JP2020077081A - Input planning support device and input planning support method - Google Patents

Abstract

To provide an input planning support device which supports input planning with high overall production efficiency.SOLUTION: The input planning support device includes production quantity acquisition means, process-by-product type acquisition means, common sub-process extraction means, product type group set generation means, sub-process processing time acquisition means, setup change time acquisition means, product type group set production time calculation means, and product type group input sequence setting means. The product type group set generation means generates product type groups by combining product types having many common sub-processes and generates product type group sets consisting of combined product type groups. A production time of each product type group set required for production of the product type group set, is calculated on the basis of acquired production quantities by product type, sub-process processing times, and setup change times. Next, an input sequence of product type groups is set on the basis of calculated product type group production times.SELECTED DRAWING: Figure 1

Description

  The present invention relates to an input plan creation support device and an input plan creation support method.

  Industrial products are generally produced by introducing raw materials and parts into a production line and sequentially passing through a plurality of processes. Then, the production line is composed of a plurality of sub-lines, and it is general that each sub-line carries out a plurality of processes. 2. Description of the Related Art In recent years, with the diversification of needs, many kinds of products are often produced on one production line. In such multi-product production, it is important to set the order and timing of product introduction so as to increase the overall production efficiency.

  A technique for increasing the above efficiency is disclosed in Patent Document 1, for example. According to this technique, first, the tact time of the post-process is back-calculated based on the work pay-out time of the post-process to calculate the work pay-out time of the previous process. Further, the takt time in the previous process is calculated back to calculate the work input time to the previous process, and the work input sequence and the work input time to the previous process are instructed. As a result, it is possible to match the payout time of the post-process for a certain sub-line and the pay-out time of another post-process, so that it is possible to prevent the occurrence of waiting time at the confluence.

  Further, Patent Document 2 discloses an invention for improving work efficiency when a large number of products are produced on a production line for mounting components on a printed circuit board. According to the present invention, a plurality of types of products are put into one mounting machine. At this time, the components that are most commonly used are placed at positions where the mounting machine can mount the earliest. Then, the component having the next most common type is placed at a position where the component can be mounted next next, and this is sequentially repeated to determine the component supply position. By doing so, the same number of products can be produced in a short time.

JP, 09-141542, A JP, 11-054991, A

  However, the technique of Patent Document 1 has a problem in that it cannot be applied to production in which a large number of steps with short processing times are continuous. In such a production, since the semi-finished products of the same kind are paid out before the ones put in the previous process are paid out, when one product is focused on, the timing of the completion of the preceding process and the start of the following process does not match. is there.

  Further, the technique of Patent Document 2 can reduce the processing time of component mounting in one mounting machine, but has a problem that it does not necessarily lead to improvement in overall production efficiency. This is because when using a plurality of facilities, the production efficiency may change greatly depending on the order of the types of products to be added to each facility.

  The present invention has been made in view of the above problems, and an object of the present invention is to provide an input plan creation support device that supports the creation of an input plan with good overall production efficiency.

  In order to solve the above problems, the input plan creation support device includes a production quantity acquisition unit, a product type process acquisition unit, a common sub process extraction unit, a product group set creation unit, a sub process processing time acquisition unit, It has a setup change time acquisition means, a product group set production time calculation means, and a product group loading order setting means. The product group set creating means creates a product group by combining products having many common sub-processes, and creates a product group set including a combination of product groups. Then, the product group set production time required to produce each product group set is calculated based on the acquired production number of each product, the sub-process processing time, and the setup change time. Then, based on the calculated product time of the product group, the order of loading the product groups is set.

  An advantage of the present invention is that it is possible to provide an input plan creation support device that supports the input plan creation with good overall production efficiency.

