JP2013003959A - Operation rule creation method and production distribution plan creation method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To create an operation rule for suppressing the occurrence of a bottleneck process.SOLUTION: A CPU 13 is configured to calculate the throughput of a facility within a predetermined period by production distribution simulation, and to determine whether or not there exists a bottleneck facility in a production distribution line by comparing the throughput of the facility with processing plan amounts. Then, the CPU 13 is configured to, when there exists the bottleneck facility, re-execute the production distribution simulation by changing the operation plan of a peripheral facility including the bottleneck facility, and to store the result of the production distribution simulation and the change content of the operation plan in association as operation rule information.

Description

  The present invention relates to an operation rule creation method for creating an operation rule for creating a production distribution plan for a production distribution line for steel products, and a production distribution line for steel products using the operation rule created by the operation rule creation method. The present invention relates to a production logistics plan creation method for creating a production logistics plan.

  In a production logistics line for products that are produced and shipped through a plurality of processes, if there is a delay from the production logistics plan in a certain process, the final product cannot be shipped by the delivery date answered by the customer. With this background, when there is a delay from the production plan in a certain process, there is a technology for re-creating a production logistics plan that uses the process as a bottleneck process to equalize the load of each process by pile-up / collapse. It has been proposed (see Patent Document 1).

JP 2009-128983 A

  However, the technology described in Patent Document 1 relates to a method for coping with a bottleneck process, and creates a production logistics plan that does not cause or minimizes the bottleneck process at the stage of creating a production logistics plan. is not. Therefore, by creating a production logistics plan that does not cause or minimizes the bottleneck process at the stage of creating a production logistics plan, production that can reduce manufacturing lead time, reduce inventory, and improve yield The provision of logistics planning technology was expected.

  In the production distribution line of steel products, the probability of occurrence of the bottleneck process is lower than that of the semiconductor device manufacturing line targeted by the technique described in Patent Document 1. For this reason, in the production distribution line of steel products, by leveling according to operation rules that do not cause or minimize the bottleneck process, instead of leveling the load on an ad hoc basis as in the technology described in Patent Document 1, There is a possibility that manufacturing lead time can be shortened, inventory can be reduced, and yield can be improved.

  The present invention has been made in view of the above-mentioned problems, and the object thereof is an operation rule creation method for creating an operation rule for suppressing the occurrence of a bottleneck process, and a production logistics plan for suppressing the occurrence of a bottleneck process. It is to provide a production logistics plan creation method.

  In order to solve the above-mentioned problems and achieve the object, the operation rule creation device according to the present invention relates to order information including information related to the product passing process and processing time, and the in-process inventory amount in each process constituting the production logistics line. In-process inventory information including information, facility specification information including information regarding the processing capacity of the equipment provided in each process, and operation plan information including information regarding the operation plan of the facility, the facility within a predetermined period A production distribution simulation step for calculating a processing amount of the apparatus, a determination step for determining whether or not a bottleneck facility exists in the production distribution line by comparing the processing amount of the facility with a processing planned amount, and the determination If it is determined in the step that there is a bottleneck facility, the profit to change the operation plan of the peripheral facility including the bottleneck facility is determined. A plan change step, a re-simulation step that re-executes the production logistics simulation step using the operation plan changed by the operation plan change step, a processing result of the re-simulation step, and an operation plan in the operation plan change step An operation rule storing step of associating the change contents with each other and storing them as an operation rule.

  In order to solve the above problems and achieve the object, the production logistics plan creation method according to the present invention creates a production logistics plan for a production logistics line based on the operation rules created by the operation rule creation device according to the present invention. Including the steps of:

  According to the operation rule creation method according to the present invention, an operation rule that suppresses the occurrence of a bottleneck process can be created. According to the production logistics plan creation method according to the present invention, a production logistics plan that suppresses the occurrence of the bottleneck process can be created.

