JP2010257306A - Production plan preparing device, production plan preparation program, and production plan preparation method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To circumvent various inconveniences from being generated accompanying increase in the numerical value of a restraining element, while obtaining advantages by a relatively large numerical value of a promoting element. <P>SOLUTION: A production plan preparing device stores at first, as pieces of basic information, information regarding a period; information about a production route (treatment capacity of each process; lead time between processes, and the like); a facility capacity of each facility (actual operation rate upper limit); production amount limitation information in every period of each of varieties (minimum and maximum production amounts); and sales unit price in each of the varieties, raw material unit price, and the like (S1). The production plan preparing device calculates the facility load distribution rate in each period, referring to the pieces of basic information (S2); calculates a marginal profit ratio of a facility load unit requirement (S3); and temporarily determines the production amount of each period so as to maximize total profit, while satisfying production amount range limitation and facility capacity limitation (S4). The production plan preparation device sets thereafter a numeric value of the maximum value or less of the total profit corresponding to the temporary determination as a lower limit value (S5) and temporarily determines the production amount of each period for minimizing the number of total operation facilities, while satisfying total profit lower limit limitation, in addition to the production amount range limitation and the facility capacity limitation (S6). <P>COPYRIGHT: (C)2011,JPO&INPIT

Description

  The present invention relates to a production plan creation device, a production plan creation program, and a production plan creation method for creating a production plan for a plurality of types of products that are produced via a manufacturing route that is composed of a combination of one or two or more processes. .

  In the processing process of raw materials such as steel, aluminum, copper, etc., a plurality of types of products are produced through a manufacturing route consisting of a combination of one or two or more processes (see Patent Document 1). Here, one or two or more facilities are associated with each process included in the manufacturing route, and even if the same process is performed, the process differs depending on the facility to be used. There will be a route. Therefore, it is often possible to apply two or more manufacturing routes even for the same type of product.

  In Patent Literature 1, considering the degree of freedom of application of various manufacturing routes as described above, the time fluctuations in demand for various products, the facility capacity, etc.・ Technology has been proposed to create a production plan for how much production is to be performed from the viewpoint of maximizing gross profit and total production.

JP 2007-26046 A

  However, with the technology of Patent Document 1, although it is possible to carry out a production plan that maximizes the total profit and the total production volume, it is possible to control the total number of operating equipment, the equipment operating rate of each period, personnel costs, maintenance costs, etc. Factors to be considered are not considered. As a result, even if gross profit and total production volume increase, the inconveniences such as increase in labor costs and maintenance costs necessary for the operation of equipment arise due to the increase in the numerical values of the above-mentioned control factors. obtain.

  An object of the present invention is to provide a production plan creation device, a production plan creation program, and a production plan capable of avoiding various inconveniences associated with an increase in the numerical value of the suppression element while obtaining a merit by a relatively large value of the enhancement element. It is to provide a creation method.

  In order to achieve the above object, according to the first aspect of the present invention, in a production plan creation device for creating a production plan for a plurality of types of products produced through a production route comprising a combination of one or more processes, respectively. , Period storage means for storing information on a period which is a basic unit of time in the production plan, and information regarding one or more manufacturing routes for each of the plurality of types of products, for each process included in each manufacturing route Manufacturing route information storage means for storing the processing capacity and the inter-process lead time; equipment capacity storage means for storing equipment capacity related to equipment used in each step of the manufacturing route for each period; and the plurality of types Production amount constraint information storage means for storing the minimum production amount and the maximum production amount for each of the products, and the production route An equipment load distribution ratio calculating means for calculating the equipment load distribution ratio for each period in the process based on the inter-process lead time, and the production quantity for each period for each of the plurality of types of products is greater than or equal to the minimum production quantity Equipment in which the total equipment load per period in each process of the production route calculated by the production range restriction, the processing capacity and the equipment load distribution ratio is less than the maximum production quantity does not exceed the equipment capacity Each of the production routes for each of the plurality of types of products that satisfies the capacity constraint and the enhancement element lower limit constraint that the numerical value of the enhancement element is equal to or greater than a predetermined lower limit value, while the numerical value of the suppression element is minimized. There is provided a production plan creation device comprising a production amount determination means for determining a production amount for each period in the process.

