JP3106027B2 - Production plan creation method - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a production plan creating method used in a production system for simultaneously producing products by processing or assembly.

[0002]

2. Description of the Related Art Japanese Patent Application Laid-Open No. 4-171166 discloses an apparatus for drafting a production plan of a production system in which a plurality of products are simultaneously produced in a plurality of facilities.

[0003]

In this conventional example, when an event that does not satisfy the constraint conditions in the work such as the number of times of mold replacement occurs in the molding line, the process can be avoided only by performing a process of avoiding the event, and thus can be kept within the constraint conditions. Thus, there is a problem that the frequency of occurrence of an event that cannot satisfy the constraint condition increases, and finally, it becomes impossible to perform the availability process.

[0004] The present invention has been made in view of the above points, and an object of the present invention is to accurately produce a production plan that satisfies constraints that occur before a process of avoiding constraints occurs. It is to provide a production planning method.

[0005]

In order to achieve the above-mentioned object, the invention according to claim 1 is based on an absolute setting such as a delivery date.
Prioritize product numbers,
If there is a part number with the same conditions,
And assign the assignment result to the specified assignment condition item.
A part number selection process to evaluate and visually prioritize part numbers, judge conditions such as equipment conditions and tool conditions for the selected part numbers, and select and register candidates for equipment and tool combinations that can be produced. And a process of selecting and assigning the best productivity candidate from a combination of registered equipment and tools.

[0006] The invention of claim 2 is the invention according to claim 1.
Product numbers, equipment and tool combinations that need to be produced
If there are product numbers that can be produced simultaneously from
During the recording process, the equipment and
Registering candidates for tool combinations is performed.
You .

[0007] The invention of claim 3 is the invention according to claim 1 .
Equipment that can be continuously produced from a combination of equipment and tools.
If there are combinations of equipment and tools, the weather for those combinations
Register a supplement and combine equipment and tools that can be produced continuously.
If it is not possible to divide, use the same equipment and the same tool
Candidates or multiple combinations of equipment and tools for production
Equipment and tools for split production with multiple tools
Process for registering candidate combinations
It is characterized by. A fourth aspect of the present invention, contact to the first aspect of the present invention
And each part number can be produced and used in multiple facilities
In a multi-product production process with multiple tools,
Combination of equipment and tools with the highest production efficiency
Process for selecting and assigning
And features.

[0008] The invention of claim 5 is the invention according to claim 1 .
And assign equipment and tools tentatively for each part number
The part number processing process of selecting part numbers by
Equipment and tool combinations that can be used and have multiple tools
A process of allocating production from the candidate
In these processing processes, holiday production possible and impossible are weighted
It is characterized by using The invention according to claim 6 is the invention according to any one of claims 1 to 5, wherein the equipment is formed by molding.
Machines and tools are molds, used to create production plans for resin molding
It is characterized by being.

[0009]

[0010]

According to the first aspect of the present invention, the delivery date and the like are set in advance.
And provisional assignment of equipment and tools for each part number
Part number priority based on the judgment made by attaching
Part number selection process and the selected part number
Equipment that can be produced by judging equipment conditions, tool conditions, etc.
Equipment candidates for selecting and registering candidate combinations of tools and tools
Registration process and combination of registered equipment and tools
Process to select and assign the best productivity candidate from
Since the process consists of a process, it is possible to draft a production plan that satisfies the constraint condition accurately, not before the occurrence of the constraint condition, but by comprehensively considering the constraint condition before it occurs.

[0011]

According to the second aspect of the invention, it is necessary to produce
Simultaneous production from a certain part number and combination of equipment and tools
If there is an appropriate product number,
Consider the part numbers that can be produced in
Since the candidates are registered, it is possible to select a combination of equipment and tools in consideration of the product number that can be produced at the same time. According to the third aspect of the present invention, a combination of equipment and a tool is provided.
The combination of equipment and tools that can be produced continuously from
If possible, register candidates for those combinations,
When the combination of equipment and tools that can be produced is not available
Is the same equipment, equipment that supports split production with the same tool,
With a combination of tools or multiple equipment and multiple tools
Equipment and tool combination candidates for split production
Since the registration process is provided, it is possible to select a candidate combination of equipment and a tool when production is possible continuously and when production is not possible continuously.

