JP2006309577A - Production plan preparation system - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a production plan preparation system allowing maximization of profit and allowing reduction of a production time of a product while observing a product delivery time desired by a customer. <P>SOLUTION: This production plan preparation system 10 has: a recording part 11 of information related to a production facility or a worker; a manufacturing plan preparation part 12 preparing at least a plan of manufacturing order of the product; a manufacturing plan change part 13 changing the manufacturing order of the prepared manufacturing plan a plurality of times, and outputting the manufacturing plan having a shortest manufacturing time from raw material to completion of the product among the manufacturing plans; a production plan preparation part 14 preparing a production plan showing all processes from arrival of the raw material of the product to shipment of the product on the basis of the information of the recording part 11 and the manufacturing plan outputted from the manufacturing plan change part 13; a production plan change part 15 changing contents of each process of the prepared production plan or order of the respective processes a plurality of times, and outputting the production plan having the most profit among the production plans; and a reading part 16. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to a production plan creation system for creating a production plan ranging from receipt of raw materials of a product to shipment of the product, and more particularly to a method for optimizing the production plan.

  In recent years, people's values have diversified and their changes are no longer. Therefore, production facilities for producing products are required to be able to produce a wide variety of products. Moreover, in order to reduce production costs, automation (unmanned production) of production facilities is required. For these reasons, many production facilities are configured such that their operation is controlled by a control device. As the control device, for example, an MC (Motion Control) device or an NC (Numerical Control) device can be considered.

  Generally, a product production line is constructed by organically connecting a plurality of production facilities. In addition, there are various types of processing such as deformation processing and cutting processing for processing products, and production facilities are determined according to the type of product.

  In addition, in order to perform product production more economically and efficiently, it is required to accurately grasp the current operation status of production facilities. Therefore, there is a production system in which a control device and a server provided in each of a plurality of production facilities are connected via a network, and a user grasps the operation status of each production facility in the server in real time.

In recent years, production plans are automatically created using simulation software or the like (see, for example, Patent Document 1).
JP 2004-94900 (Pages 4-19, FIGS. 1-10)

  However, when creating a production plan using simulation software or the like, how to create an optimal production plan is an issue. In other words, the production plan created with existing simulation software maximizes profits while complying with the delivery date of the product desired by the customer, and shortens the production time from the arrival of the raw material of the product to the shipment of the product. It was difficult.

  SUMMARY OF THE INVENTION Accordingly, an object of the present invention is to provide a production plan creation system capable of maximizing profits while observing the delivery date of a product desired by a customer and shortening the production time of the product.

In order to solve the above problems, the present invention adopts the following configuration.
That is, the production plan creation system of the present invention is a production plan creation system that creates a production plan for the product based on various information relating to the production of the product, and shows the current stock status of the raw materials of the product. Recording means for recording inventory information and operation information indicating the current operation status of the production facility of the product, and at least the manufacturing order of the products based on the inventory information and operation information recorded by the recording means A manufacturing plan creating unit for creating a manufacturing plan and a manufacturing order of the manufacturing plan created by the manufacturing plan creating unit are changed a plurality of times, and the product is completed from the raw materials among the changed manufacturing plans. Manufacturing plan changing means for outputting the manufacturing plan with the shortest manufacturing time required until the manufacturing plan, the manufacturing plan output from the manufacturing plan changing means, and the inventory information recorded by the recording means And production plan creation means for creating a production plan showing all processes performed from the arrival of the raw material to the shipment of the product based on the operation information, and each step of the production plan created by the production plan creation means Production plan changing means is provided for changing each content or the order of each step a plurality of times and outputting a production plan having the largest profit among the changed plurality of production plans.

  As described above, the production plan creation system of the present invention creates a production plan based on the current inventory information and the current operation information, and based on the production plan with the shortest production time among the production plans changed a plurality of times. Since the production plan is created and the production plan with the highest profit among the production plans that have been changed multiple times is output, the production time is the shortest and the profit is the shortest when the customer places an order. Many production plans can be created.

  In the production plan creation system, the recording means includes product identification information for identifying the product, worker identification information for identifying a worker who manufactures the product, and work performed by the worker. The work time taken from the start of work to the end of work is recorded as worker information, and when the production plan creation means receives a new order, the product identification information of the product that has received the new order and the shortest The worker identification information corresponding to the work time may be extracted from the worker information, and the production plan may be created using the extracted worker identification information.

  As a result, when a newly ordered product is produced, the worker with the shortest working time can be employed as the worker who manufactures the product, so that the product manufacturing time can be shortened accordingly. .

  In the production plan creation system, the worker identification information recorded on the first recording medium carried by the worker, and the raw material recorded on the second recording medium attached to the raw material. Reading means for reading the raw material identification information for identifying the recording material, and the recording means uses the time during which the reading means is reading the raw material identification information as the work time, and the work time and the reading at the work time. The worker identification information read by the means and the product identification information corresponding to the raw material identification information read by the reading means at the work time are associated and recorded as the worker information. Also good.

Thereby, worker identification information, product identification information, and work time can be automatically associated and recorded.
The production plan creation method of the present invention is a production plan creation method for creating a production plan for the product based on various information relating to the production of the product, and shows the current stock status of the raw materials of the product. Record inventory information and operation information indicating the current operation status of the production facility of the product, create a manufacturing plan indicating at least the manufacturing order of the product based on the recorded inventory information and operation information, and The production sequence of the created production plan is changed a plurality of times, and among the changed production plans, the production plan that takes the shortest production time from the raw materials to the completion of the product is output and the output is output. Based on the production plan and the recorded inventory information and operation information, a production plan showing all processes performed from the arrival of the raw material to the shipment of the product is created, and the produced production plan Change their contents or the respective process sequences a plurality of times for each step of, among the modified plurality of production plan, and outputs the largest production plan benefits.

