JP2019040345A - Process management device and method - Google Patents

Abstract

To further, appropriately manage a progress state of actual manufacturing.SOLUTION: A process management device for managing progress states of a plurality of jobs in a factory for manufacturing a plurality of different products in parallel by processing a plurality of raw materials as respective jobs in a plurality of prescribed processes in a prescribed order includes: a first process due date calculation part for calculating a limit process due date; a prior load time calculation part for calculating a prior load time; a second process due date calculation part for calculating a process due date on a bottleneck process basis; a prior load reference time calculation part for calculating a prior load reference time; and a progress level calculation part for calculating a relative position of a determination date on a time base with respect to the prior load reference time, the process due date on the bottleneck process basis, and the limit process due date, and calculating a progress level corresponding to the relative position in a process in which the jobs arrive on the prescribed determination date, in each job.SELECTED DRAWING: Figure 1

Description

  The present invention relates to a process management apparatus and method for managing progress in a product manufacturing process.

  2. Description of the Related Art Conventionally, a multi-product production system in which multi-product products with different delivery dates and different manufacturing procedures are produced in parallel through a process of processing a material with a plurality of facilities in a metal material production factory or the like has become widespread. In a multi-product production system, if there is unevenness in the progress of processing for a plurality of materials in a certain process, the lead time for each material will vary, making it difficult to manage the delivery date of the product to be manufactured. In addition, if the overall lead time is extended due to unevenness in the progress of processing on the material, the operating rate of the equipment is also reduced. For this reason, in a multi-product production system, it is important to construct a process management apparatus that suitably manages the progress of processing for each material.

  In the technique described in Patent Document 1, progress information or progress schedule information of a plurality of processes for producing a product is stored, progress information or progress schedule information is displayed on a display device, and the progress information or progress schedule information is displayed. Updated with input information. This makes it possible to optimize the product production plan and to appropriately manage the progress of the actual product production work.

JP 2011-90595 A

  However, there is a demand for improvement with respect to the technique described in Patent Document 1 so that the actual progress of production can be managed more appropriately.

  The present invention solves the above-described problems, and an object thereof is to provide a process management apparatus and method that can more appropriately manage the actual production progress.

The first aspect of the present invention is:
A process management apparatus that manages the progress of a plurality of jobs in a factory that produces a plurality of different products in parallel by processing a plurality of materials as jobs in a predetermined order in a plurality of processes,
For each job, starting from the delivery date of the final process, the time that goes back by the lead time between the standard processes in order to the first process with respect to the upstream process can be completed most recently in order to meet the delivery date of delivery. A first process delivery date calculation unit for calculating a critical process delivery time;
For each job, a preload is added to the total related time related to the standard processing time in the process of other jobs other than the calculation target job having the limit process delivery time earlier than the limit process delivery time of the calculation target job in each process. A preload time calculation unit to calculate as time,
For each job, in each process of the calculation target job, calculate a time difference between the time when the preceding load time is added to a predetermined reference date and the limit process delivery time, and extract a minimum value among the time differences, In each process of the calculation target job, a second process delivery date calculation unit that calculates a time that is traced back from the minimum process delivery date as the process delivery date on the bottleneck process basis,
For each job, in the first step, a time obtained by adding the preceding load time to the reference date and time is calculated as a preceding load reference time, and an Nth (N is an integer not less than 2 and not more than the number of steps of the calculation target job) ) In the process, the time obtained by adding the standard inter-process lead time from the (N-1) process to the Nth process to the preceding load reference time of the (N-1) process, and the reference date and time in the Nth process. A preceding load reference time calculation unit that calculates a later one of the times obtained by adding the preceding load times as a preceding load reference time;
In the process in which the job arrives at a predetermined determination date for each job, the determination date on the time axis with respect to the preceding load reference time, the process delivery date based on the bottleneck process criteria, and the limit process delivery date A progress level calculation unit that calculates a relative position of the target and calculates a progress level according to the relative position;
Is provided.

The second aspect of the present invention is:
A process management method for managing the progress of a plurality of jobs in a factory that produces a plurality of different products in parallel by processing a plurality of materials as jobs in a predetermined order in a predetermined plurality of steps,
For each job, starting from the delivery date of the final process, the time that has been traced back to the first process by the lead time between the standard processes in order from the upstream process can be completed most recently to meet the delivery date of delivery. A first process delivery date calculation step for calculating a critical process delivery time;
For each job, a preload is added to the total related time related to the standard processing time in the process of other jobs other than the calculation target job having the limit process delivery time earlier than the limit process delivery time of the calculation target job in each process. A preload time calculation step to calculate as time,
For each job, in each process of the calculation target job, calculate a time difference between the time when the preceding load time is added to a predetermined reference date and the limit process delivery time, and extract a minimum value among the time differences, In each process of the calculation target job, a second process delivery date calculation step for calculating a time that is traced back from the minimum process delivery date as the process delivery date on the bottleneck process basis,
For each job, in the first step, a time obtained by adding the preceding load time to the reference date and time is calculated as a preceding load reference time, and the Nth (N is an integer not less than 2 and not more than the number of steps of the job) step , The time obtained by adding the lead time between standard processes from the (N-1) process to the Nth process to the preceding load reference time of the (N-1) process, and the preceding in the Nth process at the reference date and time. A preceding load reference time calculating step for calculating a later one of the times obtained by adding the load times as a preceding load reference time;
In the process in which the job arrives at a predetermined determination date for each job, the determination date on the time axis with respect to the preceding load reference time, the process delivery date based on the bottleneck process criteria, and the limit process delivery date A progress level calculating step of calculating a relative position of the target and calculating a progress level according to the relative position;
Is provided.

  In the first aspect or the second aspect, for each job, a related time related to a processing time in a process of a job other than the calculation target job having a limit process delivery time earlier than the limit process delivery time of the calculation target job in each process. Is calculated as the preceding load time. For each job, in each process of the calculation target job, a time difference between the time obtained by adding the preceding load time to the reference date and the limit process delivery time is calculated, and the minimum value is extracted from the calculated time differences. In each process, the time that goes back the minimum value from the limit process delivery date is calculated as the process delivery date on the basis of the bottleneck process.

  The process with the minimum time difference between the time obtained by adding the preceding load time to the standard date and time and the limit process delivery date is the processing of jobs other than the calculation target job that has a limit process delivery time earlier than the limit process delivery date of the calculation target job. This means that the process has the shortest margin time from the completion of the process to the limit process delivery date of the job to be calculated. Therefore, it can be said that the process with the minimum time difference is the most difficult process to comply with the limit process delivery date. Therefore, the process having the minimum time difference is referred to as a bottleneck process.

  The process delivery date based on this bottleneck process standard is that immediately after all other jobs whose marginal process delivery time is earlier than the job to be calculated are processed in the bottleneck process when the job flows through all processes with the lead time between standard processes. In addition, it is the latest timing at which processing for the calculation target job can be started. Therefore, if processing for a job starts earlier than the process delivery date based on the bottleneck process standard, then when processing with the lead time between standard processes, the limit process delivery time in the bottleneck process is earlier than that of the job to be calculated. There is a higher possibility of waiting for the processing for the job to end. This is because, in general, processing for a job with a quick delivery date is preferentially started. As a result, according to the first aspect or the second aspect, after considering the load situation of the bottleneck process determined by the relationship with other jobs, an indication of at which timing each job should be processed Can be obtained.

  In the first mode or the second mode, for each job, in the first step, a time obtained by adding the preceding load time to a predetermined reference date and time is calculated as the preceding load reference time. In the Nth step (N is an integer equal to or larger than 2 and equal to or less than the number of job steps), lead between standard steps from the (N-1) th step to the Nth step at the preceding load reference time of the (N-1) th step. The later of the time obtained by adding the time and the time obtained by adding the preceding load time in the Nth step to the reference date and time is calculated as the preceding load reference time.

  The preceding load reference time is the earliest timing when processing for the calculation target job is started after all processing for other jobs whose limit process delivery date is earlier than that of the calculation target job is completed in all processes. In other words, when processing for a calculation target job is started earlier than the preceding load reference time, there is a possibility that another job whose limit process delivery date is earlier than that of the calculation target job will be postponed. As a result, there is a possibility of delaying delivery of other jobs.

  Moreover, in the said 1st aspect or the said 2nd aspect, in the process for which the calculation object job has arrived at the predetermined determination date for each job, the process delivery date and the limit process delivery date based on the preceding load reference time and the bottleneck process reference The relative position of the determination date and time on the time axis is calculated, and the progress level corresponding to the relative position is calculated. Therefore, according to the first aspect or the second aspect, it is possible to calculate the progress level in a finer section as compared to calculating the progress level using only the limit process delivery date. As a result, the actual production progress can be managed more appropriately.

  In the first aspect, for example, the progress level calculation unit may calculate the progress level by classifying the progress level into a plurality of levels that are indices indicating the urgency of the process. The plurality of levels may include a first level to a fourth level in order of increasing urgency of the process. The progress level calculation unit sets the progress level to be calculated as the first level when the determination date is before the preceding load reference time, the determination date is after the preceding load reference time, and When it is before the process delivery date based on the bottleneck process standard, the second level is set. When the determination date is after the process delivery date based on the bottleneck process standard and before the limit process delivery date, the third level is set. When the determination date is after the critical process delivery date, the fourth level may be set.

