JP2006004414A - Production plan generation method, production plan generation device and program - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To optimize a production quantity of each model when a plurality of kinds of models of products are manufactured and process design comprising a plurality of multi-processes exists. <P>SOLUTION: A production quantity of each span for every process design is determined by solving an optimization problem using linear programming in an optimized model configuration calculation part 30 by referring to: a process load basic unit for each process for every process design calculated by a process load basic unit calculation part 10 based on manufacturing route information stored in a manufacturing route information storage part 11; a generated cost basic unit for every process design calculated by a generated cost basic unit calculation part 20 based on a generated variable cost stored in a generated cost information storage part 21; production quantity information, material/selling price information, facility information of each term, an evaluation index and information of the term and span respectively previously registered in a production quantity information storage part 2, a material/selling price information storage part 3, a facility information storage part 4, an evaluation index storage part 5 and a term/span information setting part 6. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to a production plan creation method, a production plan creation device, and a program for optimizing the production amount of each kind when producing a plurality of kinds of products in a multi-step production process such as a factory.

  2. Description of the Related Art Conventionally, in a production process composed of multiple steps represented by a material processing system production process such as steel, aluminum and copper, products of a plurality of types are often produced. And in order to increase profits as a company while adapting to the diversified customer needs in recent years, in addition to the cost reduction by the conventional operation improvement, the product composition (product mix) to be produced, that is, the production of each product By optimizing the amount, it is necessary to make effective use of limited production resources (equipment, etc.) and maximize profits. Moreover, in the multi-process / multi-product type production process, the range of production required for each product type (the lower limit production amount lower limit value / the upper production amount upper limit value), the facility capacity of each facility, and the production It is required to determine an optimum variety configuration while considering conditions such as the degree of freedom of the route (passing process route).

As a technique for obtaining a product type configuration that maximizes profit within the range of the equipment capacity of each equipment, for example, there are techniques shown in Non-Patent Document 1 and Patent Document 1.
In the technique shown in Non-Patent Document 1, the production variable of each product type is used, the equipment load is expressed by an inequality constraint, and a product configuration that maximizes profit is obtained using linear programming.

In the technique shown in Patent Document 1, focusing on the bottleneck process in the production line, when the first half manufacturing process and the second half manufacturing process are each composed of a plurality of parallel production lines, the first half and the second half production line In this technology, how many (how many tons) of varieties are produced is determined so as to maximize the profit of the entire process. Moreover, the technique shown in Patent Document 1 has the following characteristics. As a result, the passage process route used in each product type and the production amount for each passage step route can be determined so that the sum of profits is maximized. it can.
・ Calculate the bottleneck process of each production line in advance, and profit based on the profit rate in this bottleneck process (value obtained by dividing the profit per product by the processing time in the bottleneck process) The production varieties and production quantities in each production line are determined so that the total sum of the production lines can be maximized.
・ By applying the above method in each of the first and second half of the manufacturing process, create an operation plan for the production line that maximizes the total profit for the entire process (how much can be produced in which process for each product type) To do.
・ Optimization can be performed even when the capacity of each production line is different.
-Optimal calculation can be obtained at high speed by using linear programming.

Katsuhito Hitomi “Production System Engineering” Kyoritsu Shuppan, October 20, 1990 (second edition), p. 114-115 JP 2003-36296 A

Here, in the above-described technique of Non-Patent Document 1, it is necessary to specify in advance the equipment to be used for each product type.
However, in the actual production process, there are cases where there are multiple equipment (alternative equipment) and equipment groups (alternative process routes) that can be used even with the same product type, that is, multiple ways of making (process design) may be considered. Many. For example, the following cases can be considered.
・ When there are multiple cold rolling mills in the rolling line for iron, aluminum, copper, etc., and any rolling mill can be rolled, and the number of passes (rolling count) varies depending on which rolling mill is used. ・ Batch incineration in continuous incinerators. Can be used in a furnace, and the processing time varies greatly depending on the furnace used (batch incinerator is longer) ・ Can be processed even with internal work, but can also be outsourced depending on the load. However, there is a problem that the technique described in Non-Patent Document 1 cannot be applied.

The technique of Patent Document 1 is based on the premise that the bottleneck process of each production line to be selected can be specified in advance, and that the bottleneck process is the same regardless of the type of product produced.
However, in actual production processes (especially material processing processes such as iron and aluminum), the type of equipment used and the processing time at the equipment differ depending on the kind and passing process route. The process may change, or a plurality of bottleneck processes may appear in one passage process route.
Therefore, the bottleneck process cannot be specified in advance if the type of equipment used and the processing time at the equipment differ depending on the product type and passing process route, as in the actual production process such as a raw material process. There is a problem that the technique of Patent Document 1 cannot be applied.

  The present invention has been made in view of the above problems, and in the case of producing a product of a plurality of types in a multi-step production process, there are a plurality of steps for producing a product of one type. Or a production plan creation method, a production plan creation device, and a program capable of optimizing the production amount of each product type even when there are a plurality of process designs, such as when there are alternative facilities. is there.

Means and effects for solving the problems

  In order to solve the above problems, a production plan creation method according to the present invention is a production plan creation method for optimizing the production amount of products of a plurality of varieties produced in a plurality of processes, and the minimum time for evaluating constraints A term / span information setting step for storing a unit that is a unit of production, a term that is a unit of production plan creation composed of one or more spans, and a number of terms for production plan creation, and a product for each of the types A manufacturing route information storage step for registering one or more manufacturing routes to which a facility capable of processing for a plurality of processes for manufacturing a process is assigned as a process design, and for registering the processing capability of each process for each process design; A facility information storage step for registering facility capability for each term of each facility, and a post-process for each process for each process design, taking into account the time between processes before and after the process. The evaluation index set in advance does not exceed the amount to be processed in the previous process, and satisfies the constraint that the total load for each term of each facility obtained by the processing capacity does not exceed the facility capacity. And an optimum product configuration calculating step for calculating the production amount of each span of each process design that is maximized.

  The program according to the present invention is a program for optimizing the production amount of products of a plurality of varieties produced in a plurality of processes in a computer, and a span that is a unit of a minimum time for evaluating a constraint, and one or more A term / span information setting step for storing a term that is a unit of production plan creation and the number of terms for which production plan creation is performed, and processes for a plurality of processes for manufacturing products for each of the types A manufacturing route information storage step for registering one or more manufacturing routes to which possible facilities are assigned as a process design, and for registering the processing capability of each process for each process design, and for each term of each facility, the facility capacity The facility information storage step for registering the process, the amount processed in the subsequent process while considering the time between processes before and after each process for each process design is processed in the previous process Each process design in which the preset evaluation index is maximized while satisfying the constraint that the total load for each term of each facility obtained by the processing capacity does not exceed the facility capacity. It is for making a computer perform the optimal kind structure calculation step which calculates the production amount of each span of this.

  A production plan creation device according to the present invention is a production plan creation device that optimizes the production amount of products of a plurality of varieties produced in a plurality of processes, and includes a span that is a unit of a minimum time for evaluating constraints, A term / span information setting means for storing a term, which is a unit of production plan creation composed of the above spans, and the number of terms for which production plan creation is performed, and a plurality of steps for producing a product for each of the types One or more manufacturing routes to which processable facilities are assigned are registered as a process design, and a manufacturing route information storage means for registering the processing capacity of each process for each process design, and for each term of each facility In addition, the facility information storage means for registering the facility capacity, and the amount processed in the subsequent process while considering the time between processes before and after each process for each process design does not exceed the amount processed in the previous process, In addition, while satisfying the constraint that the total load for each term of each facility determined by the processing capacity does not exceed the facility capacity, the production amount of each span of each process design that maximizes the preset evaluation index And an optimum product type composition calculating means for calculating.

According to this, a time unit called a term is used as a unit for setting the facility capacity. In addition, a time unit called span is used as a unit for determining the processing amount and the production amount (here, the production amount means the processing amount of the final process). The production volume for each process design that is registered as one or more production routes by assigning equipment that can be processed for a plurality of processes for manufacturing products is the throughput and production volume of each span for each process design process. The amount processed in the subsequent process does not exceed the amount processed in the previous process while considering the time between processes before and after each process for each process for each process design (that is, the time between processes such as cooling time) If necessary, in order to start the process k of the span t, the previous process k ′ must be completed by a time that is back from the span t by the inter-process time. The total amount of processing and production up to the span must not exceed the accumulated amount of processing up to the span of the previous process of the process, that is, only the amount of processing in the previous process is processed in the next process. Process k 'which is the previous process The processing amount or production amount of the next step, step k, must not exceed the processing amount.) In addition, the total load for each term of each equipment calculated from the processing capacity does not exceed the equipment capacity (for each equipment It is determined so that the preset evaluation index is maximized in the period (all terms) in which the production plan is created while satisfying the constraint (within the range of facility capacity for each term). Therefore, even when there are multiple processes for producing a single product type or when there are alternative facilities, it is set in advance during the production planning period (all terms). The production amount of each span of each process design that maximizes the evaluation index is determined.
Here, the “equipment capacity” of each equipment means the operating capacity of each equipment, for example, the time that can be spent on net processing (actual work rate, etc.) when the equipment is fully operated. Means. “Processing capacity” that can be processed in each process is an ability to process a product or an intermediate product in each process. For example, a product or an intermediate product that can be processed per predetermined time in each process. It means weight. The “total load for each term of each facility” obtained by the processing capacity is the total of the load for each term of actual processing in each facility. For example, a unit quantity of products is produced in each facility. This means the total processing time required for each term, and is calculated based on the processing capacity.

  Here, in the production plan creation method according to the present invention, a production quantity information storage step for registering a production quantity lower limit value and a production quantity upper limit value as a required production quantity range for each term of each of the varieties, And the constraint is that, for each term of each of the varieties, the total production amount of spans constituting the term is within a range not less than the production amount lower limit value and within the production amount upper limit value. It is preferable to satisfy the condition.

  Similarly, the program according to the present invention further includes a production quantity information storage step for registering a production quantity lower limit value and a production quantity upper limit value as a required production quantity range for each term of each of the varieties. And the constraint is that, for each term of each of the varieties, the total production amount of spans constituting the term is within a range not less than the production amount lower limit value and within the production amount upper limit value. It is preferable to satisfy the condition.

  Similarly, the production plan creation device according to the present invention is a production quantity information storage means for registering a production quantity lower limit value and a production quantity upper limit value as a required production quantity range for each of the terms of each type. And the constraint is that, for each term of each of the varieties, the total production amount of spans constituting the term is within a range not less than the production amount lower limit value and within the production amount upper limit value. It is preferable to satisfy the condition.

  According to this, for each term of each product type, the total production amount of spans constituting the term is determined within a range not less than the production amount lower limit value and within the production amount upper limit value. Therefore, by setting the production volume lower limit value, it is possible to optimize other product configurations after producing the products to be produced strategically. Further, by setting the production amount upper limit value, it is possible to optimize other product types without producing an amount that cannot be sold or stored. Furthermore, by setting the production lower limit value and the production upper limit value to the same value, it is possible to optimize other product configurations after producing a product that must be produced in a certain amount.

  Here, the production plan creation method according to the present invention is a step of creating and registering a production route to which an alternative facility is assigned as a process design based on a preset rule for the alternative facility when the alternative facility exists. Are preferably further provided.

  Similarly, the program according to the present invention further includes a step of creating and registering a manufacturing route to which an alternative facility is assigned as a process design based on a preset rule of the alternative facility when the alternative facility exists. It is preferable to have a computer execute it.

  Similarly, the production plan creation device according to the present invention is a means for creating and registering a manufacturing route to which an alternative facility is assigned as a process design based on a preset rule for the alternative facility when the alternative facility exists. Are preferably further provided.

  According to this, one or more manufacturing routes to which alternative equipment is assigned as a new process design for one manufacturing route stored in advance as a process design based on rules regarding alternative equipment (rules for alternative equipment). Created. Therefore, by optimizing the production amount for each process design including the newly created process design, it is possible to optimize the product configuration including distribution to alternative equipment.

  Here, it is preferable that the production plan creation method, the production plan creation device, and the program according to the present invention calculate the evaluation index by a linear programming method.

  According to this, when the production volume for each process design and the load of each facility necessary for the production by the process design can be handled in a linear format, linear programming can be applied to the calculation of the evaluation index. Therefore, even when the number of varieties and facilities is large, the production amount for each process design can be optimized at high speed.

  In the production plan creation method according to the present invention, when the production amount of each span of each process design that maximizes the preset evaluation index that satisfies the constraints cannot be calculated, the term of one or more of the equipments With respect to the above, the constraint relaxation step of relaxing the constraint that the total load for each term of each facility determined by the processing capacity does not exceed the facility capacity, and calculating the production amount of each span of each process design, It is preferable to further provide.

  Similarly, the program according to the present invention relates to the term of one or more of the equipments when the production amount of each span of each process design in which the preset evaluation index satisfying the constraint is maximized cannot be calculated. A constraint relaxation step of relaxing the constraint that the total load for each term of each facility determined by the processing capacity does not exceed the facility capacity, and calculating the production amount of each span of each process design; It is preferable to make it execute.

  Similarly, the production plan creation device according to the present invention is configured so that when the production amount of each span of each process design in which the preset evaluation index satisfying the constraint is maximized cannot be calculated, the one or more of the equipments Constraint relaxation means for relaxing the constraint that the total load for each term of each facility determined by the processing capacity does not exceed the facility capacity with respect to the term, and calculating the production amount of each span of each process design, Is preferably further provided.

