JP2013012100A - Production management method and production control system - Google Patents

Abstract

PROBLEM TO BE SOLVED: To suppress decrease in productivity as the entire production lines when running the production lines including production processes after a molding process while maintaining molds used for the molding process in a production management method.SOLUTION: The production management method includes: a quality transition model setting process S1; a production schedule initial setting process S2 for setting a production schedule including a review timing of maintenance time; a production line information acquisition process S6 for acquiring production line information at a review timing; a maintenance time candidate setting process S7 for setting maintenance time candidates for each review timing; a production prediction process S6 for performing a production simulation; a production schedule resetting process S9 for selecting one of evaluated prediction results and resetting a corresponding maintenance time candidate as a maintenance time; and a production schedule instruction process S3 for instructing a production schedule to the production lines.

Description

  The present invention relates to a production management method and a production management system.

Conventionally, a production line for industrial products may incorporate a molding process for molding using a mold. In such a production line, it is necessary to perform maintenance of the mold at appropriate intervals in order to prevent deterioration of the quality of the molded product based on the usage history of the mold. Since the molding apparatus cannot be produced during the mold maintenance period, there is a need for a production management method and a production management system for setting a production schedule so that productivity does not deteriorate due to mold maintenance.
As such a production management method and production management system, for example, in Patent Document 1, the central control unit is configured to input the necessary number of productions input for each product type and the priority thereof, and the current storage stored in the information storage unit. Create a production schedule based on the mold data stored in the mold storage, the mold data to be maintained in the maintenance process department, and the maintenance time required for maintenance. An injection molding processing system configured to instruct the mold transfer unit to transfer the mold and to input the molding conditions of the mold stored in the information storage unit to the injection molding machine to instruct the molding Management system is described.

JP-A-6-254932

However, the conventional production management method and production management system as described above have the following problems.
In the technique described in Patent Document 1, the required number of productions input for each product type and the priority thereof, the data of the mold stored in the current mold storage unit stored in the information storage unit, and the maintenance process unit In order to create a production schedule based on the data of the mold to be maintained in the maintenance and the maintenance time required for maintenance, it is possible to set an efficient production schedule to some extent. Due to production troubles and changes in parts arrival status, operations may not be as planned. For this reason, depending on the progress of production, there is a problem that the production efficiency as planned may not be achieved with a preset production schedule.
In particular, in the production system (production line) of the flow production system that does not have intermediate stock in the process as much as possible and consistently manufactures from the molding process to the subsequent processes such as assembly, molding according to the quantity required in the subsequent processes However, depending on the production progress of the entire production system, the number of molded products required in the subsequent process varies.
However, in the technique described in Patent Document 1, since a production schedule is set according to the necessity of maintenance of individual molds, it is impossible to schedule mold maintenance in accordance with the progress of the entire production system. For this reason, there exists a problem that productivity may fall as a whole production system.

  The present invention has been made in view of the above-described problems. When a production line including a post-production process is operated while performing maintenance of a mold used in the molding process, production as a whole production line is performed. It is an object of the present invention to provide a production management method and a production management system that can suppress deterioration in performance.

  In order to solve the above-described problems, the invention according to claim 1 includes a molding process in which molding is performed using a mold, and a post-production process in which a production operation is performed using a molded product molded in the molding process. A production management method in a production line to perform, a quality transition model setting step for setting a quality transition model of a molded product based on the usage history of the mold, an operating condition of the production line, a maintenance period of the mold, A production schedule initial setting step for setting a production schedule including a review timing for reviewing the maintenance time, and production for obtaining production progress data of the production line and use history data of the mold at the review timing. For each line information acquisition step and each review timing, a plurality of maintenance time candidates for the mold after the review timing are set. A maintenance time candidate setting step, a production simulation on the production line based on the production progress data, the usage history data of the mold, the quality transition model, and the maintenance time candidate, and after the review timing A production prediction step for predicting production and each prediction result of production predicted in the production prediction step are evaluated based on a preset condition, and one of the prediction results is selected, and the prediction result is selected. The production schedule resetting step for resetting the corresponding maintenance time candidate as the maintenance time in the production schedule, and the production schedule set in the production schedule initial setting step at the end of the production schedule initial setting step to the production line At the end of the production schedule resetting process A production schedule instruction step of serial maintenance timing instructs the reconfigured production schedule in the production line, the method comprising.

  According to a second aspect of the present invention, in the production management method according to the first aspect, the quality transition model is a method that represents a transition of a non-defective rate in molding using the mold.

  According to a third aspect of the present invention, in the production management method according to the first or second aspect, in the production schedule resetting step, as the condition, the production amount as the production line is maximized until a certain time. A method for selecting a maintenance time candidate.

  According to a fourth aspect of the present invention, in the production management method according to the first or second aspect, in the production schedule resetting step, as the condition, an intermediate stock amount of the molded product in the production line at a certain time is set as the condition. A method of selecting a maintenance time candidate that minimizes the maintenance time.

  According to a fifth aspect of the present invention, in the production management method according to the first or second aspect, in the production schedule resetting step, as the condition, an average operation rate of the production line until a predetermined time is maximized. A method for selecting a maintenance time candidate.

  According to a sixth aspect of the present invention, in the production management method according to the first or second aspect, in the production schedule resetting step, an average of products produced on the production line up to a certain time is used as the condition. A method for selecting a maintenance time candidate that minimizes the lead time is used.

  According to a seventh aspect of the present invention, in the production management method according to the first or second aspect, in the production schedule resetting step, a delivery date of a product produced on the production line until a predetermined time is used as the condition. A method of selecting a maintenance time candidate that maximizes the compliance rate.

  The invention according to claim 8 is a production management system in a production line having a molding section that performs molding using a mold and a post-process section that performs a production operation using a molded product molded by the molding section. A quality transition model setting unit for setting a quality transition model of a molded product based on the usage history of the mold, an operating condition of the production line, a maintenance timing of the mold, a review timing for reviewing the maintenance timing, , A production schedule initial setting unit that sets a production schedule, a production line information acquisition unit that acquires production progress data of the production line and use history data of the mold at the review timing, and the review timing A maintenance time candidate setting unit for setting a plurality of maintenance time candidates for the mold after the review timing, Based on the production progress data, the usage history data of the mold, the quality transition model, and the maintenance time candidates, a production prediction unit that performs production simulation on the production line and predicts production after the review timing; , Evaluating each production prediction result predicted by the production prediction unit based on a preset condition, selecting one of the prediction results, and selecting the maintenance time candidate corresponding to the prediction result A production schedule resetting unit for resetting as a maintenance time in the production schedule; and a production schedule instructing unit for instructing the production line to the production schedule set by the production schedule initial setting unit or the production schedule resetting unit. The configuration.

