JP2012168746A - Work load leveling device and work load leveling method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To quickly draft a production plan by shortening the duration of processing for determining a schedule of a manufacturing process whose work loads are leveled without exerting influence on a design schedule.SOLUTION: A work load leveling device 1000 includes: a load calculating part 210 and a capability calculating part 220 for calculating the work load and the capability of each process, respectively; a bottleneck process specifying part 230 for specifying a bottleneck process in which an amount of surpassing the capability by the work load becomes the largest in each work object; a bottleneck process leveling part 240 for leveling the load of each work object accumulated about the bottleneck process; and a non-bottleneck process schedule changing part 250 for determining a deadline date for a non-bottleneck process precedent to the bottleneck process in accordance with a change in a deadline date of the bottleneck process by the bottleneck process leveling part 240 so as to sequentially make the load of the non-bottleneck equal to or lower than the capability from the first process side and also to make the deadline date be included within a range between the longest lead time and the shortest lead time of the non-bottleneck process.

Description

  The present invention relates to a work load leveling apparatus and a work load leveling method suitable for production management of products that are designed and produced in order such as plant equipment.

  For products that are designed and produced after receiving an order, a work schedule for each process of design and manufacturing is determined for each product, and the design and production of the product is advanced according to the work schedule. When planning this work schedule, the site design capacity, production capacity, and workload are usually calculated every predetermined number of days such as weekly or monthly, and the work schedule is set so that the load of each process does not exceed the capacity. Determined. At this time, when a process in which the load exceeds the capacity (hereinafter referred to as a neck process) occurs, the work load is leveled while changing the work schedule.

  If the workload is leveled, there is a possibility that the schedule interval between the preceding and succeeding steps may be shortened or lengthened due to the change of the work schedule of the neck process. In addition, a waiting time for the next process and an in-process inventory increase, a production delay of the product occurs, and further, the quality of the product is deteriorated.

  Patent Document 1 discloses an example of a production management system that changes a schedule of a non-neck process after a schedule change of a neck process. In the production management system, three lead times, the longest lead time, the shortest lead time, and the standard lead time, are set for each process. When changing the work schedule of the neck process, the work schedule of each process The work schedule of each process is changed so that it is within the range of the longest and shortest lead time and the work load of each process does not exceed the capacity.

JP 2004-30200 A

  By the way, in products that are designed and produced in order, there are frequent cases in which the delivery date and design specifications of the product are changed after the start of product design, or the design work is delayed. In such a case, the work schedule is also changed at the production site, the load of each process fluctuates, and as a result, a process in which the load exceeds the capacity also appears. Therefore, the process manager is required to appropriately perform the work load leveling even when the product design work is in progress.

  According to the workload leveling method disclosed in Patent Document 1, when there is a neck process in which the load exceeds the capacity, the load on the neck process schedule is reduced by the crushed processing of the load in the neck process. Will be changed as follows. In addition, if the lead time of the non-neck process before and after the neck process is shorter than the set shortest lead time or longer than the longest lead time due to the crushing process of the neck process, the schedule of the non-neck process Is moved forward or backward so that it is within the range of the shortest lead time and not longer than the longest lead time, and matches the schedule of the start timing of the apparatus.

  That is, the schedule of the non-neck process is sequentially matched from the neck process to the upstream or downstream, and the start timing of the equipment, etc., matches the lead time of the non-neck process between the shortest lead time and the longest lead time. It is decided while selecting the schedule.

  Therefore, in this workload leveling method, when changing the schedule of the non-neck process from the neck process to the upstream, it is necessary to determine the schedule of the non-neck process so as to satisfy the conditions such as start timing. Therefore, it takes time to change the schedule. Therefore, in this method, it takes time to make a production plan. In particular, there is a significant difference between workload and capacity, and it is difficult to make a quick plan, such as when planning production plans by repeating the process of simulating workload leveling with manual adjustments. It becomes.

  The present invention has been made in view of the problems of the prior art described above, and an object thereof is to provide a workload leveling apparatus and a workload leveling method that enable quick production planning. .

  A workload leveling device according to the present invention is a workload leveling device for leveling the workload of each process of a manufacturing process consisting of a plurality of processes according to the capability of each process, and the production deadline for each process An input reception unit that receives input of input data including data, production capacity data, work amount data, and lead time data, a load calculation unit that calculates the work load of each process, and calculates the work capacity of each process Comparing the work load and capacity for each process with the capacity calculation part, the process that maximizes the amount that the work load exceeds the capacity is identified as the neck process, and for the neck process Neck process crushing unit for changing the deadline date of the production deadline data of some work objects, and performing the crushing process to reduce the work load of the neck process, That mountain break With the change of the deadline date of the neck process due to the processing, the deadline date of the non-neck process preceding the neck process, in order from the first process side, the load of the non-neck process is less than the capacity of the non-neck process, and A non-neck process schedule changing unit that determines that the deadline date is included within a range of the longest lead time and the shortest lead time of the non-neck process.