  According to this, when a solution for each span of each process design that satisfies the constraints cannot be obtained, the calculation is not repeated until the solution is obtained by omitting one or more constraints as in the prior art. By relaxing the constraints on facility capacity for one or more facility terms, each span of each process design that maximizes the preset evaluation index that satisfies the constraints is achieved without increasing computation time and effort. The optimal solution for the production volume can be easily obtained. And if the solution for the production volume of each span of each process design is obtained by relaxing the constraints on the equipment capacity, a measure to reduce the equipment load at the term exceeding the equipment capacity (for example, appropriate To reduce the lower limit of the production amount of various varieties) and to increase the facility capacity with the term (overtime work or to fully operate the facility capacity). It should be noted that the constraint on the facility capacity may be relaxed for some equipment terms or for all equipment terms.

  Here, in the production plan creation method according to the present invention, in the constraint relaxation step, the processing for the constraint that the total load for each term of each facility obtained by the processing capability does not exceed the facility capability. Adding a variable corresponding to the equipment load over which the total load of the term of one or more of the equipment obtained by capacity exceeds the equipment capacity, and adding the equipment overload penalty to the evaluation index, The production amount of each span of each process design that maximizes a preset evaluation index that satisfies the constraint may be calculated by linear programming.

  Similarly, the program according to the present invention obtains the constraint relaxation step based on the processing capability with respect to the constraint that the total load for each term of each facility determined by the processing capability does not exceed the facility capability. In addition to adding a variable corresponding to an equipment load overload in which the total load of the term of one or more of the equipment exceeds the equipment capacity, and adding the penalty of the equipment load over to the evaluation index, The production amount of each span of each process design that maximizes the preset evaluation index that is satisfied may be calculated by linear programming.

  Similarly, in the production plan creation device according to the present invention, the constraint relaxation means performs the processing with respect to the constraint that the total load for each term of each facility obtained by the processing capability does not exceed the facility capacity. Adding a variable corresponding to the equipment load over which the total load of the term of one or more of the equipment obtained by capacity exceeds the equipment capacity, and adding the equipment overload penalty to the evaluation index, The production amount of each span of each process design that maximizes a preset evaluation index that satisfies the constraint may be calculated by linear programming.

  According to this, for one or more equipment terms, by adding a variable corresponding to equipment overload to the equipment capacity constraint condition and relaxing the equipment capacity constraint, solving linear programming only once Therefore, it is possible to always obtain a solution for the production amount of each span of each process design that maximizes the preset evaluation index that satisfies the constraints. In addition, by adding a facility load over penalty to the evaluation index, a solution that minimizes the facility load over is given priority.

  Alternatively, in the production plan creation method according to the present invention, when the production amount of each span of each process design that maximizes the preset evaluation index that satisfies the constraints cannot be calculated, the term of one or more of the varieties is calculated. With respect to each term of each of the varieties, each of the above steps is relaxed by relaxing the total production amount of spans constituting the term within a range not less than the production amount lower limit value and within the production amount upper limit value. It is preferable to further include a constraint relaxation step for calculating the production amount of each span of the design.

  Similarly, the program according to the present invention relates to the terms of one or more of the varieties when the production amount of each span of each process design that maximizes the preset evaluation index that satisfies the constraints cannot be calculated. For each term of each of the varieties, the restriction that the total production amount of spans constituting the term is within the range between the production amount lower limit value and the production amount upper limit value is relaxed, and each process design It is preferable to further cause the computer to execute a constraint relaxation step for calculating the production amount of each span.

  Similarly, the production plan creation device according to the present invention, when the production amount of each span of each process design that maximizes the preset evaluation index that satisfies the constraints cannot be calculated, Regarding terms, for each term of each of the varieties, the restriction that the total production amount of spans constituting the term is within the range between the production amount lower limit value and the production amount upper limit value is relaxed, It is preferable to further include constraint relaxation means for calculating the production amount of each span of the process design.

  According to this, when a solution for each span of each process design that satisfies the constraints cannot be obtained, the calculation is not repeated until the solution is obtained by omitting one or more constraints as in the prior art. For terms of one or more varieties, the calculation time can be reduced by relaxing the constraint conditions (especially the constraint condition that the production volume is lower than the production volume lower limit value) regarding the production volume range (production volume lower limit value or more and production volume upper limit value or less) In addition, it is possible to easily obtain an optimal solution for the production amount of each span of each process design in which the preset evaluation index satisfying the constraint is maximized without increasing time and effort. Then, relax the constraints (particularly the constraint that the production volume is lower than the production volume lower limit value) regarding the production volume range (especially the production volume lower limit value or more) and solve the production volume for each span in each process design. Is obtained, it is possible to obtain effective information for making a decision on the next response, such as which kind of product is below the lower limit of production volume at which term. It should be noted that the constraint on the range of production volume may be relaxed for terms of some varieties or for terms of all varieties.

  Here, in the production plan creation method according to the present invention, when the constraint relaxation step cannot calculate the production amount of each span of each process design that maximizes a preset evaluation index that satisfies the constraint, For each term of each product type, the constraint that the total production amount of spans constituting the term is within the range of the production value lower limit value or more and the production amount upper limit value is one or more of the products of the product type Regarding the term, a variable corresponding to the unachieved production amount in which the total production amount of the span constituting the term did not satisfy the production lower limit value was added, and the penalty of the unachieved production amount for the evaluation index was added. In addition, the production amount of each span of each process design that maximizes the preset evaluation index satisfying the constraint may be calculated by linear programming.

  Similarly, the program according to the present invention, when the constraint relaxation step cannot calculate the production amount of each span of each process design that maximizes a preset evaluation index that satisfies the constraint, For each term, with respect to the constraint that the total production amount of spans constituting the term is within the range between the production amount lower limit value and the production amount upper limit value, the term of one or more of the varieties, A variable corresponding to the unachieved amount of production in which the total production amount of the span constituting the term did not reach the lower limit value of the production amount was added, and a penalty for the unachieved production amount was added to the evaluation index The production amount of each span of each process design that maximizes the preset evaluation index that satisfies the constraints may be calculated by linear programming.

  Similarly, in the production plan creation device according to the present invention, when the constraint relaxation step cannot calculate the production amount of each span of each process design that maximizes a preset evaluation index that satisfies the constraint, For each term of each product type, the constraint that the total production amount of spans constituting the term is within the range of the production value lower limit value or more and the production amount upper limit value is one or more of the products of the product type Regarding the term, a variable corresponding to the unachieved production amount in which the total production amount of the span constituting the term did not satisfy the production lower limit value was added, and the penalty of the unachieved production amount for the evaluation index was added. In addition, the production amount of each span of each process design that maximizes the preset evaluation index satisfying the constraint may be calculated by linear programming.

  According to this, regarding the term of one or more varieties, a variable corresponding to the unachieved amount of production is added to the constraint on the production range (above the production amount lower limit value and less than the production amount upper limit value). By relaxing the constraint and solving the linear programming method only once, it is possible to always obtain a solution for the production amount of each span of each process design in which the preset evaluation index satisfying the constraint is maximized. In addition, by adding a penalty for unachieved production to the evaluation index, a solution that minimizes unachieved production is preferentially obtained.

  Further, in the production plan creation method according to the present invention, when the constraint relaxation step cannot calculate the production amount of each span of each process design in which the preset evaluation index satisfying the constraint is maximized, For each term of a variety, the term of one or more of the varieties is against the constraint that the total production amount of spans constituting the term is within the range between the production amount lower limit value and the production amount upper limit value In addition, a 0-1 variable indicating whether or not the total of the production volume of the span constituting the term is 0 regardless of the production volume lower limit value and the production volume upper limit value is added to satisfy the constraint in advance. The production amount of each span of each process design that maximizes the set evaluation index may be calculated by a mixed integer calculation method.

  Similarly, the program according to the present invention, when the constraint relaxation step cannot calculate the production amount of each span of each process design that maximizes a preset evaluation index that satisfies the constraint, For each term, with respect to the constraint that the total production amount of spans constituting the term is within the range between the production amount lower limit value and the production amount upper limit value, the term of one or more of the varieties, A 0-1 variable indicating whether or not the total production amount of spans constituting the term is 0 regardless of the production lower limit value and the production upper limit value is set in advance to satisfy the constraints. The production amount of each span of each process design with the maximum evaluation index may be calculated by a mixed integer calculation method.

  Similarly, in the production plan creation device according to the present invention, when the constraint relaxation means cannot calculate the production amount of each span of each process design in which the preset evaluation index satisfying the constraint is maximized, For each term of each product type, the constraint that the total production amount of spans constituting the term is within the range of the production value lower limit value or more and the production amount upper limit value is one or more of the products of the product type Regarding terms, the 0-1 variable was added to indicate whether the total of the production volume of the span constituting the term should be 0 regardless of the production volume lower limit value and the production volume upper limit value, thereby satisfying the constraints. The production amount of each span of each process design that maximizes the preset evaluation index may be calculated by a mixed integer calculation method.

  According to this, due to operational constraints, production may not be possible when the production volume is lower than the lower limit value of production, and when the production volume is lower than the lower limit value, it may be a rational production plan with zero production volume. In such a case, regarding the term of one or more varieties, whether the total production amount of spans constituting the term is set to 0 regardless of the constraint condition relating to the production range (production amount lower limit value or more and production amount upper limit value or less) By adding a 0-1 variable representing whether or not, and relaxing the constraints on the range of production, solving the mixed integer programming only once, each of the preset evaluation indices satisfying the constraints is maximized The solution of the production volume of each span of the process design can always be obtained.

  The production plan creation method according to the present invention includes a product information storage step for registering a selling price and a raw material cost for each product type, and a generated cost information storage for registering a variable cost generated in each process for each process design. And the evaluation index may be set as the sum of (sales price-raw material cost-variable cost) of all terms.

  Similarly, the program according to the present invention includes a product information storage step for registering a selling price and a raw material cost for each product type, and an generated cost information storage step for registering a variable cost generated in each process for each process design. Further, the evaluation index may be set to the sum of (sale price-raw material cost-variable cost) for all terms.

  Similarly, the production plan creation device according to the present invention includes product information storage means for registering selling price and raw material cost for each type, and generated cost information for registering variable cost generated in each process for each process design. Storage means, and the evaluation index may be set as the sum of (sale price-raw material cost-variable cost) of all terms.

According to this, the production amount of each process design is determined so that the sum of (sale price-raw material cost-variable cost) of all terms as evaluation indexes becomes the maximum. Therefore, even when the same variety is produced, there are a plurality of production routes, and even when the variable costs and raw material costs are different, the overall profit can be maximized.
Here, the “variable cost” generated in each process means, for example, a cost required for processing in each process.

  The production plan creation method according to the present invention includes a product information storage step for registering a selling price and a raw material cost for each product type, and an generated cost information storage for registering a variable cost generated in each process for each process design. And the evaluation index may be set as a weighted sum of a sum of (sale price-raw material cost-variable cost) of all terms and a sum of production amounts of all terms of all varieties.

  Similarly, the program according to the present invention includes a product information storage step for registering a selling price and a raw material cost for each product type, and an generated cost information storage step for registering a variable cost generated in each process for each process design. Further, the evaluation index may be executed by a computer, and the evaluation index may be set as a weighted sum of the sum of all terms (selling price-raw material cost-variable cost) and the sum of production amounts of all terms of all varieties.

  Similarly, the production plan creation device according to the present invention includes product information storage means for registering selling price and raw material cost for each type, and generated cost information for registering variable cost generated in each process for each process design. Storage means, and the evaluation index may be set as a weighted sum of a sum of all terms (sales price-raw material cost-variable cost) and a sum of production amounts of all terms of all varieties.

  According to this, the production of each process design is maximized so that the weighted sum of the sum of (term selling price-raw material cost-variable cost) of all terms and the total amount of production of all terms of all varieties is maximized. The amount is determined. Therefore, it is possible to adjust the balance between profit and production amount with a weighted parameter, and it is possible to determine a variety configuration that increases or decreases the production amount while ensuring profit.

  Here, the production plan creation method according to the present invention further includes an inventory cost unit price storing step of registering an inventory cost unit price per unit time / unit amount for each process design, and the evaluation index is the process design Each time, it is calculated based on the inventory cost unit price from the production lead time from the start of production to the completion of production obtained based on the span for processing the first process and the span for processing the final process, and the production volume. It may be set including the inventory cost.

  Similarly, the program according to the present invention further causes a computer to execute an inventory cost unit price storing step of registering an inventory cost unit price per unit time / unit amount for each process design, and the evaluation index is the process design Each time, it is calculated based on the inventory cost unit price from the production lead time from the start of production to the completion of production obtained based on the span for processing the first process and the span for processing the final process, and the production volume. It may be set including the inventory cost.

  Similarly, the production plan creation device according to the present invention further comprises inventory cost unit price storage means for registering an inventory cost unit price per unit time / unit amount for each process design, and the evaluation index is the process design Each time, it is calculated based on the inventory cost unit price from the production lead time from the start of production to the completion of production obtained based on the span for processing the first process and the span for processing the final process, and the production volume. It may be set including the inventory cost.

  According to this, by including the inventory cost that depends on the residence time of the intermediate product (that is, the production lead time from the start of production to the completion of production) and the production cost in the evaluation function, the total profit including the inventory cost ( That is, the sum of (sale price-raw material cost-variable cost-inventory cost) of all terms, or the sum of (sell price-raw material cost-variable costs-inventory cost) of all terms and the total production amount of all terms of all varieties A production plan that maximizes the weighted sum) can be created. In particular, since the inventory cost unit price of each process from the start of manufacture to the completion of manufacture is made the same, the calculation is easy.

  The production plan creation method, the production plan creation device, and the program according to the present invention include the production lead time, the span for processing the first process, and the span for processing the final process, with the production amount for each span. It is better to calculate it by treating it as a weighted average.