  According to the production management method and the production management system of the present invention, a review timing for reviewing the maintenance time of the mold is provided, and a production simulation is performed based on the production progress data and the mold quality transition model at each review timing. In order to reset the mold maintenance time, when the production line including the post-production process is operated while maintaining the mold used in the molding process, it is possible to suppress the decrease in productivity of the entire production line. There is an effect that can be done.

It is a typical block diagram which shows schematic structure of the production management system which concerns on embodiment of this invention. It is a typical system block diagram which shows an example of the shaping | molding part and post-process part of the production management system which concerns on embodiment of this invention. It is a flowchart which shows the process flow of the production management method which concerns on embodiment of this invention. It is a graph which shows an example of the quality transition model in the production management method concerning the embodiment of the present invention. It is a graph of the production amount per unit time of the forming apparatus and the intermediate inventory amount in the post-process part for explaining the operation of the production management method according to the embodiment of the present invention.

Embodiments of the present invention will be described below with reference to the accompanying drawings.
First, a production management system according to an embodiment of the present invention will be described.
FIG. 1 is a schematic block diagram showing a schematic configuration of a production management system according to an embodiment of the present invention. FIG. 2 is a schematic system configuration diagram illustrating an example of a forming unit and a post-processing unit of the production management system according to the embodiment of the present invention.

As shown in FIG. 1, the production management system 1 of the present embodiment performs production management of a production line 10 that produces a product 25.
First, the configuration of the production line 10 will be described.
The schematic configuration of the production line 10 includes a forming unit 12, a component processing unit 26, a post-process unit 13, and a production line control unit 11.

The molding unit 12 performs molding using a mold (not shown in FIG. 1) upon receiving the supply of the molding material 20. There are no particular limitations on the mold or the number of moldings of the molding part 12, and an appropriate number of 1 or more can be adopted.
In the present embodiment, as an example, as shown in FIG. 2, the molding material 20a, respectively mold _K a by 20b to supply each molding apparatus 12a to perform molding using a _{K b,} and 12b, the maintenance time There are provided mold changers 14a and 14b for exchanging the respective molds K _a and K _b with the maintained molds K _a and K _b .
As the molding materials 20a and 20b, any suitable material can be adopted as long as it can be molded by the molding apparatuses 12a and 12b. As an example of the molding materials 20a and 20b, for example, a material such as a synthetic resin, glass, metal, or the like formed into a suitable shape such as a pellet, a lump, a powder, or a plate can be used.
The molding type of the molding apparatuses 12a and 12b is not particularly limited. Examples of the molding types of the molding materials 20a and 20b include, for example, injection molding, casting molding, extrusion molding, press molding, and the like.
Below, when distinguishing the molded product 21 by the shaping | molding apparatuses 12a and 12b, it calls the molded products 21a and 21b, respectively.

The component processing unit 26 receives supply of the processing material 27 and processes the processing material 27 without using a mold to form the component 22c. Although the component processing unit 26 may be configured by a plurality of processing devices, in the present embodiment, as shown in FIG. 2, as an example, a component processing device 16c is provided.
The component processing device 16c is not particularly limited as long as it does not use a mold. Examples of the component processing apparatus 16c include, for example, a lathe and a milling machine.

The post-process unit 13 performs a production operation using the molded product 21 molded by the molding unit 12 to produce a product 25. That is, a post-production process is performed. Here, the production work refers to the molded product 21, the component 22 c, the intermediate assembly (not shown in FIG. 1), and the product 25 during the period from when the product 25 is formed from the molded product 21 to when the product 25 is unloaded from the production line 10. It means the work to be done for.
Examples of production work include, for example, work for processing the molded product 21, work for assembling the molded products 21 or the molded product 21 with other parts, work for inspecting the molded product 21 and the product 25, and the product 25. Packing work can be listed.
The post-process unit 13 can be configured by combining one or more of these production operations as necessary.
As shown in FIG. 2, the post-process unit 13 in this embodiment includes, as an example, component processing devices 16a and 16b, inspection units 30a and 30b, an assembly device 18A, an inspection unit 31, an assembly device 18B, and an inspection unit 32. 33.

The component processing device 16a (16b) is a processing device that performs some processing or processing on the molded product 21a (21b) to form a component 22a (22b) that is a component of the product 25 from the molded product 21a (21b). .
Examples of processing and processing are not particularly limited, and examples include burrs removal, cleaning processing, cutting processing, polishing processing, laser processing, and surface processing.

Moreover, between the shaping | molding apparatus 12a (12b) and the component processing apparatus 16a (16b), the conveyance part 15a (15b) which conveys the molded product 21a (21b) is provided.
For example, a belt conveyor or a transfer robot can be adopted as the configuration of the transfer unit 15a (15b). However, the conveyance part 15a (15b) is not limited to the structure which conveys automatically, It is good also as a structure which conveys manually.
Further, the transport operation of the transport unit 15a (15b) is controlled by the production line control unit 11, and if necessary, the transport can be temporarily stopped to form an intermediate stock of the molded product 21a (21b). It is.

An inspection unit 30a (30b) for inspecting the molded product 21a (21b) is provided in the vicinity of the transport unit 15a (15b).
The inspection unit 30a (30b) may employ an inspection device that performs automatic inspection according to inspection specifications, or may be configured to manually inspect using an appropriate inspection measuring device or observation device.

The assembly apparatus 18A is an apparatus that assembles the parts 22a, 22b, and 22c to form the part assembly 23, and includes, for example, an assembly robot that performs automatic assembly. However, the assembling apparatus 18A is not limited to the automatic assembling apparatus, and may be a semi-automatic assembling apparatus that requires manpower or an assembling support apparatus that supports manual assembling.
The assembling method and the fixing method are not particularly limited. For example, an assembling method such as insertion, fitting, and screwing of parts, or a fixing method such as screw fastening, adhesion, welding, and heat fusion may be employed. it can.
Between the component processing devices 16a, 16b, and 16c and the assembly device 18A, a transport unit 17 that transports the components 22a, 22b, and 22c is provided.
The structure of the conveyance part 17 can be suitably selected from the structures employable by the conveyance part 15a.

An inspection unit 31 that inspects the components 22a, 22b, and 22c is provided in the vicinity of the transport unit 17.
The configuration of the inspection unit 31 can be appropriately selected from the configurations that can be adopted by the inspection unit 30a as necessary.

  The assembly device 18B is a device that forms the product 25 by assembling the component assembly 23 and the assembly component 24 supplied from the outside of the production line 10. The configuration of the assembly device 18B can be appropriately selected from configurations that can be adopted by the assembly device 18A.

Between the assembly apparatuses 18A and 18B, a transport unit 19A for transporting the component assembly 23 is provided. Further, in the vicinity of the assembly device 18B, a transport unit 19B that transports the product 25 to the outside of the production line 10 is provided.
The configuration of the transport units 19A and 19B can be selected as appropriate from configurations that can be adopted by the transport unit 15a.

