JP2019028819A - Production management assist system and method - Google Patents

Abstract

To assist in production management succeeding the beginning of production of goods.SOLUTION: A group of intermediate goods including intermediate goods that pass a management object process on a reference date or later is extracted from a production plan storage unit. A group of preceding processes including preceding processes which intermediate goods included in the group of intermediate goods pass prior to the management object process is extracted from the production plan storage unit. An in-progress situation of intermediate goods, which are included in the group of intermediate goods, in the preceding process included in the group of preceding processes is extracted. A date of arrival on which the intermediate goods included in the group of intermediate goods arrive the management object process, and an arrival quantity that is a quantity of intermediate goods which arrive the management object process on the arrival date are calculated based on the in-progress situation. An actual result value of a processing quantity in the management object process immediately preceding the reference date is acquired from a progress information storage unit. A cumulative value obtained by cumulating a moving average value of a difference, which is obtained by subtracting the actual result value from the arrival quantity, over a predetermined period is calculated as a balance index. Whether a production plan succeeding the reference date has to be modified is determined based on the balance index.SELECTED DRAWING: Figure 1

Description

  The present invention relates to a production management support apparatus and method for supporting production management in a factory that produces products.

  In factories that manufacture products, it is required to accurately predict the manufacturing period, which is the time required to manufacture the products (see Non-Patent Document 1). In Non-Patent Document 1, the possibility of various variations in manufacturing is estimated using past performance data, and the estimated results are used for the prediction of the manufacturing work period. Minimized.

Shiotani Masanori, 4 others, “Development of probabilistic model for manufacturing plan of plate and manufacturing standard calculation method”, Iron and Steel, Japan Iron and Steel Institute, vol. 101 (2015) No. 11, p. 574-583

  The technology described in Non-Patent Document 1 makes a production plan that reduces the delay in delivery due to the influence of variation and prevents the creation of a plan with an excessive margin that emphasizes the risk of delay. The manufacturing lead time is predicted at the stage. Therefore, in the technique described in Non-Patent Document 1, it is determined whether or not the production plan needs to be corrected with respect to fluctuations such as variations occurring in the production process at the stage after the production of the product is started. Support for production management, etc. has not been fully studied.

  The present invention solves the above-described problems, and an object of the present invention is to provide a production management support apparatus and method for supporting production management after starting production of a product.

The first aspect of the present invention is:
In a factory for processing a plurality of intermediate products in a plurality of processes in which a plurality of intermediate products pass in the order of the plan according to a predetermined production plan, and producing a plurality of order-receiving products corresponding to the plurality of intermediate products. A production management support device for supporting production management,
A production plan storage unit for storing the production plan, and a management target process preselected from the plurality of processes;
A progress information storage unit for storing progress information of production of the plurality of ordered products including in-process status for the plurality of steps of the plurality of intermediate products;
An intermediate product group extraction unit that extracts an intermediate product group including the intermediate product that passes through the management target process after a reference date from the production plan storage unit;
A preceding process group extracting unit that extracts a preceding process group including a preceding process through which the intermediate product included in the intermediate product group passes before the process to be managed from the production plan storage unit;
The in-process status of the intermediate product included in the intermediate product group with respect to the preceding process included in the preceding process group is extracted from the progress information storage unit before the reference date, and the part after the reference date is extracted. An in-process status extracting unit that extracts from the production plan storage unit;
Based on the in-process status, an arrival date when the intermediate product included in the intermediate product group arrives at the management target process, and an arrival amount that is an amount of the intermediate product that arrives at the management target process on the arrival date; An arrival information calculation unit for calculating
A cumulative value obtained by accumulating a moving average value in a predetermined period of the difference obtained by subtracting the actual value from the arrival amount, obtaining the actual value of the processing amount of the management target process most recently on the reference date. A balance index calculation unit for calculating as a balance index;
A plan correction determination unit for determining whether it is necessary to correct the production plan after the reference date based on the balance index;
Is provided.

The second aspect of the present invention is:
In a factory for processing a plurality of intermediate products in a plurality of processes in which a plurality of intermediate products pass in the order of the plan according to a predetermined production plan, and producing a plurality of order-receiving products corresponding to the plurality of intermediate products. A production management support method for supporting production management,
An intermediate product group extracting step for extracting an intermediate product group including the intermediate product that passes through a management target process selected in advance from a plurality of processes from a reference date, from a production plan storage unit that stores the production plan;
A preceding process group extracting step for extracting from the production plan storage unit a preceding process group including a preceding process through which the intermediate product included in the intermediate product group passes before the process to be managed;
The in-process status of the intermediate product included in the intermediate product group with respect to the preceding process included in the preceding process group is extracted from a progress information storage unit that stores progress information before the reference date, and the reference date Subsequent minutes are extracted from the production plan storage unit in-process status extraction step;
Based on the in-process status, an arrival date when the intermediate product included in the intermediate product group arrives at the management target process, and an arrival amount that is an amount of the intermediate product that arrives at the management target process on the arrival date; An arrival information calculation step for calculating
A cumulative value obtained by accumulating a moving average value in a predetermined period of the difference obtained by subtracting the actual value from the arrival amount, obtaining the actual value of the processing amount of the management target process most recently on the reference date. A balance index calculation step to calculate as a balance index;
A plan correction determination step for determining whether it is necessary to correct the production plan after the reference date based on the balance index;
Is provided.

  In the first aspect or the second aspect, the actual value of the processing amount of the management target process most recently acquired is obtained, and a predetermined difference of the actual value is subtracted from the arrival amount of the intermediate product that arrives at the management target process on the arrival date. A cumulative value obtained by accumulating the moving average values in the period is calculated as a balance index. Based on the balance index, it is determined whether it is necessary to correct the production plan after the reference date. Therefore, according to the first aspect or the second aspect, it is possible to determine whether or not the production plan needs to be corrected after the production of the ordered product is started.