It is a block diagram which shows the input plan preparation assistance apparatus of 1st Embodiment. It is a block diagram which shows the input plan preparation assistance apparatus of 2nd Embodiment. It is a flow chart which shows operation of a 2nd embodiment. It is a flow chart which shows details of operation of a 2nd embodiment. It is a schematic diagram which shows the image of the injection | pouring order of 2nd Embodiment. It is a block diagram which shows the input plan preparation assistance apparatus of 3rd Embodiment. It is a schematic diagram which shows the image of the injection | pouring order of 3rd Embodiment. It is a block diagram which shows the input plan preparation assistance apparatus of 4th Embodiment. It is a schematic diagram which shows the image of the injection | pouring order of 2nd Embodiment.

  Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings. However, the embodiments described below have technically preferable limitations for implementing the present invention, but the scope of the invention is not limited to the following. It should be noted that similar components in each drawing are denoted by the same reference numerals, and description thereof may be omitted.

(First embodiment)
FIG. 1 is a block diagram showing an input plan creation support device of this embodiment. The input plan creation support device of the present embodiment is a device that supports the creation of an input plan that determines the order of inputting each product in a production line that produces a plurality of product types. The input plan creation support device includes a production quantity acquisition unit 1, a product type-specific process information acquisition unit 2, a common sub process extraction unit 3, and a product type group set creation unit 4. Further, it has a sub-process processing speed acquisition means 5, a setup change time acquisition means 6, a product group set production time calculation means 7, and a product group loading sequence setting means 8.

  The production quantity acquisition means 1 acquires a target production quantity in a predetermined period on the production line based on the production plan.

  The type-specific process information acquisition unit 2 acquires the process set for each product type. This product-specific process includes at least one sub-process. That is, it is assumed that the process is composed of a series of sub-processes. The product type-specific process information also includes setup information necessary for performing the sub-process.

  The common sub-process extracting means 3 extracts sub-processes common to different types of products. This is to extract the common sub-processes when the same sub-process is included in the process of the product type even if the types are different, and to associate the products having the common sub-processes with each other.

  The product group set creating means 4 creates a product group by combining products having a common setup and many common sub-processes. This product type group is used to collectively input the product types belonging to the same product type group to the production line. Then, a product group set as a block of a plurality of product groups is created.

  The sub-process processing speed acquisition means 5 acquires the processing speed of each sub-process. The sub-process processing speed can be, for example, a standard value determined from past results.

  The setup change time acquisition means 6 obtains the setup change time required to switch the product type groups produced on the production line. Here, the setup change is an operation of exchanging materials and parts to be supplied or adjusting equipment in order to perform different sub-processes in the same equipment. The setup change time can be, for example, a standard value determined from past results.

  The product group set production time calculating means 7 is required to produce the product group set based on the set product group set, the acquired production number of each product, the sub-process processing speed, and the setup change time. Calculate product group set production time. This calculation can be performed by calculating the production time of each product type group using the sub-process processing speed and the number of productions, acquiring the setup change time required for switching the product type group, and taking the sum of these. it can.

  The product group group input order setting means 8 sets the product group input order in the product group set based on the calculated product group production time. As one method, it is possible to introduce the product groups in order of increasing production time.

  As described above, according to the present embodiment, by making a product type group set having a common sub-process, the number of setup changes is reduced, and the loading sequence is determined based on the production time. Can create a plan.

(Second embodiment)
FIG. 2 is a block diagram showing the input plan creation support device 100 of the second embodiment. The input plan creation support apparatus 100 includes a planned production quantity acquisition unit 110, a product type process information acquisition unit 120, a common sub process extraction unit 130, and a product group set creation unit 140. Further, it has a sub process processing speed acquisition unit 150, a setup change time acquisition unit 160, a product group set production time calculation unit 170, a recommended product group set setting unit 180, and a product group introduction sequence setting unit 190. As the hardware of the input plan creation support device 100, for example, a general computer including a processor and a memory can be used.

  The input plan creation support apparatus 100 acquires information necessary for creating the input plan from the storage device 200. The storage device 200 stores a planned production quantity 210, product type process information 220, sub process processing speed information 230, and setup change time information 240. As the hardware of the storage device 200, for example, a general storage device such as a hard disk or a semiconductor memory can be used.

