JP2005216074A - Production plan preparation system, production plan preparation method and program - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To accurately verify a production plan, and to quickly prepare it without generating any individual difference. <P>SOLUTION: When the order of various types of products is received, necessary manufacturing processes through which the products whose order has been received pass are decided, and a manufacturing lead time, a cycle calendar and an operation cessation schedule are read based on the necessary manufacturing processes (a step S3), and a reference time is set based on the manufacturing lead time (a step S4), and a manufacture marginal day on which a cycle is reflected is decided for each manufacturing order (a step S5), and the manufacturing order is assigned to the cycle based on the manufacture marginal day so that a plan manufacturing day can be decided (a step S6), and difference display data showing a difference between the manufacture marginal day and the plan manufacture day are outputted. The accurate verification of the setting of the cycle is operated from the output result, and production adjustment such as the change of the cycle, the change of the term of delivery and the change of the operation cessation date is executed. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

  The present invention relates to a production plan creation system, a production plan creation method, and a production plan creation program for creating a production plan when a variety of products such as steel products are produced through a necessary manufacturing process selected from a plurality of manufacturing processes.

For example, in an industry that performs mass production of tens of thousands of products per month, represented by steel products, etc., it can respond to product orders of different customers such as product types and dimensions such as steel types and produce by the delivery date. In order to complete the process, the work in progress and the newly manufactured product are combined, and a rough production plan such as a monthly unit is created with the aid of a computer.
In general, the manufacturing start time when manufacturing a thin plate product is determined by the standard lead time between the delivery date of the product order and the product type regardless of the difference in the attributes of the product order (ordered product) and the manufacturing chance. Has been decided. As a result, the production time fluctuates greatly due to disturbances such as delivery date changes and due date concentration. Sometimes it is.

  In production management based on this delivery date and standard lead time, order delivery dates were standardized.In the past, management at the production start time calculated using the delivery date as a guide automatically leveled the receipt and inventory. However, as in recent years, as the demand for products increases, production specifications (production routes) are diversified, and there are restrictions on production opportunities (cycles) for those products. If production management is not performed with the production start index changed to, the delivery date is delayed, or the production is greatly preceded by the delivery date, resulting in frequent increase in inventory. In addition, the mountain climbing work when the production load exceeds the production capacity due to the pile-up depends on the operation of the operator's sense, which has been a factor in delaying the delivery date and increasing the occurrence of the delivery-type preceding production.

Therefore, in order to keep the workload of each production process constant and to meet the delivery date of each product order, production is performed by the retroactive planning unit based on the order database of the production management system, the operation restriction condition database, and the conditions in the operation calendar. Since work days are planned from the downstream process to the upstream process, it is possible to determine the work day of the most upstream process (casting / rolling process) that keeps the work load of each production process constant. In addition, by adding the conditions in the processing amount frame table and product type combination table for each next process, the load / prediction unit accurately predicts the future load status and availability date of each order in the casting / rolling planning unit. For example, a production management device that can cope with a change in plan in advance has been proposed (see, for example, Patent Document 1). In this conventional example, a method is employed in which the production startable time of each process is calculated based on the lead time and calendar information, and an instruction group is formed by grouping orders with orders close to the production startable time.
Japanese Patent Application Laid-Open No. 8-16662 (pages 1 to 4, FIGS. 2 to 11)

However, the above-described conventional production management apparatus calculates the production start time of each process considering the operation calendar. However, there are the following problems in quickly responding to environmental changes.
(1) Calendar information is already provided, and it is not possible to follow environmental changes only by adjusting the amount according to the priority of grouping.
(2) Since only the production start time reflecting the calendar information is calculated, there is no key for judging the advance delay status in each process, and there is a case where quick short delivery cannot be handled.
(3) Changes in the delivery date due to changes in receipt cannot be reflected quickly.

  Therefore, the present invention has been made paying attention to the problems of the above conventional example, and by updating the optimal manufacturing time of all manufacturing orders every day, by presenting an index for the production plan, command, An object of the present invention is to provide a production plan production plan creation system, a production plan creation method, and a program capable of optimizing the production start date, improving the assortment rate, and further reducing the in-process and product inventory.

  In order to achieve the above object, a production plan creation system according to claim 1 is a production plan creation system for creating a production plan for producing a variety of products through a necessary manufacturing process selected from a plurality of manufacturing processes. , An order product manufacturing days calculation means for calculating the number of days required for each manufacturing process in the required manufacturing process through which the ordered product passes when a variety of products are received, and the required manufacturing process from a specified delivery date for each ordered product The final manufacturing start time calculating means for calculating the final manufacturing start time in each manufacturing process that falls within the specified delivery date retroactively based on the number of days required for manufacturing, and the order of the ordered product at the final manufacturing start time Production allocation means that allocates the production amount for each manufacturing process of the required manufacturing process through which the ordered product passes, and restrictions on the amount that can be produced in a given period of each manufacturing process Product production that outputs the deviation date between the determined planned production date and the final production start time of each ordered product group and the production amount for each process in a visible manner And a reference day deviation output means.

  The production plan creation system according to claim 2 is the invention according to claim 1, wherein the ordered product manufacturing days calculating means and the final manufacturing start time calculating means include the ordered product information and the product inventory information held in each step. Referring to FIG. 4, the order product for which product inventory information exists is configured to calculate the required number of days for processes after the process in which product inventory exists.