  According to this, since the average processing span weighted to the production amount in each span is used in the first step and the final step, the processing unit at the start of manufacturing and the processing unit at the completion of manufacturing are The inventory cost can be handled without direct linking. Therefore, the number of variables can be greatly reduced compared to the case of direct linking, and the optimization calculation can be speeded up.

  The production plan creation method according to the present invention further includes an inventory cost unit price storing step for registering an inventory cost unit price per unit time / unit amount in each process for each process design, and the evaluation index is: Each process design is calculated based on the inventory cost unit price from the inter-process lead time and the production amount in each process from the start of manufacture to the completion of manufacture obtained based on the span for processing each process. It may be set including inventory costs.

  Similarly, the program according to the present invention further causes the computer to execute an inventory cost unit price storing step of registering an inventory cost unit price per unit time / unit amount in each process for each process design, and the evaluation index is For each process design, it is calculated based on the inventory cost unit price from the inter-process lead time and the production volume in each process from the start of manufacturing to the completion of manufacturing obtained based on the span for processing each process. It may be set including the inventory cost.

  Similarly, the production plan creation device according to the present invention further comprises inventory cost unit price storage means for registering an inventory cost unit price per unit time / unit amount in each process for each process design, and the evaluation index is For each process design, it is calculated based on the inventory cost unit price from the inter-process lead time and the production volume in each process from the start of manufacturing to the completion of manufacturing obtained based on the span for processing each process. It may be set including the inventory cost.

  According to this, the residence time of the intermediate product from the start of manufacturing to the completion of manufacturing (that is, the inter-process lead time that is the time between each process from the start of manufacturing to the completion of manufacturing) and the inventory cost that depends on the production volume are evaluated. By including it in the function, the total profit including inventory cost (ie, the sum of (sell price-raw material cost-variable cost-inventory cost) of all terms, or (sell price-raw material cost-variable cost-inventory cost) of all terms Production plan that maximizes the total weight of the total sum of all the varieties and the sum of the production amounts of all the terms of all varieties. In particular, in each process from the start of manufacturing to the completion of manufacturing, the present invention can be applied when the unit cost of the inventory cost for each process is different.

  The production plan creation method, the production plan creation device, and the program according to the present invention treat the lead time between the processes as a weighted average of the production amount for each span, with respect to the span for processing each process. It is good to calculate.

  According to this, each process uses an average processing span that is weighted by the production volume in each span, so the unit of processing at the start of manufacturing and the unit of processing at the end of manufacturing are directly linked. You can handle inventory costs without it. Therefore, the number of variables can be greatly reduced compared to the case of direct linking, and the optimization calculation can be speeded up.

  In such a case, the production plan creation method according to the present invention calculates, based on the processing capacity, the load of each process for each process design when a product is produced in a unit quantity as a process load basic unit. A process load unit calculation step, and a generated cost unit calculation step for calculating the generated cost for each process design required when producing a unit quantity of a product based on the variable cost as an generated cost unit. It is preferable that the evaluation index is calculated by linear programming using the process load unit and the generated cost unit.

  Similarly, in such a case, the program according to the present invention, based on the processing capability, calculates a process load that uses the process load as a unit of process load for each process design when a product is produced in a unit quantity. A basic unit calculation step, and a generated cost basic unit calculation step for calculating, as a generated cost basic unit, an generated cost for each process design required when a product is produced in a unit quantity based on the variable cost. The calculation of the evaluation index is preferably performed by linear programming using the process load unit and the generated cost unit.

  Similarly, in such a case, the production plan creation method according to the present invention calculates, based on the processing capability, the load of each process for each process design when a product is produced in a unit quantity as a process load basic unit. A process load basic unit calculating means, and an generated cost basic unit calculating means for calculating the generated cost for each process design required when producing a unit quantity of a product based on the variable cost as an generated cost basic unit. Further, the evaluation index is preferably calculated by linear programming using the process load unit and the generated cost unit.

According to this, based on the information on the processing capacity in each process for all equipment in the production line, the process load intensity for each process of each process design (for example, each process necessary to produce 1 ton of product) Means the time for each process of the design). Therefore, restrictions on the facility capacity of each facility can be handled in a linear format based on the processing capacity in each process, and linear programming can be applied to determine the optimum product type configuration.
Also, variable cost information, which is information for each process in the process design, is aggregated as a generated cost basic unit per unit production amount for each process design. Therefore, the number of variables in the linear programming method can be reduced, and the calculation speed can be increased.

  Then, the production plan creation method, the production plan creation device, and the program according to the present invention may set the evaluation index as the sum of the production amounts of all terms of all varieties.

  According to this, the production amount of each process design is determined so that the sum of the production amounts of all the terms of all the varieties as the evaluation index is maximized. Accordingly, it is possible to determine a variety configuration that places importance on the total production volume, as in the case of giving priority to share.

  The production plan creation method according to the present invention may further include a product information storage step of registering a selling price for each of the types, and the evaluation index may be set as a sum of selling prices of all terms of all types.

  Similarly, the program according to the present invention may further cause the computer to execute a product information storage step for registering a selling price for each product, and set the evaluation index as a sum of selling prices of all terms of all products. .

  Similarly, the production plan creation apparatus according to the present invention may further include product information storage means for registering a selling price for each of the types, and the evaluation index may be set as a sum of selling prices of all terms of all types. .

  According to this, the production amount of each process design is determined so that the sum of the selling prices of all terms of all varieties as the evaluation index becomes the maximum. Therefore, it is possible to determine a variety composition that places more importance on the total deposit than profit.

  In such a case, the production plan creation method according to the present invention uses the process capability to calculate the process load as the process load basic unit for each process design when the product is produced in a unit quantity. It is preferable to further include a basic unit calculation step, and the evaluation index is calculated by linear programming using the process load basic unit.

  Similarly, in such a case, the program according to the present invention calculates a process load basic unit that calculates the load of each process for each process design when producing a unit quantity of a product based on the processing capability as a process load basic unit. Preferably, the calculation step is further executed by a computer, and the evaluation index is calculated by linear programming using the process load intensity.

  Similarly, in such a case, the production plan creation apparatus according to the present invention is a process of calculating, as a process load basic unit, the load of each process for each process design when a product is produced in a unit quantity based on the processing capacity. It is preferable to further include a load unit calculation means, and the calculation of the evaluation index is preferably performed by linear programming using the process load unit.

  Therefore, restrictions on the facility capacity of each facility can be handled in a linear format based on the processing capacity in each process, and linear programming can be applied to determine the optimum product type configuration.

  The program according to the present invention is a removable recording medium such as a CD-ROM (Compact Disc Read Only Memory), FD (Floppy (registered trademark) Disk), or MO (Magneto-Optic), or a fixed recording medium such as a hard disk. In addition to being able to be recorded and distributed, it can be distributed via a communication network such as the Internet by wired or wireless telecommunication means.

  The best mode for carrying out the production plan creation method, production plan creation apparatus, and program according to the present invention will be described below with reference to a specific example with reference to the drawings.

First, an example of the production line targeted in this embodiment will be described with reference to FIG. FIG. 2 is a diagram illustrating a production line.
As shown in FIG. 2, the production line from the raw material 100 to the product 160 includes melting (melting 01 and melting 02) 110, hot rolling 120, cold rolling (cold rolling 01, cold rolling 02 and cold rolling 03) 130. , Sinter (sintered 01 and sinter 02) 140 and slitter (slitter 01, slitter 02 and slitter 03) 150, except for hot rolling 120, is composed of a plurality of facilities having different capacities. Here, it is assumed that the equipment used and the order differ depending on the type (product type) of the product, and the arrows in the figure indicate the manufacturing routes (the individual routes will be described later based on Table 3).

  Moreover, the “actual rate” of each term shown in Table 1 is defined as the equipment capacity of each equipment. Here, the actual work rate is a ratio of time that can be spent on net processing when the equipment is operated to the maximum, and is set statistically from the operation results of the equipment. For example, if the actual working rate is 80%, it means that 19.2 hours can be spent on net processing in the day, and the remaining time is consumed for work preparation and maintenance.

  In this embodiment, the term length is 30 days (one month), and the span length is 3 days. In the present embodiment, the period for creating the production plan is set to 6 terms (about 6 months). In consideration of the fact that the load on the equipment in the first term and the final term is smaller than in other terms, in this embodiment, a term having the same information as the first term is assigned to the final term before the first term. Later, each term with the same information as the final term was added and calculated.

Next, Table 2 shows a product type table used in the present embodiment.
As shown in Table 2, there are five types of “types” from A to E, and there are two to three types of production routes as “process design” of each type. For example, in the type C, there are three types of process designs with process design numbers 5 to 7.
In addition, as shown in Table 2, each variety produces a production amount required in each term, that is, a lower limit amount to be produced in each term (“production amount lower limit value”) and more. However, there is an upper limit amount ("production amount upper limit value") that cannot be sold or stored. Therefore, it is necessary to perform production within a range between the production lower limit value and the production quantity upper limit value using any given process design.
Furthermore, as shown in Table 2, “raw material cost” and “selling price” per ton are given. In the present embodiment, the raw material cost can be set to a different value for each process design.

Next, Table 3 shows a passing process table of each process design used in the present embodiment. Here, in the passing process table, the manufacturing route in each “process design” for each “product type” is shown, and the intermediate product is manufactured through the processes in the order of “process serial number” shown in Table 3. Finally, products of each variety are manufactured. In each step, as shown in Table 3, “facility” that can be processed is assigned.
As shown in Table 3, the weight of a product or an intermediate product that can be processed per hour in each process is defined as “load” (processing capacity) in each process. For example, the type A of the process design number 1 can be processed by 30.0 tons per hour in the melting 01 that is the equipment of the process number 1.
In addition, the cost incurred for processing 1 ton in each process is defined as “variable cost”. For example, in order to process 1 ton of product type A with process design number 1, a variable cost of 45,000 yen is required for melting 01, which is a process number 1 facility.
In addition, the weight cost on the exit and entry sides of the equipment is defined as “process yield”. For example, in the melting 01 that is the equipment of the process number 1, in order to complete 99 tons of the product A of the process design number 1, it is necessary to input 100 tons. One ton is discarded as a defective part at the front and rear ends.

[First embodiment]
Next, a production plan creation method, a production plan creation device, and a program according to the first embodiment will be described. First, the production plan creation apparatus according to the first embodiment will be described with reference to FIG. FIG. 1 is a block diagram of a production plan creation apparatus according to the first embodiment.
As shown in FIG. 1, a production plan creation apparatus 1 includes a production amount information storage unit (production amount information storage unit) 2, a raw material / sale price information storage unit (product information storage unit) 3, and an equipment information storage unit (equipment). Information storage means) 4, evaluation index setting section 5, term / span information setting section (term / span information setting means) 6, process load intensity calculation section (process load intensity calculation means) 10, and manufacturing route Information storage unit (manufacturing route information storage unit) 11, generated cost unit calculation unit (generated cost unit calculation unit) 20, generated cost information storage unit (generated cost information storage unit) 21, and optimum product configuration calculation unit (Optimum product configuration calculation means) 30 and a result output unit 40.

  The production amount information storage unit 2 is for storing information on the process design number, production lower limit value, and production upper limit value that can be used for each product type. In the present embodiment, this corresponds to the columns of “process design number”, “production amount lower limit value”, and “production amount upper limit value” in the type table of Table 2 described above.

  The raw material / selling price information storage unit 3 is for storing information on the raw material cost and selling price for each product type. In the present embodiment, this corresponds to the columns of “raw material cost” and “selling price” in the type table of Table 2 described above. In the present embodiment, the raw material cost is set for each process design, and the raw material cost varies depending on the process design in all types of product types A to E.

  The facility information storage unit 4 is for storing information related to the facility capability of each facility. In the present embodiment, this corresponds to the “actual work rate” column in the product type table of Table 1 described above.

  The evaluation index setting unit 5 is for setting an evaluation index serving as a reference for optimizing the production amount of each product type. In this embodiment, either the total profit, which is the sum of (sales price-raw material cost-variable cost), or the total production, which is the sum of the production amounts of all varieties, is used as the evaluation index.

  The term / span information setting unit 6 is for setting information on the length of the term, the length of the span, and the period for creating the production plan. In the present embodiment, the term length is 30 days (1 month) and the span length is 3 days. In the present embodiment, the period for creating the production plan is set to 6 terms (about 6 months).

The manufacturing route storage unit 11 is for storing the equipment used and the order of use for each process design, and the processing capability of each process for each process design.
In the present embodiment, it corresponds to the column of “equipment” and “load” in “process serial number” in the passing process table of Table 3 described above.

  Based on the processing capability of each process stored in the manufacturing route storage unit 11, the process load basic unit calculation unit 10 is a process load basic unit for each process (process design required to make one ton of product). It means the processing time in each process for every step). The calculation method of the process load basic unit for each process for each process design in the present embodiment will be described below using Table 4.

In the present embodiment, first, in each process design number, in order from the process having the largest process serial number (final process), equipment in each process when producing 1 ton of product based on the “process yield” Calculate the outgoing weight (defined as “reference weight”). In the first step, the weight of the necessary raw material (defined as “necessary raw material”) is calculated. The calculation results are shown in Table 4 below.
As shown in Table 4, for example, in the cold rolling 02 which is the equipment of the process number 5 of the process design number 1, the reference weight is obtained by using the process yield in the slitter 03 which is the equipment of the process number 6. 1 [ton] /0.9=1.11.111111... [Ton]. Further, in the slitter 01 that is the equipment of the process serial number 4, the reference weight is 1.111111111 ... [ton] / ton using the process yield and load of the cold rolling 02 that is the equipment of the process serial number 5. 0.98 = 1.13378685 ... [tons]. Similarly, the reference weight is calculated up to the process number 1 (first process). Then, using the reference weight and the process yield of the process number 1 (first process), the necessary raw material for producing 1 ton of product is calculated. For example, in the process design number 1, the required raw material is 1.42900859... [Ton] /0.99=1.444344302.