  In the first aspect, for example, the plan correction determining unit may determine that the production plan needs to be corrected when the balance index is less than a predetermined negative value threshold. Good.

  In this aspect, it is determined that the production plan needs to be corrected when the balance index is less than a predetermined negative value threshold. Therefore, according to this aspect, it is possible to easily determine whether or not the production plan needs to be corrected only by comparing the balance index with the threshold value.

  In the first aspect, for example, an alarm issuing unit may be further provided that issues an alarm when the plan correction determining unit determines that the production plan needs to be corrected.

  In this aspect, when it is determined that the production plan needs to be corrected, an alarm is issued. Therefore, according to this aspect, it is possible to notify the user that it is necessary to correct the production plan.

  According to the present invention, since it is determined whether or not it is necessary to correct the production plan after the reference date based on the balance index, it is necessary to correct the production plan after starting production of the ordered product. It is possible to determine whether or not there is.

It is a block diagram which shows roughly the structural example of a production management assistance apparatus. It is a block diagram which shows roughly the principal part of the production line of a factory. It is a figure which shows detailed information roughly. It is a figure which shows arrival information schematically. It is a figure which shows roughly an example of transition of the in-process amount in a management object process. It is a figure which shows roughly change of the weight which stayed in the management object process for 10 days or more. It is a figure which shows roughly an example of transition of the amount of work in process in a 1st process. It is a figure which shows roughly an example of transition of the amount of work in process in a 2nd process. It is a figure which shows roughly an example of transition of the amount of work in process in a 3rd process. It is a figure which shows roughly an example of transition of the in-process amount in a 4th process. It is a figure which shows roughly the transition of the processing amount of each day in a management object process. It is a figure which shows roughly the cumulative value of the 5-day moving average of difference difference amount. It is a figure which shows detailed information roughly. It is a figure which shows roughly the arrival amount for every arrival date to a management object process. It is a figure which shows roughly the arrival amount when productivity falls compared with FIG. FIG. 16 is a diagram schematically showing a transition of a balance index in the case of FIG. 15. It is a flowchart which shows schematically operation | movement of the production management assistance apparatus of FIG.

(Knowledge that became the basis of the present invention)
First, the knowledge that forms the basis of the present invention will be described. In the stage of creating a production plan before starting the manufacture of products, the leveling of loads in each process and the rectification of physical distribution for transporting materials or intermediate products are usually achieved. However, when production of a product is actually started, the progress of product production is delayed due to various factors, and a deviation from the production plan occurs.

  As described in Non-Patent Document 1, for example, the plate manufacturing process is characterized by a large number of finishing steps after rolling, unlike other steel types. In addition, in the case of thick plates, not only the number of finishing processes is large, but it passes by the quality (quality) in each process other than the standard processes that are predetermined based on manufacturing specifications such as cutting, heat treatment, and painting. It is necessary to manage production in consideration of non-standard processes such as care, correction, and reprocessing where the presence or absence is determined. It is important to manage the production so that the load of the finishing process is leveled and the load is not concentrated on one process, but depending on the contents or quantity of the nonstandard process, the production capacity may be exceeded in the subsequent processes. There is a possibility that the load is temporarily concentrated and the delivery time of the product is delayed.

  In order to comply with the delivery date of the product, it is necessary to keep the deviation between the production plan and the progress of production within an allowable range. If the production volume is reduced or the production capacity is increased, it is certainly easy to keep the deviation between the production plan and the progress of production within an allowable range, but this is not preferable from the viewpoint of business competitiveness. It is important that the production of products be carried out in large quantities and at the lowest cost with the shortest possible delivery time. For this reason, it is normal that the countermeasures when the difference between the production plan and the progress of production becomes larger than the allowable range are relatively severe.

  When a production plan is drawn up, an important process that is a target for adjusting the load is selected as a process to be managed. Usually, a production plan is drafted so that the amount of work in progress in the process to be managed changes within a certain range. Further, when the progress status is managed, the in-process amount in the management target process is managed. This is based on the knowledge that if the load adjustment is appropriate and the production is smooth, the in-process amount in the process to be managed falls within a certain range of “fluctuation”.

  On the other hand, when the amount of work in progress in the process to be managed deviates from a certain range, production cannot catch up, causing a long stay of intermediate products and a delay in delivery of product shipment. In order to reduce this effect, various additional costs such as emergency shipping, outsourcing of partial production, and addition of personnel are generated.

  Such a situation is, so to speak, a resonance phenomenon of fluctuation between processes, and it may be difficult to deal with when the problem becomes apparent. For this reason, it is a problem in production control to grasp signs of deterioration while the fluctuation of the in-process quantity in the process to be managed is small and to keep the deviation of the in-process quantity from a certain range within an allowable range.

  Non-Patent Document 1 discloses a method for appropriately predicting a manufacturing period at the stage of planning a production plan. On the other hand, the present inventor is in order to continue smooth production before various fluctuations such as variations become large in the process after the production plan is drawn up and the production of the product is started. Judging whether or not the plan needs to be revised, we came up with a technology that supports production management.

(Embodiment)
Hereinafter, an embodiment of the present invention will be described with reference to the drawings. In each drawing, the same numerals are used about the same component.

(Constitution)
FIG. 1 is a block diagram schematically showing a configuration example of a production management support apparatus in the present embodiment. FIG. 2 is a block diagram schematically showing a main part of a production line of a factory in which the production management support apparatus according to this embodiment is used. The production management support device according to the present embodiment processes a plurality of intermediate products in a plurality of processes in which a plurality of intermediate products pass in the order of the plan according to a predetermined production plan, and a plurality of corresponding products from the plurality of intermediate products. Supporting production management in factories that produce orders.

  As shown in FIG. 2, the production line 200 of the factory whose production management is supported by the production management support apparatus in this embodiment includes a management target process 220 and a preceding process group 210 before the management target process 220. . The preceding process group 210 includes a first process 211, a second process 212, a third process 213, and a fourth process 214.