  According to a second aspect of the present invention, in the production plan creation program for creating a production plan for a plurality of types of products produced through a production route comprising a combination of one or two or more processes, the production plan includes Period storage means for storing information relating to a period which is a unit of time, information regarding one or more manufacturing routes for each of the plurality of types of products, processing capacity and inter-process lead time for each process included in each manufacturing route Manufacturing route information storage means for storing, equipment capacity storage means for storing equipment capacity related to equipment used in each step of the manufacturing route for each period, for each of the plurality of types of products, for each period Production volume constraint information storage means for storing the minimum production volume and the maximum production volume, and the setting for each period in each process of the manufacturing route A facility load distribution ratio calculating means for calculating a load distribution ratio based on the inter-process lead time, and a production amount per period for each of the plurality of types of products is not less than the minimum production amount and not more than the maximum production amount. The production capacity range constraint that the processing capacity and the equipment load distribution ratio are calculated, the equipment capacity constraint that the total equipment load per period in each process of the manufacturing route does not exceed the equipment capacity, and enhancement While satisfying the enhancement element lower limit constraint that the numerical value of the element is equal to or higher than a predetermined lower limit value, the numerical value of the suppression element is minimized, and each period in each step of the manufacturing route for each of the plurality of types of products. There is provided a production plan creation program characterized by causing a computer to function as a production amount determining means for determining a production amount.

  According to a third aspect of the present invention, in the production plan creation method for creating a production plan for a plurality of types of products produced through a production route comprising a combination of one or two or more processes, each using a computer, A period storage step for storing information relating to a period, which is a basic unit of time in a production plan, and a processing capability for each process included in each manufacturing route as information relating to one or more manufacturing routes for each of the plurality of types of products. And a manufacturing route information storage step for storing inter-process lead times, an equipment capability storing step for storing equipment capacities related to equipment used in each process of the manufacturing route for each period, and each of the plurality of types of products. , Production amount constraint information storage step for storing the minimum production amount and the maximum production amount for each period, and the production level Equipment load distribution ratio calculation step for calculating the equipment load distribution ratio for each period in each process based on the inter-process lead time, and the production amount for each period for each of the plurality of types of products The facility total load for each period in each process of the manufacturing route calculated by the production range constraint that the minimum production amount is equal to or less than the maximum production amount, the processing capacity and the equipment load distribution ratio is the equipment capacity. For each of the plurality of types of products, the numerical value of the suppression element is minimized while satisfying the facility capacity constraint that it does not exceed and the enhancement element lower limit constraint that the numerical value of the enhancement element is equal to or greater than a predetermined lower limit value. Production comprising: causing the computer to execute a production amount determination step for determining a production amount for each period in each process of a manufacturing route. Image creation method is provided.

  According to the first to third aspects, it is possible to determine the production amount in each period such that the numerical value of the suppression element is minimized while keeping the numerical value of the enhancement element at or above the predetermined lower limit value due to the enhancement element lower limit constraint. . This avoids various inconveniences (for example, inconveniences such as increased labor costs, maintenance costs, etc. necessary for operating the equipment) while gaining the benefits of relatively large values of enhancement factors. It becomes possible to do.

  Here, “equipment capacity” refers to an element related to the time that can be spent for net processing in each facility. “Processing capacity” refers to an element relating to the weight of a product that can be processed in each step. The “total equipment load” refers to the sum of the time spent for the net processing in each equipment for each period.

  The production plan creation device according to the present invention includes each step of the production route for each of the plurality of types of products such that the numerical value of the enhancement element is maximized while satisfying the production volume range restriction and the equipment capacity restriction. The production amount deciding means for tentatively deciding the production quantity for each period in the period is further provided, and the production quantity deciding means is a numerical value of the enhancement factor corresponding to the tentative decision after the provisional decision by the production quantity tentative decision means The production amount may be determined using the following numerical value as the lower limit value. In this case, after the provisional determination by the production amount provisional determination unit, the production amount determination unit makes a determination based on the result of the provisional determination (maximum value of the enhancement factor). Therefore, for example, by setting a numerical value close to the maximum value that is equal to or slightly smaller than the maximum value of the enhancement factor based on the provisional decision as the lower limit value, it is possible to sufficiently benefit from the relatively large value of the enhancement factor. Obtainable.

  In the production plan creation device according to the present invention, the production amount provisional determination means may provisionally determine the production amount by a linear programming method. According to this configuration, even when there are many types of products and equipment, it is possible to efficiently perform processing related to the production amount determination at high speed.

  In the production plan creation apparatus according to the present invention, the facility load distribution ratio calculation means is processing time for each process of the manufacturing route by the manufacturing lead time that is the sum of the inter-process lead times from the final process to the process. May be moved in the past direction, and an equipment load distribution ratio proportional to the length included in each period of the processing time after the movement may be calculated. In this case, it is possible to calculate a more realistic value of the equipment load distribution ratio on the premise that processing is performed in advance in the respective steps of the manufacturing route by the manufacturing lead time. In addition, even when the manufacturing lead time or period is changed, it is possible to perform the process relating to the production amount determination relatively easily.

  The production plan creation device according to the present invention stores a raw material price / sales price storage means for storing a raw material price and a selling price for each of the plurality of types of products, and stores information relating to a cost generated in each process of the manufacturing route Cost enhancement means, and the enhancement factor may be a total profit calculated based on information on the raw material price, the selling price, and the generated cost. Here, “gross profit” refers to the sum of profits for each period for all types of products. According to this configuration, it is possible to apply two or more production routes for the same type of product, and the profits as a whole even under complicated conditions such as raw material prices of various products and information on the costs generated in each process of the production route are different. The production plan can be made so that becomes large.