  Further, in the production plan creation system according to claim 3, in the invention according to claim 1 or 2, the order product manufacturing days calculating means, final manufacturing start time calculating means and manufacturing allocation means are always updated to the latest information. It is characterized in that the number of days, the time, and the production amount are allocated in consideration of the scheduled stop date of the manufacturing process scheduled in the production plan and the manufacturing constraint conditions.

Furthermore, the production plan creation system according to claim 4 is the invention according to any one of claims 1 to 3, wherein the production constraint condition is changed based on the deviation date output by the product production reference date deviation output means. It is characterized by having production adjustment means for performing production adjustment.
Still further, the production plan creation system according to claim 5 is the invention according to claim 3, wherein the production adjustment means is unable to adjust the production due to the change of the production constraint condition, and the production process is scheduled to be suspended. It is characterized by being configured to instruct a change.

  A production plan creation method according to claim 6 is a production plan creation method for creating a production plan for producing a variety of products through a necessary manufacturing process selected from a plurality of manufacturing processes. A step of calculating the number of days required for each manufacturing process in the required manufacturing process through which the ordered product passes when an order is received; Steps to calculate the final manufacturing start time in each manufacturing process that fits within the specified delivery date retroactively, and the required manufacturing that the ordered product passes by accumulating the order quantity of the ordered product based on the calculated final manufacturing start time The planned production date of each ordered product is determined from the step of allocating the production amount for each manufacturing process of the process and the restriction of the production capacity for each manufacturing process in the predetermined period. Products of planning the production date and the deviation date of the final production start time, is characterized by comprising a step of outputting visibly a production of each process.

  Further, the production plan creation program according to claim 7 is a program executed by a computer that creates a production plan in the case of producing a variety of products through a necessary manufacturing process selected from a plurality of manufacturing processes. Calculating the number of days required for each manufacturing process in the required manufacturing process through which the ordered product passes when a product of a product type is received; and manufacturing each required manufacturing process from the specified delivery date for each ordered product Based on the required number of days, the step of calculating the final manufacturing start time in each manufacturing process that fits within the specified delivery date, and the order quantity of the ordered product is accumulated based on the calculated final manufacturing start time. Assigning the production amount for each production process of the necessary production process that passes and the restriction of the production amount in the predetermined period of each production process, Determining the production date and causing the computer to execute a step of outputting the deviation date between the determined planned production date and the final production start time of each ordered product group and the production amount for each process in a visible manner It is characterized by that.

  According to the invention according to claim 1, claim 6 or claim 7, the number of days required for product manufacture (lead time) is calculated for each ordered product, and the necessary manufacturing process is performed from the specified delivery date based on the number of days required for product manufacture. Go back and calculate the final production start time for the ordered product within the specified delivery date in each manufacturing process, accumulate the order quantity of the ordered product based on this final manufacturing start time, and each manufacturing process of the necessary manufacturing process through which the ordered product passes A production amount is assigned to each product, and a planned production date for each ordered product is determined from the constraints on the production capacity in a predetermined period of each manufacturing process. The determined planned production date for each ordered product group and the final production start time Since the deviation date and the production amount for each process are output in a visually recognizable manner, it is possible to accurately predict the delay / preceding with respect to the delivery date, and to accurately grasp the digestion status of the ordered product. Moreover, it can be managed at the final production start time of each specific manufacturing process, can eliminate the difference due to the difference in workload and sense due to the operation by human sense, eliminate the difference due to skill level and schedule The creation work can be made uniform.

In addition, since it is possible to verify the setting of the appropriate cycle based on the delay / preceding prediction results with respect to the delivery date, production fluctuations when a production order with a short delivery date is received or a manufacturing trouble occurs is immediately reflected. The predicted result can be obtained and a quick judgment can be made.
In addition, the production plan can be managed in detail on a daily basis, and the in-process inventory and product inventory can be reduced by promoting the synchronization between manufacturing processes. The date can also be specified, and the priority order in the computer internal processing can be centrally managed.

  According to the invention of claim 2, the order product manufacturing days calculation means and the final manufacturing start time calculation means refer to the order product information and the product inventory information held in each process, and the product inventory information exists. For ordered products, it is configured to calculate the required number of days after the process where the product inventory exists, so the relationship between the ordered products and the inventory products can be derived, and unnecessary in-process inventory can be generated. In addition, it is possible to determine whether or not to accept an order for a product with an ultra-short delivery date from the inventory information.

  Further, according to the invention of claim 3, the order product manufacturing days calculating means, the final manufacturing start time calculating means and the manufacturing allocation means are scheduled to suspend the manufacturing process scheduled in the production plan which is always updated to the latest information. Since it is configured to allocate the number of days, time, and production volume in consideration of the day and manufacturing constraints, the process information is linked to the production schedule, and a highly accurate schedule can be realized. .

Furthermore, according to the invention according to claim 4, since the production adjustment means for adjusting the production by changing the production constraint condition based on the deviation date output by the product production reference date deviation output means, The production capacity in the manufacturing process can be improved, and the adjustment result can be verified again by the product manufacturing reference date deviation output means, so that production adjustment can be performed accurately without individual differences.
Still further, according to the invention according to claim 5, the production adjusting means is configured to instruct a change in the scheduled date of suspension of the manufacturing process when the production cannot be adjusted due to the change in the manufacturing constraint condition. Therefore, the production capacity in each manufacturing process can be maximized.