  The first step 211, the second step 212, the third step 213, and the fourth step 214 may each be a step that has a single facility and performs a single process on the intermediate product. Alternatively, each of the first step 211, the second step 212, the third step 213, and the fourth step 214 includes a plurality of steps that sequentially include a plurality of facilities and perform a plurality of processes on the intermediate product. May be included. As described above, the management target process 220 is an important process that is selected in advance when a production plan is drafted and is a target for adjusting the load.

  In the present embodiment, the first step 211, the second step 212, and the fourth step 214 may be the standard steps described above. The third step 213 may be the non-standard step described above in which it is determined whether or not the third step 213 is executed according to the result of quality inspection for the intermediate product processed in the second step 212. For example, among the intermediate products processed in the second step 212, an intermediate product that has failed the quality inspection result may be transported to the third step 213, processed, and then transported to the fourth step 214. On the other hand, the intermediate product having passed the quality inspection result may be transported to the fourth step 214 by omitting the third step 213. For example, the third process 213 may be a standard process, a non-standard process, or a process that does not pass in the production plan, depending on the ordered product.

  As shown in FIG. 1, the production management support apparatus 100 in this embodiment includes a display unit 110, an input unit 120, a memory 130, a storage unit 140, and a central processing unit (CPU) 150. The production management support apparatus 100 is configured by a personal computer, for example.

  The display unit 110 includes, for example, a liquid crystal display panel. The display unit 110 is controlled by the CPU 150 to display an alarm message or the like as will be described later. The display unit 110 is not limited to a liquid crystal display panel. The display unit 110 may include other panels such as an organic EL (electroluminescence) panel.

  The input unit 120 includes, for example, a mouse or a keyboard. When operated by the user, the input unit 120 outputs an operation signal indicating the operation content to the CPU 150. When the display unit 110 is a touch panel display, the touch panel display may also serve as the input unit 120 instead of the mouse or the keyboard.

  The memory 130 is configured by, for example, a semiconductor memory. The memory 130 includes, for example, a read only memory (ROM), a random access memory (RAM), an electrically erasable / rewritable ROM (EEPROM), and the like. The ROM of the memory 130 stores the control program of this embodiment that causes the CPU 150 to operate.

  The CPU 150 operates according to the control program of the present embodiment stored in the memory 130, thereby performing an intermediate product group extraction unit 151, a preceding process group extraction unit 152, an in-process status extraction unit 153, an arrival information calculation unit 154, a balance index calculation. The function of the part 155, the plan correction determination part 156, and the warning issuing part 157 is provided. Specific functions of each unit of the CPU 150 will be described later. Note that the production management support apparatus 100 may include other hardware that performs the same function instead of the CPU 150.

  The storage unit 140 is configured by, for example, a hard disk or a semiconductor memory. The storage unit 140 includes a production plan storage unit 141 and a progress information storage unit 142. Each of the storage units 141 and 142 may be composed of different media. Alternatively, each of the storage units 141 and 142 may be configured by a single medium in which the storage area is divided. Hereinafter, contents stored in the production plan storage unit 141 and the progress information storage unit 142 will be described.

On date T, a set of details to be input to the process of the production line 200 is, for example,
O (T) = {O_j (T), j = 1, 2,..., N} (1)
It is represented by As can be seen from equation (1), in the present embodiment, n details are input to the production line 200 in the process. In this specification, an intermediate product that is input to a process is referred to as a “specification”. In the expression (1), each specification O_j (T) has a manufacturing specification, quantity or weight, and delivery date corresponding to the ordered product. Note that the date T is referred to as “time T” in units of hours and minutes. Expression (1) is stored in the production plan storage unit 141.

  The production specifications include production procedures such as processes to be passed and their order in addition to performance conditions as ordered products such as standards, dimensions, and material characteristics. The process includes a standard process and a non-standard process, and further includes “entry into a shipping warehouse”. The delivery date is set, for example, as a deadline of “entry into the shipping warehouse”.

First, a method of grasping the production progress status in the management target process 220 will be described. A process set P including all processes of the production line 200 is, for example,
P = {P_j, j = 1, 2,...} (2)
It is represented by Since the management target process 220 is an element of the process set P, when the management target process 220 is represented by a symbol Px,
Px∈P (3)
It is expressed.

Among the details input to the process of the production line 200 on the date T, the set Ox (T) of the details that pass the management target process 220 is a part of the specification O (T) that is the entire set in this embodiment, In other words, it is a true subset. Therefore,
Ox (T) ⊂O (T) (4)
It is represented by The set of details Ox (T) is stored in the production plan storage unit 141.

Since the set Ppre of the process in which each specification included in the set Ox (T) of the specifications passes before the management target process 220 is a true subset of the process set P,
Ppre⊂P (5)
It is expressed. A set Ppre of processes that pass before the management target process 220 corresponds to the preceding process group 210. The production line 200 including the preceding process group 210 and the management target process 220 is stored in the production plan storage unit 141.

A set of details Ox (t) that is input to the process of the production line 200 on an arbitrary date t and passes through the management target process 220 is determined by past results and production plans. Here, the date t is, for example,
t∈ (Cr−α,..., Cr-1, Cr, Cr + 1,..., Cr + β) (6)
It is expressed. In equation (6), Cr is the current date. Since the set Ox (t) whose input date to the process is Cr or earlier has been input in the past, the set Ox (t) is determined based on the progress information representing the past results stored in the progress information storage unit 142. The set Ox (t) with the process input date after Cr (including Cr) is determined by the production plan stored in the production plan storage unit 141.