In addition, inspection parts 32 and 33 for inspecting the component assembly 23 and the product 25 are provided in the vicinity of the transport parts 19A and 19B, respectively.
The structure of the test | inspection parts 32 and 33 can be suitably selected as needed from the structures employable by the test | inspection part 30a.

The production line control unit 11 is electrically connected to the forming unit 12, the component processing unit 26, the post-processing unit 13, each conveyance unit, and each inspection unit, which are objects to be controlled in the production line 10, from the production management system 1. These control targets are controlled based on a production schedule to be described later, and production progress data of the production line 10 and mold usage history data in the molding unit 12 are acquired.
In addition, when a production work is performed by a worker in the production line 10, an instruction output unit (not shown) that gives a work instruction to the worker by an image, sound, or the like, or production progress data as needed by the worker. And an input unit (not shown) for inputting mold usage history data.

In the present embodiment, the production progress data of the production line 10 includes the forming devices 12a and 12b, the component processing devices 16a, 16b and 16c, and the assembling devices 18A and 18B. Data) of each output (production amount) actual result, non-defective product ratio actual result, operation rate actual result, and intermediate inventory actual result.
Mold usage history data includes, for example, cumulative molding count, continuous molding count, maximum allowable molding count data until maintenance, surface accuracy measurement of molding surface of molded product molded with the corresponding mold, appearance Includes measurements of foreign body inspection.
In the present embodiment, these production progress data are stored in the control target in the production line 10 and in each inspection unit.
As a device configuration of the production line control unit 11, a computer including a CPU, a memory, an input / output interface, an external storage device, and the like is employed.

Next, the configuration of the production management system 1 will be described.
As shown in FIG. 1, the function configuration of the production management system 1 includes a quality transition model setting unit 8, a production schedule initial setting unit 2, a production schedule instruction unit 3, a production line information acquisition unit 5, a maintenance time candidate setting unit 4, A production prediction unit 6 and a production schedule resetting unit 7 are provided.
In this embodiment, the production management system 1 employs a computer including a CPU, a memory, an input / output interface, an external storage device, and the like. In the production management system 1, a control program and an arithmetic program corresponding to the above functional configuration are executed by this computer, thereby realizing each control function and arithmetic function described later.

The quality transition model setting unit 8 sets a quality transition model of the molded products 21a and 21b based on the usage histories of the molds K _a and K _b .
For example, after a continuous molding for a certain period at a certain molding cycle, the quality transition model when repeating the same molding across the rest period of the forming mold K _a, for each K _b, cumulative The following formulas (1a) and (1b) representing changes in the non-defective product ratios y _a and y _b with respect to the molding number k _t and the continuous molding number k _c can be employed.

y _a = f _a (k _t , k _c ) (1a)
y _b = f _b (k _t , k _c ) (1b)

Here, the functions f _a and f _b can be determined by conducting an experiment in advance or can be determined from past production results. Further, these quality transition models are stored in the quality transition model setting unit 8 in an appropriate form such as a function, a mathematical formula, and a table that can be called up as necessary by the production prediction unit 6.
Generally, the mold, as the cumulative molding times k _t is increased, aging, such as wear and dirt adhesion to proceed, the yield rate is decreased.
In particular, in a mold used for resin molding or glass molding, it may take time until the yield rate is stabilized after continuous molding is started, for example, due to the stability of the temperature distribution of the molding apparatus. . In such a case, until the continuous molding times k _c increases to some extent, the yield rate becomes low.
However, by a die, or if the change due to continuous molding number k _c negligible, when a change due to the cumulative molding times k _t is negligible, each of the above formulas (1a), the independent variables (1b), the cumulative molding number _{k t} only, or it may be only continuous molding number _{k c.}
In the case of an operation mode in which the operation is not stopped until the maintenance time after the operation starts, the cumulative molding number k _t and the continuous molding number k _c coincide with each other, and therefore the independent variable is one variable.

Production schedules initial setting section 2, and the operating conditions of the production line 10, the mold _K a, the maintenance time of the _{K b T ma,} and _{T mb,} these maintenance time _{T ma,} and review the timing _{T r} to review the _{T mb,} the The production schedule is set.
The operating conditions of the production line 10 are such that the production plan (production amount, delivery date, etc.) of the product 25 can be achieved, and the molding conditions 21a, 21b, The operating conditions of the conveying units 15a, 15b, 17, 19A, and 19B for smoothly conveying the parts 22a, 22b, and 22c, the part assembly 23, and the product 25 are set in the same manner as in the conventional case.
These operating conditions are preferably set so that the intermediate stock amount generated in the production line 10 for waiting for processing and waiting for conveyance is as small as possible. This is because, for example, when the design of the product 25 is changed, the production plan is changed or canceled, the intermediate stock may become unusable or cannot be used immediately. This is because the load involved increases.

However, in the present embodiment, since the mold _K a, the maintenance of the _{K b} during the operation of the production line 10, to set the mold _K a, _{K b} of maintenance time _{T ma,} the _{T mb} advance, during the maintenance period Assuming that molding of the molding apparatuses 12a and 12b is stopped, the operating conditions are adjusted so that the operating rate of the production line 10 as a whole is unlikely to decrease.
For example, if it is necessary to assemble M assembly parts 23 during the maintenance period ΔT _a from the maintenance time T _ma of the mold K _a , the parts waiting for assembly by the assembly device 18A by the maintenance time T _ma The operating conditions of the forming device 12a, the transport unit 15a, the component processing device 16a, and the transport unit 17 are set so that M or more intermediate stocks of 22a are formed. Thus, for while performing maintenance of the mold K _a may supply required number of parts 22a, it can be prevented a drop in productivity due to maintenance of the mold K _a.

However, in such a production schedule, there is not much room for the intermediate inventory quantity. For example, a production equipment failure may occur, causing an unplanned outage or a non-defective product rate falling below the plan. This will affect the progress of the entire production line, resulting in an increase in lead time, a decrease in the delivery rate compliance rate, and an increase in intermediate inventory.
For example, before the maintenance time _{T ma,} for some reason, if the non-defective ratio in component processing apparatus 16c is lower than originally planned, delayed production progress in the assembling device 18A due to lack of parts 22c, parts 22a, 22b intermediate The amount of inventory becomes excessive. In particular, since the part 22a accumulates the intermediate stock amount necessary for the maintenance period, the intermediate stock amount increases.
In this case, for example, if Hayamere the maintenance timing of the die K _a, without changing the production tact time of the molding apparatus 12a, it is possible to adjust the quantity of WIP parts 22a.
For this reason, in this embodiment, review timing _Tr for reviewing the production schedule is set in the production schedule.
The review timing _Tr may be set to an appropriate time interval with reference to the actual value of the change in production progress. At least a time interval shorter than either of the maintenance times T _ma and T _mb is set. For example, it is when the intermediate inventory quantity is larger or smaller than expected relative to the initial plan.
In this embodiment, it sets so that it may become a fixed period as an example.