Hereinafter, embodiments of the present invention will be described with reference to the drawings.
FIG. 1 is a configuration diagram showing a schematic configuration of the present invention, in which a host computer 1 and a server 2 constituted by, for example, an engineering workstation are connected, and the server 2 is arranged for each production process of an ironworks, for example. An information processing terminal 3 composed of a large number of personal computers is connected via a local area network 4.

  The host computer 1 is provided with an order database DB1 for managing order data for each series, and product orders received in the order database DB1 by series are processed by a steel plate, hot rolling (hot rolling) ) Each order file F1 is classified into the type of products produced, such as orders, cold rolling (cold rolling) orders, electromagnetic steel orders, large steel orders, medium steel orders, billet orders, wire rod steel orders, etc. Store in F8, extract the current work-in-progress order and the order to be newly produced from the orders by each series stored in these order files F1 to F8, and transmit the extracted order data by series to the server 2 Is done.

  Here, as shown in FIG. 2, the order database DB1 stores demand order data in which product names, product sizes, quantities, and customer names representing product types such as demand order names, delivery dates, and materials are registered. The demand order registration file 11, the production order association file 12 that stores the production order association data representing the association between the demand order name and the production order name, and the demand order registration file 11 are converted by the production order association data, and the in-process inventory A production order data registration file 13 for storing production order data in which production order names, process order names, product names, dimensions, and quantities are registered in units of information, and production order names, dimensions, process names, and in-process devices In-process inventory information that stores in-process inventory information with registered status, quantity, post-process in-process status, quantity, etc. And a Airu 14.

The host computer 1 is provided with an in-process inventory database DB2 for managing the in-process inventory in each process for each production order. In the in-process inventory database DB2, the production order name, dimensions, process name, quantity, etc. are provided. The registered in-process inventory information is stored, and this in-process inventory information is transmitted to the server 2.
In addition, by providing this work-in-progress database DB2, by referring to the work-in-progress information stored in this database DB2, it is not possible to newly manufacture a work-in-process item that can be applied to a demand order. To. That is, a necessary new production quantity can be determined from the quantity of in-process inventory and the quantity of demand orders.

The server 2 is provided with a production plan management system 2A that creates a production plan based on the current work-in-progress order, production-scheduled order, and work-in-progress inventory information transmitted from the host computer 1.
Then, the data calculation processing unit 20a provided in the production plan management system 2A refers to the standard table 20b, the process table 20c, and the cycle calendar file 20d and corresponds to each manufacturing capability of a plurality of manufacturing processes through which each product passes. A production plan creation process for creating a production plan is performed, the production plan information is stored in the production plan information file 20e, and the production plan information is displayed on the display 20f.

The cycle calendar file 20d stores a cycle calendar in which time buckets for defining, for each product type, cycles in which one or a plurality of products can be manufactured for each manufacturing process are stored.
Incidentally, in many cases, the term “cycle” is used because a manufacturing opportunity for a cycle of the same product type is periodically provided, for example, once every several days.

In addition to the cycle calendar described above, the cycle calendar file 20d also stores an operation stop schedule for periodic repair, repair, care, etc. for each manufacturing process, and the cycle calendar and the operation stop schedule are updated daily. .
Each information processing terminal 3 accesses the data operation processing unit 20a of the production plan management system 2A and executes the production plan creation process shown in FIG.

  As shown in FIG. 3, in the production plan creation process, first, in step S1, a thick plate order, a hot rolling (hot rolling) order, a cold rolling (cold rolling) from the order database DB1 of the host computer 1 by series. Read in-process orders and new orders for products stored in the order files F1 to F8, classified into orders, electromagnetic steel orders, large steel orders, medium steel orders, billet orders, wire bar steel orders, etc. At the same time, in-process inventory information is read from the in-process inventory database DB2.

  Next, the process proceeds to step S2, and the standard process obtained by referring to the standard table 20b based on the product name and dimensions of each production order, and further the passing process with reference to the process table 20c based on the standard. decide. Here, as shown in FIG. 5, the process table registers the part data definition file 21 in which the standard, quantity, process order, raw material name, and quantity are registered, and the part name (raw material) and part type (purchased product). The part list definition file 22 to be registered, the process order, the process name, the equipment name (specific passing equipment name of the corresponding process), the manufacturing process order list file 23 in which the required time is registered, and the relationship between the equipment and the installation location are registered. An equipment list definition file 24, an alternative equipment setting definition file 25 in which the process order, process name, equipment name, and required time (time ratio with respect to the time required to pass through the equipment originally intended to pass) are registered; The cycle process order setting definition file 26 in which the cycle name representing the order, process name, and product type is registered, and the relationship between the product type corresponding to the cycle name and the equipment through which it can pass are registered. And a Le facilities set definition file 27.

  Then, for each manufacturing order, refer to the manufacturing process list file 23 to determine the passing process, that is, the manufacturing process that passes through and the passing order that passes through them (in 23 of FIG. 6, for example, the process order is indicated by AAAA). , Pass through each process in the order of BF → CC → HM → PIC → CM → CAL, and pass through each specific equipment in the order of BF → CC_4 → HM → 5PIC → CM_1 → CAL_2).