From each process through which each specification Ox_j (t) included in the set of specifications Ox (t) that is input to the process of the production line 200 on the arbitrary date t and passes through the management target process 220 passes from the management target process 220. Since the previous set Ppre (Ox_j (t)) of the preceding process is a true subset of the process set P,
Ppre (Ox_j (t)) ⊂P (7)
It is expressed. The preceding process set Ppre (Ox_j (t)) is also a true subset of the preceding process set Ppre.
Ppre (Ox_j (t)) ⊂Ppre⊂P (8)
It is also expressed.

  The set Ppre (Ox_j (t)) of the preceding process described above has passed the set Ppre that has already passed (Ox_j (t)) and the set Ppre that is scheduled to pass in the future on the current date Cr. Ox_j (t)).

  The set Ppre passed (Ox_j (t)) includes a non-standard process, but the set Ppre scheduled pass (Ox_j (t)) does not include a non-standard process because the process has not yet been executed. However, in practice, non-standard processes may be included with a considerable probability, so that part may be included in advance. Specifically, for example, a case is considered where the probability that a certain process Pz is added as a non-standard process is ρ according to past results. In this case, a method of generating a random number and adding the process Pz to the set Ppre passing schedule (Ox_j (t)) if the generated random value is equal to or less than ρ may be used.

  Further, if t ≧ Cr, the details will be introduced in the future, and the set Ppre passed (Ox_j (t)) is an empty set, and the preceding process set Ppre (Ox_j (t)) is set to the set Ppre. Only the scheduled passage (Ox_j (t)) is included.

  In this way, for a set of details Ox (t) that passes through the management target process 220 and each specification Ox_j (t) included in the set Ox (t), a process group that has already passed and a process that is scheduled to pass A group can be obtained. Then, the timing (arrival date) when the details arrive at the process to be managed 220 as a work in progress on the premise that the details pass in a certain processing time with respect to the set Ppre scheduled to pass (Ox_j (t)). The arrival amount can be calculated.

  For example, the set of processes scheduled to pass before the management target process 220 on the current date Cr in the specification Ox_j (t) is {P1, P2, P3}, the weight is w_j, and the processes of the processes P1, P2, P3 Let the days be Tt1, Tt2, and Tt3, respectively. In this case, it is considered that a device with a weight w_j arrives at the management target process 220 on the date (Cr + Tt1 + Tt2 + Tt3).

  However, in general, the processing days Tt1, Tt2, and Tt3 depend on the in-process amount in the processes P1, P2, and P3, the processing order of the details, and the like, and thus variations occur. Further, the number of days (Tt1 + Tt2 + Tt3) until arrival at the management target process 220 also varies. This number of days (Tt1 + Tt2 + Tt3) may be handled as an average value of the past processing days. Alternatively, the number of days (Tt1 + Tt2 + Tt3) may be handled as arriving distributed over a plurality of days. Here, the description will be made assuming that a certain numerical value such as “5 days” is assigned.

Next, prediction of future in-process transition in the management target process 220 will be described. A set of details TOx (t) in which the set of processes scheduled to pass on the date t is not an empty set is referred to as an “effective detail set” on the date t. At this time, the effective item O which is an element of the effective item set TOx (t) is
O∈TOx (t) (9)
The effective item O that is an element of the effective item set TOx (t), which is expressed as follows, arrives at the management target process 220 after a certain number of passage days τ and becomes a work in progress.

  Note that when considering the future in-process transition in the management target process 220, the set of details that have been passed through the preceding process group in the details that are scheduled to be input in the future becomes an empty set. Conversely, the set of details that have already arrived at the process to be managed 220 and are scheduled to pass the preceding process group is an empty set, and is not included in the effective detail set. The procedure for calculating the passage days τ will be described later. Here, the procedure for calculating the in-process transition will be described on the assumption that the number of passing days τ is known.

A set of processes scheduled to pass on the current date t = Cr of the detail O input on the past date t = Cr−α is
{P_j, j = 1,2, ...} (10)
It is assumed that Let τj be the number of days required for the specification to pass through the process P_j (that is, the number of processing days). At this time, the number of days until the statement O arrives at the management target process 220 is Στj. Therefore, the arrival date to the management target process 220 is
Cr + Στj (11)
It becomes. Note that the calculation procedure for the passage days τj of the set P_j of processes scheduled to pass will be described later, but is assumed to be known here. Hereinafter, a calculation example of the in-process transition will be described.

  FIG. 3 is a diagram schematically showing detailed information indicating the progress of the details input in the past and the details planned to be input in the future from the present, with the current date Cr as 0. FIG. As shown in FIG. 3, the detail information 300 includes a detail field 301, an input date field 302, a current process field 303, a future process field 304, a passing days field 305, an arrival date field 306, and a weight field 307. The arrival information calculation unit 154 generates detailed information 300 from the production plan stored in the production plan storage unit 141 and the progress information stored in the progress information storage unit 142.

  The details column 301 shows details. The input date column 302 indicates the input date of the details. The current process column 303 shows the process in which the corresponding details are currently in progress. A future process column 304 indicates a process for which the corresponding specification is scheduled to be processed in the future. The passing days column 305 indicates the number of days from the present to the arrival of the management target process 220. The arrival date column 306 indicates how many days later the corresponding details arrive at the management target process 220. The weight column 307 indicates the weight of the corresponding specification.

  As can be seen from the description column 301 and the input date column 302, FIG. 3 shows the details O1 to O5 input in the past two days, and the input is planned for today (Cr) and the next two days. Details Q1-Q4 are shown. As can be seen from the current process column 303 and the future process column 304, in the example of FIG. 3, the process (preceding process group) that passes through the process to be managed 220 is two processes P1 and P2. That is, in the example of FIG. 3, the configuration of FIG. 2 is simplified.

  As shown in FIG. 3, the details O2, O3, and O5 are currently in process P1, and the details O1 and O4 are in process P2. In the example of FIG. 3, although the detail O4 has been input after the details O2 and O3, it has overtaken the details O2 and O3 and arrives at the management target process 220 first.

