JP2005092381A - Production planning system - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a production planning system by which the creation time of production schedule can be shortened and which can cope with demand fluctuation, even when the number of devices used for manufacturing and the number of manufactured varieties are many, and manufactured varieties repeatedly use a device, or a plurality of different varieties use the same device. <P>SOLUTION: In this system, operating ratio of each device is computed according to time bucket, based on order data including manufactured varieties, quantity and appointed date of delivery. And, the device with comparatively high operating ratio according to time bucket, i.e. the device with possibility of becoming bottleneck, is extracted from the operating ratio data of each device according to time bucket, and the production schedule is made based on the extracted device. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

  The present invention relates to a production planning system and a production planning method for creating a production plan.

  Conventionally, a product production plan requires a lot of time for calculation in a large-scale factory having a complicated process in which the same processing is repeatedly performed because the number of devices and processes used for production is large. There was a problem. In such a complex and large-scale factory, there is a technique as described in Patent Document 1, for example, as a production plan planning method and apparatus for quickly planning a production plan. This technology is used between the basic data required for production planning and planning of equipment layout in the production process, equipment capacity data related to the time required for processing in each equipment, and equipment that is continuously produced. Data on the time required to move the product from the production device in the next process to the production device in the next process, and allocation rule data that describes in which order of which device the product is assigned to each device group, and A detailed planning procedure for determining the production equipment and production time for a predetermined number of product lots from the basic data and process time data relating to the time required for production in each process. Using the transition calculation means to calculate and the detailed planning procedure described above, a procedure specified for each process is applied to create a production plan for the entire factory.

JP-A-11-320343

  For example, in semiconductor manufacturing, the number of devices and processes used for production is large, and not only the devices are repeatedly used in the production process, but also because there are many types of products to be manufactured, different types of products use a common device. . Since the equipment is used repeatedly and different kinds of equipment are used in common, in semiconductor manufacturing, etc., the usage status of the equipment changes from time to time depending on the order quantity for each kind produced, and the combination of the kinds, and this is a bottleneck. The device will change from time to time. In order to shorten the production plan creation time, it is necessary to extract the bottleneck device that reduces the production capacity of the line from the devices used for manufacturing and then calculate the production plan. . However, since the bottleneck device constantly fluctuates depending on the combination of the order quantity and the product type, it is difficult to specify the bottleneck device in advance.

  The present invention has been made in order to solve the above-mentioned problems, and the purpose of the present invention is to increase the number of devices used for manufacturing and the number of types to be manufactured. An object of the present invention is to shorten the production plan creation time even when different varieties use the same apparatus.

  In order to solve the above-described problems, the production planning system according to the present invention calculates the operation rate of each device for each time bucket based on order data including the type, quantity, and delivery date to be manufactured. Then, from the operation rate data of each device for each time bucket, a device having a relatively high operation rate for each time bucket, that is, a device that may become a bottleneck is extracted, and based on the extracted device A production plan is created.

  More specifically, order data (including at least the product type, order quantity, and delivery date) of each product to be produced, the equipment used for production of that product by product type, the order of use of the equipment during production, and the unit requirements for each device The storage means for storing the device usage data classified by product type for storing the processing time and the operable time data for each device in which the operable time for each time bucket is registered for each device, and the order stored in the storage means Calculate the time bucket that each order uses the device from the unit required processing time and the order of use of the device usage data by quantity and product type, and calculate the required processing time of each device that aggregates the required processing time of each device by time bucket. Device-specific operation rate data for each time bucket is calculated from the aggregate value and the device-specific operation time data, and is recorded in the storage means. A calculation means, a device having a high operation rate based on the device operation rate data, selecting a device using time bucket to create a device list for use by time bucket, and storing in a storage device, order data and device usage data by product type The production quantity that the required processing time of each device for each time bucket is less than or equal to the available time for each device is calculated from the device operational availability data and the device usage list for each time bucket. And a producible quantity calculating means to be stored in the storage means.

  According to the present invention, even when the number of devices used for manufacturing and the number of types to be manufactured are large, the types to be manufactured repeatedly use the device, or when multiple different types use the same device. Therefore, the production plan creation time can be shortened, and a production plan that can quickly respond to demand fluctuations can be created.

