines of a specific facility as the contents are decided in advance. There is a problem of being limited. Also, because it is not a rational method such as identifying the problem of the plan and improving it intensively, the plan will be corrected by trial and error,
There is the problem that it takes time to plan an optimized production system.

[0014]

SUMMARY OF THE INVENTION The present invention has been made in view of the above-mentioned problems of the prior art, in which the problems relating to the planning of the production system are accurately extracted by a rational standard having general versatility, and the extraction thereof is performed. It is an object of the present invention to provide a production system planning method and a production system planning apparatus capable of efficiently planning a production system in which the above-mentioned problems are solved and which is optimized in cost and capacity.

[0015]

A production system planning method according to the present invention comprises a process plan, an equipment layout plan based on the process plan, a staffing plan based on the process plan and the equipment layout plan, and the process plan. A production system planning method using a production plan based on an equipment layout plan and a staffing plan, wherein a production line model set in each plan is used to simulate production activities to create an evaluation reference value for each plan. However, the quality of each plan is determined based on the reference value.

In the production system planning method of the present invention, it is preferable that the simulation is performed to perform scheduling for setting the operation start time of the production resource so as to minimize the production pitch.

Further, in the production system planning method of the present invention, when there is a defective plan in the determination, the plan may be corrected by manual correction processing.

Further, in the production system planning method of the present invention, if there is a defective plan in the determination, the specification may be reset.

Further, in the production system planning method of the present invention, when there is a defective plan in the judgment, the factors that deteriorate the evaluation standard value are analyzed, and the production resources are enhanced based on the analysis. The factor that deteriorates the evaluation reference value may be eliminated.

Further, in the production system planning method of the present invention, the factor that deteriorates the evaluation reference value is, for example, the bottleneck process having the longest processing time. Here, the process having the maximum average value of the pre-process work retention time is the bottleneck process.

Further, in the production system planning method of the present invention, when the occurrence of the bottleneck process is due to the human factor, the human resource for the process is increased, and then the staffing plan is performed again while keeping the total personnel cost. You may

Further, in the production system planning method of the present invention, after carrying out the staffing plan again in the staffing plan, it is judged whether or not the evaluation standard value is deteriorated, and the evaluation standard value is not deteriorated. In this case, the production plan may be made based on the staffing plan, and conversely, when the evaluation reference value is deteriorated, it may be determined whether the total personnel cost can be increased.

Further, in the production system planning method of the present invention, by judging whether or not the total personnel cost can be increased,
If it is determined that the total personnel cost can be increased, a staffing plan may be made based on the increased total personnel cost. Conversely, if it is determined that the total personnel cost cannot be increased, the site cost and/
Alternatively, a cost reduction item such as a building cost or a total personnel cost may be selected.

Further, in the production system planning method of the present invention, when the cost reduction item is the facility cost, the process plan may be based on the reduced facility cost, and the cost reduction item is the site cost and the site cost. When it is set as the building cost, the facility layout plan may be made based on the reduced site cost and / or the building cost.

Further, in the production system planning method of the present invention, when the bottleneck process is caused by a physical factor, the facility cost for the process is increased, and then the process plan is performed while keeping the total facility cost unchanged. Good.

Further, in the production system planning method of the present invention, after the process plan is executed again in the process plan, it is judged whether or not the evaluation standard value is deteriorated, and if the evaluation standard value is not deteriorated, The equipment arrangement plan may be made based on the process plan, and conversely, when the evaluation reference value is deteriorated, it may be determined whether or not the total equipment cost can be increased.

Further, in the production system planning method of the present invention, when it is determined that the total equipment cost can be increased, the process plan may be made based on the increased total equipment cost, and vice versa. When it is determined that the cost cannot be increased, the site cost and / or the building cost or the total personnel cost may be selected as a cost reduction cost item, and the reduction amount may be set.

Further, in the production system planning method of the present invention, even if the total budget is left unchanged, the cost is reduced by the reduction amount set for the selected expense item, and the plan related to the reduced cost is performed. Good.

Further, in the production system planning method of the present invention, when it is unclear whether the occurrence of the bottleneck process is due to the human factor or the physical factor, after increasing the human resources for the process, the total personnel You may plan the staffing again while keeping the expenses unchanged.

Further, in the production system planning method of the present invention, it is judged whether or not the evaluation standard value is deteriorated in the staffing plan, and if the evaluation standard value is not deteriorated, based on the manning plan. The production plan may be carried out, and conversely, if the evaluation reference value deteriorates, it may be judged whether or not the total personnel cost can be increased.

Further, in the production system planning method of the present invention, when it is determined that the total personnel cost can be increased, the staffing plan may be executed based on the increased total personnel cost, and vice versa. When it is determined that the increase of the total personnel cost is impossible, it may be determined whether the staffing can be modified.

Further, in the production system planning method of the present invention, when it is determined that the manpower cannot be corrected, the facility cost for the process is increased, and then the process plan is executed with the total facility cost kept unchanged. You may.

Further, in the production system planning method of the present invention, after the process plan is executed again in the process plan, it is judged whether or not the evaluation standard value is deteriorated, and when the evaluation standard value is not deteriorated, The equipment layout plan may be implemented based on the process plan, and conversely, when the evaluation reference value deteriorates, it may be determined whether or not the total equipment cost can be increased.

Further, in the production system planning method of the present invention, when it is determined that the total equipment cost can be increased, the process plan may be executed based on the increased total equipment cost, and vice versa. When it is determined that the facility cost cannot be increased, a cost reduction cost item may be selected and the reduction amount may be set.

Further, in the production system planning method of the present invention, the total budget is left unchanged, the cost is reduced by the reduction amount set for the selected cost item, and the plan and the subsequent steps relating to the reduced cost are executed. Good.

Further, in the production system planning method of the present invention, the cost reduction item may be selected when it is determined that the manpower can be modified.

Further, in the production system planning method of the present invention, when the cost reduction item is the equipment cost, the process planning may be executed based on the reduced equipment cost.

Further, in the production system planning method of the present invention, when the cost reduction item is the site cost and / or the building cost, the equipment layout is planned based on the reduced site cost and / or the building cost. May be.

The production system planning apparatus of the present invention comprises a process planning section for making a process plan, an equipment arrangement planning section for making an equipment arrangement plan based on the process plan, and a staff member based on the process plan and the equipment arrangement plan. A production system planning apparatus comprising: a staffing planning section for planning, a production planning section for carrying out production planning based on the process plan, equipment layout plan, and staffing plan; and an analysis / correction section, comprising: The correction unit may simulate the production activity based on the production line model set in each planning unit to create an evaluation standard value for each plan, and determine the quality of each plan based on the standard value. Characterize.

In the production system planning apparatus of the present invention, it is preferable that the simulation is performed to perform scheduling for setting the operation start time of the production resource so as to minimize the production pitch.

Further, in the production system planning apparatus of the present invention, when there is a defective plan in the determination, the plan may be corrected by the manual correction process.

Further, the production system planning apparatus of the present invention may be configured so that the specification can be reset when there is a plan which is judged to be defective in the above judgment.

Further, in the production system planning apparatus of the present invention, when there is a defective plan in the above judgment, the factors that deteriorate the evaluation reference value are analyzed, and the production resources are increased based on the analysis. Then, the factor that deteriorates the evaluation reference value may be eliminated. In that case, the factor that deteriorates the evaluation reference value may be analyzed such that the bottleneck process has the longest processing time, for example. Here, the process having the maximum average value of the pre-process work retention time is the bottleneck process.

Further, in the production system planning apparatus of the present invention, when the occurrence of the bottleneck process is due to the human factor, the human resource for the process is increased, and then the staffing plan is re-established while keeping the total personnel cost. May be configured to perform.

Further, in the production system planning apparatus of the present invention, after the staffing plan is executed again in the staffing plan, it is judged whether or not the evaluation standard value is deteriorated, and the evaluation standard value is not deteriorated. In this case, the production planning may be performed based on the staffing plan, and conversely, when the evaluation reference value deteriorates, it may be configured to determine whether the total personnel cost can be increased. .

Further, in the production system planning apparatus of the present invention, when it is determined that the total labor cost can be increased, the staffing plan may be performed based on the increased total labor cost. On the contrary, when it is determined that the total personnel cost cannot be increased, the cost reduction cost item may be selected.

Further, in the production system planning apparatus of the present invention, when the cost reduction item is the equipment cost, the process planning may be performed based on the reduced equipment cost.

Further, in the production system planning apparatus of the present invention, when the cost reduction item is the site cost and / or the building cost, the equipment placement plan is performed based on the reduced site cost and / or the building cost. It may be configured as follows.

Further, in the production system planning apparatus of the present invention, when the occurrence of the bottleneck process is due to a physical factor, the facility cost for the process is increased, and then the process plan is performed with the total facility cost left unchanged. You may comprise.

Further, in the production system planning apparatus of the present invention, after the process plan is executed again in the process plan, it is judged whether or not the evaluation standard value is deteriorated, and if the evaluation standard value is not deteriorated, The facility arrangement plan may be configured based on the process plan, and conversely, when the evaluation reference value is deteriorated, it may be configured to determine whether or not the total facility cost can be increased.

Further, in the production system planning apparatus of the present invention, when it is determined that the total equipment cost can be increased, the process planning may be performed based on the increased total equipment cost, and vice versa. When it is determined that the total facility cost cannot be increased, the site cost and / or the building cost or the total personnel cost may be selected as a cost reduction cost item, and the reduction amount may be set.