  Further, the production plan creation program of the present invention includes a computer for creating a production plan for the product based on various information relating to the production of the product, inventory information indicating a current inventory status of the raw materials of the product, and , Recording means for recording operation information indicating the current operation status of the production facility of the product, and creating a production plan indicating at least the production order of the product based on the inventory information and operation information recorded by the recording means The manufacturing plan creating means, the manufacturing order of the manufacturing plan created by the manufacturing plan creating means is changed a plurality of times, and the manufacturing time required until the product is completed from the raw material among the changed manufacturing plans. The manufacturing plan changing means for outputting the shortest manufacturing plan, the manufacturing plan output from the manufacturing plan changing means, and the inventory information and the operation information recorded by the recording means Therefore, production plan creation means for creating a production plan showing all processes performed from receipt of the raw materials to shipment of the product, each content of each step of the production plan created by the production plan creation means or the The order of each process is changed a plurality of times, and the process is made to function as a production plan changing means for outputting a production plan having the largest profit among the plurality of changed production plans.

  The production plan creation device of the present invention is a production plan creation device for creating a production plan for the product based on various information related to the production of the product, and product identification information for identifying the product, Recording means for associating the worker identification information for identifying the worker who manufactures the product with the work time taken from the start to the completion of the work for which the worker is in charge as worker information, and a new order Receiving the product identification information of the newly ordered product and the worker identification information corresponding to the shortest work time from the worker information, and using the extracted worker identification information. And production plan creation means for creating the production plan.

  The manufacturing plan changing device of the present invention is a manufacturing plan changing device that changes at least a manufacturing plan indicating a manufacturing order of products, and changes the manufacturing order of the manufacturing plan a plurality of times, and the plurality of changed manufacturing products. Among the plans, a production plan with the shortest production time from the raw materials to the completion of the product is output.

  The production plan change device of the present invention is a production plan change device for changing a production plan indicating all processes performed from arrival of raw materials of a product to shipment of the product, and each of the steps of the production plan Or the order of each step is changed a plurality of times, and a production plan having the largest profit among the plurality of changed production plans is output.

  According to the present invention, when an order is received from a customer, a production plan with the shortest production time and the largest profit can be created. Time can be shortened.

  Moreover, since the production plan is created based on the current inventory information, products can be produced using the raw materials in stock, and the number of raw materials in stock can be reduced.

Hereinafter, embodiments of the present invention will be described with reference to the drawings.
FIG. 1 is a diagram schematically showing a production plan creation system according to an embodiment of the present invention.
As shown in FIG. 1, the production plan creation system 10 includes a recording unit 11 that records various pieces of information relating to production equipment used to manufacture a product and an operator who manufactures the product, and recording by the recording unit 11. The production plan creation unit 12 that creates at least a production plan indicating the production order of products based on the information that has been changed, and the production order of the production plan created by the production plan creation unit 12 are changed a plurality of times, The manufacturing plan change unit 13 that outputs the manufacturing plan that takes the shortest manufacturing time from the raw materials to the completion of the product, and the manufacturing plan output from the manufacturing plan change unit 13 and the recording unit 11 are recorded. Each of the production plan creation unit 14 for creating a production plan showing all processes performed from the arrival of the raw material of the product to the shipment of the product, and the production plan created by the production plan creation unit 14 on the basis of the received information. Each of the contents or the order of each process is changed a plurality of times, and the production plan changing unit 15 for outputting the production plan having the largest profit among the changed production plans and the reading unit 16 are provided. Has been.

  The production plan creation system 10 may be composed of, for example, one personal computer, and includes a recording unit 11, a production plan creation unit 12, a production plan change unit 13, a production plan creation unit 14, and a production plan change unit 15. The reading unit 16 is realized by executing a program recorded in a RAM (Random Access Memory) or a ROM (Read Only Memory) of the personal computer by a CPU (Central Processing Unit) or the like. Also good.

  Further, the recording unit 11, the production plan creation unit 12, the production plan change unit 13, the production plan creation unit 14, the production plan change unit 15, and the reading unit 16 may each be constituted by a personal computer, for example. Personal computers may be connected to each other via a network. That is, the recording device having the function of the recording unit 11, the manufacturing plan creating device having the function of the manufacturing plan creating unit 12, the manufacturing plan changing device having the function of the manufacturing plan changing unit 13, and the function of the production plan creating unit 14 The production plan creation device having the function, the production plan change device having the function of the production plan change unit 15, and the reading device having the function of the reading unit 16 may be configured to transmit and receive information to and from each other via a network. .

The recording unit 11 records at least inventory information indicating the current inventory status of the raw material of the product and operation information indicating the current operating status of the production facility of the product.
In addition to the inventory information and the operation information, the recording unit 11 includes product identification information for identifying a product, worker identification information for identifying a worker who manufactures the product, and a worker in charge. The work time required from the start to the completion of the work to be performed is correlated and recorded as worker information.

  Upon receiving a new product order from the customer, the production plan creation unit 14 obtains product identification information of the newly ordered product and worker identification information corresponding to the shortest working time from the worker information. Extraction is performed, and a production plan is created using the extracted worker identification information.

  The reading unit 16 is provided in a production line or the like, for example, worker identification information recorded on a resonance tag (first recording medium) carried by the worker, and a resonance tag (second The raw material identification information for identifying the raw material recorded on the recording medium is read. The recording unit 11 uses the time during which the reading unit 16 reads the raw material identification information as a work time, and the work time, the worker identification information read by the reading unit 16 during the work time, and the work time. The product identification information corresponding to the raw material identification information read by the reading unit 16 is associated and recorded as worker information. Thereby, worker identification information, product identification information, and work time can be automatically associated and recorded.

