JP2003195927A - Production plan forming device and production plan forming program - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To form a proper production plan capable of equalizing the load to be assigned to each facility even when the total lots requested in the processing is over the processing capacity of the total facilities. <P>SOLUTION: A production decision part 8 successively selects the lot under a condition that the total processing time in each facility stored in a facility load information storing part 5 is not over the processing capacity of the corresponding facility, and the processing scheduled quantity of every combination of a product class and the process stored in a production information storing part 6 is over a minimum value as the requirement stored in a macro plan storing part 2c. The load applied to the selected lot is assigned to each facility by an assigning part 3, and an updating part 7 updates the storage contents of the facility load information storing part 5 and the production information storing part 6 on the basis of a result of the assignment. <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 plan preparation device and a production plan preparation program when a plurality of products manufactured through a plurality of processes are produced using a plurality of facilities.

[0002]

2. Description of the Related Art A technique for assigning each of a plurality of products to a plurality of production equipments or production equipments (simply referred to as "equipment" in this specification) to perform processing is disclosed in Japanese Patent Application Laid-Open No. HEI 4-1992. It is described in Japanese Patent Laid-Open No. 195677.
In the technology of this publication, the allocation probability for each facility,
Depending on the processing capacity of each equipment, the load related to the product is provisionally allocated to each equipment and piled up, and then the load is sequentially and definitely assigned to the equipment with the smallest piled amount at that time. There is. This makes it possible to create a production plan in which the load assigned to each facility is leveled, even if the available facilities and processing time differ for each product.

[0003]

SUMMARY OF THE INVENTION The technique disclosed in the above publication, when creating a production plan within a predetermined period (planning target period),
When the processing capacity of the entire equipment within the period exceeds the load required by all products that are processing candidates, it is effective to level the load assigned to each equipment. However, the technique disclosed in the above publication presupposes that all of the products that are candidates for processing are processed in one of the facilities. Therefore, conversely, if the load demanded by all products that are candidates for processing exceeds the processing capacity of the entire equipment within that period, an appropriate production plan in which the load assigned to each equipment is leveled is appropriate. Cannot be created.

Further, in a production line that handles a wide variety of products, it is necessary to consider not only the leveling of the load assigned to each equipment within the planning period, but also the balance of the processing amount for each type. However, in the technique of the above-mentioned publication, the load assigned to each facility is merely attempted to be leveled, and the load cannot be assigned to each facility in consideration of the balance of the throughput of each product type. Further, in the technique of the above publication, the load cannot be preferentially assigned to any one of the facilities, so that the load required by all products that are processing candidates exceeds the processing capability of the entire facility within that period. In this case, it is not possible to create a production plan that preferentially processes a specific product in a multi-product product.

Furthermore, in a "repetitive" production line in which the same equipment is shared by a plurality of processes, not only the leveling of the load allocated to each equipment within the planning period,
It is necessary to consider the balance of processing amount for each process. However, the technique disclosed in the above publication cannot consider the balance of the amount of processing in each process. Further, in the technique of the above publication, the load cannot be preferentially assigned to any one of the facilities, so that the load required by all products that are processing candidates exceeds the processing capability of the entire facility within that period. In this case, it is not possible to create a production plan that preferentially processes a specific process among a plurality of processes.

[0006] The load subject to the production plan is often given to each lot identified by the combination of the product type and the process to be manufactured and the quantity to be processed for each is specified. Therefore, it is desired that the production plan can be appropriately created when the load is given to each lot.

In view of these problems, the present invention has been made to achieve at least one of the following objects. First of all, one of the objectives is that even if the load related to all lots requiring processing exceeds the processing capacity of the entire equipment within the specified period, the load assigned to each equipment will be substantially leveled. It is to provide a production plan creation device capable of creating an appropriate production plan.

Another object of the present invention is to provide a production plan creating apparatus capable of allocating a load to each facility in consideration of the balance of the amount of processing for each product type.

Another object of the present invention is to provide a production plan creation apparatus capable of allocating a load to each facility in consideration of the balance of the amount of processing for each process.

Still another object of the present invention is to provide a production plan creating apparatus capable of allocating a load to each facility in consideration of product type and process priority.

[0011]

In order to achieve the above-mentioned object, a production plan creating apparatus according to a first aspect of the present invention provides a plurality of products which are manufactured through a plurality of processes and which are identified by a combination of a product type and a process. Product information storage means for storing the quantity processed in each of the lots, and one or a plurality of equipment names capable of performing the processing related to the combination for each combination of product type and process for the plurality of products. And process information storage means for storing the processing time in the equipment, macro plan storage means for storing the quantity to be processed within a predetermined period for each product type, and processing of each equipment within the predetermined period An equipment capacity storage means for storing capacity and a load relating to each of the plurality of lots are stored in the process information storage means among the one or more equipments stored in the process information storage means. 1 in the same breed and the equipment one or more combinations that can process is performed according to the steps as
Based on the processing time in the equipment for each combination stored in the process information storage means and the allocation means for stepwise allocation lot by lot, the total processing time of each equipment in each allocation stage by the allocation means Based on the equipment load information storage means for storing and the quantity processed in each of the lots stored in the product information storage means, the planned processing quantity for each combination at each allocation stage by the allocation means is stored. Production information storage means, an updating means for updating the storage contents of the equipment load information storage means and the production information storage means each time the lot is allocated by the allocation means, and the equipment load information storage Total processing time of each equipment stored in the means and processing of the equipment stored in the equipment capacity storage means While comparing with the power, a plurality of processing schedule quantities for each combination stored in the production information storage means satisfy a criterion regarding the quantity to be processed within the predetermined period stored in the macro plan storage means. Production judging means for selecting one of the lots to be assigned by the assigning means.