  In the example of FIG. 3, the number of processing days (passing days) in the process P1 is 3 days, and the processing days in the process P2 is 2 days. Therefore, as shown in the passage days column 305, the number of passage days to the management target process 220 of the details O2, O3, O5 in progress in the process P1 is 5 days, and the details O1, O4 in progress in the process P2 The number of passage days is 2 days.

  In FIG. 3, since the current date (Cr = 0) is used as a reference, the current process and the future process described in the transit days column 305 are combined for the arrival dates of the details O1 to O5 input in the past. The number of days after the passage will be the arrival date. That is, the arrival date is not the insertion date but the current date (Cr = 0) plus the number of passage days that are combined with the current passage and future passage schedules. On the other hand, regarding the arrival date of the details Q1 to Q4 planned to be introduced in the future, it is considered that the process P1 has been completed immediately after the introduction date, and the arrival date is the number of days after the passage date.

  FIG. 4 is a diagram schematically showing the arrival information 400 generated by the arrival information calculation unit 154. The arrival information calculation unit 154 generates arrival information 400 from the detailed information 300 (FIG. 3). The arrival information 400 in FIG. 4 represents information obtained by tabulating the weights of the details O1 to O5 and Q1 to Q4 shown in the detail information 300 for each arrival date and each input date.

  As shown in FIG. 4, the arrival information 400 includes an input date column 401, an arrival date column 402, and total columns 403 and 404. The input date column 401 represents the date when the details were input to the process. “Past” in the input date column 401 indicates the details O1 to O5 input in the past from the current date (Cr = 0), and “0” indicates the details input on the current date (Cr = 0). Q1 represents “Details” Q2 and Q3 which are planned to be introduced after one day, and “2” represents Detail Q4 which is planned to be introduced after two days.

  The arrival date column 402 represents the date when the details arrive at the management target process 220. “2” in the arrival date column 402 represents details O1 and O4 that are scheduled to arrive two days after the current date (Cr = 0), and “5” represents the current date (Cr = 0). Represents the details O2, O3, O5, Q1 that are scheduled to arrive 5 days after the date, and “6” is the specification Q2 that is scheduled to arrive 6 days after the current date (Cr = 0). , Q3, and “7” represents the detail Q4 that is scheduled to arrive 7 days after the current date (Cr = 0).

  The total column 403 represents the total weight of the details for each arrival date indicated in the arrival date column 402, and the total column 404 represents the total weight of the details for each input date indicated in the input date column 401.

  As shown in FIG. 4, the total weight of the specifications input in 5 days from “−2” to “2” is 150 [tons]. For this reason, from the viewpoint of leveling the load, it is desirable that details about 30 [tons] arrive at the management target process 220 every day. However, in the example of FIG. 4, 70 [tons], which is more than twice the arrival date “5”, has arrived, and the load is temporarily concentrated on the management target process 220.

  As described above, it is desirable that the details around 30 [ton / day] arrive at the management target process 220. In this case, the processing amount of the management target process 220 is usually 30 [ton / day]. Set to In this case, as shown in FIG. 4, the details for four days arrive at the management target process 220 in the three days from “5” to “7”. Therefore, in the management target process 220, a processing delay for one day is expected.

  As described above, it is necessary to monitor the variation and take measures early so that the variation such as processing delay is suppressed within the allowable range. In the example of FIGS. 3 and 4, as described above, an excessive amount of details arrives at the management target process 220 on the arrival date “5”. In order to reduce the influence of this, as can be seen from FIG. 4, for example, there is a method of reducing the input amount on the input dates “0”, “1”, “2”. However, this measure may suppress the delay of delivery due to the accumulation of details over a long period of time, but the production volume of the product decreases and the production capacity cannot be utilized to the maximum. In addition, it is unavoidable that the specification stays unavoidably, and preferentially processes the specification having a short margin with respect to the delivery date.

  FIG. 5 is a diagram schematically illustrating an example of the transition of the in-process amount in the management target process 220. FIG. 6 is a diagram schematically showing the transition of the weight that stayed in the management target process 220 for 10 days or more on each day. FIG. 7 is a diagram schematically showing an example of the transition of the in-process amount in the first step 211. FIG. 8 is a diagram schematically showing an example of the transition of the in-process amount in the second step 212. FIG. 9 is a diagram schematically showing an example of the transition of the in-process amount in the third step 213. FIG. 10 is a diagram schematically showing an example of the transition of the in-process amount in the fourth step 214. The example of FIGS. 5-10 has shown the transition for 121 days. A specific example of the transition of the in-process amount in each process will be described with reference to FIGS.

  As shown in FIG. 5, the in-process amount in the management target process 220 exceeds the weight W11 around the 50th day, and exceeds the weight W12 (= 0.8 × W11) around the 25th day and around the 100th day. The average value over the entire period is about Wa, the standard deviation σ is about Wa / 2, and the period exceeding the weights W11 and W12 deviates from 1.5σ to 2σ above the average value. .

  As shown in FIG. 6, the weight of the specification staying for a long period of 10 days or more increases rapidly around 50 days. When FIG. 5 and FIG. 6 are combined, it can be seen that if the amount of work in progress is 2σ above the average value, the risk of delivery delay increases.

  As shown in FIG. 7, the amount of work in progress in the first step 211 is large from 1 day to 10 days, and then gradually decreases. The average value over the entire period is about Wa1, the standard deviation σ is about Wa1 / 2, and the work in progress is greatly increased in 1 to 10 days including the period exceeding the weight W1. .

  As shown in FIG. 8, the amount of work in progress in the second step 212 increases from 90 days to 100 days. The average value for all periods is about Wa2, the standard deviation σ is about Wa2 / 2, and the in-process amount is higher than the average value in the period from 90 days to 100 days when the in-process amount exceeds W2. Is more than 2σ.