The production schedule instruction unit 3 is communicably connected to the production schedule initial setting unit 2, the production schedule resetting unit 7, and the production line control unit 11, and is set by the production schedule initial setting unit 2 or the production schedule resetting unit 7. The production schedule is instructed to the production line control unit 11.
The production schedule instruction unit 3 is also communicably connected to the production line information acquisition unit 5, and sends a control signal for starting the operation of the production line information acquisition unit 5 to the production line information acquisition unit 5. together, and to be able to send information of time t _r synchronized reviewing timing T _r.

The production line information acquisition unit 5, based on a control signal sent from the production schedule instruction unit 3 in reviewing timing T _r, from the production line control unit 11 is a production line information that represents the current state of the time t _r of the production line 10 To get. Production line information in this embodiment consists of a production progress data production line 10, the mold K _a in the molding portion _12, a K _b of usage history data.
Also, production line information acquisition section 5, the value of the production line information and time t _r, which is to be sent to the maintenance time candidate setting unit 4 and the production forecast unit 6.

The maintenance time candidate setting unit 4 sets a plurality of mold maintenance time candidates after the review timing _Tr based on the information sent from the production line information acquisition unit 5.
In this embodiment, based on the information from the production line information acquisition unit 5, the maintenance time candidates t _mai and t _mbj for the molds K _a and K _b are set by the following equations (2a) and (2b).

_{t mai = t r + (T} lima -t r) · (i / N a) (2a)
_{t mbj = t r + (T} limb -t r) · (j / N b) (2a)

_Here, T _{lima, T limb} each mold _K a, the longest maintenance timing acceptable in _{K b,} forming the respective maximum allowable molding limit contained mold _K a, the usage history data of the _{K b} It can be obtained by multiplying the forming tact of the devices 12a, 12b. _{Further, N a,} N _b is an integer of 2 or more, _{respectively, i = 1, ..., N} a, j = 1, ..., a _{N b.}

The production prediction unit 6 is communicably connected to the production line information acquisition unit 5, the maintenance time candidate setting unit 4, and the quality transition model setting unit 8, and the production progress data and mold information acquired by the production line information acquisition unit 5 are connected. Based on the use history data, the quality transition model set by the quality transition model setting unit 8, and the maintenance time candidates t _mai and t _mbj set by the maintenance time candidate setting unit 4, a production simulation on the production line 10 is performed. Time-series production from the review timing T _{r to} the end time t _end is predicted.
For this reason, the production prediction unit 6 includes a simulation program that calculates time series changes in production based on all devices in the production line 10 and operating conditions of manual work. As the simulation program, a configuration similar to that of a simulation program conventionally used when setting a production schedule for a production line can be employed.
Here, the end time t _end represents the time at which the production simulation is terminated, and can be appropriately set according to the contents of the evaluation of the production simulation performed by the production schedule resetting unit 7.
For this reason, the end time t _end may be set to the planned production end time or may be shorter, for example. Further, for example, it may be set to an appropriate unit break such as one day or one week.
In addition, when the evaluation of the production schedule resetting unit 7 is, for example, the lead time of the production line 10 for producing the product 25 having a fixed volume, the end time t _end is set to a sufficiently large value, The production simulation should be terminated when the output reaches the target value.

In the production simulation production forecast unit 6 is performed, volume of each production apparatus, WIP amount of the initial value (the value of t = t _r) is volume results in the production progress data is set based on the quantity of WIP results.
Further, in this production simulation, the non-defective product rate and the operating rate of the production apparatus excluding the molding devices 12a and 12b are set to the average results from the previous review timing to the current review timing from the non-defective product rate and the operating rate in the production progress data. .

Further, the prediction of the _production volume in the molding apparatuses 12a and 12b is predicted as the maintenance of the molds K _a and K _b being performed at the timing of the maintenance time candidates t _mai and t _mbj .
Here, when it is necessary to perform maintenance of the mold several times in the production simulation due to the end time t _end , the maintenance is performed at the maintenance time corresponding to the maintenance time candidates t _mai and t _mbj after the second time. Predict as you do.
Thus, changing the maintenance time, production volume per unit of time formed from reviewing the timing T _r to the start of the maintenance, the above formula (1a), the yield rate y _a based on _(1b), the transition of y _b It will change according to.

In this production simulation, a data group representing a time-series production transition after the review timing _Tr is obtained for N _a × N _b cases. Hereinafter, the result of this production simulation is referred to as a prediction result S _ij (where i = 1,..., N _a , j = 1,..., N _b ).
These prediction results S _ij are sent to the production schedule resetting unit 7.

The production schedule resetting unit 7 evaluates each production prediction result S _ij predicted by the production prediction unit 6 based on a preset condition, and selects one of the prediction results S _ij. The maintenance time candidates t _mai and t _mbj corresponding to the prediction result S _ij are _reset as the maintenance time in the production schedule.

As a condition for evaluating the prediction result S _ij , an appropriate condition corresponding to the productivity of the production line 10 can be set.
For example, it is possible to set a certain period as the evaluation period t _est and adopt a condition in which the production volume (production amount) as the production line 10 is maximized until the evaluation period t _est .
Here, the evaluation time t _est can be set as needed as long as it falls within the range in which the prediction result S _ij is calculated.
As an example of the evaluation period t _est is, for example, production scheduled end time, time to suit the specific product delivery time, mention may be made of the closing time of production line 10.
In this case, it is possible to minimize the trend of decrease in the volume due to the maintenance of the mold within the range of the prediction result _Sij . For this reason, the productivity fall of the production line 10 can be suppressed.

Further, for example, it is possible to adopt a condition in which the intermediate stock amount of the molded product in the production line 10 is minimized at the evaluation time t _est . Here, the molded product that minimizes the intermediate inventory quantity may be either the molded article 21a or 21b, or both, or the sum of the intermediate inventory quantities of the molded articles 21a and 21b. May be.
In this case, it is possible to minimize the intermediate stock amount of the molded product by performing the mold maintenance within the range of the prediction result S _ij . For this reason, even when the design change of the product 25, the change of the production plan, or the cancellation occurs, it is possible to suppress the loss due to the discard of the intermediate stock, the increase in the load related to the storage space and the inventory management.

Moreover, for example, a condition in which the average operating rate of the production line 10 until the evaluation time t _est is maximized can be employed.
Here, the average operation rate of the production line 10 means the average of the operation rates of the production apparatuses in the production line 10.
In this case, it is possible to suppress a decrease in the average operating rate of the production line 10 due to the maintenance of the mold, and to maximize the range within the prediction result _Sij . For this reason, the equipment utilization efficiency of the production apparatus of the production line 10 can be improved.