  As described above, the production plan creation system 10 creates a production plan based on the current inventory information and the current operation information, and produces the production plan based on the production plan having the shortest production time among the production plans changed a plurality of times. In addition, the production plan with the most profit among the production plans that have been changed multiple times is output, so when the order is received from the customer, the production plan with the shortest manufacturing time and the largest profit is obtained. Can be created. As a result, manufacturing time can be shortened while maximizing profit while observing the delivery date of the product desired by the customer.

  Further, since the production plan creation system 10 creates a production plan based on the current inventory information, it is possible to produce products using raw materials in stock, and to reduce the number of stocks of raw materials. it can.

  In addition, when the production plan creation unit 14 receives a new product order from a customer or the like in the production plan creation unit 14, the production plan creation system 10 corresponds to the product identification information and the shortest working time of the newly ordered product. Since the identification information is extracted from the worker information and a production plan is created using the extracted worker identification information, it is possible to employ the worker with the shortest working time as the worker who manufactures the product. As a result, the production time of the product can be shortened accordingly.

Next, the case where the production plan creation system 10 is applied to the assembly processing industry will be described.
FIG. 2 is a diagram schematically showing an overall flow from product design to product distribution in a general assembly processing industry.

As shown in FIG. 2, first, in design 20, a product is designed.
Next, when the product design is completed, the production preparation support 21 creates a production plan indicating a combination of parts and a product production order. That is, the operation performed in the production preparation support 21 corresponds to the operation performed in the manufacturing plan creation unit 12 and the manufacturing plan change unit 13.

Next, when a production plan is created, a prototype is produced in the prototype 22 based on the production plan.
Further, when the production plan is created, in the schedule plan 23, a production plan showing all processes performed from the arrival of parts to the shipment of products is created. That is, the operation performed in the schedule plan 23 corresponds to the operation performed in the production plan creation unit 14 and the production plan change unit 15.

Next, when a production plan is created, parts are procured at the arrival 24 based on the production plan, and parts are received.
Next, when trial production and arrival are completed, production 25 is performed based on information obtained by trial production and arrival.

Next, when the production of the product is finished, the product is shipped in the shipment 26.
When the product is shipped, the product 27 is distributed in the distribution 27.
FIG. 3 is a diagram schematically showing a flow of information used for creating a manufacturing plan and a production plan when the production plan creating system 10 is applied to a general assembly processing industry. In addition, the same code | symbol is attached | subjected to the same structure as the structure shown in FIG. FIG. 3 shows a system that supports support from order reception to delivery date / cost answer, material (raw material) procurement plan, production scheduling, work instruction, and progress management.

  As shown in FIG. 3, standard tooling information 30, equipment CAD (Computer Aided Design) / PDM (Product Data Management) information 31, product CAD / PDM information 32, and design BOM (E-BOM) information 33 are prepared for production. It is sent to the process plan 34 of the support 21. The process plan 34 creates a process plan used for manufacturing a product on the production line based on the standard tooling information 30, the equipment CAD / PDM information 31, the product CAD / PDM information 32, the design BOM information 33, and the like. To do.

  The tool information 35 indicates the shape, dimensions, weight, capability, and price of the tool used to manufacture the product, and is sent to the tool plan 36 and the like. The tool plan 36 creates a tool plan indicating the type of tool to be used for manufacturing a product based on the tool information 35 and the like.

  The jig information 37 indicates the shape, dimensions, weight, capability, and price of the jig used to manufacture the product, and is sent to the jig plan 38 or the like. The jig plan 38 creates a jig plan indicating the type of jig to be used for manufacturing a product based on the jig information 37 and the like.

  The gauge information 39 indicates the shape, dimensions, weight, capability, and price of the gauge, and is sent to the gauge plan 40 and the like. The gauge plan 40 creates a gauge plan based on the gauge information 39 and the like.

  The facility information 41 indicates the shape, size, weight, capability (number of axes, speed, number of tools, etc.), price, operability, setup time, and history information of the production facility such as a cutting device, and the line facility plan. 42 or the like. The line facility plan 42 creates a line facility plan indicating the types of production facilities provided in the production line based on the facility information 41 and the like. The history information is sent from the product traceability information 43 indicating the raw material, composition, and manufacturing history of the product.

The line process simulator 44 simulates the production line based on the process plan created by the process plan 34.
Further, the line / facility / work / assembly / processing interference simulator 45 is based on the process plan created in the process plan 34, the tool plan created in the tool plan 36, and the like. And simulation of machining interference.

The line process simulator 44 and the line / facility / work / assembly / processing interference simulator 45 correspond to the manufacturing plan creation unit 12 shown in FIG.
Further, the process optimization 46 corresponds to the manufacturing plan changing unit 13 shown in FIG. 1, and is a manufacturing plan simulated and created by the line process simulator 44 and the line / facility / work / assembly / processing interference simulator 45. Change the production order of products and optimize the production plan.

Here, FIG. 4 is a diagram schematically illustrating an example of a manufacturing plan.
The manufacturing plan shown in FIG. 4 shows the manufacturing process from raw materials to product completion in a hierarchical manner, with the top row representing products, the second row representing intermediate products, and the third row representing parts made from raw materials. Show. Moreover, (1)-(3) has shown the manufacture order of the product.

  In FIG. 4, first, the intermediate product A is manufactured by combining the parts A1 and A2, and then the intermediate product B is manufactured by combining the parts B1 and B2, and the intermediate product A and the intermediate product are manufactured. A production plan for producing a product in combination with B is shown. The manufacturing plan shown in FIG. 4 is a configuration in which products are manufactured according to the manufacturing order of (1) to (3). First, an intermediate product B is manufactured by combining parts B1 and B2, and then The manufacturing order may be changed so that the intermediate product A is manufactured by combining the component A1 and the component A2, and the product is manufactured by combining the intermediate product A and the intermediate product B.