  When the process for the calculation target job is started earlier than the preceding load reference time, there is a possibility that another job whose limit process delivery date is earlier than that of the calculation target job is postponed. As a result, there is a possibility of delaying delivery of other jobs. Therefore, in this aspect, the calculated progress level is the first level with the lowest urgency of the process when the determination date and time is before the preceding load reference time. Therefore, according to this aspect, since the urgency of the process is the lowest, the start of the process is urged to be weakest, and the possibility of causing a delay in the delivery of another job whose marginal process delivery date is earlier than the calculation target job is reduced. can do.

  If processing for a job starts earlier than the process delivery date based on the bottleneck process standard, then when processing is performed with the lead time between standard processes, the bottleneck process will process other jobs whose marginal process delivery time is earlier than the calculation target job. There is a higher possibility of waiting for the processing to end. Therefore, in this aspect, when the determination date is after the preceding load reference time and before the process delivery date based on the bottleneck process reference, the urgency level of the process is higher than the first level. The second level is lower than the third level. Therefore, according to this aspect, since the degree of urgency of the process is relatively low, the start of the process is urged relatively weakly. In the bottleneck process, the process for another job whose limit process delivery time is earlier than the calculation target job. It is possible to suppress the possibility of waiting for completion of.

  The process delivery date based on the bottleneck process standard is that the job flows through all processes with the standard inter-process lead time, and immediately after all other jobs that have a limit process delivery time earlier than the calculation target job are processed in the bottleneck process. That is, it is the latest timing at which the processing for the calculation target job can be started without generating unnecessary idle time. Therefore, in this aspect, when the determination date is after the process delivery date based on the bottleneck process standard and before the limit process delivery date, the urgency level of the process is higher than the second level. The third level is lower than the level. Therefore, according to this aspect, since the urgency of the process is relatively high, the start of the process is urged relatively strongly, and in the bottleneck process, all other jobs whose limit process delivery time is earlier than the calculation target job are all After the processing, the processing for the calculation target job can be started without causing a very large free time.

  When processing is started after the limit process delivery date, if the job flows through all processes with the standard inter-process lead time, the delivery date will be delayed. Therefore, in this aspect, the calculated progress level is the fourth level with the highest urgency of the process when the determination date is after the limit process delivery date. Therefore, according to this aspect, since the urgency of the process is the highest, the start of the process is most strongly urged, and the delay with respect to the delivery date can be reduced.

  In the first aspect, for example, for each job, a progress data storage unit that stores an arrival process that is a process in which the job has arrived at the determination date, and for each job, the limit process delivery date, You may further provide the management reference | standard storage part which memorize | stores the process delivery date by a bottleneck process reference | standard, and the said preceding load reference | standard time. The first process delivery date calculation unit may store the calculated limit process delivery date for each job in the management reference storage unit. The second process delivery date calculation unit may store the calculated process delivery date based on the bottleneck process standard in the management standard storage unit for each job. The preceding load reference time calculation unit may store the calculated preceding load reference time in the management reference storage unit for each job. The progress level calculation unit reads, for each job, the arrival process from the progress data storage unit, the limit process delivery date corresponding to the read arrival process, the process delivery date based on the bottleneck process standard, The advance load reference time may be read from the management reference storage unit, and the progress level in the arrival process may be calculated.

  In this aspect, for each job, the arrival process is read, the limit process delivery time corresponding to the read arrival process, the process delivery time on the bottleneck process basis, and the preceding load reference time are read, The progress level in the arrival process is calculated. Therefore, according to this aspect, it is possible to calculate the progress level in the process being processed for the job at the determination date and time.

  In the first aspect, for example, for each job, the time when the standard process lead time elapses in order from the arrival date and time when the job arrived at the first process to the final process with respect to the downstream process, An earliest completion reference time calculation unit that calculates the earliest completion reference time at which processing can be completed earliest may be further provided. The plurality of levels may further include a 0th level in which the urgency level of the processing is lower than the first level. The progress level calculation unit further calculates a relative position of the determination date and time on the time axis with respect to the earliest completion reference time in the process in which the job arrives at the determination date and time for each job, The progress level corresponding to the relative position may be calculated. The progress level calculation unit sets the progress level as the first level when the determination date and time is after the earliest completion reference time before the preceding load reference time, and before the earliest completion reference time. May be the 0th level.

  The earliest completion reference time is the time at which the lead time between standard processes has passed in order from the downstream process to the final process starting from the arrival time of the job at the first process. For this reason, there is no need to start processing for the calculation target job earlier than the earliest completion reference time. Therefore, in this aspect, the calculated progress level is set to the 0th level in which the urgency level of the process is lower than the 1st level when the determination date is earlier than the earliest completion reference time. Therefore, according to this aspect, since the urgency of the process is the lowest before the earliest completion reference time, the start of the process is urged to be weakest, and other jobs whose marginal process delivery time is earlier than the calculation target job. The possibility of causing a delay in delivery can be reduced.

  In the first aspect, for example, a progress index calculation unit that calculates a progress index indicating a progress degree may be further provided for each job in a process in which the job arrives at the determination date and time. The progress index calculation unit sets the progress index as a predetermined first reference index when the determination date is the earliest completion reference time, and sets the progress index when the determination date is the preceding load reference time. A predetermined second reference index greater than the first reference index, and when the determination date and time is a process delivery date based on the bottleneck process reference, the progress index is a predetermined third reference index greater than the second reference index; When the determination date / time is the critical process delivery date, the progress index is set to a predetermined fourth reference index larger than the third reference index, and the determination date / time is between the earliest completion reference time and the preceding load reference time. When the progress index is a first interpolation value obtained by linearly interpolating the first reference index and the second reference index, the determination date and time is the preceding load reference time and the process delivery date based on the bottleneck process reference. In the meantime, the progress index is set to a second interpolation value obtained by linear interpolation with the second reference index and the third reference index, and the determination date and time is a process delivery date based on the bottleneck process criteria and the limit process delivery date. When the interval is between, the progress index may be a third interpolation value obtained by linear interpolation between the third reference index and the fourth reference index.

  In this aspect, the progress index when the progress level is the first level is the first interpolation value, the progress index when the progress level is the second level is the second interpolation value, and the progress level is the third level. The progress index at this time is the third interpolation value. For this reason, even if the progress level is the same, the progress index becomes a different value depending on the relative position of the determination date and time with respect to the reference index. Therefore, according to this aspect, the degree of progress can be grasped in more detail.

  The first aspect may further include, for example, a display unit that displays information, and a display control unit that displays the progress level on the display unit for each job.

  In this aspect, the progress level is displayed on the display unit for each job. Therefore, according to this aspect, the progress level for each job can be easily grasped.

  In the first aspect, for example, a preset operation rate storage unit that stores an operation rate of equipment used in the step for each step, and a standard process required for processing in each step for each job. And a job data storage unit for storing time. The preceding load time calculation unit reads the operation rate of equipment used in the calculation target process from the operation rate storage unit, reads the standard processing time required for processing in the calculation target process from the job data storage unit, and A time obtained by dividing the processing time by the operating rate may be used as the related time.

  In this aspect, the operating rate of the equipment used in the calculation target process is read, the standard processing time required for processing in the calculation target step is read, and the time obtained by dividing the standard processing time by the operating rate is the related time. Used. Therefore, according to this aspect, it is possible to calculate the preload time suitable for the actual operation status by considering the operation rate of the equipment.

  According to the present invention, for each job, in the process in which the calculation target job has arrived at the predetermined determination date and time, the process delivery date and the limit process delivery date based on the preceding load reference time, the bottleneck process reference, on the time axis Since the relative position of the determination date and time is calculated and the progress level corresponding to the relative position is calculated, it is possible to calculate the progress level in finer categories than when calculating the progress level using only the limit process delivery date. it can. As a result, the actual production progress can be managed more appropriately.

It is a block diagram showing roughly an example of composition of a process management device of a 1st embodiment. It is a timing chart which shows a limit process delivery date roughly. It is a timing chart which shows a prior load time roughly. It is a timing chart which shows process delivery time margin time roughly. It is a timing chart which shows roughly the process delivery date by a bottleneck process standard. It is a timing chart which shows a preceding load standard time roughly. It is a figure which shows roughly the example of a display of the progress level in 1st Embodiment. It is a flowchart which shows schematically operation | movement of 1st Embodiment by a 1st process delivery date calculation part, a preceding load time calculation part, a 2nd process delivery date calculation part, and a preceding load reference time calculation part. It is a flowchart which shows schematically operation | movement of 1st Embodiment by a 1st process delivery date calculation part, a preceding load time calculation part, a 2nd process delivery date calculation part, and a preceding load reference time calculation part. It is a flowchart which shows schematically operation | movement of 1st Embodiment by a 1st process delivery date calculation part, a preceding load time calculation part, a 2nd process delivery date calculation part, and a preceding load reference time calculation part. It is a flowchart which shows roughly operation | movement of a progress level calculation part and a display control part. 6 is a timing chart schematically showing a limit process delivery date, a process delivery date based on a bottleneck process standard, and a preceding load reference time in a job. 13 is a timing chart schematically showing a limit process delivery date, a process delivery date based on a bottleneck process basis, and a preceding load reference time in a job different from FIG. 12. 14 is a timing chart schematically showing progress levels of the job of FIG. 12 and the job of FIG. It is a block diagram which shows roughly the structural example of the process management apparatus of 2nd Embodiment. It is a timing chart which shows the earliest completion reference time roughly. It is a figure which shows roughly the example of a display of the progress level in 2nd Embodiment. It is a figure which shows roughly the example of a display of the progress index in 2nd Embodiment. It is a timing chart which shows roughly the progress index of two jobs with the same progress level. It is a flowchart which shows schematically operation | movement of 2nd Embodiment by a 1st process delivery date calculation part, a preceding load time calculation part, a 2nd process delivery date calculation part, a preceding load reference time calculation part, and the earliest completion reference time calculation part. It is a flowchart which shows schematically operation | movement of 2nd Embodiment by a 1st process delivery date calculation part, a preceding load time calculation part, a 2nd process delivery date calculation part, a preceding load reference time calculation part, and the earliest completion reference time calculation part. It is a flowchart which shows roughly operation | movement of 2nd Embodiment by a progress level calculation part, a display control part, and a progress index | exponent calculation part.