In addition, for example, a condition that the average lead time of the product 25 produced on the production line 10 is minimized can be employed. Here, the time for comparing the prediction results _Sij may be performed at the evaluation time t _{est as} necessary, or may be performed at the time when a certain volume is produced.
In this case, an increase in the lead time of the product 25 due to the maintenance of the mold can be suppressed, and the average lead time of the product 25 can be minimized within the range of the prediction result _Sij . For this reason, while being able to improve the productivity of the production line 10, the delivery date of the product 25 can be shortened or manufacturing cost can be reduced.

Further, for example, it can be time delivery of a product 25 produced by the production line 10 until evaluation period t _est is by employing the conditions of maximum.
In this case, it is possible to suppress a decrease in the delivery date compliance rate of the product 25 due to the maintenance of the mold, and to maximize the delivery date compliance rate of the product 25 within the range of the prediction result _Sij .

The evaluation conditions described above are examples and are not limited to these evaluation conditions.
Moreover, said evaluation conditions may combine said 2 or more conditions. For example, the due date compliance rate may be a maximum value of 100% in a plurality of prediction results S _ij , and therefore, for example, a plurality of prediction results S with the maximum due date compliance rate in combination with the evaluation condition of the intermediate inventory quantity. It is possible to adopt a condition that, among _ij, the one with the smallest intermediate stock quantity is selected.
This, for example, conditions X, if there is a Y, extracts the excellent group G _X superior in terms X, corresponds to the evaluation for selecting a prediction result of the best under conditions Y in excellent group G _X.
Another evaluation, for example, conditions X, if there is a Y, the evaluation extracting constraint group G _Y satisfying the constraint condition Y, selects a prediction result of the best in the condition X within the constraints group G _Y It may be adopted.

The following examples (1) to (3) can be given as specific examples of the plurality of evaluation conditions.
(1) When the throughput of the finished product as a whole production line is required to be maximized, the minimum acceptable product rate as the lowest product rate line within the evaluation period and the minimum number of continuous moldings until the next maintenance of the mold And select the one with the highest throughput from the prediction results. Here, the throughput means the production quantity within the evaluation period.
(2) When minimizing in-process inventory waiting for conveyance and processing, set the conditions for the minimum acceptable product rate and the minimum number of continuous moldings within the evaluation period, and the prediction result that the throughput will be more than a certain level based on the prediction result And the one with the lowest in-process inventory is selected.
(3) When minimizing the accumulated defective loss of the entire production line, set the minimum acceptable product rate within the evaluation period and the minimum number of continuous moldings as a condition. As described above, the prediction result in which the in-process inventory amount falls within a certain range is extracted, and the one with the smallest accumulated defective loss of the entire production line is selected from among the prediction results. Here, the defective money is obtained, for example, as the cumulative number of defective products × cost per defective product.

Next, an example of the operation of the production management system 1 will be described focusing on the production management method of the present embodiment.
FIG. 3 is a flowchart showing a process flow of the production management method according to the embodiment of the present invention. FIG. 4 is a graph showing an example of a quality transition model in the production management method according to the embodiment of the present invention. The horizontal axis in FIG. 4 indicates the number of moldings k (times), and the vertical axis indicates the yield rate y _a (%). FIGS. 5A and 5B are graphs of the production amount per unit time of the molded product and the intermediate stock amount in the post-process part, respectively, for explaining the operation of the production management method according to the embodiment of the present invention. The horizontal axis of Fig.5 (a) shows time and a vertical axis | shaft shows the production amount per unit time of a molded article. In FIG. 5B, the horizontal axis indicates time, and the vertical axis indicates the intermediate inventory amount of the post-process part.

  The production management method of the present embodiment using the production management system 1 is a production that performs a molding process in which molding is performed using a mold and a post-production process in which a production operation is performed using a molded product molded in the molding process. A production management method for a line, comprising a quality transition model setting process, a production schedule initial setting process, a production line information acquisition process, a maintenance time candidate setting process, a production prediction process, a production schedule resetting process, and a production schedule instruction process These are methods performed in accordance with the process flow shown in FIG.

First, in step S1, a quality transition model setting process is performed. This step is a step of setting a quality transition model of the molded product based on the usage history of the mold.
First, by conducting an experiment in advance or examining past production results, the relationship between the cumulative molding number k _t and the non-defective rate y _a , y _b with respect to the continuous molding number k _c for each mold K _a , K _b. The functions f _a and f _b representing the above are obtained, and the above formulas (1a) and (1b) are determined. Then, the quality transition model setting unit 8 stores the above formulas (1a) and (1b) in an appropriate form such as a function, a mathematical formula, and a table.
Step S1 is complete | finished above.

Hereinafter, the molding apparatuses 12a and 12b will be described assuming that no rest period is provided except for maintenance. In this case, in the above formulas (1a) and (1b), since the cumulative molding number k _t and the continuous molding number k _c coincide with each other, they are simply referred to as the molding number k. Therefore, the above formulas (1a) and (1b) become the following formulas (3a) and (3b).

y _a = f _a (k) (3a)
y _b = f _b (k) (3b)

For example, the graph shown in FIG. 4 is an example of a quality transition model corresponding to the above formula (3a). Function _{f a} which curve 100 represents, during the molding number k from 1 until _{k 1,} sharply increases the _{y 1} yield rate _{y a} from _{y 0,} molding number k from _{k 1} to _{k 2,} yield rate y _a is remained approximately constant from y ₁ to y _2, the molding number k increases from k _2, after the yield rate y _a is gradually decreased, indicating a decreased change in steeply. Use limit _{k 3} of the mold _{K a,} for example, in molding times _{k 2} or more is set in advance as a condition for non-defective ratio _{y a} is _{y 3} or less. Here, 1 <k ₁ <k ₂ <k ₃ , y ₀ <y ₁ , y ₃ <y ₂ , and y ₁ and y ₂ are approximately 100%, for example, 95% to 100%.
The curve 100 corresponds to the transition of the production amount per unit time of the molded product 21a.
Further, since the elapsed time t from the start of molding and subjecting the molding tact [Delta] T _S to the molding number k is obtained, the above formula (1a), (1b), (3a), from (3b), the volume of the molded article 21a Transition can be obtained.
In this example, why the yield rate y _a is lower in molding times k ₁ below is the die K _a is an injection mold of the present embodiment, the thermal condition is stabilized in a molding number k ₁ below This is because the dimensional accuracy of the molded product 21a is not stabilized. For example, in the case of a press die or the like, such an initial reduction in the yield rate is unlikely to occur.
Also, the yield rate y _a with molding times k ₂ or more drops is because dirt and deterioration gradually increasing defective products caused the mold K _a.

Next, in step S2, a production schedule initial setting step is performed. This step is a step of setting a production schedule including the operating conditions of the production line, the maintenance time of the mold, and the review timing for reviewing the maintenance time.
In this step, the production schedule is set in the production schedule initial setting unit 2 based on the production plan of the product 25 as described above. The production schedule initial setting unit 2 sends the set production schedule to the production schedule instruction unit 3.
This is the end of step S2.