  Further, in the workload leveling device according to the present invention, the non-neck process schedule changing unit is configured based on a margin days that is the number of days obtained by subtracting the shortest lead time from the longest lead time of each process and the margin days of the process. Using the consumable days, which is the number of days after subtracting the number of days before the process, the remaining adjustment days, which are the days that can be advanced in the process, can be calculated, and the calculated residual adjustment The expiration date of the non-neck process is changed based on the number of days.

  According to the present invention, it is an object to provide a workload leveling apparatus and a workload leveling method that enable quick production planning.

  According to the present invention, it is possible to shorten the time required to determine the schedule of the non-neck process after leveling the work load of the neck process, so that a quick production plan can be made.

The figure which showed the example of the structure of the workload leveling apparatus which concerns on embodiment of this invention. The figure which showed the example of the data structure of production time limit data. The figure which showed the example of the data structure of production capacity data. The figure which showed the example of the data structure of work amount data. The figure which showed the example of the data structure of lead time data, and the specific example of the longest lead time and the shortest lead time. The figure which showed the example of the processing flow of the workload leveling process in a workload leveling process part. The figure which showed the example of the data structure of the load condition data classified by time produced | generated by the process of a load calculation part. The figure which showed the example of the data structure of the load vs capability comparison table produced | generated by the process of a neck process specific | specification part. The figure which showed the example of the detailed process flow of the neck process landslide process by a neck process landslide part. The figure which showed the example of the pile work object list | wrist used by the mountain climbing process of FIG. The figure which showed the example of the detailed processing flow of the non-neck process schedule change process by a non-neck process schedule change part. The figure which showed the example of the detailed process flow of the date change process of the non-neck process with respect to each work object in the non-neck process schedule change process of FIG. The figure which showed typically the example of the calculation process of the process which brings forward the date of a non-neck process. The figure which showed the example of the "process schedule change list" screen which is produced | generated by the neck process landslide process and the non-neck process schedule change process, and is displayed on a result output part. FIG. 15 is a diagram illustrating an example of a “schedule change status display” screen displayed on a result output unit when a “schedule change status display” button is pressed on the “process schedule change list” screen of FIG. 14; The figure which showed the example of the "load transition status display" screen displayed on a result output part, when the "load transition status display" button was pressed in the "process schedule change list" screen of FIG. The figure which showed the example of the "load transition status display" screen of the graph format displayed on a result output part, when the "load transition status display" button was pressed in the "process schedule change list" screen of FIG. The figure which showed the example of the "capability adjustment notification" screen which notifies that capability adjustment is required. The figure which showed the example of the lead time data input in the 1st modification of embodiment. The figure which showed the example of the process which calculates overload total time in the 1st modification of embodiment. The figure which showed the example of the process of calculating the allowance days of each process and the shortest lead time in the 1st modification of embodiment. The figure which showed the example of the processing flow of the workload leveling process in the 2nd modification of embodiment.

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

  FIG. 1 is a diagram showing an example of the configuration of a work load leveling apparatus 1000 according to an embodiment of the present invention. As shown in FIG. 1, the work load leveling apparatus 1000 includes an input receiving unit 100, a work load leveling processing unit 200, and a result output unit 300, and is generally used for personal computers, workstations, and the like. Realized by a simple computer.

  Here, the workload leveling processing unit 200 includes functional blocks such as a load calculation unit 210, a capability calculation unit 220, a neck process specifying unit 230, a neck process hill-breaking unit 240, and a non-neck process schedule changing unit 250. Is done. Further, the workload leveling processing unit 200 is configured to include an arithmetic processing device (CPU: Central Processing Unit) (not shown) and a storage device (semiconductor memory, hard disk device, etc.) not shown in hardware. The various functions of the functional blocks are realized by the arithmetic processing unit executing programs stored in the storage unit.

  Further, the input receiving unit 100 receives input of various input data (production deadline data 110, production capacity data 120, work quantity data 130, lead time data 140, etc.) from the outside, and the received input data is used as a work load. The data is stored in a storage device (not shown) of the leveling processing unit 200. The input receiving unit 100 is generally configured by an input device such as a keyboard or a mouse, but a communication interface device such as a LAN (Local Area Network) or an input / output port such as a USB (Universal Serial Bus). Etc. may be included.

  The result output unit 300 is a device that displays data such as the schedule, load, and capacity of each process generated and leveled by the work load leveling processing unit 200. Generally, the result output unit 300 is an LCD (Liquid Crystal). Display) or a printer, but may include a communication interface device such as a LAN and an input / output port such as a USB.

  FIG. 2 is a diagram showing an example of the data structure of the production deadline data 110. The production deadline data 110 is data in which a deadline for performing the work of each process on a predetermined work target is set, and includes “work target 111”, “process 112”, “date 113”, and the like as data fields. . Here, the name of each process of the manufacturing process subsequent to the drawing process is set in the “process 112” when the drawing process, which is the completion of the design schedule and the start of the manufacturing schedule, is the first process. Further, “work object 111” stores the name of a part to be worked in the process (the process designated by “process 112”). Further, in “Due Date 113”, a due date for completing the work on the work target (work target specified by “work target 111”) of the process is set.