  Further, the production information creation (M-BOM conversion) 47 shown in FIG. 3 converts the production plan optimized in the process optimization 46 into a predetermined format and records it as the production BOM information 48 or the like. The manufacturing BOM information 48 indicates the hierarchy, shape, processing process division processing equipment, tool, processing method, accuracy, and the like of the product configuration.

  A schedule plan (Super-ASP (Advanced scheduling and planning)) 23 corresponds to the production plan creation unit 14 and the production plan change unit 15 shown in FIG. 1, and includes tool information 35, equipment information 41, manufacturing BOM information 48, Stock information indicating the current stock status of raw materials managed by the stock management 49 corresponding to the recording unit 11 shown in FIG. 1, resource plan information 50 indicating resource allocation, layout, price, etc., order, quantity, delivery date, importance , Production plan information 51 indicating other constraints, worker skill information (work time, etc.), worker management / traceability information 52 indicating worker history, worker identification information, operation history, program library, number of productions , Alarm history, number of processing defects, cutting tool replacement history, cutting conditions, equipment / tool information, cycle time, operation Based on the manufacturing capacity database 53 in which information such as monitoring is recorded and the manufacturing cost calculated from the cost analysis 54, a production plan showing all processes performed from the arrival of parts to the shipment of products is created, and its production The content of each process of the plan or the order of each process is changed to optimize the production plan. The cost analysis 54 includes, for example, variable costs (such as raw material costs and direct labor costs), fixed costs (such as cost amortization costs and indirect labor costs), indirect costs (such as expenses and operating costs), inventory operation costs, and delays. The manufacturing cost may be calculated based on the cost.

  Further, the shipping instruction 55 creates a shipping instruction based on the production plan optimized by the schedule plan 23 and sends the shipping instruction to the warehouse management 56. The warehouse management 56 performs warehouse management based on the shipping instruction.

The purchase / subcontract instruction 57 performs a purchase or subcontract instruction based on the production plan optimized by the schedule plan 23.
Further, the manufacturing instruction issuance 58 issues a manufacturing instruction 59 based on the production plan optimized by the schedule plan 23.

  Further, the traceability management 60 corresponds to the recording unit 11 shown in FIG. 1 and sends information recorded in the operation information 61 indicating the current operation status of the production facility, the production performance information 62, and the facility capability database 53. . Equipment management (equipment diagnosis / equipment traceability) 63 manages production equipment on the production line based on operation information 61, production performance information 62, and the like. Worker management (skill management / worker traceability) 64 manages workers on the production line based on operation information 61, production performance information 62, and the like. The quality management (product traceability) 65 performs product quality management on the production line based on the operation information 61 and the production performance information 62. The machine performance evaluation 66 evaluates the machine performance based on the operation information 61 and sends the evaluation to an NCPG (Numerical Control Program) creation 67. The NCPG creation 67 creates an NCPG based on the evaluation sent from the machine performance evaluation 66.

The facility maintenance 68 performs facility maintenance based on the facility information managed by the facility management 63 and records the maintenance result in the maintenance database 69.
The maintenance database 69 records equipment ledgers, operation guidance, inspection plans, inspection guidance, inspection history, equipment drawings, maintenance statistical data, and the like.

The operation result management 70 performs operation result management based on information managed by the traceability management 60.
Further, the process management 71 performs process management based on the operation results managed by the operation result management 70.

The progress management 72 performs progress management based on the process management managed by the process management 71.
Further, the facility capacity / operation data collection 73 and the production performance data collection 74 correspond to the recording unit 11 shown in FIG. 1, and are SCADA (Supervision Control and Data Acquisition) 75, CNC (Computerized Numeric Control) / work. Various information (for example, control equipment) obtained from the machine 76, robot / conveyance equipment 77, PLC (Programmable Controller) 78, control equipment 79, measuring equipment 80, DCS (Distributed Control System) 81, data collection 82, and worker 83 79 or operation information indicating the current operation status of the production facility obtained from the DCS 81).

  Also, the equipment ledger management 84 manages the equipment basic ledger 85, the drawing / document 86, and other system linkage information 87, converts these information into XML (extensible Markup Language) data, and sends the data to the equipment information 41.

  In addition, an SCP (Supply Chain Planning) / SCM (Supply Chain Management) / ERP (Enterprise Resource Planning) 88 is performed from the order order management 89 to the production order management 90, or calculated by the cost analysis 54. The cost 91 is obtained based on the manufacturing cost. When the order entry is sent from the order order management 89, the production order management 90 replies with delivery date, cost, profit and loss, and the like.

The material / resource procurement management 92 performs procurement management of materials and resources based on the inventory information managed by the inventory management 49.
The article management 93 manages articles based on materials and resources procured and managed by the material / resource procurement management 92.

Further, the work standard / quality standard document management 94 performs document management of information created by the production preparation support 21.
The performance analysis support 95 includes tool information 35, jig information 37, gauge information 39, equipment information 41, product traceability information 43, manufacturing BOM information 48, resource plan information 50, production plan information 51, and worker management / Based on the traceability information 52, performance analysis support is performed.

Next, FIG. 5 is a diagram for explaining a method for optimizing a manufacturing plan. In addition, the same code | symbol is attached | subjected to the same structure as the structure shown in FIG.
As shown in FIG. 5, the equipment ledger / document server 96 includes equipment number register DB (DataBase) 97 for recording equipment basic ledger information 85, drawing / document DB 99 for recording equipment related drawing information 98, and other systems. Another system cooperation DB 101 that records the cooperation information 100 is provided.

  The line information system / data management server 102 also includes an operation panel 103 for monitoring, a cutting condition C / T information 104, a program library 105, and a PG / cutting condition / operation information DB 107 in which an operation history 106 is recorded. And.