  In the production plan creation device according to the present invention, the enhancement element may be a total production amount. Here, the “total production amount” refers to the sum of production amounts for each period for all types of products. According to this configuration, it is possible to apply two or more manufacturing routes for the same type of product, and the overall production amount increases even under complicated conditions such as different types of equipment used in each process of the manufacturing route. As such, production planning can be performed. In addition, for example, from the strategic point of view of securing a market share, it is possible to make a production plan that emphasizes the total production volume.

  In the production plan creation device according to the present invention, the suppression element may be the total number of operating facilities. Here, the “total number of operating facilities” refers to the total number of operating facilities for each period. According to this configuration, it is possible to apply two or more production routes for the same type of product, and suppress the total number of operating facilities even under complicated conditions such as different types of equipment used in each process of the production route, As a result, labor costs, maintenance costs, etc. necessary for operating the facilities can be reduced.

  The total number of operating facilities may be calculated with a predetermined weight depending on the priority of the facilities. In this case, a production plan can be performed in consideration of the priority of the equipment.

  The production plan creation program according to the present invention causes a computer to function as the production plan creation device according to the present invention, and is a removable recording medium such as a DVD-ROM, CD-ROM, FD (flexible disk), or MO. In addition to being able to be recorded on a fixed recording medium such as a hard disk or distributed, it can be distributed via a communication network such as the Internet by wired or wireless telecommunication means.

  According to the present invention, various inconveniences associated with an increase in the numerical value of the suppression element (for example, inconveniences such as increase in labor cost, maintenance cost, etc. necessary for operation of the equipment) while obtaining the advantage of the relatively large numerical value of the enhancement element Can be avoided.

It is explanatory drawing which shows the processing process from the raw material made into object in one Embodiment of this invention to product shipment. It is a flowchart which shows the production plan preparation program which the production plan preparation apparatus which concerns on one Embodiment of this invention performs. It is explanatory drawing for demonstrating the specific calculation example of an equipment load distribution ratio.

  Hereinafter, preferred embodiments of the present invention will be described with reference to the drawings.

  FIG. 1 is an explanatory diagram showing a processing process from raw materials to product shipment, which is a target in an embodiment of the present invention. Here, five types of equipment M01, M02, M03, M04, and M05 are prepared, and the equipment used for each process included in each manufacturing route is different (see Table 4). Products being manufactured (ie, intermediate products) and finished products (hereinafter, intermediate products and finished products are collectively referred to as “products”) are stored in a buffer as necessary.

  Table 1 is a table showing applicable manufacturing routes and the like for each product type (product type). Here, five types of A01 to A05, No. There are 15 manufacturing routes 1 to 15, and three manufacturing routes are assigned to each product type. For example, no. Three manufacturing routes of 7, 8, and 9 are applicable. In the table, the sales unit price (sales price per ton of product) and the raw material unit price (price per ton of raw material) are registered for each type.

  Tables 2 and 3 are tables showing the minimum production amount and the maximum production amount for each month of January to May for each product type. The minimum production amount is a lower limit value of the amount to be produced, and the maximum production amount is an upper limit value of the production amount that cannot be stored or sold even if it is produced any more. In the production planning apparatus of this embodiment, as will be described in detail later, the production amount of various products is determined so as to be not less than the minimum production amount and not more than the maximum production amount.

  Table 4 is a table showing details of each manufacturing route. No. In each of the manufacturing routes 1 to 15, various products are manufactured through the first to third steps shown in Table 4 in this order. In the table, the type of equipment used (M01 to M05), the weight of products that can be processed in 1 hour (processing capacity), and the weight of products on the exit side and entry side of the equipment for each process of each production route Ratio (process yield), cost required for processing for 1 hour (variable cost), lead time from the process to the next process (until shipping in the case of the final process) (inter-process lead time), and manufacturing The product type (product type: corresponding to Table 1) is registered. For example, the manufacturing route No. In the first process of 1, the equipment M01 is used to manufacture the intermediate product of the product type A01, and 2.0 tons can be processed in 1 hour. 10 tons of input is required for processing (2 tons of this difference is discarded as a defective part). In addition, the manufacturing route No. 1, it takes two days as a lead time from the first step to the second step.

  Next, a production plan creation program executed by the production plan creation apparatus according to the embodiment of the present invention will be described with reference to FIG.

