JP3110103B2 - Product production planning equipment in batch plant - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

The present invention relates to a batch plant.
Relates to the product production plan device, particularly optimal product production plans automatically product production plan in a batch plant to create
Related to the device .

[0002]

2. Description of the Related Art With the recent increase in product types and shortened production delivery times, the trend of small-lot, high-mix production in petroleum plants and chemical plants has increased, especially in batch plants. I have. Note that a batch plant is a plant that manufactures products according to a batch method.When the work of a certain process is completed, the contents of the tank of the current process are transferred to the tank of the next process, and the next process work is performed. Is to produce.

FIG. 13 shows an example of a batch plant in the chemical industry. As a process, a raw material preparation step, a polymerization step for chemically reacting raw materials, a recovery step for recovering unreacted raw materials, and a product (liquid ) In a tank, a drying step of drying the product into a solid, and a packaging step of packing the solid. In each step, dozens of tanks Tij are arranged. The operations of each process are performed according to a predetermined schedule, and finally, a quantity of products corresponding to the order is manufactured in time for the delivery date.

[0004] In such a batch plant, the results of production cost and production time vary greatly depending on the method of use and the order of use of each device (tank). For this reason,
It is necessary to formulate an optimal product production plan, most companies (1) leave the work to a specific expert, and (2) some companies use OR as a scheduling problem. (3) Considering algorithms for each manufacturing site and constructing a unique system using conventional procedural languages (Fortran, Kobol).

[0005]

However, in the first method, since the know-how is concentrated too much on the individual, the know-how is concealed, and there is a problem that a production plan cannot be established without an expert. . In the second method, an optimal solution of resource allocation within a rough time can be calculated. However, determining a more detailed order of each operation requires an enormous amount of calculation. In the third method, it is necessary to make each system independently, and it takes too much man-hour / cost, and there is a strong risk that the system needs to be reconfigured due to a change in a product / equipment or the like.

Accordingly, it is an object of the present invention to provide a product production planning apparatus in a batch plant which does not require the assistance of an expert, can perform a production plan up to the production sequence, and can further reduce the number of system construction steps. That is.

[0007]

FIG. 1 is a diagram illustrating the principle of the present invention. Reference numeral 11 denotes a product master storage unit for storing the names of the devices used in each process and the occupation time of the devices in each process, etc., corresponding to the products, and 12 for manufacturing the products specified by the order. A job generation unit 13 that generates a job for each device used in each process and determines when to submit the job, has a device name arranged in one direction and a period spanned by a predetermined time width arranged in the other direction. A job developing unit for arranging the job in the two-dimensional space in consideration of the use device and the input time, a load table created by arranging the job in the two-dimensional space, and a job table arranged at a predetermined position. An operation rate monitoring unit 16 that monitors an operation rate, which is a ratio between the total occupation time of all jobs and the maximum operable time of the apparatus at the position, 16 is a function of a job arranged in a two-dimensional space position where the operation rate is equal to or more than a set value. Predetermined Rearrangement unit for rearranging the job to a different spatial position, 17 load Te was created - a - (g Gantocha) 18 to create a production plan determination unit product production plan in a batch plant based on Bull.

[0008]

According to the product, the name of the device used in each process and the occupation time of the device in each process are stored in the product master storage unit 11 in advance, and when an order is given, The job generation unit 12 generates a job for each device used in each process to manufacture the product specified by the order, and determines the job input timing. A load table 14 is created by arranging each job in a two-dimensional space constituted by a period spanned by a predetermined time width in consideration of a device used and its input timing,
The operation rate monitoring unit 15 obtains an operation rate which is a ratio between the total occupation time of all jobs arranged at a predetermined position in the two-dimensional space and the maximum operable time of the apparatus at the position, and the relocation unit 16 sets the operation rate. Of the jobs arranged in the two-dimensional space position equal to or more than the predetermined value, a predetermined job is rearranged in another space position to reduce the operation rate to the set value or less, and the production plan determining unit 17 determines the operation rate in the batch plant based on the load table. Determine product production plan. According to this method, a relatively rough production plan is set for a period spanned by a predetermined time width (temporary allocation), and a fine production plan can be made on a daily basis based on the production plan (real allocation). There is no need to rely on specialists, and production planning can be performed up to the production sequence, and furthermore, the number of man-hours for building the system can be reduced. In addition, production planning (load tape)
Gantt chart 1 so that the constraint conditions are satisfied in the order of the products in the order of introduction time.
8 so that a highly accurate product production plan can be performed.

