JP2003316415A - Production plan change support method and its system - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a production plan change support method and its system which can cope with change of a plan at occurrence of abnormality and trouble and also can prepare a replan automatically. <P>SOLUTION: The system 10 which supports change of a production plan in case where a part of production facilities halt due to the occurrence of trouble or abnormality when a production line is automatically running based on the schedule data of the production plan prepared, in accordance with the demand for production of various kinds of products, is provided with a production lot classification means 6 to classify producible production lots based on a given evaluation conditions, a production lot display means 7 for displaying the classified production lots indicating the bases of the evaluation by every class, a production lot selection/edit means 8 for selecting the production lot desired to be incorporated in the replan from the production lots classified by evaluation conditions and for editing the production lot when the change of components in the production lot given in advance, and a schedule preparation means 9 for preparing the replan thereby. <P>COPYRIGHT: (C)2004,JPO

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a trouble or abnormality occurring in a production line or a product during the automatic production of products of various kinds through a plurality of manufacturing processes. The present invention relates to a production plan change support method and system for changing a product when an abnormality occurs and replanning a production schedule.

[0002]

2. Description of the Related Art A steelmaking production plan is designed to improve productivity, reduce manufacturing costs, and manufacture high-quality products in order to achieve delivery of production lots, restrictions on processing in each process, and composition and amount of steel types in production lots. Based on process constraints that depend on
An expert determines the timing of processing by trial and error. That is, in the conventional production planning, a skilled person in planning determines the order of manufacturing so as to satisfy the delivery date while observing the constraint condition in planning. However, as the needs of customers and the number of high-quality products increase, the types of steel types manufactured increase, and the load on planners also increases. For this reason, it is not always possible to say that the optimality of the prepared plan is sufficient, because it is often the case that attention is paid to satisfying various constraints when formulating the plan. . Therefore, a method has been proposed in which a plan is automatically created based on schedule data and the optimality thereof is realized.

For example, Japanese Unexamined Patent Publication No. 2000-315109 proposes a manufacturing schedule in which time information of casting sets is determined in succession so as to satisfy the constraint conditions of manufacturing equipment and manufacturing lot. In another example, Japanese Patent Laid-Open No. 2000-
In Japanese Patent No. 317777, a manufacturing schedule is proposed in which manufacturing lots are classified into groups according to manufacturing constraints, and manufacturing lots are extracted from groups satisfying the manufacturing constraints to determine a manufacturing order. .

[0004]

However, the above-mentioned prior art proposes a method of automatic planning in an operating state under the condition that there is no trouble in normal equipment. Therefore, in the middle of operating according to the planned manufacturing schedule, if an abnormality or trouble of the equipment or the product occurs, and the situation that the operation cannot be performed as planned occurs, the manufacturing method according to the above-mentioned conventional technique is used. It is impossible to deal with the plan change, and it is impossible to automatically formulate the manufacturing plan after the occurrence of an abnormality or trouble.
In other words, the above-mentioned conventional method does not have a function of changing the contents of a schedule once planned from the middle, and automatically and continuously creating a plan again after the past results and the work-in-process plan are revised.

Therefore, an object of the present invention is to provide a production plan change support method and system capable of coping with a plan change when an abnormality or trouble occurs and automatically preparing a re-plan. And

[0006]

A production plan change support method according to the present invention automatically operates a production line on the basis of schedule data of a production plan created in response to a production request of a wide variety of products. Is a method to support the change of production plan when some manufacturing equipment is shut down due to trouble or abnormality, and classifies the manufacturable lots based on the given evaluation conditions, From the production lots classified according to the evaluation conditions, select the production lot that you want to include in the re-planning, and edit the production lot if you need to change the components in the given production lot. It is characterized by causing a computer to execute a replan.

The production plan change support method of the present invention is
The feature is that the classified production lots are displayed by showing the basis of evaluation for each classification.

Further, the production plan change support system of the present invention for carrying out the above-mentioned production plan change support method is a production line based on the schedule data of the production plan created in response to the production demand of a wide variety of products. It is a system that supports the change of the production plan when some of the manufacturing equipment is stopped due to trouble or abnormalities when operating automatically, and can be manufactured based on the given evaluation conditions. Manufacturing lot classification means for classifying manufacturing lots, manufacturing lot display means for displaying classified manufacturing lots by showing the basis of evaluation for each classification, and incorporating into re-planning from manufacturing lots classified for each evaluation condition Manufacturing lot selection / editing means for selecting a desired manufacturing lot, and editing the manufacturing lot when it is necessary to change the components in the manufacturing lot given in advance And it is characterized by comprising: a schedule creating means for creating a re-planning thereby.