  The production plan creation apparatus according to the present embodiment is configured by, for example, a general-purpose personal computer, and includes a controller including a CPU (Central Processing Unit), ROM, RAM, and the like, and an interface. Data input to the controller and data output from the controller are performed via an interface. An input device such as a keyboard for data input and an output device such as a display for data output may be connected to the interface. A production plan creation program (see FIG. 2) according to an embodiment of the present invention is stored in the ROM of the controller, and various information (Tables 1 to 9) for executing the program is stored in the RAM of the controller. Etc.) is stored. The CPU of the controller performs each process shown in FIG. 2 while reading various programs from the RAM after reading the program from the ROM. That is, S1 to S7 described below are processes executed by the controller of the production plan creation apparatus according to the present embodiment.

  First, the controller stores the basic information input via the interface in the RAM (S1). Here, “basic information” means “information about period”, “information about manufacturing route”, “actual capacity upper limit value” of various facilities, “production restriction information” for each period for each type, This includes sales unit prices and raw material unit prices.

  The term “period” refers to a basic unit of time in the production plan, and in this embodiment is one month. In the present embodiment, as “information relating to the manufacturing route”, the manufacturing route number assigned to each product type (see Table 1), the equipment used, the processing capacity, the process yield, the variable cost for each process in each manufacturing route, In addition, the inter-process lead time (refer to the columns of “equipment”, “processing capacity”, “process yield”, “variable cost”, and “inter-process lead time” for each process in Table 4) is stored. Here, the “variable cost” is information relating to the generated cost, and in the present embodiment, means a cost required for one hour of processing for each process in each manufacturing route. The “actual operation rate upper limit value” is information relating to the facility capacity, and in this embodiment, the “actual operation rate upper limit value” of all types of facilities M01 to M05 is stored as 100%. “Production volume constraint information” refers to the minimum production volume and the maximum production volume (see Tables 2 and 3). In the present embodiment, the “sales unit price / raw material unit price” stores the selling price per ton of product and the price per ton of raw material (see Table 1).

  The “actual operation rate” refers to a ratio of time (actual operation time) spent for net processing excluding preparation and maintenance time to the total operation time of the facility. The “actual work rate upper limit value” is the upper limit value of the actual work rate, and may be determined statistically from the actual performance of the equipment. For example, when the working rate is 80%, it means that 19.2 hours are spent for net processing in the day, and the remaining time is spent for preparation and maintenance.

  After S1, the controller calculates the facility load distribution ratio for each period (each month) for each process of each manufacturing route while referring to various data stored in the RAM (S2). Then, the controller stores the calculation result in the RAM.

Here, a specific calculation example of the equipment load distribution ratio will be described with reference to FIG. FIG. 3 shows an example of the distribution of processing time until shipping through the first to third steps in a certain manufacturing route. The example shown in FIG. 3 is an example for explaining the calculation example of S2, and the period from the first step to the shipment, the processing time in each step, etc. are shown in each table such as Table 1 and Table 4. Different from the example. In this example, from the first step to shipment, a month, b month, and c month (where a = b-1 = c-2, 3 ≦ c ≦ 12, a, b, and c are natural numbers) are 3 months. The number of days Da, Db, Dc in each month of month a, month b, month c is all 30 days. In addition, it is assumed that the shipment is performed evenly in the month c, and the process in each process is performed at the same pitch as the shipment and precedes the lead time between processes. L1, L2, and L3 are inter-process lead times of the first, second, and third steps, respectively. The hatched portion in FIG. 3 indicates the processing time in each step. When calculating the equipment load distribution ratio for each period (each month) for each process of the first to third processes of the production route shown in this example, for example, in the first process, the equipment load distribution ratios r1a and b for a month The equipment load distribution ratio r1b for the month is calculated by the following formulas (1) and (2). In the example of FIG. 3, in S2, the equipment load distribution ratio r2b for the second month and the equipment load distribution ratio r2c for the second month for the second process, and the equipment load distribution ratio r3b and c for the third month for the third process. Calculation is also performed for the facility load distribution ratio r3c for the month.
r1a = (L1 + L2 + L3-Db) / Dc (1)
r1b = (Dc- (L1 + L2 + L3-Db)) / Dc (2)

  Table 5 shows the calculation result of the equipment load distribution ratio for each period (each month) for each process of each production route based on the example shown in Table 4. In this example, as shown in Table 4, since the sum of the inter-process lead times for each process is shorter than one month in all the manufacturing routes, the facility load distribution ratio is T month and T-1 month (where, 2 ≦ T ≦ 12, where T is a natural number).

  After S2, the controller calculates the equipment load basic unit of each period (each month) and the marginal profit rate of each manufacturing route for each process of each manufacturing route while referring to various data stored in the RAM. (S3). Then, the controller stores the calculation result in the RAM.

