JP2006171916A - Production planning method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a production planning method suppressing variation of a production time in each day to reduce a burden on a worker. <P>SOLUTION: This production planning method includes: a reception step S100 receiving delivery times and order reception amounts of respective mounting boards A, B; and an assignment step S106 assigning a production amount of the mounting board A to each day to the delivery time of the mounting board A on the basis of the order reception amount, and assigning a production amount of the mounting board B to each day to the delivery time of the mounting board B preferentially from a day having a shortest production time per day on the basis of the order reception amount. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to a production planning method for creating a plan for producing a production object by a delivery date.

  2. Description of the Related Art Conventionally, a production planning method has been proposed in which a product that is a production target, the quantity of the product, and a delivery date are received and a production plan for the product is made (see, for example, Patent Document 1).

In the production planning method of Patent Document 1, production of a product is assigned to a facility having the longest operable time until delivery date among a plurality of facilities that produce the ordered product. By such a method, the operation rate of each facility is improved.
Japanese Patent Laid-Open No. 2-198751

  However, the production planning method disclosed in Patent Document 1 has a problem in that production time may fluctuate greatly on each day, which places a heavy burden on an operator who tries to cope with the fluctuation.

  Therefore, the present invention has been made in view of such problems, and an object of the present invention is to provide a production planning method that suppresses the variation in production time on each day and reduces the burden on the operator.

  In order to achieve the above object, a production planning method according to the present invention is a method for creating a plan for producing the first and second production objects by respective delivery dates, wherein the first and second production methods are described. A reception step of receiving each delivery date and order quantity of the production object, and production of the first production object based on the order quantity for each day until the delivery date of the first production object Production of the second production object is prioritized from the day with the shortest production time based on the order quantity, with respect to each day until the delivery date of the second production object is allocated. And an assigning step for assigning a quantity.

  As a result, the production quantity of the second production object is assigned to each day with priority from the day with the shortest production time of the day, so that variations in production time on each day can be suppressed, The burden can be reduced.

  The production planning method may further include a leveling step of leveling the production time in each day by changing the production quantity allocated in the allocation step.

Thereby, the dispersion | variation in the production time in each day can further be suppressed.
Here, the production planning method further includes a lot consisting of the first production object having the order quantity accepted in the acceptance step, and a second production object having the order quantity accepted in the acceptance step. A determination step for determining whether or not to divide each lot based on a predetermined quantity; and a division step for dividing the lot determined to be divided in the determination step into a plurality of lots. Then, the production quantity may be allocated in the lot unit, and the production quantity may be changed in the lot unit in the leveling step. For example, in the dividing step, when the lot of the first production object received in the receiving step is divided, the lot is divided based on the quantity that can be produced per unit time. Then, when dividing the lot of the second production object received in the reception step, the lot is divided on the basis of the quantity capable of producing the second production object per unit time.

  As a result, since the first and second production objects are handled as lots in a predetermined quantity unit, the burden of making a production plan is reduced as compared with the case where the first and second production objects are handled individually. be able to.

  Further, the leveling step includes a changing step for changing the production quantity assigned in the assigning step in units of lots, and a time calculating step for calculating a production time for each day in the state changed in the changing step, Based on the production time for each day calculated by the time calculation step, a leveling determination step for determining whether or not leveling of the production time for each day is promoted by the change in the change step; and the leveling Including a change determination step that adopts a change in the change step when determined to be promoted in the determination step, and a change determination step that does not adopt the change in the change step when determined not to be promoted in the leveling determination step. It is good as a feature.

Thereby, the production time in each day can be evaluated and leveled reliably.
Further, in the allocation step, the one day is set based on a production rate when the setting of the equipment for producing the first and second production objects is optimized for production of the first production object. In the time calculation step, based on the production speed when the setting of the equipment is optimized for the production of all production objects allocated on the day The production time for each day may be calculated.

  Thereby, on the day when only the first production object is produced, the equipment setting is optimized for the production of the first production object, and on the day when only the second production object is produced, the equipment setting is performed. Is optimized for the production of the second production object, and on the day when the first and second production objects are produced, if the facility setting is optimized for the production of the first and second production objects, It is not necessary to change the setting of the equipment on each day, and the production time on each day can be surely leveled.

  In addition, the production planning method is further changed by the leveling step on the assumption that the setting of the equipment is optimized for the production of all production objects allocated on the day in units of days. 1st which specifies the 1st transition pattern which replaces each lot assigned to each day so that the days when the setting of the equipment becomes the same in the state may continue in units of days, and shows the setting for the day of the equipment The pattern specifying step may be included.

  Thereby, since the day when the setting of an installation becomes the same continues, the frequency | count of performing the setting change (setup) of an installation can be reduced. As a result, overall production time can be shortened, and the burden on the operator can be further reduced.

  Further, the production planning method may further include setting each facility setting based on the premise in a state in which the leveling step has been changed, with a plurality of groups based on a portion having the smallest number of transitions between the settings. And a second pattern specifying step for specifying a second transition pattern indicating a setting for each day of the facility by changing to a common group setting for each group.

  Thereby, if the setting of the equipment is set to the group setting, the number of times the equipment setting is changed (setup) can be reduced. As a result, overall production time can be shortened, and the burden on the operator can be further reduced.

  Further, the production planning method further includes a first required for producing the first and second production objects by the respective order quantities when the setting of the equipment is the first transition pattern. In the first calculation step for calculating the total production time including the time required to change the setting of the equipment, and when the setting of the equipment is the second transition pattern, the first and second production targets A second calculation step of calculating a second total production time required to produce the product in the order quantity, including a time required to change the setting of the equipment, and the first and second total production times. When the comparison determination step for determining which is shorter and the first total production time is determined to be shorter in the comparison determination step, the setting of the equipment is determined to be the first transition pattern. First And a second determination step for determining the setting of the equipment as the second transition pattern when it is determined in the comparison determination step that the second total production time is shorter. It may be characterized.