According to the first aspect, when creating the production plan, first, one lot is selected, and the production determining means determines whether or not the lot is to be assigned by the assigning means. Then, for the lot to be assigned, the processing time related to the combination of the product type and the process corresponding to the lot stored in the process information storage unit is stored in the equipment load information storage unit, and the processing schedule related to the combination is stored. The quantity is stored in the production information storage means.
Hereinafter, the same procedure is repeatedly performed for all lots that are candidates for processing, and each time the allocation means allocates the equipment, the update means stores the stored contents of the equipment load information storage means and the production information storage means. Will be updated. In performing the above process, the production judging means compares the total processing time of each equipment with the processing capacity of the equipment, and the planned processing quantity for each combination of product type and process stored in the production information storage means. Selects a lot from a plurality of lots to be assigned to each facility by the allocating means so as to satisfy the criteria regarding the quantity to be processed within the predetermined period stored in the macro plan storing means. Therefore, even if the load required for all lots that are processing candidates exceeds the processing capacity of the entire equipment within a predetermined period, the load allocated to each equipment is considered while considering the processing capacity of each equipment. It becomes possible to create an appropriate production plan that is substantially leveled.

Further, since the production information storage means stores the planned processing quantity for each combination of product type and process,
When the production judging means selects the lot to be assigned to each facility by the assigning means, it is possible to select the lot in consideration of the balance for each combination of product type and process. Therefore, it becomes possible to create a production plan in consideration of the balance of the processing amount for each product type and the processing amount for each process.

It should be noted that the expression "the planned processing quantity satisfies the criteria regarding the quantity to be processed" means that the planned processing quantity is larger than the processing quantity or smaller than the processing quantity. It means that the number of objects to be processed is n times (n is a natural number), the number of objects to be processed is within ± n, or the like.

Further, the production plan creating apparatus of claim 2 further comprises a judgment order storage means for storing an order in which each of the plurality of lots is judged with respect to the selection by the production judgment means. It has a feature.

According to the second aspect, the production judging means sequentially judges whether or not each lot is to be allocated by the allocating means based on the lot judging order stored in the judging order storing means. By giving a small number that can be judged quickly as a judgment order to lots with high frequency, the load required by all lots that are processing candidates exceeds the processing capacity of the entire equipment within that period. Even if there is a load, it is possible to reliably assign the load related to the combination of the product type and the process having a high priority.

Further, in the production plan creating apparatus of claim 3, the order stored in the judgment order storage means is determined according to the high priority of each product type stored in the macro plan storage means. It is characterized by that.

According to the third aspect of the present invention, the order stored in the judgment order storage means is determined according to the high priority of each type stored in the macro plan storage means. Therefore, a lot related to a product having a high priority is determined with a higher priority than a lot related to another product, which increases the possibility of being selected. Therefore, it is possible to create a production plan that considers the priority for each product type, even if the load required for all lots that are candidates for processing exceeds the processing capacity of the entire equipment within the specified period. Becomes

Further, in the production plan creating apparatus of claim 4, the macro plan storing means stores the quantity to be processed within the predetermined period for each process.

According to a fourth aspect of the present invention, the macro plan storing means stores a quantity to be processed within the predetermined period for each process, so that at least one of the facilities is shared by a plurality of processes. However, the load can be assigned while balancing the load assigned to each facility and the balance of the throughput of each process.

Further, in the production plan creating apparatus of claim 5, the processing capacity of each equipment within the predetermined period stored in the equipment capacity storage means is obtained by subtracting the scheduled stop time of the equipment from the predetermined period. It is characterized by being time.

According to the fifth aspect, it is possible to create a more appropriate production plan in consideration of the reduction in processing capacity related to the scheduled stoppage of each facility.

Further, in the production planning apparatus of claim 6, the allocating means can carry out the processing relating to the load of each of the plurality of lots related to the combination of the same kind and process of the lot. Allocation to one or more of the facilities substantially evenly.

According to the sixth aspect, it is possible to further level and allocate the loads related to a plurality of lots to each facility. In this case, a value obtained by dividing the processing time of a certain equipment of a certain lot by the number of the equipment capable of processing the lot may be equally assigned to each equipment.

Further, in the production plan creating apparatus of claim 7, the production judging means stores the total processing time of each equipment stored in the equipment load information storing means in the equipment capacity storing means. The lot to be assigned by the assigning means is selected from the plurality of lots so as not to exceed the processing capacity.

According to the seventh aspect, by selecting the lot so that the total processing time of each equipment does not exceed the processing capacity of the equipment, a production plan in which an excessive load is not allocated to each equipment is created. It is possible.

Further, in the production plan creating apparatus according to the present invention, the production judging means determines the planned processing quantity stored in the production information storing means for the combination of the same product type and process as the lot related to the selection judgment. When the quantity to be processed within the predetermined period stored in the macro plan storage means is already exceeded, the lot is not selected as an allocation target by the allocation means.

According to the eighth aspect, the lot allocating means is based on whether the planned processing quantity stored in the production information storing means has already exceeded the quantity to be processed within the predetermined period stored in the macro plan storing means. Since it is determined whether or not the lots are to be allocated by, the lots to be produced can be selected so that the maximum quantity that satisfies the macro plan can be processed.

Further, in the production plan creating apparatus of claim 9, the macro plan storing means stores a plurality of types of quantities to be processed within the predetermined period for each product type, and the production judging means has a plurality of types. With respect to the quantity of, the items to be assigned by the assigning means are sequentially selected from the plurality of lots.