Each means in the present invention has the following actions.

(1) Manufacturing lot classification means If an equipment that cannot be processed occurs due to an abnormality or trouble, it can be manufactured by other equipment even during trouble depending on the evaluation conditions based on the information of the equipment that cannot be used. Evaluate manufacturing lots and manufacturing lots to prevent production volume reduction due to troubles. Then, the production lots that must be processed by the unusable equipment and the production lots that can be processed by the operating equipment are classified. Also, in order to prevent the production volume from decreasing due to the generation of unusable equipment, we evaluate the production lots that can be produced with the operating equipment and the production lots that are advantageous for maintaining the production volume and those that are not.

(2) Manufacturing lot display means In order to facilitate rescheduling after trouble has occurred, manufacturing lots classified according to the evaluation conditions are displayed with the grounds for evaluation shown for each classification.

(3) Manufacturing lot selection / editing means A manufacturing lot to be incorporated in the rescheduling is selected from the manufacturing lots classified according to the evaluation conditions. Also, if you want to select a production lot based on evaluation items that cannot be classified under the evaluation conditions (for example, delivery date, downstream process supply and demand), the operator who formulates the schedule evaluates and selects the production lot that you want to incorporate into the reschedule formulation. To do. Further, in order to maintain the production amount, or due to the delivery date and the supply-demand relationship of the lower process, the editing is performed so that the constituent elements in the given manufacturing lot can be changed.

(4) Schedule creating means Based on the classified manufacturing lots, the manufacturing lots for re-scheduling after manufacturing or after the setting of work-in-process due to a trouble are used to set operational constraint conditions. Automatically create a satisfying plan.

[0014]

BEST MODE FOR CARRYING OUT THE INVENTION Embodiments of the present invention will be described below with reference to the drawings. FIG. 1 is a configuration diagram of a production plan change support system showing an example of an embodiment of the present invention. The system 10 is linked to the production plant 1, the production line management unit 2, and the manufacturing order planning unit 3, and is composed of a manufacturing material source / equipment operation status storage unit 4, an in-process lot processing unit 5, and a manufacturing lot classification. It comprises a means 6, a manufacturing lot display means 7, a manufacturing lot selecting / editing means 8 and a schedule creating means 9. Specifically, it is composed of a network connecting computers. In the figure, 11 is an input unit, 12
Is a display unit.

The production order of various products (for example, continuous casting set) to be produced according to requirements is planned based on a given material source (for example, steel type and production amount in converter). Created in Part 3. For the production plan created by the manufacturing sequence planning unit 3, for example, a plan for one day the following day is prepared on the previous day. The planning information created by the manufacturing order planning unit 3 does not include the operating time / inactivity information of the equipment required in the manufacturing order, the material that specifies the manufacturing time, or the planned material source, and the manufacturing time information is not added. It also has information such as the source of the material. Then, the plan information created by the manufacturing order planning unit 3 is sent to the production line management unit 2. In the production factory 1, the production lines are operated in the manufacturing order based on the production line management information sent from the production line management unit 2. In this way, normal automatic production is carried out according to the manufacturing order. Also,
The schedule data created by the manufacturing order planning unit 3 is sent to and stored in the manufacturing material source / facility operating status storage unit 4.

If any trouble occurs in the above-mentioned production line in operation, depending on the degree of the trouble, the schedule established by the manufacturing sequence planning unit 3 on the previous day is reviewed, and the trouble occurs from the point where the trouble occurs to the subsequent time. It becomes necessary to formulate the production plan again while considering the production conditions on the production line. Here, in the production line, due to a trouble of the production line or an abnormality of the product, for example, it is necessary to perform in-process processing of the product in the middle of production or scheduled to be produced or substitute processing with another product. When it occurs, it is processed as follows.

FIG. 2 is a flow chart showing the procedure for changing the already established production plan. The processing procedure will be described below with reference to FIGS. 1 and 2.