  Thereby, since the first and second total production times are compared and the setting of the equipment corresponding to the shorter one is determined, the operator can easily set the equipment to reduce the overall production time. Can be achieved reliably.

  The present invention can be realized not only as such a production planning method, but also as a production planning apparatus and program for performing production planning using the method, and as a storage medium for storing the program. .

  The production planning method of the present invention has an effect that the burden on the operator can be reduced by suppressing variations in production time on each day.

  Hereinafter, a production planning method according to an embodiment of the present invention will be described with reference to the drawings.

  FIG. 1 is an explanatory diagram for explaining a situation in which production planning is performed using the production planning method according to the embodiment of the present invention.

  The production planning method according to the present embodiment is a method of receiving an order from a customer for, for example, a mounting board (product to be manufactured) on which electronic components are mounted, and making a plan for producing the mounting board by the delivery date. Thus, it is characterized in that the burden on the worker is reduced by suppressing the variation in production time on each day.

  The customer orders, for example, 100 mounting boards A on June 30 and 140 mounting boards B on July 1 from the factory.

  In the factory, for example, a component mounting machine 100 capable of producing five types of mounting boards A to E and a production planning apparatus 10 that performs production planning based on the production planning method of the present embodiment are installed.

  The component mounting machine 100 produces mounting boards A to E by mounting electronic components on the board.

  The production planning device 10 is configured as a personal computer in which dedicated software is installed, for example, and performs production planning by the production planning method of the present invention in accordance with the user's operation on the keyboard, and the result of the production planning on the display. Is displayed. For example, as a result of the production plan, the production planning apparatus 10 produces 100 mounting boards A, 20 mounting boards B, and 120 mounting boards C as of June 1, On the second day, the display unit 40 displays that 40 mounting boards D and 80 mounting boards E should be produced.

  Such a production planning device 10 performs production planning of the mounting boards A to E so that the variation in production time in each day in the component mounting machine 100 is reduced.

FIG. 2A is an external view showing the external appearance of the component mounter 100.
The component mounting machine 100 includes two sub facilities (a front sub facility 110 and a rear sub facility 120) that perform component mounting simultaneously and independently. Each sub-equipment 110, 120 is an orthogonal robot type mounting stage, and includes component supply units 115a and 115b, a multi-mounting head 112, an XY robot 113, a component recognition camera 116, and a tray supply unit 117. Each of the component supply units 115a and 115b includes an array of a maximum of 48 component cassettes 114 for storing component tapes. The multi-mounting head 112 is also called a 10-nozzle head or simply a head, and has 10 suction nozzles that can suck up to 10 components from the component cassette 114 and mount them on the substrate. The XY robot 113 moves the multi mounting head 112. The component recognition camera 116 is used for two-dimensionally or three-dimensionally inspecting the suction state of the component sucked by the multi-mounting head 112. The tray supply unit 117 supplies tray parts. Each such sub-equipment 110, 120 executes component mounting on the board in charge of each sub-equipment 110, 120 independently of (in parallel with) the other sub-equipment.

  The “component tape” is actually a plurality of components of the same component type arranged on a tape (carrier tape) and supplied in a state of being wound around a reel (supply reel) or the like. The

  Specifically, the component mounting machine 100 is a mounting machine having both functions of a component mounting machine called a high-speed mounting machine and a component mounting machine called a multi-function mounting machine. A high-speed mounting machine is a facility characterized by high productivity that mainly mounts electronic parts of □ 10 mm or less at a speed of about 0.1 seconds per point. A multi-function mounting machine is a large model of □ 10 mm or more. It is equipment for mounting electronic parts, odd-shaped parts such as switches and connectors, and IC parts such as QFP (Quad Flat Package) and BGA (Ball Grid Array).

  In other words, the component mounting machine 100 is designed to be able to mount almost all kinds of electronic components (from 0.4 mm × 0.2 mm chip resistance to 200 mm connector as components to be mounted) A production line can be configured by arranging a required number of the component mounting machines 100.

FIG. 2B is a plan view showing the main configuration of the component mounter 100.
The shuttle conveyor 118 is a moving table (component conveyor) for loading the components taken out from the tray supply unit 117 and transporting them to a predetermined position where the multi-mounting head 112 can suck them. The nozzle station 119 is a table on which replacement nozzles for accommodating various types of component types are placed.

  The two component supply units 115a and 115b constituting each sub-equipment 110 (or 120) are respectively arranged on the left and right with the component recognition camera 116 interposed therebetween. Therefore, the multi-mounting head 112 that has picked up the components in the component supply unit 115a or 115b moves to the mounting point of the board 20 after passing through the component recognition camera 116, and performs an operation of sequentially mounting all of the sucked components. repeat. “Mounting point” refers to a coordinate point on a board on which a component is to be mounted, and components of the same component type may be mounted at different mounting points.

  FIG. 3 is a schematic diagram showing the positional relationship between the multi-mounting head 112 and the component cassette 114.

  The multi-mounting head 112 is a working head called “gang pickup system”, and can attach up to ten suction nozzles 112a to 112b. At this time, the parts from each of up to ten parts cassettes 114 can be attached. Can be adsorbed simultaneously (by a single up-and-down motion).