According to the ninth aspect, by sequentially using a plurality of types of quantities to be processed for each product type stored in the macro plan storage means, the minimum required processing amount is secured for each product type. It is possible to create a production plan that gradually increases the product processing amount. For example, it is possible to create a production plan that multi-steps the processing amount for each product type, such as "minimum necessary amount", "preferably necessary amount", "necessary and sufficient amount", and "excess amount". become able to.

Further, the production plan creation program according to any one of claims 10 to 18 is a program which allows a computer to function as the production plan creation device according to any one of claims 1 to 9. Each has the same effect. The program described in each of claims 10 to 18 can be distributed by being recorded on a removable recording medium such as a CD-ROM, FD, MO or a fixed recording medium such as a hard disk, or by wire or It can be distributed through a communication network such as the Internet by wireless telecommunication means.

[0032]

BEST MODE FOR CARRYING OUT THE INVENTION Hereinafter, preferred embodiments of the present invention will be described with reference to the drawings.

FIG. 1 is a block diagram of a production plan creating apparatus according to this embodiment. Targets of production plan creation using the production plan creation apparatus 1 shown in FIG. 1 are a plurality of products each manufactured through a plurality of processes using a plurality of facilities. As shown in FIG. 2, each product is manufactured by sequentially passing through 30 steps from step 1 to step 30 or a part of the steps. In addition, each product is manufactured by being processed by each facility in units of lots identified by a combination of product type and process.

When manufacturing a plurality of products for which a production plan is to be created using the production plan creation apparatus 1, the total load of the products is the closest to the processing capacity of the entire equipment, which is a bottleneck in creating a production plan. There is a neck process. Therefore, in the present embodiment, the process performed by the production plan creation device 1 will be described by focusing on the neck process.
Further, in the present embodiment, it is assumed that the same equipment is used in a plurality of neck processes, that is, the equipment is shared by a plurality of neck processes. As one specific example, as shown in FIG.
In the three neck processes of the process 3, the process 13, and the process 23, the four facilities M-1, M-2, M-3 included in the facility group X,
At least two of M-4 are shared. Step 3, Step 1
3 and all lots processed in process 23 per process, 1 out of 4 of these 4
It shall be processed only once. At this time, usable equipment and its processing time vary depending on the combination of product type and process. In addition, in FIG. 3, the buffer means the step 2, the step 1 which is a step before the step 3, the step 13 and the step 23.
2. This is a place where lots processed in step 22 are retained until the lot advances to the equipment group X in which the next step is performed.

As shown in FIG. 1, the production planning apparatus 1
Includes a basic information storage unit 2, an allocation unit 3, a production lot storage unit 4, an equipment load information storage unit 5, a production information storage unit 6, an update unit 7, and a production determination unit 8. There is.

The basic information storage unit 2 stores various basic information used when creating a production plan. The basic information storage unit 2 includes a product information storage unit 2a and a process information storage unit 2
b, macro plan storage unit 2c, facility capacity storage unit 2d
And a judgment order storage unit 2e.

The product information storage unit 2a stores the quantity processed in each lot for all lots to be processed within a certain period. Table 1 shows the product information storage unit 2
A specific example of the stored contents of a is shown. Three types of products (type A,
In the example shown in Table 1 in which the product types B and C) are manufactured, the processing quantity of the <lot 1>, which is the process number 3 in the product type A, is 3, and in the same manner, each is a combination of product type and process. For each of the 15 identified lots from <lot 1> to <lot 15>, the processed quantity is stored therein. Two or more lots may exist for a combination having the same type and process. In the example of Table 1, lot 2 and lot 3 are lot 7 and lot 8
Indicates that lot 11, lot 12, and lot 13, and further lot 14 and lot 15 are lots having the same combination of types and processes.

[0038]

[Table 1]

The process information storage unit 2b stores, for each combination of product types and processes of a plurality of manufactured products, one or a plurality of facility names capable of performing the process relating to the combination, and the processing time at the facility. I remember with. Table 2 shows a specific example of the stored contents of the process information storage unit 2b.
In the example shown in Table 2, when the combination of product type and process is process number 3 and product type A, two of M-1 and M-2 of the four facilities included in the facility group X can be used. It is said that the processing time at that time is 120 minutes per one, and in the same manner, the usable equipment names and the processing time there are stored for each of the nine combinations of three types and three processes. ing.

[0040]

[Table 2]

The macro plan storage unit 2c stores, for each combination of product type and process, the minimum number and the maximum number of the required quantity (required quantity) to be processed within the planning period. Then, either the minimum number or the maximum number is set in the macro plan storage unit 2c as the required amount. Table 3 shows a specific example of the stored contents of the macro plan storage unit 2c. Here, the maximum number and the minimum number are determined, for example, in consideration of the production progress degree for each product type and the load balance between the processes in the entire production line. In the present embodiment, the maximum number is treated as a number that is desired to be processed at least, and the minimum number is treated as a number that does not need to be processed any more. In the example shown in Table 3, when the combination of product type and process is process number 3 and product type A, the minimum number is 0 and the maximum number is 3, and in the same manner, 3 product types and 3 product types will be described below. The minimum number and the maximum number to be processed within the planned period (24 hours in this example) are stored for each of a total of 9 combinations of processes. Furthermore, the macro plan storage unit 2
In c, the priority of the combination is stored for every nine combinations of three types and three processes. The priority indicates that the smaller this value is, the more the priority should be processed. As described below,
Based on this priority, the order in which each of the plurality of lots is judged with respect to the selection in the later-described production judgment section 8 stored in the judgment order storage section 2e is determined.