  FIG. 3 is a diagram showing an example of the data structure of the production capacity data 120. The production capacity data 120 is data in which the production capacity for each predetermined period (for example, one week) is set as a work input possible time, and the data fields thereof are “total date 121”, “process 122”, “capacity 123”. Etc. In the present embodiment, it is assumed that the data of “ability 123” of each “process 122” is totaled every week. The data of “capability 123” is calculated by the capability calculator 220 based on the number of workers engaged in the work of “process 122”, the number of devices necessary for the work, and the like.

  FIG. 4 is a diagram showing an example of the data structure of the work amount data 130. The work amount data 130 is data in which the amount of work and the time required for work in each process of each work target are set, and the data fields include “work object 131”, “process 132”, and “work product amount 133”. ”,“ Work required time 134 ”, and the like.

  FIG. 5 is a diagram showing (a) an example of the data structure of the lead time data 140 and (b) a specific example of the longest lead time and the shortest lead time. The lead time data 140 is data representing the number of days from the initial process to the completion of the process, and has “process 141”, “longest lead time 142”, and “shortest lead time 143” as its data fields. That is, in this embodiment, the longest lead time and the shortest lead time are set for each process, and the schedule of each process is longer than the shortest lead time and shorter than the longest lead time. It is required to be set.

  FIG. 6 is a diagram illustrating an example of a processing flow of the workload leveling process in the workload leveling process unit 200. The work load leveling processing unit 200 uses the data such as the production deadline data 110, the production capacity data 120, the work amount data 130, the lead time data 140, and the like input via the input receiving unit 100 to determine the work load of each process. Generate a leveled production schedule.

  An arithmetic processing device (hereinafter simply referred to as an arithmetic processing device) (not shown) of the workload leveling processing unit 200 starts from the outside via the input receiving unit 100 before starting the workload leveling processing in step S10 and subsequent steps. Input data such as production deadline data 110, production capacity data 120, work quantity data 130, and lead time data 140 are input and stored in a storage device (not shown).

  When starting the workload leveling process, the arithmetic processing unit first executes a load calculation process by the load calculation unit 210 (step S10). That is, the arithmetic processing unit calculates the load of each process as a work required time for each aggregation date in a predetermined period based on the production deadline data 110 and the work amount data 130, and loads the time-dependent load status data 150 shown in FIG. Is generated. Then, the generated load status data 150 classified by time is stored in a storage device (not shown) of the work load leveling processing unit 200.

  FIG. 7 is a diagram illustrating an example of a data structure of the time-dependent load status data 150 generated by the processing of the load calculation unit 210. As illustrated in FIG. 7, the load status data 150 classified by time includes “aggregation date 151”, “process 152”, “load 153”, and the like as data fields. In the present embodiment, the “total date 151” is a one-week interval date. Therefore, the “load 153” stores data obtained by totaling the work required time in the “process 152” in the week including the “total date 151”.

  That is, the arithmetic processing unit has a process name (for example, process X) for each process name included in “process 112” of the production deadline data 110, and the date of “due date 113” is the load status by period. All records corresponding to the week (for example, 2010/03/12) of “Aggregation date 151” of data 150 are extracted, and further, the operation target (for example, part A, part is extracted from “work target 111” of the extracted record. B) is extracted.

  Subsequently, the arithmetic processing apparatus refers to the work amount data 130 and extracts a record in which the “work target 131” matches the extracted work target. Then, the “required work time 134” included in the extracted records is totaled, and the “step 152” (for example, 2010/03/12) of the “total date 151” (for example, 2010/03/12) in the load status data 150 classified by period. , “Load 153” for step X).

  Returning to the description of FIG. 6, the arithmetic processing apparatus next executes a neck process specifying process by the neck process specifying unit 230 (step S <b> 20). That is, the arithmetic processing device compares the “load 153” of the time-dependent load status data 150 generated in step S10 with the “capability 123” of the production capacity data 120, and the “load 153” exceeds the “capacity 123”. Identify the largest process.

  Specifically, the arithmetic processing unit generates the load vs. capacity comparison table 160 shown in FIG. 8 by combining the load status data 150 by time and the production capacity data 120 using the aggregation date and the process as keys. The load vs. capability comparison table 160 is stored in a storage device (not shown) of the work load leveling processing unit 200.

  FIG. 8 is a diagram illustrating an example of the data structure of the load vs. capability comparison table 160 generated by the process of the neck process specifying unit 230. As shown in FIG. 8, the load vs. capacity comparison table 160 has “total date 161”, “process 162”, “load 163”, “capability 164”, and the like as data fields. Here, “load 163” is a copy of “load 153” of the load status data 150 by time, and “capability 164” is a copy of “capability 123” of the production capability data 120.