  Note that only one component tape is loaded into the component cassette 114 called “single cassette”, and two component tapes are loaded into the component cassette 114 called “double cassette”. In addition, the set position of the component cassette 114 (or component tape) in the component supply units 115a and 115b is referred to as “value on the Z axis” or “position on the Z axis (Z number)”. A serial number or the like whose left end is “Z1” is used. The “Z-axis” refers to a coordinate axis that specifies the arrangement position (set position) of the component cassette 114 set for each component mounting machine 100 (or the sub-equipment when a sub-equipment is provided). Here, as an important procedure for determining the mounting order of components, determining the arrangement (position on the Z axis) of the component type (or component tape or component cassette 114 storing the component tape). Is mentioned.

FIG. 4 is a flowchart showing an overall processing operation performed by the production planning apparatus 10.
First, the production planning apparatus 10 performs an order receiving process for receiving orders (delivery date and order quantity) of the mounting boards A to E (step S100).

  Next, the production planning device 10 receives all the ordered mounting boards A, all ordered mounting boards B, all ordered mounting boards C, all ordered mounting boards D, and All the ordered mounting boards E are regarded as one lot. Then, the production planning device 10 determines whether or not each lot should be divided (step S102).

  When it is determined in step S102 that the lot is to be divided (Y in step S102), the production planning apparatus 10 performs a dividing process of dividing the lot into a plurality of small lots (step S104). Hereinafter, when the lot before being divided is distinguished from the divided small lot, it is referred to as a large lot, and when the lot and the large lot are not distinguished from each other, they are simply referred to as a lot.

  Next, the production planning apparatus 10 performs, for example, a lot assignment process for assigning each lot received for each day from the next day after the order is received to the delivery date (step S106).

  After the lot allocation process, the production planning device 10 calculates the production time in the common array for each day, and performs the leveling process for the production time (step S108). In other words, the production planning apparatus 10 suppresses variations in production time in the common array on each day by exchanging and moving the lots allocated every day in the lot allocation process (step S106). Here, the common arrangement means that all kinds of mounting boards allocated in one day can be produced without replacing the component cassette 114, and the production time (tact) per one mounting board is the shortest. This is an arrangement on the Z-axis of the component cassette 114 optimized to be. That is, the common arrangement is a setting of the equipment as the component mounting machine 100 optimized for the production of all the production objects allocated on the day in units of days.

In addition, such a leveling process determines the lot to be produced on a daily basis.
After the leveling process, the production planning apparatus 10 performs a production grouping process that identifies a common array transition pattern (common array pattern P1) that shortens the production time in all production processes (step S110). Furthermore, the production planning apparatus 10 performs a regrouping process that identifies a common array transition pattern (common array pattern P2) that shortens the production time in all production processes from a viewpoint different from the production grouping process (step S112). .

  Then, the production planning device 10 performs a production time evaluation process for selecting a pattern having a short total production time from the common array patterns P1 and P2 (step S114). Thereby, the common arrangement pattern to be actually performed is determined, and the lot to be produced on each day, that is, the production plan is determined by the determination of the common arrangement pattern.

  The production planning apparatus 10 that has determined the production plan in this way displays the production plan on the display (step S116).

Here, the order processing described above will be described in detail.
The production planning apparatus 10 creates order data indicating the type, number (order quantity), delivery date, and the like of the mounting board that has been ordered.

FIG. 5 is a data content display diagram showing the contents of the order data.
The order data dt1 includes a board field n1 for storing the type of the mounting board for which the order has been received, a number field n2 for storing the number of the mounting boards of that type, and a delivery date field for storing the delivery date of the mounting board of that type. There is a tact field n4 for storing n3 and a tact of that type of mounting board.

  For example, the board column n1 stores the mounting board A as the type of the mounting board that has been ordered, and the number field n2 stores 100 as the number of the mounting boards A. In addition, the delivery date column n3 stores June 30 as the delivery date of the mounting board A, and the tact column n4 stores 100 seconds as the tact of the mounting board A.

  Here, the tact of each mounting board stored in the order data dt1 is, for example, the shortest production time per mounting board realized by optimizing the arrangement of the component cassette 114 with respect to the mounting board. Alternatively, the tact is a time corresponding to 70% of the quotient obtained by dividing the number of mounting points of the mounting board by the maximum number of mounting times per unit time of the component mounting machine 100. Hereinafter, when the arrangement of the component cassettes 114 corresponding to the tact stored in the order data dt1 is distinguished from the common arrangement, it is referred to as a unique arrangement.

Next, the lot division process described above will be described in detail.
6A to 6E are explanatory diagrams for explaining the lot division processing.

  The production planning device 10 is configured to mount a large lot La of the mounting board A on the basis of the number of units that can be produced for a unit time corresponding to, for example, 1/8 to 1/5 of the operation time per day of the component mounting machine 100. It is determined whether or not the large lot Lb of the substrate B, the large lot Lc of the mounting substrate C, the large lot Ld of the mounting substrate D, and the large lot Le of the mounting substrate E should be divided.

  For example, the unit time corresponding to one-eighth of the operation time per day of the component mounting machine 100 is 8 hours × (1/8) = 1 hour (3600 seconds) when the operation time per day is 8 hours. It is. As indicated by the order data dt1, the tact time of the mounting board A is 100 seconds. Therefore, the number of units that can be produced in the unit time (3600 seconds) of the mounting board A is the tact time (100 seconds). It becomes 36 sheets of the quotient obtained by division. Therefore, the production planning apparatus 10 determines that it is necessary to divide because the number of large lots La (100) of the mounting board A is larger than the number of producible sheets (36) in the unit time. As a result, as shown in FIG. 6A, the production planning apparatus 10 divides a large lot La having 100 mounting boards A as a unit into two small lots having 36 mounting boards A as a unit. It is divided into La1 and La2 and a small lot La3 with 28 mounting boards A as a unit.