[0042]

[Table 3]

The equipment capacity storage unit 2d stores the processing capacity of each equipment within the planned period. In the present embodiment, the processing capacity of each piece of equipment stored in the equipment capacity storage unit 2d is a time (equipment operating time) obtained by subtracting the planned stop time of the equipment from the planning period. Table 4 shows a specific example of the stored contents of the facility capacity storage unit 2d. In the example shown in Table 4, for the equipment M-1, the planning period 1440 minutes (=
It is said that the scheduled stop time of 1 day = 24 hours) is 200 minutes, and the deduction facility processing capacity is 1240 minutes. Similarly, for the total of four facilities from M-1 to M-4 , Scheduled stop time and facility processing capacity are stored respectively.

[0044]

[Table 4]

The judgment order storage unit 2e stores the order in which each of a plurality of lots is judged regarding the selection by the production judgment unit 8 which will be described later. Table 5 shows the judgment order storage unit 2e.
A specific example of the stored contents of In the example shown in Table 5, it is assumed that the judgment order of the lot 14 is 1, and the judgment order of the lot 15 is 2. In the same manner, the lot 1 to the lot 15 are
For all five lots, one of the judgment orders from 1 to 15 is stored in association with each other. As described above, the priority (determination order) stored in the determination order storage unit 2e is determined based on the priority stored in the macro plan storage unit 2c. As a result, the lot relating to the combination of the product type and the process having a high priority is selected by the production determination unit 8 in preference to other lots. The priority stored in the determination order storage unit 2e may be determined based on the priority for each lot, the delivery date, or a combination thereof.

[0046]

[Table 5]

The allocating unit 3 determines the load of each of the 15 lots to be allocated by the production judging unit 8 among the one or a plurality of facilities stored in the process information storage unit 2b. One lot is assigned step by step to one or a plurality of facilities capable of performing the process related to the same product type and process combination as the lot. When the allocation is performed by the allocation unit 3, the lot number related to the allocation is stored in the production lot storage unit 4. afterwards,
Regarding the lot numbers stored in the production lot storage unit 4, the SA (simulated annealing) method or G
By using a combinatorial optimization algorithm such as the A (Genetic Algorithm) method, it is possible to create a production schedule that maximizes productivity in the neck process.

The equipment load information storage unit 5 uses the processing time in the equipment for each combination of product type and process stored in the process information storage unit 2b to perform the total processing in each equipment in each allocation stage by the allocation unit 3. Remember the time. For example, as shown in FIG. 3, three steps (step 3, step 1)
3, the process 23), four equipments in the equipment group X (equipment M-1)
~ M-4) is used, four installations M-1 ~
For each of M-4, the total processing time in the equipment is stored in the equipment load information storage unit 5 (see FIGS. 5 and 8).

The production information storage unit 6 is the product information storage unit 2a.
Based on the quantity to be processed in each lot stored in, the planned processing quantity for each combination of product type and process in each allocation stage by the allocation unit 3 is stored. For example, Table 2
As shown in FIG. 3, the process information storage unit 2 indicates processable equipment names for each of a total of nine combinations of three types and three processes.
When stored in b, the planned processing quantity of each of the nine combinations is stored in the production information storage unit 6 (see FIGS. 6 and 9).

The updating unit 7 updates the stored contents of the equipment load information storage unit 5 and the production information storage unit 6 every time the load related to the lot is allocated to each equipment by the allocation unit 3. As a result, the storage contents of the equipment load information storage unit 5 and the production information storage unit 6 are always maintained to reflect the latest allocation result by the allocation unit 3.

The production judging unit 8 determines that the total processing time of each facility stored in the facility load information storage unit 5 is the facility capacity storage unit 2d.
The planned processing quantity for each combination stored in the production information storage unit 6 is kept within the planning target period stored in the macro planning storage unit 2c as much as possible while not exceeding the processing capacity of the facility stored in. From the plurality of lots picked up one by one, the lots to be assigned by the assigning unit 3 are selected so that the minimum number to be processed is reached.
Then, with respect to the thus selected ones, the allocation unit 3 allocates the lot numbers to the production target lot storage unit 4, and the storage contents of the equipment load information storage unit 5 and the production information storage unit 6 are initialized. After the production is done, the production judgment unit 8
Is a combination stored in the production information storage unit 6 while preventing the total processing time of each facility stored in the facility load information storage unit 5 from exceeding the processing capacity of the facility stored in the facility capacity storage unit 2d. Allocation by the allocator 3 from a plurality of lots picked up one by one such that the planned processing quantity for each is as much as possible to be equal to or more than the maximum number to be processed within the planning period stored in the macro plan storage 2c. Select what you want.

Production planning apparatus 1 shown in FIG.
Is configured by an information processing device such as a general-purpose personal computer. The information processing device contains hardware such as a CPU, a ROM, a RAM, a hard disk, and a drive device for an FD or a CD.
A production plan creation program for causing the information processing apparatus to function as the production plan creation apparatus 1 is stored in the hard disk (this program is stored in a removable recording medium such as a CD-ROM, FD, MO, etc. , Which can be installed on a computer). Then, the above-mentioned respective units 2 to 8 are constructed by combining these hardware and software.