FIG. 1 is a schematic diagram showing a production distribution line for steel products, which is a target for which a production distribution plan creation system according to an embodiment of the present invention creates a production distribution plan. FIG. 2 is a block diagram showing a configuration of a production logistics plan creation system according to an embodiment of the present invention. FIG. 3 is a diagram showing an example of order information stored in the order information DB shown in FIG. FIG. 4 is a diagram illustrating an example of in-process inventory information stored in the in-process inventory DB illustrated in FIG. FIG. 5 is a diagram illustrating an example of facility specification information stored in the facility specification DB illustrated in FIG. 2. FIG. 6 is a diagram showing an example of operation plan information stored in the operation plan DB shown in FIG. FIG. 7 is a diagram showing an example of failure occurrence probability information stored in the failure occurrence probability DB shown in FIG. FIG. 8 is a diagram illustrating an example of operation rule information stored in the operation rule DB illustrated in FIG. FIG. 9 is a flowchart showing a flow of operation rule creation processing according to an embodiment of the present invention. FIG. 10 is a diagram illustrating an example of the product distribution simulation condition and the product distribution simulation result. FIG. 11 is a diagram illustrating an example of the product distribution simulation condition and the product distribution simulation result. FIG. 12 is a diagram illustrating an example of the product distribution simulation condition and the product distribution simulation result. FIG. 13 is a flowchart showing a flow of operation plan change processing according to an embodiment of the present invention.

  Hereinafter, with reference to the drawings, the configuration and operation of a production logistics plan creation system according to an embodiment of the present invention will be described.

[Production logistics line for steel products]
First, with reference to FIG. 1, a production logistics line for steel products, which is a target for which a production logistics plan creation system according to an embodiment of the present invention creates a production logistics plan, will be described. However, the production distribution line for which the present invention creates a production distribution plan is not limited to the production distribution line for steel products shown in FIG.

  FIG. 1 is a schematic diagram showing a production distribution line for steel products, which is a target for which a production distribution plan creation system according to an embodiment of the present invention creates a production distribution plan. As shown in FIG. 1, in this production distribution line 100, first, a rolling process is performed on a steel product in a rolling mill, and the steel product after the rolling process is completed is cooled in a cooling place. Next, the steel product cooled in the cooling place is subjected to a finishing process in any one of the finishing facilities 1 to 3 and then placed in the product place. Then, the steel product placed in the product place is shipped to the customer by the shipping equipment.

[Production logistics planning system configuration]
Next, with reference to FIG. 2 thru | or FIG. 8, the structure of the production physical distribution plan preparation system which is one Embodiment of this invention is demonstrated. FIG. 2 is a block diagram showing a configuration of a production logistics plan creation system according to an embodiment of the present invention. FIG. 3 is a diagram showing an example of order information stored in the order information DB 2 shown in FIG. FIG. 4 is a diagram illustrating an example of in-process inventory information stored in the in-process inventory DB 3 illustrated in FIG. FIG. 5 is a diagram illustrating an example of facility specification information stored in the facility specification DB 4 illustrated in FIG. 2. FIG. 6 is a diagram illustrating an example of operation plan information stored in the operation plan DB 5 illustrated in FIG. 2. FIG. 7 is a diagram illustrating an example of failure occurrence probability information stored in the failure occurrence probability DB 6 illustrated in FIG. FIG. 8 is a diagram showing an example of operation rule information stored in the operation rule DB 7 shown in FIG.

  As shown in FIG. 2, the production logistics plan creation system 1 according to an embodiment of the present invention includes an order information database (DB) 2, an in-process inventory DB 3, an equipment specification DB 4, an operation plan DB 5, a failure occurrence probability DB 6, an operation. A rule DB 7, a production logistics plan creation device 10, an input device 20, and an output device 30 are provided.

  The order information DB 2 stores order information in which information related to the passing process and processing time of steel products supplied to the production logistics line 100 shown in FIG. 1 is recorded in the order of processing. Specifically, as shown in FIG. 3, the order information includes unique identification information (product ID) given to each steel product, and the thickness, width, weight, location classification of the steel product corresponding to the product ID, It includes the cooling time, the passing process, the processing time 1, the processing time 2, an alternative availability flag, and information related to the planned shipping date. In addition, a storage division means the division of the cooling storage place where steel products are mounted. The passing process means the type of the finishing equipment used in the finishing process. The processing time 1 means the processing time in the finishing equipment through which the steel product passes first. The processing time 2 means the division determined based on the processing time in the finishing equipment through which the steel product passes second. The substitutability flag indicates whether or not the processing in the finishing equipment 1 can be replaced by the finishing equipment 3, and is set when the replacement is possible and when the replacement is impossible.