(Step S1): When a trouble or abnormality of the production line occurs, information on the product subject to the trouble or abnormality can be obtained from the production factory 1 by the production line management unit 2
Then, the production line management section 2 transfers it to the manufacturing order management section 3. Also, the production plan change support system 1
In 0, the trouble information is input from the input unit 11 to the in-process lot processing means 5. From the trouble information, the situation (lot number, manufacturing progress status, etc.) of the product (hereinafter referred to as trouble product) that is the subject of the trouble or abnormality, or if there are products that are being manufactured in parallel at the same time, The production line management unit 2 confirms the status (lot number, manufacturing progress status, etc.) of the product (work-in-process), and the work-in-process information is sent to the manufacturing order management unit 3.

(Step S2): In the manufacturing order management unit 3,
The operator determines the processing method of the in-process material from the preparation of the material source of the substitute product and the progress of manufacturing the troubled product, and determines the processing step of the in-process material. Data necessary for the work-in-process processing process (work-in-process lot number, work-in-process manufacturing equipment number, etc.) are input to the work-in-process material processing unit 5 from the input unit 11 and the manufacturing material source / facility operating status storage unit 4 in FIG. It should be noted that the display unit 1 is used for input instructions to each means in FIG. 1 and confirmation of setting conditions.
Check in 2.

(Step S3): The procedure after step S3 is automatically performed, and the re-plan is automatically formulated. In other words, due to troubles or abnormalities, the input unit 1 stores information such as suspension information and work-in-progress information of manufacturing equipment whose manufacturing has been disabled.
1 and the manufacturing material source / facility operating status storage means 4 to the manufacturing lot classification means 6. Therefore, in step S3, the production lot classification means 6 classifies the materials necessary for reschedule and those not, based on the given evaluation conditions. Unmanufactured manufacturing lots when troubles or abnormalities occur are selected in the following priority order when manufacturing by rescheduling based on the evaluation conditions. 1) Priority is given to the production lot advantageous for maintaining the production amount. For example, a manufacturing lot that can easily manufacture many same lots in a short time with a passing process in manufacturing. 2) Next, a manufacturing lot with a small number of products per unit time, or an alternative manufacturing facility can be used. 3) Manufacturing lots with few passing steps in 3) The next is manufacturing possible but complicated manufacturing lots with various passing steps in manufacturing 4) Not selectable, that is, manufacturing lots that have to be processed in a suspended facility are selected Excluded from the target.

(Step S4): In order to facilitate the preparation of the re-schedule after the occurrence of trouble, the production lots classified by the evaluation conditions are evaluated by the production lot display means 7 (the above selection criteria 1) to 4 )) Is displayed on the display unit 12.

(Step S5): The production lot selecting / editing means 8 selects a production lot to be incorporated in the re-schedule formulation from the production lots classified according to the evaluation conditions. Also, if you want to select a production lot based on evaluation items that cannot be classified under the evaluation conditions (for example, delivery date, downstream process supply and demand), the operator who formulates the schedule evaluates and selects the production lot that you want to incorporate into the reschedule formulation. To do. In addition, the production lot is edited when it is necessary to change the components in the production lot given in advance in view of the maintenance of the production amount, the delivery date and the supply and demand relationship of the lower process.

(Step S6): In the schedule creating means 9, the work-in-process materials are arranged so that the already-manufactured products and the work-in-process materials in case of trouble are not replaced with other products and the manufacturing time is not changed. Automatically develop a plan for allocating product processes to non-disruptive and operational equipment.

[0024]

EXAMPLE FIG. 3 shows an example of a production plan for a product for one day. The horizontal axis represents time, and the vertical axis represents manufacturing equipment. LD indicates a converter equipment, RE1 to RE8 indicate secondary smelting equipment, and CC1 to CC4 indicate continuous casting equipment. As shown in FIG. 3, the hot metal tapped from the converter equipment (LD) has a secondary smelting equipment which passes from among a plurality of secondary smelting equipment (RE1 to RE8) depending on the product. After being processed in a predetermined secondary smelting facility, it is cast in any of continuous casting facilities (CC1 to CC4) depending on the shape and cross-sectional shape of the product. Moreover, the number attached to the casting start portion of each product (here, the continuous casting set) represents the serial number of the continuous casting set. For example, the serial number set for CC3 is M0.
It is 1.