Further, in the production system planning apparatus of the present invention, the total budget is left unchanged, the cost is reduced by the reduction amount set for the selected expense item, and the planning related to the reduced cost is performed. You may.

Further, in the production system planning apparatus of the present invention, when it is unclear whether the occurrence of the bottleneck process is due to the human factor or the physical factor, after increasing the human resources for the process, the total personnel It may be configured such that the staffing plan is carried out again while keeping the expenses unchanged.

Further, in the production system planning apparatus of the present invention, after the staffing plan is executed again in the staffing plan, it is judged whether the evaluation standard value is deteriorated, and the evaluation standard value is not deteriorated. In this case, after carrying out the staffing plan again, the production planning may be carried out based on the staffing plan. Conversely, if the evaluation norm value deteriorates, whether or not the total personnel cost can be increased is determined. It may be configured to make a determination.

Furthermore, in the production system planning apparatus of the present invention, when it is determined that the total personnel cost can be increased, the staffing plan may be performed based on the increased total personnel cost. On the contrary, when it is determined that the total personnel cost cannot be increased, it may be configured to determine whether or not the staffing can be corrected.

Further, in the production system planning apparatus of the present invention, when it is determined that the manpower cannot be corrected, the facility cost for the process is increased, and then the process plan is performed while keeping the total facility cost unchanged. It may be configured as follows.

Further, in the production system planning apparatus of the present invention, after the process plan is executed again in the process plan, it is judged whether or not the evaluation standard value is deteriorated, and if the evaluation standard value is not deteriorated, The facility arrangement plan may be configured based on the process plan, and conversely, when the evaluation reference value is deteriorated, it may be configured to determine whether or not the total facility cost can be increased.

Further, in the production system planning apparatus of the present invention, when it is determined that the total equipment cost can be increased, the process planning may be performed based on the increased total equipment cost, and vice versa. When it is determined that the total facility cost cannot be increased, the cost reduction item may be selected and the reduction amount may be set.

Further, in the production system planning apparatus of the present invention, the total budget is left unchanged, the cost is reduced by the reduction amount set for the selected expense item, and the plan related to the reduced cost is performed. You may.

Further, the production system planning apparatus of the present invention may be configured to select the cost reduction item when it is determined that the manpower can be corrected.

Further, in the production system planning apparatus of the present invention, when the cost reduction item is the equipment cost, the process planning may be performed based on the reduced equipment cost.

Further, in the production system planning apparatus of the present invention, when the cost reduction item is the site cost and / or the building cost, the equipment layout plan is performed based on the reduced site cost and / or the building cost. It may be configured as follows.

The computer-readable program of the present invention is a computer-readable program used for planning a production system, and is a procedure for making a process plan and a procedure for making an equipment layout plan based on the process plan. And a procedure for performing a staffing plan based on the process plan and the equipment layout, and a procedure for performing a production plan based on the process plan, the equipment layout plan, and the staffing plan,
The procedure of performing each of the plans includes a procedure of setting a production line model, a procedure of simulating a production activity by the production line model, a procedure of creating an evaluation standard value of each plan by the simulation, and the standard value. It is characterized by including a procedure for judging the quality of each plan.

In the computer-readable program of the present invention, it is preferable that the simulation includes a procedure for performing a scheduling for setting the operation start time of the production resource so as to minimize the production pitch.

Further, the computer-readable program of the present invention may include a procedure for manually correcting a plan that has been determined to be defective in the determination.

Furthermore, the computer-readable program of the present invention may include a procedure for resetting the specifications when there is a plan that has been determined to be defective in the determination.

Further, in the computer-readable program of the present invention, when there is a plan that is judged to be defective in the above judgment, a procedure for analyzing the factors that deteriorate the evaluation reference value, and the analysis based on the analysis And a step of eliminating a factor that deteriorates the evaluation reference value by increasing production resources. In that case, the factor that deteriorates the evaluation reference value is analyzed to be, for example, the bottleneck process having the longest processing time. Here, the process having the maximum average value of the pre-process work retention time is the bottleneck process.

Further, in the computer-readable program of the present invention, if the occurrence of the bottleneck process is due to human factors, the human resources for the process are increased, and then the total labor cost is left unchanged and redistributed. It may also include procedures for staffing.

Further, in the computer-readable program of the present invention, after the staffing plan is executed again in the staffing plan, it is determined whether the evaluation standard value is deteriorated, and the evaluation standard value is deteriorated. If not, it may include a procedure to make a production plan based on the staffing plan, and conversely, if the evaluation standard value deteriorates, it may include a procedure to determine whether the total personnel cost can be increased. .

Further, the computer-readable program of the present invention may include a procedure for carrying out a staffing plan based on the increased total labor cost when it is determined that the total labor cost can be increased. On the contrary, when it is determined that the total personnel cost cannot be increased, a procedure for selecting a cost reduction cost item may be included.

Further, the computer-readable program of the present invention may include a procedure for making a process plan based on the reduced equipment cost when the cost reduction item is the equipment cost.

Further, in the computer-readable program of the present invention, when the cost reduction item is the site cost and / or building cost, the process plan is based on the reduced site cost and / or building cost. May be included.

Further, in the computer-readable program of the present invention, when the occurrence of the bottleneck process is due to a physical factor, the facility cost for the process is increased and then the process plan is left unchanged. It may include a procedure to be performed.

Further, in the computer-readable program of the present invention, after the process plan is re-executed in the process plan, it is determined whether or not the reference value is deteriorated, and the evaluation reference value is not deteriorated. , And may include a procedure for making an equipment placement plan based on the process plan, and conversely, if the evaluation reference value deteriorates, may include a procedure for determining whether or not the total equipment cost can be increased.

Furthermore, the computer-readable program of the present invention may include a procedure for making a process plan based on the increased total facility cost when it is determined that the total facility cost can be increased. On the contrary, if it is determined that the total facility cost cannot be increased, a procedure for setting a site cost and / or a building cost or a total personnel cost, and setting the reduced cost may be included.

Further, in the computer-readable program of the present invention, for the expense items selected by keeping the total budget, the cost is reduced by the set reduction amount, and the plan related to the reduced cost is performed. Procedures may be included.

Further, in the computer-readable program of the present invention, when it is unclear whether the bottleneck process is caused by human factors or physical factors, after increasing human resources for the process, It may include a procedure for re-planning the staffing while keeping the total personnel cost unchanged.

Further, in the computer-readable program of the present invention, after the staffing plan is executed again in the staffing plan, it is determined whether the evaluation standard value is deteriorated, and the evaluation standard value is deteriorated. If not, it may include a procedure to make a production plan based on the staffing plan, and conversely, if the evaluation standard value deteriorates, it may include a procedure to determine whether the total personnel cost can be increased. .

Further, the computer-readable program of the present invention may include a procedure for carrying out a staffing plan based on the increased total personnel cost when it is determined that the total personnel cost can be increased. On the contrary, when it is determined that the total personnel cost cannot be increased, a procedure for determining whether or not the staffing can be corrected may be included.

Further, in the computer readable program of the present invention, when it is determined that the staffing cannot be modified, the facility cost for the process is increased, and then the process is performed while keeping the total facility cost unchanged. It may include planning steps.

Further, in the computer-readable program of the present invention, after executing the process plan again in the process plan, it is judged whether or not the evaluation standard value is deteriorated, and the evaluation standard value is not deteriorated. In this case, a procedure for making an equipment placement plan based on the process plan may be included, and conversely, if the evaluation reference value deteriorates, a procedure for determining whether or not the total equipment cost can be increased may be included.

Further, the computer-readable program of the present invention may include a procedure for making a process plan based on the increased total facility cost when it is determined that the total facility cost can be increased. On the contrary, when it is determined that the total equipment cost cannot be increased, a procedure for selecting a cost reduction cost item and setting the reduction amount may be included.

Further, in the computer-readable program of the present invention, the total budget is left unchanged, the cost is reduced by the reduction amount set for the selected expense item, and the plan related to the reduced cost is performed. Procedures may be included.

Further, the computer-readable program of the present invention may include a procedure for selecting a cost reduction expense item when it is determined that the manpower can be modified.

Furthermore, the computer-readable program of the present invention may include a procedure for making a process plan based on the reduced facility cost when the cost reduction item is the facility cost.

Further, in the computer-readable program of the present invention, when the cost reduction item is the site cost and / or the building cost, the facility allocation plan is based on the reduced site cost and / or the building cost. May be included.

The computer readable program of the present invention is stored in the computer readable recording medium.

[0088]

Since the present invention is configured as described above, a process plan, equipment layout plan,
The problems in the production plan of the staffing plan are rationally extracted. Therefore, you can concentrate on the problem,
Problem solving can be done quickly.

According to the preferred embodiment of the present invention, if the problem is minor, the problem can be solved manually, so that the processing can be further speeded up.

Further, according to another preferable mode of the present invention, since the specification can be reset, the delay of the processing due to the nonconformity of the specification can be eliminated.

Further, according to another preferred embodiment of the present invention, whether the occurrence of the problem is due to a human factor, a physical factor, or whether it is unclear whether the problem occurs is properly dealt with. it can.

[0092]

BEST MODE FOR CARRYING OUT THE INVENTION Hereinafter, the present invention will be described based on the embodiments with reference to the accompanying drawings, but the present invention is not limited to such embodiments.

FIG. 1 shows a schematic configuration of a production system planning apparatus (hereinafter abbreviated as a planning apparatus) to which a production system planning method according to an embodiment of the present invention is applied. The planning apparatus K is a production system. Each plan related to the above plan is analyzed, the production system is analyzed by the simulation based on the created plan, the problem points are extracted, and the constraint is established as the standard for the plan creation so as to solve the extracted problem points. It is supposed that the conditions will be corrected, thereby making the planning of the production system efficient and labor-saving.