Hereinafter, an embodiment of a production planning system of the present invention will be described with reference to the drawings.
FIG. 1 is a functional block diagram showing the configuration of an embodiment of a production planning system of the present invention.
In the production planning system of the present invention, the operation rate of each device is calculated for each time bucket based on order data including the type, quantity, and delivery date to be manufactured. Then, a device having a relatively high operation rate for each time bucket, that is, a device that may become a bottleneck is extracted from the operation rate data of each device for each time bucket. A production plan is created based on the extracted device. Here, the time bucket is a unit period for setting a production amount of a product to be produced in the production plan.

  In the embodiment shown in FIG. 1, the production planning system 100 includes a storage unit 106 in which a device-specific device usage master 111 and a device-specific operation time master 112 are stored. This storage means 106 also stores device-by-device operating rate data, time-bucket-by-time-use device list, and order-by-order production-capable quantity data, which are data obtained by the respective means of the production planning system.

An example of the device usage master 111 by product type is shown in FIG.
The device usage master for each type stores the usage order of the devices used for manufacturing the products, the device ID of the device to be used, and the unit required processing time in that device. FIG. 4 shows an example of the device-specific device usage master data of the product type AAA. For example, the device ID in the use order 1 is M1 and the unit required processing time is 1.46 hours. The ID of the device in order 2 is M3, and data such as a unit required processing time of 2.84 hours is stored.

An example of the device-usable operation time master 112 is shown in FIG.
The device operable time master stores the time available for each time bucket in association with the device ID. In the example shown in FIG. 5, the operable time in the time bucket from May 11, 2003 to May 17, 2003 is 168 hours for the device whose device ID is M1, and the device whose device ID is M2 is operated in the same time bucket. Similarly, data is stored such that the possible time is 168 hours, the operable time in the time bucket from May 18, 2003 to May 24, 2003 for the device having the device ID M1 is 168 hours.

  The order data 110 is input data to the production planning system 100 of this embodiment, and is order data including the product type, quantity, and delivery date.

The production planning system 100 of this embodiment receives the order data 110 as input, and first calculates the device-specific operation rate data in the device-specific operation rate calculation means 101.
The device-specific operation rate calculating means 101 uses the order delivery date and the device usage order from the order delivery date based on the order quantity and delivery date of the order data 110 and the unit required processing time and use order of the device usage master 111 by product type. With reference to the processing time, a time bucket in which each order passes through the device to be used is obtained. For each time bucket, the required processing time is calculated by multiplying the quantity of the order by the unit required processing time, and totalized for each device. Subsequently, the total value of the required processing time for each device is divided by the device operable time for each time bucket of the device operable time master 112 to calculate the device operating rate data 113 for each time bucket, and the storage means 106. To record.
FIG. 6 shows an example of the operation rate data for each device.
As shown in FIG. 6, the operation rate data for each device stores data such as the operation rate for each time bucket in association with the device ID. In FIG. 6, for example, for the device with the device ID M1, the operation rate of the time bucket from May 11, 2003 to May 17, 2003 is 92.4%.

Next, the used device selecting unit 102 selects a device having a high operating rate for each time bucket from the operating rate data 113 for each device calculated by the operating rate calculating unit 101 for each device, and creates a used device list 114 for each time bucket. The device used by time bucket 114 is also stored in the storage unit 106.
As another example of the used device selection unit 102, when selecting a device having a high operation rate for each time bucket from the device-specific operation rate data 113, it is possible to use a used device selection parameter. Possible device selection parameters include (1) the threshold of operating rate, (2) the number of devices to be selected, (3) the ratio of the number of devices to be selected with respect to the total number of devices, and any of these parameters The device to be used for each time bucket is selected by using the used device selection parameter, and a device list for each time bucket is created.

FIG. 7 shows an example of the device list used by time bucket.
As shown in FIG. 7, the time bucket used device list includes data such that the time bucket is used from May 11, 2003 to May 17, 2003, for example, M2,. It is remembered.

  Then, the producible quantity calculating means 103 calculates the required processing time of each device for each time bucket from the order data 110, the device usage master for each product 111, the device available operation time master 112, and the device usage list for each time bucket. The production quantity for each order, each time bucket, and each apparatus is determined so as not to exceed the operable time of each apparatus, and is calculated as order-by-order production possible quantity data 115 and stored in the storage means 106.