According to the fourth aspect of the present invention, each product number is
Multi-product that can be produced with equipment and uses multiple tools
In the production process, the most effective
Select and select combinations of equipment and tools with high rates
With a process of attaching
The most efficient combination of equipment and tools
Can be selected and assigned. Claim
According to the invention of the fifth aspect, equipment and tools are temporarily selected for each product number.
Part number processing process of assigning and selecting part numbers, and multiple
Equipment that can be produced with multiple equipment and uses multiple tools
Process for allocating production from candidate combinations of tools and tools
Process, and in these processes, holiday production is possible.
Can be produced on holidays because Noh and Impossible are used as weights
No or no, select a part number or a combination of equipment and tools.
Take a large factor in the decision factor when choosing
Can avoid holiday production in advance. Claim
The invention according to claim 6 is the invention according to any one of claims 1 to 5,
The equipment is a molding machine, the tool is a mold, and the resin molding production
Because it is used for image creation, the production plan of resin molding
Can be planned.

[0014]

(Embodiment 1) FIG. 2 shows the configuration of a production plan creating apparatus which employs the method of the present invention and is actually realized by a computer. This embodiment is based on this production plan creating apparatus. Will be explained.

First, the factory to which the present embodiment is applied has a process of producing a molded product, and has one or more dies for each product number, and can perform molding using the dies. It is assumed that one or more molding machines exist. Here, it is assumed that the molding machine is the equipment and the mold is the tool, and that various data of the molding machine and the mold are stored in the data storage unit 1 in FIG. 2 in advance.

[0016] Figure 1 shows the overall processing flow in the present embodiment, first, in the first process flow, producing
The part numbers that must be checked are checked, and if there are any part numbers that must be produced, the selection conditions, such as the number of mold exchanges and exchangeable time zones, stored in advance in the data storage unit 1 for those part numbers are determined. A part number selection process for assigning priorities and selecting the part number having the highest priority is performed.

The part number selection processing is performed by the part number selection arithmetic processing device 3, and FIG. 3 shows an example of a flowchart of the part number selection processing. Here, when assigning another part number to the equipment to which the part number has been assigned once, if a method is used in which the already assigned part number is assigned to other equipment, there is a possibility that processing will be in an infinite loop. After assigning the assigned part numbers, do not assign them to other equipment.
Alternatively, the assignment must be changed only within certain restrictions. Therefore, since the part number assigned first is considered to be a part number for which production is to be preferentially secured, it is required to assign the part number so that the assignment does not need to be changed later.

Therefore, in the part number selection process, among the conditions for selecting the part number, the condition set in advance is to determine whether the type is a different color type corresponding to the part number selected immediately before or a type desired to be continuously produced. There is a condition and a condition called a delivery date. In addition, the conditions that the value is converted according to the situation at the time of allocation include the condition of the limit value of the number of times of changing the mold, the condition of the idle time generated by the mold changing time zone and the color changing time zone, and the types that do not want to be produced on holidays. There is a condition of whether or not production is performed on holidays, a condition of dispersion of the load of the molding machine, and a condition of production efficiency (since production capacity varies depending on molding).

The part number selection processor 3 selects the part number with the earliest delivery date from the delivery date data stored in the data storage unit 1 based on the flowchart of FIG. 3 and determines whether there is a part number with the same delivery date. Check, and if there is no part number with the same delivery date, select the part number with the earliest delivery date.
If there is a part number with the same delivery date, provisional assignment processing is performed for all candidates. That is, if the assignment is performed under the current assignment status, it is determined which molding machine should be assigned. Practically, the molding machine and the mold are temporarily allocated, and all the values that change depending on the above-described allocation status are calculated. This calculation is based on a score table such as Table 1 in which the score is determined in advance for each condition, and is calculated for each product number, and the one with the highest score is determined as the product number with the highest allocation priority at the present time, and the product number is determined. Select Such a molding machine and mold
The process of assigning the
This is called temporary allocation processing.
U. In the case of the same score, the end time is calculated and the one with less wasted time is selected.