Specifically, the planning device K includes a process planning unit 10 for creating a process plan, an equipment layout planning unit 20 for creating a facility layout plan, and a staffing planning unit 30 for creating a staffing plan.
And a production planning unit 40 that creates a production plan, and each planning unit 1
A database unit 50 that stores various data used for planning in 0, 20, 30, 40 and a plan content that is a processing result thereof, and each planning unit 10, 20, 3,
Analyzing each plan created by 0, 40, extracting problems, and then correcting the constraint conditions formulated as the standard for planning, based on this, each planning unit 10, 20, 30,
An analysis / correction processing unit 60 that causes the system 40 to create a plan again and performs various processes for planning the production system.
And will be provided as main components. Thus, such a planning device K is realized by incorporating software, which is a program for executing each processing described below, in a computer as hardware. Hereinafter, each component of the planning device K will be specifically described.

The process planning unit 10 sets the order of each process for processing and assembling a product, and carries out various processes for creating a process plan for allocating equipment to each process. Specifically, the process plan includes each of process sequence constraints based on the product structure and process sequence constraints based on manufacturing know-how (for example, a process sequence that is desirable for reducing welding distortion), which will be described later. It is created according to the constraints.

The equipment layout planning unit 20 carries out various kinds of processing for creating a equipment layout plan for arranging the equipment allocated to each process in the process plan in the factory building.

FIG. 2 shows an example of the equipment layout plan. That is, there is a factory site A as shown in FIG. 3A, and as shown in FIG. 2B, between the facilities a, b, c, d, e, f, g allocated to each process. The work is indicated by each arrow h,
When machining is performed while moving in the flow indicated by i, j, k, l, and m, for example, under the policy of minimizing the work transfer distance between each equipment, it is shown in FIG. A plan B ₁ is created in which each facility is arranged in a line on the factory premises as described above, and each facility is worked as shown in FIG. 2D under the policy of minimizing the walking distance of the operator of the facility. According to the flow of, the plan B ₂ densely arranged is prepared.

The staffing planning unit 30 accepts the contents of the process plan and the equipment layout plan, and executes various processes for creating a staffing plan for allocating workers to each process.

FIG. 3 shows an example of the staffing plan. That is,
There processing step of the product P _11, P _12, ... is composed of the steps of, each worker _{H 1, H 2, H 3} , ... each step P ₁₁ of,
Skills for P ₁₂ , ... Are digitized (numerical values represent the work efficiency coefficient by multiplying the standard man-hours) as shown in FIG. 8A, and the standard man-hours of each process P ₁₁ , P ₁₂ ,. Consider the case shown in b).

At this time, as shown in FIG. 7C, the time required for processing the constituent parts W ₁ , W ₂ , W ₃ of the product is leveled to complete the respective parts W ₁ , W ₂ , W ₃ . The time is synchronized and adjusted so that the parts W ₁ , W ₂ , W ₃ are sent to the assembly process via the buffer BF at substantially the same time. At the same time, the work assignment is determined so that the work times of the workers H ₁ , H ₂ , H ₃ , ... Are leveled.

The production planning unit 40 accepts the contents of the process plan, the equipment layout plan, and the staffing plan, so as to satisfy the production demand (for example, the demand regarding the production item, the production amount, and the delivery date) for the production system. Various processes are performed to create a production plan that performs scheduling for operating production resources.

FIG. 4 shows an outline of the production plan. In the figure,
(A) is a production consisting of each process P ₁ , P ₂ , ... Arranged along the flow of the work and each of the production resources r ₁ , r ₂ , ... An example of the line model C is shown. Here, the production resource refers to an element used for production activities such as production equipment and workers. FIG. 2B shows an example of a Gantt chart D showing the time zones in which the production resources r ₁ , r ₂ , ... Operate. FIG. 6C is a load mountain diagram E that is created based on the Gantt chart D and represents the load status of each production resource in each process.
An example is shown.

The database unit 50 includes the planning units 10, 2
It includes a plan content information storage unit 51 that stores information about the plan contents in 0, 30, and 40, and a basic information storage unit 52 that stores information that is the basis of the production system plan.

The plan content information storage unit 51 stores the process sequence information and equipment allocation information as the plan content of the process plan, the equipment layout information as the plan content of the equipment layout plan, the staff layout information as the plan content of the staffing plan, Also, the production plan information as the plan contents of the production plan is stored.

As shown in FIG. 5, the basic information storage unit 52 includes a budget information database 53, a production resource information database 54, a factory information database 55, a production request information database 56, a product information database 57 and a production technology information database 58. Including.

The budget information database 53 stores information on the budget of the production system (hereinafter referred to as budget information). The budget information includes information on equipment introduction costs, land purchase costs, building construction costs, and personnel costs.

The production resource information database 54 stores information on production resources (hereinafter referred to as production resource information). The production resource information includes equipment information such as equipment / jigs specifications / price / operation cost unit price that can be equipped or introduced in the factory, and worker information such as worker skill / labor cost unit price. .

The factory information database 55 stores information on the site and building of the factory which constitutes the production system (hereinafter referred to as factory information). The factory information includes information about land unit price and factory building unit price.

The production request information database 56 stores information on production requests for the planned production system (hereinafter referred to as production request information). The production request information includes information on product types, specifications, and production pitches (production speeds).

The product information database 57 includes information on each process for realizing a product (hereinafter, referred to as process information) and information on a general process (eg, member processing process, coating process) (hereinafter, referred to as process information) General process information) is stored.

The production technology information database 58 stores information on production technology (hereinafter referred to as production technology information). The production technology information includes information on manufacturing know-how (hereinafter referred to as manufacturing know-how information) that defines a desired process sequence.

Further, the analysis / correction processing unit 60 analyzes each plan, extracts a problem point, and corrects the constraint condition of each plan based on this, thereby optimizing the cost and capability. Implement the process of planning the production system.

The planning process will be described below.

6 to 9 show the main flow of the planning process.

Step S1: The specifications of the production system are input to the planning device K and stored in the basic information storage section 52.

Step S2: Based on the input specifications, the process planning section 10 carries out a process plan creating process. The process plan creation process will be described below.

1. Process planning process

A process plan is prepared while taking into account the entered specifications, especially the constraints such as equipment introduction costs. The process plan includes a process sequence and a plan relating to equipment allocation, and the evaluation standard thereof is, for example, the load leveling degree between processes for a standard work. Here, the basic policy is to introduce equipment that is as inexpensive as possible if the required production pitch can be realized. Hereinafter, the process sequence setting process and the equipment allocation process will be sequentially described.

1-1. Process sequence setting process

FIG. 10 shows the procedure of the process order setting process.
In this process sequence setting process, the process sequence is determined or tentatively determined based on the fragmentary process sequence constraint condition (hereinafter, referred to as process sequence constraint) that is extracted in the following steps.

Step S41: Extract process order constraints based on the product structure. For example, the process order designated by the design department and the process order uniquely determined from the design information (for example, when a plurality of components are inserted on one axis) are applicable.

Step S42: Extract the process order constraint based on the capability / characteristic of the production resource. That is, when the production equipment to be used is specified, such as using existing production equipment, and the process sequence is restricted based on the capacity / characteristics of the production equipment (for example, due to the capacity restriction of the bending equipment, , When it is necessary to perform the cutting work prior to the bending work).

Step S43: Extract the process order constraint based on the manufacturing know-how. That is, the process sequence is set based on the knowledge of the desired process sequence held by the manufacturing department (for example, marking is performed prior to cutting work because it is easier to print at the material stage. And).

Step S44: Each step S4 described above
The process order is determined according to the process order constraints extracted in steps 1, 42 and 43. Here, when the process order is not uniquely determined, an appropriate order is temporarily selected from the orders that satisfy all the extracted process order constraints.

1-2. Equipment allocation processing

FIG. 11 shows the procedure of equipment allocation processing. In this equipment allocation process, equipment is allocated to each process whose execution order has been set in the process order setting process.

Step S51: Referring to the production pitch of the production requirement information in the production requirement information database 56 and the information on the standard product, the production pitch required for the standard product (hereinafter referred to as the required production pitch). ), Production resource information database 54
List from the equipment information in each process. That is, equipment that satisfies the required production pitch is listed from the equipment information (see FIG. 17) for all processes that require production equipment.

Step S52: For each process, it is judged whether or not the equipment that satisfies the required production pitch is listed from the equipment information, and if there is no production equipment that can satisfy the required production pitch, the process concerned After performing the process division process of step S53 for
Return to. On the other hand, if the equipment that can satisfy the required production pitch is listed for each process, step S54
Proceed to.

Step S54: For each process, the lowest cost production equipment is selected from the listed production equipment.

Step S55: Select a transfer facility for transferring a work (product) between the processes. At this time, the lowest cost is selected from the transportation facilities having the ability not to hinder the achievement of the required production pitch.

Step S56: The total equipment cost of the production system is calculated from the above results, and this is compared with the equipment budget.
Here, if the total equipment cost is less than or equal to the equipment budget, the process ends, and if the total equipment cost exceeds the equipment budget, the process proceeds to step S57.

Step S57: Search each facility for which there is a spare capacity and can carry out the work in two or more processes, and assign the work in the other process to the range in which the required production pitch can be achieved. Reduce unnecessary equipment or equipment costs.