(Knowledge that became the basis of the present invention)
FIG. 2 is a timing chart schematically showing the limit process delivery date of the job JB calculated by the first process delivery date calculation unit 151 (FIG. 1 described later) in the first embodiment of the present invention. The knowledge that is the basis of the present invention will be described first with reference to FIG.

  In a metal material production factory or the like, a plurality of different products are produced in parallel by processing a plurality of materials as jobs in a predetermined order in predetermined steps. In the present embodiment, as shown in FIG. 2, for example, the first process delivery date calculation unit 151 starts from the delivery delivery date DT of the job JB, starting from the final process (equipment 8 in FIG. 2) from the standard process lead time SLT. By going back to the upstream process, the limit process delivery date PDT indicating the time limit for completing the process in each process (equipment 7 to equipment 1) is calculated as the limit process delivery date PD7 to PD1. In the present embodiment, the first process delivery date calculation unit 151 calculates a limit process delivery date PDT for each job.

  The inter-process lead time is a time difference between processing end times in two consecutive processes. That is, the inter-process lead time is the time from the process end time of the previous process to the process end time of the next process. The standard inter-process lead time SLT is an average value or median value calculated in advance from the past actual inter-process lead time in units of combinations of the preceding and following processes. The standard inter-process lead time SLT is stored in the inter-process lead time storage unit 142 (FIG. 1 described later).

  If the processing end time in each process is delayed from the limit process delivery date, if the job flows with the standard inter-process lead time SLT, the job will not be in time for the delivery delivery date. Therefore, in the past, the progress has been managed so that the processes in the facilities 1 to 7 are completed by the critical process delivery times PD1 to PD7. For example, the number of days left until the critical process delivery date is used as an index, and if the number of days left is less than a certain value, a warning is output to the target job so that production delays do not occur in the middle of the process. Is generally known. Alternatively, a method of instructing a manufacturing procedure so as to preferentially process an operation with a short allowance time until the process delivery date is well known. However, the management based only on the critical process delivery date has the following problems.

(X) There is no guideline to start processing in the process:
If the safety aspect of not delaying the limit process delivery time is considered too much, the processing start time of each process will be too early, and the work in process will increase. Conversely, if the process start time is set at the last minute so that the process is completed at the process delivery date, the delay in the upstream process may be propagated to the downstream process, and the delivery date may be delayed.

(Y) I don't know the impact on other jobs:
If the process start time of each process is set too early in consideration of the safety aspect that it is not delayed with respect to the limit process delivery date, processing of other jobs with earlier limit process delivery times will be delayed. As a result, there is a high possibility that the postponed job will be delayed in the delivery date. However, it is difficult to consider the degree of this possibility.

(Z) Management taking into account equipment load is difficult:
If there is a bottleneck equipment with a high equipment load in the middle, even if the process upstream of the bottleneck equipment can process the job earlier than the limit process delivery date, if the job waits in front of the bottleneck equipment, Will increase. In the case of a job shop type in which the order of processes differs depending on the job, a job that passes through a high load facility and a job that passes through only a low load facility should have different margin times for the limit process delivery date even if the limit process delivery date is the same. . However, it is difficult to determine this difference in margin time.

Therefore, the present inventor has conceived the technique of the present disclosure with the aim of the following items that solve the above-described problems. That is,
(A) An index serving as a guideline for starting the process in the process is provided.
(B) It is possible to determine whether the processing timing of a target job that is focused as a management target in progress management is likely to affect other jobs from the viewpoint of observing the delivery date.
(C) It is possible to modify a standard as a guide for progress management in accordance with the load status of the equipment.
(D) Even in the case of a job shop type in which equipment and order used by a job are different, it is possible to perform progress management in consideration of the load status of equipment that differs depending on the job.

(Embodiment)
Hereinafter, embodiments of the present invention will be described with reference to the drawings. In the drawings, the same components are denoted by the same reference numerals, and detailed description thereof is omitted as appropriate.

(Constitution)
FIG. 1 is a block diagram schematically showing a configuration example of a process management apparatus 100 in the first embodiment. As shown in FIG. 1, the process management apparatus 100 according to the first embodiment includes a display 110, an input unit 120, a memory 130, a storage device 140, and a central processing unit (CPU) 150.

  The process management apparatus 100 according to the first embodiment processes a plurality of materials as jobs in a plurality of processes (equipment) and produces a plurality of ordered products in parallel. For example, in a job shop type multi-product production factory, Manage the progress of processing for each material. Each ordered product is produced by processing the material by equipment corresponding to the process in the order of the process predetermined for each ordered product.

  The display 110 (corresponding to an example of a display unit) includes, for example, a liquid crystal display panel. The display 110 is controlled by the CPU 150 and displays the progress level in the process for each job as will be described later. The display 110 is not limited to a liquid crystal display panel. The display 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 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 has a clock function that counts the date and time. The CPU 150 operates in accordance with the control program of the present embodiment stored in the memory 130, whereby the first process delivery date calculation unit 151, the preceding load time calculation unit 152, the second process delivery date calculation unit 153, and the preceding load reference time calculation. Unit 154, progress level calculation unit 155, and display control unit 156. Each function of the CPU 150 will be described later.

  The storage device 140 is configured by, for example, a hard disk or a semiconductor memory. The storage device 140 includes a job data storage unit 141, an inter-process lead time storage unit 142, an operation rate storage unit 143, a management reference storage unit 144, and a progress data storage unit 145. Each of the storage units 141 to 145 may be composed of different media. Alternatively, each of the storage units 141 to 145 may be configured by one medium in which the storage area is divided.

  The job data storage unit 141 indicates, for each job, the order of equipment to be used (that is, the order of the passing process), the standard processing time in each equipment, the delivery date of delivery, and the current progress status (which process has been advanced). Pre-stored. As the standard processing time in each facility, an average value or a median value of actual values when the same product in the past is processed in the same process may be used. The current progress status may be represented by the processing end time of each process. That is, if the process end time of each process is described, it indicates that the process has been processed, and if the process end time is not described, it indicates that the process has not been processed.

  The inter-process lead time storage unit 142 stores in advance a standard inter-process lead time SLT (FIG. 2) in a combination of preceding and succeeding processes for each job. The inter-process lead time storage unit 142, for example, for the job shown in FIG. 2, each standard inter-process lead time SLT from the equipment 1 to the equipment 2, the equipment 2 to the equipment 3,. Is stored in advance. For example, past actual values of inter-process lead times when processed by the facility 1 and then processed by the facility 2 are accumulated, and an average value or median value of the actual values is calculated in advance. Then, the average value or median value of the actual values is stored in the inter-process lead time storage unit 142 as the standard inter-process lead time SLT from the equipment 1 to the equipment 2.

  The operating rate storage unit 143 stores a standard operating rate in advance for each facility. The operating rate is the ratio of the maximum time that can be spent on job processing within 24 hours per day. For example, the operation rate is less than 100% because the equipment cannot be moved during the maintenance time and the break time of the worker. For example, in FIG. 2, the operation rate storage unit 143 stores the operation rate set for each facility in a standard manner such that the operation rate of the facility 1 is 50% and the operation rate of the facility 2 is 80%.

  As will be described later, the management criterion storage unit 144 stores the calculation results of the first process delivery date calculation unit 151, the second process delivery date calculation unit 153, and the preceding load reference time calculation unit 154. The progress data storage unit 145 stores the progress status of each job at the current date and time, that is, which equipment is processing each job.

  As described above, the first process delivery date calculation unit 151 completes the process in each process by going back to the upstream process from the final process by the lead time between the standard processes starting from the delivery delivery date for each job as described above. The process delivery date representing the deadline is calculated. If the processing end time for a job in a certain process is delayed from the calculated process delivery date, the job will not be in time for the delivery date. Therefore, the calculated process delivery date is referred to as a limit process delivery date. The first process delivery date calculation unit 151 stores the calculated limit process delivery date of each process in the management reference storage unit 144 for each job.

  FIG. 3 is a timing chart schematically showing the preceding load time calculated by the preceding load time calculating unit 152. The preceding load time calculation unit 152 calculates the preceding load time for each process for each job. The preceding load time is the actual processing time (an example of the related time) obtained by dividing the standard processing time in the calculation target process of another job with a limit process delivery time earlier than the limit process delivery date of the calculation target job by the operation rate. Equivalent time).