Information recorded in the equipment ledger / document server 96 and the line information system / data management server 102 is sent to the database 108.
The database 108 includes resource plan information 109 indicating resource allocation, layout, price, etc., production plan / order information 110 indicating production plan / order order, product specifications, performance, price, product configuration, shape, material, and the like. Design BOM information 33 indicating surface roughness, etc., production BOM information 48 indicating equipment configuration stage, shape, processing equipment, tool, processing method, accuracy, etc., equipment information 41, and tool information 35 are recorded, and PG library / Equipment information collection result DB111 in which cutting conditions / cycle time / operation information is recorded is provided. The facility information collection record DB 111 records the minimum, maximum, and average of record data.

  Further, the line simulation 112 (knowledge flow system, production preparation execution process) corresponds to the process optimization 46 shown in FIG. 3, and includes the line process simulator 44 and the line / facility / work / assembly shown in FIG. The manufacturing plan created in the property / machining interference simulator 45 is optimized. The line simulation 112 is software realized by executing a program on a computer or the like, for example.

First, in step S1, the line simulation 112 divides each process shown in the manufacturing plan, and generates or adds manufacturing information.
Next, in step S2, the line simulation 112 creates a process plan based on the manufacturing information, and allocates resources (production equipment, workers, etc.) to the process plan.

  Next, in step S <b> 3, the line simulation 112 performs interference verification using the workability simulation, performs assembly verification using the assembly performance simulation, and performs process verification.

  Next, in step S4, the line simulation 112 calculates a cycle time (manufacturing time required from the raw material to completion of the product) and evaluates the capability. In addition, as a calculation method of cycle time, the calculation method shown by FIG. 7 etc. of Unexamined-Japanese-Patent No. 2004-227028 etc. can be considered, for example.

Next, in step S5, the line simulation 112 determines whether the manufacturing plan is optimal.
When it is determined that the production plan is not optimal (No in step S5), in step S6, the line simulation 112 detects a stay process / work and a bottleneck process / work.

  Next, in step S7, the line simulation 112 calculates and evaluates the equipment capacity utilization rate and calculates and evaluates the worker load factor. Note that the equipment capacity utilization rate is, for example, equipment capacity utilization rate = actual production capacity (actual operating time per day) / (design capacity (operating time possible per day) × operating rate (total operation on the production line) It may be calculated by the ratio of the operating amount of the production facility to the amount)). The worker load factor is, for example, worker load factor = actual work load (actual work time per day) / (normally possible load (work time per day) × operating rate (total of production line) The ratio may be calculated by the ratio of the work amount of the worker to the work amount)). The production system capability achievement rate can be calculated by, for example, production system capability achievement rate = actual production number / (design capability production number × operation rate).

  Next, in step S8, the line simulation 112 performs bottleneck analysis to clarify the problem. For example, as a bottleneck analysis, there are “Is there a problem in equipment capacity?”, “Which equipment is there if there is a problem in equipment capacity?”, “Is there a problem in the load on workers?”, “Workers If there is a problem with the load, which worker? "," Is there a problem with the buffer (the place where the parts are temporarily stored)? "," If there is a problem with the buffer, which buffer? " , "Is there a problem with flow balance?", "If there is a problem with flow balance, which flow (process)?", "Is there a problem with transportation time?", "When there is a problem with transportation time." "Which flow (process)?"

  Next, in step S9, the line simulation 112 optimizes the equipment process. For example, when the cycle time is minimized under various constraints as the optimization of the equipment process, the work capacity and the process order are adjusted respectively.

  Next, in step S10, the line simulation 112 adjusts the entire process and returns to step S1. For example, as the adjustment of the entire process, in order to increase the facility capacity utilization rate under various restrictions, the process configuration / order, the personnel allocation, and the load distribution of workers are adjusted. Step S9 or S10 corresponds to the operation of the production plan changing unit 13 shown in FIG.

Here, an example of the method for adjusting the process configuration / order will be described.
FIG. 6 is a diagram illustrating an example of processing a part. The parts shown in FIG. 6 are formed in a rectangular parallelepiped, and a predetermined shape of processing holes is provided on two adjacent surfaces of the six surfaces of the rectangular parallelepiped with a plurality of cutting devices or the like.

  As shown in FIG. 6, one of the two processed surfaces 135 has two circular processed holes (1-1-1, 1-1-2) and one rectangular processed hole ( 2-1-1) is provided. The other processing surface 136 is provided with one circular processing hole (1-2-1) and two rectangular processing holes (2-2-1, 2-2-2).

  Next, FIG. 7 is a diagram showing the order of the drilling process for each processing hole provided in the component shown in FIG. In addition, the order of the said process hole drilling process is corresponded to the manufacture order of the product in the said manufacture plan.

  FIG. 7 shows a simulation 1 showing the entire drilling process before the order of the drilling process for each processed hole is changed, and a simulation 2 showing the entire drilling process after the order of the drilling process is changed. . It should be noted that the tool change time (tool change time shown in FIG. 7) required for providing the machining hole in the cutting apparatus is shorter than the time required for rotation of the component (component rotation time shown in FIG. 7).

  In the simulation 1 shown in FIG. 7, first, using a tool for providing a circular machining hole, machining holes 1-1-1 and 1-1-2 are provided on the machining surface 135, and then a part is rotated. Then, a machining hole 1-2-1 is provided in the machining surface 136, and then a tool for rotating the component again to provide a square machining hole is replaced with a machining hole 2-1-1 in the machining surface 135. And the parts are rotated again to provide machining holes 2-2-1 and 2-2-2 on the machining surface 136.