[0020]

[Table 1]

Table 2 shows the result of provisional assignment.
Part number selection process that determines the priority order of part numbers
5 shows a specific specific calculation result of a certain product number (tentatively referred to as A product number and B product number). As a provisional allocation result, the A product number is from 10:00 on November 1 (Sunday) to November It will be produced on the 12th machine until 13; 10 on Wednesday, 4th, and the B number will be from 19:01 on November 4th (Tuesday) to November 5th.
The result was that it was produced until 23:20 on Wednesday (Wed). Mold change number at this time is determined that <br/> already 2 Kaikin type exchanged in November 1 takes place, limiting the mold change times of 11 January within 5 times It is. Similarly, on November 4, the number of confirmations was 5 and the limit was 8
On November 5, the number of confirmations is six and the limit is eight.
For A part as a user-specified parameters produced in 12 Unit (forming machine name), for example a 100-point, B No.
Is produced by the No. 8 machine, and is set to, for example, 80 points, and these parameters are input from the input device 2. The A part number is a part number that has a problem when production is performed on a holiday, and the B part number has no particular problem. Here, the start date of the number of times of mold replacement shown in Table 2 will be briefly described. For example, a type switching operation (for example, a molding color exchange operation or a mold exchange operation) is always required on the day when production of a lot of a certain product number starts and ends. In the case where a part number is assigned to a currently operating molding machine on a predetermined day and molding is performed, if the mold needs to be replaced, the mold replacement frequency is zero before the assignment including the other molding machines.
In this case, if the part number is assigned to the molding machine, the number of mold replacements becomes one. This means that you the date on which the mold number of exchanges has become 1 by this allocation with the mold exchange number of the start date. Since also varieties effect work, Ru work der that require human intervention,
There is a limit on the number of times a day can be performed, and therefore it is checked whether there is room for the upper limit of the number of mold replacements, and this is the limit on the number of mold replacements.

[0022]

[Table 2]

According to the obtained results shown in Table 2, since the A part number takes the end time in the mold change time zone, the idle time is 0, but the B part number is 23:20, so that the type cannot be switched. . Therefore, since the type change work is not performed until 9:00 on the next day, for example, the time 580 minutes until 9:00 on the next day is the idle time. Under these conditions, a score is calculated for the A part number and the B part number according to each condition. The A part number has a problem if production is performed on a holiday.
0 points, for the load of the part number is little that has not been yet allocation process in the part number only 12 Units that can not be produced, for example, 5
A score is added to the zero point and the user-specified parameter is, for example, 100 points, and the total is calculated. Also, since the B part number does not end in the mold change time zone, for example, -1
For example, -100 points because the number of mold replacements on the day of the end of 00 is still two, and -100 points, and a part number that can be produced only with the No. 8 machine. The points are added to 150 points, for example, the user-specified parameter is 100 points, and the total is calculated.

By the way, when the score is obtained for each product number as described above, the score is -350 for the product number A and -270 for the product number B.
In the part number selection process in which the B part number with a higher score has a higher selection order, and the B part number is selected, if production is performed on a holiday, the part number which has a particular problem or For a product number to be produced, weighting is set for each product number in the volume mode as a determination factor that 0-holiday production is possible, 1-less production is desired on holidays, and 2-holiday production is not possible . If holiday production is not allowed here,
An extraordinarily high score (500 in the table 1, whereas the score of the other judgment factors is 100 or less) is added, and the volume mode is multiplied to obtain a minus factor.

In this way, it is possible to avoid the selection of a product number when there is a possibility that holiday production will be performed. When the above-mentioned part number selection process is completed, the selected part number is used for production. Search for molds and molding machines, and, based on the reservation status (time zone for which use has already been decided for the production of other part numbers, etc.) and maintenance plans, etc., the time zone during which production can be performed using the molding machine and mold. To explore. At this time, considering the workability, select a time zone in which continuous production can be performed so as to minimize the type change work such as mold replacement, and the molding machine, mold, production start time, Identify all production end time candidates.