  As described above, since the tact time of the mounting board B is 50 seconds, the number of products that can be produced in the unit time (3600 seconds) of the mounting board B is a quotient obtained by dividing the unit time (3600 seconds) by the tact (50 seconds). 72 sheets. Therefore, the production planning apparatus 10 determines that it is necessary to divide because the number of large lots Lb (140) of the mounting board B is larger than the number of possible productions (72) in the unit time. As a result, as shown in FIG. 6B, the production planning apparatus 10 divides a large lot Lb with 140 mounting boards B as a unit into a small lot Lb1 with 72 mounting boards B as a unit. , 68 mounting boards B are divided into small lots Lb2 with one unit.

  Further, since the tact time of the mounting substrate C is 80 seconds, the number of products that can be produced per unit time (3600 seconds) of the mounting substrate C is 45 pieces of the quotient obtained by dividing the unit time (3600 seconds) by the tact time (80 seconds). Become. Therefore, the production planning apparatus 10 determines that it is necessary to divide since the number of large lots Lc (170) of the mounting substrate C is larger than the number of producible sheets (45) in the unit time. As a result, as shown in FIG. 6C, the production planning apparatus 10 converts the large lot Lc having 170 mounting substrates C as a unit into three small lots having 45 mounting substrates C as a unit. It is divided into Lc1, Lc2, Lc3 and a small lot Lc4 with 35 mounting boards C as a unit.

  Further, since the tact time of the mounting substrate D is 75 seconds, the production possible number of the mounting substrate D in the unit time (3600 seconds) is 48 pieces of the quotient obtained by dividing the unit time (3600 seconds) by the tact (75 seconds). Become. Therefore, the production planning apparatus 10 determines that it is not necessary to divide the mounting substrate D because the number of large lots Ld (40 sheets) is smaller than the number of producible sheets (48 sheets) in the unit time. As a result, as shown in FIG. 6D, the production planning apparatus 10 treats the large lot Ld with 40 mounting boards D as a unit as one lot without dividing it.

  Similarly, since the tact time of the mounting board E is 30 seconds, the number of products that can be produced per unit time (3600 seconds) of the mounting board E is a quotient obtained by dividing the unit time (3600 seconds) by the tact time (30 seconds). 120 sheets. Therefore, the production planning apparatus 10 determines that there is no need to divide because the number of large lots Le (110) of the mounting board E is smaller than the number of producible sheets (120) in the unit time. As a result, as shown in FIG. 6E, the production planning apparatus 10 treats the large lot Le having 110 mounting boards E as a unit as one lot without dividing it.

Next, the lot allocation process described above will be described in detail.
FIGS. 7A to 7E are explanatory diagrams for explaining the lot assignment processing. In each graph of Drawing 7 (a)-(e), a horizontal axis d is shown as a date and vertical axis t is shown as production time.

  The production planning apparatus 10 identifies the lot with the shortest delivery date, and assigns the lot to the day before the delivery date and the shortest production time t.

  For example, the production planning apparatus 10 first identifies the lots La1 to La3 on June 30 with the shortest delivery date from all the lots. Then, as shown in FIG. 7A, the production planning apparatus 10 allocates these lots La1 to La3 on June 28, 29, and 30 so as not to exceed the delivery date.

  Next, the production planning device 10 identifies the L1 and Lb2 on July 1 with the shortest delivery date from the remaining lots that are not allocated. Then, as shown in FIG. 7B, the production planning device 10 assigns the lots Lb1 and Lb2 in order from July 1 with the shortest production time t among the days before the delivery date. For example, the production planning device 10 allocates the lot Lb1 on July 1 and allocates the lot Lb2 on June 28.

  As described above, the production planning apparatus 10 identifies the lots Lc1 to Lc4 on July 1 with the shortest delivery date from the remaining lots that are not assigned. Then, as shown in FIG. 7 (c), the production planning device 10 assigns the lots Lc1 to Lc4 to June 29, June 30, and the shortest production time t among the days before the delivery date. Allocate in order from July 1st. For example, the production planning device 10 assigns the lot Lc1 on June 29, assigns the lot Lc2 on June 30, assigns the lot Lc3 on July 1, and assigns the lot Lc4 on June 28.

  Further, the production planning apparatus 10 identifies the July 2 lot Ld with the shortest delivery date from the remaining lots that are not assigned. Then, as shown in FIG. 7 (d), the production planning device 10 assigns the lot Ld to July 2 with the shortest production time t among the days before the delivery date.

  Furthermore, the production planning apparatus 10 identifies the July 2 lot Le having the shortest delivery date from the remaining lots that are not assigned. Then, as shown in FIG. 7E, the production planning device 10 allocates the lot Le to July 2 with the shortest production time t among the days before the delivery date.

FIG. 8 is a flowchart showing the flow of lot allocation processing.
First, the production planning device 10 identifies the lot with the shortest delivery date (step S200). If there are a plurality of lots with the shortest delivery time, the production planning apparatus 10 identifies any one of the lots. Further, for example, when there are a plurality of lots with the shortest delivery time, such as the lots Lb1, Lb2 and the lots Lc1 to Lc4, and these lots are roughly divided into a plurality of groups according to the type of the mounting board, The production planning device 10 first identifies any one of these groups. And the production planning apparatus 10 specifies any one lot in order from the group.

  Next, the production planning device 10 assigns the lot specified in step S200 to the day with the shortest production time t among the days before the delivery date (step S202). Here, if there are a plurality of days with the shortest production time t, the production planning apparatus 10 allocates a lot on the day closest to the present among these days, for example (step S202).

  When the lot is allocated in step S202, the production planning apparatus 10 calculates the production time t on the day when the allocation is performed for the next processing in step S202 (step S204).