  The planned production quantity information 210 holds the number of products produced in a predetermined period for each product type. The predetermined period is, for example, one day or one week.

  The product type-specific process information 220 includes sub-process information 221 that represents the sub-processes that make up the process of each product type, and setup information 222 that represents the setup required to carry out each sub-process. Here, the sub-steps represent elements of processing such as mixing certain materials, performing certain processing, and mounting certain parts. Further, the setup is a preparation at the equipment or work point, and is an operation necessary for carrying out sub-processes such as supply of materials and parts, preparation of jigs and tools, and adjustment of equipment. A plurality of sub-processes are often carried out at one facility or work point, and it is general that a plurality of sub-processes can be carried out by one setup. That is, there is a lump of sub-processes that can be carried out by one setup, and there are cases where setup change is required when switching sub-processes and cases where setup change is not required. As will be described later, a product type group is created so that setup change does not occur during sub-process processing of one product type group.

  The sub-process processing speed information 230 is information indicating the processing speed of each sub-process, and can be expressed as the number of sub-process processes that can be executed in a unit time. The sub-process processing speed can be set to a standard value that is determined from, for example, equipment specifications or an average value of past results.

  The setup change time information 240 represents the time required to change the setup such as equipment. As described above, when switching sub-processes, there are cases where setup change is necessary and cases where setup change is not necessary.

  Next, the configuration and function of each part of the input plan creation support device 100 will be described. The planned production quantity acquisition unit 110 acquires the planned production quantity information 210 from the storage device 200.

  The product type process information acquisition unit 120 acquires product type process information 220 from the storage device 200. At this time, the sub-process information 221 included in the product-specific process information 220 that represents the sub-process that constitutes the product-specific process and the setup information 222 that represents the necessary setup are also acquired.

  The common setup extraction unit 130 compares the setup information 222 of each product with respect to the type of product planned for production, extracts the setup common to the types, and creates a temporary group having the common setup. Next, the common sub-process extraction unit 131 extracts the sub-processes common to the types of products in the temporary group. The product type group set creating unit 140 creates a product type group set by combining persons having many common sub-processes in the temporary group. At this time, various grouping can be performed depending on the number of common sub-steps used for grouping. However, by setting a threshold value for the number of common sub-steps, the grouping method can be determined. Further, a plurality of thresholds may be provided to create a plurality of product type group sets. In this way, by creating a plurality of product group sets and comparing the merits and demerits, a product group set with high production efficiency can be set.

  The sub-process processing speed acquisition unit 150 acquires the sub-process processing speed of the sub-process used in the created product type group.

  The setup change time acquisition unit 160 acquires the setup time required when switching the product group from the setup change time information 240.

  The product group set production time calculation unit 170 calculates the production time of each product group set. The production time of the product group set can be calculated as follows. First, for one product in the product group, the production time for one product is calculated based on the sub-processes that make up the process and the sub-process processing speed. By multiplying this by the production number of the product, the production time of the product can be obtained. In the same way, the production times of other varieties are calculated, and the production times of the respective varieties are added together in the varieties group. To this result, the setup time generated when the product group is switched can be added to calculate the product group set production time.

  The recommended product group set setting unit 180 compares the plurality of product group set production times calculated as described above and sets the recommended product group set. As the recommended product type group set, for example, a product type group that has the shortest overall production time can be recommended. However, in an actual production line, there are cases where there are restrictions associated with the supply of parts and the setup change. Therefore, a plurality of recommended product type group sets may be set in order from the one having the shortest production time so that the operator can judge the superiority or inferiority.

  The product group loading sequence setting unit 190 sets the order of loading product groups within the recommended product group set determined above. The order can be, for example, the order of longest product group production time. Although not shown, the recommended product type group set and the set input order can be output to the outside by displaying them on the display unit of the input plan creation support device or printing them on a printer.