  Therefore, the arithmetic processing device compares “load 163” and “capability 164” in the capability load comparison table 160, and sums the excess amount in which “load 163” exceeds “capability 164” for each process. The process with the largest total excess amount is identified as the neck process.

  Returning to the description of FIG. 6 again, the arithmetic processing unit next executes a neck process crushed process by the neck process crushed unit 240 (step S30). That is, the arithmetic processing unit eliminates the state where the load exceeds the capacity for the neck process specified in step S20 by changing the “date 113” of the production deadline data 110.

  Next, the arithmetic processing device executes a non-neck process schedule changing process by the non-neck process schedule changing unit 250 (step S40). That is, the arithmetic processing unit performs a process of changing the schedule of processes other than the neck process for the work target of the neck process whose work schedule has been changed in step S20.

  Next, the arithmetic processing unit determines whether or not the mountain climbing process has been completed for all the neck processes (step S50), and if not completed (No in step S50), the process returns to step S30, The processing after step S30 is executed again. Further, when the leveling process has been completed for all the neck processes (Yes in step S50), the arithmetic processing unit executes a schedule change result display process (step S60), and ends the workload leveling process. To do.

  Of the above processes, the detailed process flow of the neck process crushed process (step S30) will be described separately with reference to FIGS. The detailed process flow of the non-neck process schedule change process (step S40) will be described separately with reference to FIGS.

  FIG. 9 is a diagram illustrating an example of a detailed processing flow of the neck process hill-breaking process by the neck process hill-breaking unit 240. As shown in FIG. 9, the arithmetic processing apparatus first refers to the load vs. capacity comparison table 160 shown in FIG. 8, and selects the latest day of “counting date 161” of the neck process to be processed as the evaluation target week. (Step S310), it is determined whether or not the “load 163” of the week to be evaluated exceeds the “capability 164” (step S320).

  As a result of the determination, when the “load 163” of the week to be evaluated exceeds the “ability 164” (Yes in step S320), the arithmetic processing unit selects a work target that can be crushed, The deadline is set to the deadline one week before (step S330), that is, the “deadline 113” of the production deadline data 110 is advanced by one week. Here, the work target that can be moved forward is a difference in the number of days between the due date before the landslide and the due date after the landslide is less than the difference between the longest lead time 142 and the shortest lead time 143 of the neck process. Shall. In this embodiment, the priority for selecting a work target that can be crushed is set as follows: (1) in order of increasing number of days ahead, (2) in the case of the same number of days in advance, in order of increasing “load 163”. However, the present invention is not limited to this.

  Next, the arithmetic processing unit recalculates “load 163” based on the result of the mountain climbing process up to step S330 (step S340), and updates the load vs. capacity comparison table 160.

  On the other hand, if “load 163” does not exceed “capability 164” as a result of the determination in step S320 (No in step S320), the arithmetic processing device skips the processes in steps S330 and S340.

  Next, the arithmetic processing unit determines whether or not the first week is the mountain to be evaluated as the evaluation week (steps S320 to S340 have been processed) (step S350). After setting the week to be evaluated one week ahead (1 week ahead) (step S350), the process returns to step S320, and the processes after step S320 are executed again. Further, when the first week has been processed as the evaluation week (Yes in step S350), the neck process devastating process is terminated.

  Next, a specific example of the processes in steps S330 and S340 in the neck process mountain break process shown in FIG. 9 (hereinafter, the process of these steps is simply referred to as a mountain break process) will be described with reference to FIG. . Here, FIG. 10 is a diagram showing an example of the pile work target list 170 used in the mountain climbing process of FIG. 9, wherein (a) is an example of the pile work target list 170 before step S330, and (b). These are examples of the stacking work target list 170 after step S330. This pile work target list 170 is stored in a storage device (not shown) of the work load leveling processing unit 200.

  As shown in FIGS. 10A and 10B, the pile work target list 170 includes “work target 171”, “mountain breakability 172”, “mountain break candidate 173”, “work load 174”, “mountain break” It has a previous date 175 ”and a“ date 176 after landslide ”. Note that the “date 175 before landslide” here is “date 113” set in the settlement deadline data before starting the neck process landslide in FIG. 9, and “date 176 after landslide”. "Means the due date obtained after the processing of steps S330 and S340.

  According to FIG. 10 (a), for example, the total workload of process Z on April 2, 2010 is “2010/04/02” for the value of “date 176 after landslide”. The value is the sum of the values of “workload 174”, and in this example is “90 (time)”. On the other hand, as for the capacity of the week of April 2, 2010, “50 (hours)” is obtained from the value of “capability 164” in the load vs. capacity comparison table 160 shown in FIG. Is read as step Z).

  In the processing of step S330, the arithmetic processing device first identifies a work target that can be crushed. In the example of FIG. 10A, it is specified that the part C cannot be crushed and other parts can be crushed. Therefore, as shown in FIG. 10B, the arithmetic processing unit records the information on whether or not the mountain collapse is possible in the data field of “whether or not mountain collapse is possible 172”. The part C cannot be crushed because the difference between the “date 175 before landslide” and the “date 176 after landslide” in FIG. 10A is 28 days, which is further advanced one week. In this case, the difference is 35 days, and the difference between the longest lead time and the shortest lead time in process Z exceeds 30 days.