In addition, by having the alternative equipment setting definition file 25, when production concentrates on a specific process, it can be determined whether transfer to another alternative equipment is possible.
In addition, by having a cycle facility setting definition file 27 in which the correspondence between the type of product corresponding to the cycle name and the name of the facility through which it can pass (for example, shape steel, plating COAT, etc.) is registered, When a production plan is created by accumulating the required manufacturing time for each equipment and each process, by referring to the required time registered in the manufacturing process order list file 23, the production capacity for each equipment and each process is obtained. It is possible to determine whether or not the upper limit is exceeded, so that it is possible to create a production plan with high accuracy.

  Next, the process proceeds to step S3, where the manufacturing capability lead time is read with reference to the process table 20c based on the passing process for each manufacturing order, and the corresponding product type in the cycle calendar is read from the production plan file 20d. A cycle manufacturing opportunity (hereinafter referred to as a cycle chance) and an operation stop schedule are read. Here, the manufacturing ability lead time stored in the process table 20c is calculated based on the actual processing days of each manufacturing process of a plurality of manufacturing process lines for manufacturing various types of products, from the processing results, history, etc. at the time of product manufacturing. It is generated by determining each reference processing day of manufacturing ability lead time representing the lead time between each manufacturing process and manufacturing process based on the actual processing days. Here, the manufacturing ability lead time is set as a lead time in consideration of the processing time for each process and the movement time to the next manufacturing process.

  Next, the process proceeds to step S4, and a reference time representing a manufacturable range is set based on the read manufacturing ability lead time. This reference time is a generic name for the earliest manufacturable date and the latest manufacturable date described below, with the horizontal axis shown in FIG. 6 taking time, and the vertical axis showing the steel output process, hot rolling process, tandem rolling. As shown in the chart with various processes up to the delivery date such as process TA, continuous annealing process CAL, plating process EGL, etc., first, the steelmaking process that is the initial process on the order date (today) that is the earliest manufacturing start date When the earliest manufacturable date D10 is set, the hot-rolling process to the plating process EGL, which are the downstream manufacturing processes from the earliest manufacturable date D10, for each process with the manufacturing ability lead time described in the rightmost column The earliest manufacturable dates D11 to D14 are set, and the shortest delivery date D15 is set from the plating step EGL with the manufacturing ability lead time.

Further, retroactively from the actual delivery date D25, the latest manufacturable dates D24 to D20 for each process are sequentially set with respect to each upstream process with a manufacturing lead time.
Thus, in each manufacturing process, by setting the earliest manufacturable date D1i (i = 0 to 5) and the latest manufacturable date D2i, in each manufacturing process, the manufacturing order is placed before the earliest manufacturable date D1i. It is impossible to manufacture, and if the manufacture is started later than the latest production date D2i, the actual delivery date cannot be satisfied, and the delivery date is delayed, and the earliest production date D1i and the latest production date D2i Production of a production order that satisfies the actual delivery date can be performed by starting production of the production order within a period between the two.

Next, the process proceeds to step S5, and the production limit date determined by the production constraint reflecting the latest cycle chance set in the operation suspension schedule and the cycle calendar from the delivery date is determined for each production process for all production orders. .
Next, the process proceeds to step S6, where each production order is assigned to a cycle chance on the basis of the calculated production limit date for each production process, and the planned production date is determined as shown in FIG. Process.

  Next, the process proceeds to step S7, and for each cycle chance type of each manufacturing process, a deviation display that displays the product manufacturing reference date deviation based on the planned manufacturing date on which the allocation is completed, the weight of the manufacturing order, and the set weight of the cycle chance Data is formed and displayed on the display 3b. Here, as shown in FIG. 7, in the deviation display data, the production date is plotted on the horizontal axis and the production limit date is plotted on the vertical axis, and the region where the production date matches the production limit date is colored, for example, in blue. The delivery date compliance boundary display area is displayed, the area above the delivery date compliance boundary display area is set as a preceding area preceding the delivery date colored in white, for example, and the lower area is displayed as a delivery delay area colored in red, for example. The production order name and weight are displayed, the deviation display part 41 showing the degree of deviation and the quantity of the production planned date with respect to the delivery date, and the cycle chance and its set quantity corresponding to the production date below the deviation display part 41 A cycle schedule display unit 42 is shown.

  Next, the process proceeds to step S8, where it is determined whether or not a load balance that can be manufactured for each attribute of the manufacturing order is established in each manufacturing process. If the load balance is established, the process proceeds to step S9 and each manufacturing process is performed. For each process, the production plan data including the production limit date, allocation cycle name, planned production date, production order name, weight and delivery date achievement status is stored in the production plan file 20e, and the production order creation process for each production process is performed. The process ends after it has been done.

