JP2006338602A - Production scheduling method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a production scheduling method that can plan a production schedule flexibly adaptable to production status by simplifying combinations of equipment. <P>SOLUTION: The production scheduling method includes an intermediate schedule part expansion process (Step S1) of forming equipment groups into which equipment is classified in advance, and according to intermediate schedule information representing an assembly schedule of models, expansion of part production to the equipment groups, a schedule allocation process (Step S2) of calculating reference dates of production starts of the parts broken down in the intermediate schedule part expansion process, a lot collective process (Step S3) of rearranging the production order of the parts with the production start reference dates calculated in the schedule allocation process such that the same type of parts having close production start dates in processes are produced in a lot, and a load leveling process (Step S4) of, after the lot sizing step, calculating daily loads on each equipment group and reassigning loads on dates when the calculated loads exceed a daily allowance of the equipment group to the next day or preceding day. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

 The present invention relates to a production schedule planning method for planning a part machining process in a mass production type product.

  In the package for the schedule plan in the conventional feeder sheet metal press working, schedule allocation and time allocation are performed for each final equipment. That is, it is general that parts are developed from an assembly plan, and a function of assigning a plan for each facility and day is combined with a function of assigning by hour within the same day.

JP 2000-263390 A (6th to 9th pages, FIG. 1)

In such a schedule plan for feeder sheet metal press processing, there are innumerable combinations of processing procedures using multiple facilities in the sheet metal press process, and the production sequence and processing equipment may be changed depending on the workplace situation on the production day. Because there are many, there was a problem that these commercial packages could not cope well.
Patent Document 1 shows a system in which equipment is divided into groups and the load is checked for each group of equipment in order to verify the possibility of additional production by comparing the capacity of the production equipment and the product load. Yes.
However, in Patent Document 1, although the efficiency of the load check is improved, the production schedule is not drafted, and the above-mentioned problem is not solved.

 The present invention has been made to solve the above-described problems, and has an object to obtain a production schedule planning method capable of planning a production schedule that can flexibly correspond to a production situation by simplifying a combination of facilities. Yes.

 In the production schedule planning method according to the present invention, a first procedure for forming an equipment group in which each equipment is classified in advance and deploying parts production to the equipment group based on the medium schedule information indicating the assembly schedule of the model, The second procedure for calculating the production start reference date for the parts developed by this first procedure, and the parts for which the production start reference date is calculated by this second procedure for the production start date within the process The third procedure for batch production by changing the production order of parts so that the same parts in close proximity are produced together, and the daily load for each equipment group is calculated after execution of this third procedure. , Including a fourth procedure for leveling the load by distributing the load on the day when the calculated load exceeds the daily allowance of the facility group to the nearest day, and the schedule for each facility group after the completion of the fourth procedure Output plan Is shall.

  As described above, the present invention forms a facility group in which each facility is classified in advance, and based on the medium schedule information indicating the assembly schedule of the model, the first procedure for deploying parts production to the facility group, The second procedure for calculating the base date for starting production for the parts developed by the first procedure, and the part for which the base date for starting production is calculated by this second procedure, Calculate the daily load for each equipment group after executing this third procedure, and the third procedure to change the production order of parts so that the same parts that are close together are produced together. Includes a fourth procedure for leveling the load by distributing the load on the day when the calculated load exceeds the daily capacity of the facility group to the nearest day, and scheduling by facility group after the completion of the fourth procedure Output. Combinations can simplify flexibly with accommodate production status, there is an effect that processing speed can be increased.

Embodiment 1 FIG.
Hereinafter, a production schedule planning method according to the first embodiment will be described using a feeder sheet metal press working process in a mass production product as a model.
In the conventional feeder sheet metal press process, there are innumerable combinations of processing procedures using a plurality of facilities, and there are many cases in which the production order and processing facilities are changed depending on the workplace situation on the production day. In order to deal with things that cannot be handled well, grouping multiple facilities and scheduling production schedules in units of equipment groups simplify the factors of equipment and make it possible to respond flexibly to production conditions. .

1 is an overall configuration diagram showing a production schedule planning system according to Embodiment 1 of the present invention.
In FIG. 1, the feeder schedule expansion unit 1 refers to the schedule information 2 during assembly, part configuration information 3, TS information 4 by equipment group (G), calendar 5 by equipment group, etc. stored in the storage device. The processing device develops the production schedule of the parts and outputs the sheet metal schedule information 6. It has a manual input device for creating and outputting a facility group schedule 7 from the sheet metal schedule information 6 and manually inputting the facility time allocation 8 based on this schedule plan 7.
Here, the equipment group (G) -specific TS information 4 is the production capacity (production amount per hour) for each part, each process, and each equipment group. The equipment group-specific calendar 5 is an operation calendar for each equipment group, and holds information on whether the day is a holiday, whether there is an overtime, and whether there is a night shift. In the field, it is necessary to change the work style for each equipment group, and for this reason, a calendar is provided for each equipment group.