  The in-process inventory DB 3 stores in-process inventory information in which information about the in-process inventory amount in each process constituting the production distribution line 100 shown in FIG. 1 is recorded in units of steel products. Specifically, as shown in FIG. 4, the in-process inventory information is placed in the area corresponding to the place ID and the 4-digit unique identification information (placement ID) assigned to each area in the cooling place. The product ID assigned to the steel product being placed, the place classification of the area corresponding to the place ID, and the information regarding the cooling start time and the cooling end time of the steel product placed in the area corresponding to the place ID are included. In the present embodiment, the first digit of the placement ID indicates the width category (S, M, L) of the area corresponding to the placement ID, and the second to fourth digits of the placement ID are assigned to the area corresponding to the placement ID. The assigned address (001 to 999) is shown.

  The facility specification DB 4 stores information on the processing capacity (the number of accommodations in the case of placement) of facilities provided in each process of the production logistics line 100 shown in FIG. 1 as facility specification information. Specifically, as shown in FIG. 5, the facility specification information includes information indicating the relationship between the placement section of the cooling place and the character information of the first and second to fourth digits of the place ID. Has information on the number of steel products that can be accommodated.

  The operation plan DB 5 stores information on an operation / suspension plan for facilities provided in each process of the production distribution line 100 shown in FIG. 1 as operation plan information. Specifically, as shown in FIG. 6, the operation plan information includes information indicating whether or not the finishing facilities 1 to 3 are scheduled to operate or stop in each time zone.

  The failure occurrence probability DB 6 stores information on failure occurrence probability of equipment provided in each process of the production distribution line 100 shown in FIG. 1 as failure occurrence probability information. Specifically, the failure occurrence probability information includes information on the failure occurrence interval and the failure stop time of the finishing equipment 1 to 3 as shown in FIG.

  The operation rule information DB 7 stores, as operation rule information, information related to operation rules for preventing a bottleneck process from occurring for each facility in the production distribution line 100 shown in FIG. Specifically, as shown in FIG. 8, the operation rule information includes information about the target facility and an operation rule that prevents the target facility from becoming a bottleneck facility. This operation rule information is created by an operation rule creation process to be described later.

  The production distribution plan creation device 10 is configured by an information processing device such as a workstation or a personal computer, and includes a RAM 11, a ROM 12, and a CPU 13 as main components. The RAM 11 temporarily stores a control program and control data related to processing executed by the CPU 13 and functions as a working area of the CPU 13. The ROM 12 stores a control program and control data such as a production distribution plan creation program 14 for realizing an operation rule creation process described later. The CPU 13 controls the overall operation of the production logistics plan creation apparatus 10 by executing a control program stored in the ROM 12.

  The input device 20 includes an information input device such as a keyboard, a mouse pointer, and a numeric keypad, and is operated when an operator inputs various types of information to the production distribution plan creation device 10. The output device 30 is configured by an output device such as a display device or a printing device, and outputs various processing information of the production logistics plan creation device 10.

[Operation rule creation process]
In the production logistics plan creation system 1 having such a configuration, the production logistics plan creation device 10 creates an operation rule that suppresses the occurrence of the bottleneck process by executing the operation rule creation process shown below. Hereinafter, with reference to the flowchart shown in FIG. 9, the operation of the production logistics plan creation device 10 when the operation rule creation processing is executed will be described. The operation of the production / distribution plan creation apparatus 10 shown below is realized by the CPU 13 executing the production / distribution plan creation program 14 stored in the ROM 12.

  FIG. 9 is a flowchart showing a flow of operation rule creation processing according to an embodiment of the present invention. The flowchart shown in FIG. 9 starts at the timing when the operator instructs the execution of the operation rule creation process by operating the input device 20, and the operation rule creation process proceeds to the process of step S1.