Next, in step S3, a production schedule instruction process is performed. This step is a step of instructing the production line of the production schedule set in the production schedule initial setting step when executed at the end of step S2.
That is, the production schedule is instructed to the production line 10 by transmitting the production schedule sent from the production schedule initial setting unit 2 to the production line control unit 11 of the production line 10. Thereby, the production in the production line 10 is started.
This is the end of step S3.

Next, step S4 is a step of determining whether or not to end production management.
The production schedule instruction unit 3 refers to the elapsed time and determines whether or not the scheduled production end time in the production schedule instructed to the production line 10 has been reached.
When the scheduled production end time is reached, the production management is terminated.
If the scheduled production end time has not been reached, the process proceeds to step S5.

Step S5 is a step of determining whether or not the review timing has been reached.
The production schedule instruction unit 3 refers to the elapsed time and determines whether the review timing _Tr instructed to the production line 10 has been reached.
When the review timing _Tr is reached, the production schedule instruction unit 3 notifies the production line information acquisition unit 5 that the review timing _Tr has been reached. Thereby, the process proceeds to step S6.
If the review timing _Tr has not been reached, the process proceeds to step S4.

Here, the control flow of the production line control unit 11 will be described.
When starting the control operation, the production line control unit 11 stands by until a production schedule is instructed from the production management system 1.
When step S3 is performed and the production schedule is instructed from the production schedule instruction unit 3, step S20 is started.
Step S <b> 20 is a step of setting a production schedule based on an instruction from the production schedule instruction unit 3.
Upon receiving the production schedule instruction from the production schedule instruction unit 3, the production line control unit 11 converts the production schedule into control information for each device portion of the production line 10 as necessary, and stores it.
Above, step S20 is complete | finished.

Next, step S21 is a step of determining whether or not the production schedule ends.
The production line control unit 11 refers to the elapsed time and determines whether or not the scheduled production end time in the production schedule instructed from the production schedule instruction unit 3 has been reached.
When the scheduled production end time is reached, control to end production is performed.
If the scheduled production end time has not been reached, the process proceeds to step S22.
When step S21 is executed for the first time, since production has not started, it is determined that the scheduled production end time has not been reached.

Step S22, mold K _a in the production _schedule, is a step of determining whether or not reached the maintenance timing of K _b.
The production line control unit 11 refers to the elapsed time and determines whether or not the maintenance time of any of the molds K _a and K _b has been reached.
When the maintenance time is reached, the process proceeds to step S23.
If the maintenance time has not been reached, step S23 is skipped and the process proceeds to step S24.
When step S22 is executed for the first time, it is determined that the maintenance time has not been reached because production has not started.

Step S23 is a step of maintaining the mold that has reached the maintenance time.
In the present embodiment, when the maintenance of the die _K a _{(K b),} the mold exchanging machine 14a (14b), the mold _K a replacement prepared in advance and _{(K b)} for automatically changing. Then, the mold lowered from the molding apparatus 12a (12b) performs maintenance work such as inspection, repair, and cleaning offline.
For this reason, the period of replacement is a period for stopping molding due to maintenance.
However, depending on the type of the mold, when it is impossible to be always available a mold for replacement, until back to maintain the mold K _a disconnecting the molding apparatus 12a (12b) as a maintenance period, Molding may be stopped.

Step S24 is a step of controlling a control target in the production line 10 according to the production schedule.
That is, when the production schedule is set in the production line control unit 11, the production line control unit 11 determines the molding apparatuses 12a and 12b and the component processing apparatuses 16a, 16b, and 16c based on the operating conditions of the production line 10 in the production schedule. The operations of the assembling apparatuses 18A and 18B and the conveying units 15a, 15b, 17, 19A, and 19B are controlled. Thereby, the production work by the production line 10 is performed.
Here, the instruction regarding the production work through manual labor is made by an instruction output unit (not shown).
If the production schedule is changed in step S20, the control is switched based on the changed production schedule.
Thus, step S24 is completed, and the process proceeds to step S25 described later.

Here, the production flow in the production line 10 will be briefly described.
As shown in FIG. 2, in the molding apparatus 12a (12b), when the mold K _a (K _b ) is mounted by the mold exchanger 14a (14b) and the molding material 20a (20b) is supplied, Molding is performed according to the molding tact. The molded product 21a (21b) thus formed is transported to the inspection unit 30a (30b) by the transport unit 15a (15b), and is inspected.
The molded product 21a (21b) that has passed the inspection is conveyed to the component processing apparatus 16a (16b) by the conveying unit 15a (15b). When the progress of the component processing device 16a (16b) is stagnant, it becomes a transfer waiting and becomes an intermediate stock of the molding device 12a (12b) or waits for processing after being transferred to the component processing device 16a (16b). It becomes an intermediate stock of the component processing apparatus 16a.
The component 22a (22b) processed by the component processing device 16a (16b) is transported to the inspection unit 31 by the transport unit 17 and inspected, and then transported to the assembly device 18A.
In parallel with this, in the component processing device 16c, the processing material 27 is processed to manufacture the component 22c, and is transported to the inspection unit 31 by the transport unit 17 and inspected, and then transported to the assembly device 18A.

Since the assembling apparatus 18A assembles the parts 22a, 22b, and 22c, the assembling apparatus 18A cannot be assembled unless one or more of them are transported, resulting in a delay in production progress.
For example, if the non-defective product rate of the molding device 12a is reduced and the yield of the molded product 21a is reduced as compared with the production plan, or if a trouble occurs in the component processing device 16a and the production tact or the non-defective product rate is reduced, Insufficient supply of the parts 22a may lead to such a delay in production.
When the number of parts necessary for the assembly is obtained, a part assembly 23 is formed, and after being conveyed to the inspection unit 32 by the conveying unit 19A, the non-defective product is conveyed to the assembling apparatus 18B.
In the assembling apparatus 18B, the assembly component 24 and the component assembly 23 supplied from the outside are assembled and conveyed as a product 25 to the inspection unit 33 that performs final inspection. If the inspection unit 33 determines that the product is non-defective, it is held as a shipping stock, and when the planned number is collected, the product is shipped outside the production line 10.

Step S <b> 25 is a step in which the production line control unit 11 determines whether there is an instruction to acquire production line information from the production schedule instruction unit 3.
If there is no instruction, the process proceeds to step S21 and the above steps are repeated.
If there is an instruction, the process proceeds to step S26.

Step S26 is a step in which the production line control unit 11 collects production line information and transmits it to the production line information acquisition unit 5 of the production management system 1.
In the present embodiment, the production line control unit 11 acquires the production progress data of the production line 10 and the usage history data of the mold as production line information and transmits them to the production line information acquisition unit 5.
Above, step S26 is complete | finished.
When step S26 ends, the production line control unit 11 proceeds to step S21 and repeats the above steps.