Next, based on the “reference weight” and “load” in each process, the processing time (defined as “reference time”) in each process when producing 1 ton of product is calculated. Table 4 shows the calculation results.
As shown in Table 4, for example, in the cold rolling 01 which is the equipment of the process number 3 of the process design number 1, the reference time is 1.28839415... [Ton] /60.0 [ton / hr] = 0.021473236 ... [hr].

  The generated cost information storage unit 21 is for storing a cost generated for processing 1 ton in each process, that is, a variable cost. In the present embodiment, this corresponds to the “variable cost” column in the passage process table of Table 3 described above.

  Based on the variable cost stored in the generated cost information storage unit 11, the generated cost basic unit calculation unit 20 generates the generated cost basic unit for each process design (the cost for each process design generated to make one ton of product). Means). The calculation method of the generated cost basic unit for each process design in the present embodiment will be described below using Table 7 and Table 8.

In the present embodiment, first, one ton of product is produced based on the “variable cost” stored in the generated cost information storage unit 21 and the “reference time” calculated by the process load basic unit calculation unit 10. The cost (defined as “reference cost”) generated in each process is calculated. Here, the weight on the entry side of each facility is used as the reference weight. Table 4 shows the calculation results.
As shown in Table 4, for example, in process design number 2, in hot rolling, which is the equipment of process serial number 2, the standard cost is 21 [thousands based on the variable cost of hot rolling and the standard time of hot rolling. Yen / hr] × 0.021473236... [Tons] = 4.509379509... [1000 yen].

  Next, the calculated reference costs for each process are tabulated for each process design number, and the generated cost basic unit for each process design is calculated. Table 5 shows the calculation results.

  The optimum product configuration calculation unit 30 generates the generated cost basic unit for each process design calculated by the generated cost basic unit calculation unit 20 and the process load basic unit for each process for each process design calculated by the process load basic unit calculation unit 10. Production amount information stored in the production amount information storage unit 2, raw material / sale price information stored in the raw material / sale price information storage unit 3, facility information stored in the facility information storage unit 4, and setting in the evaluation index setting unit 5 With reference to the evaluation index, the constraint on the facility capacity, the constraint on the range of production volume (above the production volume lower limit value and within the production volume upper limit value), and the constraint on the production volume of the preceding and following processes (in this embodiment, The time between processes before and after the process is all set to 0.), and the production amount for each process design that maximizes the evaluation formula is determined.

  In the present embodiment, the production amount of each span for each process design is determined by solving the optimization problem of the following equation 1 using linear programming.

  The formula shown in the above formula 1 is an evaluation formula when the evaluation index is profit. However, when the evaluation index is a production amount, the following formula 2 may be used as the evaluation formula.

The result output unit 40 is an output device (display, hard disk, printer, or the like) for displaying the calculation result of the optimum product configuration calculation unit 30 via an output interface (not shown). As the calculation result, the optimized product configuration, the profit for the optimized product configuration, the load status of the equipment, and the like are output.
The output interface is a program or hardware that performs data conversion and communication for outputting the calculation result in the optimum product configuration calculation unit 30 to the result output unit 40 (display, hard disk, printer, or the like).

In the present embodiment, the optimized variety configuration output in the result output unit 40 is shown in Tables 6 to 8 and FIGS. 4 to 5 below. In Tables 6 to 8 and FIGS. 4 to 5, optimization is performed to maximize profit (the evaluation index is maximum profit), and optimization is performed to maximize production (the evaluation index is maximum production). Two types of cases were implemented.
Table 6 shows the amount of production per span within the term of each process design optimized for maximum profit. Table 7 shows the total production of all terms for each process design optimized for maximum profit. Table 8 shows the sum of the production amounts of all the terms in each process design optimized to maximize the production amount.
FIG. 4 shows the transition of the production amount of each term in each process design optimized for maximum profit. FIG. 5 shows the transition of the production volume of each term in each process design optimized to maximize the production volume. 4 (a-1) to (e-1) and FIGS. 5 (a-1) to (e-1) are the products in the varieties A to E, that is, the process design numbers (FIGS. 4 and 4). 5 corresponds to “Product” in FIG. 5) and shows changes in the production amount of products 1 to 11. 4 (a-2) to (e-2) and FIGS. 5 (a-2) to (e-2) are varieties (corresponding to “Item” in FIGS. 4 and 5) A to The relationship between the transition of the production amount of the product E and the range of production amount in each term (corresponding to “Production range” in FIGS. 4 and 5) is shown. Here, the range of the production volume means a range of the production volume lower limit value or more and the production volume upper limit value or less in each term.

The following can be understood from Tables 6 to 8 and FIGS.
-The production volume of each product is within the range of the production volume lower limit value and the production volume upper limit value shown in Table 2.
・ The ratio of the process design used for each product type (production ratio) can be obtained.
・ Depending on the evaluation index, the composition of the product and the ratio of the process design used differ.

Next, Table 9 below shows the profits and production amounts for the optimized product configuration output in the result output unit 40. Table 9 shows the results for both the case where the evaluation index is the maximum profit and the case where the production volume is the maximum.
Here, the profit is the sum of (selling price−raw material cost−variable cost), and the total production is the sum of the production of all varieties.

  From Table 9, when profit is maximized, the profit is increased by about 19.9% than when the production volume is maximized, and when the production volume is maximized, the profit is maximized by about 5. It can be seen that 2% production increases.

Furthermore, the following table 10 and table 11 show the load status of the facility for the optimized product configuration output in the result output unit 40. Table 10 shows the results when the evaluation index is the maximum profit. Table 11 shows the results when the evaluation index is the maximum production amount.
Here, the load state of the equipment means the total load (in this embodiment, the process load source for each process design) with respect to the equipment capacity (in this embodiment, span time × actual operation rate for each equipment). It means the ratio of unit x production amount). 100% indicates that the facility capacity and total load of each facility are the same.

  From the results of Table 10 and Table 11, it can be seen that the variety configuration is determined within the range of the equipment capacity of the designated equipment. Moreover, the equipment which becomes a bottleneck can be judged concretely from this result, and it can utilize for the examination of operation improvement and the equipment capacity improvement of an equipment.

Next, the processing procedure of the production plan creation method using the production plan creation device 1 according to the first embodiment will be described with reference to FIG. FIG. 3 is a flowchart illustrating the processing procedure of the production plan creation method according to the first embodiment.
The process of the production plan creation method according to the first embodiment described below can be read and executed by the CPU as a program in the computer as well. Further, this program can be installed in various computer storage devices by recording it in a removable storage medium such as a CD-ROM, FD, or MO.

As shown in FIG. 3, first, in advance, the cost information generated for each process design, manufacturing route information, production volume information, raw material / sale price information, equipment information, evaluation index, and data on terms and spans are input. , Generation cost information storage unit 21 such as magnetic storage device, manufacturing route information storage unit 11, production amount information storage unit 2, raw material / sale price information storage unit 3, equipment information storage unit 4, evaluation index storage unit 5, and term Registered in the span information setting unit 6 (step S1: production amount information storage step, product information storage step, facility information storage step, term / span information setting step, generated cost information storage step).
For details of this step, the generated cost information storage unit 21, the production route information storage unit 11, the production amount information storage unit 2, the raw material / sale price information storage unit 3, and the facility information storage unit of the production plan creation apparatus 1 described above. 4. The description is the same as the description of the evaluation index storage unit 5 and the term / span information setting unit 6, and the description thereof is omitted.

Next, based on the manufacturing route information stored in the manufacturing route information storage unit 11, the process load unit calculation unit 10 calculates a process load unit for each process for each process design (step S2: process load). Basic unit calculation step).
Note that the details of this step are the same as those described in the process load intensity calculation unit 10 of the production plan creation apparatus 1 described above, and a description thereof will be omitted.

Further, based on the generated variable cost stored in the generated cost information storage unit 21 and the reference time calculated by the process load unit calculation unit 10, the generated cost unit calculation unit 20 generates the generated cost source for each process design. A unit is calculated (step S3: cost generation unit calculation step).
The details of this step are the same as those described in the generated cost basic unit calculation unit 20 of the production plan creation apparatus 1 described above, and a description thereof is omitted.

Then, in the optimum product configuration calculation unit 30, the generated cost basic unit calculated by the generated cost basic unit calculation unit 20, the process load basic unit calculated by the process load basic unit calculation unit 10, and the production amount information storage unit 2 in advance. Referring to the production volume information, raw material / sale price information, equipment information, and evaluation index respectively registered in the raw material / sale price information storage unit 3, the equipment information storage unit 4 and the evaluation index storage unit 5, the linear programming method By using this to solve the optimization problem, the production amount for each process design is determined (step S4: optimal product configuration calculation step).
The details of this step are the same as the description of the optimum product configuration calculation unit 30 of the production plan creation apparatus 1 described above, and a description thereof will be omitted.

Finally, the calculation result of the optimum product configuration calculation unit 30 is displayed on the result output unit 40, that is, the output device (display, hard disk, printer, etc.) (step S5).
The details of this step are the same as those described in the result output unit 40 of the production plan creation apparatus 1 described above, and a description thereof is omitted.

As described above, according to the production plan creation method, the production plan creation device, and the program according to the first embodiment, as a unit for setting the facility capacity based on the information set in the term / span information setting unit 6 A unit of time called a term is used. In addition, a time unit called a span is used as a unit for determining the processing amount and the production amount. The production quantity for each process design assigned to the optimum route type composition calculation unit 30 and capable of processing a plurality of steps for producing a product and registered in the production route storage unit 11 as one or more production routes is as follows. The amount processed in the previous process is the amount processed in the subsequent process while considering the inter-process time between the previous and subsequent processes for each process in the process design, with the processing amount and production amount of each span for each process of the process design as decision variables And the total load for each term of each facility calculated from the processing capacity stored in the manufacturing route storage unit 11 does not exceed the facility capacity of each facility previously stored in the facility information storage unit 4 (each It is determined so that the evaluation index set in advance in the evaluation index storage unit 5 is maximized during the production plan creation period (all terms) while satisfying the constraint of within the facility capacity range of each facility term.
Therefore, even when there are multiple processes for producing a single product type or when there are alternative facilities, it is set in advance during the production planning period (all terms). The production amount of each span of each process design that maximizes the evaluation index is determined.

Further, for each term of each product type, the total production amount of spans constituting the term is determined within a range not less than the production amount lower limit value stored in advance in the production amount information storage unit 2 and within the production amount upper limit value.
Therefore, by setting the production amount lower limit value as the lower limit amount, it is possible to optimize other product configurations after producing the products to be produced strategically. Further, by setting the production amount upper limit value as the upper limit amount, it is possible to optimize other product configurations without producing an amount that cannot be sold or stored. Furthermore, by setting the production lower limit value and the production upper limit value to the same value, it is possible to optimize other product configurations after producing a product that must be produced in a certain amount.

In addition, the production amount of each process design is determined so that the sum of (sale price−raw material cost−variable cost) of all terms as evaluation indexes stored in the evaluation index storage unit 5 is maximized.
Therefore, even when the same variety is produced, there are a plurality of production routes, and even when the variable costs and raw material costs are different, the overall profit can be maximized.

Further, the production amount of each process design is determined so that the sum of the production amounts of all the terms of all the varieties, which are the evaluation indexes stored in the evaluation index storage unit 5, is maximized.
Accordingly, it is possible to determine a variety configuration that places importance on the total production volume, as in the case of giving priority to share.

In addition, the optimum product configuration calculation unit 30 applies linear programming to the evaluation index calculation.
Therefore, even when the number of varieties and facilities is large, the production amount for each process design can be optimized at high speed.

The process load unit calculation unit 10 performs the process for each process in each process design based on the information regarding the processing capability in each process stored in advance in the manufacturing route information storage unit 11 for all the facilities in the production line. The basic unit of load (for example, the time per process of each process design required to produce 1 ton of product) is calculated.
Therefore, the constraints on the facility capacity of each facility can be handled in a linear format based on the processing capacity in each process, and the linear programming can be applied to the determination of the optimal product configuration in the optimal product configuration calculation unit 30. .

In addition, the generated cost basic unit calculation unit 20 uses the variable cost information, which is information for each process in the process design stored in advance in the generated cost information storage unit 21, for each process design. It is aggregated as a cost generation unit.
Therefore, in the calculation of the evaluation index by the linear programming method in the optimum product configuration calculation unit 30, the number of variables can be reduced, and the calculation speed can be increased.

[Second Embodiment]
In the production plan creation method, the production plan creation device, and the program according to the first embodiment described above, a case where a production route that can be used for each type is set in advance as a process design is described. Depending on the case, there may be an alternative facility, and the present invention can also be applied when an alternative facility exists. Here, as a modification of the production plan creation method and the production plan creation device and the program according to the first embodiment, the production plan creation method and the production according to the second embodiment when there are rules regarding alternative equipment The plan creation device and the program will be described. First, the production plan creation apparatus 1 according to the second embodiment will be described with reference to FIG. FIG. 6 is a block diagram of a production plan creation apparatus according to the second embodiment.

  As shown in FIG. 6, in the production plan creation device 1 according to the second embodiment, a manufacturing route generation unit (manufacturing route) (based on a manufacturing route generation unit) based on an alternative facility rule registered and stored in advance in the alternative facility rule storage unit 13. The generation means) 12 creates a manufacturing route in the alternative facility as a new process design and stores it in the manufacturing route information storage unit 11.