  Then, the production planning apparatus 10 determines whether there is a lot that has not been assigned (step S206). When it is determined that it exists (Y in step S206), the production planning apparatus 10 repeatedly executes the processing from step S200, and when it is determined that it does not exist (N in step S206), the lot allocation process ends.

  By such lot allocation processing, all lots of the respective mounting boards A to E that have been ordered are allocated on each day.

  As described above, in this embodiment, for each mounting board A to E, the production quantity of the mounting board is given priority over the day until the delivery date of the mounting board, starting with the day with the shortest production time per day. Since only the order quantity is assigned in units of lots, variation in production time on each day can be suppressed, and the burden on the operator can be reduced.

Next, the above leveling process will be described in detail.
The production planning device 10 calculates the production time based on the common array for each day when the lot is assigned on each day by the lot assignment process.

  For example, the lot La1 of the mounting board A, the lot Lb2 of the mounting board B, and the lot Lc4 of the mounting board C are allocated on June 28 by the lot allocation process described above. Here, if the arrangement of the component cassettes 114 of the component mounting machine 100 is a common arrangement for the mounting board A, the mounting board B, and the mounting board C, the tact for each of the mounting boards is more than the tact for the original arrangement. become longer. As a result, the production time on June 28 is longer than the production time shown in FIG.

  FIG. 9 is an explanatory diagram for explaining tact in each case of the unique array and the common array.

  In the arrangement of component cassettes 114 (unique arrangement) corresponding to the production of only the mounting board A, the tact time of the mounting board A is 100 seconds. Further, in the unique arrangement of the mounting board B, the tact time of the mounting board B is 50 seconds. Furthermore, in the unique arrangement of the mounting substrate C, the tact time of the mounting substrate C is 80 seconds.

  On the other hand, when the component cassettes 114 are set in a common arrangement corresponding to the mounting board A, the mounting board B, and the mounting board C to be produced on June 28, the production planning apparatus 10 sets the tact of the mounting board A to 120. The tact of the mounting board B is calculated as 60 seconds, and the tact of the mounting board C is calculated as 90 seconds.

  Thus, by using a common arrangement, each tact becomes longer, and as a result, the production time for each day also becomes longer accordingly.

FIG. 10 is a diagram showing the production time in the case of common arrangement for each day.
As shown in FIG. 10, there may be variations in the production time t1 of each day when they are arranged in common every day.

  Therefore, the production planning device 10 exchanges or moves the lots allocated on each day so that the production time t1 is leveled on each day even when they are arranged in common.

FIG. 11 is an explanatory diagram for explaining lot replacement and movement.
For example, when each lot is allocated as shown in FIG. 11A by the lot allocation process, the production planning apparatus 10 arbitrarily selects two lots from the allocated lots. And as shown in FIG.11 (b), if the production planning apparatus 10 selects lot La3 and lot Lc4, for example, they will mutually replace. When such lot replacement is performed, the production planning device 10 derives the production time t1 in the case of being arranged in common every day, and determines whether or not the production time t1 for each day is leveled.

  Further, the production planning apparatus 10 arbitrarily selects one lot from among the assigned lots as shown in FIG. For example, when the production planning apparatus 10 selects the lot Lc4, the production planning apparatus 10 moves the lot Lc4 from June 28 to June 30 as shown in FIG. When such a lot movement is performed, the production planning apparatus 10 derives the production time t1 in the case of being arranged in common every day as described above, and whether or not the production time t1 for each day is leveled. Is determined.

  The lot replacement and movement as described above is performed so that each of the mounting boards A to E is produced by the delivery date corresponding to the order quantity.

  In this way, the production planning apparatus 10 performs a change by lot replacement and movement, determines whether leveling is promoted, and adopts the replacement or movement when promoted.

FIG. 12 is a flowchart showing the flow of the leveling process.
First, the production planning apparatus 10 calculates the production time by the common arrangement for each day in a state where each lot is assigned by the lot assignment process (step S300).

  Next, the production planning apparatus 10 repeatedly performs the following operations from step S302 to S312 by the number obtained by doubling the number of lots. For example, as shown in FIG. 11, when the number of lots is 11, it is repeatedly executed 22 times.

  That is, the production planning apparatus 10 arbitrarily selects two lots from the allocated lots by generating random numbers, for example (step S302). In this selection, an empty lot is also selected. Therefore, when one of the two selected lots is an empty lot, only the other one lot is actually selected.

  The production planning apparatus 10 replaces or moves the selected lot (step S304). That is, when two non-empty lots are selected in step S302, the production planning apparatus 10 replaces the two lots. Further, when two lots including one empty lot are selected in step S302, the production planning apparatus 10 replaces the two lots. That is, the production planning device 10 moves a non-empty lot to the position of an empty lot.

  Here, the production planning device 10 again calculates the production time by the common arrangement every day in a state where the lots are exchanged or moved (step S306).

  Then, the production planning device 10 compares the daily production time calculated in step S306 with the previous daily production time, and whether or not the production time on each day is leveled compared to the previous time. Is determined (step S308).

  When it is determined that the level has been leveled (Y in step S308), the production planning apparatus 10 employs the lot replacement or movement performed in the immediately preceding step S304 (step S310). When it is determined that the level is not leveled (N in Step S308), the production planning apparatus 10 returns the lot to the original position without adopting the lot replacement or movement performed in the immediately preceding Step S304. Return (step S312).

  By repeating the operations from step S302 to S312 as described above, the production time on each day is leveled.

  FIG. 13 is a diagram showing lot allocation and production time for each day after the leveling process is performed.

