JP2010165283A - Equipment load plan preparation device, method therefor, program therefor and recording medium - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide an equipment load plan preparation device, a method therefor, a program therefor and a recording medium, for finding a defect in an equipment load plan as a result of load calculation. <P>SOLUTION: The equipment load plan preparation device S includes: a loading device 1 determining a work date for each production process based on a delivery time for each order of a plurality of products, and performing virtual loading based on the determined work date; a backward load balancing device 4 performing virtual balancing at a date in a direction reverse to a flow of time so that virtual load for each equipment exceeding processing capability of the equipment falls within the processing capability; a forward load balancing device 6 performing virtual balancing for moving the loads made before an earliest production start date after the movement of the load to a date in a direction along the flow of the time; and a defect decision device 7 deciding whether there is a defect hindering implementation of the equipment load plan in the equipment load plan after the movement of the load. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  In the present invention, when a plurality of products are produced on a production line composed of a plurality of processes (equipment), an equipment load plan indicating how much of each equipment is processed within a predetermined planning period is created. The present invention relates to an equipment load plan creation device and an equipment load creation method. And this invention relates to the program of this installation load preparation method, and the recording medium which recorded this program.

  The equipment load plan calculates the processing amount (load) required for production in each process (or each equipment) according to the order quantity for each order, and the capacity of each process (or each equipment) This shows a so-called loading plan (plan for processing an order in each process (or facility)) for processing the load within the range. For example, in an equipment load plan in an industry represented by material products, the load in each process is calculated according to the quantity and type of the order, and the unit period (loading the order is loaded within the capacity of the equipment) The unit period to be processed in each facility is determined so as to meet the delivery date of the order. In the following description, unless otherwise specified, the term “process” also means equipment.

  In this equipment load plan, when a production line is composed of a plurality of processes, if the load of a certain order is adjusted in a certain process, there is a high possibility that the influence will affect other processes. Therefore, by breaking the load in one process, the load of other equipment must be broken, and the processing capacity of the equipment cannot be utilized to the maximum, and there is a possibility that a delay in delivery date occurs. In addition, in order to meet the delivery date of the order, if the production is performed more than necessary in advance, there is a high possibility that the in-process inventory will increase.

  For this reason, for example, in Patent Document 1, the difference between the latest production start date that can be made in time for delivery even if processing is started the latest and the planned production date that is obtained by temporarily loading the load is the load adjustment. There has been proposed a method of adjusting the load so that the production range is not allowed, and the delay in delivery is not allowed, and the preceding production is minimized.

The method disclosed in Patent Document 1 has the following features.
(1) For example, by using the standard lead time based on the actual work time in the actual factory, the earliest manufacturable date in each process is calculated from the order date (today) for each order, and the load depends on that value. The planned production date is calculated by stacking.
(2) Using the standard lead time, the latest production possible date in each process is calculated from the delivery date for each order.
(3) The load is adjusted for each process in order from the upper process within the load stackable range calculated from (1) and (2) above. In this case, when all the loads can be piled up so that they are within the load capacity within the load capacity range, it is possible to create a load plan that does not cause a delay in delivery for all orders (i.e. Process precedence constraints are respected by updating the earliest manufacturable date of the lower process from the results of process load adjustments). Furthermore, in this adjustment, it is considered that the load accumulation date is delayed as much as possible in order to reduce the in-process inventory by considering the difference between the load accumulation date and the latest manufacturable date.
(4) In the above (3), when the load cannot be adjusted in each step, the production constraint condition is changed, the planned shutdown date of the equipment is changed, and the like. As a result, it is possible to make a load plan that satisfies the delivery date of all orders.
(5) The above (3) and (4) are performed for all the steps.

  According to the technique disclosed in Patent Document 1, it is possible to formulate a load plan that reduces the in-process inventory as much as possible while satisfying the delivery date.

JP-A-2005-216074

  By the way, in the method disclosed in Patent Document 1, when the load calculation of the equipment load plan is performed by the steps (1) to (5) under the standard operation condition constraint, the equipment load plan is used. There is a possibility that a problem may occur, and there is a possibility that the user will not notice when a problem occurs in the equipment load plan.

  The present invention is an invention made in view of the above-described circumstances, and its purpose is to create an equipment load plan that can be found when a trouble occurs in the equipment load plan created as a result of load calculation. An apparatus, an equipment load plan creation method, an equipment load planning program, and a recording medium in which the equipment load planning program is recorded.

  As a result of various studies, the present inventor has found that the above object is achieved by the present invention described below. That is, in one aspect according to the present invention, in an equipment load plan creation device for creating an equipment load plan in the case of producing a plurality of products through a plurality of manufacturing processes, the delivery date and a predetermined standard lead time set in advance Based on the delivery date for each order of the plurality of products, determine the work date and time to perform each manufacturing process, to the equipment corresponding to each manufacturing process based on the determined work date and time for the production of the product A load pile unit that virtually piles the load according to the order amount, and when the load amount virtually piled on each facility by the load pile unit exceeds the processing capacity of the facility, Back that performs a virtual landslide that moves each order to the date and time in the opposite direction of the flow of time so that the load accumulated in the equipment that exceeds the processing capacity is within the processing capacity. If the date and time after the movement of the load load crushing unit and the load moved by the backward load crushing unit is earlier than the earliest manufacturing start date, the load was piled before the earliest manufacturing start date and time. The forward load hill-climbing unit that performs virtual landslides that move the load to the time flow and forward date and time, and the equipment load plan after the movement of the load moved by the forward load hill-climbing unit, And a failure detection unit that determines whether or not there is a failure that hinders the execution of the load plan.

  According to another aspect of the present invention, in an equipment load plan creation method for creating an equipment load plan when a plurality of products are produced through a plurality of manufacturing processes, a delivery date and a predetermined standard lead time set in advance are prepared. Based on the above, for each order of the plurality of products, a work date and time for performing each manufacturing process is determined based on the delivery date, and a facility corresponding to each manufacturing process is determined based on the determined work date and time. Load stacking step for virtually stacking the load according to the order amount, and when the amount of load virtually stacked on each facility by the load stacking step exceeds the processing capacity of the facility In order to keep the load accumulated in the equipment exceeding the processing capacity within the processing capacity, a virtual mountain break is performed for each order at a date and time in the opposite direction to the flow of time. Loads piled before the earliest manufacturing start date and time when the date and time after the movement of the load moved by the word load unloading step and the backward load unloading step are before the earliest manufacturing start date To the forward load landslide step for performing a virtual landslide, and the facility load plan after the movement of the load moved by the forward load landslide step is A defect finding step for determining whether or not there is a defect that hinders the execution of the plan.

  According to another aspect of the present invention, there is an equipment load plan creation program for creating an equipment load plan using a computer in the case of producing a plurality of products through a plurality of manufacturing processes. Based on a predetermined standard lead time set in advance, a work date and time for performing each manufacturing process is determined for each order of the plurality of products based on the delivery date, and each manufacturing process is determined based on the determined work date and time. A load stacking function for virtually stacking loads corresponding to the order quantity for manufacturing products to the corresponding facilities, and the amount of load virtually stacked on each facility by the load stacking function If the processing capacity exceeds the processing capacity, the load accumulated in the equipment exceeding the processing capacity will be within the processing capacity. The backward load load-climbing function for performing a virtual mountain-climbing, and the earliest production when the date and time after the movement of the load moved by the backward load-climbing function is earlier than the earliest production start date. A forward load landslide function that performs a virtual landslide that moves the load piled before the start date and time to the date and time in the forward direction, and the load moved by the forward load landslide function It is an equipment load plan creation program for executing a trouble finding function for determining whether or not there is a trouble that hinders the implementation of the equipment load plan in the equipment load plan after movement.