  On the other hand, if the determination result of step S8 is that the load balance is not established, the process proceeds to step S10, and the production start date or delivery date is changed, the cycle chance combination is changed, the operation suspension schedule is changed based on the displayed deviation display data. It is determined whether or not there is an adjustment request for performing production adjustment such as a change. If there is no adjustment request, the process proceeds to step S11 and guidance information indicating that an adjustment request needs to be made is displayed on the display 3b, and then the step is performed. Returning to S8, when an adjustment request is made, the process proceeds to step S12, where it is determined whether or not the adjustment request is a change in manufacturing start date or delivery date. After the transition to the production adjustment process for changing the production start date or delivery date for the relevant production order, Returning to step S4, when it is not a change in the production start date or delivery date, the process proceeds to step S14, and after performing production adjustment processing such as a change in the combination of cycle chances and a change in the operation suspension schedule according to the adjustment request, the step S5 Return to.

  Further, as shown in FIG. 8, in the planned manufacturing date determination process in step S6, first, in each manufacturing process in which a cycle chance is set in step S21, the cycle chance is passed for each type of cycle chance. All the production orders are extracted, then the process proceeds to step S22, the extracted production orders are sorted in ascending order of the production limit date, and then the process proceeds to step S23, where the production orders are set to the set weight of the cycle chance. Allocation is performed to the set cycle chance while paying and receiving the weight of the manufacturing order, and then the process proceeds to step S24, and the process is terminated after determining the allocated date as the planned production date.

Next, the operation of the above embodiment will be described.
In the host computer 1, the received product order is input, the in-process status of the in-process product order is input, and the product order that can be ordered can be input.
In normal operations, there are two types of cases: creating an actual production plan based on a newly ordered product order, and providing sales expansion order support that selects a product order that can be ordered and absorbs fluctuations in production capacity. It is done.

  When creating a production plan based on a newly ordered product order, the newly ordered product order is input to the host computer 1. For this product order, a demand order name, delivery date, product name, dimensions, quantity, and customer name are input. The in-process inventory information file is not created for the newly ordered product order, so the current in-process status is registered in the in-process inventory information file 14 for the previously ordered product order.

  That is, as shown in Fig. 2, assuming that product orders with two demand order names AAAA-XXXXX-XX and AAAA-YYYYY-YY with quantities of 50000kg and 150,000kg have been previously received, AAAA and BBBB, as shown in Fig. 5, for the product name AAAA, slabs are formed by continuously casting the molten iron extracted from the blast furnace (BF) from the molten steel refined at the steelmaking plant with a continuous casting machine (CC), This slab is hot-rolled (HM), pickled (PIC), cold-rolled (CM), further annealed (CAL) and shipped as a product. Product name BBBB is also removed from the blast furnace. Cast and refined molten steel is continuously cast by a continuous casting machine (CC) to form a slab, which is hot-rolled (HM), pickled (PIC), cold-rolled (CM), and further plated. It shall be shipped as a product after (COAT).

  In addition, products handled at steelworks are not limited to the above products, but products that are shipped after rolling a slab formed by continuous casting after thick plate rolling, as a product by hot rolling the slab Products to be shipped, products that have been cold-rolled and subsequently annealed before being electroplated, and are subjected to another coating process before being shipped as products, and products that are shipped by performing other plating such as hot dipping instead of electroplating There are a wide variety of product forms such as processing products purchased from other manufacturers and shipping them as products.

  Returning to FIG. 2 again, both of these demand orders are not new orders, but are in-process inventory information units, and for one demand order, 20000 kg and 30000 kg production orders AAAA-XXXXX-XX -AA and AAAA-XXXXX-XX -BB is divided into two parts, and the other demand order is divided into five parts of production orders AAAA-YYYYY-YY-AA to AAAA-YYYYY-YY-EE for each 30,000 kg, and a production order is generated for each of these orders. A data registration file 13 is formed.

Production order AAAA-XXXXX-XX-AA is in-process state before hot rolling HM, and production order AAAA-XXXXX-XX-BB is in-process state after hot rolling HM. AAAA-YYYYY-YY-AA is the in-process state before cold rolling CM, and these are stored in the in-process inventory information file 14.
When the production plan process shown in FIG. 3 is executed by the production plan management system 2A of the server 2 in this state, as shown in FIG. 5, first, in step S1, the new order product order information stored in the host computer 1 and After the in-process inventory information is read, the process proceeds to step S2, and the passing process for each manufacturing order is determined with reference to the standard table and the process table.

  In the example of FIG. 5, the process order AAAA representing the product type is slab by continuously casting the molten iron obtained from the blast furnace (BF) from the molten steel obtained by refining at the steelmaking factory with a continuous casting machine (CC) as described above. This slab is hot-rolled (HM), pickled (PIC), cold-rolled (CM), continuously annealed (CAL), and then shipped as a product. The slab is formed by continuously casting the molten steel obtained from the blast furnace from the blast furnace using a continuous casting machine (CC), hot rolling (HM), pickling (PIC), and cold rolling. (CM), plating (COAT), and the process of shipping as a product is determined.

  On the other hand, when the cycle calendar created at the present time and stored in the cycle calendar file 20d is displayed on the display 3b, as shown in FIG. 9, the tandem cold mill TA between 1st and 30th of a certain month is shown. Cycle Y is set from 11th to 15th, cycle Z is set from 6th to 10th, cycle A1 is cycle A1 of 11th and 12th days by electrogalvanized EGL, and cycle A2 is 17th to 19th. And the cycle A3 of the 23rd and 24th, the cycle B is set to the 13th to 15th, and the cycle C is set to the 20th to 22nd. Further, in the continuous annealing furnace CAL, as shown in FIG. 8, for example, an operation stop schedule for stopping operation for periodic repair is set to 15th to 18th.