  Next, the operation of the input plan creation support device 100 will be described. FIG. 3 is a flowchart showing the operation of the input plan creation support device 100. First, the planned production quantity is acquired (S1). Next, a temporary group is created for the types of products that have the same setup (S2). Next, in the temporary group, types having common sub-processes are combined to create a type group (S3). At this time, different product groups may be created according to the number of common sub-processes. Next, a product group set is created as a combination of the created product groups. At this time, different types of product groups are handled as different product group sets. As described above, since there is not one way to create a product group set as a combination of product groups, all possible product group sets are comprehensively created (S4). Next, the production time of each product group set is calculated (S5). Details of this calculation will be described later. Then, the production time of each candidate product group set is calculated by adding up the calculated production time of each product group and the setup change time required when producing each product group (S5). Next, the calculated overall production times are compared to determine a recommended product type group set (S6). In principle, a product group set with a short production time is recommended, but a plurality of product group sets may be recommended. Next, the production times of the product groups in the product group sets are compared to set the order of loading the product groups (S7). For example, the loading order can be set such that the product type group having a long production time is loaded first. Then, the recommended product group set, the product group introduction order within the product group set, the necessary setup change, the estimated production time, etc. are output to the outside (S8). At this time, information on the second and third product group sets as well as the product product group set with the highest production efficiency may be displayed.

  FIG. 4 is a flowchart showing details of the process of S4 of the flowchart of FIG. In calculating the production time of each product group, a loop process L1 for calculating the production time of each product in the product group is executed. In L1, first, the sub-process required to produce the product type is acquired (S41). Next, the processing speed of this sub-process is acquired (S42). Using the sub-process and the sub-process processing speed, the production time of the one product is calculated (S43). This is multiplied by the number of products produced to calculate the production time for the product type (S44). The processes of S41 to S44 are performed until all the products in the product group set are completed. Next, the production time of the product group set is calculated by taking the sum of the production times of the product groups that make up the product group set and summing it with the required setup change time (S45). The above calculation of the production time of the product type group is repeated until all the set product type group sets are completed (L2).

  As described above, it is possible to set a product type group set with high production efficiency and to set the loading order of product type groups within the set. FIG. 5 is a schematic diagram showing an image of charging when the above-described charging order is set. Τ in the figure represents the production time of the product group, and its length is assumed to be proportional to the production time. As shown in FIG. 5, starting the product Gr (group) 1 having the longest production time τ1 into the production line, the product Gr2 (production time τ2) and the product Gr3 (production time τ3) are introduced. I try to put them in order.

(Third Embodiment)
In the second embodiment, the case where there is one production line has been described, but it is general that an actual production line is provided with a plurality of sub-lines capable of producing the same product type. In the present embodiment, an input plan creation support device suitable when there are a plurality of sub-lines will be described.

  FIG. 6 is a block diagram showing an input plan creation support device 101 of the third exemplary embodiment. The input plan creation support apparatus 101 has a subline information acquisition unit 141 in addition to the configuration of the input plan creation support apparatus 100 of the second embodiment. Further, the product type group set creation unit 142 operates to create the product type group set by reflecting the subline information 232. In addition, since the processing speed may be different between sub-lines even in the same sub-process, the storage device 201 holds the sub-line information 231 and the sub-process processing speed information 232 which is distinguished for each sub-line. The production time of each product type group set can be the same as that of the second embodiment, but the production time and the necessary setup change may differ depending on the sub-line to be input. Therefore, when the products are put into different sub-lines, they are handled as different product group sets even if the combined products are the same. With such a treatment, it is possible to calculate the production time of each product group set and compare the superiority and inferiority without being aware of the existence of the sub-lines.

  FIG. 7 is a schematic diagram showing an image of the input when the input sequence of the product type groups is determined by the input plan creation supporting apparatus 101 of the present embodiment. In the present embodiment, the loading order including the designation of the sub-line to be loaded is set. In FIG. 7, the long product Gr1 having the longest production time τ1 is first put into the subline 1 (processing capacity P1) having the highest processing capacity P. Then, the product type Gr2 having the next longest production time τ2 is first put into the sub-line 2 (processing capacity P2) having the next highest processing capacity. Hereinafter, the product type Gr3 and the product type Gr4 are sequentially introduced into the sub line 3 and the sub line 1, respectively.