  And in another aspect according to the present invention, a recording medium for recording a facility load plan creation program for creating a facility load plan using a computer when producing a plurality of products through a plurality of manufacturing steps, Based on the delivery date and a predetermined standard lead time set in advance on the computer, the work date and time for performing each manufacturing process is determined based on the delivery date for each order of the plurality of products, and the determined work date and time is used as a reference. The load stacking function for virtually stacking the load corresponding to the order quantity for the production of the product on the equipment corresponding to each manufacturing process, and the load virtually stacked on each facility by the load stacking function When the amount of water exceeds the processing capacity of the equipment, the flow of time for each order is set so that the load accumulated in the equipment exceeding the processing capacity is within the processing capacity. The backward load load-climbing function that performs virtual mountain-climbing that is moved in the reverse direction and the date and time after the movement of the load that has been moved by the backward load-climbing function is earlier than the start date of production. A load load piled up before the earliest manufacturing start date and time is moved to a time flow and a forward date and time, a forward load load break function for performing a virtual load break, and the forward load load break function Equipment load plan creation program for executing a fault detection function for determining whether or not there is a fault that hinders the implementation of the equipment load plan in the equipment load plan after the movement of the load moved by Is a recording medium.

  The equipment load plan creation device, equipment load plan creation method, equipment load plan creation program, and equipment load plan creation program recording medium having such a configuration, equipment for producing a plurality of products through a plurality of manufacturing processes. A load plan is created by performing load stacking, performing backward load collapse in a predetermined case, and performing forward load collapse in a predetermined case. Then, it is determined whether or not the created equipment load plan has a defect that hinders the implementation of the equipment load plan. For this reason, when a malfunction occurs in the created equipment load plan, it can be found. For example, by visually or audibly presenting the determination result, a user such as an operator can recognize that a defect has occurred in the created equipment load plan.

  In addition, in the equipment load plan creation device described above, when it is determined by the trouble discovery unit that the trouble exists, the operation restriction that is a condition to be observed when creating the equipment load plan is relaxed and a new one is created. It further comprises an operation constraint relaxation unit for creating an operation constraint.

  When a failure has occurred in the created facility load plan, in order to obtain a better facility load plan with a smaller degree of failure, the load on the facility load plan may be calculated again after changing the operation constraints. Yes, in this case, the operation constraints are changed on a trial and error basis. For this reason, users such as operators have to repeat complicated operations. According to this configuration, when it is determined by the defect detection unit that the defect is present in the created facility load plan, the operation constraints that are conditions to be observed when creating the facility load plan are alleviated. New operational constraints are automatically created by the operational constraint mitigation unit. For this reason, for example, it is possible to automatically create an equipment load plan again with the load pile unit, backward load pile unit and forward load pile unit under the automatically created new operation constraints. The user is freed from the complicated work.

  Further, in the above-described equipment load plan creation device, the defect detection unit may be configured as follows when the delivery date of the order is not observed in the equipment load plan after the load moved by the forward load crushing unit. It is determined that a defect exists.

  According to this configuration, there is provided an equipment load plan creation device that determines that the defect exists when an order delivery date is not observed. For this reason, it is possible to make an equipment load plan that satisfies the delivery date of the order by relieving the operation restrictions by paying attention to the delivery date of the order. In particular, in a configuration in which the equipment load plan creation device includes an operation restriction alleviation unit, the user is freed from the complicated work in making such equipment load plans.

  Further, in the above-described equipment load plan creation device, the defect finding unit adds a predetermined amount to the equipment load plan after the movement of the load moved by the forward load crushing unit within a predetermined period. It is characterized in that it is determined that the defect exists when it cannot be manufactured.

  According to this configuration, there is provided an equipment load plan creation device that determines that the problem exists when a predetermined amount cannot be manufactured within a predetermined period set in advance. For this reason, it is possible to create an equipment load plan that can produce a predetermined amount within the predetermined period by relaxing the operation restrictions by focusing on manufacturing the predetermined amount within the predetermined period. It becomes. In particular, in a configuration in which the equipment load plan creation device includes an operation restriction alleviation unit, the user is freed from the complicated work in making such equipment load plans.

  In the above-described equipment load plan creation device, the operation constraint relaxation unit creates the new operation constraint by relaxing processing capacity or delivery time.

  According to this configuration, by reducing processing capacity or delivery date, for example, it is possible to create an equipment load plan that complies with the delivery date of an order, and it is possible to select an order that reduces the minimum delivery date. Become. In addition, for example, according to this configuration, it is possible to create an equipment load plan for manufacturing a predetermined amount within a predetermined period, for example, by reducing the processing capacity or the delivery date. It becomes possible to obtain the processing capacity of the limited equipment.

  The equipment load plan creation device may further include a priority determination unit that sets a priority order with respect to an order of loads to be crushed by the backward load crumb unit.

  According to this configuration, it is possible to execute backward load crushing in order from the order of higher priority, which makes it possible to easily deal with orders with strict delivery dates.

  The equipment load plan creation device may further include a priority determination unit that sets a priority order with respect to an order of loads to be crushed by the forward load crushed unit.

  According to this configuration, it is possible to execute forward load crushing in order from the order with the highest priority, and thus it is possible to easily cope with orders with strict delivery dates.

  The equipment load plan creation device, the equipment load plan creation method, the equipment load plan creation program, and the recording medium on which the equipment load plan creation program according to the present invention is recorded can be detected when a failure occurs in the created equipment load plan. can do.

It is a block diagram which shows the structure of the equipment load plan preparation apparatus in embodiment. It is a block diagram which shows the structure of the backward load pile apparatus in the said equipment load plan preparation apparatus. It is a block diagram which shows the structure of the backward load crushing apparatus in the said equipment load plan preparation apparatus. It is a block diagram which shows the structure of the forward load crushing apparatus in the said equipment load plan preparation apparatus. It is a block diagram which shows the structure of the malfunction determination apparatus in the said equipment load plan preparation apparatus. It is a block diagram which shows the structure of the operation restriction relaxation apparatus in the said equipment load plan preparation apparatus. It is a figure which shows the installation information in the said installation load plan preparation apparatus. It is a figure which shows the process information in the said equipment load plan preparation apparatus. It is a figure which shows the order information in the said equipment load plan preparation apparatus. It is a flowchart which shows operation | movement of the equipment load plan preparation apparatus in embodiment. It is a figure which shows the load pile result in one specific example. It is a figure which shows the state in the middle of the backward load crushed calculation in one specific example. It is a figure which shows the backward load collapse result in one specific example. It is a figure which shows the state in the middle of the forward load landslide calculation in one specific example. It is a figure which shows the result of the forward load collapse in one specific example. It is a figure which shows the result of the forward load collapse in one specific example. It is a figure which shows the result of the forward load collapse in one specific example.

Hereinafter, an embodiment according to the present invention will be described with reference to the drawings. In addition, the structure which attached | subjected the same code | symbol in each figure shows that it is the same structure, The description is abbreviate | omitted suitably.
(Configuration of the embodiment)
FIG. 1 is a block diagram illustrating a configuration of an equipment load plan creation device according to an embodiment. FIG. 2 is a block diagram showing a configuration of a backward load stacking device in the equipment load plan creation device. FIG. 3 is a block diagram showing a configuration of a backward load crushing device in the equipment load plan creation device. FIG. 4 is a block diagram showing a configuration of a forward load leveling device in the equipment load plan creation device. FIG. 5 is a block diagram showing a configuration of a failure determination device in the equipment load plan creation device. FIG. 6 is a block diagram showing a configuration of an operation constraint relaxation apparatus in the equipment load plan creation apparatus. FIG. 7 is a diagram showing facility information in the facility load plan creation device. FIG. 7A shows the facility information in the first case, and FIG. 7B shows the facility information in the second case. FIG. 8 is a diagram showing process information in the equipment load plan creation device. FIG. 9 is a diagram showing order information in the equipment load plan creation device. FIG. 9A shows the order information in the case of the first case, and FIG. 9B shows the order information in the case of the second case.

  In FIG. 1, an equipment load plan creation device S includes a master information storage device M (M1, M2), a backward load stacking device 1, an overload determination device 2, a load collapse break priority determination device 3, The load load crushing device 4, the startable day constraint satisfaction determination device 5, the forward load crushing device 6, the failure determination device 7, and the operation constraint relaxation device 8 are configured.

  The master information storage device M is composed of a plurality of separate devices. In the example shown in FIG. 1, the master information storage device M includes two devices, ie, the master information storage device M1 and the master information storage device M2. May be. Moreover, although the equipment load plan preparation apparatus S is comprised by the several apparatus M (M1, M2) and 1-8 of the separate body in the example shown in FIG. 1, it is one apparatus integrally or some These devices may be composed of a plurality of devices including a device in which one device is combined. For example, the equipment load plan creation device S may be configured to include a master information storage device M and a device (equipment load plan creation main body device) in which the devices 1 to 8 are integrated into one device. . Each of these devices M, 1 to 8 (or devices when integrated together) is connected to a communication network (communication network) and configured to exchange data with each other via this communication network. Yes.