Next, returning to the flow of the production management system 1, the steps after step S6 will be described.
In step S6, a production line information acquisition process is performed. This process is a process of acquiring production line production progress data and mold usage history data, which are production line information, at the review timing.
That is, the production line information acquisition unit 5, based on the notification from the production schedule instruction unit 3, with respect to the production line control unit 11 of the production line 10, at time t _r, the production progress data production line 10, forming A control signal indicating an instruction to acquire the usage history data of the molds K _a and K _b in the unit 12 is transmitted, and the data reception from the production line control unit 11 is awaited.
When step S26 is executed in the production line control unit 11, the production progress data and the usage history data of the molds K _a and K _b are transmitted and received by the production line information acquisition unit 5.
Each received data is sent to the maintenance time candidate setting unit 4 and the production prediction unit 6.
This is the end of step S6.

Next, in step S7, a maintenance time candidate setting step is performed. This step is a step of setting a plurality of mold maintenance time candidates after the review timing for each review timing.
That is, the maintenance time candidate setting unit 4 sets the maintenance time candidates t _mai and t _mbj by the above formulas (2a) and (2b), and sends them to the production prediction unit 6.
Above, step S7 is complete | finished.

Next, in step S8, a production prediction process is performed. This step is a step of performing production simulation on the production line based on production progress data, mold usage history data, quality transition model, and maintenance time candidates, and predicting production after the review timing.
The production prediction unit 6 is sent from the production progress data sent from the production line information acquisition unit 5, mold usage history data, the quality transition model set by the quality transition model setting unit 8, and the maintenance time candidate setting unit 4. Based on the maintenance time candidates t _mai and t _mbj , a production simulation in the production line 10 is performed to predict time-series production until the end time t _end .
The prediction result S _ij is sent to the production schedule resetting unit 7.
Above, step S8 is complete | finished.

In general, when the progress of the entire production line 10 is delayed, it is not easy to determine whether the mold should be maintained as originally planned or whether the maintenance timing should be changed.
If the maintenance period is advanced, maintenance will be performed before the non-defective product rate decreases, and the occurrence of defective losses can be suppressed and the intermediate inventory can be reduced. If the cycle is repeated, the total number of maintenance is increased and the throughput is lowered. Further, since the time when the maintenance can be resumed and the production can be started again is deviated, it is impossible to determine whether the product restoration can be supplied in real time at the timing when the production return is required from the production system.
Conversely, if the maintenance time is delayed, it is possible to secure the number of molded products for the time being, but delaying the maintenance time causes a decrease in the yield rate of molded products, resulting in a decrease in total throughput and a decrease in defective loss. There is also a possibility of increase. In addition, since it is not possible to start production again after maintenance, it is impossible to determine whether the real-time request from the entire production system can be met.

The prediction result S _{ij according} to the present embodiment includes the production progress results at the review timing _Tr and the production amount for each production device based on the linkage of all production devices on the production line 10, the intermediate inventory amount, the change in the operation rate, etc. Predictions are included. This makes it possible to predict the production volume, inventory amount, average operating rate, delivery time compliance rate, average product lead time, and the like for the entire production line 10.
Below, in order to demonstrate the effect | action of production simulation, an example of the prediction result of the shaping | molding apparatus 12a is demonstrated.

For example, production per unit of time moldings 21a in the forming device 12a are, from time t ₀ to time t _r, assuming that change as the curve ab of FIG. 5 (a), and the size of the production b, accumulated production volume up to time t _r has been acquired as the production progress data. Here, the time t ₀ is the time you restart the production and maintenance of the mold K _a, time t _r is a review timing T _r.
Curve ab in FIG. 5 (a), for example, corresponds to the change in the yield rate from the molding count Once the molding apparatus 12a shown in FIG. 4 to k ₂ times, are initially yield rate y _a of the molding Since it is low, the production volume decreases, and when the number of moldings exceeds a certain number, a substantially constant production volume per unit time can be obtained.
At this time, the change record of the intermediate inventory amount of the part 22a waiting to be assembled in the assembling apparatus 18A is, for example, as shown by a curve AB in FIG. That is, since the time t ₀ before the molding apparatus 12a is stopped by maintenance, WIP amount decreases. When the supply of the molded article 21a is started at time t _0, the processability of the part 22a by the component processing apparatus 16a starts, decreasing the quantity of WIP is reduced, eventually turns into an intermediate inventory increase.

For each set maintenance time candidate at maintenance time candidate setting unit 4, when the production simulation, production of moldings 21a Considering rest of the molding by the maintenance of the mold after time t _r can be estimated.
For example, as an example, maintenance time candidates t _ma1 and t _ma2 (where t _ma1 <t _ma2 ) shown in FIG. _5A are set as the maintenance time. These are, in molding times, corresponding to the molding number between k ₂ and k _3, respectively.

Production forecast parts 22a is, the operation rate of parts processing device 16a, the yield rate is obtained by using the actual values up to time t _r. Likewise, it obtained by using the actual values of up uptime time t _r of the assembly apparatus 18A.
As a result, as shown in FIG. 5B, when the maintenance is performed from time t _ma1 , the transition of the curve 104 indicated by the solid line is changed. When the maintenance is performed from time t _ma2 , the change of the curve 105 indicated by the broken line is changed. , Each obtained as a prediction result. In FIG. 5B, a straight line 106 indicates a necessary stock amount for preventing the assembly of the assembly apparatus 18A from stopping.
Curve 104 and 105 are both, although from time _{t r} to just after the time _{t ma1, t ma2} parts inventory amount increases, the peak (see FIG. 5 (b) _C 1, _{C 2} points) After the maintenance period, it starts to decrease, and after the maintenance period is minimized (see points D ₁ and D _{2 in} FIG. 5B), the molding apparatus 12a resumes molding and increases again. .

The transition of the curve 104 is obtained when the maintenance is started while the non-defective product rate is high in the molding apparatus 12a, and the transition of the curve 105 is obtained when the molding is continued in the molding apparatus 12a even if the good product ratio decreases. .
From the viewpoint of not increasing the molding efficiency and the intermediate inventory amount, the transition of the curve 104 is preferable to the transition of the curve 105. However, in the transition of the curve 104, the inventory amount necessary for assembling the assembly apparatus 18A before the end of the maintenance is obtained. It will break. For this reason, the assembly of the assembly device 18A is stopped due to the out of parts, and the production amount of the part assembly 23 is reduced.
Therefore, the productivity in the post-process section 13 is reduced, and the turnover of the curve 104 is lower in the output of the production line 10 as a whole.