Next, a production plan preparation process using the production plan preparation apparatus 1 according to the present embodiment will be described along the examples shown in Tables 1 to 5 with further reference to FIGS. 4 to 10. . FIG. 4 is a flow chart depicting a procedure for creating a production plan using the production plan creation device 1 shown in FIG. FIG. 5 is a schematic diagram illustrating the final stored contents of the equipment load information storage unit 5 when the required amount is the minimum number.
FIG. 6 is a schematic diagram illustrating the final storage content of the production information storage unit 6 when the required amount is the minimum number. Figure 7
It is a schematic diagram which shows the lot selected by the production determination part 8 and the lot which was not selected when the required quantity was made into the minimum number. FIG. 8 is a schematic diagram illustrating the final stored contents of the equipment load information storage unit 5 when the required amount is the maximum number.
FIG. 9 is a schematic diagram illustrating the final stored contents of the production information storage unit 6 when the required amount is the maximum number. Figure 10
FIG. 4 is a schematic diagram showing lots selected by the production determination unit 8 and lots not selected when the required quantity is the maximum number.

First, in step S1, the minimum number (lower limit value) of the maximum number and the minimum number for each combination of product type and process stored in the macro plan storage unit 2c is set as a required amount for each combination. . For example,
In the examples shown in Tables 1 to 5, as can be seen from Table 3, the required amount is set to 0 in the case of the type A in the step 3, and the required amount is 3 in the case of the type A in the step 13. Is set to.

Next, in step S2, one lot having the smallest determination order (lot having the highest priority) stored in the determination order storage unit 2e among the lots not yet picked up in this step is picked up. It Hereinafter, the lot picked up in step S2 is referred to as lot L. For example, in the examples shown in Tables 1 to 5, as can be seen from Table 5, 15 lots are sequentially picked up in the order of lot 14, lot 15, lot 6, ....

In step S3, the planned processing quantity stored in the production information storage unit 6 for the combination of the product type and the process corresponding to the lot L has already exceeded the minimum number set in the macro plan storage unit 2c for the combination. The production determination unit 8 determines whether or not it is. As a result, when the planned processing quantity is not more than the minimum quantity (S3: YES), the process proceeds to step S4. On the other hand, if the planned processing quantity is greater than or equal to the minimum quantity (S3: N
O), it is determined that it is not selected as an allocation target, and the process proceeds to step S8.

In step S4, the number of equipments having a sufficient processing capacity (that is, equipments that can be used at present) among the equipments that can perform the processing relating to the combination of the product type and the process corresponding to the lot L Is calculated by the production determination unit 8. Specifically, with respect to each of one or a plurality of equipments capable of performing the processing related to the combination stored in the process information storage portion 2b, the storage contents of the equipment load information storage portion 5 are investigated to determine the processing capacity. It is determined whether or not the capacity has been reached, and the number of equipment that has not reached the processing capacity is obtained. At this time, it is not determined that the capacity of the piled equipment exceeds the residual processing capacity because the processing capacity has a margin.

A more specific process in step S4 will be described. (A) First, as the initial value of the set ΩL of equipment capable of performing processing relating to the lot L, the set of usable equipment listed in Table 2 stored in the process information storage unit 2b is registered, and the processing is performed. As the initial value of the possible equipment number ML, the number of equipment belonging to the set ΩL is registered. For example, in the examples shown in Tables 1 to 5, when the lot L is the lot 14 (process 23, product type C), ΩL = {M-3, M-4} and ML = 2. (B) The load on one piece of equipment is defined as PL = (processing time of lot A in equipment A) / ML. That is, it is assumed that the load PL is piled up for all the equipment included in ΩL. For example, in the examples shown in Tables 1 to 5, when the lot L is the lot 14 (process 23, product type C), as can be seen from Tables 1 and 2, PL = (120 minutes × 4 pieces) / 2 Stand = 240 minutes. (C) At this time, if the load PL piled up in all the equipment in ΩL is less than or equal to the residual processing capacity of each equipment, the initial value of ΩL is set as the set of equipment that can process lot L, and ML is set. The initial value of is the number of facilities that can process lot L. At this time, PL calculated in (b) is used as the load for one piece of equipment. (D) On the other hand, if there is equipment with a piled load PL exceeding the residual processing capacity, a set obtained by deleting that equipment from the initial value of ΩL is set as a set ΩL of equipment capable of processing lot L, and the initial ML is set. The number of facilities M that can process the lot L is obtained by subtracting the number of facilities deleted from the value.
Let be L. At this time, as the load on one piece of equipment, PL is newly calculated from the same formula as that calculated in (b) using the changed ML.

Then, in step S5, step S4
The production determination unit 8 determines whether or not the number of equipments capable of processing the lot L (the number of equipments having a sufficient processing capacity) ML calculated in step 1 is 1 or more. As a result, if ML ≧ 1 (S5: YES), it is determined to select as an allocation target, and the process proceeds to step S6. on the other hand,
If ML = 0 (S5: NO), it is determined that it is not selected as an allocation target, and the process proceeds to step S8.

In step S6, the allocation unit 3 allocates the load related to the lot of the lot L, which is the allocation target by the production determination unit 8, to the equipment that can be used in Step S4. It is stored in the production lot storage unit 4.

Then, in step S7, step S6
The updating unit 7 updates the storage contents of the equipment load information storage unit 5 and the production information storage unit 6 based on the allocation result in step S1. That is, the loads PL are evenly piled up in each usable facility. For example, in the examples shown in Tables 1 to 5, the lot L targeted for allocation is the lot 14 (process 23, product type C).
If it is, as shown in FIG. 5, the equipment load information storage unit 5
24 in the load storage area related to the equipment M-3 and the equipment M-4.
0 minute load is added respectively. At the same time, as shown in FIG. 6, four planned processing quantities are added to the planned processing quantity storage area related to the combination of the process 23 and the product type C in the production information storage section 6. In addition, the vertical line filled in each device column in FIG. 5 and FIG. 8 indicates the processing capacity of each facility stored in the facility capacity storage unit 2d, and in FIG. 6 and FIG. The horizontal line entered in each combination column indicates the required amount (here, the minimum number or the maximum number) set in the macro plan storage unit 2c.