  The master information storage device M is a device for storing master information. For example, a volatile storage element such as a RAM (Random Access Memory), a ROM (Read Only Memory) or a rewritable EEPROM (Electrically Erasable Programmable Read Only Memory). ) And the like and a peripheral circuit thereof. For example, the master information storage device M may be configured to include a hard disk. For example, the master information storage device M may be configured to include a server computer. The master information is basic information necessary for creating (planning) an equipment load plan, and includes, for example, equipment information related to equipment, manufacturing process information related to product manufacturing, order information related to product ordering, and the like.

  The equipment information includes equipment processing capacity information related to the processing capacity of the equipment set (specified) in accordance with predetermined operation restrictions, and a standard lead time (standard lead time) set in advance based on the actual work time in the actual equipment. Time). For example, as shown in FIG. 7, the facility processing capacity information is stored in the master information storage device M in a look-up table indicating a correspondence relationship between the facility and the processing capacity corresponding thereto. In the example shown in FIG. 7, the facility is represented by a facility identifier (for example, facility 1), and the processing capacity is a processing amount that can be processed per day (daily unit processing amount, ton / day). It is represented. For example, in FIG. 7A, the equipment of equipment 1 has a processing capacity of 40 ton / day. The standard lead term may use a time based on a target time or the like instead of the actual work time.

  For example, as shown in FIG. 8, the manufacturing process information includes an order, process information indicating a manufacturing process for manufacturing the ordered product, whether production of the ordered product is started, and production start. (In the case of work-in-progress), it is stored in the master information storage device M as a look-up table indicating the correspondence with work-in-process information indicating which process is in the manufacturing process. In the example shown in FIG. 8, the order is represented by an order identifier (for example, order A), the process information represents a manufacturing process for manufacturing the ordered product in the order of the processes, and the in-process information represents the order information. If the production of the ordered product has not started, it is indicated by information indicating that fact (for example, not yet started), and if the production of the ordered product has been started, it is indicated by information indicating the current process. ing. For example, the order of order A is produced in the manufacturing process in order of process 1 → process 2 → process 3 → process 4 and is a work in progress and is currently process 4, and for example, the order of order D is It is produced in the manufacturing process in the order of each process of process 1 → process 2 → process 4, and has not started yet. The facility 1 processes the process 1, the facility 2 processes the process 2, the facility 3 processes the process 3, and the facility 4 processes the process 4.

  For example, as shown in FIG. 9, the order information is stored in the master information storage device M in a look-up table indicating a correspondence relationship between the order, the delivery date of the ordered product, and the order quantity of the ordered product. Is done. In the example shown in FIG. 9, an order is represented by an order identifier, a delivery date is represented by a date with the current date as the first day, and an order quantity is represented by a weight (order weight) expressed in ton units. ing. For example, in FIG. 9A, the order of order A has a delivery date of 1 day and an order weight of 20 tons. For example, an order of order C has a delivery date of 2 days and an order weight of 10 tons. is there.

  Here, in this embodiment, the standard lead time is one day between all orders and all processes, and the yield drop that occurs when passing through each process, which usually occurs in a material factory, is not considered ( Yield drop 0) And, when manufacturing a product, the order of each manufacturing process shown in FIG. 8 is observed. Such conditions are set in the equipment load plan creation device S.

  The backward load stacking device 1 refers to the master information necessary for processing in the master information storage device M, and does not consider the facility capacity, but loads the load in order to manufacture products according to the order quantity for all orders. It is a device that virtually piles up on the basis of delivery date. To load a load is to assign a load to the equipment for each unit period. In this embodiment, the unit period is one day because the standard lead time is one day for all orders and all processes. More specifically, the backward load stacking apparatus 1 determines the work date and time for performing each manufacturing process based on the delivery date for each order based on the delivery date and a predetermined standard lead time set in advance. This is a device that virtually piles up the load corresponding to the order quantity for manufacturing the product on the equipment corresponding to each manufacturing process based on the work date and time, for example, as shown in FIG. In addition, a work date and time determination unit 11 and a backward load stacking unit 12 are provided. The work date determination unit 11 refers to master information necessary for processing from the master information storage device M, and acquires a delivery date for each order as a reference date for stacking loads in order to virtually stack loads. . For example, in the example shown in FIG. 9A, since the delivery date of the order G is 6 days, the sixth day is acquired as the reference date. The backward load stacking unit 12 receives the reference date (delivery date) of the acquired stacking for all orders from the work date and time determination unit 11 and goes back from the delivery date to the first step from the last step in the manufacturing process. The process is piled up without considering the equipment capacity, with each process as a load in order going back to the process.

  The overload determination device 2 receives the stacking result for all orders from the backward load stacking device 1, and the amount of the stacked load exceeds the processing capacity of the facility at any date and time in the stacking result. This is a device that determines whether or not the current flow is traced back from the latest day when the load is piled up (the farthest future).

  The load-climbing priority determination device 3 refers to the master information stored in the master information storage device M, extracts and determines and sets the priority when the load is crushed. The load leveling priority determination device 3 sets a priority order with respect to the order of the load to be crushed by the backward load leveling device 4 with respect to the backward load leveling device 4. Then, the load leveling priority determination device 3 sets a priority order with respect to the order of the load to be crushed by the forward load leveling device 6 with respect to the forward load leveling device 4.

  The backward load crushing device 4 receives the priority from the load crushing priority determination device 3 and the determination result from the overload determination device 2, and the amount of load piled up in the determination result is calculated. When it is determined that the processing capacity of the facility has been exceeded, an order to be crushed is determined based on the priority input from the load divergence priority determination device 3, and the load of the determined order is determined. It is a device that moves in the opposite direction to the flow of time and performs virtual load collapse. To divide the load is to cancel the load assignment, remove the load assigned to the facility, and load the load in another facility or another unit period. The amount of load to be crushed may be the entire order quantity (order quantity unit), or may be a part of the order quantity. As shown in FIG. 3, for example, the backward load devastating device 4 includes an overload determination load devolatilization target equipment determination unit 41, a backward load devolatilization target determination unit 42, and a backward load devastating unit 43. The preceding relation constraint satisfaction unit 44 is provided. The overload determination load collapse target facility determination unit 41 receives the determination result from the overload determination device 2 and determines that the load amount piled up in the determination result exceeds the processing capacity of the facility. Is extracted. The backward load collapse target determination unit 42 receives the priority from the load collapse priority determination device 3 and the extraction result from the load excess determination load collapse target facility determination unit 41, and determines the load excess determination load. From the orders extracted by the hill-climbing target equipment determining unit 41, an order (target order) for performing a landslide is determined based on the priority input from the load-climbing priority determination device 3. . The backward load landscaping unit 43 receives the determination result from the backward load landslide target determination unit 42, and the date and time when the load of the target order determined by the backward load erosion target determination unit 42 was originally piled up It is moved before (moving in the direction opposite to the flow of time) to perform virtual load collapse. Here, in the process of going back in time, it is allowed to load more in the past than the available day (today). When the prior relationship constraint satisfaction unit 44 affects the other equipment of the same order (target order) by crushing the load by the backward load crushing unit 43, the backward load crushing unit 43 causes the backward load crushing unit 43 to change the processing order of the products. Satisfy the predecessor relationship.

  The startable day constraint fulfillment determination device 5 receives the crushed mountain break result from the backward load load collapse device 4, and in the mountain break result, the load of any order is less than the available day (today). It is determined whether or not there is a pile before.