FIG. 2 is a diagram showing grouping of press facilities in the production schedule planning system according to Embodiment 1 of the present invention.
In FIG. 2, for each press, a press name, a series type, a model series name, a model type, a lot grouping indicating the grouping of the press equipment, a lot size put into the equipment, and a lead time when using this equipment are set. Yes. In the lot grouping, 80 to 160 t press is set as one group, and 200 to 300 t press is set as another group.
FIG. 3 is a flowchart showing the flow of schedule development processing of the production schedule planning system according to Embodiment 1 of the present invention.
In FIG. 3, the schedule plan 7 for every equipment group is output by step S1-S4.

FIG. 4 is an image diagram showing a middle schedule part development process of the schedule development process of the production schedule planning system according to the first embodiment of the present invention.
4A is a diagram showing medium schedule information, FIG. 4B is a diagram showing component configuration information, FIG. 4C is a diagram showing process route information for each component, and FIG. 4D. These are figures which show a component expansion image.
The medium schedule information in FIG. 4A shows the number of units produced and the date of assembly for each model, and the part name (panel) for each model is shown by the part configuration information in FIG. 4B. ) Process route information shows the process and order of execution for each panel, and the part development image of FIG. 4D shows the model, the panel, and the process.

FIG. 5 is an image diagram showing schedule allocation processing of the production schedule planning system according to Embodiment 1 of the present invention.
FIG. 6 is a diagram showing lot summarization processing of the production schedule planning system according to Embodiment 1 of the present invention.
In FIG. 6, parts (panels) indicated by A and B indicate that lots can be collected.

FIG. 7 is an image diagram showing a postponing process of the load leveling process of the production schedule planning system according to the first embodiment of the present invention.
FIG. 8 is an image diagram showing the advance processing of the load leveling process of the production schedule planning system according to Embodiment 1 of the present invention.
FIG. 9 is a diagram showing a schedule by facility group of the production schedule planning system according to Embodiment 1 of the present invention.
In FIG. 9, the equipment group (line) to produce, the production date, and the production quantity are shown for each part.

Next, the operation will be described.
First, the concept of grouping press facilities will be described. The press equipment is classified into large presses and small presses based on weight. In FIG. 2, the classification result is shown in the lot grouping column.
Next, schedule development using grouping of press facilities will be described.
The schedule expansion process is a process for enumerating parts (panels) necessary for each model from the schedule schedule during assembly in the target month and obtaining a start date for each production process (group of press facilities) of those parts. The production process has a process required for each part and proceeds in a predetermined order. Therefore, each process plan must be produced in time for the assembly date or the next process start date. This can be solved by calculating the lead time of each part process from the start date of the next process (the assembly date in the case of the final process).
In addition, depending on the process, there is a process that needs to be adjusted so that the daily load does not exceed the daily load capacity. In these processes, the production plan on the day that exceeds the daily load is shifted from the start date of the next process to the maximum preceding date (the date when the assembly can be started from the assembly date) on the day before or after. Do not exceed the daily load.

FIG. 3 shows a flow of a series of schedule development processes.
Step S1 is a medium schedule parts development process (first procedure), step S2 is a schedule allocation process (second procedure), and step S3 is a lot summarization process (third procedure). Step S4 is a load leveling process (fourth procedure), and includes a postponing process and a forwarding process. Each of these processes will be described in detail below. By these steps S1 to S4, the schedule group by facility group 7 is output.

Next, the medium schedule parts development process in step S1 will be described.
The middle schedule parts expansion process is a process of developing and reading the assembly data of each model existing in the assembly schedule information 2 with necessary parts and production processes. The data read here is used to perform the subsequent processing.
The contents of the data to be read are all necessary information, and most of the data required thereafter (with some exceptions) is read into the memory here. The image developed from the model to parts and processes is as shown in FIG.
The production number and assembly date for each model are obtained from the schedule information during assembly in FIG. 4A, and the part name (panel) for each model is obtained from the part configuration information in FIG. 4B. The process for each part (panel) is obtained from the process route information of c), and based on these, the part development image of FIG. 4D is obtained. This development is performed with reference to the equipment group-specific TS information 4.