As described above, in the process plan creation process, after the process sequence is set or provisionally set according to various process sequence constraints, the one with the lowest cost among the facilities that can satisfy the required production pitch is assigned to each process. The process order setting process and the facility allocation process are performed as if they were allocated. The above plan contents are stored in the plan contents information storage unit 51 as process order information and equipment allocation information.

When the process plan creation processing in step S2 is completed, the process planning unit 10 activates the equipment layout planning unit 20,
It progresses to step S3 of FIG.

Step S3: Accept the contents of the process plan,
The equipment layout planning unit 20 executes the equipment layout planning process. The equipment layout plan creation process will be described below.

2. Equipment layout planning process

In the equipment layout plan creation processing, the equipment allocated to each process is arranged on the factory premises or inside the factory building while considering the contents of the process plan and the constraints such as the land purchase cost / building construction cost. In addition, the evaluation standard of the equipment layout plan is
For example, the total movement time of a standard work is set.

FIG. 12 shows the procedure of the equipment layout plan preparation process.

Step S61: Plan content information storage unit 51
By referring to the process order information and the equipment allocation information in, the required installation area for each rough process is calculated by integrating a series of processes. Here, the rough process includes, for example, a processing process (including specific processes such as cutting, drilling, and bending), a component coating process,
It refers to a set of processes corresponding to general manufacturing stage divisions such as parts assembly process and inspection process.

Step S62: The installation form of the equipment in each schematic process is determined. That is, according to the work type and equipment type of each process, for example, by selecting from standard process arrangement patterns such as U-shaped arrangement and linear arrangement, the arrangement of the equipment or the equipment installation shape in the rough process To decide.

Step S63: The width of the passage for conveying the work (product) between the processes is determined. That is, the required passage width is calculated in consideration of the shape and quantity of the workpieces to be transported and the transportation mode (for example, a large number of workpieces are stacked on a pallet and transported).

Step S64: Arrangement of each rough process in the factory building. At this time, consider the width of the passage and arrange it so that the transport distance between each rough process is as small as possible.
The layout of each rough process is determined by searching using an optimization method such as a genetic algorithm.

Step S65: It is determined whether or not each of the schematic steps is arranged in the factory building. If it is arranged, the process is terminated, and if all the facilities are not accommodated in the factory building, the process proceeds to step S66.

Step S66: The distance margin between each facility in the general process is reduced to reduce the installation area of each general process, or the distance margin between each general process is reduced, and the process returns to step S62.

As described above, in the equipment layout plan creation process, the equipment installation form of each general process is set, and each equipment is arranged in the factory building so as to determine the layout of each general process in the factory building. , If each facility cannot be accommodated in the factory building, reduce the distance between the facilities in the rough process, or reduce the distance between each rough process so that all the rough processes can be placed in the factory building. Set the arrangement of each equipment in.

As described above, when the equipment layout plan creation process of step S3 of FIG. 6 is completed, the plan contents are stored in the plan content information storage unit 51 as the equipment layout information, and the equipment layout planning unit 20 makes the staffing plan. Start the unit 30 and step S
Go to 4.

Step S4: Upon accepting the contents of the process plan and the equipment layout plan, the staffing planning unit 30 carries out a staffing plan preparation process. The staffing plan creation process will be described below.

3. Staffing planning process

A staffing plan is prepared in consideration of the contents of the process plan and the equipment layout plan, and the constraint of the personnel cost. The evaluation standard of the staffing plan is, for example, the appropriateness of the worker operating rate.

FIG. 13 shows the procedure of the staffing plan preparation processing.

Step S71: The standard work time in each process is estimated based on the process information (product processing information) in the product information database 57 and the past work record. That is, the work amount of each process is represented by the work time when a standard worker processes it.

Step S72: The standard work time in each process is integrated to calculate the total work time of the production system.

Step S73: A worker to be assigned to each process is selected based on the worker information stored in the production resource information database 54. That is, the information about the skill coefficient of each worker is acquired from the worker information, and the result obtained by multiplying this skill coefficient by the working time of one day (for example, 8 hours) is added up, and the result is the total of the above-mentioned production system. Select workers to equal work time. here,
The skill coefficient of the worker is a work efficiency coefficient that is increased or decreased in proportion to the processing speed with the value “1” for the standard worker (see FIG. 3).

Step S74: In consideration of the skill coefficient of each worker selected in the above step S73, the process acceptance of each worker is set so that the work load of each worker is as uniform as possible.

As described above, in the staffing plan creation processing, the work required for each process is performed based on the information on the work skill of each employable worker shown in the worker information, that is, the information on the work speed. Each worker shall be assigned to each process so that the quantity can be achieved.

When the staffing plan preparation process of step S4 of FIG. 6 is completed, the staffing information as the contents of the plan is stored in the plan contents information storage unit 51, and the staffing planning unit 30 activates the production planning unit 40. , And proceeds to step S5. Step S
5: The production planning unit 40 executes the production planning process after receiving the contents of the process plan, the equipment layout plan, and the staffing plan.
The production planning process will be described below.

4. Production planning process

The production plan is carried out while considering the contents of the process plan, the equipment layout plan and the staffing plan, and the constraints such as the required production pitch. The evaluation standard of the production plan is, for example, that the production pitch is short.

FIG. 14 shows the procedure of the production planning process.

The production plan is carried out by using simulation software such as a so-called scheduler or line simulator.

Here, the scheduler refers to software having a function of sequentially allocating work to each production resource, creating a Gantt chart as shown in FIG. 4B, and outputting the Gantt chart.

As shown in FIG. 4A, the line simulator uses a production line model in which a production line of a production system is modeled, and a work is put into this to produce each production resource. Software that has a function of sequentially investigating the behavior of each production resource at that time so as to perform an operation simulation and finally creating and outputting a Gantt chart (eg; Witness (trade name), Automod ( Product name)). Hereinafter, a case where a production plan is created using a line simulator will be described.

Step S81: The production simulator in the production system is simulated by the line simulator with reference to each information in the basic information storage unit 52, the process sequence information, the equipment allocation information, the equipment layout information and the staff layout information. Create a model of each process required for

Step S82: The manufacturing policy to be followed when the production plan is created is set according to the judgment of the planner. For example, in consideration of the easiness of processing each work, etc., the order of loading each work on the production line is set so that the production system operates efficiently. In addition, for example, the lot size and work priority (dispatching rule) of products that allow the production system to operate efficiently are set.

Step S83: A simulation is carried out using the above results to create a production plan.

As described above, in the production planning process, the simulation is carried out by accepting the contents of the process plan, the equipment layout plan and the staffing plan, and thereby the operating time of each production resource is minimized so as to minimize the production pitch. Scheduling is performed to set the band.

When the production plan creating process in step S5 of FIG. 6 is completed, the plan content is stored in the plan content information storage unit 51 as production plan information, and then the process proceeds to step S6.

Step S6: Process plan, facility layout plan,
The contents of the staffing plan and the production plan, and the evaluation for each plan based on the above evaluation standard are presented to the planner as the evaluation standard value.

Step S7: Whether or not each plan is satisfactory is determined according to the planner's judgment based on the contents of the plan and the evaluation reference value. Here, if each plan is satisfactory, the process is terminated, and if not, the process proceeds to step S8.

Step S8: A method of modifying each plan is selected according to the planner's judgment. That is, if the budget set in step S1 described above is unreasonable and the specifications need to be changed, the process returns to step S1 and the dissatisfied portion of the plan can be easily corrected. If it is efficient to proceed to step S9,
The manual correction process is performed, and the process ends.

In other cases, that is, when the specification change is unnecessary or impossible and the manual correction process is not executed, the process proceeds to step S10.

Step S10: An evaluation standard value deterioration factor analysis process for analyzing the cause of unsatisfactory contents of each plan, that is, the factor that deteriorates the evaluation standard value of each plan is executed. Hereinafter, the evaluation rule deterioration factor analysis processing will be described.

5. Evaluation reference value deterioration factor analysis processing

The evaluation standard value deterioration factor analysis processing is composed of each procedure for analyzing the cause of the poor evaluation standard value of each plan relating to the plan of the production system. Here, in general, when the evaluation standard value of the production plan is not good, it seems that there is a high need for plan review. Therefore, in this embodiment, the evaluation reference value deterioration factor analysis processing when the evaluation reference value of the production plan is not good will be described.

FIG. 15 shows each procedure of the factor analysis process for deterioration of the evaluation reference value.

That is, as a factor that deteriorates the evaluation standard value of the production plan, that is, a factor that lengthens the production pitch as a whole, the process with the longest processing time, that is, the process in the bottleneck state (hereinafter, Such a process is called a bottleneck process). Moreover, such a bottleneck process is often not found without planning a production plan. In order to analyze this, in this evaluation normative value deterioration factor analysis processing, it is possible to check how much work is accumulated before each process,
Extract the bottleneck process in the production system. The procedure will be described below.

Step S91: Time during which the work stays before each process (hereinafter, referred to as pre-process work staying time)
Is calculated, and the process having the largest average value of the pre-process work retention time is searched for.

Step S92: The process having the largest average value of the pre-process work retention time is extracted as the bottleneck process.

Step S93: The main production resources of the bottleneck process are analyzed, and it is determined that this production resource is a resource with insufficient capacity (hereinafter referred to as a resource with insufficient capacity) that causes the bottleneck state, The process ends.

When the evaluation reference value deterioration factor analysis process of step S10 of FIG. 6 is completed, the process proceeds to step S11.

Step S11: Depending on the resource lacking capacity extracted in the evaluation reference value deterioration factor analysis processing, the process proceeds to either step S12 of FIG. 7, step S20 of FIG. 8 or step S27 of FIG.