  Further, in the process of step S330, the work targets that can be crushed are selected as landslide targets in order from the largest work load until the total work load falls below the work ability “50 (hours)”. The due date 176 after the landslide is set one week before April 2, 2010. The advance period is set to one week because the load calculation process (see FIG. 6, step S10) is performed in units of one week, for example, and the advance period is limited to one week. Do not mean.

  Further, in FIG. 10B, the “target” value recorded in the data field of “candidate 173” is selected as the target for the landslide. As a result, among the work targets piled up in the process Z on April 2, 2010, the value of “date 176 after landslide” is “2010/04/02” is “part C”. , “Part E” and “Part F” only, and the workload of the process Z on April 2, 2010 is “work load 174” of “part C”, “part E”, and “part F”. The total is 45 hours, which is less than 50 hours of capacity.

  FIG. 11 is a diagram illustrating an example of a detailed processing flow of the non-neck process schedule changing process by the non-neck process schedule changing unit 250. As shown in FIG. 11, the arithmetic processing unit starts the iterative process up to the end of the iterative process (step S450) while designating the work object for all work objects included in the production deadline data 110 (step S410). .

  The arithmetic processing apparatus first, for the designated work object, the due date of the work object (“date 113” for the work object of the non-neck process of the production deadline data 110) is executed just before the neck process is crushed. It is determined whether or not it has been changed in the process (FIG. 9, step S30) (step S420).

  And as a result of the determination, when the due date of the work target has been changed (Yes in step S420), the arithmetic processing unit calculates the number of days ahead of the non-neck process of the work target, and the non-neck process The due date (“date 113” for the work target of the non-necking process of the production deadline data 110) is changed to the date due to the calculated number of advance days (step S430). Next, the arithmetic processing unit changes the aggregation date of the work target in accordance with the change of the due date, recalculates the load of the non-neck process (step S440), and uses the recalculated load as time-dependent load status data. 150 is reset to the data field of “load 153”.

  If the due date of the work object has not been changed in the determination in step S420 (No in step S420), the arithmetic processing device skips the processes in steps S430 and S440.

  Next, the arithmetic processing unit determines whether or not the processing in step S420 and subsequent steps has been executed for all work targets, and if not performed for all work targets, the step is performed for the work targets that have not been executed. The processing after S420 is executed again, and if it has been executed for all work objects, the non-neck process schedule change processing is terminated (step S450).

  FIG. 12 is a diagram illustrating an example of a detailed processing flow of the non-neck process due date change process (step S430) for each work target in the non-neck process schedule change process of FIG. As shown in FIG. 12, the arithmetic processing unit first sets the number of advance days D obtained by the neck process crawl process to the remaining adjustment days R (step S431).

  Next, the arithmetic processing unit sets the next process of the drawing process as the schedule change process for which the advance days calculation is performed (step S432), and calculates the margin days S and the consumable days C of the schedule change process. (Step S433). Here, the surplus days S means the number of days obtained by subtracting the “minimum lead time 143” from the “longest lead time 142” of the process, and the consumable days C is the number of days of the process from the surplus days of the process. The number of days after subtracting the number of days left in the previous process.

  Next, the arithmetic processing unit determines whether or not the remaining adjustment days R is less than or equal to the consumable days C of the process (step S434), and if the remaining adjustment days R is greater than the consumable days C (step S434). Yes in S434), the due date of the schedule change step is advanced by the number of consumable days C (step S435), and the remaining adjustment days R are reduced by subtracting the consumable days C from the remaining adjustment days R (that is, (RC) to update (step S436). Further, the arithmetic processing apparatus sets the next process of the process as the schedule change process (step S437), returns to step S433, and repeatedly executes the processes after step S433.

  On the other hand, if it is determined in step S434 that the remaining adjustment days R is less than or equal to the consumable days C (No in step S434), the due date of the schedule change process is set to the remaining adjustment days R of the process preceding the relevant process. 12 days ahead of the number of days obtained by adding the number of advance days (step S438), and the due date changing process of the non-neck process in FIG.

  FIG. 13 is a diagram schematically illustrating an example of a calculation process of a process for advancing the due date of a non-neck process. FIG. 13A shows the due date of each process before the schedule change and the due date of the neck process (process Z) changed by the neck process flank process. That is, in this example, the due date of the neck process (process Z) is advanced from September 9 to August 25. In the case of this example, in the process of step S431 in FIG. 12, the remaining adjustment days R is set to 15 days, which is the days D ahead of the neck process.

  Next, FIG. 13B shows an example in which the date of the process X, which is the next process of the drawing, is advanced from June 1 to May 22 by the processing of steps S432 to S435 in FIG. It is shown.