  For example, in FIG. 3, the limit process delivery date PD4 in the equipment 4 of the job JB is March 14th. The prior load time calculation unit 152 is a job data storage unit that calculates the standard processing time in the facility 4 for jobs other than the job JB whose deadline for the limit process in the facility 4 is earlier than March 14 and is unprocessed in the facility 4 141 to read. The preceding load time calculation unit 152 reads the operation rate of the equipment 4 from the operation rate storage unit 143. The preceding load time calculation unit 152 calculates a total time of actual processing times obtained by dividing the standard processing time for each job in the facility 4 by the operation rate of the facility 4. This total time (9.8 days in the example of FIG. 3) is the preceding load time PLT of the equipment 4.

  The preceding load time calculation unit 152 calculates the preceding load time for each process of the job JB (equipment 1 to 8 in FIG. 3). The preceding load time calculation unit 152 further calculates a preceding load time in each process using a job other than the job JB as a calculation target job. As a result, the preceding load time calculation unit 152 calculates the preceding load time for every job and for each process through which the job passes.

  For example, the preceding load time PLT of the facility 4 is the total time of standard processing time / operation rate for jobs to be processed by the facility 4 prior to the calculation target job (job JB in FIG. 3). Therefore, it is considered that if processing for job JB is started after the preceding load time PLT, processing for other jobs will not be disturbed.

  FIG. 4 is a timing chart schematically showing the process delivery time margin calculated by the second process delivery time calculation unit 153. FIG. 5 is a timing chart schematically showing the process delivery date based on the bottleneck process criterion calculated by the second process delivery date calculation unit 153.

  The second process delivery date calculation unit 153 calculates the time difference between the time obtained by adding the preceding load time PLT to the reference date and time SDT and the limit process delivery time as the process delivery margin time DMT. For example, in FIG. 4, as described above, the preceding load time PLT of the equipment 4 is 9.8 days, and the limit process delivery date PD4 is March 14. Further, the reference date and time SDT is, for example, the current date and time, and is 0:00 on March 1 in FIG. Therefore, the process delivery time allowance time DMT of the equipment 4 is 3.2 days. If processing is started during this process delivery margin time DMT, it will not adversely affect the processing of other jobs whose marginal process delivery is earlier than their own job (job to be calculated, job JB in FIG. 4). There is an advantage that its own job (job to be calculated, job JB in FIG. 4) is not delayed by the limit process delivery date.

  The second process delivery time calculation unit 153 compares the process delivery time allowance times DMT of the facilities 1 to 8 and extracts the minimum process delivery time allowance time DMTmin that is the minimum value. In the example of FIG. 4, the process delivery allowance time DMT of the facility 6 is 2.2 days, which is the minimum process delivery allowance time DMTmin. Hereinafter, the process (equipment 6 in FIG. 4) having the minimum process delivery margin time DMTmin is referred to as a “bottleneck process”.

  The second process delivery date calculation unit 153 calculates a delivery date obtained by subtracting the minimum process delivery time margin DMTmin from the limit process delivery date PDT in all processes (in FIG. 5, equipment 1 to 8). Calculate as The second process delivery date calculation unit 153 calculates a process delivery date BNT based on the bottleneck process standard in each process for each job. The second process delivery date calculation unit 153 stores the calculated process delivery date BNT based on the bottleneck process standard in the management standard storage unit 144.

  The process delivery date BNT based on the bottleneck process standard has an adverse effect on the processing for jobs in all processes (including the bottleneck process) whose marginal process delivery date PDT is earlier than its own job (job to be calculated, job JB in FIG. 5). When all jobs are processed with the standard inter-process lead time, it can be said that it is the latest timing that does not cause a job waiting time (unnecessary equipment idle time) in the bottleneck process. In other words, in the upstream process from the bottleneck process, if processing for a job is started later than the process delivery time BNT based on the bottleneck process standard, the bottleneck process may have idle time for waiting for the arrival of the job. And the margin time for the limit process delivery date PDT is shortened.

  FIG. 6 is a timing chart schematically showing the preceding load reference time calculated by the preceding load reference time calculation unit 154. For example, in FIG. 6, in the first process (facility 1), the preceding load reference time calculation unit 154 calculates time TP1 obtained by adding the preceding load time PLT to the reference date and time SDT as the preceding load reference time TP of the first process.

  In the second process (facility 2), the preceding load reference time calculation unit 154 precedes the second process by the time TP21 obtained by adding the inter-process lead time SLT to the preceding load reference time TP of the first process and the reference date and time SDT. The later time TP22 is calculated as the preceding load reference time TP of the second step by comparing with the time TP22 to which the load time PLT is added.

  In the Nth process (N is an integer not less than 2 and not more than the number of processes of the calculation target job), the preceding load reference time calculation unit 154 sets the standard inter-process lead time SLT at the preceding load reference time of the (N-1) process. The added time and the time obtained by adding the preceding load time PLT in the Nth step to the reference date and time SDT are calculated, and the later time is calculated as the preceding load reference time TP in the Nth step.

  The preceding load reference time calculation unit 154 calculates the preceding load reference time in each process for each job. The preceding load reference time calculation unit 154 stores the calculated preceding load reference time TP in the management reference storage unit 144. The preceding load reference time TP can be said to be the earliest processing timing that does not adversely affect all other jobs whose deadline for deadline process is earlier than their own job.

  The preceding load reference time calculation unit 154 may compare this time until the Nth process becomes the final process (equipment 8 in FIG. 6), but until the Nth process becomes the bottleneck process. You may end. This is because, after the bottleneck process, the time obtained by adding the inter-standard process lead time SLT to the preceding load reference time of the (N-1) th process is equal to the preceding load time in the Nth process on the reference date and time SDT. This is because it is later than the time when PLT is added. The preceding load reference time TP coincides with the process delivery date BNT based on the bottleneck process reference after the bottleneck process, as shown in FIG.

  The calculation by the first process delivery date calculation unit 151, the preceding load time calculation unit 152, the second process delivery date calculation unit 153, and the preceding load reference time calculation unit 154 is performed in advance, for example, one month ahead from the current (calculation start date). It will be done for up to order products. On the other hand, the operations of the progress level calculation unit 155 and the display control unit 156 described below are performed in order to check the progress status during manufacturing of the ordered product.

  FIG. 7 is a diagram schematically showing a display example of the progress level calculated by the progress level calculation unit 155 and displayed on the display 110 by the display control unit 156.

  For example, when the user instructs the progress level calculation unit 155 to evaluate the progress level using the input unit 120, the progress level calculation unit 155 acquires the current date and time as the determination date and time from the CPU 150. The progress level calculation unit 155 reads from the progress data storage unit 145 the progress status of each job, which process (equipment) each job has reached at the current date and time. The progress level calculation unit 155 reads, for each read job, the limit process delivery date PDT of the arrival process that has arrived, the process delivery date BNT based on the bottleneck process standard, and the preceding load reference time TP from the management standard storage unit 144.

  The progress level calculation unit 155 calculates the relative position of the current date and time (determination date) on the time axis with respect to the limit process delivery date PDT, the process delivery date BNT based on the bottleneck process criteria, and the preceding load reference time TP. The progress level calculation unit 155 calculates the progress level in four steps as follows according to the calculated relative position.

  In other words, if the current date is before the preceding load reference time TP, the progress level calculation unit 155 sets the progress level to a level LV1 (corresponding to an example of the first level) indicating that there is no need to rush. If the current date and time is after the preceding load reference time TP and before the process delivery date BNT based on the bottleneck process reference, the progress level calculation unit 155 indicates the level LV2 (second Equivalent to an example of a level). The progress level calculation unit 155 indicates that if the current date and time is after the process delivery date BNT based on the bottleneck process criteria and before the limit process delivery date PDT, the progress level should be processed earlier LV3 (Corresponding to an example of the third level). If the current date and time is after the limit process delivery date PDT, the progress level calculation unit 155 sets the progress level to level LV4 (corresponding to an example of the fourth level) indicating that it should be processed quickly.

  FIG. 7 shows an example in which the calculation target job JB has arrived at the facility 3 and the current date is March 10th. In FIG. 7, the current date and time is after the preceding load reference time TP and before the process delivery date BNT on the bottleneck process basis. Therefore, the progress level calculation unit 155 sets the progress level in the equipment 3 of the job JB to a level LV2 that represents that processing is possible.

  The display control unit 156 displays the progress level calculated by the progress level calculation unit 155 on the display 110 for each job. The display control unit 156 displays, for example, FIG. By viewing the screen of FIG. 7 displayed on the display 110, the user understands that the progress level in the equipment 3 of the job JB is the level LV2.

(Operation)
8 to 10 show the first process due date calculation unit 151, the preceding load time calculation unit 152, the second process delivery date calculation unit 153, and the preceding load reference time calculation unit 154 of the process management apparatus 100 shown in FIG. It is a flowchart which shows the operation | movement of embodiment roughly. For example, when instructed by the user using the input unit 120, the operation of FIG. 8 is started.

  In step S800 of FIG. 8, the first process delivery date calculation unit 151 sets the first job as the calculation target job. In step S805, the first process delivery date calculation unit 151 acquires the delivery date of the set job from the job data storage unit 141, and calculates the standard inter-process lead time between all processes in the set job as the inter-process lead time. Obtained from the storage unit 142. In step S810, the first process delivery date calculation unit 151 calculates the limit process delivery date PDT of all the processes in the set job. The first process delivery date calculation unit 151 stores the calculated limit process delivery dates PDT of all processes in the management reference storage unit 144 in association with the set jobs.