  The forward load leveling device 6 receives the priority from the load leveling priority determination unit 3 and the start date constraint satisfaction determination result from the start date constraint satisfaction determination unit 5, and the start date constraint In the satisfaction determination result, when it is determined that the load is loaded before the start date, an order for performing the mountain collapse based on the priority input from the load mountain collapse priority determining device 3 is made. This is a device for tentatively determining an equipment load plan by making a virtual landslide to determine and move the determined order load in the forward direction with the flow of time. Note that the priority in this case is the same (same system) as that used in the backward load crushing device 4 described above, or another different priority (another priority system). May be. For example, as shown in FIG. 4, the forward load devastating device 6 includes an available-to-be-committed date constraint eliminating unit 61, an overload determination load devolatilization target facility determining unit 62, a forward load devastating target determining unit 63, A load crushing unit 64 and a preceding relationship constraint satisfaction unit 65 are provided. The possible start date constraint canceling unit 61 receives the start possible date constraint satisfaction determination result from the possible start date constraint satisfaction determination device 5, and loads the load before the possible start date in the possible start date constraint satisfaction determination result. If it is determined that the load is piled up before the available start date (today), the load is moved to the future while satisfying the order processing relations of the order, and all the loads before the available start date are all in the future. The mountain is going down. The load overload determination load evacuation target facility determination unit 62 receives the landslide result of the landslide in the future from the startable day constraint cancellation unit 61, and from the earliest day when the load is piled up, the time flow and forward direction In each facility, it is determined whether or not the load exceeds the processing capacity. The forward load landslide target determination unit 63 receives the priority from the load landslide priority determination device 3 and the determination result of the overload determination load evacuation target facility determination unit 62, and prioritizes the load landslide priority. Based on the priority input from the degree determining device 3, an order for performing a mountain climbing (target order) is determined. The forward load landscaping section 64 receives the determination result from the forward load landslide target determination section 63, and the load of the target order determined by the forward load landslide target determination section 63 is earlier than the date and time when the load was originally stacked. This is a device that temporarily determines the equipment load plan by moving to (in the opposite direction to the flow of time) and performing virtual landslides. And when the prior relationship constraint satisfaction part 65 affects other equipment of the same order (target order) by crushed the load by the forward load crushed part 63, the forward load crushed part 63 is informed of the processing order of the products. Satisfy the predecessor relationship.

  The failure determination device 7 receives the load calculation result from the forward load crushing device 6, that is, the provisional facility load plan, and this provisional facility load plan has a problem that hinders the implementation of the facility load plan. For example, as illustrated in FIG. 5, the apparatus is configured to include a defect finding unit 71 that detects whether or not the temporary facility load plan has a defect. Defect determination (determination of the appropriateness of the equipment load plan) is whether or not the manufacture of each order satisfies the order information. In this embodiment, the manufacture of each order satisfies the delivery date and the order quantity (compliance) ) Is determined from whether or not. When manufacturing according to the equipment load plan, if the production of each order satisfies the delivery date and the order quantity, it is determined that the provisional equipment load plan is appropriate, that is, there is no defect, and the equipment load plan If the manufacture of each order does not satisfy at least one of the delivery date and the order quantity, it is determined that the provisional equipment load plan is not valid, that is, there is a problem. In addition, other viewpoints, for example, a point such as whether the operating rate of the facility is equal to or higher than a certain value, may be additionally employed as a criterion for defect determination (validity determination). When it is determined from the determination result of the defect determination device 7 that the temporary facility load plan is not defective, the temporary facility load plan is set as the final facility load plan. Then, the failure determination device 7 outputs the determination result to the operation constraint relaxation device 8.

  The operation constraint relaxation device 8 receives a determination result from the failure determination device 7, and stores the predetermined data when the determination result is a determination result that the temporary facility load plan has a failure. While the operational constraints used to create the provisional equipment load plan are relaxed, if the judgment result is a judgment result that the provisional equipment load plan is not defective, the equipment load plan, etc., is output as not shown. It is a device that outputs to the device. Operational constraints are conditions that must be observed when creating an equipment load plan. The operation restrictions to be relaxed include, for example, the processing capacity of the facility, the delivery date of the order, the order quantity of the order, and the like in this embodiment. The reduction of the processing capacity is performed by increasing the processing capacity within a predetermined range, for example, setting the processing capacity to 20% of the initial value. The order delivery date is relaxed by, for example, delaying the delivery date in the order information within a predetermined range, such as delaying the delivery date by 3 days. The order quantity is reduced by reducing the order quantity in the order information such as setting the order quantity to 10% reduction within a predetermined range. The item of the operation condition to be relaxed may be arbitrarily determined, for example, may be determined in order by assigning priority to the relaxation items, or determined according to the content determined as a failure in the failure determination device 7 May be. Further, the mitigation amount (the degree and degree of mitigation) may be set to a predetermined amount in advance, or may be determined according to the content determined as a malfunction in the malfunction determination device 7, for example. For example, as shown in FIG. 6, the operation constraint relaxation apparatus 8 includes a new operation constraint creation unit 81, an operation constraint storage unit 82, a failure result storage unit 83, a load calculation result storage unit 84, and an overall result output unit. 85. When the determination result is input from the failure determination device 7 and the determination result is a determination result that the provisional equipment load plan has a failure, the new operation constraint creation unit 81 has an operation constraint item that can be relaxed. When there are a plurality of items, a new operation constraint is created by relaxing an operation constraint on one or more items among the plurality of items. The newly created new operation constraint is stored in the master information storage device M from the new operation constraint creation unit 81 of the operation constraint relaxation device 8, and is used to create an equipment load plan based on the new operation constraint. The operation constraint storage unit 82 receives an operation constraint via the new operation constraint creation unit 81 and stores the operation constraint. The defect result storage unit 83 receives the defect result from the defect determination device 7 and stores the defect result. The load calculation result storage unit 84 receives the provisional facility load plan determined to be a defect from the defect determination device 7 and stores the provisional facility load plan. When the determination result is input from the defect determination device 7 and the determination result is a determination result indicating that there is no defect in the temporary equipment load plan, the overall result output unit 85 stores the determination result in the operation constraint storage unit 82. The operation restriction, the failure result stored in the failure result storage unit 83, and the equipment load plan stored in the load calculation result storage unit 84 are output to the output device (not shown).

  The output device (not shown) is, for example, a display device such as a CRT display, LCD, organic EL display, or plasma display, or a printing device such as a printer.

  Each of these devices M and 1-8 (devices when they are integrated together) can be constituted by, for example, a computer, more specifically a server computer, a personal computer, or the like. Moreover, each program for operating each apparatus M, 1-8 (the apparatus when it is integrated together), such as an equipment load plan creation program for creating an equipment load plan, and execution of these programs The various data necessary for the data is stored in one or a plurality of these devices M, 1 to 8 (the devices when they are integrated together).

  Note that the equipment load plan creation device S may further include an external storage device (not shown) as necessary. The external storage device is, for example, a flexible disk, a CD-ROM (Compact Disc Read Only Memory), a CD-R (Compact Disc Recordable), a DVD-R (Digital Versatile Disc Recordable), a Blu-ray Disc (Blu-ray Disc), etc. An apparatus that reads data from and / or writes data to a medium, such as a flexible disk drive, a CD-ROM drive, a CD-R drive, a DVD-R drive, and a Blu-ray disk drive.

  Here, when the equipment load plan creation program for creating the equipment load plan, master information, and the like are not stored, the equipment load plan creation device S uses the recording medium recorded with these programs, master information, and the like. It may be configured to be installed (stored) in each device via an external storage device. Alternatively, the equipment load plan creation device S may be configured such that data such as the created equipment load plan is recorded on a recording medium via the external storage device.

Next, the operation of this embodiment will be described.
(Operation of the embodiment)
FIG. 10 is a flowchart illustrating the operation of the equipment load plan creation device according to the embodiment. FIG. 11 is a diagram illustrating a load pile result in one specific example. FIG. 12 is a diagram illustrating a state in the middle of the backward load collapse calculation in one specific example. FIG. 13 is a diagram showing a backward load collapse result in one specific example. FIG. 14 is a diagram illustrating a state in the middle of forward load crush calculation in one specific example. FIG. 15 is a diagram illustrating a result of forward load crushing in one specific example. FIG. 16 is a diagram illustrating the result of forward load crushing in one specific example. FIG. 17 is a diagram illustrating a result of forward load crushing in one specific example. In addition, the broken line parallel to the horizontal axis of FIG. 11 thru | or FIG. 17 shows the processing capacity of an installation.

  Hereinafter, the operation of the equipment load plan creation device S will be described with a specific example. This specific example is an example for more specifically explaining the operation of the equipment load plan creation device S. In this specific example, the initial facility processing capacity is the data shown in FIG. 7 described above, the order is the data shown in FIG. 9 described above, and the manufacturing process for manufacturing the ordered product is described above. The data shown in FIG.