  Then, a new production order h on today (1st) is accepted, and the passing process of this production order h is set to steel output, hot rolling, tandem cold mill TA, continuous annealing furnace CAL, and electrogalvanizing EG. In addition, the cycle that can be manufactured is cycle Z for tandem cold mill TA, cycle A for electrogalvanized EGL, and delivery time is 24 days. Further, as shown in the right end side of FIG. 8, the production lead time for the production order h is 2 days between steel rolling and hot rolling, 4 days between hot rolling and tandem cold mill TA, and tandem cold mill. One day is set between TA and continuous annealing furnace CAL, one day is set between continuous annealing furnace CAL and electrogalvanizing, and two days are set by delivery date.

  When creating a production plan for this production order h, when the production plan creation process of FIG. 3 is executed, the information on the production order h is read in step S1, and then the process proceeds to step S2, where the passing process is performed. After the determination, the process proceeds to step S3, and the manufacturing ability lead time, the cycle A and Z of the cycle calendar, and the operation stop schedule are read.

  In step S4, a reference time is set. As shown in FIG. 6, this reference time is set as 3 days after the production lead time (2 days) set from the steel production start date, with today (1 day) set as the steel production start date D10. The earliest production start date D11 of hot rolling is set on the day, then the earliest production start date D12 of the tandem cold mill TA is set on the seventh day after the production lead time (4 days), and then the production lead time ( On the 8th day after the 1st), the earliest production start date D13 of the continuous annealing furnace CAL is set, and then on the 9th day after the production lead time (1 day), the earliest production start date D14 of the electrogalvanized EGL is set. Finally, the shortest delivery date D15 is set to 11 days after the manufacturing ability lead time (2 days).

On the other hand, the latest production date D24 for electrogalvanized EGL is set on the 22nd and the latest production date D23 for the continuous annealing furnace CAL is set on the 21st. The latest production date D22 of the tandem cold mill TA is set on the 20th, the latest production date D21 of the hot rolling is set on the 16th, and the latest production date D20 of the steel is set on the 14th. To do.
Therefore, in each production process, production satisfying the delivery date D25 is possible by producing the production order h between the earliest manufacturable date D1i and the latest manufacturable date D2i.

  Next, the process proceeds to step S5 in FIG. 3 to determine a production limit date reflecting the cycle. As shown in FIG. 8, the production limit date is set to cycle C in electrogalvanized EGL on the 22nd, which is a production lead time (2 days) later than the delivery date 24th. Cannot be manufactured, the manufacturing limit date L14 is set on the last day 19 of the cycle A2 constituting the cycle A in which the manufacturing order h can be manufactured. Next, the production limit date of the continuous annealing furnace CAL is set to 18 days after the production ability lead time (1 day) from the production limit date L14 of the electrogalvanized EGL. Since the operation is suspended for regular repair during the day, the production limit date L13 of the continuous annealing furnace CAL is set on the 15th before the operation suspension. Next, the production limit date of the tandem cold mill TA is set to 14 days after the production lead time (1 day) from the production limit date L13 of the continuous annealing furnace CAL. On this 14th, the tandem cold mill TA is set. Since the cycle Y is set and the manufacturing order h cannot be manufactured, the final day 10 of the cycle Z in which the manufacturing order h can be manufactured is set as the manufacturing limit date L12 of the tandem cold mill TA. The production limit date L11 for hot rolling is set to 6 days after the production limit lead time (4 days) from the production limit date L12 of the tandem cold mill TA, and finally the production capability from the production limit date 6 for hot rolling. The production limit date L10 of the steel output is set on the 4th day after the lead time (2 days).

For other new or in-process production orders, the same production limit date is determined, and then the process proceeds to step S6, where the planned production date determination process shown in FIG. Determine the day.
In this planned manufacturing date determination process, first, in step S21, all manufacturing orders a to n manufactured in the corresponding manufacturing process, for example, cycle A of electrogalvanized EGL, are extracted, and these manufacturing orders a to n are the limit manufacturing thereof. By sorting in ascending order of the day L14, the sorting result shown in FIG. 10B is obtained.

  Next, the production orders a to n are assigned to the cycles A1 to A3 constituting the cycle A of the electrogalvanized EGL shown in FIG. 9A from the sort result. At this time, the set amount of the cycle A1 is 11 days and 12 days. Assuming a total of 800 tons of 400 tons per day, a cycle A2 of 17 days and 18 days of 400 tons and 19 days of 300 tons total of 1100 t, a cycle A3 or 23 days of 400 tons, and 24 days of 300 tons of 700 tons. From the sort result, the weights of the production orders a to n are assigned while receiving and paying so that the weight does not exceed the set amount for each cycle A1 to A3.

  That is, in the example of FIG. 9, since the total weight of the production orders a and b is 400 t, these are allocated on the 11th day of the cycle A1, and the weight of the production order c is 400 t. Since the total weight of the production orders d to f is 400t, the allocation is made on the 17th of the cycle A2, and the total weight of the production orders g and h is 400t, so the allocation is made on the 18th of the cycle A2 and the production order. Since the weight of i is 300 t, it is assigned as it is on the 19th of the cycle A2, and the total weight of the production orders j to l is 400 t. Therefore, the weight is assigned on the 23rd of the cycle A3 and the weight of the production order m is 300 t. As it is assigned on the 24th of cycle A3 as it is, there is not enough cycle A for production order n. Processing.