Next, Table 12 shows an example of the alternative equipment rule that is input to the alternative equipment rule storage unit 13 of the production plan creation device 1 according to the second embodiment.
As shown in Table 12, it is shown that the slitter 02 (“alternative equipment” shown in Table 12) can be used instead of the slitter 01 of the product type F (“original equipment” shown in Table 12). In this case, the load [ton / hr] is 0.8 times (“load coefficient” shown in Table 12), and the variable cost [thousand yen / ton] is 1.2 times (“variation coefficient” shown in Table 12). ), The process yield is specified to be 88% ("process yield" shown in Table 12). If the raw material unit price changes, the raw material unit price may be specified. Further, although the unit of the variable cost is different from the unit in the above-described embodiment, in this modified example, the “variable cost” and the “reference weight (each equipment The cost (reference cost) generated in each process when producing 1 ton of product may be calculated based on the “weight on the entry side”.

  Here, the process design (process design numbers 12 and 13) of the type F registered in advance in the manufacturing route information storage unit 11 is as shown in Table 13.

Next, while referring to the process design (process design numbers 12 and 13) of the type F registered in advance, based on the alternative equipment rule (Table 12) stored in the alternative equipment rule storage unit 13, the original Table 14 shows new process designs (process design numbers 14 and 15) of the type F created by assigning alternative facilities instead of facilities.
As shown in Table 14, the process design number 12 to the process design number 14 and the process design number 12 to the process design number 15 are created in accordance with the above-described alternative equipment rule (Table 12).

  The process design (process design numbers 14 and 15) for the created product F is stored in the manufacturing route information storage unit 11 together with the process design (process design numbers 12 and 13) of the product F registered in advance. In the optimum product configuration calculation unit 30, the production amount for each process design including the process design (process design numbers 12 to 15) for the product F is optimized. And the optimal production amount can be obtained for each of the production amount process design numbers 12 to 15 of the type F. That is, it is possible to obtain an optimum ratio of equipment transfer from the slitter 01 to the slitter 02.

  In addition, the procedure of the process of the production plan creation method using the production plan creation apparatus 1 according to the second embodiment is based on the substitute equipment rules stored in the substitute equipment rule storage unit 13 as shown in FIG. Then, a new process design is created by the manufacturing route generation unit 12 (step S0: manufacturing route generation step), the newly generated process design is registered as manufacturing route information, and the generated cost information and production for each process design is registered. Data on quantity information, raw material / sale price information, facility information, evaluation index, and term / span are inputted, and cost generation information storage unit 21 such as magnetic storage device, production route information storage unit 11 and production amount information storage are respectively stored. Registered in the unit 2, the raw material / sale price information storage unit 3, the equipment information storage unit 4, the evaluation index storage unit 5 and the term / span information setting unit 6 (step S1). The subsequent procedure is the same as in the first embodiment, and a description thereof will be omitted. Further, the process of the production plan creation method according to the second embodiment can be similarly read and executed by the CPU as a program in a computer. Further, this program can be installed in various computer storage devices by recording it in a removable storage medium such as a CD-ROM, FD, or MO.

  As described above, according to the production plan creation method, the production plan creation device, and the program according to the second embodiment, the manufacturing route generation unit 12 uses the substitute equipment rule stored in the substitute equipment rule storage unit 13. By storing the newly created process design in the manufacturing route information storage unit 11, it is possible to obtain an optimum ratio of equipment transfer to alternative equipment.

[Third embodiment]
In the production plan creation method, the production plan creation device, and the program according to the first embodiment and the second embodiment described above, the solution of the production amount of each span of each process design that satisfies the constraints may not be obtained. It is possible. In such a case, the production plan creation method, the production plan creation device, and the program according to the third embodiment may be applied. First, a production plan creation device according to a third embodiment will be described with reference to FIG. FIG. 8 is a block diagram of a production plan creation device according to the third embodiment.
As shown in FIG. 8, the production plan creation device 1 includes a production amount information storage unit 2, a raw material / sale price information storage unit 3, an equipment information storage unit 4, an evaluation index setting unit 5, and a term / span information setting. Unit 6, process load unit calculation unit 10, manufacturing route information storage unit 11, generated cost unit calculation unit 20, generated cost information storage unit 21, optimum product configuration calculation unit 30, and constraint relaxation unit ( (Constraint relaxation means) 31 and a result output unit 40. In addition, the same code | symbol is attached | subjected about the same member as the production plan creation apparatus which concerns on 1st embodiment, and the description is abbreviate | omitted.

  The constraint relaxation unit 31 includes the generated cost basic unit for each process design calculated by the generated cost basic unit calculating unit 20 in the optimum product configuration calculating unit 30 described in the first embodiment, and the process load basic unit calculating unit 10. Process load basic unit for each process for each calculated process design, production amount information stored in the production amount information storage unit 2, raw material / sale price information stored in the raw material / sale price information storage unit 3, and equipment information storage unit 4 Referring to the facility information stored in step 1 and the evaluation index set by the evaluation index setting unit 5, restrictions on facility capacity, restrictions on the production range (above the production volume lower limit value and within the production volume upper limit value), and before and after If there is no solution for the production amount for each process design that maximizes the evaluation formula while taking into account the constraints on the production volume of the process, the constraints on the facility capacity of the evaluation formula, or the production volume range (production volume Production above the lower limit To relax the constraint on within the upper limit value), to determine the production of each process design at the optimal product mix calculation unit 30. The production plan creation device 1 according to the second embodiment including the constraint relaxation unit 31 is an optimization problem of the equation shown in the equation 1 in the production plan creation device 1 optimum product configuration calculation unit 30 according to the first embodiment. However, the present invention can also be applied to the case where the solution of the optimization problem of the equation shown in Equation 1 is obtained in the optimum product configuration calculation unit 30.

  Here, an embodiment will be described in which the constraint relaxation unit 31 relaxes the constraint condition related to the facility capacity of the evaluation formula. For example, in the constraint relaxation unit 31, the optimal product configuration calculation unit 30 uses the linear programming method using the following equation 3 in which the constraint condition related to the facility capacity of the evaluation equation shown in equation 1 is relaxed. By solving the optimization problem, the production volume of each span for each process design is determined.

In the equation shown in Equation 3, V _mt is a non-negative variable corresponding to the equipment load over in the span t of the equipment m, and is added to the equation shown in Equation 1 by subtracting it into the constraints on the equipment capacity. ing. As a result, even if there is no solution that satisfies the constraint on the equipment capacity in the formula shown in Equation 1, V _mt cancels the excess of the equipment capacity (equipment load over), so Exists. In the evaluation formula, a term for subtracting the penalty coefficient is added. By setting this penalty coefficient to a sufficiently large value, first, a solution that minimizes V _mt is obtained preferentially. If there is a solution that satisfies all the constraints of the equation shown in Equation 1, Even in the equation shown in 3, all V _mts become zero, and the same solution as the equation shown in Equation 1 can be obtained. On the other hand, only when there is no solution in the equation shown in Equation 1, the solution in the equation shown in Equation 3 becomes a solution that exceeds the facility capacity because V _mt has a positive value. Therefore, by solving the linear programming method only once, an optimal solution can be obtained, and at the same time, when the equipment capacity is over, the user decides which of the following is to be dealt with which equipment capacity is over in which span. It is possible to obtain useful information.

  In addition, an embodiment will be described in which the constraint relaxation unit 31 relaxes the constraint condition related to the production range (between the production amount lower limit value and the production amount upper limit value). For example, in the constraint relaxation unit 31, the optimum product configuration calculation unit 30 uses the linear programming method using the following equation 4 in which the constraint condition related to the facility capacity of the evaluation equation shown in equation 1 is relaxed. By solving the optimization problem, the production volume of each span for each process design is determined.

In the equation shown in Equation 4, a non-negative variable W _ju corresponding to the production amount not reached in the term u of the product type j is added to the constraint on the production amount lower limit value. As a result, even if there is no solution that satisfies the constraint on the lower limit of the production amount in the equation shown in Equation 1, the solution in the equation shown in Equation 4 always exists because W _ju cancels out the shortage. In addition, in the evaluation formula, a term for subtracting the penalty coefficient for them is added, and by setting this penalty coefficient to a sufficiently large value, the solution that minimizes the first is given priority, If there is a solution that satisfies all the constraints of the equation shown in Equation 1, all W _ju are zero even in the equation shown in Equation 4, and the same solution as the equation shown in Equation 1 is obtained. On the contrary, only when there is no solution in the equation shown in Equation 1, the solution in the equation shown in Equation 4 becomes a solution whose production volume has not been reached because W _ju has a positive value. Therefore, by solving the linear programming method only once, an optimal solution can be obtained, and at the same time, when the production volume is not achieved, the user decides which kind of product will be insufficient in which term, and decides the next response It is possible to obtain information that is effective for doing so.

  By the way, the production amount lower limit value for each term of each product type may be set to an amount corresponding to one charge which is a unit production amount processed in a melting furnace or a converter in the production of steel or aluminum, for example. possible. This is a restriction that production cannot be performed in a smaller quantity due to operational restrictions, and it is meaningless for a production plan with a production quantity smaller than the lower limit of production quantity. Rather, a production plan with zero production quantity is preferred. It may be a reasonable time. Therefore, in such a case, another embodiment different from the case where the constraint condition relating to the production range (the production amount lower limit value or more and the production amount upper limit value or more) of the evaluation formula described above is relaxed (equation shown in Formula 4). Becomes effective. Here, another embodiment will be described in the case where the constraint condition regarding the range of the production amount of the evaluation formula (the production amount lower limit value or more and within the production amount upper limit value) is relaxed. For example, in the constraint relaxation unit 31, the optimum product configuration calculation unit 30 using the mixed integer programming method using the equation shown in the following equation 5 in which the constraint condition related to the facility capacity of the evaluation equation shown in equation 1 is relaxed. By solving the optimization problem, the production volume of each span for each process design is determined.

In the equation shown in Equation 5, an integer variable Z _{ju of} 0-1 representing whether to produce the product type j in the term u or to make the production amount zero is introduced. As a result, when Z _ju is 1, the upper and lower limits of the production amount are the same as the expression shown in Equation 1, and when Z _ju is 0, the upper and lower limits of the production amount are both 0. Therefore, the solution is not produced. In the formula shown in Equation 5, the reason why Z _ju is not included in the evaluation formula is that the evaluation formula that usually maximizes profit and production volume requires a solution to produce as much as possible. This is because a solution in which Z _ju is 1 is preferentially obtained. The equation shown in Equation 5 includes an integer variable Z _{ju of} 0-1 in addition to a continuous variable. Therefore, when solving this problem, it is sufficient to solve by using mixed integer programming instead of linear programming. Therefore, by solving a mixed integer programming method only once, an optimal solution can be obtained, and at the same time, if the production volume is not reached, Z _ju of any product type becomes 0 and a solution of zero production volume is obtained. Therefore, it is possible to obtain information effective for the user to make a decision on the next response, such as which kind of product is lacking in terms. In the equation shown in Equation 5, the processing time increases compared to the equation shown in Equation 4 using linear programming in order to solve the mixed integer programming problem. It is possible to prevent a production plan that cannot be produced in quantity.

  In the embodiment for deciding the production amount for each process design by relaxing the constraint condition regarding the facility capacity of the above-described evaluation formula or the constraint condition regarding the range of production volume (production quantity lower limit value or more and production quantity upper limit value or less). The production volume was determined by introducing variables that relaxed the constraints on all equipment / spans, varieties / terms, and solving the optimization problems in the equations shown in Equations 3-5. The production amount may be determined by introducing a variable in which the constraint condition is relaxed for the product type / term and solving the optimization problem of the equations shown in Equations 3-5. Further, in the embodiment in which the production amount for each process design is determined by relaxing the constraint condition relating to the production range (between the production amount lower limit value and within the production amount upper limit value), for example, the production amount upper / lower limit value is set to zero. The production amount is determined by solving the optimization problem of the equation shown in Equation 5 only for the product type and term, and the production amount is determined by solving the optimization problem of the equation shown in Equation 4 for the other product types and terms. Alternatively, an embodiment in which the constraint condition is relaxed depending on the type and term may be selected.

Next, the processing procedure of the production plan creation method using the production plan creation device 1 according to the third embodiment will be described with reference to FIG. FIG. 9 is a flowchart illustrating the processing procedure of the production plan creation method according to the third embodiment. In addition, about the step same as the procedure of the process of the production plan preparation method using the production plan preparation apparatus 1 which concerns on 1st embodiment, the same code | symbol is attached | subjected and the description is abbreviate | omitted.
The process of the production plan creation method according to the second embodiment described below can be read and executed by the CPU as a program in the computer as well. Further, this program can be installed in various computer storage devices by recording it in a removable storage medium such as a CD-ROM, FD, or MO.

  As shown in FIG. 9, first, the cost information for each process design, manufacturing route information, production volume information, raw material / sale price information, equipment information, evaluation index, and data on terms and spans are input in advance. , Generation cost information storage unit 21 such as magnetic storage device, manufacturing route information storage unit 11, production amount information storage unit 2, raw material / sale price information storage unit 3, equipment information storage unit 4, evaluation index storage unit 5, and term Registered in the span information setting unit 6 (step S1: production amount information storage step, product information storage step, facility information storage step, term / span information setting step, generated cost information storage step). Next, based on the manufacturing route information stored in the manufacturing route information storage unit 11, the process load unit calculation unit 10 calculates a process load unit for each process for each process design (step S2: process load). Basic unit calculation step). Further, based on the generated variable cost stored in the generated cost information storage unit 21 and the reference time calculated by the process load unit calculation unit 10, the generated cost unit calculation unit 20 generates the generated cost source for each process design. A unit is calculated (step S3: cost generation unit calculation step).