Next, in step S9, a production schedule resetting process is performed. In this process, each prediction result of production predicted in the production prediction process is evaluated based on preset conditions, one of the prediction results is selected, and a maintenance time candidate corresponding to the prediction result is maintained. It is a process of resetting as time.
That is, the production schedule resetting unit 7 evaluates the prediction result S _ij sent from the production prediction unit 6 based on preset conditions, selects one of the prediction results S _ij , and this prediction The maintenance time candidates t _mai and t _mbj corresponding to the result S _ij are _reset as the maintenance time.
As the evaluation conditions, the various conditions already described can be employed.
For example, in the example shown in FIG. 5B, when the operation rate of the assembling apparatus 18A affects the production volume of the production line 10, if the evaluation is performed under the condition that maximizes the production volume of the production line 10, the maintenance time Is reset to _tma2 .
Further, for example, in the example shown in FIG. 5B, when the intermediate inventory amount of the production line 10 affects the intermediate inventory amount of the molding apparatus 12 a, the intermediate inventory amount of the production line 10 becomes the minimum. If the evaluation is performed under the conditions, the maintenance time is _reset to t _ma1 .

In this way, when step S9 ends, the process proceeds to step S3, and each step from step S3 is repeated.
As a result, after the second time step S3 is executed, the production line control unit 11 is instructed by the production schedule resetting process, the production schedule whose maintenance time is reset.
Therefore, in step S23 of the production line control unit 11, after the review timing _Tr , within the range of the prediction result _Sij based on the production simulation considering the production progress of the production line 10 and the productivity change due to the maintenance of the mold, The optimum maintenance time is instructed under certain evaluation conditions.
By such a process flow, the production of the product 25 is continued until the production end time on the production schedule is reached.

  According to the production management method of the present embodiment using the production management system 1, a review timing for reviewing the mold maintenance timing is provided, and a production simulation is performed based on the production progress data and the mold quality transition model at each review timing. Thus, even if a deviation from the production plan occurs, such as a change in production progress, the influence of the mold maintenance on the productivity can be suppressed. For this reason, when operating the production line including a post-production process, maintaining the metal mold | die used for a shaping | molding process, the fall of productivity as the whole production line can be suppressed.

  In the above description of the embodiment, the production line 10 includes the die changers 14a and 14b, and the die is automatically exchanged according to the control signal of the production line control unit 11. The mold may be manually replaced or maintained based on an instruction displayed on the instruction output unit from the production line control unit 11.

  In the above description of the embodiment, the example in which the maintenance time candidates of the mold are set at equal intervals has been described. However, this is an example, and the maintenance time candidates are set at unequal intervals. Also good.

  In the above description of the embodiment, an example in which the production line 10 includes the component processing unit 26 in addition to the forming unit 12 and the post-processing unit 13 has been described. However, the component processing unit 26 may be omitted.

  Moreover, all the components described in the above embodiment can be implemented by being appropriately combined or deleted within the scope of the technical idea of the present invention.

DESCRIPTION OF SYMBOLS 1 Production management system 2 Production schedule initial setting part 3 Production schedule instruction | indication part 4 Maintenance time candidate setting part 5 Production line information acquisition part 6 Production prediction part 7 Production schedule reset part 8 Quality transition model setting part 10 Production line 11 Production line control Part 12 Molding part 12a, 12b Molding device 13 Post-process part 16a, 16b, 16c Component processing device 18A, 18B Assembly device 21, 21a, 21b Molded product 22a, 22b Component 23 Component assembly 24 Assembly component 25 Product 26 Component processing part 30a, 30b, 31, 32, 33 inspection unit _K a, _{K b} die Tr reviewing timing _y a, _{y b} yield rate Sij prediction result _{T ma, T mb} maintenance timing _{t mai, t MBj} maintenance timing candidates

Claims (8)

A production management method in a production line for performing a molding process for molding using a mold and a post-production process for performing a production operation using a molded product molded in the molding process,
A quality transition model setting step for setting a quality transition model of a molded product based on the usage history of the mold;
A production schedule initial setting step for setting a production schedule including operating conditions of the production line, maintenance time of the mold, and review timing for reviewing the maintenance time;
In the review timing, production line information acquisition step of acquiring production progress data of the production line and usage history data of the mold,
For each review timing, a maintenance time candidate setting step for setting a plurality of maintenance time candidates for the mold after the review timing;
Based on the production progress data, the usage history data of the mold, the quality transition model, and the maintenance time candidates, a production prediction process for performing production simulation on the production line and predicting production after the review timing; ,
Each production prediction result predicted in the production prediction step is evaluated based on a preset condition, one of the prediction results is selected, and the maintenance time candidate corresponding to the prediction result is selected as the production A production schedule resetting process to be reset as a maintenance time in the schedule;
The production schedule set in the production schedule initial setting step is instructed to the production line at the end of the production schedule initial setting step, and the production schedule in which the maintenance time is reset is set at the end of the production schedule resetting step. A production schedule instruction process for instructing the production line;
A production management method comprising: The production management method according to claim 1, wherein the quality transition model represents a transition of a non-defective rate in molding using the mold. In the production schedule resetting step,
The production management method according to claim 1, wherein a maintenance time candidate that maximizes the production amount as the production line is selected as the condition until a certain time. In the production schedule resetting step,
The production management method according to claim 1, wherein a maintenance time candidate that minimizes an intermediate inventory of the molded product in the production line at a certain time is selected as the condition. In the production schedule resetting step,
The production management method according to claim 1, wherein a maintenance time candidate that maximizes an average operating rate of the production line until a certain time is selected as the condition. In the production schedule resetting step,
The production management method according to claim 1, wherein a maintenance time candidate that minimizes an average lead time of products produced on the production line until a certain time is selected as the condition. In the production schedule resetting step,
The production management method according to claim 1, wherein a maintenance time candidate that maximizes a delivery date compliance rate of products produced on the production line before a certain time is selected as the condition. A production management system in a production line having a molding part that performs molding using a mold and a post-process part that performs a production operation using a molded product molded in the molding part,
A quality transition model setting unit for setting a quality transition model of a molded product based on the usage history of the mold;
A production schedule initial setting unit for setting a production schedule including operating conditions of the production line, a maintenance time of the mold, and a review timing for reviewing the maintenance time;
At the review timing, a production line information acquisition unit that acquires production progress data of the production line and usage history data of the mold,
A maintenance time candidate setting unit that sets a plurality of maintenance time candidates of the mold after the review timing for each review timing;
Based on the production progress data, the usage history data of the mold, the quality transition model, and the maintenance time candidates, a production prediction unit that performs production simulation on the production line and predicts production after the review timing; ,
Each production prediction result predicted by the production prediction unit is evaluated based on a preset condition, one of the prediction results is selected, and the maintenance time candidate corresponding to the prediction result is selected as the production A production schedule resetting unit to reset as a maintenance time in the schedule;
A production schedule instruction unit for instructing the production line of a production schedule set by the production schedule initial setting unit or the production schedule resetting unit;
A production management system comprising:

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