  On the other hand, in the simulation 2 shown in FIG. 7, the process for providing the machining hole 1-2-1 of the simulation 1 is moved to the last process, and the process for providing the machining hole 2-1-1 is changed to the machining hole 1- It shows what has moved after the process of 1-2 is completed. First, using a tool for forming a circular machining hole, machining holes 1-1-1 and 1-1-2 are formed on the machining surface 135. Next, the tool is replaced with a tool for forming a rectangular processing hole, a processing hole 2-1-1 is provided in the processing surface 135, and then rotated to rotate a processing hole 2-2 in the processing surface 136. 1 and 2-2-2 are provided, and the tool is changed to a tool for providing a rectangular processing hole again, and a processing hole 1-2-1 is provided on the processing surface 136.

  As described above, since the order of the drilling process (process configuration / order) is changed so that the number of times of rotating the parts is reduced, the entire work time in the drilling process can be shortened. Thereby, cycle time can be shortened.

  FIG. 8 is a diagram illustrating an example of adjustment of load distribution. FIG. 8A is a diagram showing each load (working time of the worker) in each assembly process before adjustment of load distribution. FIG. 8B is a diagram illustrating the loads in each assembly process after adjusting the load distribution. Each assembly process is assumed to be composed of three assembly processes (assembly A1, assembly A2, and assembly A3). Further, as shown in FIG. 8A, the total load of the assembly A1 before adjustment is 10 minutes, the total load of the assembly A2 is 15 minutes, and the total load of the assembly A3 is 11 minutes.

  First, as shown in FIG. 8B, among the entire manufacturing operations of the assembly A2, as a manufacturing operation that can be moved to another process, a manufacturing operation corresponding to a load of 1 minute and a load of 2 minutes are supported. Extract manufacturing operations.

  Next, out of the manufacturing work corresponding to the extracted 1-minute load and the manufacturing work corresponding to the 2-minute load, the manufacturing work corresponding to the 2-minute load is moved to the assembly A1 to cope with the 1-minute load. The manufacturing operation to be performed is moved to assembly A3.

Thereby, all the loads of the assemblies A1 to A3 are all 12 minutes, and the loads of the assemblies A1 to A3 can be averaged.
If it is determined in step S5 in FIG. 5 that the manufacturing plan is optimal (step S5 is Yes), in step S11, the line simulation 112 generates the manufacturing BOM information created in the manufacturing information creation 47 shown in FIG. Manufacturing information used to create 48 is created. The manufacturing information may be composed of a process plan, an equipment plan, and a tool plan. The manufacturing information creation 47 shown in FIG. 3 is included in the process plan, the equipment plan, and the tool plan. Based on this, manufacturing BOM information 48 may be created.

  Here, FIG. 9 is a diagram for explaining conditions when it is determined that the manufacturing plan is optimal. In addition, the vertical axis | shaft of the graph shown in FIG. 9 has shown cycle time (manufacturing time until a certain product is completed from a raw material), and the horizontal axis has shown the frequency | count of change of a manufacturing plan. In the production plan, the product production order is changed so that the cycle time approaches the optimal solution every time the production plan is changed.

  As a condition for determining that the manufacturing plan is optimal, for example, the number of times of changing the manufacturing plan (for example, 1000 times) is set in advance, and the number of times of changing the manufacturing plan exceeds the set number of changes. Can be considered.

  Another method for determining that the manufacturing plan is optimal is, for example, when the difference between the cycle time of the manufacturing plan changed this time and the cycle time of the manufacturing plan changed last time is equal to or less than a predetermined time. It is done.

Next, FIG. 10 is a diagram for explaining a production plan optimization method. In addition, the same code | symbol is attached | subjected to the same structure as the structure shown in FIG.
The schedule 23 (Super-ASP) shown in FIG. 10 is software realized by executing a program on a computer or the like, for example, and the real-time constraints 113 are the current parts, intermediate products, and products in advance. Such as inventory information indicating production status and resource capability information indicating production line, production equipment, jigs and tools, raw materials, workers, etc., and ordering new products from customers and the status of in-process orders (current products) If there is an inquiry about (production status), a constraint condition is created based on inventory information and resource capability information, and the constraint condition is sent to the scheduling engine 114.

  The scheduling engine 114 creates a material plan, a production plan, and a resource capacity plan based on the constraint conditions and the manufacturing BOM information 48, and sends the production plan to the throughput maximization plan 115 and the process change plan 116.

  The throughput maximization plan 115 is calculated based on sales (for example, estimation of a charge charged to a customer, etc.) when the production plan is sent (inquiry), and the profit that will be obtained by the production plan. Sales) and variable costs (such as raw material costs and overtime costs of workers), and the profit is sent to the scheduling engine 114 (throughput). Note that the throughput maximization plan 115 includes, for example, sales calculated from the type and number of products ordered by the customer, and the cost analysis 54 shown in FIG. 3 is variable costs, fixed costs, overhead costs, inventory operation costs, and delays. The profit may be calculated based on the manufacturing cost calculated based on the cost.

  Further, when a production plan is sent (inquiry), the process change plan 116 changes the contents of each process of the production plan using the line simulation 117 or routes the order of each process of the production plan. The change is made using the simulation 118, and the changed production plan is sent to the scheduling engine 114 (capability answer).

Here, FIG. 11 is a diagram illustrating an example of the line simulation 117.
FIG. 11 shows a series of production processes (incoming 24, production 25 (processing, assembly, testing) and shipment 26 shown in FIG. 2) from the arrival of a part to the shipment of a product in a certain product.

  For example, when the line simulation 117 is used, as shown in FIG. 11, the load of the worker is adjusted in the arrival 24, or the load of the worker is adjusted in the process of the production 25. In the assembly process of the production 25, the cycle time is adjusted in the assembly process, and in the production 25 test process, the waiting time or the number of waits (indicating the progress of the work for testing the quality of the product) The number of stays) is adjusted, and in the shipment 26, the buffer amount indicating the degree of congestion in the temporary storage place of the product is adjusted.

Thus, when the line simulation 117 is used, the contents of each process of the production plan can be changed.
FIG. 12 is a diagram illustrating an example of the route simulation 118.