  When the creation of the equipment load plan is started, in FIG. 10, first, in step S1, the master information necessary for processing in the master information storage device M is referred to by the backward load stacking device 1, and the delivery date of the order is determined. By setting the final load process date and time of the order as the load pile date and time, the load pile date and time of the final process in each order and equipment unit is determined without considering the equipment capacity. Subsequently, in step S2, the backward load stacking apparatus 1 determines each process in order from the last process to the upper process in the unit of equipment according to the standard lead time based on the load stacking date and time of the final process. The manufacturing process for manufacturing custom products is piled up. By operating in this way, the backward load stacking device 1 refers to the master information necessary for processing in the master information storage device M, and does not consider the processing capacity of the equipment, In order to manufacture the corresponding product, each load in the manufacturing process of the product is virtually piled up based on the delivery date.

  More specifically, for example, in the case of the order A, the delivery date is 1 day, the order weight is 20 ton, and the final process is the process 4. Therefore, the backward load stacking apparatus 1 is shown in FIG. As shown in Fig. 4, the process 4 having a production amount of 20 tons is piled up on the first day (today, today) of the equipment 4. In the case of this order A, since the process 4 is in progress from the in-process information of the process information and the process has been completed up to the process 3, the backward load stacking apparatus 1 determines the backward load stack of the order A. The process ends. Further, for example, in the case of the order H, since the delivery date is 10 days, the order weight is 20 ton, and the final process is the process 4, the backward load stacking device 1 is as shown in FIG. Step 4 with a production amount of 20 tons is piled up on the 10th day of the facility 4. And in the case of this order H, since the in-process information of the process information is not yet started, the backward load stacking device 1 needs to pile up all the processes of the manufacturing process, and the final is based on the 10th day. By determining the processing date and time for each of the steps 1 to 4 in order of the standard lead time from the step 4 of the step to the step 1 of the upper step, a manufacturing process for manufacturing the product of the order H is piled up. That is, the backward load stacking apparatus 1 stacks the process 4 with the production amount of 20 tons on the 10th day of the equipment 4, the process 3 with the production volume of 20 tons on the 9th day of the equipment 3, and the process 2 with the production quantity of 20 tons. On the 8th day of 2, the process 1 having a production amount of 20 tons is piled on the 7th day of the equipment 1. Further, for example, in the case of order I, since the delivery date is 10 days, the order weight is 20 ton, and the final process is step 4, the backward load stacking apparatus 1 is as shown in FIG. Step 4 with a production amount of 20 tons is piled up on the 10th day of the facility 4. Here, on the 10th day of the facility 4, as described above, the process 4 of the order H is piled up with a production amount of 20 tons, and the processing capacity of the facility 4 is not sufficient. At this time, since the equipment capacity is not taken into consideration, the process 4 of the order I is also piled up on the 10th day of the equipment 4 (the load is piled up virtually). And in the case of this order I, since the in-process information of the process information has not been started, the backward load stacking device 1 needs to pile up all the processes of the manufacturing process, and the final is based on the 10th day. By determining the processing date and time for each of the steps 1 to 4 in order from the step 4 of the process to the step 1 of the upper process according to the standard lead time, the manufacturing process for manufacturing the product of the order I is piled up. That is, the backward load stacking apparatus 1 stacks the process 4 with the production amount of 20 tons on the 10th day of the equipment 4, the process 3 with the production volume of 20 tons on the 9th day of the equipment 3, and the process 2 with the production quantity of 20 tons. On the 8th day of 2, the process 1 having a production amount of 20 tons is piled on the 7th day of the equipment 1.

  When the above-described steps S1 and S2 are executed for each of the orders A to K, as shown in FIG. 11, the manufacturing processes of all orders are piled up without considering the processing capacity of the equipment. .

  Subsequently, in step S3, whether or not the load amount (manufacturing amount) piled up by the load overload determination device 2 exceeds the processing capacity of the facility at any date and time in the pile result of the manufacturing process of all orders and the facility. No (whether it is within the capacity of the equipment) is determined by going back in time (in the opposite direction to the time) from the latest day when the load is piled up (the farthest future) Is done. As a result of this determination, if the amount of load piled up for all facilities and all dates / times does not exceed the facility capacity (if within the capacity of the facility) (Yes), step S4 is executed. On the other hand, when the amount of load piled up exceeds the facility capacity (not within the range of the facility capacity) (No), step S5 is executed.

  In step S4, the load overload determination device 2 sets the load pile result in the backward load pile device 1 as a temporary facility load plan, and step S10 is executed.

  In step S5, since the stacking is performed without considering the processing capacity of the facility in step S2, there may be a case where the stacking exceeds the processing capacity of the facility. That is, in step S5, when the backward load crushing device 4 determines that the amount of load piled up in the determination result in step S3 exceeds the processing capacity of the facility, the load crushing priority determination device. An order to perform a mountain break is determined based on the priority input from No. 3, and the load of this determined order is moved in the direction opposite to the flow of time while relaxing the start date restriction, and a virtual load collapse Is done. As the priority index, for example, in this embodiment, the delivery date of the order is used, and as the delivery date is later (future), the priority is set higher.

  More specifically, in the example shown in FIG. 11 in the backward load pile result, the second day, the third day, the fourth day, the sixth day, the seventh day, the eighth day, the ninth day, and the tenth day. In the eyes, the piled load exceeds the capacity of the facility. For this reason, step S5 is performed with respect to these. In the example shown in FIG. 11, as shown by white arrows in FIG. 12 from the 10th day which is the last day of the planning period, the equipment whose load exceeds the processing capacity while proceeding in the opposite direction to the flow of time. Is selected, and the load is crushed. More specifically, at the latest date and time when the load is piled up (the 10th day in the example shown in FIG. 11), it is confirmed whether or not there is a piece of equipment that is loaded with a load exceeding the facility capacity. The If there is no such equipment at the date and time, the same process is executed by advancing one day in the opposite direction of the time flow (going back one day). In the example shown in FIG. 11, in the facility 4 on the 10th day, a load is piled up exceeding the processing capacity of the facility 4. For this reason, the load piled up on the 10th is moved to the 9th day until the load falls within the range of the processing capacity of the facility 4. Here, since the delivery times of the orders H, I, J, and K are the same, for example, the load is left in the original date and time in order of the old number of the order. Therefore, in this case, as shown in FIG. 12, the load of the order K is left on the original 10th day, and the loads of the other orders H, I, and J are crushed on the 9th day. At the time of this landslide, the load of process 3 to process 1 in order H, I, J is also gradually collapsed as a result of the landslide so as to satisfy the preceding relationship in the process order of the manufacturing process, as shown in FIG. In addition, process 3 of orders I, J, K is crushed on the eighth day of equipment 3, process 2 of orders I, J, K is crushed on the seventh day of equipment 2, and orders I, J, , K step 1 is crushed on the sixth day of facility 1.

  And on the 10th day, since there is no equipment that is piled up in excess of the equipment capacity, the process proceeds one day in the opposite direction to the flow of time, and the above processing is repeatedly executed. The backward load collapse result shown in FIG. 13 is obtained. In this backward load crushing process, as described above, in the process of going back in time, it is permitted to load a load before the start date (today) (relaxation of the start date constraint).

  Subsequently, in step S6, the load of any order in the crushed result (for example, the backward load crushed result shown in FIG. 13) in the backward load crushed device 4 by the start date constraint satisfaction determination device 5 is determined. It is determined whether or not there is a pile before the start date (today). As a result of this determination, if all the loads are not piled up prior to the start date (Yes), step S7 is executed, while the piled loads are higher than the start date. In the case where there are piles before, step S8 is executed.

  In step S7, the start date constraint satisfaction determination device 5 sets the load load collapse result in the backward load load collapse device 4 as a provisional facility load plan, and step S10 is executed.

  In step S8, the landslide has occurred in step S7 without considering the possible start date, and thus there is a case where the load is piled up in the past from the possible start date, and processing for eliminating this is performed. In other words, in step S8, the forward load crushing device 6 determines an order to carry out a hill-climbing based on the priority inputted from the load crushing priority determination device 3, and the load of the determined order is determined by the time. A virtual landslide that is moved in the forward direction with the flow is performed, and subsequently, in step S9, the virtual landslide is temporarily determined as an equipment load plan.