  In the case of this example, in step S432, process X, which is the next process of the drawing, is set as the schedule change process. In step S433, a difference of 10 days between the longest lead time 50 days and the shortest lead time 40 days of the process X is set as the margin days S of the process X, and 10 days of allowance days of the process X as the consumable days C Is set to 10 days obtained by subtracting 0 days in the outgoing drawing, which is the previous process of process X. Furthermore, in step S434, since 15 days of remaining adjustment days R is larger than 10 days of consumable days C of process X, step S435 is executed, and the due date of process X is 10 days of consumable days C of process X. , Be put forward.

  Next, FIG. 13C shows an example in which the due date of the process Y is advanced from July 21 to July 6 by the processes of steps S436, S437, S433, S434, and S438 of FIG. ing.

  In the case of this example, in step S436, the remaining adjustment days R is deducted 10 days of the consumable days C from 15 days, and the new remaining adjustment days R is 5 days. In step S437, the process Y is set in the schedule change process, and in step S433, 20 days is set as the surplus days S of the process Y, and the consumable days C are set from the surplus days of the process Y to 20 days. 10 days after subtracting 10 extra days of X are set. Furthermore, in step S434, since 5 days of the remaining adjustment days R is smaller than 10 days of the consumable days C of the process Y, step S438 is executed, and the due date of the process Y that is the schedule change process is the remaining adjustment days R It is advanced by 15 days, which is obtained by adding 10 days ahead of the previous process (process X) on the 5th.

  FIG. 14 is a diagram illustrating an example of a “process schedule change list” screen 310 that is generated by the neck process crushed process and the non-neck process schedule change process and displayed on the result output unit 300. As shown in FIG. 14, the “process schedule change list” screen 310 has data for “schedule before change”, “schedule after change”, “schedule difference”, and “margin days” for each process and each work target. Are displayed, and as a button for switching display contents, for example, a “date change status display” button 311 and a “load transition status display” button 312 are displayed.

  FIG. 15 shows an example of the “schedule change status display” screen 310a displayed on the result output unit 300 when the “schedule change status display” button 311 is pressed on the “process schedule change list” screen 310 of FIG. It is a figure. As shown in FIG. 15, on the “schedule change status display” screen 310a, the change status of the schedule before and after the change of each process is shown, and the spare days and advance days of each process are also displayed. The In FIG. 15, only the schedule change status of the part B is displayed as the work target. However, the schedule change status of all the work targets may be displayed, and a plurality of tasks appropriately selected by the user may be displayed. You may make it display the schedule change condition of object.

FIG. 16 shows an example of a “load transition status display” screen 310b displayed on the result output unit 300 when the “load transition status display” button 312 is pressed on the “process schedule change list” screen 310 of FIG. It is a figure.
As shown in FIG. 16, on the “load transition status display” screen 310b, the “pre-leveling workload” and the “leveling post-leveling workload” are displayed for each aggregation date for the neck process or the process specified by the user. , “Ability” is displayed. Further, as an index indicating the effect of the work load leveling process, the sum of the load and capacity deviation (absolute value of the difference) on each date is displayed.

FIG. 17 shows a graph-type “load transition status display” screen 310c displayed on the result output unit 300 when the “load transition status display” button 312 is pressed on the “process schedule change list” screen 310 of FIG. It is the figure which showed the example.
As shown in FIG. 17, the “load transition status display” screen 310 c displays the transition of workload and process capability for each aggregation date before and after the workload leveling process in a graph. You can see the effect of at a glance.

  In the case of the present embodiment, when the workload leveling process (see FIG. 6) is executed, the possibility that a process or time when the load exceeds the capacity cannot be denied. Therefore, in the present embodiment, when the process and time when the load exceeds the capacity for execution of the workload leveling process remain, the process and the time when the load exceeds the capacity are presented to the user. , Notify that some kind of capacity adjustment is necessary for the time.

  FIG. 18 is a diagram showing an example of a “necessity adjustment notification” screen 310 d for notifying that the ability adjustment is necessary. As shown in FIG. 18, in the “necessity adjustment notification” screen 310d, the load of “Process Y” whose aggregation date is “2010/03/26” is 90 hours, which exceeds the capacity of 80 hours. . In such a case, the data is highlighted and displayed, or the display color is changed from the surrounding color to alert the user. Further, a message notifying that the ability adjustment is necessary may be displayed, and further, the adjusted ability necessary for the ability adjustment may be displayed.

  As described above, according to the present embodiment, it is possible to reduce the time required to determine the schedule of the non-neck process after leveling the work load of the neck process, and as a result, it is possible to make a quick production plan. In particular, when there is a large discrepancy between the workload and capacity, it is possible to repeatedly adjust the discrepancy between the workload and capacity while making manual adjustments, enabling more appropriate production planning. It becomes.

  Further, according to the present embodiment, it is possible to level the work load without changing the design schedule. As a result, it is possible to suppress the schedule pressure on the work target whose design has already progressed, and it is possible to save time and effort for adjusting the schedule between the design department and the manufacturing department. In the present embodiment, the first process in which the drawing date cannot be changed is used. However, the present invention is not limited to this, and the arrival date of parts or the date when work can be started is set as the first process in which the schedule cannot be changed. However, it is also possible to level the work load by the same method as in this embodiment.