That is, if the resource with insufficient capacity is a human resource such as a worker, the process proceeds to the human factor elimination process in step S12 and thereafter, and if it is a physical resource such as equipment, the physical factor elimination process in step S20 and later is performed. move on. If it is unclear whether the resource lacking capacity is a physical resource or a human resource, the process proceeds to the exploratory factor elimination process in and after step S27.

The human factor elimination process will be described below.

6. Human factor elimination processing

Step S12: The bottleneck process is arranged in the process so that the average value of the pre-process work retention time in the process is increased to the extent that it does not become the maximum in all processes. Increase the number of workers.

Step S13: In order to avoid the influence on other plans, that is, so as not to affect the facility cost and the land / building cost, the staffing plan is recreated with the total personnel cost left unchanged.

Step S14: Evaluation standard value of manning plan,
That is, it is investigated whether or not the adequacy of the worker operating rate is deteriorated, and if it is not deteriorated, it is considered that there is no problem even if the labor cost is left unchanged, and the processing following step S5 (production plan creation processing) in FIG. Proceed to.

If the evaluation reference value of the staffing plan has deteriorated, the process proceeds to step S15.

Step S15: The personnel cost increased in step S12 described above is added to the total personnel cost and set as a new total personnel cost.

Step S16: It is determined according to the planner's judgment whether or not the increase of the total budget due to the increase of the total personnel cost is acceptable. If the increase in personnel expenses can be directly reflected in the increase in the total budget, the process proceeds to step S4 (manning plan creation process) in FIG. 6, and if the increase in the total budget is unacceptable, the process proceeds to step S17.

Step S17: Each plan before re-creating the process plan is presented to the planner and evaluated in step S13.

Step S18: An item for reducing the budget is selected according to the planner's judgment, and the reduction amount is set. That is, the budget reduction target and the reduction amount are set according to the bird's-eye view of the planner, such as reducing the factory site or reducing the cost of the equipment.

Step S19: When the facility cost is targeted for reduction in the above-mentioned step S18, the process proceeds to step S2 (process plan creation processing) and subsequent steps, and when the site / building cost is targeted for reduction, step S3 (Facility placement plan creation process) The process proceeds to the following process.

As described above, in the human factor elimination process, the bottleneck state of the bottleneck process is eliminated by increasing the capacity of the human production resource which is the main production resource. As a result, it becomes possible to intensively improve the problems relating to the design of the production system and raise the capacity of the entire production system so as to satisfy the production requirements.

Next, the physical factor elimination process after step S20 of FIG. 8 will be described.

7. Physical factor elimination processing

Step S20: Physical production of the process so that the average value of the pre-process work residence time in the bottleneck process is increased to such an extent that the average value of the process-free work retention time is not the maximum in all processes. Increase resources.

Step S21: In order to avoid the influence on other plans, that is, in order not to affect the site / building cost and the personnel cost, the process plan is recreated with the total equipment cost left unchanged.

Step S22: Evaluation standard value of process plan,
That is, it is investigated whether or not the inter-process load level of the standard work has deteriorated, and if it has not deteriorated, it is considered that there is no problem even if the total equipment cost is deferred, and step S3 in FIG. ) Proceed to the following processing. On the other hand, when the evaluation standard value of the process plan is deteriorated, the process proceeds to step S23.

Step S23: The equipment cost of the process increased in step S22 described above is added to the total equipment cost and set as a new total equipment cost.

Step S24: It is judged according to the planner's judgment whether or not the increase of the total budget due to the increase of the equipment cost is acceptable. If the increase in the facility cost can be directly reflected in the increase in the total budget, the process proceeds to step S2 (process plan creation processing) in FIG. 6, and conversely, if the increase in the total budget is unacceptable, the process proceeds to step S25.

Step S25: Each plan before re-creating the process plan is presented to the planner in step S21 described above and the evaluation is obtained.

Step S26: After the planner selects the expense item for reducing the budget and sets the reduction amount, the process following step S2 (process plan creation process) is carried out. That is, the cost to be budget-reduced is set by the planner's bird's-eye view, such as reducing the factory site or reducing the total number of workers.

As described above, in the physical factor elimination process, the bottleneck state of the process is eliminated by increasing the capacity of the physical production resource which is the main production resource of the bottleneck process. As a result, it becomes possible to intensively improve the problems relating to the design of the production system and raise the capacity of the entire production system so as to satisfy the production requirements.

Next, a description will be given of the exploratory factor elimination processing which is executed when it is not clear whether the factor causing the process to be the bottleneck state is the physical factor or the human factor.

8. Exploratory factor elimination processing

Step S27: When it is not specified whether the resource lacking capacity is a physical resource or a human factor in the analysis processing of the deterioration factor of the evaluation reference value, first, the average value of the pre-process work retention time in the bottleneck process is set. However, the personnel cost of the process will be increased to the extent that it does not become the maximum in all processes, and the human production resources of the process will be enhanced. this is,
This is because, when comparing the flexibility of equipment and workers, it is easy to adjust the workers assigned to each process.

Step S28: In order to avoid the influence on other plans, that is, so as not to affect the facility cost and the site / building cost, the staffing plan is prepared with the total personnel cost left unchanged.

Step S29: Evaluation standard value of staffing plan,
That is, it is investigated whether or not the appropriateness of the worker operating rate has deteriorated, and if it does not deteriorate, it is considered that there is no problem even if the labor cost is left unchanged, and the process proceeds to step S5 and subsequent steps in FIG.

On the contrary, when the evaluation reference value of the staffing plan is deteriorated, the process proceeds to step S30.

Step S30: The personnel cost increased in step S29 described above is added to the total personnel cost and set as a new total personnel cost.

Step S31: It is determined according to the planner's judgment whether or not the increase of the total budget due to the increase of the total personnel cost is acceptable. If the increase in personnel expenses can be directly reflected in the increase in the total budget, the process proceeds to step S5 in FIG. 6, and conversely, if the increase in the total budget is unacceptable, the process proceeds to step S5.
Proceed to 32.

Step S32: It is determined according to the planner's judgment whether or not the bottleneck state can be resolved by modifying the staffing plan. If the bottleneck state can be resolved by modifying the staffing plan, step S3
If it is not possible to proceed to the processing of 3 or less and vice versa, the processing proceeds to the physical factor elimination processing of step S20 and the followings.

Step S33: The plans before the creation of the staffing plan is presented to the planner in step S28 and the evaluation is obtained.

Step S34: According to the planner's judgment, a budget item for reducing the budget is selected and the reduction amount is set. That is, the budget reduction target and the reduction amount are set by the planner's bird's-eye view judgment such as reducing the factory site or reducing the cost of the equipment.

Step S35: When the facility cost is targeted for reduction in the above-mentioned step S34, the process proceeds to step S2 (process plan creation processing) and subsequent steps, and when the site / building cost is targeted for reduction, the step S3 (equipment placement plan creation processing) The processing proceeds to the following steps.

As described above, in the exploratory factor elimination process, even if it is not specified whether the resource lacking capacity is the physical resource or the human resource, the human resource which can be easily adjusted is adjusted first. When it is difficult to eliminate the bottleneck state by re-blending, it is possible to eliminate the bottleneck state by adjusting physical resources. This makes it possible to efficiently modify each plan related to the design of the production system.

The production system design method of this embodiment will be described below with reference to specific examples.

Consider the case of designing a production system for producing a reinforcing member (hereinafter, simply referred to as a member) 70 for a large steel structure such as a ship as shown in FIG.

Here, in manufacturing the member 70, a material such as a shaped steel is cut into a shape suitable for reinforcing the structure, a marking 71 is provided to identify each member, and each cut surface 72 is finished. Will be implemented. Also, the required production pitch of the reinforcing member K is 240 pieces / day (working time is 1
8 hours per day). Hereinafter, a case of creating each plan related to the design of such a production system will be described.

11. Create process plan

11-1. Process sequence setting

The order of performing the steps for manufacturing the member 70 is set. The manufacturing process of the member 70 is the following three processes.

(1) Cutting process for cutting the end of the member

(2) Marking process

(3) Finishing process of end cut surface

Here, there is a process sequence constraint based on the product structure that the cutting process of (1) needs to be performed before the finishing process of (3) is performed.

Further, there is a process order constraint based on the manufacturing know-how that it is better to carry out the marking step (2) before the cutting step so that clamping can be easily performed at the time of marking.

In accordance with the above process sequence restrictions, the process sequence is set in the order of the marking process, the cutting process and the finishing process.

11-2. Equipment allocation

The work amount of each process per member is as follows.

That is, the work amount in the cutting process: 400 mm
(Millimeter) cutting and marking process workload: 4
Marking of 0 characters, work amount of finishing process: Finishing of a cutting area (hereinafter referred to as SA) obtained by multiplying a cutting line length (400 mm) by a plate thickness.

At this time, the work amount of each process per day (240 pieces / day) is as follows.

That is, the cutting process: (400 × 240)
mm, marking process: (40 × 240) characters, finishing process: (SA × 240) mm ² (square millimeter),
Is. The standard product thickness is 15 mm.

Next, under such a design condition, referring to the equipment information in the production resource information database 54, the equipment list up in step S51 and the step S51 described above are performed.
55 transportation equipments are selected.

FIG. 17 shows an example of a candidate list in which the candidates of equipment that can be used in each process are extracted from the equipment information. In the figure, (a) shows the equipment candidate list 81 for the cutting step, (b) shows the equipment candidate list 82 for the marking step, and (c) shows the equipment candidate list 83 for the finishing step.