  More specifically, in the backward load landslide results, in the example shown in FIG. 13, loads loaded on the facilities 1 and 4 are piled before the start date (today). Therefore, step S8 is executed for these. As shown in FIG. 14, all the loads on such equipment are moved after the start date. Here, for example, in the present embodiment, as in the case of the backward load crushing process, the delivery date is used as an index for breaking the load piled up on the same day. Of course, another index may be used. In addition, the order of the facilities that break down the load does not affect the result even if the load of any facility breaks down. In addition, when the prior relationship in the process order of the manufacturing process is not satisfied due to the collapse of the load, the prior relationship constraint is satisfied by adjusting the load of other orders. In this embodiment, for all orders A to K, the start date is set as the first day for convenience, but this start date may be variably set for each order. .

  After all the loads piled up before such a possible start date are collapsed in the forward load, it is determined whether or not the load exceeds the processing capacity of the facility in each facility. When the load exceeds the facility capacity, as described above, the load exceeding the facility capacity is moved to the future (next day) based on the delivery date, and is crushed. After the excess of the load processing capacity is resolved for all the facilities of the day, the same process is executed by advancing one day. For example, in the example shown in FIG. 13, as described above, the load piled on the equipment 1 and the equipment 4 is piled before the start date, so the load of the order D of the equipment 1 and the order of the equipment 4 The load of A is moved to the day when it can be started. If it does so, the load of the order D of the installation 2 in the 1st day shown in FIG. As a result, as shown in FIG. 14, loads of the orders A to K are piled up on the facilities 1 to 4. Here, as can be seen from FIG. 14, the loads on the equipment 4 on the first day and the equipment 2 on the second day exceed the processing capacities of the equipment 4 and 2. For this reason, the load crushing after the start possible date is executed as follows.

  That is, it is determined for all facilities whether the load does not exceed the processing capacity of the facility at the earliest date and time when the load is piled (in the example shown in FIG. 14, the first day). In the example shown in FIG. 14, the load in the facility 4 exceeds its processing capacity. The loads accumulated in the equipment 4 are the order A and the order C. Here, since the delivery date of the order C is later, the load of the order C is moved in the future (second day) as shown in FIG. In the order C, the process of the equipment 4 is the final process in the process 4, and therefore it is not necessary to consider the influence on the other processes of the order C. As a result, for all the facilities on the first day, since there is no facility whose load exceeds its processing capacity, the date and time is advanced one day in the future (the second day is advanced). Such a process is repeated until the accumulated load for all the facilities in all the planning periods does not exceed the processing capacity. In addition, when there is an excess of load in a plurality of processes at the same date and time, load crushing is executed from equipment with a large excess amount. As a result, as shown in FIG. 15, loads of the orders A to K are piled up on the facilities 1 to 4.

  Subsequently, in step S10, whether or not the provisional equipment load plan input from the forward load crushing device 6 by the trouble determination device 7 has a trouble that impedes the execution of the equipment load plan is present. Determined. As a result of this determination, when it is determined that there is no defect in the temporary equipment load plan (when it is determined that the temporary equipment load plan is valid) (No), step S11 is executed. If it is determined that there is a defect in the facility load plan (when it is determined that the provisional facility load plan is not valid) (Yes), step S12 is executed.

  In step S11, the determination result (reasonable result) is input from the defect determination device 7 to the operation constraint relaxation device 8, and the operation load relaxation device 8 sets the forward load mountain break result in the forward load mountain break device 6 as an equipment load plan. Along with this equipment load plan, the operation constraint mitigation device 8 stores the operation constraint stored in the operation constraint storage unit 82, the failure result stored in the failure result storage unit 83, and the load calculation result storage unit 84. The provisional facility load plan that has been made is output to the output device (not shown) by the overall result output unit 85, and this processing is terminated.

  In step S12, a determination result (failure result) is input from the failure determination device 7 to the operation constraint relaxation device 8, and the failure result is stored (stored and stored) in the failure result storage unit 83 by the operation constraint relaxation device 8. Then, the temporary equipment load plan determined to be this failure is stored in the load calculation result storage unit 84, and the operation constraints (FIGS. 11 to 15) used to create the temporary equipment load plan determined to be this failure. 7 (A), FIG. 8 and FIG. 9 (A) are stored in the operation constraint storage unit 82 and used to create a provisional equipment load plan determined to be the malfunction. The new operational constraints (new operational constraints) are created. Then, the process returns to step S1 in order to create an equipment load plan under the newly created new operation constraint.

  For example, in the example shown in FIG. 15, in step S10, the defect determination device 7 compares the delivery date of all orders with the stacking date / time of the final process of the order, and the stacking date / time of the final process of the order C is the third day. On the other hand, the delivery date is the second day, the pile date and time of the final process of order G is the seventh day, while the delivery date is the sixth day, and the pile date and time of the final process of order K is the eleventh day. On the other hand, since the delivery date is the 10th day, it is judged that the accumulation date and time of the final process has passed the delivery date, and the orders of orders C, G, K are not in time for delivery (the delivery date is delayed). In Step S9, it is determined that the provisional facility load plan shown in FIG.

  As a result, step S12 is executed. In step S12, first, the failure result storage unit 83 stores the failure result, the load calculation result storage unit 84 stores the provisional equipment load plan determined as the failure, and the operation constraint storage unit 82 stores the failure. 15 used in the creation of the temporary equipment load plan shown in FIG. 15, the operation constraints shown in FIGS. 7A, 8, and 9 </ b> A (this operation constraint is appropriately referred to as “first operation constraint”). Is called). Then, the operation constraint used to create the provisional equipment load plan determined as the problem by the new operation constraint creation unit 81 is relaxed, and a new operation constraint (new operation constraint) is created. In the example shown in FIG. 15, as described above, since it was determined in step S10 that a defect occurred due to a delivery delay, the new operation constraint creation unit 81 relaxes at least one of the facility processing capacity and the order delivery date. By doing so, a new operation constraint is created.

  More specifically, for example, a case where a new operation constraint is created by relaxing the constraint due to the processing capacity of the facility will be described. First, the new operation constraint creating unit 81 processes the facility in response to the failure result. Identify processes (equipment) that lack capacity. In the example shown in FIG. 15, in the order C in which a defect occurs, the in-process information of the order C is the process 4, and the equipment that processes the process 4 is the equipment 4. The cause is identified as the lack of processing capacity of the facility 4. In the order G in which a defect has occurred, the in-process information of the order G has not yet started. In the provisional equipment load plan, the processes 1 to 4 are processed by the equipment 1 to the equipment 4, and the process 4 is performed based on the delivery date. Or, as can be seen from the results of the landslide process due to the forward load crushing process in the process 1, the equipment 1 to the equipment 3 performs the processing of the order G in a time zone that meets the delivery date by using the standard lead time. Therefore, the cause of the delivery delay of the order G is specified as the lack of processing capacity of the equipment 4 that is processing the process 4. In order K, which has a defect, the in-process information of order K has not yet been started, and in the provisional equipment load plan, process 1 to process 4 are processed by equipment 1 to equipment 4, and based on the delivery date. As can be seen from the results of the landslide process in steps 4 to 1, the equipment 1 to equipment 3 performs processing using the standard lead time in the time zone that meets the delivery date. Therefore, the cause of the delay in delivery of the order K is specified as the lack of processing capacity of the equipment 4 that is processing the process 4. In this way, a process (equipment) in which the processing capacity of the facility is insufficient is identified in response to the failure result. Subsequently, in order to eliminate the delay in delivery due to an order that has not been delayed in delivery without causing a delay in delivery, the degree of relaxation that relaxes the processing capability of the equipment that caused the delivery delay is determined. Again, the processing capacity of the equipment required for each order unit (for each order) is calculated. Then, the maximum value is extracted from the calculated processing capacity of the necessary equipment, and this maximum value is set as the processing capacity of the equipment necessary for solving the problem of delay in delivery. In the example shown in FIG. 15, as described above, it is determined that the processing capacity of the equipment 4 needs to be relaxed for the order C, the processing capacity of the equipment 4 is determined to be relaxed for the order G, and the equipment for the order K It is judged that the processing capacity of No. 4 needs to be relaxed. For order C, order A and order B, which are not delayed in delivery date, without causing a delay in delivery date, in order to eliminate the delay in delivery date, equipment 4 has ordered order A, order B and order C by the second day. Therefore, the necessary processing capacity is 25 ton / day (= 50 ton / 2 day). For order G, order A or order F, which has not been delayed in delivery, in order to eliminate the delay in delivery without causing a delay in delivery, equipment 4 has to add 130 tons of order A through order G by the sixth day. Therefore, the necessary processing capacity is about 21.7 ton / day (= 130 ton / 6day). Then, for order K, order A or order J, which is not delayed in delivery date, without causing a delay in delivery date, in order to eliminate the delay in delivery date, the facility 4 has to change the order A or order J by the 10th day. Since it is necessary to process a total of 210 tons, the necessary processing capacity is about 21 tons / day (= 210 tons / 10 days). Therefore, the maximum value 25 ton / day among these 25 ton / day, about 21.7 ton / day, and 21 ton / day is set as the processing capacity of the equipment necessary for solving the problem of delay in delivery. By such processing, the new operation constraint creating unit 81 appropriately sets the operation constraint shown in FIG. 7B, FIG. 8 and FIG. 9A as the new operation constraint (this operation constraint is referred to as “second operation constraint”). Create a name). Then, the above-described step S1 to step S11 are executed again using the second operation restriction, thereby creating a (non-defective) facility load plan shown in FIG.