Next, the schedule allocation process in step S2 will be described.
The schedule assignment process is a process for calculating a production start reference date for the developed parts information. The start date calculated here is treated as a reference date because the start date is changed in a process after this process depending on the process. As a basic idea, the start date of each process is calculated from the subsequent process using the lead time of the part so that the production of the part (panel) is in time for the assembly schedule date. For this schedule allocation, a calendar 5 by facility group is used.
Therefore, the first process is the final process of each part, and the date from the assembly plan date to the lead time is set as the start date. Prior to that, the reference date is the day after the lead time from the start date of the next process. The image is shown in FIG.

The schedule assignment here calculates the start date from the subsequent process for each part, so if the processing order is processed in descending order of the process order for each part, it can be assigned without problems. . However, if there is a schedule adjustment of “lot batch processing” and “load leveling processing” described later, it is necessary to process all parts at once for each process, and in order to process one process, It is necessary to determine the start date of all parts processed in the process.
Therefore, if there is a part for which the start date of the next process is not determined among the parts processed in a certain process, this process is not completed. As a specific example, “Step 1” is the first step for most parts, and when “Step 1” is processed, the start date of the next step for all parts is determined. . However, in the case of “step 3”, as shown in FIG. 4C, “step 4” is the next step in “PANEL2”, but when “step 4” is processed, “PANEL3” Step 3 "is the next step. This makes it impossible to process either process first. In short, in a process in which such an order exists, it is impossible to adjust the schedule of “lot batch processing” and “load leveling processing”.
Considering the reverse, the process with schedule adjustment should not have a case where the process order is reversed in parts. Also, since the order of the allocation process is to process the process with schedule adjustment after processing the process without schedule adjustment, the process with schedule adjustment needs to be continuous from the top of each part. is there.

In summary, (1) a process with schedule adjustment must be continuous (multiple) from the top process of each part. (2) There should be no case where the process order is reversed in units of parts in a process with schedule adjustment. It turns out that.
After all parts are assigned a schedule, the order of the parts assigned on the same day is determined. This order is determined according to the production order of the models assigned on the same day of the medium schedule information.

Next, the lot summarizing process in step S3 will be described.
For each of the press (80/160) group and the press (200/300) group in FIG. 2, lots are grouped based on the schedule after schedule allocation. The lot summarization process is a process of changing the production order so that parts with the same drawing number whose production start dates are close in the process can be produced collectively.
As shown in FIG. 6, the lot grouping range (assembly date) and maximum lot size are determined for each part, and within that range, lots are grouped in order from the earliest start date of the corresponding process using the drawing number as a key. Go. Since this process needs to consider all the parts in the process, it is assumed that all parts have been assigned a schedule.

In FIG. 6, the drawing number PANEL1 indicated by A is the lot summarization range 4 days (start date 1/5 to 1/8), the quantity after the lot summarization is 300, and the maximum lot size is 400 or less. It can be summarized.
In addition, in FIG. 6, the drawing number PANEL3 indicated by B is a lot summarizing range of 4 days (start date 1/5 to 1/8), and is a quantity 600 after lot summarization, which exceeds the maximum lot size 400, It cannot be summarized. For this reason, the bottom part shown by B in FIG. According to this, since the number after grouping is 300 and the maximum lot size is 400 or less, lots can be grouped.

Next, the load leveling process in step S4 will be described.
For processes that require schedule adjustment, it is necessary to perform load leveling. The load leveling process calculates the daily load according to the schedule determined by the schedule allocation process and the lot-sizing process, and distributes the load of the day exceeding the daily allowance to the next day or the next day. It is processing. For the calculation of the daily allowance, the equipment group-specific TS information 4 and the equipment group-specific calendar 5 are used.
The range allocated at this time is allocated so as not to exceed the range from the maximum preceding date (assembly date-maximum preceding days) to the start date of the next process. The allocation on the previous day is “advanced” and the distribution on the next day is “advanced”, and the details of each will be described below.

First, a postponing process is performed in which the overflowing load is distributed toward a later date. Iterates from the first production plan date of the target month to the last assembly date. Even if the load is overflowing, if the next day is the start date of the next process, it cannot be distributed. Therefore, at this time, there is still a high possibility that there is a day that exceeds the daily load.
FIG. 7 shows an image of the postponing process. FIG. 7 shows a state in which the load exceeding 8H of 1/5 and 1/7 is postponed the next day.

Next, the advance processing will be described.
The processing that distributes the amount of the load that could not be suppressed by the postponing process to the previous day and keeps it within the allowable amount of the day is the forward processing. Since the advance processing is assigned to the previous day from the parts that were assigned later, the image is like returning the advance processing, but the range that can be advanced is up to the maximum preceding day, so the start date assigned by schedule allocation As a result, it is possible to distribute until the previous day, and as a result, it is possible to keep the amount that cannot be held down by the postponement within the allowable amount of the day. However, when there are too many schedules during assembly, there may be a case where a day exceeding the daily allowance remains after this processing.
FIG. 8 shows an image of the advance processing. In FIG. 8, the 1/8 load that protrudes the processing result 8H of FIG. 7 is advanced to 1/7 the previous day so that it falls within 8H, and the amount exceeding 8H on the previous day 1/7 is further increased to the previous day 1 / 6 ahead of schedule.