  As shown in FIG. 9, the amount of work in progress in the third step 213 increases from 20 days to 40 days. The average value for all periods is about Wa3, and the standard deviation σ is a little larger than Wa3, and in the period when the in-process amount exceeds W3, the in-process amount fluctuates 2σ or more above the average value. Yes.

  As shown in FIG. 10, the in-process amount in the fourth step 214 has a shape in which the increase in the in-process amount in the first step 211 to the third step 213 is overlapped. The average value of all the periods is about Wa4, the standard deviation σ is about Wa4 / 3, and the period in which the in-process amount fluctuates 2σ or more above the average value is around 50 days and around 110 days. From FIG. 5 to FIG. 10, it can be seen that the delay of the preceding process affects the subsequent process.

  Returning to FIG. 1, the balance index calculation unit 155 calculates a balance index representing the degree of balance between the in-process amount and the productivity (specifically, the processing amount) in the management target process 220. The balance index calculation unit 155 calculates an in-process amount difference that is a difference in in-process amount between adjacent dates in the management target process 220 by using the following formula (12), and calculates a difference in processing amount between adjacent dates. A certain processing amount difference is calculated using the following equation (13), and a difference amount between these differences is calculated using the following equation (14).

Work in progress difference = work in progress on date N−work in progress on date (N−1) (12)
Processing amount difference = processing amount on date N−processing amount on date (N−1) (13)
Difference difference amount = In-process difference-Processing amount difference (14)
If the processing amount is constant, the processing amount difference becomes 0. However, since the processing amount actually changes due to a change in productivity, the processing amount difference is considered. As a result, fluctuations in productivity can be taken into consideration.

  The balance index calculation unit 155 further calculates the M-day moving average of the difference difference amount. The balance index calculation unit 155 calculates a cumulative value obtained by accumulating the M-day moving average as a balance index, as shown in Expression (15).

Balance index = Σ (M-day moving average of difference difference) (15)
When the in-process amount and the processing amount do not fluctuate greatly and the production is stable, the balance index is generally kept at zero.

  FIG. 11 is a diagram schematically showing the transition of the processing amount of each day in the management target process 220. FIG. 12 is a diagram schematically illustrating a cumulative value of the 5-day moving average of the difference difference amount. 11 and 12 show the transition of 121 days, similar to FIGS.

  The balance index calculation unit 155 uses the in-process data in the management target process 220 shown in FIG. 5 and the processing amount data in the management target process 220 shown in FIG. ) To calculate the in-process amount difference, the processing amount difference, and the difference difference amount. The balance index calculation unit 155 calculates a 5-day moving average from the calculated difference difference amount, and further calculates a cumulative value of the 5-day moving average.

  As shown in FIG. 12, the cumulative value has a large peak around 50 days. As a result, it can be seen that the amount of work in progress greatly increases in the period around 50 days, and the balance between the amount of work in progress and the amount of processing is lost.

  As described above, the cumulative value (that is, the balance index) of the 5-day moving average should be approximately 0 and becomes a positive value after becoming a negative value. For example, in FIG. 12, a negative value on the 10th to 30th appears as a positive value after the 40th. The cumulative value becomes a negative value because the progress of the preceding process (the fourth process 214 in the present embodiment) is delayed and the details arriving at the management target process 220 are decreasing. Thereafter, when the details arrive at the management target process 220 in a concentrated manner, the balance index swings to a positive value.

  As shown in FIG. 11, in the period of 40 days to 50 days, the processing amount in the management target process 220 is decreased, and this decrease in the processing amount contributes to an increase in the balance index. Thereafter, the amount of treatment increased from the 50th to the 55th, and the balance index started to decrease after the 50th. Also, as shown in FIG. 12, the balance index shows a negative value on the 80th to 90th, and it swings positively after the 100th, indicating that the in-process amount is increasing. However, as shown in FIG. 11, the amount of processing is not reduced, and the fluctuation width of the balance index is also reduced.

  As described above, it is necessary to manage production so that the balance index considering the balance between the in-process amount of the specification arriving at the management target process 220 and the processing amount in the management target process 220 does not greatly deviate from “near zero”. is there. Further, when the balance index deviates in the negative direction, it can be predicted that it will deviate in the positive direction in the future.

  Returning to FIG. 1, the plan correction determination unit 156 sets a negative threshold value in advance, and determines whether the balance index is less than the threshold value. The threshold value which is a negative value is stored in, for example, the ROM of the memory 130 as a part of the control program of the present embodiment. If the balance index is less than the threshold value, the plan correction determining unit 156 notifies the alarm issuing unit 157 to that effect. The alarm issuing unit 157 issues an alarm when notified that the balance index is less than the threshold value. As a result, the user can take measures such as confirming the progress and reviewing the production plan.

  The arrival information calculation unit 154 calculates the arrival date and the arrival amount of the details to the management target process 220 based on the standard work schedule. In each of the steps 211 to 214, a standard construction period that is a standard passage period (for example, the number of passage days) is set. This standard construction period is a period set based on past results, and is also a management value that processing should be completed within that period. For example, “standard construction period 3 days” means that the process should be completed within 3 days on average in the process. However, even if the standard construction period is set to 3 days, for example, details to be processed urgently may be completed in 1 day. Moreover, the specification with a low priority may stay for a long period exceeding 3 days. The passage period is affected by the processing order in the process.

  For example, when the standard work schedule is K [days], as a rough estimate, the amount to be processed of the weight W of the specification is around K [days] so that the standard work schedule K [days] is an average value. Are distributed and arranged. In the present embodiment, as an equal distribution, W / 2K is arranged on each day of 1 [day] to 2K [day] with the standard work schedule K [day] as the center. In the example of FIGS. 3 and 4, the passage days of the processes P1 and P2 are 3 days and 2 days, respectively, which means that the standard work schedule K is 3 days and 2 days, respectively.