As shown in FIG. 13, lots La1, La2, and Lc2 are allocated on June 28, lots Lb1 and Lc1 are allocated on June 29, and lot La3 is allocated on June 30. Lc3 is allocated, lots Lb2 and Lc4 are allocated on July 1, and lots Ld and Le are allocated on July 2. In the state where lots are allocated in this way, the production times t1 of each day when the common arrangement is performed are approximately equal and leveled. In addition, by making the component cassettes 114 a common arrangement on each day, it is possible to save the trouble of changing the arrangement of the component cassettes 114 on that day.
Such a leveling process determines the lot to be produced on a daily basis.

Next, the production grouping process described above will be described in detail.
The production planning device 10 performs grouping of the common arrangement so that the setup loss is reduced when the lot to be produced on a daily basis is determined. Here, the setup loss refers to the time required for setup for the operator to change the arrangement of the component cassettes 114 by stopping the component mounting machine 100.

  FIG. 14 is an explanatory diagram for explaining a common array pattern determined by the leveling process.

  In the common arrangement pattern P determined by the leveling process, as shown in FIG. 14, the common arrangement changes every day. That is, the common arrangement (common arrangement AC) of the mounting board A and the mounting board C on June 28, the common arrangement (common arrangement BC) of the mounting board B and the mounting board C on June 29, and June 30. Is a common array AC, a common array BC on July 1, and a common array (common array DE) of the mounting board D and the mounting board E on July 2.

  However, in such a common arrangement pattern P, the operator must change the arrangement of the component cassettes 114 to a common arrangement corresponding to the day every day. As a result, four setups occur, resulting in a long setup loss.

  Therefore, the production planning device 10 changes the production dates of the lots assigned in units of days so that the same common array days are consecutive.

  FIG. 15 is a diagram showing lot allocation and production time for each day after the production date is changed.

  For example, as shown in FIG. 15, the production planning device 10 determines the production dates of the lots Lb1 and Lc1 and the lots so that the dates of the same common array are consecutive from the allocation determined by the leveling process (see FIG. 13). Replace the production dates of La3 and Lc3. Thus, the production planning apparatus 10 groups the common array AC on consecutive June 28 and 29, groups the common array BC on consecutive June 30 and July 1, and sets the common array DE to 7 Group on the 2nd of the month.

FIG. 16 is a diagram showing a common arrangement pattern determined by the production grouping process.
The production planning apparatus 10 changes the common arrangement pattern P to the common arrangement pattern P1 as shown in FIG. 16 by the production grouping process. In other words, the production planning apparatus 10 has a common array AC that becomes a common array AC on June 28 and 29, a common array BC on June 30 and July 1, and a common array DE on July 2. The pattern P1 is specified.

  In such a common array pattern P1, the number of setups can be reduced to only two, and the setup loss can be shortened.

Next, the above-described re-grouping process will be described in detail.
When the lot to be produced on a daily basis is determined, the production planning apparatus 10 performs grouping in a common arrangement so that the setup loss is reduced from a viewpoint different from the production grouping process.

FIG. 17 is an explanatory diagram for explaining the re-grouping process.
In the common arrangement pattern P determined by the leveling process as described above, the common arrangement must be changed every day as shown in FIG. That is, as shown in FIG. 17A, the number of times of transition from the common array AC to the common array BC is two times, the number of times of transition from the common array BC to the common array AC is one, and the common array BC is changed to the common array ED. The number of times of transition is one.

  Therefore, the production planning device 10 identifies a part having the smallest number of transitions between the common arrays. That is, the number of transitions between the common array AC and the common array BC is three, but the number of transitions between the common array BC and the common array DE is one. The area between the array BC and the common array DE is specified.

  Then, the production planning device 10 reviews the common array with the part (between the common array BC and the common array DE) as a boundary. That is, the production planning apparatus 10 produced the common array AC and the common array BC in a common array ABC corresponding to the mounting board A, the mounting board B, and the mounting board C, rather than making a transition between them. Therefore, it is determined that the setup loss is reduced.

  As a result, the production planning apparatus 10 changes the common arrangement pattern P determined by the leveling process to a common arrangement pattern P2 as shown in FIG. That is, the production planning apparatus 10 specifies the common array pattern P2 that is the common array ABC from June 28 to July 1, and the common array DE on July 2. As a result, the production planning apparatus 10 groups the common array ABC from June 28 to July 1, and groups the common array DE on July 2. The lots to be produced on each day are the same as those determined by the leveling process.

  In such a common array pattern P2, the number of setups can be reduced to one, and the setup loss can be shortened.

Next, the production time evaluation process described above will be described in detail.
The production planning device 10 compares the total production time including the setup loss due to the common arrangement pattern P1 with the total production time including the setup loss due to the common arrangement pattern P2, and selects the common arrangement pattern having a short total production time. To do.

FIG. 18 is an explanatory diagram for explaining the total production time of each common array pattern.
Based on the common array pattern P1, the production planning apparatus 10 uses the tact (110 seconds, 90 seconds) of the mounting board A and the mounting board C in the common array AC, and the mounting board B and the mounting in the common array BC. Each tact (60 seconds, 100 seconds) of the substrate C and each tact (80 seconds, 45 seconds) of the mounting substrate D and the mounting substrate E in the common array DE are specified.

  In addition, the production planning device 10 specifies the number of mounted substrates produced at each common arrangement based on each lot in which production dates are changed in the production grouping process. For example, the production planning apparatus 10 specifies lots La1, La2, La3 and lots Lc2, Lc3 in the common array AC, and therefore specifies the number of mounting boards A as 100 and the number of mounting boards C as 90. Identify. Similarly, the production planning apparatus 10 specifies lots Lb1 and Lb2 and lots Lc1 and Lc4 in the common array BC, and therefore specifies the number of mounting boards B as 140 and the number of mounting boards C as 80. To do. Furthermore, since the lot Ld and the lot Le are produced in the common array DE, the production planning device 10 specifies the number of mounting boards D as 40 and specifies the number of mounting boards E as 110.