In the plan of FIG. 3, continuous casting is maintained by adjusting the tapping timing of the converter and the start time of secondary smelting. A plan is established so that the casting of the next product starts at the end of casting of each product in the continuous casting facility. And again, Figure 3 shows that each product is manufactured at 12 pm
The example shows a case where CC2 continuous casting equipment has a trouble (circle mark) after the progress to 30 minutes, and CC2 cannot be manufactured. At this time, the finished products among the products and the products (work-in-process) which are started before the trouble occurs and are in the middle of manufacturing are as shown in FIG. These products are products whose troubles cannot be changed before and after the suppression, and when troubles occur, CC
The equipment of No. 2 becomes unusable.

The procedure here is the in-process lot processing means 5
In (step S2), the head of the M01 continuous casting set (manufacturing department) of the CC3 facility is already in the process of being manufactured, and it can be manufactured even after the trouble has occurred, so the manufacturing is performed as planned. C
Because the equipment of C2 cannot operate because of trouble,
Successive casting sets that can be manufactured by CC1 and CC3 and CC4 are selected by the manufacturing lot classification means 6 (step S3) based on the given evaluation conditions. Further, the production lot selection / editing means 7 (step S4) is used to change the components of the K02 continuous casting set (production lot) of the CC1 equipment to four.
Edit to change from 6 charges to 6 charges. In addition, the production lot K03 (CC
For 1) and K04 (CC1), a production lot of almost the same type was introduced from the production schedule of the next day or later,
Change to (CC1), K11 (CC1), M02 (CC3). FIG. 5 shows an example of a change plan in the case where the re-plan after the work-in-process material of FIG. 4 is automatically created based on the above result.

In the present embodiment, the preparation of a re-plan when a trouble or abnormality occurs has been described, but the present invention can be applied even when there is an urgent interrupt request for a product.

[0028]

As described above, according to the present invention, in a production line that is operating automatically, when a trouble or abnormality occurs, the planned production cannot be performed, so that the trouble or abnormality occurs. We changed the product when it occurred,
Manufacturing schedule re-planning can be created automatically.

[Brief description of drawings]

FIG. 1 is a schematic block configuration diagram of a production plan change support system showing an embodiment of the present invention.

FIG. 2 is a flowchart showing a procedure of a production plan change support method.

FIG. 3 is a diagram showing an example of a production plan for one day before a trouble occurs.

FIG. 4 is a diagram showing a setting result of actual products, work-in-process materials, and equipment suspension when a trouble occurs in the production plan of FIG.

FIG. 5 is a diagram showing an example of a change plan when a re-plan after a trouble occurs is automatically created.

[Explanation of symbols]

1 production plant 2 Production line management department 3 Manufacturing Order Planning Department 4 Manufacturing material source / equipment operation status storage means 5 In-process lot processing means 6 Manufacturing lot classification means 7 Manufacturing lot display means 8 Manufacturing lot selection / editing means 9 Schedule creation means 10 Production plan change support system 11 Input section 12 Display

Claims (3)

[Claims] 1. When a production line is automatically operated on the basis of schedule data of a production plan created in response to a production request of a wide variety of products, a part of the production is caused by trouble or abnormality. This is a method to support the change of the production plan when the equipment is stopped, and classifies the manufacturable lots that can be manufactured based on the given evaluation conditions, and re-plans from the production lots classified according to the evaluation conditions. It is characterized by selecting a manufacturing lot to be incorporated and, when it is necessary to change a component in a given manufacturing lot, editing the manufacturing lot, thereby causing a computer to execute a replan. Production plan change support method. 2. The production plan change support method according to claim 1, wherein the classified production lots are displayed by showing the basis of evaluation for each classification. 3. Partial production due to occurrence of trouble or abnormality when the production line is automatically operated based on the schedule data of the production plan created in response to the production request of a wide variety of products. This is a system that supports changes in production plans when equipment is shut down.Manufacturing lot classification means that classifies manufacturing lots that can be manufactured based on given evaluation conditions, and the classified manufacturing lots are evaluated for each classification. The production lot display means that shows and displays the basis of the above, and the production lot to be incorporated into the re-plan is selected from the production lots classified according to the evaluation conditions. A production lot selecting / editing means for editing a production lot when necessary, and a schedule creating means for creating a re-plan by that are provided. Production plan change support system.