  FIG. 12 shows a series of production processes of a certain product, as in FIG. 11. In the assembly process of production 25, either one of assembly A and assembly B can be selected. In the test process, either one of the test A and the test B can be selected.

  In the production process shown in FIG. 12, for example, “production process in which production is performed in the order of arrival 24, processing, assembly A, assembly B, test A, and shipment 26” or “incoming 24, processing, assembly B, test A, test”. Various production processes such as “B, production process in which production is performed in the order of shipment 26” can be considered.

As described above, when the route simulation 118 is used, the order of each process of the production plan can be changed.
Then, the scheduling engine 114 obtains a plurality of production plans by querying the throughput maximization plan 115 and the process change plan 116 a plurality of times, and based on the production plan with the most profit among the obtained production plans, The material procurement instruction 119, the resource reorganization 120, and the manufacturing instruction 121 are created, and the delivery date schedule and the manufacturing cost are answered to the customer.

  Next, FIG. 13 is a diagram illustrating an example of a database in which information indicating constraint conditions used for creating a production plan and a production plan is recorded. Each database shown in FIG. 13 is an object-oriented database, and includes SCADA 75, CNC / machine tool 76, robot / conveying device 77, PLC 78, control device 79, measuring device 80, DCS 81, and data collection 82 shown in FIG. , And various information obtained from the worker 83 and the like are recorded.

As shown in FIG. 13, there are four types of constraint conditions: work conditions, raw material birth conditions, processing conditions, and physical distribution conditions, and the current product quality is confirmed according to these conditions.
The work condition includes an operator trace OBJ (object) 122 and the like. For example, the worker trace OBJ 122 is a worker CD sent from worker information of the personnel system, worker name, gender, height, weight, affiliation, classification (regular employee, etc.), assignment date, occupation, skill / carrier, The skill level (working time) and the like are recorded. The worker CD is changed to the person in charge CD when stored in a database other than the worker trace OBJ122.

  In addition, the raw material starting conditions include a raw material trace OBJ123, a raw material purchase trace OBJ124, a raw material arrival trace OBJ125, and the like. For example, in the raw material trace OBJ123, a product name, a purchase order number, a received lot number, a storage location, a received date (time), and a person in charge CD are recorded. The raw material purchase trace OBJ 124 records the product name, purchase order number, quantity, supplier CD, delivery date, and person in charge CD. In addition, in the raw material arrival trace OBJ125, the product name, purchase order number, arrival lot number, procurement source CD, arrival date (time), shipping date (time), storage location, and person in charge CD are recorded. Yes.

  Further, as processing conditions, there are a product manufacturing trace OBJ126, a production facility trace OBJ127, a product insurance trace OBJ128, and a warehouse management trace OBJ129. For example, the product manufacturing trace OBJ 126 includes a product name, a manufacturing number, a lot number, a supplier (previous process), a payee (post process), an arrival date and time, a shipping date and time, a manufacturing date (time), and a usage. Equipment CD, person-in-charge CD, sub-configuration (raw material or previous process product) number 1, sub-configuration number 2, etc. are recorded. The production equipment trace OBJ 127 records equipment name, equipment number, use condition (situation), date of manufacture (time), person in charge CD, program (PG), tool configuration 1, and the like. In addition, the product name trace, OBJ128, product name, serial number, environmental condition (temperature, humidity), test result, test date, time, and person in charge CD are recorded. Also, in the warehouse management trace OBJ129, the product name, production number, lot number, storage location, environmental conditions (temperature, humidity), warehousing date / time, shipping date / time, sales order number, and person in charge CD are recorded. Has been.

  The distribution conditions include a distribution management trace OBJ130. For example, in the distribution management trace OBJ 130, a product name, a manufacturing number, a lot number, a shipping destination, a shipping quantity, a shipping date, a sales order number, and a person in charge CD are recorded.

Next, a method for acquiring the work time of the worker will be described.
FIG. 14 is a diagram for explaining an example of an operation time acquisition method.
FIG. 14 schematically shows a production line 131 for manufacturing a certain product.

  The production line 131 is provided with a plurality of scanners 132 corresponding to the reading unit 16 shown in FIG. 1, and the scanners 132 are attached to worker information and the like recorded on the resonance tag 133 carried by the worker. The raw material identification information recorded on the resonance tag 134 is read and sent to the scheduling engine 114 shown in FIG. For example, information on the operator trace OBJ122 shown in FIG. 13 is recorded on the resonance tag 133, and information on the raw material trace OBJ124 shown in FIG. 13 is recorded on the resonance tag 134. The resonance tag 134 may be introduced at the intermediate product block level.

  In addition, the production line 131 is divided into five processes of receiving 24, processing of production 25, assembly of production 25, testing of production 25, and shipment 26. Each process has a process at the beginning and end of the process. Each is provided with a scanner 132 (IN, OUT).

  For example, when the scanner 132 provided at the beginning of the process reads the information of the resonance tags 133 and 134, the counter starts counting, and when the scanner 132 provided at the end of the process reads the information of the resonance tags 133 and 134, You may comprise so that the count of a counter may be complete | finished. And you may comprise so that the time counted by the counter may be recorded on the operator trace OBJ122 shown in FIG. 13 as a skill level.

  Further, for example, the measuring device 80 shown in FIG. 3 is provided in the test process of the production line 131, and the measurement result obtained by the measuring device 80 is recorded in the product storage trace OBJ128 shown in FIG. The information recorded in (1) may be sent to the real-time constraint condition 113 shown in FIG. 10 as a real-time constraint condition.

  In addition, although the said embodiment demonstrated the case where the production plan preparation system 10 was applied to the process assembly industry, you may apply the said production plan preparation system 10 to other living industries, such as a food and beverage industry.