As described above, when the allocation to the cycles A1 to A3 is completed, the processing dates of the cycles A1 to A3 that are the allocation destinations of the respective manufacturing orders a to m are determined as the planned manufacturing dates, as shown in FIG. Create an assignment completion list that displays the production limit date, assignment cycle name, planned production date, production order name, and weight.
Next, the process proceeds to step S7 in FIG. 3 to create deviation display data for displaying the product manufacturing reference date deviation shown in FIG.

As shown in FIG. 7, the deviation display data includes a deviation display unit 41 formed in a table format in which the horizontal axis represents the planned production date and the vertical axis represents the production limit date. The cycle schedule display unit 42 that represents the cycle chance and the set amount corresponding to the manufacturing date on the side, and the deviation display unit 41 is based on the allocation completion list created in the above-described planned manufacturing date determination process, The production order name and weight are written at the intersection position between the planned production date and the production limit date of the production orders a to m.
The deviation display data is displayed on the display 3b or printed by a printer.

  Referring to the deviation display data in FIG. 8, in each of the production orders a to m for which the allocation has been completed, the production displayed in the delivery date compliance boundary display area colored in blue, for example, in which the planned production date and the production limit date match. For orders a, g, l, and m, this means that production is completed on the delivery date, and production orders b, c, and so on displayed in the preceding region colored in, for example, white above the delivery date compliance boundary display region For h and d, this means that the product is produced with a margin in the delivery date. Further, for the production orders d to f, j and k displayed in the delivery delay region colored in red, for example, below the delivery date compliance boundary display region, the delivery date is given. This means that production is delayed. The degree of separation from the due date compliance boundary display region in the preceding region and the due date delay region represents the degree of deviation of the production plan date from the due date.

Therefore, from the display result of the deviation display unit 41, it is possible to determine at a glance the production order that is delayed in delivery date and the number of days behind the delivery date, change the planned production date, change the number of cycles or the set amount, and stop the operation. By dealing with the change of the delivery date by changing the date or by negotiating with different delivery dates, the delivery delay can be eliminated.
By the way, in the example of FIG. 9 described above, 13 days are added to the cycle A1 of the electrogalvanized EGL, and the production order d to f is assigned to the 13th by enabling the production of 400t in this 13 days. This cycle can be moved forward in cycles A2 and A3, production orders g and h on the 17th cycle A2, production orders i and j on the 18th, production orders k and l on the 19th, The production order m can be produced on the 23rd of the cycle A3 and the production order n can be produced on the 25th, thereby eliminating the delivery delays of all the production orders d to f, j and k that have been delayed. And smoothing and efficiency of production can be achieved.

Conversely, if the production orders for the preceding area increase, it can be determined that there are too many cycle setting amounts or cycle setting dates, and the cycle setting amount or cycle setting date is reduced as necessary. Thus, the set amount or set date of other cycles can be increased.
The production plan is determined while stacking the production adjustment from the lower process to the upper process, that is, electrogalvanizing → continuous annealing furnace CAL → tandem cold mill TA → hot rolling → steeling.

Then, when the load balance of the attribute unit of the manufacturing order is established in all the processes, the process proceeds from step S8 to step S9, and the allocation completion list of each manufacturing process at that time is stored in the production plan file 20e. At the same time, a manufacturing instruction is created for each manufacturing process, a manufacturing instruction is issued to the manufacturing process, and actual production is started.
Further, the present invention is not limited to the use in creating an actual production plan, but can also be used as a simulation for receiving a short delivery date order, and it is possible to quickly determine whether or not the short delivery date order can be accepted.

  As described above, according to the above embodiment, the limit manufacturing date reflecting the operation suspension schedule and the cycle is determined, and the manufacturing order is sorted in ascending order based on the limit manufacturing date and assigned to the cycle to determine the planned manufacturing date. Therefore, it is possible to accurately predict the delay / preceding with respect to the delivery date from the limit manufacturing date and the planned manufacturing date, and it is possible to accurately grasp the digestion status of the received manufacturing order. Moreover, it can be managed with specific production limit dates, eliminates differences due to differences in workload and sensation due to human-like operations, and eliminates differences due to skill level, making schedule creation work uniform Can be achieved.

In addition, it is possible to verify the setting of the appropriate cycle (cycle setting date and setting amount) based on the delay / preceding prediction result with respect to the delivery date, so that a manufacturing order with a short delivery date or a manufacturing trouble occurs. Therefore, it is possible to obtain a prediction result that immediately reflects the production fluctuation in this case, and to make a quick judgment.
In addition, the production plan can be managed in detail on a daily basis, and the in-process inventory and product inventory can be reduced by promoting the synchronization between manufacturing processes. The date can also be specified, and the priority order in the computer internal processing can be centrally managed. In terms of delivery time, export orders can be placed on the basis of the date of arrival at the port of the vessel, and in Japan, the date of receipt can be used as the basis.