  In step S815, the first process delivery date calculation unit 151 determines whether or not all jobs have been completed. If all jobs have not been completed (NO in step S815), the process proceeds to step S820. In step S820, the first process delivery date calculation unit 151 sets the next job as a calculation target job. Thereafter, the process returns to step S805, and the above steps are repeated. On the other hand, if all jobs have been completed (YES in step S815), the process proceeds to step S825.

  In step S825, the preceding load time calculation unit 152 sets the first job as the calculation target job. In step S830, the preceding load time calculation unit 152 sets the first process as the calculation target process in the set job. In step S <b> 835, the preceding load time calculation unit 152 manages, in the set process (calculation target process), another job having a limit process delivery time earlier than the limit process delivery date of the set job (calculation target job). Obtained from the storage unit 144.

  In step S840, the preceding load time calculation unit 152 acquires the operation rate of the equipment used for the set process from the operation rate storage unit 143. The preceding load time calculation unit 152 acquires, from the job data storage unit 141, each standard processing time in the set process of the other job acquired in step S835. The preceding load time calculation unit 152 calculates the total time of each standard processing time / operation rate as the preceding load time. The preceding load time calculation unit 152 stores the calculated preceding load time in the management reference storage unit 144 in association with the calculation target job and the calculation target process.

  In step S845, the preceding load time calculation unit 152 determines whether or not all the processes have been completed. If all the processes have not been completed (NO in step S845), the process proceeds to step S850. In step S850, the preceding load time calculation unit 152 sets the next process as a calculation target process. Thereafter, the process returns to step S835, and the above steps are repeated.

  On the other hand, if all processes have been completed (YES in step S845), the process proceeds to step S855. In step S855, the preceding load time calculation unit 152 determines whether all jobs have been completed. If all jobs have not been completed (NO in step S855), the process proceeds to step S860. In step S860, the preceding load time calculation unit 152 sets the next job as the calculation target job. Thereafter, the process returns to step S830, and the above steps are repeated. On the other hand, if all jobs have been completed (YES in step S855), the process proceeds to step S900 in FIG.

  In step S900, the second process delivery date calculation unit 153 sets a reference date and time. The reference date and time may be the current date and time as described above. The second process delivery date calculation unit 153 may set a reference date and time instructed by the user using the input unit 120, for example. In step S905, the second process delivery date calculation unit 153 sets the first job as the calculation target job. In step S910, the second process delivery date calculation unit 153 calculates the time difference between the time obtained by adding the preceding load time to the reference date and the limit process delivery date for all processes. The second process delivery date calculation unit 153 stores the minimum value of the calculated time difference in the RAM of the memory 130. In step S <b> 915, the second process delivery date calculation unit 153 calculates a process delivery date based on the bottleneck process standard using the minimum value stored in the RAM of the memory 130 for all processes. The second process delivery date calculation unit 153 stores the process delivery date based on the bottleneck process standard in the management standard storage unit 144 in association with the calculation target job.

  In step S920, the second process delivery date calculation unit 153 determines whether or not all jobs have been completed. If all jobs have not been completed (NO in step S920), the process proceeds to step S925. In step S925, the second process delivery date calculation unit 153 sets the next job as the calculation target job. Thereafter, the process returns to step S910, and the above steps are repeated. On the other hand, if all jobs have been completed (YES in step S920), the process proceeds to step S1005 in FIG.

  In step S1005, the preceding load reference time calculation unit 154 sets the first job as the calculation target job J. In step S <b> 1010, the preceding load reference time calculation unit 154 acquires the preceding load time of the first step of the calculation target job from the management reference storage unit 144. The preceding load reference time calculation unit 154 stores, in the management reference storage unit 144, the time obtained by adding the preceding load time of the first process to the reference date and time as the preceding load reference time of the first process in association with the calculation target job. To do. In step S1020, the preceding load reference time calculation unit 154 sets “2” to the count value N that counts the order of the steps as the Nth step.

  In step S <b> 1025, the preceding load reference time calculation unit 154 acquires the preceding load reference time of the (N−1) -th process of the calculation target job J from the management reference storage unit 144. The preceding load reference time calculation unit 154 acquires the standard inter-process lead time from the (N−1) -th process to the N-th process from the inter-process lead time storage unit 142. The preceding load reference time calculation unit 154 calculates a time obtained by adding the standard inter-process lead time from the (N-1) process to the Nth process to the preceding load reference time of the (N-1) process. The time is stored in the RAM of the memory 130 as the first time.

  In step S1030, the preceding load reference time calculation unit 154 acquires the preceding load time of the Nth step of the calculation target job from the management reference storage unit 144. The preceding load reference time calculation unit 154 calculates a time obtained by adding the preceding load time of the Nth process to the reference date and time, and stores the calculated time in the RAM of the memory 130 as the second time. In step S1035, the preceding load reference time calculation unit 154 compares the first time stored in the RAM of the memory 130 with the second time, and sets the later one as the preceding load reference time of the Nth step, and the calculation target job J Are stored in the management reference storage unit 144 in association with

  In step S <b> 1040, the preceding load reference time calculation unit 154 determines whether or not the process order count value N has reached the final process M (J) of the calculation target job J. If the count value N is not the final process M (J) of the calculation target job J (NO in step S1040), the process proceeds to step S1045. On the other hand, if the count value N is the final process M (J) of the calculation target job J (YES in step S1040), the process proceeds to step S1050.

  In step S <b> 1045, the preceding load reference time calculation unit 154 increments the process order count value N by one. Thereafter, the process proceeds to step S1025, and the above steps are repeated. In step S1050, the preceding load reference time calculation unit 154 determines whether all jobs have been completed. If all jobs have not been completed (NO in step S1050), the process proceeds to step S1055. In step S <b> 1055, the preceding load reference time calculation unit 154 sets the next job as the calculation target job J. Thereafter, the process returns to step S1010, and the above steps are repeated. On the other hand, if all jobs have been completed (YES in step S1050), the processing in FIG. 10 ends.

  In this embodiment, steps S800 to S820 correspond to an example of a first process delivery time calculation step, steps S825 to S860 correspond to an example of a preceding load time calculation step, and steps S900 to S925 correspond to a second process delivery time calculation step. Steps S1005 to S1055 correspond to an example of a calculation step, and steps S1005 to S1055 correspond to an example of a preceding load reference time calculation step.

  FIG. 11 is a flowchart schematically showing operations of the progress level calculation unit 155 and the display control unit 156 of the process management apparatus 100 shown in FIG. For example, when the display of the progress level is instructed using the input unit 120, the operation of FIG. 11 is started.

  In step S1100, the progress level calculation unit 155 sets a determination date and time. The progress level calculation unit 155 may acquire the current date and time from the CPU 150 and set the current date and time as the determination date and time. Alternatively, the progress level calculation unit 155 may set a future date and time as the determination date and time. In step S1105, the progress level calculation unit 155 sets the first job as the calculation target job. In step S1110, the progress level calculation unit 155 acquires the progress status of the set job, that is, the process (equipment) where the set job has arrived from the progress data storage unit 145.

  In step S1115, the progress level calculation unit 155 stores the management standard storage of the preceding load reference time of the process (equipment) in which the set job has arrived, the process delivery date based on the bottleneck process criteria, and the limit process delivery date. From the unit 144. In step S1120, the progress level calculation unit 155 calculates the relative position of the determination date and time on the time axis with respect to the preceding load reference time, the process delivery date based on the bottleneck process criteria, and the limit process delivery date. In step S <b> 1125, the progress level calculation unit 155 calculates a progress level based on the calculated relative position, and stores the calculated progress level in the RAM of the memory 130.

  In step S1130, the progress level calculation unit 155 determines whether or not all jobs have been completed. If all the jobs have not been completed (NO in step S1130), the process proceeds to step S1135. In step S1135, the progress level calculation unit 155 sets the next job as a calculation target job. Thereafter, the process returns to step S1110, and the above steps are repeated.

  On the other hand, if all the jobs have been completed (YES in step S1130), the process proceeds to step S1140. In step S1140, the display control unit 156 displays the progress level on the display 110 for each job. Thereafter, the process of FIG. 11 ends. In the present embodiment, steps S1100 to S1135 correspond to an example of a progress level calculation step.

(Specific examples of progress levels)
Even if the marginal process delivery time in a process of two jobs is the same, the case where the progress level calculated by the progress level calculation unit 155 differs when the subsequent passing process is different will be described with reference to FIGS. Is done.

  FIG. 12 is a timing chart schematically showing the limit process delivery date PDT, the process delivery date BNT based on the bottleneck process reference, and the preceding load reference time TP in the job JB1 passing through the facilities 1, 3, 4, 6, and 8. FIG. 13 is a timing chart schematically showing the limit process delivery date PDT, the process delivery date BNT based on the bottleneck process reference, and the preceding load reference time TP in the job JB2 passing through the facilities 1, 2, 3, 5, 7, and 8. is there. FIG. 14 is a timing chart schematically showing progress levels of the job JB1 (FIG. 12) and the job JB2 (FIG. 13).

  As shown in FIG. 12 and FIG. 13, the job JB1 and the job JB2 are job shop type production processes because the passing processes are different from each other. As can be seen from FIGS. 12 and 13, the limit process delivery date PDT in the facility 3 is the same on March 13 for both the job JB1 and the job JB2. The reference date and time SDT is 0:00 on March 1 for both job JB1 (FIG. 12) and job JB2 (FIG. 13).