  “Equipment load intensity” refers to the time required to produce 1 ton of product in each process (each facility). The basic unit of equipment load for each period (each month) is calculated by the product of "load in the relevant process required for production of 1 ton of product" and "equipment load distribution ratio for the relevant month" calculated in S2. . Here, “the load in the process required for the production of 1 ton of product” is “the time in the process required for the production of 1 ton of product (the reciprocal of the“ processing capacity ”stored in S1)” and “product 1 It is calculated by the product of the raw material weight required for production of tons (value obtained from the “process yield” stored in S1). For example, based on the calculation result of the equipment load distribution ratio shown in Table 5, when calculating the equipment load basic unit for each period (each month) of T month and T-Jan, Numerical values shown in each column.

  “Marginal profit rate” refers to the profit obtained by selling 1 ton of product. The “marginal profit rate” is calculated by subtracting the sum of “raw material price per ton of product” and “generated cost per ton of product” from “unit sales price”. Here, the “sales unit price” is the value stored in S1 (see Table 1). The “raw material price per ton of product” is calculated by the product of “raw material unit price” stored in S1 and “raw material weight required for production of 1 ton of product”. The “generated cost per ton of product” is calculated by the sum of “generated cost basic unit in each process (generated cost required for production of 1 ton of product)”. “Generated cost unit in each process” includes, for example, “raw material weight required for production of 1 ton of product (value obtained from“ process yield ”stored in S1)” and “the process required for production of 1 ton of product” Time (reciprocal of “processing capacity”) ”and the cost required for one hour of processing (“ variable cost ”in Table 4).

  Table 5 shows the specific calculation results of the “marginal profit ratio”, and the above “per unit of cost generated in each process”, “cost generated per tonne of product” and “per unit tonne of product” “Raw material prices” are also shown.

  After S3, the controller tentatively determines the production amount of each period (each month) in each production route for each product type by linear programming while referring to various data stored in the RAM (S4). Then, the controller stores the temporary determination result in the RAM.

  In S4, the “production range restriction” that the production amount in each period (each month) is not less than the minimum production amount and not more than the maximum production amount, and the total equipment for each period (each month) in each process (each facility) The production amount of each period (each month) is tentatively determined so that the total profit is maximized while satisfying the “equipment capacity constraint” that the load does not exceed the equipment capacity. Here, the “total equipment load” is calculated from the “basic equipment load” calculated in S3. “Does not exceed the facility capacity” means that in this embodiment, the “actual working time” determined by the “actual operation rate upper limit value” stored in S1 is not exceeded. “Gross profit” refers to the sum of profit for each period (month) for all types of products, and is calculated from the “marginal profit rate” calculated in S3.

  S4 is performed based on the following equation. Here, as described above, since the term is one month (30 days) and the upper limit of the actual work rate is 100% in all types of equipment, the actual workable time in each month is 720 hours in all types of equipment.

  Table 6 shows an example of each period (each month) production amount provisionally determined in S4. Table 7 shows the operating rate of each facility (each month) corresponding to the numerical values in Table 6. From Table 6, “Production range constraint” is satisfied (that is, the production amount in each period (each month) in each production route is not less than the minimum production amount and not more than the maximum production amount shown in Tables 2 and 3) I understand). In addition, it can be seen from Table 7 that the “equipment capacity constraint” is satisfied (that is, the operating rate of each facility (each month) does not exceed 100%).

  After S4, the controller sets a value obtained by multiplying the total profit calculated in S4 by 0.99 as a “total profit lower limit value” and stores it in the RAM (S5). Here, when the production volume tentatively determined in S4 is the value shown in Table 6, the gross profit calculated from the sales unit price shown in Table 1 and the generated cost and raw material price shown in Table 5 is “103329.78 thousand. "Yen". Therefore, in S5, a value (= 102296.48 thousand yen) obtained by multiplying "1033299.778 thousand yen" by 0.99 is set as the "total profit lower limit value".

  After S5, in addition to the above-mentioned “production range constraint” and “equipment capacity constraint”, the controller satisfies the “total profit lower limit constraint” in which the total profit becomes equal to or greater than the total profit lower limit set in S5. The production amount of each period (each month) in each production route for each product type that minimizes the total number of operating facilities is determined (S6). Here, the “total number of operating facilities” refers to the total number of facilities operating in each period.

  S6 is performed based on the following equation. Here, as described above, since the term is one month (30 days) and the upper limit of the actual work rate is 100% in all types of equipment, the actual workable time in each month is 720 hours in all types of equipment.

  Table 8 shows an example of production amount for each period (each month) determined in S6. Table 9 shows the operating rate of each facility (each month) corresponding to the numerical values in Table 8. From Table 8, “Production range constraint” is satisfied (that is, the production amount in each period (each month) in each manufacturing route is not less than the minimum production amount and not more than the maximum production amount shown in Tables 2 and 3). I understand). In addition, it can be seen from Table 9 that the “equipment capacity constraint” is satisfied (that is, the operating rates of each period (each month) of various facilities do not exceed 100%). Further, in this example (that is, when the production amount determined in S6 is the value shown in Table 8), the gross profit is “102296.48 thousand yen”, which is equal to the lower limit value of the gross profit set in S5, It can be seen that the "gross profit lower limit" is satisfied.