[0009]

【Example】

(a) Overall Configuration FIG. 2 is a configuration diagram of an embodiment of a product production planning system in a batch plant according to the present invention, and the same parts as those in FIG. In the figure, reference numeral 11 denotes a product master storage unit for storing the names of devices used in each process, the occupation time of the device in each process, the attributes of products, etc., corresponding to the products, and 12 specifies the order. A job generation unit that generates a job for each input device used in each process for manufacturing a product, and determines the input time of the job, etc., is a device in which a device name is unidirectionally spanned by a predetermined time width. A job developing unit 14 for arranging the jobs in a two-dimensional space in which the jobs are used and their input timings in a two-dimensional space in which the jobs are arranged in the other direction; 15 is an operation rate monitoring unit that monitors an operation rate which is a ratio between the total occupation time of all jobs arranged at a predetermined position and the maximum operable time of the apparatus at the position. Placed in dimensional space Rearrangement unit for rearranging the predetermined job to another spatial location of the job,
Reference numeral 17 denotes a production plan determining unit for preparing a product production plan in a batch plant on a daily basis based on the prepared load table. Reference numeral 18 denotes a Gantt chart for expressing the prepared product production plan. Are arranged in order, and the date and time are arranged in a horizontal direction, and a two-dimensional space configuration is adopted, and jobs are arranged at intersections.

The production plan determining section 17 refers to the created load table (provisionally allocated production plan) to generate an allocation order (job queue) in order of products in order of earlier input. A creation unit 17a and a constraint queue creation unit 17b that refers to the attribute data of the product and finds and arranges constraints that must be satisfied in the manufacture of the product.
A constraint condition storage unit 17c for storing constraint conditions of each attribute;
It has a Gantt chart creation unit 17d that allocates jobs (process jobs) of each order in a job queue order on a Gantt chart to determine a product production plan so as to satisfy the constraints.

The product master stored in the product master storage unit 11 has the data structure diagram shown in FIG. 3, and corresponds to each of the products A, B,. (2) Number of charges in each process, (3) Occupied time in each process for manufacturing products, (4) Name of equipment that can be input in each process, (5) To each input device A distribution ratio (priority) for distributing occupation time, and (6) product attribute data are stored. It should be noted that the number of charges (the number of batches of the order) and the occupation time are for a product of a predetermined unit amount, and the order is issued in this unit. The attribute data is used to determine a constraint condition at the time of manufacturing a product, and will be described later.

(B) Overall operation job generation When an order (including a product name, a delivery date, and a quantity) is input, the job generation unit 12 generates an order based on the order and the product master. A job is generated for each input device used in each step to manufacture the product specified in the step S, and the device occupancy time, input date, and the like of the job are determined.

The device occupancy time of each job can be calculated by multiplying the process occupancy time by the device distribution ratio.
The input date is determined sequentially from the job in the post-process in consideration of the delivery date, the occupation time of the device in each process, and the maximum operable time of the device in one day. For example, the delivery date is September 20,
Occupation time of the equipment used in the final process is 10 hours,
Assuming that the maximum operable time of the apparatus in one day is 12 hours (known), September 19 to which the time obtained by subtracting 10 hours from the delivery date with 1 day as 12 hours belongs is determined as the input date.
If the occupation time of the apparatus in the next step is 10 hours, the input date is similarly determined to be September 18. The raw materials and the like are products used in other processes, and must be produced before introducing the products using the raw materials. For such a raw material, it is necessary to set the delivery date to the input date of the product using the raw material and determine the input date. ,

As described above, a job is generated for each input device used in the process, and job information including the device occupation time and the input date of the job is determined. FIG. 4 is an explanatory diagram of the job, in which the product names of the orders are A and B, and the delivery dates are September 20 and September 22, respectively. The jobs OD11 to OD11 are provided for each device used in each process. OD14, OD21 to OD
26 are generated, and the occupation time and the input date are determined as the job information.