(First Modification of Embodiment)
As described above, in the workload leveling apparatus 1000 in the embodiment described so far, the shortest lead time of each process is input from the outside via the input receiving unit 100, but in the embodiment described below, In the first modified example, the work load leveling apparatus 1000 first calculates the overload amount of each process, and then sets the shortest lead time of each process according to the calculated overload amount.

FIG. 19 is a diagram illustrating an example of the lead time data 140a input in the first modification of the embodiment.
As shown in FIG. 19, in the first modification of the embodiment, the shortest lead time is set only for the final process (E process), and is not set for other processes. Incidentally, in the lead time data 140a, the longest lead time of the final process (process E) is 200 days, and the shortest lead time is 150 days. Accordingly, the margin for the final process is 50 days.

  In the first modification of this embodiment, the workload leveling process executed by the arithmetic processing unit of the workload leveling process unit 200 is substantially the same as the workload leveling process shown in FIG. Since there is a difference between the sections, only the different processing will be described here.

FIG. 20 is a diagram illustrating an example of a process of calculating the overload total time in the first modification of the embodiment.
The arithmetic processing unit generates the load vs. capacity comparison table 160 as shown in FIG. 20A by the neck process specifying process (FIG. 6: step S20). Calculate the total overload time for each process as shown. In the load vs capacity comparison table 160, the total load overload time is the sum of the times when the “load 163” for each “aggregation date 161” exceeds the “capability 164” for each process included in the “process 162”. Say time. In the example of the load vs capacity comparison table 160 shown in FIG. 20A, the load vs capacity data is described only for the process X, but actually, the process Y, the process Z, and the process E are described. There is also data on.

FIG. 21 is a diagram illustrating an example of a process of calculating the allowance days and the shortest lead time of each process in the first modification of the embodiment.
The arithmetic processing unit generates total overload time data 180 as shown in FIG. 21A based on the total overload time of each process calculated as shown in FIG. Here, the total overload time data 180 has “process 181”, “total overload time 182”, and “total accumulated overload time 183” as data fields. In addition, the value of “cumulative overload time 183” of each process is obtained by accumulating the value of “total overload time 182” of the process preceding the process to the value of “total overload time 182” of the process. Value.

  Next, the arithmetic processing unit sets the “margin days S” of each process so as to be proportional to the value of the “cumulative overload total time 183”. Here, since the surplus days S are given to the process E which is the final process (see FIG. 19), the arithmetic processing unit calculates the ratio of the surplus days S to the value of the “cumulative overload total time 183” (= 50/1000) can be calculated. Therefore, the arithmetic processing unit calculates the margin days S of other processes using the ratio.

  Next, the arithmetic processing unit calculates the shortest lead time of each process based on the definition of the number of days S that is the number of days obtained by subtracting the shortest lead time from the longest lead time.

  If the shortest lead time and the allowance days S are determined based on the above procedure, a larger allowance days can be given to a process with a large overload. In this case, since it is easy to eliminate the overload of a process having a large overload, the calculation amount of the arithmetic processing device is reduced, and the efficiency of the work load leveling process is improved.

(Modification 2 of embodiment)
FIG. 22 is a diagram illustrating an example of a processing flow of the workload leveling process in the second modification example of the embodiment. The processing flow of the workload leveling process in the second modified example of this embodiment is the neck specified by the neck process specifying process (FIG. 6: Step S20) in the processing level of the workload leveling process shown in FIG. Not only the process but also all the processes are changed so as to eliminate the overload.

  Therefore, in the process flow of FIG. 22, the neck process specifying process (step S20) in the process flow of FIG. 6 is deleted, and a process (step S20a) in which the final process is a neck process is added instead. Further, a process of setting the neck process as the process immediately before the current neck process (step S51) and a process of determining whether or not the neck process is the first process (step S52) are added.

  That is, the overload of each process is eliminated from the last process to the first process in the reverse order of the process progress. In the case of the second modification of this embodiment, in the non-neck process schedule change process (step S40), it is assumed that the schedule is not changed for a process that has already finished the mountain-climbing process.