However, if there is no candidate for a molding machine, a mold, a production start time, and a production end time that can be continuously produced, a time period during which production can be performed a plurality of times in the same molding machine is possible. To explore. In other words, there is at least two times during which the part number is produced by the same molding machine.
The processing up to this point is the equipment candidate registration processing. If there are still no candidates that can be produced, a plurality of molding machines are used to search for a time zone in which the production can be performed in a plurality of times by using a plurality of or one mold. This search process is a facility candidate registration process. In this case, the same product number is produced by different molding machines.

In this way, a combination of a molding machine and a mold having the highest productivity is selected from among several combinations based on production conditions such as the number of divisions and the upper limit of the number of times of mold replacement. The machine and the mold are reserved, and the production plan for that part number is assigned. The candidate registration operation processing device 4 and the assignment operation processing device 5 perform equipment candidate registration processing according to the processing flows shown in FIGS. Where the number of divisions
Means that it cannot be divided and produced by the same molding machine as described above
When searching for
If one part number cannot be produced continuously, one part number
Is produced in multiple batches,
The number of times it is produced. Also divided into multiple molding machines
Describes the number of times a product number is produced multiple times.
U.

That is, in the equipment candidate registration processing, a mold capable of producing the part number selected in the part number selection processing is selected, and it is determined whether there is another part number that can be simultaneously produced by the selected mold. If there is a part number that can be produced at the same time, it is necessary to produce the part number, and if the layout processing has not been performed yet, a candidate for a mold and a molding machine to be produced at the same time is selected and registered. If there is no part number to be produced at the same time, a candidate for a mold and a molding machine that can produce only that part number is registered.

In the equipment candidate registration process, it is determined whether or not the selected product number is different in color from the previously assigned product number. A process is performed to determine whether or not production can be performed using the same molding machine and mold as the previously assigned part number. The term "color difference" used herein refers to a type in which the same material can be used for the mold and the molding machine, except for the material. If production is possible, only production using this mold and molding machine is considered as a candidate. If production is not possible or if it is not a different color, register all combinations of molding machines and dies whose product numbers can be produced, and make sure that the registered molding machines and dies are continuously assigned to each Judge. If they cannot be continuously assigned, it is determined whether or not they can be divided and produced in the molding machine, and if they can be produced, they are registered as candidates. The same processing is performed for all combinations of the mold and the molding machine, and candidates are set. At this time, if there are no candidates, allocation is performed as much as possible using the combination of the mold and the molding machine in order, and if the required number of products can be produced, it is used for that production. All the molding machines and dies are registered as the only candidates.

When making this assignment, the number of mold exchanges,
Mold change time, color change time, etc. must be considered
Such have conditions are considered so as to satisfy all. The output information of the candidates includes a mold, a molding machine, a production start time, and a production end time. Here, the registration of the above candidates means the equipment and tools
When there are multiple combinations, etc.,
This means registering all combinations as candidates. So
And select the best candidate from these registered candidates.
This is the selection of candidates.
The processing is performed by the equipment candidate selection arithmetic processing unit 6 as described above. Toes
The equipment candidate selection arithmetic processing device 6 determines to which equipment the selected product number can be assigned from among the setting candidates registered by the candidate registration arithmetic processing device 4 by the processing flow shown in FIG. I do.

In other words, the equipment candidate selection arithmetic processing unit 6 performs a process of allocating the selected product number to a place considered to be optimal among the registered equipment candidates. The number of divisions, the number of extra mold exchanges, the mold exchange time zone, the idle time caused by the color exchange time zone, whether or not the type that is not produced dispersion,
Priorities are assigned based on the conditions of production efficiency (since production capacity differs depending on the molding machine). Scores are calculated for each candidate as shown in Table 3 for these conditions, the highest score is comprehensively determined, the best molding machine and mold are determined, and the part numbers are allocated. Perform processing. That is, the selected
If there is a possibility that the product number may be produced by multiple molding machines
Table 3 shows the contents of each production plan.
And the assigned production plan (possibility of production)
Scores for each molding machine) and select the better one.
Select. Table 3 shows the basic parameters and score weights for that.
Here is the data that defines the attachment.