  The distributed arrangement of the weight W in the specification is not limited to the uniform distribution. Alternatively, for example, around K [day], (K-1) [day] is 0.1 × W, K [day] is 0.6 × W, and (K + 1) [day] is 0.2 ×. W and (K + 2) [days] may be distributed unevenly, such as 0.1 × W. Further alternatively, the total processing amount may be concentrated at 1.0 [W] in K [days]. This is the simplest case.

  FIG. 13 is a diagram schematically showing detailed information 1300 representing the passing weight of each step. As shown in FIG. 13, the detailed information 1300 includes a process column 1301, a passage date column 1302, a detailed column 1303, and total columns 1304 and 1305. In the example of FIG. 13, the process column 1301 includes processes P1 and P2 as in FIG. The passage date column 1302 represents a passage date when the allocated weight of the specification passes through each process. The description column 1303 includes the specifications O1 to O5 and Q1 to Q4 as in the example of FIG. The total column 1304 represents the passing weight for each passing date in each step. The total column 1305 represents the weight for each specification. The numerical value in the total column 1305 is the same as the numerical value in the weight column 307 in FIG.

  The detailed information 1300 represents the passing weight of the processes P1 and P2 when the weight of the specification is evenly distributed in the example of FIG. 3 for each passing date. For example, in the specification O2, since the standard work period K of the process P1 is 3 and 2K = 6, the weight 20 [tons] is evenly distributed on the 1st to 6th days of the process P1. And each of the equally distributed is the standard work period K = 2 of the process P2 and 2K = 4, so that it is further equally distributed over 4 days of the process P2. For example, 3.3 [tons] per day in the process P1 is equally distributed over 4 days from the 2nd to the 5th in the process P2. For example, 3.3 [tons] on the second day of the process P1 is equally distributed over four days from the third to the sixth of the process P2. Others are also allocated in the same way and aggregated for each passing date.

  In FIG. 13, the total weight described in the total column 1304 corresponding to the process P1 represents the arrival amount at the process P2. Further, the total weight described in the total column 1304 corresponding to the process P2 represents the amount of arrival at the management target process 220.

  FIG. 14 is a diagram schematically showing an arrival amount for each arrival date to the management target process 220. A transition 1401 in FIG. 14 represents an arrival amount for each arrival date with the passing date of the process P2 shown in FIG. 13 as the arrival date to the management target process 220. A transition 1402 in FIG. 14 represents the arrival amount on the arrival date in FIG. 4 and corresponds to the case where the arrival date is concentrated on the standard work schedule K [day] without being evenly distributed.

  As shown in FIG. 14, in the transition 1401, the fluctuation range of the in-process amount is smoothed compared to the transition 1402. However, in any of the transitions 1401 and 1402, it is possible to read the tendency that the delay load is concentrated after 4 to 5 days.

  Thus, in order to reduce the weight 26 [tons] concentrated on the passage date “4” of the process P 2 by calculating the arrival date and the arrival amount to the management target process 220, it is planned to input in the future. Measures such as delaying the input timing of the detailed specifications Q2 to Q4 can be considered. Further, by calculating the arrival date and the arrival amount in the state where the details Q2 to Q4 are delayed, it is possible to confirm the effect that the concentration of the details is reduced.

  FIG. 15 is a diagram schematically showing an arrival amount when the productivity of the management target process 220 is lower than that in FIG. 14. For example, when the productivity of the management target process 220 is reduced from 3 to 6 days and the processing amount is reduced by 10 [tons / day], the transitions 1501 and 1502 are shown in FIG. 10 [ton / day] is added to the arrival amount (in-process amount) on the 3rd to 6th. As a result, the degree of load concentration is further emphasized.

  FIG. 16 is a diagram schematically showing the transition of the balance index in the case of FIG. The transitions 1601 and 1602 in FIG. 16 show the same tendency as the transitions 1501 and 1502 in FIG. 15 if the initial value is zero.

  For example, the plan correction determination unit 156 may have a balance index of 20 or more, a management level where the load is concentrated and production adjustment is necessary. In the example of the transition 1601 in FIG. 16, the plan correction determination unit 156 may determine that it is necessary to correct the plan to reduce the load on the date “3”. The alarm issuing unit 157 may display a message on the display unit 110 indicating that the plan needs to be corrected. For example, the user may correct the production plan so as to delay the input timing of the details for future input so that the balance index is less than the management level of 20.

(Operation)
FIG. 17 is a flowchart schematically showing the operation of the production management support apparatus of FIG. The operation in FIG. 17 is executed when instructed by the user using the input unit 120, for example. The user may instruct the execution of the operation of FIG. 17 once a day, for example.

  In step S <b> 1700, the intermediate product group extraction unit 151 acquires a management target process stored in the production plan storage unit 141. In step S1705, the intermediate product group extraction unit 151 selects an intermediate product group including intermediate products that pass the management target process after the reference date (for example, the current date) from the production plan stored in the production plan storage unit 141. The extracted intermediate product group is stored in, for example, the RAM of the memory 130.

  In step S <b> 1710, the preceding process group extraction unit 152 extracts and extracts the preceding process group through which the intermediate product group passes before the management target process from the production plan stored in the production plan storage unit 141. The group is stored in a memory 130 such as a RAM.

  In step S1715, the in-process status extraction unit 153 determines the intermediate product for the preceding process group on the reference date from the production plan stored in the production plan storage unit 141 and the progress information stored in the progress information storage unit 142. The in-process status of the group is extracted, and detailed information 1300 (FIG. 13) is generated. The in-process status extracting unit 153 stores the generated detailed information 1300 in, for example, the RAM of the memory 130.

  In step S1720, the arrival information calculation unit 154 calculates the arrival date and the arrival amount at which the intermediate product group in progress in the preceding process group 210 arrives at the management target process 220 from the detailed information 1300, and calculates the calculated arrival date. The arrival amount is stored in, for example, the RAM of the memory 130. In step S1725, the balance index calculation unit 155 acquires the processing amount of the management target process 220 (for example, the average value in the past one week from the current date) in the latest period of the reference date. The balance index calculation unit 155 calculates a balance index using the acquired processing amount, arrival date, and arrival amount. The balance index calculation unit 155 stores the calculated balance index in, for example, the RAM of the memory 130.