[0015] Job development and creation of load table (temporary split)
The load table 14 has a two-dimensional space in which the device names of all the processes are arranged in the vertical direction in the order of the processes, and the periods spanned by a predetermined time width are arranged in the horizontal direction. FIG. 5 is an example of a two-dimensional space, in which horizontal periods (upper, middle, late) are arranged in the horizontal direction. Each intersection (a box in the unit of a thick frame is called a box) has columns for entering the total occupation time, maximum operable time, occupancy rate, piled-up job name, and assigned job name. Has become. The total occupation time is the sum of the occupation times of all the jobs placed in the box, the maximum operable time is the maximum time the device can operate during the period of the box,
The operating rate is a value obtained by dividing the total occupation time by the maximum operable time, the piled job is a job arranged (stacked) in the box, and the allocated job is a job finally allocated to the box.

Therefore, the job developing section 13 stores each job in 2
When arranging in a dimensional space, (1) determine an arrangement box in a two-dimensional space in consideration of a device to be used and a submission time of the job, and then (2) determine a device occupation time of the job by a total occupation time of the box. (Initial value is zero), and (3) the job name is registered in the stacking job column, whereby each job is stacked in each box, and after all the jobs are stacked, (4) the operation rate calculating unit 15 The operating rate in each box is calculated and entered in a predetermined column.

As described above, for example, each job shown in FIG. 4 is arranged in a two-dimensional space, and the load table shown in FIG.
In other words, a temporary job assignment table is generated. In FIG. 6, the piled-up job and the layout job column are omitted, and the maximum operable time of each box is 240 hours (24 hours / day). In addition, although the period of each box is set to upper, middle and late, the accuracy of the provisional assignment can be improved by shortening the span of the time width.

When the generation of the relocation load table 14 is completed, the relocation unit 16 reads the operation rate of each box and checks whether there is a box having a preset value (for example, 100%) or more. If the job exists, the job with the lower priority among the jobs arranged in the box is rearranged in another box.

FIG. 7 is a flowchart of the relocation processing of the relocation unit 16. First, it is checked whether or not there is a box whose operation rate is equal to or greater than the set value (step 101).
2), the relocation processing (temporary allocation processing) ends.

However, if there is a box whose operation rate is equal to or greater than the set value in step 101, the priority of the jobs stacked in the box is determined (step 103). The priority order is determined in consideration of the following (1) to (4). In other words, (1) Jobs in process are assigned to the box with the highest priority, (2) Jobs corresponding to products for which the delivery date is specified are likely to have a shorter assignment target period, and the time selection range is Low priority, higher priority than non-delivered product jobs. (3) Some products have a high distribution rate to devices, and only certain devices can be used. (4) Although some jobs are generated for each process depending on the product, if the operation rate of the box to which the other process job related to the process job whose priority is to be determined belongs is high,
Increase the priority of the job. In addition, (3) and (4) calculate the following formula R = Σ (operating rate / distribution rate) / number of processes from the operating rate and distribution rate of the box to which each process job according to the product belongs. The priority is determined according to the size. Next, a piled job with the highest priority is selected (step 104), and it is checked whether the maximum operable time of the box ≧ the occupation time of the job (1) is satisfied (step 105). Then, the target pile job is registered in the assignment job column of the box (step 106).

Thereafter, the occupation time of the job is subtracted from the maximum operable time of the box, the subtraction result is set as the maximum operable time of the box, and the occupation time of the job is calculated from the total occupation time of the box. Subtraction is performed, and the subtraction result is set as the total occupation time of the box (step 1).
07).

When the update of the maximum operable time and the total occupation time is completed, the operating rate is calculated (step 108), and the process returns to the beginning and repeats the subsequent processing. If the operation rate of the predetermined box exceeds the set value (100%), step 1
07, the operation rate is further increased, and becomes the target box in step 101 again.
Subsequent processing is repeated, and eventually the maximum operable time is used up, Expression (1) is not satisfied, and unassigned jobs remain in the target box.

In such a case, since "NO" is given in step 105, another assignable box is selected and registered in the assignment job column (step 109). That is, a box that is earlier in time than the box to which the unassigned job belongs (a box whose operating rate exceeds the set value) and a box with a smaller operating rate among boxes of other devices that can execute the work of the unassigned job. Select (1)
Make sure that the formula is satisfied and assign. If Expression (1) is not satisfied for all the destination boxes, the backward box to which the unallocated job belongs is considered.

After the assignment, the occupation time of the assigned job is subtracted from the maximum operable time of the assignment destination box,
The subtraction result is set as the maximum operable time of the allocation destination box, and the occupation time of the job is subtracted from the total occupation time of the original box, and the subtraction result is set as the total occupation time of the original box (step 110). . Thereafter, the operation rate is calculated (step 108), and the process returns to the beginning to repeat the subsequent processing. As a result, the operation rate of all boxes is 100
%, The provisional assignment process ends.