  In the above description, the processing capacity of the facility is fixed from the first day to the twelfth day, but this may be variable. When a provisional equipment load plan that does not cause a defect is calculated, it is also possible to calculate the processing capacity of the minimum amount of equipment. In this case, the amount that must be processed for each facility and day is set as the processing capacity of the facility.

  On the other hand, for example, a case where a new operation constraint is created by relaxing the constraint due to the delivery date of an order only for a predetermined date will be described. In this case, the number of days of delay is preset for the degree of relaxation of the delivery date constraint. The order (product) selection method that delays the delivery date differs depending on the order characteristics (characteristics) such as strict delivery date order and pre-production products. It is preferable to set in advance. Here, for example, it is assumed that the number of days of delay is preset to one day, and the delivery date relaxation priority of order B, order F, and order J is preset to be high. Therefore, the new operation constraint creation unit 81 delays the delivery date of order B, order F, and order J by one day, respectively, so that the new operation constraint is shown in FIG. 7 (A), FIG. 8 and FIG. 9 (B). An operation restriction (this operation restriction is appropriately referred to as “third operation restriction”) is created. That is, in the third operation restriction, the delivery date of order B is changed from the second day to the third day, the delivery date of order F is changed from the sixth day to the seventh day, and the delivery date of order J is 10 days. It has been changed from eye to day 11. Then, the above-described step S1 to step S11 are executed again using the third operation restriction, thereby creating a (non-defective) equipment load plan with no defects shown in FIG. In this case, in step S11, not only the first operation constraint and the third operation constraint but also the second operation constraint may be output.

  In the above, the equipment load plan without any problems was created by delaying the delivery date of Order B, Order F, and Order J, which have higher delivery date relaxation priority, by one day, but it was created under the third operation restriction. If there is a defect in the installed equipment load plan, the new operation restriction that gradually relaxes the delivery time constraints such as the fourth new operation restriction and the fifth new operation restriction until the equipment load plan without any trouble is created. Are sequentially created, and the above-described steps S1 to S12 are executed again using the new operation constraints.

  In the above description, the delivery dates of all orders of order B, order F, and order J with high delivery date relaxation priority are delayed, but the delivery date constraints are relaxed one by one, and the above-described steps S1 to S12 are executed again. May be. Note that this case is the same as the case where the delivery date relaxation priority is set finely so that the delivery date relaxation priorities of order B, order F and order J are different from each other.

  Since it operates in this way, the equipment load plan creation device S and the equipment load plan creation method and the equipment load plan creation program implemented in the equipment load plan creation apparatus S in the present embodiment include the created equipment load plan. You can find out if something goes wrong. Then, by visually or audibly outputting the determination result by the output device (not shown), a user such as an operator can recognize that a defect has occurred in the created equipment load plan. Become. The same applies to the recording medium in which the equipment load plan creation program is recorded. The determination result is output by, for example, character output indicating the determination result, repetition of turning on and off, or a voice message indicating the determination result.

  In the above-described embodiment, the operation constraint relaxation device 8 is provided, and when it is determined that there is a defect in the facility load plan, the operation constraint used when creating the facility load plan is relaxed and a new operation is performed. The constraints are automatically created by the operation constraint relaxation device 8. Then, for example, each of the above-described steps S1 to S12 is executed. For this reason, the user is freed from the troublesome work described above, for example, creating an equipment load plan by changing the operation constraints on a trial and error basis. And by creating each equipment load plan under multiple operation constraints, when a problem occurs, multiple equipment load plans can be presented, and the problem has been resolved by more appropriate operation restriction relaxation. The equipment load plan can be selected.

  In the above-described embodiment, the defect determination device 7 determines that a defect exists when the delivery date of the order is not observed. Thus, in this embodiment, the equipment load plan creation apparatus S which determines that a malfunction exists when the delivery date of an order is not observed is provided. For this reason, it is possible to make an equipment load plan that satisfies the delivery date of the order by relieving the operation restrictions by paying attention to the delivery date of the order. In particular, since the equipment load plan creation device S includes the operation restriction mitigation device 8, the user is freed from the complicated work described above in making such equipment load plans.

  Further, in the above-described embodiment, the operation constraint relaxation device 8 creates a new operation constraint by relaxing at least one of the order delivery date and the facility processing capacity. Therefore, by reducing the processing capacity or delivery date, for example, it is possible to create an equipment load plan that complies with the delivery date of the order, and it is possible to select an order that reduces the minimum delivery date.

  Further, in the above-described embodiment, the equipment load plan creation device S includes the load leveling priority determination device 3, and prioritizes the order of loads to be crushed by the backward load leveling device 4. In addition to the setting, the forward load crushing device 6 sets a priority order for the order of the load to be crushed. For this reason, backward load leveling can be executed in order from the highest priority order, and this makes it possible to easily handle orders with strict delivery dates. In addition, forward load crushing can be executed in order from the highest priority order, which makes it possible to easily deal with orders with strict delivery dates.

  In the above-described embodiment, the failure determination device 7 is configured to determine that there is a failure in the provisional facility load plan when the delivery date of the order is not observed. When a predetermined amount cannot be manufactured within a predetermined period set in advance, the provisional equipment load plan may be determined to be defective. With this configuration, it is possible to provide the equipment load plan creation device S that determines that there is a malfunction when a predetermined amount cannot be manufactured within a predetermined period set in advance. For this reason, it is possible to create an equipment load plan that can produce a predetermined amount within the predetermined period by relaxing the operation restrictions by focusing on manufacturing the predetermined amount within the predetermined period. It becomes. In particular, in the configuration in which the equipment load plan creation device S includes the operation restriction mitigation device 8, the user is freed from the complicated work described above in making such equipment load plans. In addition, for example, by reducing processing capacity or delivery time, it becomes possible to create an equipment load plan for manufacturing a predetermined amount within a predetermined period set in advance. It becomes possible to ask for ability.

  For example, in the above-described embodiment, the predetermined period is 10 days, and the predetermined production amount is 210 ton. In the example shown in FIG. 15, the production amount is 200 ton within 10 days of the predetermined period. Yes, since 210 tons of the predetermined production amount cannot be processed, the failure determination device 7 determines in step S10 that there is a failure in the provisional facility load plan.

  For this reason, step S12 is executed. In step S12, the new operation constraint creation unit 81 compares the processing capacity of the equipment for a predetermined period of 10 days with the required processing amount to relax the operation constraint and create a new operation constraint. The processing capacity of a new facility is calculated, and a new operation constraint is created with the calculated processing capacity. In the example shown in FIG. 11, from the equipment information shown in FIG. 7A, the processing capacity of the equipment 1 is 400 ton (= 40 ton × 10 day), and the processing capacity of the equipment 2 is 300 ton (= 30 ton × 10 day). The processing capacity of the facility 3 is 400 ton (= 40 ton × 10 day), and the processing capacity of the facility 4 is 200 ton (= 20 ton × 10 day). On the other hand, the required processing amount is 210 tons. Therefore, it can be seen that the processing capacity of the facility 4 is insufficient. Therefore, the new operation constraint creation unit 81 increases the processing capacity of the equipment 4 to 21 ton / day (= 210 ton / 10day) (5% increase) or more so that the predetermined amount 210 ton can be processed in a predetermined period of 10 days. In addition, for example, 21 ton / day (increase of 5%) which is a necessary minimum processing capacity is relaxed to create a new operation constraint. Using this new operation restriction, the above-described steps S1 to S12 are executed again, and an equipment load plan free from defects is created.