  In the process of step S1, the production / distribution plan creation device 10 uses the information stored in the order information DB2, the in-process inventory DB3, the equipment specification DB4, the operation plan DB5, and the failure occurrence probability DB6 to store the production / distribution line 100. A simulation model imitating the state is constructed, and a processing quantity in each facility is calculated by executing a production logistics simulation using the constructed simulation model. Specifically, first, the production / distribution plan creation device 10 arranges steel products in each place based on the in-process inventory information stored in the in-process inventory DB 3. Next, based on the order information stored in the order information DB 2, the production distribution plan creation device 10 sequentially puts steel products into the rolling mill and places the steel products after the completion of the rolling process in the cooling yard. . Next, based on the order information stored in the order information DB 2, the production distribution plan creation device 10 supplies the steel product after the cooling time has passed to the refining equipment, and the steel product after the refining process is completed. Place it in the product area. Then, the production distribution plan creation device 10 uses the shipping facility to ship the product placed in the product place based on the order information stored in the order information DB 2. Thereby, the process of step S1 is completed and the operation rule creation process proceeds to the process of step S2.

  In the process of step S2, the production / distribution plan creation device 10 has an excess or deficiency of the processing amount with respect to the planned amount in any of the rolling mill and the finishing equipment 1 to 3 based on the processing result of step S1. It is determined whether or not. As a result of the determination, if there is no excess or deficiency of the processing amount with respect to the planned amount, the production logistics plan creation device 10 ends the series of operation rule creation processing. On the other hand, if an excess or deficiency of the processing amount of the planned amount has occurred, the production distribution plan creation device 10 determines that a bottleneck process has occurred, and advances the operation rule creation processing to the processing in step S3. .

  In the process of step S3, the production / distribution plan creation device 10 causes the bottleneck process to be caused based on the operating rate of each facility, the difference between the processing amount and the planned amount, and the time transition of the yard usage rate. Is identified as a bottleneck facility. Specifically, when the working days of 10 days are set in the rolling mill and the finishing equipment 1 to 3, when the processing time of each equipment is set to the state shown in FIG. As shown in FIGS. 10 (b) and 10 (c), the operating rate and the processing amount are lower than the processing capacity in any equipment, and the usage rate of the cooling place is 100% or more as shown in FIG. 10 (d). The product will not stay before. That is, the bottleneck process has not occurred. On the other hand, when the processing time of each process is set to the state shown in FIG. 11 (a) and the processing time of the finishing equipment 1 exceeds 10 working days, as shown in FIG. 11 (b). It can be seen that the operating rate of the finishing equipment 1 reaches 100%, and the processing amount of each equipment is equal to or less than the target value as shown in FIG. Moreover, as shown in FIG.11 (d), the time slot | zone where the utilization factor of a cooling place reaches 100% has generate | occur | produced twice. According to the configuration of the production distribution line 100 shown in FIG. 1, the upstream rolling process is stopped when the usage rate of the cooling yard reaches 100%. Therefore, the reason why the processing amount in the rolling process does not reach the target value in FIG. 11C is considered to be that the usage rate of the cooling place has reached 100%. Further, in FIG. 11C, the reason why the processing amount of the finishing equipment 2 and 3 does not reach the target amount is that the finishing equipment 2 and 3 share the same cooling space as the finishing equipment 1 and rolling. This is probably because the supply of steel products from the process is stopped. From the above, in this case, the production logistics plan creation device 10 can specify that the finishing equipment 1 is a bottleneck equipment. Thereby, the process of step S3 is completed and the operation rule creation process proceeds to the process of step S4.

  In the process of step S4, the production distribution plan creation device 10 changes the operation plan of the bottleneck equipment specified by the process of step S3 and its peripheral equipment so that the bottleneck process is eliminated. The details of this operation plan change process will be described later with reference to the flowchart shown in FIG. Thereby, the process of step S4 is completed and the operation rule creation process proceeds to the process of step S5.