  In FIG. 12, the process having the minimum process delivery margin time DMTmin among the process delivery margin time, which is the time difference between the time obtained by adding the preceding load time PLT to the reference date and time SDT and the limit process delivery time PDT, Is the longest facility 6. Therefore, the facility 6 becomes a bottleneck process.

  On the other hand, the job JB2 shown in FIG. In FIG. 13, a process having a minimum process delivery margin time DMTmin of the minimum value among the process delivery margin times which are the time difference between the time obtained by adding the preceding load time PLT to the reference date and time SDT and the limit process delivery date PDT is the equipment 7. . Therefore, the facility 7 becomes a bottleneck process.

  As can be seen from FIGS. 12 and 13, the minimum process delivery time margin DMTmin is longer for job JB2 (FIG. 13) than for job JB1 (FIG. 12). Therefore, the process delivery time BNT based on the bottleneck process standard for the equipment 3 in the job JB1 (FIG. 12) is March 11, whereas the process delivery time BNT based on the bottleneck process standard for the equipment 3 in the job JB2 (FIG. 13). The process delivery date BNT is March 9, which is two days earlier than the job JB1.

  In FIG. 14, the determination date and time is set to March 10. The process delivery date BNT based on the bottleneck process standard of job JB1 is March 11. Therefore, when the job JB1 has progressed to the facility 3 at the determination date (March 10), the progress level calculation unit 155 indicates that the calculated progress level can be processed. Let it be LV2. Therefore, when processing in the facility 3 for the job JB1 is started at the time of determination date (that is, earlier than the process delivery date BNT based on the bottleneck process standard), if the process proceeds with the standard inter-process lead time, the bottleneck process It turns out that there is a possibility of waiting at (facility 6).

  On the other hand, the process delivery date BNT based on the bottleneck process standard of job JB2 is March 9. For this reason, when the job JB2 has progressed to the facility 3 at the determination date (March 10), the progress level calculation unit 155 should process the calculated progress level early. It is assumed that the level is LV3. Therefore, when the processing in the equipment 3 for the job JB2 is started at the time of the determination date (that is, the time later than the process delivery date BNT based on the bottleneck process standard), if the process proceeds with the standard inter-process lead time, the bottleneck process It is found that there is a low possibility of waiting at (facility 7), and there is a possibility that it can be processed and shipped early.

  Thus, according to this embodiment, even if the limit process delivery date is the same, it is possible to perform different evaluations on the progress level.

(effect)
As described above, in the first embodiment, not only process management considering only the delivery date of one's own job by the limit process delivery date, but also the load on the equipment and the influence on other jobs are integrated. Process management that takes into account this is possible. In other words, the progress level calculation unit 155 evaluates the progress of the job in four stages instead of only two stages based on the limit process delivery date.

  In the first embodiment, for each job, the standard processing time / operating rate in the relevant process of other jobs whose marginal process delivery time is earlier than their own job (calculation target job) is summed up in all the processes that pass. Thus, the preload time is calculated. The process in which the time difference between the time obtained by adding the preceding load time to the reference date and time and the limit process delivery date is the minimum value is referred to as the bottleneck process of each job. The process delivery time on the basis of the bottleneck process is calculated so that this minimum time difference is ensured in all processes.

  The process delivery date based on this bottleneck process standard is that when the job flows through all processes with the standard inter-process lead time, other jobs that have a limit process delivery time earlier than their own job (calculation target job) in the bottleneck process Immediately after all are processed (that is, without generating unnecessary idle time), it is the latest timing at which the processing for the own job can be started.

  Therefore, in the upstream process of the bottleneck process, if the processing for the job starts earlier than the process delivery date based on the bottleneck process standard, then the limit process delivery time will be Is more likely to wait for the completion of processing for another job earlier than its own job (job to be calculated). This is because, in general, processing for a job with a quick delivery date is preferentially started. As a result, by using the process delivery date based on the bottleneck process standard, the load status of the bottleneck process determined by the relationship with other jobs is taken into consideration, and an indication of when each job should be processed Can be obtained.

  In the first embodiment, in the first step of the job, a time obtained by adding the preceding load time to the reference time is calculated as the preceding load reference time. In the subsequent Nth process (N is an integer of 2 or more and the number of job processes or less), the later of the time determined by the lead time between standard processes and the end time of the preceding load time is the preceding load. Calculated as the reference time.

  This preload reference time starts processing for one's own job (calculation target job) after all the processing for other jobs whose marginal process delivery time is earlier than their own job (calculation target job) is completed in all processes. If so, it is the earliest timing. In other words, when processing for one's own job (calculation target job) is started earlier than the preceding load reference time, another job whose limit process delivery time is earlier than its own job (calculation target job) is postponed, It may cause delays in the delivery of other jobs. In this way, the influence on other jobs can be taken into account by using the preceding load reference time.

  In the first embodiment, after starting the processing for the job and starting manufacturing the ordered product, in the process that is being processed for the job at the determination date and time, the prior load reference time and the bottleneck process reference The progress level is distinguished by the relative positional relationship on the time axis of the determination date with respect to the process delivery date and the limit process delivery date, and the progress level is displayed on the display 110 for each job.

In the first embodiment, the determination date is
(A) Before the preceding load reference time,
(B) From the preceding load reference time to the process delivery date based on the bottleneck process reference,
(C) From the process delivery date to the limit process delivery date based on the bottleneck process standard,
(D) After the critical process delivery date,
Are distinguished in four stages. As a result, the priority of each job that has progressed to the same equipment can be evaluated in a finer category than the standard set only by the limit process delivery date.

  Furthermore, the load status of the bottleneck process or the process other than the bottleneck process, which differs depending on the job, is reflected in the above criteria (A) to (D). For this reason, the first embodiment can be easily applied to a job shop type production process that uses different equipment or order depending on the type of product.

  Next, the process management apparatus in the second embodiment will be described focusing on differences from the first embodiment. As in the first embodiment, the process management apparatus according to the second embodiment processes a plurality of materials as jobs in a plurality of processes (equipment) and produces a plurality of ordered products in parallel. For example, a job shop type Manages the progress of processing for each material in a multi-product production factory. Each ordered product is produced by processing the material by equipment corresponding to the process in the order of the process predetermined for each ordered product.

(Constitution)
FIG. 15 is a block diagram schematically showing a configuration example of the process management apparatus 100 in the second embodiment. As shown in FIG. 15, the process management apparatus 100 in the second embodiment includes a display 110, an input unit 120, a memory 130, a storage device 140, and a CPU 150.

  The ROM of the memory 130 stores the control program according to the second embodiment that causes the CPU 150 to operate. The CPU 150 has a clock function that counts the date and time. The CPU 150 operates in accordance with the control program of the second embodiment stored in the memory 130, so that the first process delivery date calculation unit 151, the preceding load time calculation unit 152, the second process delivery date calculation unit 153, and the preceding load reference time It has functions of a calculation unit 154, a progress level calculation unit 155, a display control unit 156, an earliest completion reference time calculation unit 157, and a progress index calculation unit 158. The functions of the earliest completion reference time calculation unit 157 and the progress index calculation unit 158 will be described later.

  The job data storage unit 141 further stores in advance the arrival date and time when the material (job) arrives at the first process (that is, the first process) for each job (that is, the date and time when the job was submitted to the first process). ing. The management reference storage unit 144 further stores the calculation result of the earliest completion reference time calculation unit 157.

  FIG. 16 is a timing chart schematically showing the earliest completion reference time calculated by the earliest completion reference time calculation unit 157. The earliest completion reference time calculation unit 157 reads, for each job, the standard inter-process lead in order from the downstream process to the final process starting from the arrival date and time AT when the material (job) arrives at the first process (that is, the first process). The time when each time SLT has elapsed is calculated as the earliest completion reference time FT at which processing can be completed earliest. In other words, the earliest completion reference time calculation unit 157 starts processing immediately from the arrival date and time AT of the job to the first process regardless of the process delivery date, and processes subsequent processes with the standard inter-process lead time SLT. The process end time of each process is calculated as the earliest completion reference time FT. The earliest completion reference time calculation unit 157 stores the calculated earliest completion reference time FT in the management reference storage unit 144.

  In FIG. 16, the limit process delivery date PDT shown on the right and the earliest completion reference time FT shown on the left are both the same because the standard inter-process lead time SLT has elapsed for each process. It is a shape line.

  The calculation by the first process delivery date calculation unit 151, the preceding load time calculation unit 152, the second process delivery date calculation unit 153, the preceding load reference time calculation unit 154, and the earliest completion reference time calculation unit 157 is performed in advance, for example, the present (calculation start) From 1 day to 1 month ahead. On the other hand, the operations of the progress level calculation unit 155, the display control unit 156, and the progress index calculation unit 158 are performed to check the progress status during the manufacture of the ordered product.

  FIG. 17 is a diagram schematically showing a display example of the progress level calculated by the progress level calculation unit 155 and displayed on the display 110 by the display control unit 156 in the second embodiment.

  The progress level calculation unit 155 of the second embodiment acquires the current date and time as the determination date and time from the CPU 150 when, for example, the user instructs the evaluation of the progress level using the input unit 120. The progress level calculation unit 155 reads from the progress data storage unit 145 the progress status of each job, which process (equipment) each job has reached at the current date and time. The progress level calculation unit 155 stores, for each read job, the limit process delivery date PDT of the arriving process that has arrived, the process delivery date BNT based on the bottleneck process standard, the preceding load reference time TP, and the earliest completion reference time FT. Read from the unit 144.