  Then, the constraint condition relaxation unit 31 relaxes the constraint conditions for some equipment / spans, types / terms (step S7: constraint relaxation step). Next, in the optimum product configuration calculation unit 30, the generated cost basic unit calculated by the generated cost basic unit calculation unit 20, the process load basic unit calculated by the process load basic unit calculation unit 10, and the production amount information storage unit in advance 2, referring to the production volume information, the raw material / sale price information, the facility information, and the evaluation index respectively registered in the raw material / sale price information storage unit 3, the equipment information storage unit 4 and the evaluation index storage unit 5, and in step S7 The production amount for each process design is determined by solving the optimization problem while considering the relaxed constraint conditions for some equipment / spans, varieties / terms (step S4). Specifically, the production volume is determined by introducing variables with relaxed constraints on some equipment / spans, varieties / terms, and solving the optimization problem of the equations shown in equations 3-5 (step S7, S4). The details of this step are the same as the description of the optimum product configuration calculation unit 30 and the constraint condition relaxation unit 31 of the production plan creation apparatus 1 described above, and a description thereof will be omitted.

  Next, it is determined whether or not the solution for the production amount for each process design has been obtained in the optimum product configuration calculation unit 30 (step S6). If the optimum product configuration calculation unit 30 cannot obtain a solution for the production amount for each process design (step S6: NO), the process returns to step S7, and the constraint condition relaxation unit 31 further reduces the constraint conditions. Increase span, variety, and term (step S7).

  On the other hand, when the solution for the production amount for each process design is obtained in the optimum product configuration calculation unit 30 (step S6: YES), the calculation result in the optimum product configuration calculation unit 30 is output as the result output unit 40, that is, the output. The information is displayed on a device (display, hard disk, printer, etc.) (step S5).

  In the process procedure of the production plan creation method using the production plan creation apparatus 1 according to the third embodiment shown in FIG. 9, the constraint conditions are relaxed for some equipment / spans, product types / terms (steps). S7) When the optimum product configuration calculation unit 30 cannot obtain a solution for the production amount for each process design (step S6: NO), the process returns to step S7, and the constraint relaxation unit 31 sequentially relaxes the constraint. The form of increasing the equipment, span, product type, and term has been shown. However, the constraint condition relaxing unit 31 from the beginning alleviates the constraint condition for all the equipment, span, product type, and term, so that the optimum product configuration calculating unit 30 A solution of the production amount for each process design may be obtained by one calculation. Specifically, the production volume is determined by introducing variables with relaxed constraints for all facilities / spans, varieties / terms, and solving the optimization problem of the equations shown in equations 3-5 (steps S7, S4). ).

  Here, the production plan is actually created using the production plan creation method, the production plan creation device, and the program of the third embodiment. For example, in the production plan creation method, production plan creation apparatus, and program of the first embodiment described above, the actual operation rate shown in Table 1, the type table shown in Table 2, and the passing process table of each process design shown in Table 3 are as follows. When the same conditions are used and the time conditions between processes are changed, load concentration occurs, and there is a case where the solution of the production amount for each process design cannot be obtained. In such a case, when the constraint condition related to the facility capacity is relaxed by using the production plan creation method, the production plan creation device, and the program according to the second embodiment, the facility usage rate (the first one shown in Table 15 below) The results of the production plan creation method and production plan creation apparatus of the embodiment, and the description of the equipment usage rate shown in Table 10 when the program is used) are obtained.

  As shown in Table 15, by generating a solution in which the equipment usage rate exceeds 100% in terms 1 to 5 of the slitter 02 and terms 5 and 6 of the slitter 03, it is avoided to end up with no solution results.

  In addition, when the production plan creation method, the production plan creation device, and the program according to the third embodiment are used to relax the constraints on the range of production volume, the production volume per term for each product type as shown in Table 16 below. Result is obtained.

  As shown in Table 17, in comparison with the production lower limit value for each term of each variety shown in Table 2, the variety B in term 1 has not reached the production lower limit value, and the variety in term 6 A avoids ending up with no solution by producing a solution that does not produce at all and does not reach the lower limit of production.

  By seeing the above results, the user can obtain information for determining the next action, such as increasing the operating rate of a heavily loaded facility or adjusting the production lower limit of the product type.

  As described above, according to the production plan creation method, the production plan creation apparatus, and the program according to the third embodiment, a solution for the production amount of each span of each process design that satisfies the constraints is obtained by the optimum product configuration calculation unit 30. If there is not, the calculation is not repeated many times until the solution is obtained by omitting one or more constraint conditions as in the prior art. In the constraint relaxation unit 31, the constraint condition related to the facility capacity or the production volume range (production By relaxing the constraint condition (especially the constraint condition that it is greater than or equal to the production volume lower limit value) related to the production volume lower limit value or less and the production volume upper limit value or less) It is possible to easily obtain an optimal solution for the production amount of each span of each process design that maximizes the evaluation index. Then, when the constraint relaxation unit 31 relaxes the constraint condition related to the facility capacity and the solution of the production amount of each span of each process design is obtained, the facility load on the term exceeding the facility capacity is reduced. It is possible to examine the possibility of responding (for example, reducing the lower limit of production of appropriate varieties) and increasing the facility capacity with that term (overtime work or fully operating the facility capacity). . In addition, the constraint relaxation unit 31 relaxes the constraint condition (particularly, the constraint condition that the production amount is lower than the production amount lower limit value) and the span of each process design. If the solution of the production amount is obtained, it is possible to obtain information effective for making a decision on the next response, such as which kind of product is below the production amount lower limit value at which term.

[Fourth embodiment]
In the production plan creation method, the production plan creation device, and the program according to the first to third embodiments described above, restrictions on equipment capacity and restrictions on the production volume range (production quantity lower limit value or more and production quantity upper limit value or less). , And taking into account the constraints on the production volume of the preceding and following processes, one of the evaluation indices of gross profit, which is the sum of (selling price-raw material cost-variable cost), and gross production, which is the sum of the production quantities of all varieties The amount of production for each process design that maximizes the volume is being sought. Therefore, it does not consider the total profit including the inventory cost that depends on the time from the start of production to the completion of production (manufacturing lead time). 1 (that is, even if the start of production is advanced), the total profit (= total of (selling price−raw material cost−variable cost)) does not deteriorate, so that a production plan with a production lead time longer than necessary may be created. Therefore, when considering the total profit including the inventory cost, the production plan creation method, the production plan creation device, and the program according to the fourth embodiment can be applied. First, a production plan creation device according to a fourth embodiment will be described with reference to FIG. FIG. 10 is a block diagram of a production plan creation device according to the fourth embodiment.

  As shown in FIG. 10, the production plan creation device 1 includes a production amount information storage unit 2, a raw material / sale price information storage unit 3, an equipment information storage unit 4, an evaluation index setting unit 5, and a term / span information setting. Unit 6, inventory cost unit price storage unit (inventory cost unit price storage means) 7, process load unit calculation unit 10, manufacturing route information storage unit 11, generated cost unit calculation unit 20, and generated cost information storage unit 21, an optimum product configuration calculation unit 30, and a result output unit 40. In addition, the same code | symbol is attached | subjected about the same member as the production plan creation apparatus which concerns on 1st embodiment, and the description is abbreviate | omitted.

  The evaluation index setting unit 5 is for setting an evaluation index serving as a reference for optimizing the production amount of each product type. In the present embodiment, (the selling price−the raw material cost−the variable cost−the inventory cost). ) As the evaluation index.

  The inventory cost unit price storage unit 7 is for registering an inventory cost unit price per unit time / unit amount for each process design.

  The optimum product configuration calculation unit 30 generates the generated cost basic unit for each process design calculated by the generated cost basic unit calculation unit 20 and the process load basic unit for each process for each process design calculated by the process load basic unit calculation unit 10. The production amount information stored in the production amount information storage unit 2, the raw material / sale price information stored in the raw material / sale price information storage unit 3, the facility information stored in the facility information storage unit 4, and the inventory cost unit price storage unit 7 Referring to the registered inventory cost unit price and the evaluation index set by the evaluation index setting unit 5, restrictions on equipment capacity, restrictions on the range of production volume (above the production volume lower limit value and within the production volume upper limit value), and before and after The production quantity for each process design that maximizes the evaluation formula is determined in consideration of restrictions on the production quantity of the process.

  In the present embodiment, using linear programming, for example, when the production lead time becomes long, the inventory cost depending on the production lead time and the production amount is increased. By solving the optimization problem, the production volume of each span for each process design is determined.

In the formula shown in Equation 6, the total profit = {sales price− (raw material cost + variable cost + inventory cost)} as the evaluation formula. The inventory cost of each process design is
1) A weighted average of the production volume in each span for each span (eg, day) to process the final process.
2) A weighted average of the production amount in each span is performed for each span to be processed in the first step.
3) Multiply the difference between 1) and 2) by total production volume and inventory cost unit price. (In the equation shown in Equation 6, the total production amount is canceled in about minutes.)
Is calculated.

  FIG. 11 shows an image of inventory cost calculation according to the present embodiment. FIG. 11 shows the calculation of inventory cost for a certain process design according to the present embodiment. In FIG. 11, a light-colored rectangle indicates a production amount by span (in this embodiment, day) in each process. The dark rectangles (first step and final step) indicate a case where it is assumed that the total production amount at the time when the production amount is weighted and averaged is processed. In other words, in the equation shown in Equation 6, the inventory cost is calculated by assuming that the intermediate product corresponding to the total production amount stays in the production line during this period. Therefore, in the present embodiment, the production amount in each process and each span (day) does not need to be linked to which day production is completed, and the number of variables can be greatly reduced, so that optimization calculation is possible. Can be speeded up. In addition, when associating the production completion date and the production amount of each process, as shown in FIG. 12, it is possible to calculate the exact inventory cost. Since it is necessary to divide by the mesh “whether it corresponds to the finished product”, the number of variables increases explosively, and the calculation time for optimization greatly increases.

  Next, a process procedure of a production plan creation method using the production plan creation device 1 according to the fourth embodiment will be described. The process procedure of the production plan creation method according to the fourth embodiment includes the same steps as the process procedure of the production plan creation method according to the first embodiment, and will be described with reference to FIG. Further, the process of the production plan creation method according to the fourth embodiment can be similarly read and executed by the CPU as a program in a computer. Further, this program can be installed in various computer storage devices by recording it in a removable storage medium such as a CD-ROM, FD, or MO.

  As shown in FIG. 3, the processing procedure of the production plan creation method using the production plan creation apparatus 1 according to the fourth embodiment is as follows. First, the generated cost information, the production route information, and the production amount for each process design Information, raw material / sale price information, facility information, evaluation index, term span, and inventory cost unit price data are input, and the generated cost information storage unit 21 such as a magnetic storage device, the production route information storage unit 11, and the production volume, respectively. The information storage unit 2, the raw material / sale price information storage unit 3, the equipment information storage unit 4, the evaluation index storage unit 5, the term / span information setting unit 6, and the inventory cost unit price storage unit 7 are registered (step S1: Production amount information storage step, product information storage step, equipment information storage step, term / span information setting step, generated cost information storage step, inventory cost unit price storage step). In addition, about the procedure of step S2, S3, it is the same as that of 1st embodiment, The description is abbreviate | omitted.

  Then, in the optimum product configuration calculation unit 30, the generated cost basic unit calculated by the generated cost basic unit calculation unit 20, the process load basic unit calculated by the process load basic unit calculation unit 10, and the production amount information storage unit 2 in advance. Production quantity information, raw material / sale price information, facility information, evaluation index, and raw material / sale price information storage unit 3, equipment information storage unit 4, evaluation index storage unit 5, and inventory cost unit price storage unit 7, respectively. The production amount for each process design is determined by referring to the inventory cost unit price and solving the optimization problem using the linear programming method (step S4: optimum product configuration calculation step). Note that the procedure of step S5 is the same as that of the first embodiment, and a description thereof will be omitted.

  As described above, according to the production plan creation method, the production plan creation device, and the program according to the fourth embodiment, the residence time of the intermediate product (that is, the production lead time that is the time from the start of production to the completion of production). And the production cost that depends on the production volume are included in the evaluation function, so that the total profit including the inventory cost (ie, the sum of (sales price-raw material cost-variable cost-inventory cost) of all terms is maximized) It is possible to create a plan, and in particular, since the unit cost of inventory costs for each process from the start of manufacturing to the completion of manufacturing is the same, calculation is easy.

[Fifth embodiment]
In the production plan creation method, the production plan creation device, and the program according to the fourth embodiment described above, the inventory cost is calculated with the same inventory cost unit price for each process, but the invention is not limited thereto. That is, when the inventory cost unit price is different in each process, the production plan creation method, the production plan creation device, and the program according to the fifth embodiment can be applied. First, a production plan creation apparatus according to the fifth embodiment will be described. The production plan creation device according to the fifth embodiment includes the same members as those of the production plan creation device according to the fourth embodiment, and will be described with reference to FIG.

  As shown in FIG. 10, the production plan creation device 1 includes a production amount information storage unit 2, a raw material / sale price information storage unit 3, an equipment information storage unit 4, an evaluation index setting unit 5, and a term / span information setting. Unit 6, inventory cost unit price storage unit 7, process load basic unit calculation unit 10, manufacturing route information storage unit 11, generated cost basic unit calculation unit 20, generated cost information storage unit 21, and optimum product configuration calculation The unit 30 and the result output unit 40 are configured. In addition, the same code | symbol is attached | subjected about the same member as the production plan creation apparatus which concerns on 1st embodiment, and the description is abbreviate | omitted.