  When considering the production time of the product group set, it is necessary to consider the setup change time in addition to the processing capacity of the sub line. The number of set-up changes and the set-up change time per time change depending on the product group and the sub-lines to be put in. In the present embodiment, it is assumed that the required setup change and setup change time are reflected in the setting of the subline information 231 and the product type group set.

  By doing so, the product group having a longer production time is first put into the sub-line having a higher processing capacity, so that the production efficiency can be improved.

(Fourth Embodiment)
The second and third embodiments have been described on the assumption that the setup change time is uniquely determined by determining the subline and the product type group to be switched, but the setup change time also changes depending on the available resources. The input plan creation support apparatus of the present embodiment creates a product type group set that distinguishes cases where available resources are different, and examines the possibility of improving production efficiency.

  FIG. 8 is a block diagram showing the input plan creation support device 102 of this embodiment. In addition to the configuration of the input plan creation support apparatus 101 of the third exemplary embodiment, the input plan creation support apparatus 102 includes a setup change time acquisition unit 161 that acquires the resource-specific setup change time information 241 held in the storage device 202. I have it. The resource-based changeover time information is information about changeover times that are distinguished by the amount of available resources. The product type group set creation unit 143 of the input plan creation support device 102 creates a product type group set so that if the resources are different even if the combination of product types and input sublines is the same, they are treated as different product type group sets. To do. By making such a distinction, as in the second and third embodiments, it is possible to calculate the overall production time for each product group set and select a product group set with good production efficiency.

  FIG. 9 is a schematic diagram showing the relationship between usable resources and setup change time T. In the case of FIG. 9A, there is one worker M, which is a human resource, and one hardware resource H. At this time, the time required for the setup change 1 is T1a. However, when the number of workers M is two as shown in FIG. 9B, the time required for the setup change 1 is shortened to T1b. Further, as shown in FIG. 9C, the hardware resources are two, so that the time required for the setup change 1 is shortened to T1c. The product type group set creation unit 143 creates a product type group set so that different product group sets are created even when only the resources are different. Therefore, subsequent calculations can be performed in the same manner as in the second and third embodiments. Then, production efficiency can be improved, product group sets can be created, sub-line loading sequences can be set, and resources can be allocated. Since it is common that the available resources are limited, it is desirable to display a plurality of candidates for each available resource in the output of the result of the product type group set and the input order.

  As described above, according to the present embodiment, it is possible to improve production efficiency including effective allocation of resources.

  A program that causes a computer to execute the processes of the above-described first to fourth embodiments and a recording medium that stores the program are also included in the scope of the present invention. As the recording medium, for example, a magnetic disk, a magnetic tape, an optical disk, a magneto-optical disk, a semiconductor memory, or the like can be used.

  The present invention has been described above using the above-described embodiment as an exemplary example. However, the present invention is not limited to the above embodiment. That is, the present invention can apply various aspects that can be understood by those skilled in the art within the scope of the present invention.

1 production number acquisition means 2 product type process information acquisition means 3 common sub process extraction means 4 product type group set creation means 5 sub process processing speed acquisition means 6 setup change time acquisition means 7 product group set production time calculation means 8 product group input sequence Setting means 100 Input plan creation support device 110 Planned production quantity acquisition unit 120 Product type-specific process information acquisition unit 130 Common setup extraction unit 131 Common sub process extraction unit 140 Product group set creation unit 150 Sub process processing speed acquisition unit 160 Setup change time acquisition Part 170 Product group set production time calculation unit 180 Recommended product group set setting unit 190 Product group input sequence setting unit 200 Storage device 210 Planned production quantity information 220 Product type process information 230 Sub process processing speed information 240 Setup change time information

Claims (10)