As the production quantity calculation means 103, the production quantity for each order, each time bucket, and each apparatus is determined from the order data 110, the apparatus usage master 111 for each product type, and the operation available time master 112 for each apparatus, and the total apparatus usage order is determined. Calculate another production quantity,
It is also possible to register in order-by-order production possible quantity data.

  The specific processing contents of the used device selecting means 102 for calculating the production possible quantity for every device used order will be described next. Here, two ways will be described.

The first consists of the following steps (1) to (3).
(1) A device having a relatively high operation rate is selected from the device-specific operation rate data 113, and a time bucket-based device list 114 is created and recorded in the storage unit 106.
(2) After completion of the processing of (1) or after the completion of the processing of (3), the device usage list by time bucket 114 recorded in the storage means 106, the order data 110, the device usage master by product type 111, and the operation by device. The production possible quantity in the production quantity quantity data by order 115 created by the production quantity calculation means 103 from the production time master 112 is compared with the production quantity by production order using all devices to determine whether they are equal or not equal. If they are equal, the process ends. If they are not equal, the following process (3) is executed.
(3) A device having the highest operating rate is selected from the devices not in the device-by-time bucket list 114, the device is added to the device-by-bucket list 114 by time bucket, and the device-by-time bucket list 114 is recreated. . Then, it is recorded in the storage means 106, and the process (1) is executed.

The second consists of the following steps (1) to (3).
(1) The device with the lowest operation rate is selected from the device-specific operation rate data 113, and the time bucket-based use device list 114 is created and recorded in the storage unit 106.
(2) After the process of (1) above or after the completion of the process of (3) below, the device usage list by time bucket 114 recorded in the storage means 106, the order data 110, the device usage master for each product type 111, and the device The production available quantity data 115 by order produced by the production available quantity calculation means 103 from the separate operation available time master 112 is compared with the production possible quantity by all equipment use orders to determine whether or not they are equal. If not equal, the process ends. If equal, the following process (3) is executed.
(3) Delete the device with the lowest operating rate from the time bucket use device list 114, recreate the time bucket use device list 114, record it in the storage means 106, and execute the process (1). To do.

FIG. 8 shows an example of quantity data that can be produced by order.
In the order-by-order production-capable quantity data 115, all-device-usable production-by-order production quantity is registered. As shown in FIG. 8, the order-by-order production-capable quantity data stores a production quantity in a time bucket, a production-by-order quantity that can be produced by using all devices, and the like for each order ID. In FIG. 8, for example, for an order with an order ID of 00001, the production volume of the time bucket from May 18, 2003 to May 24, 2003 is 2.48, and the production available quantity for all devices is 1.98. It is a sheet.

The production planning system 100 of the present embodiment further includes an operation rate display unit 104 for each device, and displays the operation rate data 113 for each device and each device for each time bucket on the screen.
FIG. 9 shows a screen display example of the device-specific operation rate display means 104. The device-specific operation rate data 113 calculated by the device-specific operation rate calculation unit 101 and recorded in the storage unit 106 is, for example, for each time bucket as shown in FIG. The ID of the device used in the time bucket is taken on the horizontal axis, and the operation rate of each device is shown on the vertical axis, and displayed as a bar graph. Thus, by having a means for displaying, the operating rate of each device for each time bucket becomes obvious at a glance.

Further, the production planning system 100 of the present embodiment has a production quantity display means 105, is calculated by the production quantity calculation means 103, and is stored in the storage means 106 for each order, each time bucket, and each equipment order. Separate production quantity data 115 is displayed on the screen by the production quantity display means 105.
FIG. 10 shows a screen display example of the production quantity display means. As shown in FIG. 10, the production possible quantity display means 105 displays a time bucket, a production quantity, a production possible quantity for every equipment use order, etc. for each order ID. In this example, for an order with an order ID of 00001, the production volume for the time bucket from May 18, 2003 to May 24, 2003 is 1.98, and the total production available quantity is 1.98. It has become.