  The evaluation index setting unit 5 is for setting an evaluation index serving as a reference for optimizing the production amount of each product type. In the present embodiment, (the selling price−the raw material cost−the variable cost−the inventory cost). ) As the evaluation index.

  The inventory cost unit price storage unit 7 is for registering an inventory cost unit price per unit time / unit amount of each process for each process design.

  The optimum product configuration calculation unit 30 generates the generated cost basic unit for each process design calculated by the generated cost basic unit calculation unit 20 and the process load basic unit for each process for each process design calculated by the process load basic unit calculation unit 10. The production amount information stored in the production amount information storage unit 2, the raw material / sale price information stored in the raw material / sale price information storage unit 3, the facility information stored in the facility information storage unit 4, and the inventory cost unit price storage unit 7 Referring to the registered inventory cost unit price and the evaluation index set by the evaluation index setting unit 5, restrictions on equipment capacity, restrictions on the range of production volume (above the production volume lower limit value and within the production volume upper limit value), and before and after The production quantity for each process design that maximizes the evaluation formula is determined in consideration of restrictions on the production quantity of the process.

  In the present embodiment, the linear programming method is used, for example, when the inter-process lead time is increased, the inventory cost depending on the inter-process lead time and the production amount is increased. By solving the equation optimization problem, the production volume of each span for each process design is determined.

In the expression shown in Equation 7, the total profit = {sales price− (raw material cost + variable cost + inventory cost)} as the evaluation formula. The inventory cost of each process design is
1) A weighted average of the production amount in each span is performed for each span (for example, day) for processing step k.
2) Each span for processing step k ′ = k−1 (step immediately before step k) is weighted average of the production amount in each span.
3) Multiply the difference between 1) and 2) by the production volume at step k and the inventory cost unit price at step k. (In the equation shown in Equation 7, the production amount in step k is canceled in about minutes.)
4) Repeat 1) to 3) from the second step (k = 2) to the final step (k = Ki).
Is calculated.

  FIG. 13 shows an image of inventory cost calculation according to the present embodiment. FIG. 13 shows the calculation of the inventory cost for a certain process design according to the present embodiment. In FIG. 13, a light-colored rectangle indicates a production amount by span (in this embodiment, day) in each process. Moreover, the dark rectangle (the 1st process-the 4th process) shows the case where it is assumed that the total production amount at the time when the production amount is weighted and averaged is processed. Compared to FIG. 11 of the fourth embodiment described above, it can be seen that the inventory cost is calculated individually between the processes. In other words, in the equation shown in Equation 7, the intermediate product corresponding to the production amount in the current process is considered to have stayed between the previous process during this time, and the inventory cost in each process is calculated, and these are totaled. The total inventory cost. Therefore, the present embodiment can be applied to cases where the inventory cost unit price differs between processes (for example, a warehouse fee is charged between specific processes). In addition, the production volume in each process and each span (day) does not need to be linked to which day production is completed, and the number of variables can be greatly reduced (the same variables as in the fourth embodiment). Number), optimization calculation can be speeded up.

  Next, the processing procedure of the production plan creation method using the production plan creation device 1 according to the fifth embodiment includes the same steps as the processing procedure of the production plan creation method according to the fourth embodiment. The description is omitted. Further, the process of the production plan creation method according to the fifth embodiment can be similarly read and executed by the CPU as a program in a computer. Further, this program can be installed in various computer storage devices by recording it in a removable storage medium such as a CD-ROM, FD, or MO.

  As described above, according to the production plan creation method, the production plan creation device, and the program according to the fifth embodiment, the residence time of the intermediate product from the start of manufacture to the completion of manufacture (that is, from the start of manufacture to the completion of manufacture). By including the inventory cost that depends on the production amount and the inventory cost that depends on the production amount in each process, the total profit including the inventory cost (ie (sales price-raw material cost-variation of all terms) It is possible to create a production plan that maximizes the sum of (cost-inventory cost), especially when the unit cost of inventory cost for each process is different in each process from the start of manufacturing to the completion of manufacturing. it can.

  The preferred embodiments of the present invention have been described above. However, the present invention is not limited to the above-described embodiments, and various modifications can be made as long as they are described in the claims.

In the above-described embodiment, the evaluation index is maximized profit and maximized production, but is not limited thereto.
For example, it may be a weighted sum of profit and production. This case can be applied to the following cases.
・ To increase profits as much as possible while securing production volume.
・ When making the production volume as small as possible and making the profit as large as possible (for the evaluation index, the production volume is negatively weighted).
・ If profits are the same, a product structure with a large production volume is desirable.

For example, the total sales may be maximized by using the evaluation index as the sum of the selling prices for each product type.
In this case, it can be applied when it is desired to determine a variety configuration that places more importance on the total deposit than profit.

  Furthermore, in the above-described embodiment, the inter-process time between the preceding and following processes is calculated as 0. However, the present invention is not limited to this and can be applied even when the inter-process time between the preceding and following processes is set. In this case, the inter-process time is set in advance in the manufacturing route storage unit 11, and the optimum product configuration calculation unit 30 satisfies the restrictions on the manufacturing amount of the preceding and following processes including the inter-process time (the above formula 1 and 2) Determine the production amount for each process design that maximizes the evaluation formula.

1 is a block diagram of a production plan creation device according to a first embodiment. It is a figure which shows an example of the production line made into the object of this embodiment. It is the flowchart explaining the procedure of the process of the production plan preparation method which concerns on 1st embodiment. It shows the transition of production volume of each term in each process design optimized for maximum profit. It shows the transition of the production volume of each term of each process design optimized to maximize the production volume. It is a block diagram of a production plan creation device according to a second embodiment. It is the flowchart explaining the procedure of the process of the production planning method which concerns on 2nd embodiment. It is a block diagram of the production plan preparation apparatus which concerns on 3rd embodiment. It is the flowchart explaining the procedure of the process of the production plan preparation method which concerns on 3rd embodiment. It is a block diagram of the production plan creation apparatus which concerns on 4th embodiment. The calculation of the inventory cost about a certain process design which concerns on 4th embodiment is shown. The figure shows the calculation of the inventory cost for a process design in which the production completion date and the production amount of each process are linked. It shows calculation of inventory costs for a certain process design according to the fifth embodiment.

Explanation of symbols

1 Production Plan Creation Device 2 Production Volume Information Storage Unit (Production Volume Information Storage Unit)
3. Raw material / sale price information storage (product information storage means)
4 Equipment information storage unit (equipment information storage means)
5 Evaluation index setting section 6 Term / span information setting section (term / span information setting means)
7 Inventory cost unit price storage unit (Inventory cost unit price storage means)
10 Process load unit calculation unit (Process load unit calculation means)
11 Manufacturing route information storage unit (Manufacturing route information storage means)
12 Manufacturing route generator (Manufacturing route generator)
13 Alternative equipment rule storage unit 20 Generated cost intensity unit (Occurred cost intensity unit)
21 Generated cost information storage unit (generated cost information storage means)
30 Optimal variety composition calculation part (optimum variety composition calculation means)
31 Constraint Relaxation Unit (Constraint Relaxation Means)
S0 Production route generation step S1 Production volume information storage step, product information storage step, equipment information storage step, term / span information setting step, generated cost information storage step, inventory cost unit price storage step S2 process load intensity unit calculation step S3 generated cost Basic unit calculation step S4 Optimal product configuration calculation step S7 Restriction relaxation step

Claims (57)