As shown in Table 3, these conditions are calculated for each candidate, the highest score is comprehensively determined, and the best molding machine and mold are determined. Performs part number assignment processing .

[0033]

[Table 3]

Table 4 shows a specific example of calculating the score.
In this example, the B part number is selected in the part number selection processing, and two candidates are registered in the candidate registration processing as shown in Table 4. In this case, the candidate I is produced by using, for example, a molding machine of No. 2 using a mold, for example, KQ1540-0PI. At this time, the production start time is 13:00 on Tuesday, November 10
The production end time was 15:00 on Friday, November 13, and the required production time A was 4440 minutes. The number of divisions is "1" because continuous production has been secured. The idle time B is 120 minutes of the mold exchange time. Further, the remaining number C of die changing times obtained by subtracting the determined number from the limit value of the die changing number on November 10 is three, and the remaining number D of die changing times on November 13 is two. . The user-specified parameter is, for example, 60,000 points because of the second machine. On the other hand, candidate II is, for example, a die KQ1540-
When production is performed using 0PJ, other values are as shown in Table 4. Here, the condition of the B part number is not a part number that needs to be produced as a set, but that there is no problem if it is produced on a holiday.

When the score is calculated based on these conditions,
Candidate I is the division number "1" - 10000 points, -4440 points from the required production time A, -120 points from idle time, 6,000 and 10000 points from the remaining number of mold change times, -60000 points from the user specified parameters And the total is -585
60 points. Candidate II is, the number of divisions by the "1" - 100
00 points, -8820 points from required production time A, -60 points from idle time, 2000 points and 15 points from remaining number of die change
From the user-specified parameter of 000 points, it becomes -20,000 points, and the total is -21880 points. From these results, candidate II was selected, and B part number was determined using a molding machine and a mold of candidate II.
The production is decided from 13:00 on the 6th of the month to 16:00 on the 12th and is allocated .

[0036]

[Table 4]

[0037] In the above Symbol allocation process of, when the production to the holiday has been carried out, part number or of particular issues and for part number you do not want too much production, as the volume mode, as shown in Table 1, 0 holiday production Possible, 1—I do not want to produce too much on holidays. If holiday production is not possible, an extra high score (10000 in Table 3) is added, and this is multiplied by the volume mode to obtain a minus factor. As a result, equipment candidates when holiday production is likely to be performed are avoided as much as possible.

As described above, when a facility plan is selected and a production plan is drafted, the drafted production plan is stored in the production plan file 7 and displayed on the production plan display device 8. If the part number has been selected in advance,
What is necessary is just to perform the process shown in the flowchart of FIG.

Although the above embodiment is used for preparing a production plan of a molded product, the method of the present invention can be used for a production plan of other products, and the present invention is not particularly limited to the embodiment.

[0040]

According to the first aspect of the present invention, it is determined based on absolute conditions set in advance, such as a delivery date , and a priority is given to a product number.
If there is a part number with the same conditions as above,
Temporary allocation of tools is performed, and the result of the allocation is
An item number selection process to evaluate the allocation condition items and prioritize product numbers <br/> and judge conditions such as equipment conditions and tool conditions for the selected product numbers, It consists of a facility candidate registration process of selecting and registering candidate combinations, and a process of selecting and allocating the best productivity candidate from a combination of registered facilities and tools, so that constraints are avoided. It is possible to accurately plan a production plan that satisfies the constraints by considering the constraints before the occurrence, rather than after the occurrence.

According to the second aspect of the present invention, it is necessary to produce
Simultaneous production from a certain part number and combination of equipment and tools
If there is an appropriate product number,
Consider the part numbers that can be produced in
Since the candidates are registered, it is possible to select a combination of equipment and tools in consideration of the product number that can be produced at the same time. According to the third aspect of the present invention, a combination of equipment and a tool is provided.
The combination of equipment and tools that can be produced continuously from
If possible, register candidates for those combinations,
When the combination of equipment and tools that can be produced is not available
Is the same equipment, equipment that supports split production with the same tool,
With a combination of tools or multiple equipment and multiple tools
Equipment and tool combination candidates for split production
Since the registration process is provided, it is possible to select a candidate combination of equipment and a tool when production is possible continuously and when production is not possible continuously.