  Here, with reference to Table 7 and Table 9, the operation rate based on S4 (provisional decision) and S6 (decision) will be compared. In Table 7 (tentatively determined occupancy rate), all types of equipment are expected to operate during the entire period (all months). (Moon) (the facility M01 is not in operation in April and May). That is, in S6 (determination), the production amount is determined so that the total number of operating facilities is smaller than in S4 (provisional determination).

  After S6, the controller outputs the result of S6 to an output device such as a display or a printer via the interface (S7). As a result to be output, in addition to the production amount in each period (each month) in each production route for each product type determined in S6, data determined depending on the determination in S6 (equipment operating rate in each period (each month)) , Total operating equipment, equipment load status, etc.).

  As described above, according to the production plan creation apparatus according to the present embodiment, the “total number of operating facilities” is minimized while keeping the total profit at or above the lower limit set in S5 due to the “total profit lower limit constraint”. The production amount of each period can be determined. As a result, while taking advantage of a relatively large value of “total profit”, various inconveniences associated with the increase in “total number of operating facilities” (for example, increase in labor costs, maintenance costs, etc. necessary for operating equipment) Inconvenience) can be avoided.

Moreover, according to the production plan creation device according to the present embodiment, the following effects can also be obtained. That is,
By storing the minimum production amount and the maximum production amount of each product for each period as “production amount constraint information” (S1), it is possible to appropriately cope with fluctuations in demand.
-By calculating the equipment load distribution ratio based on the inter-process lead time (S2), due to the difference in the manufacturing lead time (total of the inter-process lead times from the final process to the process) in each process of the manufacturing route Therefore, it is possible to appropriately cope with the fluctuations in the equipment load over time.
The equipment load for each period is determined subordinately by determining the production amount for each period of various products (S6). In such a case, it is possible to create a production plan at a higher speed than in the case where the calculation is performed using the equipment load for each period as a decision variable.

In addition, according to the production plan creation device according to the present embodiment, specifically, the following production plan can be performed. For example,
-For a certain product, for example, from the strategic point of view of securing market share, the minimum production value can be reduced and the minimum production volume can be increased to make the production of the product more than a certain level. . For the remaining types of products, an appropriate production amount can be determined within the range of the remaining capacity.
・ By setting the maximum production volume, it is possible to prevent the production of excessive quantities that cannot be sold or stored.
-By making the minimum production volume and the maximum production volume of a certain period the same for a certain product, it is possible to determine the production volume in that period to be a constant value. For the remaining types of products, an appropriate production amount can be determined within the range of the remaining capacity.

  Furthermore, the production plan creation apparatus according to the present embodiment sets a numerical value equal to or lower than the value of the gross profit corresponding to the temporary decision S4 in S5 after S4 (provisional decision), and then in S6. Determine production volume. Therefore, a numerical value close to the maximum value that is equal to or slightly smaller than the maximum value of the total profit based on the provisional determination in S4 (in this embodiment, a value obtained by multiplying the total profit calculated in S4 by 0.99). By setting as the lower limit value, it is possible to sufficiently obtain a merit due to a relatively large numerical value of the total profit.

  The production plan creation device according to the present embodiment performs S4 (provisional determination) by linear programming. As a result, even when there are many types of products and equipment, it is possible to perform processing relating to the production amount determination efficiently and at high speed.

  As can be seen from FIG. 3, the production plan creation device according to the present embodiment is the sum of the inter-process lead times from the final process to the process for each process in the manufacturing route in S2 (calculation of the equipment load distribution ratio). The processing time is moved in the past direction by a certain manufacturing lead time, and the equipment load distribution ratio proportional to the length included in each period of the processing time after the movement is calculated. In this case, it is possible to calculate a more realistic value of the equipment load distribution ratio on the premise that processing is performed in advance in the respective steps of the manufacturing route by the manufacturing lead time. In addition, even when the manufacturing lead time or period is changed, it is possible to perform the process relating to the production amount determination relatively easily.

  In S1, the production plan creation apparatus according to the present embodiment, in S1, information on raw material prices and sales prices (in this embodiment, raw material unit prices and sales unit prices) for each of a plurality of types of products, and information on costs generated in each process of the manufacturing route (this book In the embodiment, the variable cost) is stored. In S4, provisional determination is performed so that the “gross profit” calculated based on the information on the raw material price, the sales price, and the generated cost stored in S1 is maximized. As a result, it is possible to apply two or more manufacturing routes for the same type of product, and the overall profit is large even under complicated conditions such as different information on raw material prices of various products and generated costs in each process of the manufacturing route. The production plan can be performed as follows.