  This can be said to both forward and backward, but by performing these processes, the production order must not change even if the start date changes. This is because if the production order is changed here, the order of the production plans changed in the lot-sizing process is broken. For this reason, when moving forward, the parts to be distributed are moved to the beginning of the next day, and when moving forward, they are moved to the end of the previous day. (See Figs. 7 and 8)

  A sheet metal schedule 6 is created as a processing result of steps S1 to S4 described above, and a schedule plan table for each equipment group is output. This is an output format shown in FIG. 9, and display on the screen system is also possible, enabling output as paper. FIG. 9 shows the equipment group (line) to be produced, the production date, and the production quantity.

Next, time allocation (fifth procedure) to each equipment press is performed based on the equipment group schedule chart of FIG. The case where a human performs time allocation will be described below.
The facility group schedule in FIG. 9 indicates the scheduled production parts and quantities for each facility group on the day, and the time unit allocation to the final processing facility is performed by a human using a whiteboard.
By using the equipment group schedule table of FIG. 9, the production parts for each day are allocated time by time as a production plan for the day. At this time, the writer (on-site supervisor) plans the parts (production equipment and production equipment) to be produced on that day, taking into account the on-site conditions (production status, equipment status, personnel status up to yesterday) and mold change time. The process order will be formulated sequentially.
The time allocation of production parts by equipment and hour for the day of the day is entered on the site whiteboard.

  In the above description, it has been described that the time allocation of production parts for the day is performed by humans, but it can also be performed in the same manner by the main processing device.

According to the first embodiment, facilities are grouped to produce a production schedule, so that the combination of facilities can be simplified, the production status can be flexibly handled, and processing can be simplified.
In addition, since the facilities are grouped, it is easy to perform batch summarization processing and load leveling processing.
Furthermore, the processing speed of the main processing device can be increased.

BRIEF DESCRIPTION OF THE DRAWINGS It is a whole block diagram which shows the production schedule planning system by Embodiment 1 of this invention. It is a figure which shows grouping of the press equipment of the production schedule planning system by Embodiment 1 of this invention. It is a flowchart which shows the flow of the schedule expansion | deployment process of the production schedule planning system by Embodiment 1 of this invention. It is an image figure which shows the middle schedule part expansion | deployment process of the schedule expansion | deployment process of the production schedule planning system by Embodiment 1 of this invention. It is an image figure which shows the schedule allocation process of the production schedule planning system by Embodiment 1 of this invention. It is a figure which shows the lot summarization process of the production schedule planning system by Embodiment 1 of this invention. It is an image figure which shows the postponement process of the load leveling process of the production schedule planning system by Embodiment 1 of this invention. It is an image figure which shows the advance process of the load leveling process of the production schedule planning system by Embodiment 1 of this invention. It is a figure which shows the schedule plan according to equipment group of the production schedule planning system by Embodiment 1 of this invention.

Explanation of symbols

1 Feeder schedule development 2 Assembly schedule information 3 Parts configuration information 4 TS information by equipment group 5 Calendar by equipment group 6 Sheet metal schedule information 7 Schedule plan by equipment group 8 Time allocation by equipment

Claims (3)

  A facility group that classifies each facility in advance, and the first procedure to deploy parts production to the facility group based on the medium schedule information that indicates the assembly schedule of the model, the parts that have been deployed by this first procedure The second procedure for calculating the base date for starting production for the parts, and for the parts for which the base date for starting production was calculated by this second procedure, the same parts that are close to each other in the process A third procedure for rearranging lots by changing the production order of parts so as to produce, and after execution of this third procedure, the daily load for each equipment group is calculated. Includes a fourth procedure for leveling the load by allocating the load on the day exceeding the group's daily allowance to the adjacent day, and outputting a schedule by facility group after the completion of the fourth procedure Production schedule Field method.   The production schedule planning method according to claim 1, further comprising a fifth procedure for performing time allocation for each facility on the current day based on the facility group schedule. In the fourth procedure, the load on the day exceeding the daily allowance of the equipment group is postponed to the next day, and then the load on the day exceeding the daily allowance of the equipment group is applied to the previous day. 3. The production schedule planning method according to claim 1 or 2, wherein the forward processing is performed.

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