  In the process of step S5, the production / distribution plan creation device 10 executes the production / distribution simulation again based on the bottleneck facility changed by the process of step S4 and the operation plan of its peripheral facilities. Thereby, the process of step S5 is completed and the operation rule creation process proceeds to the process of step S6.

  In the process of step S6, the production logistics plan creation device 10 determines whether or not the processing amount is excessive or deficient with respect to the planned amount in any process based on the processing result of step S5. As a result of the determination, if there is no excess or deficiency of the processing amount with respect to the planned amount, the production logistics plan creation device 10 advances the operation rule creation processing to the processing of step S9. On the other hand, if there is an excess or deficiency of the processing amount with respect to the planned amount, the production distribution plan creation device 10 advances the operation rule creation processing to the processing of step S7.

  In the process of step S7, the production logistics plan creation device 10 determines whether or not the number of times the operation plan has been changed has reached a predetermined number of repetitions. As a result of the determination, if the number of times the operation plan has been changed has not reached the predetermined upper limit number of times, the production distribution plan creation device 10 advances the operation rule creation processing to the processing in step S8. On the other hand, when the number of times the operation plan has been changed reaches a predetermined repetition upper limit number, the production distribution plan creation device 10 ends a series of operation rule creation processing.

  In the process of step S8, the production / distribution plan creation device 10 changes the facility for changing the operation plan. Thereby, the process of step S8 is completed and the operation rule creation process proceeds to the process of step S4.

  In the process of step S9, the production logistics plan creation device 10 associates information on the bottleneck equipment with information on the change contents of the operation plan performed so as to eliminate the bottleneck equipment based on the processing result of step S4. And stored in the operation rule DB 7 as operation rule information. Specifically, when the refining facility 1 is a bottleneck facility as shown in FIG. 11, a production plan of a product that can be replaced by the refining facility 3 by the operation plan changing process as shown in FIG. When the bottleneck equipment is eliminated by allocating the finishing equipment for the day, the production distribution plan creation device 10 stores this information in the operation rule DB 7 as an operation rule. Thereby, the process of step S9 is completed and a series of operation rule creation processes are complete | finished. Thereafter, the production logistics plan creation device 10 creates a production logistics plan by referring to the operation rule information stored in the operation rule DB 7 when creating the production logistics plan of the production logistics line 100 shown in FIG. .

[Operation plan change processing]
Next, the operation plan change process in step S4 will be described with reference to the flowchart shown in FIG.

  The flowchart shown in FIG. 13 starts at the timing when the process of step S3 is completed, and the operation plan change process proceeds to the process of step S11.

  In the process of step S11, the production distribution plan creation device 10 counts the number of orders passing through the bottleneck facility based on the order information stored in the order information DB2. Thereby, the process of step S11 is completed and the operation plan change process proceeds to the process of step S12.

  In the process of step S12, the production distribution plan creation device 10 refers to the information of the alternative processing flag included in the order information and searches for equipment (transfer destination equipment) that can substitute the product processed in the bottleneck equipment. Then, the processing surplus capacity (processing capacity amount−processing amount) of the searched transfer destination facilities is tabulated. Thereby, the process of step S12 is completed and the operation plan change process proceeds to the process of step S13.

  In the process of step S13, the production distribution plan creation device 10 determines whether there is processing capacity of the transfer destination facility based on the processing result of step S12. As a result of the determination, if there is processing capacity of the transfer destination facility, the production distribution plan creation apparatus 10 advances the operation plan change process to the process of step S14. On the other hand, when there is no processing capacity of the transfer destination facility, the production distribution plan creation device 10 advances the operation plan change process to the process of step S15.

  In the process of step S14, the production logistics plan creation device 10 determines the number of bottleneck equipment orders counted by the process of step S11 based on the information regarding the processing capacity of the bottleneck equipment stored in the equipment specification DB4. Among them, the production plan for orders that exceed the processing capacity of the bottleneck equipment is assigned to the transfer destination equipment. Thereby, the process of step S14 is completed and a series of operation plan change processes are complete | finished.