  The progress level calculation unit 155 stores the current date and time (determination date) on the time axis with respect to the limit process delivery date PDT, the process delivery date BNT on the bottleneck process basis, the preceding load reference time TP, and the earliest completion reference time FT. The relative position is calculated. In accordance with the calculated relative position, the progress level calculation unit 155 calculates the progress level in five steps as follows in the second embodiment.

  That is, if the current date is before the earliest completion reference time FT, the progress level calculation unit 155 sets the level LV0 (corresponding to an example of the 0th level) indicating that the process should be stopped. If the current date and time is after the earliest completion reference time FT and before the preceding load reference time TP, the progress level calculation unit 155 indicates the level LV1 (as an example of the first level) indicating that there is no need to rush. Equivalent). If the current date and time is after the preceding load reference time TP and before the process delivery date BNT based on the bottleneck process reference, the progress level calculation unit 155 indicates the level LV2 (second Equivalent to an example of a level). The progress level calculation unit 155 indicates that if the current date and time is after the process delivery date BNT based on the bottleneck process criteria and before the limit process delivery date PDT, the progress level should be processed earlier LV3 (Corresponding to an example of the third level). If the current date and time is after the limit process delivery date PDT, the progress level calculation unit 155 sets the progress level to level LV4 (corresponding to an example of the fourth level) indicating that it should be processed quickly.

  FIG. 17 illustrates an example in which the calculation target job JB has arrived at the facility 3 and the current date and time is March 10 as in FIG. 7 of the first embodiment. In FIG. 17, the current date and time is after the preceding load reference time TP and before the process delivery date BNT based on the bottleneck process reference. Therefore, the progress level calculation unit 155 sets the progress level in the equipment 3 of the job JB to a level LV2 that represents that processing is possible.

  The display control unit 156 displays the progress level calculated by the progress level calculation unit 155 on the display 110 for each job. For example, the display control unit 156 displays FIG. 17 on the display 110. By viewing the screen of FIG. 17 displayed on the display 110, the user understands that the progress level of the equipment 3 of the job JB is the level LV2.

  FIG. 18 is a diagram schematically illustrating a display example of the progress index calculated by the progress index calculation unit 158 and displayed on the display 110 by the display control unit 156.

  The reference index used to calculate the progress index is a progress index at a boundary between progress levels, which is determined in advance. In other words, the reference index is a progress index at the earliest completion reference time FT, the preceding load reference time TP, the process delivery time BNT based on the bottleneck process reference, and the limit process delivery time PDT, which are respectively determined in advance. Each of these predetermined reference indices is stored in the ROM of the memory 130 as a part of the control program of the second embodiment, for example.

  In the example of FIG. 18, the reference index at the boundary between the level LV0 and the level LV1 (earliest completion reference time FT) is set to “0” (corresponding to an example of the first reference index). The reference index at the boundary between the level LV1 and the level LV2 (preceding load reference time TP) is set to “10” (corresponding to an example of the second reference index). Further, the reference index of the boundary between the level LV2 and the level LV3 (process delivery date BNT based on the bottleneck process reference) is set to “20” (corresponding to an example of the third reference index). Further, the reference index of the boundary between the level LV3 and the level LV4 (limit process delivery date PDT) is set to “30” (corresponding to an example of the fourth reference index).

  The progress index calculator 158 calculates a progress index between the reference index and the reference index by linear interpolation of the two reference indexes. The progress index calculation unit 158 stores the calculated reference index in the RAM of the memory 130. In the example of FIG. 18, the boundary between the level LV2 and the level LV3 with the reference index “20” is April 10, and the boundary between the level LV3 and the level LV4 with the reference index “30” is 4. The month is 20th. Therefore, the progress index calculation unit 158 calculates the progress index of April 16, which is the determination date (current date), as the progress index “26” by linear interpolation between the reference index “20” and the reference index “30”. To do.

  The reference index is not limited to the example of FIG. It is sufficient that a difference is provided between the two reference indexes so that the progress index between the reference index and the progress index is appropriately calculated by linear interpolation.

(Specific example of progress index)
A case where the progress index calculated by the progress index calculation unit 158 is different even when the progress levels in a certain process of two jobs are the same will be described with reference to FIG.

  FIG. 19 is a timing chart schematically showing progress indexes of jobs JB3 and JB4 having the same progress level LV3. In FIG. 19, the earliest completion reference time FT is the same March 3 for both jobs JB3 and JB4, and the limit process delivery date PDT is the same March 13 for both jobs JB3 and JB4. On March 10, which is the determination date, both the jobs JB3 and JB4 have progressed to the facility 3, and the progress level is the same level LV3.

  On the other hand, the progress index of job JB3 is “22”, and the progress index of job JB4 is “25”. That is, it can be understood that the job JB4 should be prioritized even if the limit process delivery date PDT and the progress level are the same. This is because the job JB4 has a relatively large delay from the process delivery date BNT based on the bottleneck process standard, and it is highly necessary to advance the process for the bottleneck process earlier.

(Operation)
20 and 21 show the first process delivery date calculation unit 151, the preceding load time calculation unit 152, the second process delivery date calculation unit 153, the preceding load reference time calculation unit 154, and the earliest completion of the process management apparatus 100 shown in FIG. 7 is a flowchart schematically showing the operation of the second embodiment by a reference time calculation unit 157. In the second embodiment, as in the first embodiment, the operation shown in FIG. 8 is performed by the first process delivery date calculation unit 151 and the preceding load time calculation unit 152, and the second process delivery date calculation unit 153 performs the operation shown in FIG. Operation is performed. In the second embodiment, as in the first embodiment, for example, when an instruction is given by the user using the input unit 120, the operation of FIG. 8 is started.

  In the second embodiment, if “YES” is determined in the step S920 in FIG. 9, the process proceeds to a step S1005 in FIG. Steps S1005 to S1055 in FIG. 20 are the same as steps S1005 to S1055 in FIG. In step S1050 in FIG. 20, when all the jobs are completed (YES in step S1050), the process proceeds to step S2100 in FIG.

  In step S2100 of FIG. 21, the earliest completion reference time calculation unit 157 sets the first job as the calculation target job. In step S2105, the earliest completion reference time calculation unit 157 acquires the arrival date and time of the set job at the first step from the job data storage unit 141. In step S2110, the earliest completion reference time calculation unit 157 acquires the standard inter-process lead time between all processes in the set job from the inter-process lead time storage unit 142.

  In step S2115, the earliest completion reference time calculation unit 157 calculates the earliest completion reference time FT for all processes after the second process in the set job. The earliest completion reference time calculation unit 157 stores the calculated earliest completion reference times FT of all processes in the management reference storage unit 144 in association with the set job.

  In step S2120, the earliest completion reference time calculation unit 157 determines whether or not all jobs have been completed. If all jobs have not been completed (NO in step S2120), the process proceeds to step S2125. In step S2125, the earliest completion reference time calculation unit 157 sets the next job as a calculation target job. Thereafter, the process returns to step S2105, and the above steps are repeated. On the other hand, if all jobs have been completed (YES in step S2120), the process ends.

  FIG. 22 is a flowchart schematically showing the operation of the second embodiment by the progress level calculation unit 155, the display control unit 156, and the progress index calculation unit 158 of the process management apparatus 100 shown in FIG. For example, when the display of the progress level and the progress index is instructed using the input unit 120, the operation of FIG. 22 is started.

  Steps S1100 to S1110 in FIG. 22 are the same as steps S1100 to S1110 in FIG. In step S2200 following step S1110, the progress level calculation unit 155 determines the earliest completion reference time of the process (equipment) where the set job has arrived, the preceding load reference time, the process delivery date based on the bottleneck process reference, The limit process delivery date is acquired from the management reference storage unit 144.

  In step S2205, the progress level calculation unit 155 calculates the relative position of the determination date and time on the time axis with respect to the earliest completion reference time, the preceding load reference time, the process delivery date based on the bottleneck process criteria, and the limit process delivery date. To do. In step S <b> 2210, the progress level calculation unit 155 calculates the progress level based on the calculated relative position, and stores the calculated progress level in the RAM of the memory 130. In step S2215, the progress index calculation unit 158 calculates a progress index and stores the calculated progress index in the RAM of the memory 130.

  In step S2220, progress level calculation unit 155 determines whether or not all jobs have been completed. If all the jobs have not been completed (NO in step S2220), the process proceeds to step S2225. In step S2225, the progress level calculation unit 155 sets the next job as a calculation target job. Thereafter, the process returns to step S1110, and the above steps are repeated.

  On the other hand, if all the jobs have been completed (YES in step S2220), the process proceeds to step S2210. In step S2210, the display control unit 156 displays a progress level and a progress index on the display 110 for each job. Thereafter, the process of FIG. 22 ends.

(effect)
As described above, in the second embodiment, the earliest completion reference time calculation unit 157 uses the arrival date and time (input date and time) of the job to the first process as a starting point, and the time obtained by adding the standard inter-process lead time SLT. The process end time of the second process is calculated, and the process end time of each process determined by repeating this process until the final process is calculated as the earliest completion reference time FT.