In the above embodiment, the case where the cycles Y, Z and AC in the tandem cold mill TA and the electrogalvanized EGL are set in units of one day has been described. However, the present invention is not limited to this, and is in units of half a day. Alternatively, the time unit may be set.
In the above embodiment, the case where the manufacturing ability lead time is used has been described. However, the present invention is not limited to this, and a standard lead time set in accordance with the manufacturing order type may be used.
Furthermore, in the said embodiment, although the case where a production plan was performed with respect to steel products was demonstrated, this invention is not limited to this, Of course, it can apply also to the production plan of products other than steel products. it can.

It is a schematic structure figure showing one embodiment of the present invention. It is explanatory drawing which shows the file structure in a host computer. It is a flowchart which shows an example of the production plan creation process performed with an information processing terminal. It is a flowchart which shows the specific example of the plan manufacture date determination process of FIG. It is explanatory drawing which shows an example of the process table used for a production plan process. It is a figure where it uses for description of a reference time setting process. It is a figure which shows the example of an output of deviation display data. It is a figure where it uses for description of a limit manufacturing date determination process. It is a figure with which it uses for description of the allocation process of a manufacturing order.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Host computer 2 Server 2A Production plan management system 3 Information processing terminal 3a Information processing terminal main body 3b Display 3c Keyboard 3d Mouse 4 Local area network 11 Demand order registration file 12 Production order association file 13 Production order registration file 14 In-process inventory information file 20a Data processing unit 20b Standard table 20c Process table 20d Cycle calendar file 20e Production plan file 20f Display 21 Parts data definition file 22 Parts list definition file 23 Manufacturing process order list file 24 Equipment list definition file 25 Alternative equipment setting definition file 26 Cycle process Order setting definition file 27 Cycle equipment setting definition file

Claims (7)

In a production plan creation system that creates a production plan when producing various types of products through a necessary manufacturing process selected from multiple manufacturing processes,
Ordered product manufacturing days calculation means for calculating the number of days required for each manufacturing process in the required manufacturing process through which the ordered product passes when receiving a variety of products, and the required manufacturing process from the specified delivery date for each ordered product. A final manufacturing start time calculating means for calculating the final manufacturing start time in each manufacturing process that falls within the specified delivery date retrospectively based on the required manufacturing days, and the order quantity of the ordered product at the final manufacturing start time The production date is determined based on the production allocation means for assigning the production amount for each production process of the required production process through which the ordered product passes, and the production limit for each production process in the specified period. And a product production reference date deviation output means for outputting the deviation date between the determined planned production date of each ordered product group and the final production start time and the production amount for each process in a visible manner. Production planning system which is characterized the door.   The order product manufacturing days calculating means and the final manufacturing start time calculating means refer to the order product information and the product inventory information held in each process, and for the ordered products for which the product inventory information exists, the process after the process where the product inventory exists The production plan creation system according to claim 1, wherein the required number of days is calculated for the process.   The order product manufacturing days calculation means, the final manufacturing start time calculation means and the manufacturing allocation means are always considered in consideration of the scheduled stop date of the manufacturing process and the manufacturing constraint conditions in the production plan updated to the latest information, 3. The production plan creation system according to claim 1 or 2, wherein the production plan is configured to allocate a production amount and a time.   4. The apparatus according to claim 1, further comprising a production adjustment unit configured to perform production adjustment by changing a production constraint condition based on a deviation date output by the product manufacturing reference day deviation output unit. Production planning system.   4. The production according to claim 3, wherein the production adjustment means is configured to instruct a change in the scheduled stop date of the manufacturing process when the production cannot be adjusted due to a change in the production constraint condition. Planning system. In a production plan creation method for creating a production plan when producing various types of products through a necessary manufacturing process selected from a plurality of manufacturing processes,
Calculating the number of days required for each manufacturing process in the required manufacturing process through which the ordered product passes when receiving a multi-product order; and each manufacturing process of the required manufacturing process from the specified delivery date for each of the ordered products Based on the number of days required for manufacturing, the step of calculating the final manufacturing start time in each manufacturing process that falls within the specified delivery date, and the order quantity of the ordered product is accumulated based on the calculated final manufacturing start time. Allocate the production amount for each manufacturing process of the necessary manufacturing processes that pass through, and determine the planned manufacturing date of each ordered product from the constraints on the production capacity during the predetermined period of each manufacturing process. A production plan creation method comprising: a step of outputting the deviation date between the planned production date of the group and the final production start time and the production amount for each process in a visually recognizable manner. In a program that is executed by a computer that creates a production plan when producing various types of products through a necessary manufacturing process selected from a plurality of manufacturing processes,
Calculating the number of days required for each manufacturing process in the required manufacturing process through which the ordered product passes when receiving a multi-product order; and each manufacturing process of the required manufacturing process from the specified delivery date for each of the ordered products Based on the number of days required for manufacturing, the step of calculating the final manufacturing start time in each manufacturing process that falls within the specified delivery date, and the order quantity of the ordered product is accumulated based on the calculated final manufacturing start time. Allocate the production amount for each manufacturing process of the necessary manufacturing processes that pass through, and determine the planned manufacturing date of each ordered product from the constraints on the production capacity during the predetermined period of each manufacturing process. A production plan composition characterized by causing a computer to execute a step of outputting a deviation date between a planned production date of the group and the final production start time and a production amount for each process in a visually recognizable manner. Program.

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