A production plan creation method for optimizing the production amount of products of multiple varieties produced in multiple processes,
A term / span information setting step for storing a span that is a unit of minimum time for evaluating constraints, a term that is composed of one or more spans and that is a unit for producing a production plan, and the number of terms for producing a production plan;
For each product type, one or more manufacturing routes to which equipment capable of processing a plurality of processes for manufacturing a product are assigned are registered as a process design, and the processing capability of each process is registered for each process design. Route information storage step;
Facility information storage step for registering facility capacity for each term of each facility;
The term of each facility determined by the processing capability, and the amount processed in the subsequent process does not exceed the amount processed in the previous process while considering the inter-process time between the preceding and following processes for each process for each process design. Optimum product configuration calculation step for calculating the production amount of each span of each process design that maximizes the preset evaluation index while satisfying the constraint that the total load for each does not exceed the facility capacity;
A production plan creation method characterized by comprising: A production amount information storage step for registering a production amount lower limit value and a production amount upper limit value as a required production amount range for each term of each of the varieties,
The constraint is that, for each term of each of the varieties, a condition is satisfied that a total production amount of spans constituting the term is within a range not less than the production amount lower limit value and within the production amount upper limit value. The production plan creation method according to claim 1, wherein:   A manufacturing route generation step of creating and registering a manufacturing route to which an alternative facility is assigned as a process design based on a preset rule of the alternative facility when an alternative facility exists, further comprising: Item 3. A production plan creation method according to item 1 or 2.   4. The production plan creation method according to claim 1, wherein the calculation of the evaluation index is performed by a linear programming method.   When the production amount of each span of each process design that maximizes a preset evaluation index that satisfies the constraint cannot be calculated, the terms of each facility determined by the processing capacity with respect to the terms of one or more of the facilities The constraint relaxation step of relaxing the constraint that the total load for each term does not exceed the facility capacity and calculating the production amount of each span of each process design is further provided. The production plan creation method according to any one of the above. The constraint relaxation step includes:
For the constraint that the total load for each term of each facility determined by the processing capacity does not exceed the facility capacity, the total load of the term of one or more of the facilities determined by the processing capacity is the facility capacity And adding a variable corresponding to the equipment load over which exceeds the above, and adding a penalty for the equipment overload to the evaluation index, the predetermined evaluation index satisfying the constraint is maximized 6. The production plan creation method according to claim 5, wherein the production amount of each span is calculated by a linear programming method.   When the production amount of each span of each process design that maximizes the preset evaluation index that satisfies the constraint cannot be calculated, for each of the terms of each of the varieties, Relax the constraint that the total production volume of the spans that constitute the term is within the range of the production volume lower limit value and within the production volume upper limit value, and calculate the production volume of each span for each process design The production plan creation method according to claim 2, further comprising a step. The constraint relaxation step includes:
When the production amount of each span of each process design that maximizes the preset evaluation index that satisfies the constraint cannot be calculated, the total production amount of spans that constitute the term for each term of each product type Is the range of the production volume lower limit value or more and the production volume upper limit value or less, with respect to the term of one or more of the varieties, the total production volume of the spans constituting the term is the production volume lower limit value The variable corresponding to the unachieved production amount that did not satisfy the value is added, and the penalty for the unachieved production amount is added to the evaluation index, and the preset evaluation index satisfying the constraint is maximized The production plan creation method according to claim 7, wherein the production amount of each span of each process design is calculated by a linear programming method. The constraint relaxation step includes:
When the production amount of each span of each process design that maximizes the preset evaluation index that satisfies the constraint cannot be calculated, the total production amount of spans that constitute the term for each term of each product type Is a range that is greater than or equal to the production volume lower limit value and within the production volume upper limit value, for one or more of the varieties of the varieties, the total production volume of the span that constitutes the term is the production volume lower limit A 0-1 variable indicating whether to be 0 regardless of the value and the production amount upper limit value, and the production amount in each span of each process design in which the preset evaluation index satisfying the constraint is maximized Is calculated by a mixed integer calculation method. The production plan creation method according to claim 7, wherein: A product information storage step for registering the selling price and raw material cost for each of the types;
An accrued cost information storage step for registering variable costs generated in each process for each process design; and
10. The production plan creation method according to claim 1, wherein the evaluation index is set as a sum of all terms (sales price−raw material cost−variable cost). A product information storage step for registering the selling price and raw material cost for each of the types;
An accrued cost information storage step for registering variable costs generated in each process for each process design; and
10. The evaluation index is set as a weighted sum of a sum of all terms (sales price-raw material cost-variable cost) and a sum of production amounts of all terms of all varieties. The production plan creation method according to any one of the above. An inventory cost unit price storing step of registering an inventory cost unit price per unit time / unit amount for each process design,
For each process design, the evaluation index is calculated from the production lead time from the start of production to the completion of production obtained based on the span for processing the first process and the span for processing the final process, and the production amount. The production plan creation method according to claim 10 or 11, wherein an inventory cost calculated based on an inventory cost unit price is set.   The manufacturing lead time is calculated by treating the span for processing the first process and the span for processing the final process as a weighted average of the production amount for each span, respectively. Production plan creation method. An inventory cost unit price storing step for registering an inventory cost unit price per unit time / unit amount in each process for each process design;
The evaluation index is calculated from the inter-process lead time in each process from the start of manufacturing to the completion of manufacturing obtained based on the span for processing each process for each process design, and the production cost. The production plan creation method according to claim 10 or 11, wherein an inventory cost calculated based on the inventory cost is set.   15. The production plan creation method according to claim 14, wherein the inter-process lead time is calculated by treating a span for processing each process as a weighted average of a production amount for each span.   10. The production plan creation method according to any one of claims 1 to 9, wherein the evaluation index is set as a sum of production amounts of all terms of all varieties. A product information storage step of registering a selling price for each product type,
10. The production plan creation method according to claim 1, wherein the evaluation index is set as a sum of selling prices of all terms of all varieties. Based on the processing capacity, a process load basic unit calculation step for calculating the load of each process for each process design when producing a unit quantity of a product as a process load basic unit,
Based on the variable cost, it further comprises a generated cost unit calculation step for calculating a generated cost for each process design required when producing a unit quantity of the product as a generated cost unit,
16. The production plan creation method according to claim 10, wherein the calculation of the evaluation index is performed by linear programming using the process load basic unit and the generated cost basic unit. Based on the processing capacity, further comprising a process load basic unit calculation step of calculating the load of each process for each process design when producing a unit quantity of a product as a process load basic unit,
18. The production plan creation method according to claim 16 or 17, wherein the calculation of the evaluation index is performed by linear programming using the process load basic unit. A program for optimizing the production volume of products of multiple varieties produced in multiple processes on a computer,
A term / span information setting step for storing a span that is a unit of minimum time for evaluating constraints, a term that is composed of one or more spans and that is a unit for producing a production plan, and a number of terms for producing a production plan;
For each product type, one or more manufacturing routes to which equipment capable of processing a plurality of processes for manufacturing a product are assigned are registered as a process design, and the processing capability of each process is registered for each process design. Route information storage step,
Facility information storage step for registering facility capacity for each term of each facility,
The term of each facility determined by the processing capability, and the amount processed in the subsequent process does not exceed the amount processed in the previous process while considering the inter-process time between the preceding and following processes for each process for each process design. Optimal product configuration calculation step for calculating the production amount of each span of each process design that maximizes a preset evaluation index while satisfying the constraint that the total load of each does not exceed the facility capacity,
A program that causes a computer to execute. For each term of each of the varieties, the computer further executes a production amount information storage step for registering a production amount lower limit value and a production amount upper limit value as a required production amount range,
The constraint is that, for each term of each of the varieties, a condition is satisfied that a total production amount of spans constituting the term is within a range not less than the production amount lower limit value and within the production amount upper limit value. The program according to claim 20, wherein:   When a substitute facility exists, the computer further executes a production route generation step of creating and registering a production route to which the substitute facility is assigned as a process design based on a preset rule of the substitute facility. The program according to claim 20 or 21.   The program according to any one of claims 20 to 22, wherein the calculation of the evaluation index is performed by a linear programming method.   When the production amount of each span of each process design that maximizes a preset evaluation index that satisfies the constraint cannot be calculated, the terms of each facility determined by the processing capacity with respect to the terms of one or more of the facilities The computer further executes a constraint relaxation step of relaxing a constraint that a total load for each term does not exceed the facility capacity and calculating a production amount of each span of each process design. The program according to any one of 20 to 22. The constraint relaxation step includes:
For the constraint that the total load for each term of each facility determined by the processing capacity does not exceed the facility capacity, the total load of the term of one or more of the facilities determined by the processing capacity is the facility capacity And adding a variable corresponding to the equipment load over which exceeds the above, and adding a penalty for the equipment overload to the evaluation index, the predetermined evaluation index satisfying the constraint is maximized The program according to claim 24, wherein the production amount of each span is calculated by a linear programming method.   When the production amount of each span of each process design that maximizes the preset evaluation index that satisfies the constraint cannot be calculated, for each of the terms of each of the varieties, Relax the constraint that the total production volume of the spans that constitute the term is within the range of the production volume lower limit value and within the production volume upper limit value, and calculate the production volume of each span for each process design The program according to claim 21 or 22, further causing the computer to execute the step. The constraint relaxation step includes:
When the production amount of each span of each process design that maximizes the preset evaluation index that satisfies the constraint cannot be calculated, the total production amount of spans that constitute the term for each term of each product type Is the range of the production volume lower limit value or more and the production volume upper limit value or less, with respect to the term of one or more of the varieties, the total production volume of the spans constituting the term is the production volume lower limit value The variable corresponding to the unachieved production amount that did not satisfy the value is added, and the penalty for the unachieved production amount is added to the evaluation index, and the preset evaluation index satisfying the constraint is maximized 27. The program according to claim 26, wherein the production amount of each span of each process design is calculated by a linear programming method. The constraint relaxation step includes:
When the production amount of each span of each process design that maximizes the preset evaluation index that satisfies the constraint cannot be calculated, the total production amount of spans that constitute the term for each term of each product type Is a range that is greater than or equal to the production volume lower limit value and within the production volume upper limit value, for one or more of the varieties of the varieties, the total production volume of the span that constitutes the term is the production volume lower limit A 0-1 variable indicating whether to be 0 regardless of the value and the production amount upper limit value, and the production amount in each span of each process design in which the preset evaluation index satisfying the constraint is maximized 27. The program according to claim 26, wherein the value is calculated by a mixed integer calculation method. Product information storage step for registering selling price and raw material cost for each product type,
For each process design, the generated cost information storage step for registering the variable cost generated in each process is further executed by the computer,
The program according to any one of claims 20 to 28, wherein the evaluation index is set as a sum of (sale price-raw material cost-variable cost) of all terms. Product information storage step for registering selling price and raw material cost for each product type,
For each process design, the generated cost information storage step for registering the variable cost generated in each process is further executed by the computer,
29. The evaluation index is set as a weighted sum of the sum of all terms (sales price-raw material cost-variable cost) and the sum of production amounts of all terms of all varieties. The program as described in any one. For each process design, the inventory cost unit price storage step of registering the inventory cost unit price per unit time / unit amount is further executed by the computer,
For each process design, the evaluation index is calculated from the production lead time from the start of production to the completion of production obtained based on the span for processing the first process and the span for processing the final process, and the production amount. The program according to claim 29 or 30, wherein the program is set including an inventory cost calculated based on an inventory cost unit price.   The said manufacturing lead time is calculated by treating the span which processes a 1st process, and the span which processes a last process as a weighted average of the production amount for every span, respectively. program. For each process design, the computer further executes an inventory cost unit price storage step for registering an inventory cost unit price per unit time / unit amount in each process,
The evaluation index is calculated from the inter-process lead time in each process from the start of manufacturing to the completion of manufacturing obtained based on the span for processing each process for each process design, and the production cost. The program according to claim 29 or 30, wherein the program is set including an inventory cost calculated based on the program.   34. The program according to claim 33, wherein the inter-process lead time is calculated by treating a span in which each process is processed as a weighted average of a production amount for each span.   29. The program according to any one of claims 20 to 28, wherein the evaluation index is set as a sum of production amounts of all terms of all varieties. For each product type, let the computer execute a product information storage step for registering the selling price,
The program according to any one of claims 20 to 28, wherein the evaluation index is set as a sum of selling prices of all terms of all varieties. Based on the processing capacity, a process load basic unit calculation step of calculating the load of each process for each process design when producing a unit quantity of a product as a process load basic unit,
Based on the variable cost, let the computer execute the generated cost basic unit calculation step of calculating the generated cost for each process design required when producing a unit quantity of the product as the generated cost basic unit,
35. The program according to claim 29, wherein the calculation of the evaluation index is performed by linear programming using the process load basic unit and the generated cost basic unit. Based on the processing capacity, when the product is produced in a unit quantity, the process load basic unit calculation step of calculating the load of each process for each process design as the process load basic unit is further executed by the computer,
The program according to claim 35 or 36, wherein the calculation of the evaluation index is performed by linear programming using the process load basic unit. A production plan creation device that optimizes the production amount of products of multiple varieties produced in multiple processes,
A term / span information setting means for storing a span that is a unit of minimum time for evaluating constraints, a term that is composed of one or more spans and is a unit for producing a production plan, and a number of terms for producing a production plan;
For each product type, one or more manufacturing routes to which equipment capable of processing a plurality of processes for manufacturing a product are assigned are registered as a process design, and the processing capability of each process is registered for each process design. Route information storage means;
Facility information storage means for registering facility capacity for each term of each facility;
The term of each facility determined by the processing capability, and the amount processed in the subsequent process does not exceed the amount processed in the previous process while considering the inter-process time between the preceding and following processes for each process for each process design. Optimum product configuration calculating means for calculating the production amount of each span of each process design in which the preset evaluation index is maximized while satisfying the constraint that the total load does not exceed the facility capacity,
A production plan creation device comprising: Production amount information storage means for registering a production amount lower limit value and a production amount upper limit value as a required production amount range for each term of each of the varieties,
The constraint is that, for each term of each of the varieties, a condition is satisfied that a total production amount of spans constituting the term is within a range not less than the production amount lower limit value and within the production amount upper limit value. 40. The production plan creation apparatus according to claim 39.   A manufacturing route generation means for creating and registering a manufacturing route to which an alternative facility is assigned as a process design based on a preset rule of the alternative facility when there is an alternative facility, further comprising: Item 41. The production plan creation device according to Item 39 or 40.   42. The production plan creation device according to any one of claims 39 to 41, wherein the calculation of the evaluation index is performed by a linear programming method.   When the production amount of each span of each process design that maximizes a preset evaluation index that satisfies the constraint cannot be calculated, the terms of each facility determined by the processing capacity with respect to the terms of one or more of the facilities The constraint relaxation means which relaxes the constraint that the total load for each term does not exceed the facility capacity and calculates the production amount of each span of each process design is further provided. The production plan creation device according to any one of the above. The constraint relaxation means is
For the constraint that the total load for each term of each facility determined by the processing capacity does not exceed the facility capacity, the total load of the term of one or more of the facilities determined by the processing capacity is the facility capacity And adding a variable corresponding to the equipment load over which exceeds the above, and adding a penalty for the equipment overload to the evaluation index, the predetermined evaluation index satisfying the constraint is maximized 44. The production plan creation apparatus according to claim 43, wherein the production amount of each span is calculated by a linear programming method.   When the production amount of each span of each process design that maximizes the preset evaluation index that satisfies the constraint cannot be calculated, for each of the terms of each of the varieties, Relax the constraint that the total production volume of the spans that constitute the term is within the range of the production volume lower limit value and within the production volume upper limit value, and calculate the production volume of each span for each process design 42. The production plan creation apparatus according to claim 40 or 41, further comprising means. The constraint relaxation means is
When the production amount of each span of each process design that maximizes the preset evaluation index that satisfies the constraint cannot be calculated, the total production amount of spans that constitute the term for each term of each product type Is the range of the production volume lower limit value or more and the production volume upper limit value or less, with respect to the term of one or more of the varieties, the total production volume of the spans constituting the term is the production volume lower limit value The variable corresponding to the unachieved production amount that did not satisfy the value is added, and the penalty for the unachieved production amount is added to the evaluation index, and the preset evaluation index satisfying the constraint is maximized 46. The production plan creation apparatus according to claim 45, wherein the production amount of each span of each process design is calculated by a linear programming method. The constraint relaxation means is
When the production amount of each span of each process design that maximizes the preset evaluation index that satisfies the constraint cannot be calculated, the total production amount of spans that constitute the term for each term of each product type Is a range that is greater than or equal to the production volume lower limit value and within the production volume upper limit value, for one or more of the varieties of the varieties, the total production volume of the span that constitutes the term is the production volume lower limit A 0-1 variable indicating whether to be 0 regardless of the value and the production amount upper limit value, and the production amount in each span of each process design in which the preset evaluation index satisfying the constraint is maximized 46. The production plan creation apparatus according to claim 45, wherein the value is calculated by a mixed integer calculation method. Product information storage means for registering the selling price and raw material cost for each product type;
For each of the process designs, the cost information storage means for registering the variable cost generated in each process is further provided,
48. The production plan creation apparatus according to any one of claims 39 to 47, wherein the evaluation index is set as a sum of (sale price-raw material cost-variable cost) of all terms. Product information storage means for registering the selling price and raw material cost for each product type;
For each of the process designs, the cost information storage means for registering the variable cost generated in each process is further provided,
The evaluation index is set as a weighted sum of the sum of all terms (sales price-raw material costs-variable costs) and the sum of production amounts of all terms of all varieties. The production plan creation device according to any one of the above. Inventory cost unit price storage means for registering the inventory cost unit price per unit time / unit amount for each process design further comprises:
For each process design, the evaluation index is calculated from the production lead time from the start of production to the completion of production obtained based on the span for processing the first process and the span for processing the final process, and the production amount. 50. The production plan creation device according to claim 48 or 49, wherein an inventory cost calculated based on an inventory cost unit price is set.   The manufacturing lead time is calculated by treating the span for processing the first step and the span for processing the final step as a weighted average of the production amount for each span, respectively. Production plan creation device. Inventory cost unit price storage means for registering the inventory cost unit price per unit time / unit amount in each process for each process design,
The evaluation index is calculated from the inter-process lead time in each process from the start of manufacturing to the completion of manufacturing obtained based on the span for processing each process for each process design, and the production cost. 50. The production plan creation device according to claim 48 or 49, wherein the production cost is set including an inventory cost calculated based on the production cost.   53. The production plan creation apparatus according to claim 52, wherein the inter-process lead time is calculated by treating a span for processing each process as a weighted average of the production amount for each span.   48. The production plan creation device according to any one of claims 39 to 47, wherein the evaluation index is set as a sum of production amounts of all terms of all varieties. Product information storage means for registering the selling price for each of the types,
48. The production plan creation apparatus according to any one of claims 39 to 47, wherein the evaluation index is set as a sum of selling prices of all terms of all varieties. Based on the processing capacity, a process load unit calculation means for calculating the load of each process for each process design when producing a unit quantity of a product as a process load unit,
Based on the variable cost, it further comprises generated cost basic unit calculating means for calculating the generated cost for each process design required when producing a unit quantity of the product as the generated cost basic unit,
54. The production plan creation apparatus according to any one of claims 48 to 53, wherein the evaluation index is calculated by a linear programming method using the process load unit and the generated cost unit. Based on the processing capacity, further comprising a process load basic unit calculating means for calculating the load of each process for each process design when producing a unit quantity of a product as a process load basic unit,
56. The production plan creation apparatus according to claim 54 or 55, wherein the calculation of the evaluation index is performed by a linear programming method using the process load basic unit.

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