FIG. 18 shows an example of a candidate list obtained by extracting from the equipment information the equipment candidates that can be used as the transportation equipment for carrying the work between the processes.

In the equipment candidate list 81, each equipment G ₁ ,
For G ₂ and G ₃ , the thickness of the section steel to be cut (10, 15,
20 mm) for each cutting capability (unit: mm / min), equipment size, and price information.

In the equipment candidate list 82, each equipment G ₁₁ , G
₁₂ and G _13, information about ability (unit: number of characters / minute), size, and price is shown.

In the equipment candidate list 83, each equipment G is
_{For 21} , G ₂₂ and G _23, information on capacity (unit: mm / min), size and price is shown.

In the equipment candidate list 83, the member 70
The plate thickness is as small as 30 mm at maximum, which means that each equipment G ₂₁ ,
Since the finishable width of G ₂₂ and G ₂₃ is smaller than the finishable width (for example, 50 mm), the linear velocity of the finish is substituted for the parameter relating to the ability.

In the transportation facility candidate list 84 of FIG. 18, the transportation capability of each transportation facility L ₁ , L ₂ , L ₃ (unit: m /
Seconds), size and price information.

Each equipment candidate list 81, 82, 8
Required production pitch (240 pcs / day = 30 pcs / hour = 0.5 pcs /
Each equipment that can meet the requirements) is listed.

That is, cutting process: facilities G ₂ , G ₃ , marking process: facilities G ₁₁ , G ₁₂ , G ₁₃ , finishing process:
G _22, G _23, but are listed respectively.

Next, the lowest cost equipment is selected from these equipments in accordance with step S54 described above.

[0246] That is, the cutting process: facilities G _2, marking process: facilities G _11, finishing step: G _{2 2,} but are selected respectively.

Here, whether the load balance between the processes is good or bad is judged, and when the load balance is bad, that is, when the ratio of the processing time in each process is larger than a predetermined reference value α (α: α> 1). To correct this, the equipment assigned to the process with the longest processing time is replaced with the one with the shortest processing time. In the specific example, the load balance between the processes is also good, so that the selection example described above is maintained.

[0248] Further, the transportation equipment between each process is selected from the transportation equipment candidate list 84 so that the transportation process does not become a bottleneck factor. At this time, if a buffer can be provided between each process, it is possible to cover the lack of capacity even when a transfer facility having low transfer capacity is selected.

However, whether or not the buffer can be provided cannot be determined without implementing the equipment layout plan. Therefore, here, it is assumed that a buffer cannot be installed, and a rule is set to select equipment having as high a transfer capacity as possible. According to this rule, the transport facility L ₃ is selected from the transport facility candidate list 84.

12. Equipment placement plan

An arrangement plan is prepared for arranging the equipment assigned to each process in the process plan.

FIG. 19 shows an example 91 of creating a layout plan. Here, a separate equipment is assigned to each process,
Accept the contents of the process plan and arrange each equipment in the order of the process.

As a method of arranging the equipment, a plurality of types such as a straight line type and a U-type are prepared, and an appropriate type is selected from among them in consideration of the shape of the installation space and the work transfer system.

[0254] In this example, the straight-line arrangement is adopted to utilize the space of 5m x 3m in the existing factory.
Further, assuming that there is no room to install a work buffer between each equipment, the transportation equipment is maintained as the equipment L ₃ . If there is room to install a work buffer, it is possible to select a cheaper facility with a low transfer capacity.

13. Staffing plan

A worker is assigned to each process. Here, the work required to be performed by the worker in each step of producing the member 70 is as follows.

That is, the material loading operation in the cutting step is 10 seconds / one material, and the product unloading operation is 5 seconds / one product in the finishing step. The required production pitch of the member 70 is 0.5 pieces / minute, that is, 2 minutes / piece, and the walking time between steps is sufficiently short, so that one worker can execute each work. Therefore, the total number of workers assigned to each process is one.

14. Production planning

Let us consider a case where there is a demand to produce members of various plate thicknesses in just-in-time. In order to meet this demand, members with various plate thicknesses shall be produced by a single-flow method. The following description will be given by ignoring the transportation time because the transportation time between steps is sufficiently shorter than the processing time of each step.

FIG. 20A shows a production plan example 92 when the plate thicknesses of the members 70 are all the same (15 mm). Further, in FIG. 20B, each member 70 having a different plate thickness,
For example, a production plan example 93 in the case of alternately producing each member having a plate thickness of 20 mm and 10 mm is shown.

In the production plan example 92, since the processing time of each process is almost the same, the bottleneck process does not occur and each equipment is always in full operation. Therefore, the required production pitch is satisfied.

However, in the production plan example 93, the work stays in the marking process among the respective processes, so that the required production pitch is not satisfied. This is because the cutting process, which is a post process of the marking process, is in a bottleneck state. That is, although the average required time of the cutting process in the production plan example 93 is 2 minutes / 1 member, which is the same as that in the production plan example 92, it takes more than the average time to cut the 20 mm thick member, which results in that Even when the work of the marking process, which is the previous process, is completed, there is a time period T in which the work cannot be performed because the work cannot be sent to the cutting process.

When the bottleneck state of the cutting process is eliminated, since the main production resource of the cutting process is the machine (automatic equipment), the physical factor elimination process of step S20 and subsequent steps described above is executed to Eliminate bottleneck conditions by increasing physical production resources.

Specifically, the candidate list 8 in FIG. 17 (a)
Referring to 1, replace the equipment G ₂ with a higher capacity equipment G ₃ . As a result, the total equipment cost is increased, but offsetting this increase by reducing other equipment costs is not feasible because the required production pitch cannot be achieved.

Therefore, the planner judges whether or not the increase in the total budget due to the increase in the equipment cost is recognized, and if it is approved, it is the final plan. If not, is it possible to reduce the personnel cost? It will be examined whether or not.

As described above, in the production system designing method of the embodiment, when the evaluation standard value of the production plan is not good,
Analyze the production plan, determine the process with a long pre-process work retention time as the bottleneck process, and eliminate the bottleneck state by increasing the main production resources of the process, so that the production requirements are satisfied, It is possible to efficiently plan a production system that is optimized in terms of cost and capacity.

The present invention has been described above based on the embodiments, but the present invention is not limited to such embodiments, and various modifications can be made. For example, in the present embodiment, the manufacturing equipment of the reinforcing block is described as an example, but the application of the present invention is not limited to the manufacturing equipment of the reinforcing block, and can be applied to various manufacturing equipments such as gas. It can also be applied to turbine manufacturing equipment.

[0268]

As described in detail above, according to the present invention,
This has an excellent effect that problems in the process plan, equipment layout plan, staffing plan, and production plan can be reasonably extracted when planning the production system. for that reason,
The excellent effect that the problem can be dealt with intensively and the problem can be solved promptly is obtained.

According to the preferred embodiment of the present invention, since the specification can be reset, the excellent effect of eliminating the processing delay due to the nonconformity of the specification can be obtained.

Further, according to another preferred embodiment of the present invention, whether the occurrence of the problem is due to a human factor, a physical factor, or whether it is unclear whether or not it is unclear. The excellent effect that it can be obtained is obtained.

[Brief description of drawings]

FIG. 1 is a block diagram showing a schematic configuration of a production system planning apparatus to which a production system planning method according to an embodiment of the present invention is applied.

FIG. 2 is a schematic diagram showing the concept of a facility layout plan.

FIG. 3 is a schematic diagram showing the concept of a staffing plan.

FIG. 4 is a schematic diagram showing the concept of a production plan.

FIG. 5 is a block diagram showing details of a basic information storage unit.

FIG. 6 is a part of a flowchart showing an outline of a production system planning process.

FIG. 7 is a part of a flowchart showing an outline of a production system planning process.

FIG. 8 is a part of a flowchart showing an outline of a production system planning process.

FIG. 9 is a part of a flowchart showing an outline of a production system planning process.

FIG. 10 is a flowchart showing a procedure of a process sequence setting process of a process plan creation process.

FIG. 11 is a flowchart showing a procedure of equipment allocation processing of process plan creation processing.

FIG. 12 is a flowchart showing a procedure of a facility layout plan creation process.

FIG. 13 is a flowchart showing the procedure of a staffing plan creation process.

FIG. 14 is a flowchart showing the procedure of a production plan creation process.

FIG. 15 is a flowchart showing a procedure of an evaluation reference value deterioration factor analysis process.

FIG. 16 is a perspective view showing a reinforcing member as a production target in a specific example of the production system design.

FIG. 17 is a table showing a candidate list of equipment assigned to each process of a specific example.

FIG. 18 is a table showing a candidate list of transfer equipment for transferring a work between steps of a specific example.

FIG. 19 is a schematic diagram showing the contents of a facility layout plan in a specific example.

FIG. 20 is a schematic diagram showing the contents of a production plan in a specific example.