The processing of the production planning system of the present embodiment described above will be described in time series with reference to FIGS.
FIG. 2 is a sequence diagram of processing of the production planning system in one embodiment of the present invention.
FIG. 11 is a flowchart of a device-specific operation rate calculation process.

  First, in the process 201 of FIG. 2, the device-specific operation rate calculation unit 101 performs a process of calculating the device-specific operation rate data 113 from the order data 110, the product-specific device usage master 111, and the device-specific operation available time master 112. .

FIG. 11 shows details of the operation rate calculation processing for each device.
As the operation rate calculation processing for each device, first, in S1101, a time bucket through which each order passes through the device is obtained. This time bucket calculation process refers to the order data 110 in which the type, delivery date, order quantity, etc. are stored, and the type-specific device usage master 111 in which the device ID and unit required time are stored for each type of usage order. calculate. Specifically, for each type of order, the equipment used from the time the type is put into the production line to completion is extracted in the order of use, and each order is determined from the quantity of the order of the type and the unit required time. It is calculated in which time bucket it passes after the device is used until it is completed.

  Next, in step S1102, the required processing time for each device is tabulated for each time bucket from input to completion based on the data on which time bucket each order passes through the used device. And it represents with the operating time of each apparatus for every time bucket and every apparatus.

  Subsequently, in S1103, by referring to the device-by-device operable time master 112, the device-by-device and time-bucketable operation time stored in the device-by-device available time master 112, the time bucket-by-device and device-by-device calculated in S1102 Divide the operating time of the device to calculate the operating rate for each time bucket and for each device. The calculation result of the operation rate by device shown in S1103 of FIG. 11 is obtained by displaying the operation rate data by device of FIG. 6 in another display format.

Next, the process is executed in the order of the process 202, the process 203, the process 204, the process 205, and the process 206, and the process is repeated until it is determined that the process 205 is finished.
In the process 202, the use device selection unit 102 selects a device having a relatively high operation rate from the operation rate data for each device recorded in the storage unit 106, and creates a device usage list for each time bucket. The created device operation rate data is recorded in the storage means 106.

  In the process 203, the producible quantity calculating means 103 calculates the required processing time of each device for each time bucket from the device-specific device usage master and the device-usable time master recorded in the storage means 106. In order not to exceed the possible time, the production quantity for each order using equipment is determined by determining the production quantity for each order and time bucket. The calculated production-capable quantity for each device use order is registered in the production-capable quantity data for each order recorded in the storage unit 106.

In the process 204, the production-capable quantity calculation means 103 creates order-by-order production-capable quantity data from the time-bucket use apparatus list, the product-specific apparatus use master, and the apparatus-capable operation time master recorded in the storage means 106. for,
The production quantity data for each order is generated by determining the production quantity for each order, for each time bucket, and for each apparatus so that the required processing time of each apparatus for each time bucket does not exceed the operable time of the apparatus. The produced order-specific production quantity data is recorded in the storage means 106.

  In processing 205, the use device selection means 102 compares the production quantity of the order-by-order production-capable quantity data recorded in the storage means 106 with the total production-use available quantity, and determines whether they are equal or not equal. If they are equal, the process ends. If they are not equal, process 206 is executed.

  In the process 206, the used device selecting unit 102 selects a device having the highest operating rate from the devices not in the time bucket used device list recorded in the storage unit 106, and the device is included in the time bucket used device list. , Re-create the list of devices used by time bucket, record it in the storage means 106, and execute the process 202.

  In the present embodiment, as described above, the bottleneck device candidates that change from time to time can be extracted for each time bucket by calculating the operating rate of each device for each time bucket based on the order. And since the apparatus considered in a production plan is narrowed down beforehand to the apparatus with the high operation rate which becomes the candidate of the bottleneck apparatus, and a production plan is created, production time of a production plan can be shortened.

It is a figure which shows the structure of the production planning system of one Embodiment of this invention. It is a sequence chart which shows the process of one Embodiment of this invention. It is a figure explaining an example of order data. It is a figure explaining an example of the apparatus usage master classified by kind. It is a figure explaining an example of the operation possible time master classified by apparatus. It is a figure explaining an example of operation rate data classified by apparatus. It is a figure explaining an example of a use apparatus list classified by time bucket. It is a figure explaining an example of quantity data which can be produced according to order. It is a figure which shows the example of a screen display of the operation rate according to apparatus. It is a figure which shows the example of a screen display of production possible quantity. It is a figure explaining the operation rate calculation process classified by apparatus in one Embodiment of this invention.