It is a figure which shows typically the production plan preparation system of embodiment of this invention. It is a figure which shows typically the whole flow from the product design of general assembly processing industry to the physical distribution of a product. It is a figure which shows typically the flow of the information used for preparation of a production plan or a production plan, when a production plan preparation system is applied to a general assembly processing industry. It is a figure which shows an example of a manufacturing plan. It is a figure for demonstrating the optimization method of a manufacturing plan. It is a figure which shows the example of a process of components. It is a figure which shows the order of a drilling process. It is a figure which shows an example of adjustment of load distribution. It is a figure for demonstrating the conditions at the time of judging that a manufacturing plan is optimal. It is a figure for demonstrating the optimization method of a production plan. It is a figure which shows an example of line simulation. It is a figure which shows an example of route simulation. It is a figure which shows an example of the database by which the information which shows the constraint conditions used for preparation of a manufacturing plan or production plan is recorded. It is a figure for demonstrating an example of the acquisition method of work time.

Explanation of symbols

DESCRIPTION OF SYMBOLS 10 Production plan preparation system 11 Recording part 12 Manufacturing plan preparation part 13 Manufacturing plan change part 14 Production plan preparation part 15 Production plan change part 16 Reading part

Claims (8)

A production plan creation system for creating a production plan for the product based on various information relating to production of the product,
Recording means for recording inventory information indicating a current inventory status of the raw materials of the product and operation information indicating a current operation status of a production facility of the product;
Based on the inventory information and operation information recorded by the recording means, a manufacturing plan creating means for creating a manufacturing plan indicating at least the manufacturing order of the products;
The manufacturing plan of the manufacturing plan created by the manufacturing plan creating means is changed a plurality of times, and among the changed manufacturing plans, a manufacturing plan that takes the shortest manufacturing time from the raw materials to completion of the product is selected. Production plan change means to output;
Based on the manufacturing plan output from the manufacturing plan changing unit and the inventory information and the operation information recorded by the recording unit, a production plan showing all processes performed from the arrival of the raw material to the shipment of the product is created. Production plan creation means,
The contents of each process of the production plan created by the production plan creating means or the order of each process is changed a plurality of times, and the production plan with the most profit among the changed production plans is output. Production plan change means,
A production plan creation system characterized by comprising: The production plan creation system according to claim 1,
The recording means includes product identification information for identifying the product, worker identification information for identifying an operator who manufactures the product, and work from the start of work to the end of work performed by the worker. Record it as worker information in association with time,
When the production plan creation means receives a new order, it extracts the product identification information of the newly ordered product and the worker identification information corresponding to the shortest working time from the worker information, Creating the production plan using the extracted worker identification information;
Production planning system characterized by that. The production plan creation system according to claim 2,
Reading the worker identification information recorded on the first recording medium carried by the worker and the raw material identification information for identifying the raw material recorded on the second recording medium attached to the raw material With means,
The recording means uses the time when the reading means is reading the raw material identification information as the work time, the work time, the worker identification information read by the reading means during the work time, and the work time. In association with the product identification information corresponding to the raw material identification information read by the reading means to record as the worker information,
Production planning system characterized by that. A production plan creation method for creating a production plan for the product based on various information related to production of the product,
Recording inventory information indicating the current inventory status of the raw materials of the product and operation information indicating the current operating status of the production facility of the product;
Based on the recorded inventory information and operation information, create a production plan indicating at least the production order of the products,
Changing the production sequence of the created production plan a plurality of times, and outputting a production plan having the shortest production time from the raw materials to completion of the product among the changed production plans;
Based on the output production plan and the recorded inventory information and operation information, create a production plan showing all the processes performed from the arrival of the raw material to the shipment of the product,
Changing the contents of each step of the created production plan or the order of each step a plurality of times, and outputting the production plan with the most profit among the plurality of changed production plans;
A production plan creation method characterized by that. Based on various information relating to the production of the product, a computer for creating a production plan for the product,
Recording means for recording inventory information indicating a current inventory status of the raw material of the product and operation information indicating a current operation status of a production facility of the product;
Production plan creation means for creating a production plan showing at least the production order of the products based on the inventory information and operation information recorded by the recording means;
The manufacturing plan of the manufacturing plan created by the manufacturing plan creating means is changed a plurality of times, and among the changed manufacturing plans, a manufacturing plan that takes the shortest manufacturing time from the raw materials to completion of the product is selected. Production plan change means to output,
Based on the manufacturing plan output from the manufacturing plan changing unit and the inventory information and the operation information recorded by the recording unit, a production plan showing all processes performed from the arrival of the raw material to the shipment of the product is created. Production plan creation means,
The contents of each process of the production plan created by the production plan creating means or the order of each process is changed a plurality of times, and the production plan with the most profit among the changed production plans is output. Production plan change means,
Production plan creation program to function as. A production plan creation device for creating a production plan for the product based on various information relating to the production of the product,
A worker associating product identification information for identifying the product, worker identification information for identifying a worker who manufactures the product, and a work time required from the start to completion of the work for which the worker is responsible Recording means for recording as information;
When a new order is received, product identification information of the newly ordered product and the worker identification information corresponding to the shortest work time are extracted from the worker information, and the extracted worker identification information Production plan creation means for creating the production plan using
A production plan creation device comprising: A production plan change device for changing a production plan indicating at least a production sequence of products,
Changing the manufacturing order of the manufacturing plan a plurality of times, and outputting a manufacturing plan having the shortest manufacturing time required for the product to be completed from the raw materials among the changed manufacturing plans;
A manufacturing plan change device characterized by that. A production plan change device for changing a production plan indicating all processes performed from arrival of raw materials of a product to shipment of the product,
Changing each content of each step of the production plan or the order of each step a plurality of times, and outputting a production plan with the largest profit among the plurality of changed production plans;
A production plan change device characterized by that.

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