According to the fourth aspect of the present invention, each product number is
Multi-product that can be produced with equipment and uses multiple tools
In the production process, the most effective
Select and select combinations of equipment and tools with high rates
With a process of attaching
The most efficient combination of equipment and tools
Can be selected and assigned. Claim
According to the invention of the fifth aspect, equipment and tools are temporarily selected for each product number.
Part number processing process of assigning and selecting part numbers, and multiple
Equipment that can be produced with multiple equipment and uses multiple tools
Process for allocating production from candidate combinations of tools and tools
Process, and in these processes, holiday production is possible.
Can be produced on holidays because Noh and Impossible are used as weights
No or no, select a part number or a combination of equipment and tools.
Take a large factor in the decision factor when choosing
Can avoid holiday production in advance. Claim
The invention according to claim 6 is the invention according to any one of claims 1 to 5,
The equipment is a molding machine, the tool is a mold, and the resin molding production
Because it is used for image creation, the production plan of resin molding
Can be planned.

[0043]

[Brief description of the drawings]

FIG. 1 is an overall processing flowchart of an embodiment of the present invention.

FIG. 2 is a configuration diagram of a production plan creation device employing the method of the present invention.

FIG. 3 is a flowchart of a part number selection process.

FIG. 4 is a flowchart of a candidate registration process.

FIG. 5 is a flowchart of a candidate registration process.

FIG. 6 is a flowchart of an allocation process.

FIG. 7 is a flowchart of a candidate selection process.

FIG. 8 is an overall processing flowchart of another embodiment.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Data storage part 2 Input device 3 Part number selection arithmetic processing device 4 Candidate registration arithmetic processing device 5 Assignment arithmetic processing device 6 Equipment candidate selection arithmetic processing device 7 Production plan file 8 Production plan display device

──────────────────────────────────────────────────続 き Continued on the front page (58) Field surveyed (Int.Cl. ⁷ , DB name) G05B 19/418 G06F 17/60 108 B23Q 41/08

Claims (6)

(57) [Claims] 1. An absolute condition set in advance such as a delivery date .
And prioritize the part numbers, and the conditions are the same
If there is a part number, make a temporary allocation of equipment and tools,
Evaluate the result of the allocation with the specified allocation condition items.
A part number selection process for prioritizing part numbers, and equipment candidate registration processing for judging conditions such as equipment conditions and tool conditions for the selected part numbers and selecting and registering candidates for combinations of equipment and tools that can be produced. A production plan creation method comprising: a process; and a process of selecting and assigning a candidate having the highest productivity from a combination of registered equipment and tools. 2. If there is a part number that can be produced at the same time from the combination of the part number that needs to be produced and the combination of the equipment and the tool, the equipment candidate registration process will take into account the part number that can be produced at the same time. 2. The production plan creation method according to claim 1, wherein candidates are registered. 3. If there is a combination of equipment and tools that can be continuously produced from the combination of equipment and tools, candidates for those combinations are registered, and a combination of equipment and tools that can be produced continuously cannot be obtained. In the process of registering the same equipment, equipment corresponding to split production with the same tool, candidates for tool combination or multiple equipment, equipment corresponding to split production with multiple tools, candidate for tool combination 2. The production plan creation method according to claim 1, further comprising: 4. In a multi-product production process in which each part number can be produced by a plurality of facilities and a plurality of tools are used, a combination of facilities and tools having the highest production efficiency is determined from preset conditions. 2. The production plan creation method according to claim 1, further comprising a process of selecting and assigning. 5. A combination of a tool and a tool, in which a tool and a tool are tentatively selected and assigned for each product number and assigned and a product number is selected, and a plurality of tools can be used for production and a plurality of tools are used. 2. The production plan creating method according to claim 1, further comprising processing steps of allocating production from the candidates, wherein holiday production possible and impossible are used as weights in these processing steps. 6. The apparatus according to claim 1, wherein the equipment is a molding machine, and the tool is a mold, which is used for preparing a production plan for resin molding.
5. The production plan creation method according to any one of items 5 to 5.