Next, in step S8, it is determined whether or not all lots to be processed are picked up and subjected to the determination regarding the selection of the allocation target by the production determination unit 8. As a result, if it is determined that all lots have been picked up (S8: YES), step S9
Proceed to.

At this time, if the minimum number is set as the required amount in the macro plan storage unit 2c, the stored contents of the equipment load information storage unit 5 and the production information storage unit 6 are as shown in FIGS. 5 and 6, respectively. Has become. Similarly, if the maximum number is set as the required amount in the macro plan storage unit 2c,
The storage contents of the equipment load information storage unit 5 and the production information storage unit 6 are as shown in FIGS. 8 and 9, respectively. As can be seen from these drawings, according to the present embodiment, the production determination unit 8 selects only some of the lots as the allocation targets as described above, instead of selecting all the lots as allocation targets. Therefore (see FIG. 7 and FIG. 10), it is possible to process the quantity greater than the required quantity while keeping the load assigned to each equipment below the processing capacity of each equipment.

In the above-mentioned example, when the minimum quantity is set as the required quantity, as is clear from FIG.
1, 3, 4, 12, 13, 9, 10 are not selected. For example, the lot 8 is not selected because the lot 7 having the same product type and the same process and a high priority is selected first, and the minimum number 4 of the combination of the product type C has already been reached in the process 13.

When the maximum quantity is set as the required quantity, as is apparent from FIG. 10, lots 3, 13, and 9 are set.
Is not selected. Regarding lots 3 and 13, lots 3 and 13 are respectively selected by first selecting lots having the same type and process and having a high priority (lot 2 for lot 3, lots 11 and 12 for lot 13). Not selected because the product type and process have already reached the maximum number for the same combination. For lot 9,
Although the required amount for each combination of product type and process was not reached at the time of picking up, if lot 9 is selected, it will not be selected because it exceeds the processing capacity of the facility.
Lot 10 that has the same combination of product type and process as Lot 9
Is selected as an allocation target although it was picked up after lot 9. This is because the lot 10 has a smaller number of pieces to be processed and a shorter processing time than the lot 9, so that the processing capacity of the equipments M-1 and M-2 capable of processing the lot 10 is within the range. Lot 1
This is because the load of 0 has subsided.

If it is determined in step S8 that there is a lot that has not been picked up yet (S8).
8: NO), returning to step S2, the same processing as described above is repeatedly performed.

In step S9, the macro plan storage unit 2c
Two types of requirement stored in (minimum number and maximum number)
It is determined whether the allocation has been completed for. When it is determined that the allocation is completed (S9: YE
S), the production planning procedure is ended. On the other hand, if it is determined that the allocation has not been completed (S9: NO), that is, if the allocation has not been performed when the required amount is the maximum number, the process proceeds to step S10.

In step S10, the macro plan storage unit 2
Among the maximum number and minimum number for each combination of product type and process stored in c, the maximum number (upper limit value) is set as the required amount for each combination. For example, Table 1
~ In the example shown in Table 5, as can be seen from Table 3, step 3
In case of product type A, the required quantity is set to 3 and the process 13
In the case of the type A, the required quantity is set to 3. Then, after the stored contents of the equipment load information storage unit 5 and the production information storage unit 6 are cleared, the process returns to step S2 and the same processing is repeated.

As a result of performing such processing, the lot numbers to be assigned can be stored in the production lot storage unit 4 for the two types of required quantities, the maximum quantity and the minimum quantity. After that, as described above, by using the combination optimization algorithm, it is possible to create a production plan that maximizes the productivity in the neck process. Although the production plan creation procedure has been described here focusing on the neck process, the same procedure may be performed for processes other than the neck process.

As described above, the following advantages can be obtained by the production plan creation device 1 according to this embodiment. (1) While comparing the processing capacity of the equipment and the load assigned to the equipment, the lot to be processed is determined so that the planned quantity to be processed for each combination of product type and process is the required quantity set in the macro plan or more. Therefore, the load on the equipment and
It is possible to create a production plan that balances the processing amount balance for each combination of product type and process. (2) It is possible to create a production plan that balances the load on the equipment and the balance of the processing amount for each combination of the product type and the process even when a large number of products are produced by the equipment shared by a plurality of processes. It will be possible. (3) Since the idle period within the planning period is taken into consideration as the processing capacity of the equipment, it is possible to create an appropriate production plan that reflects the scheduled stoppage due to regular maintenance or meal breaks. (4) The production determination unit 8 according to the high priority for each combination of product type and process stored in the macro plan storage unit 2c.
The order of lots picked up in is decided. Therefore, there is a high possibility that a lot related to a combination of a product type and a process having a high priority is selected before being picked up from a lot related to another combination. Therefore, even if the load required for all lots exceeds the processing capacity of the entire equipment within the planned period, it is based on the priority that considers the production progress status for each product type and the load status for each process. It is possible to create a production plan. (5) The load PL, which is obtained by dividing the total processing time of a lot by the number of facilities that can process the lot, is allocated to one or a plurality of facilities substantially evenly. Load can be assigned. Further, for example, even when there is an alternative facility, it is possible to accurately stack a load on each facility. (6) First, a lot to be allocated is selected based on the minimum required quantity set in the macro plan, and then a lot to be allocated is selected based on the minimum required quantity. Therefore, for each combination of product type and process,
If a minimum processing amount is secured and the processing capacity of the equipment has a margin, a lot can be selected within the maximum required number.