DESCRIPTION OF SYMBOLS 100 Input reception part 110 Production deadline data 120 Production capacity data 130 Work quantity data 140 Lead time data 150 Load condition data according to time 160 Load vs capacity comparison table 170 Stack work object list 180 Overload total time data 200 Work load leveling process part 210 Load Calculation Unit 220 Capacity Calculation Unit 230 Neck Process Identification Unit 240 Neck Process Mountain Breaking Unit 250 Non-Neck Process Schedule Change Unit 300 Result Output Unit 1000 Work Load Leveling Device

Claims (8)

A work load leveling device for leveling the work load of each process of a manufacturing process comprising a plurality of processes according to the capability of each process,
Production deadline data representing the deadline date for ending work to be performed in each process, capability data representing ability that is workable time in each process, and work required for performing work to be performed in each process An input receiving unit that receives input of input data including work amount data representing a long time, and lead time data composed of data of the longest lead time and the shortest lead time for each process;
Based on the production deadline data and the work amount data, a load calculation unit that calculates a work load of each process for each predetermined aggregation date;
Comparing the work load and capacity for each process, a neck process identifying unit that identifies the process that maximizes the amount that the work load exceeds the capacity as the neck process,
Among the loads of work targets piled up for the neck process, the deadline process of the neck process is performed to change the deadline date of some work objects and reduce the work load of the neck process. When,
With the change of the due date of the work target of the neck process by the neck process crushed portion, the due date of the non-neck process preceding the neck process of the work object, in order from the first process side, the non-neck process A non-neck process schedule changing unit that determines that the load of the non-neck process is equal to or less than the capacity of the non-neck process and that the due date is included in the range of the longest lead time and the shortest lead time of the non-neck process;
A result output unit that outputs data on the due date and load of each operation target of each process changed by the neck process crushed part and the non-neck process schedule change part;
A workload leveling device characterized by comprising: The non-neck process schedule changing part is:
Using a marginal number of days that is the number of days obtained by subtracting the minimum lead time from the longest lead time of each process, and a consumable number of days that is the number of days that is obtained by subtracting the marginal number of days preceding the process from the margin days of the process The remaining adjustment days, which is the number of days that the deadline date can be advanced in the process, is calculated, and the deadline date of the non-neck process is changed based on the calculated remaining adjustment days. The workload leveling device described in 1. Among the shortest lead times accepted by the input receiving unit, the shortest lead time for the process excluding the final process is unset data,
The non-neck process schedule changing part is:
The number of days proportional to the cumulative total load overload time, which is the cumulative time from the first step of the total overload time during which the load exceeds the capacity in each process, is set as the number of days for the relevant process, The work load leveling device according to claim 1, wherein the shortest lead time of the process is set from the longest lead time of the process. The result output unit
When the load of each of the processes changed by the neck process devastating part and the non-neck process schedule changing part exceeds capacity, a message notifying that capacity adjustment is necessary for the process, and The workload leveling apparatus according to any one of claims 1 to 3, wherein at least one of the capacity data adjusted so that the load does not exceed the capacity is output. A work load leveling method for leveling the work load of each process of a manufacturing process consisting of a plurality of processes according to the capability of each process by a computer including an arithmetic processing unit, an input device, and an output device. ,
The arithmetic processing unit includes:
Via the input device, production deadline data representing the due date for ending the work of the work target in each process, capability data representing the ability that is the workable time in each process, and the work target in each process Input acceptance processing for accepting input of input data including work quantity data representing the time required to perform the work and lead time data consisting of data of the longest lead time and the shortest lead time for each process;
Based on the production deadline data and the work volume data, a load calculation process for calculating the work load of each process for each predetermined aggregation date;
Comparing the work load and capacity for each process, the neck process specifying process for identifying the process that maximizes the amount that the work load exceeds the capacity as the neck process,
Among the loads of work targets piled up with respect to the neck process, the deadline process of a part of the work process is changed to change the deadline of the work of the neck process, and the neck process crushed process is performed to reduce the work load of the neck process. When,
With the change of the due date of the work target of the neck process due to the neck process crushed, the non-neck process, in order from the first process side, the due date of the non-neck process preceding the neck process of the work object A non-neck process schedule change process for determining that the load of the non-neck process is equal to or less than the capacity of the non-neck process and that the deadline date is included in the range of the longest lead time and the shortest lead time of the non-neck process;
A result output process for outputting the deadline date and load data of each work target of each process changed by the neck process crushed process and the non-neck process schedule change process to the output device;
A workload leveling method characterized by executing The arithmetic processing unit includes:
In the non-neck process schedule change process, the number of days that are the days obtained by subtracting the shortest lead time from the longest lead time of each process, and the number of days before the process is subtracted from the days of the process. Using the consumable days, which is the number of days, calculates the remaining adjustment days, which is the number of days that can be advanced in the process, and changes the deadline date of the non-neck process based on the calculated remaining adjustment days The workload leveling method according to claim 5, wherein: Among the shortest lead times accepted at the input reception, the shortest lead time for the process excluding the final process is unset data,
The arithmetic processing unit includes:
In the non-neck process schedule change process, the number of days proportional to the total accumulated overload time, which is the accumulated time from the first process of the total overload time during which the load exceeds the capacity in each process, is set as the margin days of the process. The work load leveling method according to claim 5, further comprising: setting the shortest lead time of the process from the number of days left and the longest lead time of the process. The arithmetic processing unit includes:
In the result output process, when the load of each process changed by the neck process crushed process and the non-neck process schedule change process exceeds the capacity, the load exceeds the capacity. The workload leveling method according to any one of claims 5 to 7, wherein at least one of a message and data on a capacity adjusted so that the load does not exceed the capacity is output. .

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