  In other words, the earliest completion reference time starts processing immediately from the arrival date and time (input date and time), and after that, when the production is advanced with the lead time between standard processes regardless of the process delivery date (that is, completed and shipped as soon as possible) The reference time of In this case, if the lead time between the standard processes is also set to the shortest time, the earliest completion reference time means the reference time for production on the express.

  As described above, according to the second embodiment, the process timing (reference) for keeping the process delivery date with respect to the process timing (reference time) when the process is preferentially advanced regardless of the process delivery date. Time) can be determined. For this reason, it is possible to grasp the difficulty of complying with the process delivery date.

(Modified embodiment)
(1) In the first and second embodiments, the preceding load time calculation unit 152 uses the total time of the actual processing time obtained by dividing the standard processing time by the operating rate as the preceding load time, but is not limited thereto. The preceding load time calculation unit 152 may use the total time of the standard processing times as the preceding load time without dividing by the operation rate. In this case, the operation rate storage unit 143 (FIG. 1) may not be provided.

  (2) In the first embodiment, the display control unit 156 displays the progress level calculated by the progress level calculation unit 155 on the display 110 in a display form as shown in FIG. Not limited. For example, the display control unit 156 may display the calculation target job and process (equipment) on the display 110 in a table format in which the progress level is associated.

  Similarly, in the second embodiment, the display control unit 156 displays the progress level calculated by the progress level calculation unit 155 and the progress index calculated by the progress index calculation unit 158 as shown in FIG. Although it is displayed on the display 110 in a display form, it is not limited to this. For example, the display control unit 156 may display the display 110 in a table format in which jobs and processes (equipment) to be calculated, a progress level, and a progress index are associated with each other.

DESCRIPTION OF SYMBOLS 100 Process management apparatus 110 Display 141 Job data memory | storage part 143 Operation rate memory | storage part 144 Management reference | standard storage part 145 Progress data memory | storage part 150 CPU
151 First Process Delivery Time Calculation Unit 152 Advance Load Time Calculation Unit 153 2nd Process Delivery Time Calculation Unit 154 Advance Load Reference Time Calculation Unit 155 Progress Level Calculation Unit 156 Display Control Unit 157 Earlier Completion Reference Time Calculation Unit 158 Progress Index Calculation Unit

Claims (8)

A process management apparatus that manages the progress of a plurality of jobs in a factory that produces a plurality of different products in parallel by processing a plurality of materials as jobs in a predetermined order in a plurality of processes,
For each job, starting from the delivery date of the final process, the time that has been traced back to the first process by the lead time between the standard processes in order from the upstream process can be completed most recently to meet the delivery date of delivery. A first process delivery date calculation unit for calculating a critical process delivery time;
For each job, a preload is added to the total related time related to the standard processing time in the process of other jobs other than the calculation target job having the limit process delivery time earlier than the limit process delivery time of the calculation target job in each process. A preload time calculation unit to calculate as time,
For each job, in each process of the calculation target job, calculate a time difference between the time when the preceding load time is added to a predetermined reference date and the limit process delivery time, and extract a minimum value among the time differences, In each process of the calculation target job, a second process delivery date calculation unit that calculates a time that is traced back from the minimum process delivery date as the process delivery date on the bottleneck process basis,
For each job, in the first step, a time obtained by adding the preceding load time to the reference date and time is calculated as a preceding load reference time, and an Nth (N is an integer not less than 2 and not more than the number of steps of the calculation target job) ) In the process, the time obtained by adding the standard inter-process lead time from the (N-1) process to the Nth process to the preceding load reference time of the (N-1) process, and the reference date and time in the Nth process. A preceding load reference time calculation unit that calculates a later one of the times obtained by adding the preceding load times as a preceding load reference time;
In the process in which the job arrives at a predetermined determination date for each job, the determination date on the time axis with respect to the preceding load reference time, the process delivery date based on the bottleneck process criteria, and the limit process delivery date A progress level calculation unit that calculates a relative position of the target and calculates a progress level according to the relative position;
A process management apparatus comprising: The progress level calculation unit calculates the progress level by dividing it into a plurality of levels that are indices indicating the urgency of processing,
The plurality of levels include a first level to a fourth level in order of increasing urgency of the processing,
The progress level calculation unit sets the progress level to be calculated as the first level when the determination date is before the preceding load reference time, the determination date is after the preceding load reference time, and When it is before the process delivery date based on the bottleneck process standard, the second level is set. When the determination date is after the process delivery date based on the bottleneck process standard and before the limit process delivery date, the third level is set. And when the determination date and time is after the critical process delivery date, the fourth level,
The process management apparatus according to claim 1. For each job, a progress data storage unit that stores an arrival process that is a process in which the job arrives at the determination date and time,
For each of the jobs, a management criterion storage unit that stores the marginal process delivery date, the process delivery date based on the bottleneck process criteria, and the preceding load reference time is further provided.
The first process delivery date calculation unit stores the calculated limit process delivery date in the management reference storage unit for each job,
The second process delivery date calculation unit stores, for each job, the calculated process delivery date based on the bottleneck process standard in the management standard storage unit,
The preceding load reference time calculation unit stores the calculated preceding load reference time in the management reference storage unit for each job,
The progress level calculation unit reads, for each job, the arrival process from the progress data storage unit, the limit process delivery date corresponding to the read arrival process, the process delivery date based on the bottleneck process standard, Read the preceding load reference time from the management reference storage unit, and calculate the progress level in the arrival process,
The process management apparatus according to claim 1. For each job, the time at which the standard process lead time elapses in order from the downstream process to the final process, starting from the arrival date and time when the job arrived at the first process, can be completed earliest. It further includes an earliest completion reference time calculation unit that calculates the earliest completion reference time.
The plurality of levels further includes a 0th level in which the urgency level of the processing is lower than the first level,
The progress level calculation unit further calculates a relative position of the determination date and time on the time axis with respect to the earliest completion reference time in the process in which the job arrives at the determination date and time for each job, Calculate the progress level according to the relative position,
The progress level calculation unit sets the progress level as the first level when the determination date and time is after the earliest completion reference time before the preceding load reference time, and before the earliest completion reference time. Is the 0th level,
The process management apparatus according to claim 2. A progress index calculation unit that calculates a progress index representing the degree of progress in the process where the job arrives at the determination date and time for each job,
The progress index calculator is
When the determination date and time is the earliest completion reference time, the progress index is a predetermined first reference index,
When the determination date and time is the preceding load reference time, the progress index is a predetermined second reference index larger than the first reference index,
When the determination date and time is a process delivery date based on the bottleneck process standard, the progress index is a predetermined third standard index greater than the second standard index,
When the determination date and time is the critical process delivery date, the progress index is set as a predetermined fourth reference index larger than the third reference index,
When the determination date is between the earliest completion reference time and the preceding load reference time, the progress index is a first interpolation value obtained by linear interpolation between the first reference index and the second reference index,
A second interpolation value obtained by linearly interpolating the progress index with the second reference index and the third reference index when the determination date / time is between the preceding load reference time and the process delivery date based on the bottleneck process reference age,
A third interpolation value obtained by linearly interpolating the progress index with the third reference index and the fourth reference index when the determination date is between the process delivery date and the limit process delivery date based on the bottleneck process criterion; To
The process management apparatus according to claim 4. A display for displaying information;
A display control unit for displaying the progress level on the display unit for each job;
The process management apparatus according to any one of claims 1 to 5, further comprising: An operation rate storage unit that stores the operation rate of equipment used in the process set in advance for each process,
A job data storage unit for storing a standard processing time required for processing in each step for each job;
The preceding load time calculation unit reads the operation rate of equipment used in the calculation target process from the operation rate storage unit, reads the standard processing time required for processing in the calculation target process from the job data storage unit, and The time obtained by dividing the processing time by the operating rate is used as the related time.
The process management apparatus of any one of Claims 1-6. A process management method for managing the progress of a plurality of jobs in a factory that produces a plurality of different products in parallel by processing a plurality of materials as jobs in a predetermined order in a predetermined plurality of steps,
For each job, starting from the delivery date of the final process, the time that has been traced back to the first process by the lead time between the standard processes in order from the upstream process can be completed most recently to meet the delivery date of delivery. A first process delivery date calculation step for calculating a critical process delivery time;
For each job, a preload is added to the total related time related to the standard processing time in the process of other jobs other than the calculation target job having the limit process delivery time earlier than the limit process delivery time of the calculation target job in each process. A preload time calculation step to calculate as time,
For each job, in each process of the calculation target job, calculate a time difference between the time when the preceding load time is added to a predetermined reference date and the limit process delivery time, and extract a minimum value among the time differences, In each process of the calculation target job, a second process delivery date calculation step for calculating a time that is traced back from the minimum process delivery date as the process delivery date on the bottleneck process basis,
For each job, in the first step, a time obtained by adding the preceding load time to the reference date and time is calculated as a preceding load reference time, and the Nth (N is an integer not less than 2 and not more than the number of steps of the job) step , The time obtained by adding the lead time between standard processes from the (N-1) process to the Nth process to the preceding load reference time of the (N-1) process, and the preceding in the Nth process at the reference date and time. A preceding load reference time calculating step for calculating a later one of the times obtained by adding the load times as a preceding load reference time;
In the process in which the job arrives at a predetermined determination date for each job, the determination date on the time axis with respect to the preceding load reference time, the process delivery date based on the bottleneck process criteria, and the limit process delivery date A progress level calculating step of calculating a relative position of the target and calculating a progress level according to the relative position;
A process management method comprising:

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