As a result, in a production line in which loads associated with a plurality of lots are assigned to any of a plurality of facilities for processing, when the lots to be processed within the planning period are determined, the production line targeted especially However, (i) is a repetitive process in which the same equipment is shared by a plurality of processes, (ii) there are a wide variety of target product types, and the devices and processing times that can be used vary depending on the process and product type, and / or (iii) Even in a complicated situation where the scheduled stop time differs for each equipment, load leveling and ensuring the balance of processing amount for each product type and process combination within the scope of equipment capacity It is possible to select a lot to be processed while satisfying both. The production plan creation device 1 according to the present embodiment can be applied to various fields such as manufacturing of semiconductor devices and rolling of copper and aluminum.

Although the preferred embodiments of the present invention have been described above, the present invention is not limited to the above-described embodiments, and various design changes are possible within the scope of the claims. Is. For example, in the above-described embodiment, in step S3 of FIG. 4, it is determined whether or not the planned processing quantity is equal to or more than the minimum number (or maximum number) based on the planned processing quantity before allocation of the load related to the lot. Alternatively, the determination may be made based on the planned processing quantity after allocation. Further, the macro plan storage unit 2c stores two types of quantities, a minimum quantity and a maximum quantity, and an intermediate value thereof.
You may have more than two types of quantities to process, 1
It may have a quantity to be processed of a type.

The production plan creating apparatus 1 of the above-mentioned embodiment has the judgment order storage unit 2e, and the lot is picked up according to the priority stored therein, but the judgment order storage unit is not always necessary. Alternatively, lots may be randomly picked up. Further, in the production plan creation device 1 of the above-described embodiment, the macro plan storage unit 2c stores the quantity to be processed for each combination of product type and process, but it is processed not for each combination but for each product type or process. The quantity to be stored may be stored. Further, the processing capacity of each facility stored in the facility capacity storage unit 2d may be the planned time itself, not the time obtained by subtracting the scheduled stop time. Further, the allocator 3 does not have to equally allocate the load to a plurality of usable equipments. For example, a large load may be applied to a part of the equipments and a small load may be applied to the remaining equipments. You may give it. Further, the above-described embodiment relates to the repeating process in which the equipment is shared by a plurality of processes, but the present invention can be applied to processes other than the repeating process.

[0074]

As described above, according to the present invention,
Even if the required load of all lots that are processing candidates exceeds the processing capacity of the entire equipment within the specified period,
It becomes possible to create an appropriate production plan in which the loads related to the lots allocated to each facility are substantially leveled while considering the processing capacity of each facility. Further, when the production judging means selects a lot to be assigned to each equipment by the allocating means from a plurality of lots, it becomes possible to select a lot in consideration of the balance for each combination of product type and process. Therefore, it becomes possible to create a production plan in consideration of the balance of the processing amount for each product type and the processing amount for each process.

[Brief description of drawings]

FIG. 1 is a block diagram of a production plan creation device according to an embodiment of the present invention.

FIG. 2 is a process diagram of a product produced by the production plan creating apparatus shown in FIG.

FIG. 3 is a schematic diagram for explaining a repeating process in which equipment is shared by a plurality of processes.

FIG. 4 is a flowchart illustrating a procedure for creating a production plan using the production plan creation device shown in FIG.

FIG. 5 is a schematic diagram illustrating the final stored contents of the equipment load information storage unit illustrated in FIG. 1 when the required amount is the minimum number.

FIG. 6 is a schematic diagram illustrating the final stored contents of the production information storage unit illustrated in FIG. 1 when the required amount is the minimum number.

FIG. 7 is a schematic diagram showing lots selected and not selected by the production determination unit shown in FIG. 1 when the required quantity is the minimum number.

FIG. 8 is a schematic diagram illustrating the final stored contents of the equipment load information storage unit illustrated in FIG. 1 when the required amount is the maximum number.

FIG. 9 is a schematic diagram illustrating the final storage content of the production information storage unit illustrated in FIG. 1 when the required amount is the maximum number.

10 is a schematic diagram showing lots selected and not selected by the production determination unit shown in FIG. 1 when the required quantity is the maximum number.

[Explanation of symbols] 1 Production planning device 2 Basic information storage 2a Product information storage unit (product information storage means) 2b Process information storage unit (process information storage means) 2c Macro plan storage unit (macro plan storage means) 2d Equipment capacity storage unit (equipment capacity storage means) 2e Judgment order storage unit (judgment order storage means) 3 Allocation unit (allocation means) 4 Production target lot storage 5 Equipment load information storage unit (equipment load information storage means) 6 Production information storage unit (production information storage means) 7 Update unit (update means) 8 Production judgment section (production judgment means)

Claims (18)