Explanation of symbols

DESCRIPTION OF SYMBOLS 100 ... Production planning system, 101 ... Operation rate calculation means classified by apparatus, 102 ... Used apparatus selection means, 103 ... Production quantity calculation means, 104 ... Operation rate display means classified by apparatus, 105 ... Production quantity display means, 106 ... Memory means.

Claims (6)

A production planning system for creating a production plan for producing a plurality of products using a plurality of devices,
Order data including at least product type, order quantity and delivery date for each product, device used for production of the product for each product type, use order of the device, and device usage by product type including at least unit required processing time in the device Storage means for storing data, and operation-permitted time data for each device in which operation-permitted time for each time bucket is registered for each device;
Referring to the order quantity and delivery date of the order data stored in the storage means and the unit required processing time and the order of use of the device usage data by type, each order obtains a time bucket for using the device, and each time bucket The required processing time for each device is calculated, and the operation rate data for each device for each time bucket is calculated from the total value of the required processing time for each device and the available time data for each device, and the operation for each device is recorded in the storage means. Rate calculation means;
Select a device with a high operation rate based on the device operation rate data to create a time bucket use device list, and use device selection means for storing in the storage unit;
From the order data, device usage data for each product type, operation available time data for each device, and device usage list for each time bucket, the required processing time for each device for each time bucket is calculated to be less than the operation available time for that device. And a production quantity calculation means for storing in the storage means as order-by-order production quantity data. The use device selection means includes:
As a parameter for selecting a device to be used, a device to be used is selected based on either the operation rate data for each device and the threshold of the operation rate or the number of devices to be selected or the ratio of the number of devices to be selected with respect to the total number of devices. 2. The production planning system according to claim 1, wherein a list of devices to be used for each time bucket is created. The production quantity calculation means determines the production quantity by order, time bucket, and equipment from the order data, device usage data by product type, and operation available time data by device, and determines the production quantity by order of all devices used. Calculated and stored as the quantity data that can be produced by order,
The use device selection means includes:
(1) A step of selecting a device having a relatively high operation rate from the device operation rate data, creating a time bucket use device list, and recording it in the storage unit;
(2) After the process of (1) or after the process of (3) below is completed, the device-by-time-bucket list recorded in the storage means, the order data, the device-specific device-usage master, and the device can be operated. Comparing the production possible quantity of the production possible quantity data by order created by the production quantity calculation means from the time master and the production possible quantity by all equipment use orders, the process ends if they are equal, and if they are not equal, A step of executing the process of (3);
(3) Select the device with the highest operating rate from the devices not in the use device list by time bucket, add the device to the use device list by time bucket, and recreate the use device list by time bucket, Recording in the storage means and executing the processing of (1);
The production planning system according to claim 1, wherein: The production quantity calculation means determines the production quantity by order, time bucket, and equipment from the order data, device usage data by product type, and operation available time data by device, and determines the production quantity by order of all devices used. Calculate and store as the quantity data that can be produced by order,
The use device selection means includes:
(1) A step of selecting a device having the lowest operating rate from the operating rate data for each device, creating a used device list for each time bucket, and recording it in the storage unit;
(2) After the process of (1) or after the process of (3) below is completed, the device-by-time-bucket list recorded in the storage means, the order data, the device-specific device-usage master, and the device can be operated. Compare the production possible quantity of the production possible quantity data by order created by the production quantity calculation means from the time master and the production possible quantity by all equipment use orders, and if not equal, the process ends. A step of executing the process of 3),
(3) The step of deleting the device with the lowest operating rate from the list of devices used by time bucket, recreating the device list used by time bucket, recording it in the storage means, and executing the processing of (1) The production planning system according to claim 1, wherein:   5. The production planning system according to claim 2, further comprising a device-specific operation rate display unit that displays device-specific operation rate data for each device and each time bucket on a screen. Production planning system. 5. The production planning system according to claim 2, further comprising a production quantity display means for displaying the production quantity data by order, by time bucket, and by order according to the order. Production planning system characterized by

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