  Moreover, in the above-described embodiment, the backward load collapse destination is basically the past (performs pre-production) from the relevant point in time, and if there are one or more alternative facilities in the target facility, Alternative facilities may be candidates. As a result, it is possible to ease restrictions on the start date of production when backward load crushing is performed, and it is possible to cope with situations where delays in delivery are unavoidable, reducing the occurrence of delays in delivery. it can. When an alternative facility is also a candidate, the load is allowed to be loaded before the available start date calculated from the order reception date (today). At this time, the facility capacity before the start date includes provisionally setting a convenient value (for example, an average value).

  In the above-described embodiment, the forward load collapse destination is basically the future from the corresponding time (the process is deferred), and if there is an alternative facility in the target facility, the alternative facility may be a candidate. This makes it possible to satisfy the constraints on the earliest manufacturing start date when performing forward load crushing. Furthermore, because load crushing is performed along the time axis, it is unlikely that there will be a difference in delivery delays for orders that have delivery dates at the same time, and even if delivery delays occur, leveling of delivery delays will be achieved Can do. And when alternative equipment is also a candidate, it is possible to satisfy the start date restriction by deferring all the loads accumulated before the start date.

  Further, in the above-described embodiment, when a failure (a plurality of types of failures) has occurred in one temporary equipment load plan due to a plurality of causes, it should be solved by, for example, setting a priority in advance. A defect may be selected.

  In order to express the present invention, the present invention has been properly and fully described through the embodiments with reference to the drawings. However, those skilled in the art can easily change and / or improve the above-described embodiments. It should be recognized that this is possible. Therefore, unless the modifications or improvements implemented by those skilled in the art are at a level that departs from the scope of the claims recited in the claims, the modifications or improvements are not covered by the claims. To be construed as inclusive.

S Equipment load plan creation device M Master information storage device 1 Backward load stacking device 2 Overload judgment device 3 Load crushing priority determination device 4 Backward load crushing device 5 Startable day constraint satisfaction judgment device 6 Forward load crushing Device 7 Failure determination device 8 Operation constraint relaxation device 71 Failure discovery unit 81 New operation constraint creation unit 82 Operation constraint storage unit 83 Failure result storage unit 84 Load calculation result storage unit 85 Overall result output unit

Claims (10)

In the equipment load plan creation device that creates equipment load plans when producing multiple products through multiple manufacturing processes,
Based on the delivery date and a predetermined standard lead time set in advance, a work date and time for performing each manufacturing process is determined for each order of the plurality of products based on the delivery date, and each production is performed based on the determined work date and time. A load pile unit that virtually piles the load corresponding to the order quantity for the production of the product into the equipment corresponding to the process;
When the amount of load virtually piled on each facility by the load pile unit exceeds the processing capacity of the facility, the load piled on the facility exceeding the processing capacity is within the processing capacity. In order to do so, a backward load mountain climbing unit that performs virtual mountain climbing, moving to the date and time opposite to the flow of time for each order,
When the date and time after the movement of the load moved by the backward load crushing unit is earlier than the earliest production start date, the load piled before the earliest production start date and time is changed in order of time flow. A forward load hill-climbing unit that moves in the direction date and time
A fault detection unit for determining whether or not there is a fault that hinders the implementation of the equipment load plan in the equipment load plan after the movement of the load moved by the forward load crushing unit. A facility load plan creation device. When it is determined by the defect detection unit that the defect exists, an operation constraint relaxation unit that creates a new operation constraint by relaxing the operation constraint that is a condition to be observed when creating the equipment load plan is further provided. The equipment load plan creation device according to claim 1, comprising: The defect finding unit determines that the defect exists when the equipment load plan after the load moved by the forward load crushing unit does not comply with the delivery date of the order. The equipment load plan creation apparatus according to claim 1 or 2. In the case where the defect finding unit is not able to produce a predetermined amount within a predetermined period set in advance in the equipment load plan after the movement of the load moved by the forward load crushing unit, The equipment load plan creation device according to claim 1, wherein it is determined that a defect exists. The equipment load plan creation device according to any one of claims 2 to 4, wherein the operation constraint relaxation unit creates the new operation constraint by relaxing processing capacity or delivery date. 6. The apparatus according to claim 1, further comprising a priority determination unit that sets a priority order with respect to an order of a load to be crushed by the backward load crumb unit. Equipment load plan creation device of description. 6. The apparatus according to claim 1, further comprising a priority determination unit that sets a priority order with respect to an order of a load to be crushed by the forward load flank unit. 7. Equipment load planning equipment. In an equipment load plan creation method for creating an equipment load plan when producing a plurality of products through a plurality of manufacturing processes,
Based on the delivery date and a predetermined standard lead time set in advance, a work date and time for performing each manufacturing process is determined for each order of the plurality of products based on the delivery date, and each production is performed based on the determined work date and time. Load stacking step for virtually stacking the load corresponding to the order quantity for the production of the product to the equipment corresponding to the process,
When the amount of loads virtually piled on each facility by the load pile step exceeds the processing capacity of the equipment, the load piled on the equipment exceeding the processing capacity is within the processing capacity. In order to do so, a backward load-climbing step that performs a virtual mountain-climbing that moves to the date and time opposite to the flow of time for each order,
If the date and time after the movement of the load moved by the backward load crushing step is earlier than the earliest manufacturing start date, the load piled before the earliest manufacturing start date and time, A forward load hill-climbing step that performs a virtual landslide,
A failure detection step for determining whether or not there is a failure that hinders the implementation of the equipment load plan in the equipment load plan after the movement of the load moved by the forward load crushing step. A featured facility load plan creation method. A facility load plan creation program for creating a facility load plan using a computer when producing a plurality of products through a plurality of manufacturing processes.
Based on the delivery date and a predetermined standard lead time set in advance, a work date and time for performing each manufacturing process is determined for each order of the plurality of products based on the delivery date, and each production is performed based on the determined work date and time. Load stacking function for virtually stacking the load corresponding to the order quantity for the production of products in the equipment corresponding to the process,
When the amount of load virtually piled on each equipment by the load pile function exceeds the processing capacity of the equipment, the load piled on the equipment exceeding the processing capacity is within the processing capacity. In order to do so, a backward load escaping function that performs a virtual landslide that moves to the date and time opposite to the flow of time for each order,
When the date and time after the movement of the load moved by the backward load crushing function is earlier than the earliest production start date, the load piled before the earliest production start date and time is expressed in the order of time flow. A forward load hill-climbing function that performs a virtual landslide,
In order to execute a fault finding function for determining whether or not there is a fault that hinders the implementation of the equipment load plan in the equipment load plan after the movement of the load moved by the forward load crushing function. Facility load planning program. A recording medium for recording a facility load plan creation program for creating a facility load plan using a computer when producing a plurality of products through a plurality of manufacturing processes,
Based on the delivery date and a predetermined standard lead time set in advance, a work date and time for performing each manufacturing process is determined for each order of the plurality of products based on the delivery date, and each production is performed based on the determined work date and time. Load stacking function for virtually stacking the load corresponding to the order quantity for the production of products in the equipment corresponding to the process,
When the amount of load virtually piled on each equipment by the load pile function exceeds the processing capacity of the equipment, the load piled on the equipment exceeding the processing capacity is within the processing capacity. In order to do so, a backward load escaping function that performs a virtual landslide that moves to the date and time opposite to the flow of time for each order,
When the date and time after the movement of the load moved by the backward load crushing function is earlier than the earliest production start date, the load piled before the earliest production start date and time is expressed in the order of time flow. A forward load hill-climbing function that performs a virtual landslide,
In order to execute a fault finding function for determining whether or not there is a fault that hinders the implementation of the equipment load plan in the equipment load plan after the movement of the load moved by the forward load crushing function. A recording medium that records a facility load plan creation program.

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