[Explanation of symbols]

K production system planning device 10 Process Planning Department 20 Equipment placement planning department 30 Staffing Planning Department 40 Production Planning Department 50 Database Department 51 Plan content information storage 52 Basic Information Storage

   ─────────────────────────────────────────────────── ─── Continued front page    (72) Inventor Koichi Fukumoto             1-1 Kawasaki-cho, Akashi-shi Kawasaki Heavy Industries Stock Association             Inside the company Akashi factory F term (reference) 3C100 AA02 AA03 AA05 AA16 AA22                       BB02 BB13 BB17

Claims (103)

[Claims] 1. A process plan, an equipment layout plan based on the process plan, a staffing plan based on the process plan and the equipment layout plan, and a production plan based on the process plan, the equipment layout plan and the staffing plan. A production system planning method used, wherein a production line model set in each plan is used to simulate a production activity to create an evaluation reference value for each plan, and the quality of each plan is determined by the reference value. A production system planning method characterized by the above. 2. The production system planning method according to claim 1, wherein the simulation schedules the operation start time of the production resources so as to minimize the production pitch. 3. The production system planning method according to claim 1, wherein, when there is a defective plan in the determination, the plan is corrected by a manual correction process. 4. The production system planning method according to claim 1, wherein if there is a defective plan in the determination, the specifications are reset. 5. If there is a plan that is judged to be defective in the judgment, a factor that deteriorates the evaluation reference value is analyzed, and based on the analysis, production resources are increased to deteriorate the evaluation reference value. The production system planning method according to claim 1, wherein the factor is eliminated. 6. The production system planning method according to claim 5, wherein the factor that deteriorates the evaluation reference value is analyzed as a bottleneck process. 7. The production system planning method according to claim 6, wherein the process having the maximum average value of the pre-process work residence time is the bottleneck process. 8. When the bottleneck process occurs due to a human factor, the human resource for the process is increased, and then the staffing plan is performed again while keeping the total personnel cost unchanged. The production system planning method described. 9. After carrying out the staffing plan again, it is judged whether or not the evaluation standard value is deteriorated, and if the evaluation standard value is not deteriorated, the production plan is carried out based on the manning plan. 9. The production system planning method according to claim 8. 10. After carrying out the staffing plan again, it is judged whether or not the evaluation standard value is deteriorated, and if the evaluation standard value is deteriorated, it is judged whether or not the total personnel cost can be increased. 9. The production system planning method according to claim 8. 11. The production system planning method according to claim 10, wherein when it is determined that the total labor cost can be increased, the staffing plan is performed based on the increased total labor cost. 12. The production system planning method according to claim 10, wherein a cost reduction item is selected when it is determined that the total personnel cost cannot be increased. 13. When the cost reduction item is a facility cost,
13. The production system planning method according to claim 12, wherein the process planning is performed based on the reduced equipment cost. 14. The facility allocation plan according to claim 12, wherein, when the cost reduction item is the site cost and / or the building cost, the equipment placement plan is performed based on the reduced site cost and / or the building cost. Production system planning method. 15. The production according to claim 6, wherein when the occurrence of the bottleneck process is caused by a physical factor, the facility cost for the process is increased, and then the process plan is carried out while keeping the total facility cost unchanged. System planning method. 16. The method according to claim 16, wherein after carrying out the process plan again, it is judged whether or not the evaluation standard value is deteriorated, and when the evaluation standard value is not deteriorated, the equipment arrangement plan is carried out based on the process plan. 16. The production system planning method according to claim 15. 17. The method is characterized in that after carrying out the process planning again, it is judged whether or not the evaluation standard value is deteriorated, and if the evaluation standard value is deteriorated, whether or not the total equipment cost can be increased. 16. The production system planning method according to claim 15. 18. The production system planning method according to claim 17, wherein when it is determined that the total facility cost can be increased, the process plan is performed based on the increased total facility cost. 19. The production system planning method according to claim 17, wherein when it is determined that the total equipment cost cannot be increased, a cost reduction item is selected and the reduction amount is set. 20. The production system according to claim 19, wherein the total budget is deferred, the cost is reduced by the reduction amount set for the selected expense item, and the plan related to the reduced cost is performed. How to plan. 21. When it is unclear whether the bottleneck process occurs due to a human factor or a physical factor, after increasing human resources for the process, the staffing plan is re-established while keeping the total personnel cost. The production system planning method according to claim 6, which is performed. 22. After carrying out the staffing plan again, it is judged whether or not the evaluation standard value is deteriorated, and if the evaluation standard value is not deteriorated, the production plan is carried out based on the staffing plan. 22. The production system planning method according to claim 21, which is characterized in that 23. After carrying out the staffing plan again, it is judged whether or not the evaluation standard value is deteriorated, and if the evaluation standard value is deteriorated, it is judged whether or not the total personnel cost can be increased. 22. The production system planning method according to claim 21, which is characterized in that. 24. The production system planning method according to claim 23, wherein when it is determined that the total labor cost can be increased, the staffing plan is performed based on the increased total labor cost. 25. The production system planning method according to claim 24, wherein when it is determined that the increase of the total personnel cost is impossible, it is determined whether or not the staff can be corrected. 26. The process plan according to claim 25, wherein, when it is determined that the staffing cannot be modified, the facility cost for the process is increased, and then the process plan is performed with the total facility cost remaining unchanged. Production system planning method. 27. After carrying out the process plan again, it is judged whether or not the evaluation standard value is deteriorated, and if the evaluation standard value is not deteriorated, the equipment arrangement plan is carried out based on the process plan. The production system planning method according to claim 26. 28. After carrying out the process planning again, it is judged whether or not the evaluation standard value is deteriorated, and if the evaluation standard value is deteriorated, it is judged whether or not the total equipment cost can be increased. The production system planning method according to claim 26. 29. The production system planning method according to claim 28, wherein when it is determined that the total facility cost can be increased, the process plan is performed based on the increased total facility cost. 30. The production system planning method according to claim 28, wherein when it is determined that the total facility cost cannot be increased, a cost reduction item is selected and the reduction amount is set. 31. The production system according to claim 30, characterized in that the total budget is left unchanged, the cost is reduced by the reduction amount set for the selected expense item, and the subsequent plan related to the reduced cost is performed. How to plan. 32. When it is determined that the staff can be modified,
26. The production system planning method according to claim 25, wherein cost reduction items are selected. 33. When the cost reduction item is equipment cost,
33. The production system planning method according to claim 32, wherein the process planning is performed based on the reduced equipment cost. 34. The facility arrangement plan is carried out based on the reduced site cost and / or building cost when the cost reduction item is the site cost and / or building cost. Production system planning method. 35. A process planning section for performing a process plan, an equipment layout planning section for carrying out an equipment layout plan based on the process plan, and a staffing planning section for carrying out a staffing plan based on the process plan and the equipment layout plan. And a production planning department that makes a production plan based on the process plan, equipment layout plan and manning plan,
A production system planning apparatus including an analysis / correction unit, wherein the analysis / correction unit simulates production activities based on a production line model set in each of the planning units, and an evaluation standard for each of the plans. A production system planning device characterized by creating a value and judging the quality of each plan based on the standard value. 36. The production system planning apparatus according to claim 35, wherein the simulation schedules the operation start time of the production resource so as to minimize the production pitch. 37. If there is a plan that is judged to be defective in the determination, the plan can be corrected by manual correction processing.
The described production system planning device. 38. The production system planning apparatus according to claim 35, wherein if there is a defective plan in the determination, the specification can be reset. 39. If there is a plan that is judged to be defective in the determination, a factor that deteriorates the evaluation reference value is analyzed, and based on the analysis, production resources are increased to deteriorate the evaluation reference value. The production system planning apparatus according to claim 35, wherein the production system planning apparatus is configured to eliminate a factor. 40. The factor that deteriorates the evaluation reference value is
40. The production system planning apparatus according to claim 39, which is configured to analyze as a bottleneck process. 41. The production system planning apparatus according to claim 40, wherein the process having the maximum average value of the pre-process work retention time is a bottleneck process. 42. If the occurrence of the bottleneck process is due to human factors, after increasing human resources for the process,
The production system planning apparatus according to claim 40, wherein the production system planning apparatus is configured to perform a staffing plan again while keeping the total personnel cost unchanged. 43. It is configured that after carrying out the staffing plan again, it is judged whether or not the evaluation standard value is deteriorated, and if the evaluation standard value is not deteriorated, the production plan is carried out based on the staffing plan. 43. The production system planning device according to claim 42, wherein 44. A structure for determining whether or not the evaluation standard value is deteriorated after carrying out the staffing plan again and, if the evaluation standard value is deteriorated, determining whether the total personnel cost can be increased or not. 43. The production system planning device according to claim 42, wherein 45. The production system plan according to claim 44, wherein when it is determined that the total personnel cost can be increased, the staffing plan is performed based on the increased total personnel cost. apparatus. 46. The production system planning apparatus according to claim 44, wherein when it is determined that the total personnel cost cannot be increased, a cost reduction cost item is selected. 47. When the cost reduction item is a facility cost,