  In S6, the production plan creation apparatus according to the present embodiment makes a determination so that the “total number of operating facilities” is minimized. As a result, two or more manufacturing routes can be applied to the same type of product, and the total number of operating facilities can be reduced even under complicated conditions such as different types of equipment used in each process of the manufacturing route. Labor costs, maintenance costs, etc. necessary for operation of the system can be reduced.

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

  For example, in the above-described embodiment, as shown in Table 1, the sales unit price and the raw material unit price of each type are constant regardless of the manufacturing route and time, but may vary depending on the manufacturing route and time.

  In the above-described embodiment, as shown in Table 4, the number of steps is set to three (first to third steps) in all the manufacturing routes, but not limited to this, the number of steps is changed for each manufacturing route, etc. Various process designs are possible.

  The expressions shown in S2 to S6 are examples, and calculations may be performed by various other methods.

  Steps S4 and S5 are not essential requirements of the present invention and can be omitted.

  The “lower limit value of the enhancement element” is set in S5 based on the result of provisional determination in S4 in the above-described embodiment (that is, automatically set by calculation), but is not limited thereto. For example, the user may input an appropriate value as the lower limit value through the interface of the production plan creation apparatus.

  As the “equipment capacity”, the “actual operation rate upper limit value” is exemplified in the above-described embodiment, but the present invention is not limited to this, and various other standards can be used as long as they are standards related to the time that can be spent on net processing in each equipment. Applicable elements. The “equipment capacity” may depend not only on the equipment but also on the period.

  As the “processing capacity”, in the above-described embodiment, “weight of a product that can be processed in one hour” is exemplified, but the present invention is not limited to this, and if it is an element related to the weight of a product that can be processed in each step, Various other factors can be applied, such as the weight of a product that can be processed per day instead of one hour.

  In the above-described embodiment, “gross profit” is exemplified as the “enhancement factor”. However, the present invention is not limited to this, and “total production amount (sum of production amounts per period for all types of products)”, “ Various other factors that should be improved are applicable, such as “both gross profit and total production” and “total sales (sum of sales of all types of products for each period)”. In addition, when “both gross profit and total production volume” are set as “improvement factors”, a production plan that takes into account the balance between the two may be performed by weighting the total profit and total production volume. .

  By applying “total production” as an “enhancement factor”, it is possible to apply two or more production routes for the same type of product, and the complicated conditions that the types of equipment used in each process of the production route are different. In this case, the production plan can be performed so that the overall production amount becomes large. In addition, for example, from the strategic point of view of securing a market share, it is possible to make a production plan that emphasizes the total production volume. In the case where “total production” is set as “enhancement factor”, the evaluation formula shown in the above equation 1 may be replaced with the following formula, for example.

  In the above-described embodiment, “total number of operating facilities” is exemplified as “suppressing element”, but is not limited to this, and “total operating facility rate (sum of facility operating rates in each period)”, “total personnel” Costs (sum of labor costs associated with equipment operation in each period) "," total maintenance expenses (sum of maintenance expenses associated with equipment operation in each period) "," combination of these ", and other various values that should be suppressed The element can be applied. In addition, a production plan may be performed in consideration of balance by adding weights. Here, when the “total number of operating facilities” calculated with a predetermined weight according to the priority of each facility is used as the “suppression factor”, the evaluation formula shown in the above formula 2 is replaced with one of the following two formulas, for example: do it. In Equation 4, the priority of each facility is constant regardless of the time, but in Equation 5, the priority of each facility is varied depending on the time.

  The “period”, which is a basic unit of time in the production plan, is not limited to one month, and can be set in various ways such as one day, one week, and one year.

  The production plan creation program according to the present invention may be written in a read-only manner in a storage unit of a computer as a production plan creation device, or recorded on a removable recording medium such as a CD-ROM when necessary. It may be read and written to the storage unit, or may be transmitted via an electric communication line such as the Internet and written to the storage unit.

S1 Basic information storage step (period storage means, production route information storage means, equipment capacity storage means, production volume constraint information storage means, raw material price / sales price storage means, generated cost storage means)
S2 Equipment load distribution ratio calculation step (equipment load distribution ratio calculation means)
S3 Equipment load basic unit / marginal profit rate calculation step S4 Temporary determination step of production volume
S5 Total profit lower limit setting step S6 Production amount determination step (Production amount determination means)
S7 Result output step

Claims (10)