[Claims] 1. A product information storage unit for storing the quantity processed in each of a plurality of lots identified by a combination of product types and processes for a plurality of products manufactured through a plurality of processes, and a plurality of product information storage units. Process information storage means for storing, for each product type and process combination of the product, one or more facility names capable of performing the process relating to the combination and the processing time at the facility, within a predetermined period. Macro plan storage means for storing the quantity to be processed for each product type, equipment capacity storage means for storing the processing capacity of each equipment within the predetermined period, and load for each of the plurality of lots. , One or more of the one or more facilities stored in the process information storage means capable of performing a process relating to the same product type and process combination as the lot Assigning means for stepwise assigning one lot to the equipment, and each equipment in each assigning step by the assigning means based on the processing time in the equipment for each combination stored in the process information storage means. Of equipment load information storage means for storing the total processing time, and based on the quantity processed in each of the lots stored in the product information storage means, for each of the combinations in each allocation step by the allocation means. Production information storage means for storing a planned processing quantity; update means for updating the storage contents of the equipment load information storage means and the production information storage means every time the lot is assigned by the assignment means, The total processing time of each facility stored in the facility load information storage means and the total processing time stored in the facility capacity storage means. While comparing the processing capacity of the facility, the planned processing quantity for each combination stored in the production information storage means is stored in the macro plan storage means and used as a reference for the quantity to be processed within the predetermined period. A production plan creating apparatus comprising: a production determining unit for selecting a lot to be assigned by the assigning unit from a plurality of lots so as to satisfy the requirement. 2. The production according to claim 1, further comprising a judgment order storage unit for storing an order in which each of the plurality of lots is judged with respect to selection by the production judgment unit. Planning device. 3. The method according to claim 2, wherein the order stored in the judgment order storage means is determined according to the high priority of each product type stored in the macro plan storage means. Production planning device. 4. The production plan creating apparatus according to claim 1, wherein the macro plan storing means stores the quantity to be processed within the predetermined period for each process. 5. The processing capacity of each equipment within the predetermined period stored in the equipment capacity storage means is a time obtained by subtracting a scheduled stop time of the equipment from the predetermined period. The production plan creation device according to any one of 1 to 4. 6. The allocating means substantially equalizes the load on each of the plurality of lots to one or a plurality of the facilities capable of performing a process related to the same product type and process combination as the lot. 6. The production plan creation device according to claim 1, wherein the production plan creation device is assigned to. 7. The production judging means is provided with a plurality of processing units so that the total processing time of each piece of equipment stored in the equipment load information storage means does not exceed the processing capacity of the equipment stored in the equipment capacity storage means. 7. The production plan creation device according to claim 1, wherein a lot to be assigned by the assigning means is selected from the lots. 8. The predetermined period during which the planned production quantity stored in the production information storage means is stored in the macro plan storage means for the combination of the same product type and process as the lot related to the selection decision. The production planning apparatus according to any one of claims 1 to 7, wherein the lot is not selected as an allocation target by the allocation unit when the quantity to be processed is already exceeded. 9. The macro plan storage means stores a plurality of types of quantities to be processed within the predetermined period for each product type, and the production determination means stores a plurality of the lots for the plurality of kinds of quantities. 9. The production plan creation device according to claim 1, wherein items to be assigned by the assigning means are sequentially selected from among the items. 10. A product information storage means for storing the quantity processed in each of a plurality of lots identified by a combination of product types and processes for a plurality of products manufactured through a plurality of processes, For each combination of product type and process for a product, process information storage means for storing the name of one or more equipments capable of performing the processing related to the combination and the processing time at the equipment, and processing within a predetermined period. Macro plan storage means for storing the required quantity for each product type, equipment capacity storage means for storing the processing capacity of each equipment within the predetermined period, load related to each of the plurality of lots, the process information One or more of the one or more of the equipment stored in the storage means capable of performing processing relating to the same product type and process combination as the lot Allocating means for allocating one lot to the equipment step by step, based on the processing time in the equipment for each combination stored in the process information storage means, total processing of each equipment in each allocating step by the allocating means Facility load information storage means for storing time, based on the quantity processed in each of the lots stored in the product information storage means, the planned processing quantity for each combination in each allocation step by the allocation means Production information storage means for storing, updating means for updating the storage contents of the equipment load information storage means and the production information storage means each time the lot is allocated by the allocation means, and the equipment load information The total processing time of each equipment stored in the storage means and the total processing time of the equipment stored in the equipment capacity storage means. While comparing the processing capacity of the equipment, the planned processing quantity for each of the combinations stored in the production information storage means satisfies the standard concerning the quantity to be processed within the predetermined period stored in the macro plan storage means. A program for creating a production plan for causing a computer to function as production determining means for selecting one of a plurality of lots to be assigned by the assigning means. 11. The computer according to claim 10, further comprising a determination order storage unit for storing an order in which each of the plurality of lots is determined with respect to selection by the production determination unit. Production planning program. 12. The order stored in the judgment order storage means is determined according to the high priority of each product type stored in the macro plan storage means. Production planning device. 13. The production plan creation program according to claim 10, wherein the macro plan storage means stores the quantity to be processed within the predetermined period for each process. 14. The processing capacity of each equipment within the predetermined period stored in the equipment capacity storage means is a time obtained by subtracting a scheduled stop time of the equipment from the predetermined period. The production plan creation program according to any one of 10 to 13. 15. The allocating means substantially equalizes the load on each of the plurality of lots to one or a plurality of the facilities capable of performing a process related to the same product type and process combination as the lot. The production plan creation program according to any one of claims 10 to 14, wherein the production plan creation program is assigned to. 16. The production determining means is configured to prevent the total processing time of each equipment stored in the equipment load information storage means from exceeding the processing capacity of the equipment stored in the equipment capacity storage means. 16. The production plan creating program according to claim 10, wherein a lot to be assigned by the assigning means is selected from the lots. 17. The predetermined period during which the production decision means stores the planned processing quantity stored in the production information storage means for the combination of the same product type and process as the lot related to the selection decision in the macro plan storage means. The production plan creating program according to any one of claims 10 to 16, wherein the lot is not selected as an allocation target by the allocation means when the quantity to be processed is already exceeded. 18. The macro plan storing means stores a plurality of types of quantities to be processed within the predetermined period for each product type, and the production judging means stores a plurality of lots for a plurality of kinds of quantities. 18. From among the above, the objects to be assigned by the assigning means are sequentially selected.
The program for producing a production plan according to any one of 1.