The production system planning apparatus according to claim 46, wherein the production system planning apparatus is configured to perform the process planning based on the reduced equipment cost. 48. When the cost reduction item is a site cost and / or a building cost, the facility allocation plan is configured based on the reduced site cost and / or building cost. The production system planning device according to claim 46. 49. When the bottleneck process occurs due to a physical factor, the facility cost is increased for the process, and then the process plan is performed while keeping the total facility cost unchanged. Item 40. The production system planning device according to item 40. 50. After the process plan is carried out again, it is determined whether or not the evaluation standard value is deteriorated, and if the evaluation standard value is not deteriorated, the equipment arrangement plan is made based on the process plan. 50. The production system planning device according to claim 49, wherein: 51. It is configured to judge whether the evaluation standard value is deteriorated after carrying out the process plan again, and if the evaluation standard value is deteriorated, to judge whether the total equipment cost can be increased. 50. The production system planning device according to claim 49, wherein: 52. The production system planning apparatus according to claim 51, wherein when it is determined that the total equipment cost can be increased, the process plan is performed based on the increased total equipment cost. . 53. The production system according to claim 51, wherein when it is determined that the total facility cost cannot be increased, a cost reduction cost item is selected and the reduction amount is set. Planning equipment. 54. The total budget is deferred, the cost is reduced by the reduction amount set for the selected expense item, and the subsequent plan related to the reduced cost is performed. 53. The production system planning device described in 53. 55. When it is unclear whether the bottleneck process occurs due to a human factor or a physical factor, after increasing the human resources for the process, the staffing plan is re-established while keeping the total personnel cost. The production system planning apparatus according to claim 40, which is configured to perform. 56. It is configured such that after carrying out the staffing plan again, it is judged whether or not the evaluation standard value is deteriorated, and if the evaluation standard value is not deteriorated, the production plan is carried out based on the staffing plan. 56. The production system planning device according to claim 55, wherein 57. A structure for determining whether or not the evaluation norm value is deteriorated after carrying out the staffing plan again, and if the evaluation norm value is deteriorated, whether or not the total personnel cost can be increased 56. The production system planning device according to claim 55, wherein 58. The production system plan according to claim 57, wherein when it is determined that the total labor cost can be increased, the staffing plan is performed based on the increased total labor cost. apparatus. 59. The production system planning apparatus according to claim 57, wherein when it is determined that the total personnel cost cannot be increased, it is configured to determine whether or not the staffing can be corrected. . 60. When it is determined that the staffing cannot be modified, the facility cost is increased for the process, and then the process plan is performed while keeping the total facility cost unchanged. The production system planning device according to claim 59. 61. The method is configured such that after the process plan is carried out again, it is determined whether or not the evaluation standard value is deteriorated, and if the evaluation standard value is not deteriorated, the equipment arrangement plan is performed based on the process plan. The production system planning apparatus according to claim 60, characterized in that: 62. It is configured to determine whether or not the evaluation standard value is deteriorated after carrying out the process plan again, and if the evaluation standard value is deteriorated, to judge whether or not the total equipment cost can be increased. The production system planning apparatus according to claim 60, characterized in that: 63. The production system planning apparatus according to claim 62, wherein when it is determined that the total equipment cost can be increased, a process plan is performed based on the increased total equipment cost. . 64. The production system according to claim 62, wherein when it is determined that the total equipment cost cannot be increased, a cost reduction expense item is selected and the reduction amount is set. Planning equipment. 65. The total budget is deferred, the cost is reduced by the reduction amount set for the selected expense item, and the subsequent plan related to the reduced cost is performed. 64. A production system planning device according to 64. 66. If it is determined that the staff can be modified,
The production system planning apparatus according to claim 59, wherein the production system planning apparatus is configured to select a cost reduction item. 67. When the cost reduction item is a facility cost,
The production system planning method according to claim 66, wherein the method is configured to perform the process planning based on the reduced equipment cost. 68. When the cost reduction item is a site cost and / or a building cost, the facility allocation plan is configured based on the reduced site cost and / or building cost. The production system planning device according to claim 66. 69. A computer-readable program used for planning a production system, comprising a procedure for making a process plan, a procedure for making an equipment layout plan based on the process plan, and the process plan and equipment equipment layout. Including a procedure for making a staffing plan based on the above, and a procedure for making a production plan based on the process plan, equipment layout plan, and staffing plan, and the procedure for making each plan is a procedure for setting a production line model. And including a procedure of simulating a production activity by the production line model, a procedure of creating an evaluation reference value for each plan by the simulation, and a step of determining the quality of each plan based on the reference value. A computer readable program for. 70. The computer-readable program according to claim 69, further comprising a step of performing a scheduling for setting an operation start time of a production resource so as to minimize a production pitch by the simulation. . 71. The computer-readable program according to claim 69, further comprising the step of manually correcting the plan when there is a defective plan in the determination. 72. The computer-readable program according to claim 69, further comprising a step of resetting specifications when there is a plan that is determined to be defective in the determination. 73. If there is a defective plan in the judgment, a procedure for analyzing a factor that deteriorates the evaluation reference value, and based on the analysis, increase production resources to deteriorate the evaluation reference value. 70. The computer-readable program according to claim 69, further comprising a procedure for eliminating the factor causing the problem. 74. A factor that deteriorates the evaluation reference value is
74. The computer readable program of claim 73, comprising a procedure for analyzing as a bottleneck process. 75. The computer-readable program according to claim 74, further comprising a step of setting a process having the maximum average value of the pre-process work residence time as a bottleneck process. 76. If the occurrence of the bottleneck process is due to human factors, after increasing human resources for the process,
75. The computer-readable program of claim 74, further comprising the step of re-planning the staffing while keeping the total labor cost unchanged. 77. After carrying out the staffing plan again, it is judged whether or not the evaluation standard value is deteriorated, and if the evaluation standard value is not deteriorated, a production plan is carried out based on the staffing plan. 77. The computer readable program of claim 76, comprising. 78. A step of determining whether or not the evaluation standard value is deteriorated after carrying out the staffing plan again and, if the evaluation standard value is deteriorated, determining whether or not the total personnel cost can be increased. 77. The computer-readable program according to claim 76, wherein: 79. The computer-readable medium according to claim 78, further comprising a step of performing a staffing plan based on the increased total labor cost when it is determined that the total personnel cost can be increased. Possible programs. 80. The computer-readable program according to claim 78, further comprising a step of selecting a cost reduction expense item when it is determined that the increase of the total labor cost is impossible. 81. When the cost reduction item is a facility cost,
81. The computer-readable program according to claim 80, further comprising a procedure for planning a process based on the reduced equipment cost. 82. When the cost reduction item is a site cost and / or a building cost, the method includes a step of performing a process plan based on the reduced site cost and / or building cost. A computer-readable program according to claim 80. 83. When the occurrence of the bottleneck process is caused by a physical factor, the process further comprises the step of increasing the facility cost for the process and then planning the process while keeping the total facility cost unchanged. Item 74. A computer-readable program according to Item 74. 84. After carrying out the process plan again, it is judged whether or not the reference value is deteriorated, and if the evaluation reference value is not deteriorated, a procedure for performing an equipment placement plan based on the process plan is included. 84. The computer readable program according to claim 83. 85. After carrying out the process planning again, it is judged whether or not the reference value is deteriorated, and when the evaluation reference value is deteriorated,
84. The computer-readable program according to claim 83, further comprising a procedure for determining whether or not the total equipment cost can be increased. 86. The computer-readable computer-readable medium according to claim 85, further comprising a step of performing a process plan based on the increased total facility cost when it is determined that the total facility cost can be increased. Programs. 87. The computer according to claim 86, further comprising the step of setting a cost reduction expense item and setting the reduction amount when it is determined that the total facility cost cannot be increased. A readable program. 88. A method comprising the steps of, with the total budget deferred, reducing the cost for the selected expense item by the set reduction amount, and carrying out a plan and subsequent steps relating to the reduced cost. Item 87. A computer-readable program according to Item 87. 89. If it is unclear whether the bottleneck process occurs due to a human factor or a physical factor, after increasing the human resources for the process, the staffing plan is re-established while keeping the total personnel cost. 75. The computer-readable program of claim 74, comprising the steps of performing. 90. After carrying out the staffing plan again, it is judged whether or not the evaluation standard value is deteriorated, and if the evaluation standard value is not deteriorated, a production plan is carried out based on the manning plan. 90. The computer-readable program of claim 89, comprising. 91. After carrying out the staffing plan again, it is determined whether or not the evaluation standard value is deteriorated, and if the evaluation standard value is deteriorated, a procedure for determining whether or not the total personnel cost can be increased 90. The computer-readable program of claim 89, comprising. 92. The computer according to claim 91, further comprising the step of performing a staffing plan based on the increased total labor cost when it is determined that the total personnel cost can be increased. Possible programs. 93. The computer-readable computer-readable medium according to claim 91, further comprising a step of determining whether or not the staffing can be corrected when it is determined that the total personnel cost cannot be increased. Programs. 94. If it is determined that the staffing cannot be modified, the method further comprises the step of increasing the facility cost for the process and then planning the process while keeping the total facility cost unchanged. A computer readable program according to claim 93. 95. A step of determining whether or not the evaluation standard value is deteriorated after carrying out the process plan again and, if the evaluation standard value is not deteriorated, performing a facility arrangement plan based on the process plan is included. The computer readable program according to claim 94, characterized in that: 96. A step of determining whether or not the evaluation standard value is deteriorated after carrying out the process plan again and, if the evaluation standard value is deteriorated, determining whether or not the total equipment cost can be increased. The computer readable program according to claim 94, characterized in that: 97. The computer readable medium according to claim 96, further comprising a step of performing a process plan based on the increased total facility cost when it is determined that the total facility cost can be increased. Programs. 98. The computer according to claim 96, further comprising the step of selecting a cost reduction expense item and setting the reduction amount when it is determined that the total facility cost cannot be increased. A readable program. 99. The method comprises the steps of deferring a total budget, reducing a cost by a reduction amount set for a selected expense item, and carrying out a plan and subsequent steps relating to the reduced cost. 98. A computer readable program according to 98. 100. The computer-readable program according to claim 93, further comprising a step of selecting a cost reduction item when it is determined that the staffing can be modified. 101. The computer-readable program according to claim 100, further comprising a step of performing a process plan based on the reduced facility cost when the cost reduction item is the facility cost. 102. When the cost reduction item is a site cost and / or a building cost, the method includes a procedure for planning an equipment layout based on the reduced site cost and / or building cost. A computer-readable program according to claim 100. 103. A computer-readable recording medium comprising the computer-readable program according to any one of claims 69 to 102.