In a production line that produces multiple varieties using at least one facility,
Production number acquisition means for obtaining the production number of each said variety,
At least one sub-process that is set for each said product, and the setup necessary to carry out the sub-process, product-specific process information acquisition means for acquiring product-specific process information including,
Common sub-process extracting means for extracting a common sub-process that is the sub-process that is common between different types of process information,
Variety group set creating means for creating a kind group by combining the kinds having many common sub-processes with the same setup and creating a kind group set combining the kind groups,
Sub-step processing speed acquisition means for acquiring the sub-step processing speed of each of the sub-steps,
In the equipment, setup change time acquisition means for obtaining a setup change time required for setup change for switching the certain sub-process to another sub-process,
Based on the number of productions and the sub-process processing speed, a product group production time required to produce the product group is calculated, and each product group set is calculated from the product group production time and the setup change time. Product group set production time calculating means for calculating product group set production time required for production of
And a type group input sequence setting means for setting an input order of the type groups based on the type group production time. The product group set creating means,
Creating a plurality of product type group sets different in at least one of the product type group, the sub-process processing speed, or the setup change time,
The product group set production time calculation means,
Calculate the production time for each product group set,
Based on the calculated product group set production time, has a product group set recommending means for setting the recommended product group set,
The input plan creation support device according to claim 1, wherein The product type group set recommendation means is
The input plan creation support apparatus according to claim 2, wherein the product group set is shortly prioritized to recommend the product group set. The product group input sequence setting means,
The input plan creation support apparatus according to any one of claims 1 to 3, wherein the input sequence is set so that the product group having a long production time for the product group is preferentially input. When the production line includes a plurality of sub-lines,
The product group set creating means,
The production plan creation support apparatus according to claim 1, wherein the production line group set is created by distinguishing the sub-lines into which the product type groups are input. If there is a difference in the processing capacity of the sub-line,
The product group input sequence setting means,
6. The input plan creation support apparatus according to claim 5, wherein the input order is set so that the product group having the long product time of the product group is preferentially input to the sub line having a high processing capacity. The setup change time acquisition means acquires the setup change time when the resource for performing the setup change is changed,
The product group set creating means,
The input plan creation support device according to any one of claims 1 to 6, wherein another product type group set is created when the setup change times are different. On a production line that produces multiple varieties using at least one facility,
Acquire the production number of each of the above varieties,
Obtaining process information for each product type including at least one sub-process set for each of the product types and a setup necessary for performing the sub-process,
Extracting a common sub-process that is the sub-process that is common between different types of process information,
Create a product group by combining the products that have the same common setup and many common sub-processes,
Create a product group set that combines the product groups,
Obtaining the sub-step processing speed of each of the sub-steps,
In the equipment, to acquire the setup change time required for the setup change for switching the certain sub-process to another sub-process,
Based on the number of production and the sub-process processing speed, calculate a product group production time required to produce the product group,
From the product type group production time and the setup change time, calculate a product type group set production time required for producing each of the product type group sets,
A method for supporting the input plan creation, wherein the input order of the type groups is set based on the production time of the type groups. Creating a plurality of product type group sets different in at least one of the product type group, the sub-process processing speed, or the setup change time,
Calculate the production time for each product group set,
The input plan creation support method according to claim 8, wherein the recommended product type group set is set based on the calculated product type group set production time. On a production line that produces multiple varieties using at least one facility,
Obtaining the number of productions of each said variety,
At least one sub-process that is set for each of the product types, and a step of acquiring process information for each product type including setup necessary for performing the sub-process,
A step of extracting a common sub-process that is the sub-process that is common between different types of process information,
Creating a product type group by combining the product types that have the same common setup and many common sub-processes,
Creating a product group set that combines the product groups,
Obtaining a sub-process processing speed of each of the sub-processes,
In the equipment, a step of acquiring a setup change time required for a setup change for switching the certain sub-process to another sub-process,
Calculating a product group production time required to produce the product group based on the number of productions and the sub-process processing speed;
Calculating a product group set production time required for production of each product group set from the product group production time and the setup change time;
And a step of setting an input order of the product groups based on the product group production time.

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