  In step S1730, the plan correction determination unit 156 determines whether or not the balance index is less than a negative threshold value. If the balance index is greater than or equal to the threshold (NO in step S1730), the process in FIG. 17 ends. If the balance index is less than the threshold value (YES in step S1730), the process proceeds to step S1735.

  In step S1735, the plan correction determining unit 156 notifies the alarm issuing unit 157 that confirmation of the progress is necessary. In step S1740, upon receiving this notification, the warning issuing unit 157 issues a warning for notifying that confirmation of the progress status is necessary. The alarm issuing unit 157 may display a message on the display unit 110 indicating that confirmation of the progress status is necessary. Thereafter, the process of FIG. 17 ends.

(effect)
As described above, in the present embodiment, if the calculated balance index is less than a negative threshold value, an alarm is issued. As described above, when the balance index largely fluctuates to a negative value, production delay occurs in the preceding process group, and it is highly possible that the load will concentrate on the process to be managed in the future. Therefore, according to the present embodiment, if the calculated balance index is less than a negative threshold value, it is possible to take measures such as confirming the progress by issuing an alarm.

(Modified embodiment)
In the above embodiment, the plan correction determination unit 156 determines whether or not the balance index is less than a negative threshold value in step S1730 in FIG. 17, but is not limited thereto. In step S1730 of FIG. 17, the plan correction determination unit 156 may determine whether or not the balance index exceeds a threshold value that is a positive value. In step S1735 of FIG. 17, the plan correction determining unit 156 may notify the alarm issuing unit 157 that the production plan needs to be corrected. In step S1740 of FIG. 17, the alarm issuing unit 157 may receive a notification and display a message on the display unit 110 indicating that the production plan needs to be corrected.

  As described above, when the balance index greatly fluctuates to a positive value, it indicates that the load is concentrated on the management target process 220. Therefore, according to this modified embodiment, the user can take measures such as correcting the production plan.

DESCRIPTION OF SYMBOLS 110 Display part 141 Production plan memory | storage part 142 Progress information memory | storage part 151 Intermediate product group extraction part 152 Preceding process group extraction part 153 In-process status extraction part 154 Arrival information calculation part 155 Balance index calculation part 156 Plan correction judgment part 157 Alarm issuing part

Claims (4)

In a factory for processing a plurality of intermediate products in a plurality of processes in which a plurality of intermediate products pass in the order of the plan according to a predetermined production plan, and producing a plurality of order-receiving products corresponding to the plurality of intermediate products. A production management support device for supporting production management,
A production plan storage unit for storing the production plan, and a management target process preselected from the plurality of processes;
A progress information storage unit for storing progress information of production of the plurality of ordered products including in-process status for the plurality of steps of the plurality of intermediate products;
An intermediate product group extraction unit that extracts an intermediate product group including the intermediate product that passes through the management target process after a reference date from the production plan storage unit;
A preceding process group extracting unit that extracts a preceding process group including a preceding process through which the intermediate product included in the intermediate product group passes before the process to be managed from the production plan storage unit;
The in-process status of the intermediate product included in the intermediate product group with respect to the preceding process included in the preceding process group is extracted from the progress information storage unit before the reference date, and the part after the reference date is extracted. An in-process status extracting unit that extracts from the production plan storage unit;
Based on the in-process status, an arrival date when the intermediate product included in the intermediate product group arrives at the management target process, and an arrival amount that is an amount of the intermediate product that arrives at the management target process on the arrival date; An arrival information calculation unit for calculating
A cumulative value obtained by accumulating a moving average value in a predetermined period of the difference obtained by subtracting the actual value from the arrival amount, obtaining the actual value of the processing amount of the management target process most recently on the reference date. A balance index calculation unit for calculating as a balance index;
A plan correction determination unit for determining whether it is necessary to correct the production plan after the reference date based on the balance index;
A production management support device comprising: The plan correction determination unit determines that the production plan needs to be corrected when the balance index is less than a predetermined negative value threshold.
The production management support apparatus according to claim 1. An alarm issuing unit that issues an alarm when it is determined by the plan correction determining unit that the production plan needs to be corrected,
The production management support apparatus according to claim 1 or 2. In a factory for processing a plurality of intermediate products in a plurality of processes in which a plurality of intermediate products pass in the order of the plan according to a predetermined production plan, and producing a plurality of order-receiving products corresponding to the plurality of intermediate products. A production management support method for supporting production management,
An intermediate product group extracting step for extracting an intermediate product group including the intermediate product that passes through a management target process selected in advance from a plurality of processes from a reference date, from a production plan storage unit that stores the production plan;
A preceding process group extracting step for extracting from the production plan storage unit a preceding process group including a preceding process through which the intermediate product included in the intermediate product group passes before the process to be managed;
The in-process status of the intermediate product included in the intermediate product group with respect to the preceding process included in the preceding process group is extracted from a progress information storage unit that stores progress information before the reference date, and the reference date Subsequent minutes are extracted from the production plan storage unit in-process status extraction step;
Based on the in-process status, an arrival date when the intermediate product included in the intermediate product group arrives at the management target process, and an arrival amount that is an amount of the intermediate product that arrives at the management target process on the arrival date; An arrival information calculation step for calculating
A cumulative value obtained by accumulating a moving average value in a predetermined period of the difference obtained by subtracting the actual value from the arrival amount, obtaining the actual value of the processing amount of the management target process most recently on the reference date. A balance index calculation step to calculate as a balance index;
A plan correction determination step for determining whether it is necessary to correct the production plan after the reference date based on the balance index;
A production management support method comprising:

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