  By specifying the tact and the number of sheets in this way, the production planning apparatus 10 calculates the production time for each mounting board at each common arrangement. For example, the production planning apparatus 10 calculates the production time of 100 mounting boards A at the time of the common array AC as 110 (seconds) × 100 (sheets) = 11000 (seconds), and produces 90 boards of the mounting board C. The time is calculated as 90 (seconds) × 90 (sheets) = 8100 (seconds).

  In addition, the production planning apparatus 10 specifies the time required for setup for changing the common array AC to the common array BC (setup loss) and the setup loss for changing the common array BC to the common array DE. For example, it is assumed that the production planning apparatus 10 requires only 5 minutes (300 seconds) to change only one component cassette 114. Then, the production planning apparatus 10 specifies 6000 seconds obtained by multiplying the number of parts cassettes 114 to be changed (20) by 300 seconds as a setup loss for changing the common array AC to the common array BC. Further, the production planning apparatus 10 specifies 7500 seconds, which is 300 seconds multiplied by the number of parts cassettes 114 changed (25), as a setup loss for changing the common array BC to the common array DE.

  The production planning apparatus 10 calculates the total production time (47250 seconds) of the common arrangement pattern P1 by integrating the production time and the setup loss for each mounting board at each common arrangement specified as described above.

  In the same manner as described above, the production planning device 10 performs the tacts (113 seconds, 65 seconds, 102 seconds) of the mounting board A, the mounting board B, and the mounting board C in the common array ABC based on the common array pattern P2. And each tact (80 seconds, 45 seconds) of the mounting board D and the mounting board E in the common array DE is specified.

  Further, the production planning device 10 specifies the number of produced mounting boards at each common arrangement based on each lot assigned by the leveling process. For example, the production planning apparatus 10 specifies lots La1 to La3, lots Lb1 and Lb2, and lots Lc1 to Lc4 in the common array ABC. Therefore, the production planning apparatus 10 specifies the number of mounting boards A as 100, and determines the number of mounting boards B. 140 is specified, and the number of mounting boards C is specified as 170. Similarly, since the lot Ld and the lot Le are produced in the common array DE, the production planning device 10 specifies the number of mounting boards D as 40 and specifies the number of mounting boards E as 110.

  By specifying the tact and the number of sheets in this way, the production planning apparatus 10 calculates the production time for each mounting board at each common arrangement. For example, the production planning device 10 calculates the production time of 100 mounting boards A at the time of the common array ABC as 113 (seconds) × 100 (sheets) = 11300 (seconds), and produces 140 mounting boards B. The time is calculated as 65 (seconds) × 140 (sheets) = 9100 (seconds), and the production time of 170 mounting boards C is calculated as 102 (seconds) × 170 (sheets) = 17340 (seconds).

  In addition, the production planning apparatus 10 specifies a setup loss for changing the common array ABC to the common array DE. For example, as described above, the production planning apparatus 10 specifies 3000 seconds, which is 300 seconds multiplied by the changed number (10) of the component cassettes 114, as the setup loss.

  The production planning apparatus 10 calculates the total production time (48890 seconds) of the common arrangement pattern P2 by integrating the production time and the setup loss for each mounting board at each common arrangement specified in this way.

  When the total production time of the common array patterns P1 and P2 is calculated in this way, the production planning apparatus 10 selects a common array pattern having a short total production time from these patterns. In other words, in the above example, the production planning device 10 selects the common arrangement pattern P1 having a short total production time.

  As a result, the production planning apparatus 10 produces a production plan as shown in FIG. 15, that is, produces lots La1, La2, and Lc2 on June 28, and produces lots La3 and Lc3 on June 29. On June 30th, lots Lb1 and Lc1 are produced, on July 1st lots Lb2 and Lc4 are produced, and on July 2nd, the plans to produce lots Ld and Le are displayed on the display. The production planning apparatus 10 should produce the common array AC on June 28 and 29, the common array BC on June 30 and July 1, and the common array DE on July 2. On the display.

  As described above, in the production time evaluation process, the common arrangement pattern having the shorter total production time including the setup loss is selected, so that the operator can change the arrangement of the component cassettes 114 of the component mounter 100. It is easy to know whether production can be performed efficiently. As a result, the overall production time can be reliably reduced.

  In the present embodiment, an example has been described in which the number of times of setup is two by the production grouping process and the number of times of setup is one by the regrouping process. However, when the number of setups is 3 due to the production grouping process, a common arrangement pattern may be specified such that the number of setups is 2 or 1 in the regrouping process. In this case, the common arrangement pattern having the shortest total production time is selected from the three common arrangement patterns.

  In the present embodiment, the production of the mounting board has been described as an example. However, the present invention is not limited to the mounting board, and may be another production object instead of the mounting board.

  The production planning apparatus of the present invention has an effect of reducing the burden on the operator by suppressing the variation in production time on each day, for example, a production planning apparatus for producing a production target such as a mounting board. Can be applied to.