In a production plan creation device that creates a production plan for a plurality of types of products that are produced via a production route that consists of a combination of one or two or more processes,
A period storage means for storing information relating to a period which is a basic unit of time in the production plan;
Manufacturing route information storage means for storing processing capability and inter-process lead time for each process included in each manufacturing route as information on one or more manufacturing routes for each of the plurality of types of products;
Equipment capacity storage means for storing equipment capacity related to equipment used in each step of the manufacturing route for each period;
Production amount constraint information storage means for storing the minimum production amount and the maximum production amount for each period for each of the plurality of types of products,
Equipment load distribution ratio calculating means for calculating the equipment load distribution ratio for each period in each process of the manufacturing route based on the inter-process lead time;
The production route calculated by the production amount range restriction that the production amount for each of the plurality of types of products is not less than the minimum production amount and not more than the maximum production amount, the processing capacity and the equipment load distribution ratio. The numerical value of the suppression element while satisfying the equipment capacity constraint that the total equipment load per period in each step of the process does not exceed the equipment capacity and the enhancement element lower limit constraint that the numerical value of the enhancement element is equal to or greater than a predetermined lower limit value A production plan creation device, comprising: a production amount determination means for determining a production amount for each period in each step of the production route for each of the plurality of types of products such that the product is minimized. Tentatively determine the production volume for each period in each step of the production route for each of the plurality of types of products so that the numerical value of the enhancement factor is maximized while satisfying the production volume range constraint and the equipment capacity constraint Further comprising provisional means for temporarily determining production volume,
The production amount determining means, after the provisional determination by the production amount provisional determination means, determines the production amount with a numerical value equal to or less than the numerical value of the enhancement element corresponding to the provisional determination as the lower limit value. The production plan creation device according to claim 1.   3. The production plan creation apparatus according to claim 2, wherein the production amount provisional determination means provisionally determines the production amount by a linear programming method.   The facility load distribution ratio calculation means moves the processing time in the past direction by the manufacturing lead time that is the sum of the inter-process lead times from the final process to the process for each process of the manufacturing route, and after the movement The production plan creation device according to claim 1, wherein an equipment load distribution ratio proportional to a length included in each period of the processing time is calculated. Raw material price / sales price storage means for storing raw material prices and sales prices for each of the plurality of types of products;
Further comprising generated cost storage means for storing information on the generated cost in each process of the manufacturing route,
The production plan according to claim 1, wherein the enhancement factor is a gross profit calculated based on information on the raw material price, the sales price, and the generated cost. Creation device.   The production plan creation device according to claim 1, wherein the enhancement element is a total production amount.   The production plan creation device according to claim 1, wherein the suppression element is the total number of operating facilities.   The production plan creation apparatus according to claim 7, wherein the total number of operating facilities is calculated by adding a predetermined weight according to the priority of the facilities. In a production plan creation program for creating a production plan for a plurality of types of products that are produced via a production route that consists of a combination of one or more processes,
A period storage means for storing information relating to a period which is a basic unit of time in the production plan;
Manufacturing route information storage means for storing processing capability and inter-process lead time for each process included in each manufacturing route as information on one or more manufacturing routes for each of the plurality of types of products,
Equipment capacity storage means for storing equipment capacity related to equipment used in each step of the manufacturing route for each period,
Production amount constraint information storage means for storing the minimum production amount and the maximum production amount for each period for each of the plurality of types of products,
Equipment load distribution ratio calculating means for calculating the equipment load distribution ratio for each period in each process of the manufacturing route based on the lead time between processes, and
The production route calculated by the production amount range restriction that the production amount for each of the plurality of types of products is not less than the minimum production amount and not more than the maximum production amount, the processing capacity and the equipment load distribution ratio. The numerical value of the suppression element while satisfying the equipment capacity constraint that the total equipment load per period in each step of the process does not exceed the equipment capacity and the enhancement element lower limit constraint that the numerical value of the enhancement element is equal to or greater than a predetermined lower limit value A production plan creation program for causing a computer to function as a production amount determination means for determining a production amount for each period in each step of the production route for each of the plurality of types of products such that the product is minimized. In a production plan creation method for creating a production plan for a plurality of types of products produced through a production route consisting of a combination of one or more processes, each using a computer,
A period storage step for storing information relating to a period that is a basic unit of time in the production plan;
A manufacturing route information storage step for storing processing capability and inter-process lead time for each process included in each manufacturing route as information relating to one or more manufacturing routes for each of the plurality of types of products,
A facility capacity storage step for storing facility capacity related to facilities used in each process of the manufacturing route for each period,
Production amount constraint information storage step for storing the minimum production amount and the maximum production amount for each of the plurality of types of products,
An equipment load distribution ratio calculating step for calculating an equipment load distribution ratio for each period in each process of the manufacturing route based on the inter-process lead time; and
The production route calculated by the production amount range restriction that the production amount for each of the plurality of types of products is not less than the minimum production amount and not more than the maximum production amount, the processing capacity and the equipment load distribution ratio. The numerical value of the suppression element while satisfying the equipment capacity constraint that the total equipment load per period in each step of the process does not exceed the equipment capacity and the enhancement element lower limit constraint that the numerical value of the enhancement element is equal to or greater than a predetermined lower limit value A production plan creation method that causes the computer to execute a production amount determination step for determining a production amount for each period in each step of the production route for each of the plurality of types of products such that .