  In the process of step S15, the production distribution plan creation device 10 refers to the operation plan information stored in the operation plan DB 5, and determines whether the bottleneck facility is in a dormant state. As a result of the determination, if the bottleneck facility is in the dormant state, the production distribution plan creation apparatus 10 advances the operation plan change process to the process of step S16. On the other hand, if the bottleneck facility is not in the dormant state, the production logistics plan preparation device 10 advances the operation plan change process to the process of step S18.

  In the process of step S <b> 16, the production distribution plan creation device 10 changes the pause state of the bottleneck facility to the operating state. Thereby, the process of step S16 is completed and the operation plan change process proceeds to the process of step S17.

  In the process of step S17, the production distribution plan creation device 10 calculates the number of orders totaled by the process of step S11 based on the information regarding the processing capability of the bottleneck equipment stored in the equipment specification DB4. It is determined whether or not the processing capacity is exceeded. As a result of the determination, if the number of orders is equal to or greater than the processing capacity, the production logistics plan creation apparatus 10 advances the operation plan change process to the process of step S18. On the other hand, if the number of orders is not equal to or greater than the processing capacity, the production logistics plan creation device 10 ends the series of operation plan change processing.

  In the process of step S <b> 18, the production / distribution plan creation device 10 outputs warning information indicating that the bottleneck facility cannot be eliminated to the output area 30. Thereby, the process of step S18 is completed and a series of operation plan change processes are complete | finished.

  As is clear from the above description, in the operation rule creation process according to an embodiment of the present invention, the CPU 13 calculates the processing amount of the equipment within a predetermined period by the production logistics simulation, and the processing amount of the equipment and the processing planned amount. To determine whether there is a bottleneck facility in the production distribution line. Then, when the bottleneck facility exists, the CPU 13 changes the operation plan of the peripheral facility including the bottleneck facility, executes the production distribution simulation again, and associates the result of the production distribution simulation with the change contents of the operation plan. Stored as operation rule information. Thereby, the operation rule which suppresses generation | occurrence | production of a bottleneck process can be created. In addition, by creating a production logistics plan based on the created operation rules, a production logistics plan that suppresses the occurrence of the bottleneck process can be created.

  Although the embodiment to which the invention made by the present inventor is applied has been described above, the present invention is not limited by the description and the drawings that form a part of the disclosure of the present invention according to this embodiment. That is, other embodiments, examples, operational techniques, and the like made by those skilled in the art based on the present embodiment are all included in the scope of the present invention.

1 Production logistics planning system 2 Order information DB
3 In-process inventory DB
4 Equipment specifications DB
5 operation plan DB
6 Failure probability DB
7 Operation Rule DB
10 Production logistics plan creation device 11 RAM
12 ROM
13 CPU
14 Production logistics plan creation program 20 Input device 30 Output device

Claims (3)

Equipment including order information including information related to product passing process and processing time, in-process inventory information including information related to in-process inventory in each process constituting the production logistics line, and information related to processing capacity of equipment provided in each process A production logistics simulation step for calculating the amount of processing of the equipment within a predetermined period based on the operation plan information including the specification information and information on the operation plan of the equipment;
A determination step of determining whether or not a bottleneck facility exists in the production distribution line by comparing the processing amount of the facility and a processing plan amount;
When it is determined in the determination step that bottleneck equipment exists, an operation plan change step for changing an operation plan of peripheral equipment including the bottleneck equipment;
A re-simulation step of executing the production logistics simulation step again using the operation plan changed by the operation plan change step;
An operation rule storage step for associating and storing the processing result of the re-simulation step and the operation plan change content in the operation plan change step as an operation rule;
An operation rule creation method characterized by including:   The re-simulation step includes a step of changing the operation plan until the processing amount of the facility is equal to or less than a processing plan amount, and executing the production logistics simulation step again, and the operation rule storing step is a processing of the facility. The operation rule creation method according to claim 1, further comprising a step of storing, as an operation rule, a change in the operation plan when the amount becomes equal to or less than the processing plan amount.   A production logistics plan creation method comprising the step of creating a production logistics plan for the production logistics line based on an operation rule created by the operation rule creation method according to claim 1.

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