It is explanatory drawing for demonstrating the condition which performs a production plan using the production planning method in embodiment of this invention. It is a figure for demonstrating a component mounting machine same as the above, Comprising: (a) is an external view which shows the external appearance of a component mounting machine, (b) is a top view which shows the main structures of a component mounting machine. It is a schematic diagram which shows the positional relationship of a multi mounting head same as the above and a component cassette. It is a flowchart which shows the whole processing operation which a production planning apparatus same as the above performs. It is a data content display figure which shows the content of order data same as the above. It is explanatory drawing for demonstrating lot division processing same as the above. It is explanatory drawing for demonstrating a lot allocation process same as the above. It is a flowchart which shows the flow of a lot allocation process same as the above. It is explanatory drawing for demonstrating the tact in each case of an original arrangement | sequence and a common arrangement | sequence. It is a figure which shows the production time at the time of being arranged in common every day. It is explanatory drawing for demonstrating replacement and movement of a lot same as the above. It is a flowchart which shows the flow of the leveling process same as the above. It is a figure which shows the allocation and production time of each day lot after the leveling process same as the above is performed. It is explanatory drawing for demonstrating the pattern of the common arrangement | sequence determined by the leveling process same as the above. It is a figure which shows the allocation and production time of the lot of each day after a production date same as the above is changed. It is a figure which shows the common arrangement | sequence pattern determined by the production grouping process same as the above. It is explanatory drawing for demonstrating the re-grouping process same as the above. It is explanatory drawing for demonstrating the total production time of each common sequence pattern same as the above.

Explanation of symbols

DESCRIPTION OF SYMBOLS 10 Production planning apparatus 100 Component mounting machine 114 Component cassette AE Mounting board

Claims (14)

A method of creating a plan for producing the first and second production objects by their respective delivery dates,
An accepting step of accepting the delivery date and order quantity of each of the first and second production objects;
For each day until the delivery date of the first production object, the production quantity of the first production object is allocated based on the order quantity, and each day until the delivery date of the second production object. Allocating the production quantity of the second production object with priority from the day with the shortest production time based on the order quantity. The production planning method further includes:
The production planning method according to claim 1, further comprising a leveling step of leveling the production time in each day by changing the production quantity allocated in the allocation step. The production planning method further includes:
Predetermining whether or not to divide the lot consisting of the first production target of the order quantity received in the reception step and the lot consisting of the second production target of the order quantity received in the reception step A determination step for determining based on the quantity of
Dividing the lot determined to be divided in the determination step into a plurality of lots,
In the allocation step, the production quantity is allocated in the lot unit,
The production planning method according to claim 2, wherein in the leveling step, the production quantity is changed in units of lots. In the dividing step,
When dividing the lot of the first production object received in the reception step, the lot is divided on the basis of the quantity capable of producing the first production object per unit time and received in the reception step. 4. The production according to claim 3, wherein when the lot of the second production object is divided, the lot is divided based on a quantity capable of producing the second production object per unit time. 5. Planning method. The leveling step includes:
A change step of changing the production quantity allocated in the allocation step in units of lots;
In the state changed in the changing step, a time calculating step for calculating the production time in each day;
Based on the production time on each day calculated by the time calculation step, a leveling determination step for determining whether or not the leveling of the production time on each day is promoted by the change in the change step;
When it is determined that the leveling determination step promotes, the change in the change step is adopted, and when it is determined that the leveling determination step does not promote, a change determination step that does not adopt the change in the change step is performed. The production planning method according to claim 3, wherein the production planning method is included. In the allocation step,
The day on which the daily production time is the shortest based on the production speed when the setting of the equipment for producing the first and second production objects is optimized for the production of the first production object Identify
In the time calculating step,
6. The production time for each day is calculated based on the production speed when the setting of the equipment is optimized for production of all production objects assigned on the day in units of days. The production planning method described. In the changing step,
The production planning method according to claim 5 or 6, wherein the production quantities assigned in the assignment step are replaced in units of lots. In the changing step,
The production planning method according to claim 5 or 6, wherein the production quantity allocated in the allocation step is moved to another day in units of lots. The production planning method further includes:
Assuming that the setting of the equipment is optimized for the production of all production objects allocated on the day in units of days, the setting of the equipment is the same in the state where the change by the leveling step has been performed. Including a first pattern specifying step for specifying a first transition pattern indicating a setting for each day of the facility by replacing each lot allocated in each day so that a certain day is continuous. The production planning method according to claim 7 or 8. The production planning method further includes:
In the state in which the leveling step is changed, each setting of the equipment based on the premise is classified into a plurality of groups based on a part having the smallest number of transitions between the settings, and is common to each group. The production planning method according to claim 9, further comprising: a second pattern specifying step of specifying a second transition pattern indicating a setting for each day of the facility by changing to a group setting. The production planning method further includes:
In the case where the setting of the equipment is the first transition pattern, the first total production time required to produce the first and second production objects by the respective order quantities is changed to the setting of the equipment. A first calculation step for calculating including the time required for
In the case where the setting of the facility is the second transition pattern, the second total production time required to produce the first and second production objects by the respective order quantities is changed to the setting of the facility. A second calculation step for calculating including the time required for
A comparison determination step of determining which of the first and second total production times is short;
A first determination step for determining the setting of the equipment as the first transition pattern when it is determined in the comparison determination step that the first total production time is shorter;
And a second determination step of determining the setting of the facility as the second transition pattern when it is determined in the comparison determination step that the second total production time is shorter. Item 10. The production planning method according to Item 10. A production planning device for creating a plan for producing the first and second production objects by their respective delivery dates,
Receiving means for receiving the delivery date and order quantity of each of the first and second production objects;
For each day until the delivery date of the first production object, the production quantity of the first production object is allocated based on the order quantity, and each day until the delivery date of the second production object. On the other hand, a production planning apparatus comprising: an allocating means for allocating the production quantity of the second production object with priority from the day with the shortest production time based on the order quantity. The production planning device further includes:
The production planning apparatus according to claim 12, further comprising leveling means for leveling the production time on each day by changing the production quantity allocated by the allocation means.   The program which makes a computer perform the step contained in the production planning method of any one of Claims 1-11.

Images