The production plan determination (real allocation) load table 14 stores the temporary allocation positions of each job. However, as described above, the temporary allocation is based on the delivery date and the device occupation time, and the jobs are arranged from the post-process. Therefore, the jobs are gathered near the delivery date, and the earlier in time (the nearer the production start date). ) Tend to have more room,
In addition, there is a possibility that the cleaning time and the constraints before and after the job are not satisfied.

As described above, the production plan determining section 17 (FIG. 2) places importance on the position of each job in the temporary allocation according to the flow chart shown in FIG. Gantch a process job for manufacturing
(Gantt chart creation). That is, each job (process job) provisionally assigned to the load table is assigned to an order to which the job belongs (called an order job).
An order job cue to be fully allocated on the Gantt chart is generated (step 201), and jobs are sequentially extracted from the order job cue (step 202). If the target order job runs out, all
Assuming that the real job has been completely allocated, the real allocation process is terminated (step 203). If there is a target order job, a constraint queue for the target order job is created (step 204). -Allocate each process job constituting the job on the Gantt chart (step 20).
5) It is determined whether all the constraints are satisfied (step 20).
6) If there are constraints that are not satisfied, the constraints are relaxed as necessary (step 207), and the assignment is
The process is repeated to satisfy the constraint conditions, and thereafter, the process returns to step 202 to repeat the same processing for the next target order job.

In the tentative assignment, when the operation rate is high, the jobs are concentrated in a certain period, and the delivery deadline is broken, the job group is assigned in the full assignment (to be described later) in the actual assignment process. If the ratio is low and there is room in the allocation space, the temporary allocation position is regarded as important, and allocation is performed in accordance with the temporary allocation position.

The job queue creation load table 14 stores temporary allocation results for each process job. The job queue creation unit 17a represents each job (process job) by the name of the order (order job) to which the job belongs, and extracts and arranges the order jobs in order from the box with the earliest input time to arrange the job queue. Is created (step 201 in FIG. 8). For example, if the contents of the load table using the order job names A, B, C, D, E, F, and G are as shown in FIG. 9, the order jobs are extracted in order from the beginning. Then, the order jobs are arranged in order of delivery date, then the order jobs are extracted in the order of middle and late, and arranged in order of delivery date to create a job queue. Therefore, in the example of FIG. 9, the early delivery date is B, C, A, and the middle delivery date is D,
E, if the late delivery date is G, F, the job queue is B,
C, A, D, E, G, F.

Generation of constraint queue Product master stored in storage unit 11
Contains attribute data of the product. For example, FIG.
As shown in (1), the product master-PMT has values (A, resident / non-resident, used / unused, etc.) corresponding to various attributes (cleaning attribute, resident / non-resident attribute, refrigerant use attribute ...) for each product. ··)It is included. On the other hand, the constraint condition storage unit 17
As shown in FIG. 9, a constraint condition extraction rule RSR corresponding to each attribute value and a constraint condition RSC are stored in c.

Therefore, before assigning each process job of a predetermined order on the Gantt chart, the constraint queue creating unit 17
b indicates an attribute value corresponding to the product of the order in the product master PM
T is read out, and the constraint conditions corresponding to the attribute values are read out from the constraint condition storage unit 17c and arranged to generate a constraint queue (step 204 in FIG. 8).

The assignment process 11 is given O - is a flow diagram of the processing (step 205) assigning on bets - the steps jobs da Gantocha.
The Gantt chart creation unit 17d obtains the process job constituting the target order job extracted from the job queue and its use device (step 301), and then obtains a free time list of each device on the Gantt chart (step 301). 302). FIG. 12 is a diagram showing the relationship between the Gantt chart and the free time list.

Next, it is determined whether the job is to be assigned by justification or justification (step 303). When the assignment is to be made by justification, the process jobs are sequentially allocated to the idle time from the upper process of the target order job (step 30).
4) It is checked whether or not each constraint condition of the constraint queue is satisfied (step 305). If it is not satisfied, it is reassigned to a backward free time so as to satisfy the constraint condition (step 306). Next, it is checked whether or not all the process jobs have been allocated (step 307). If all the process jobs have been allocated, the real allocation processing of one order job is completed. Is repeated. When the next process job is moved according to the constraint condition, the constraint time is checked by going back to the upper process when the end time of the preceding process job is set as the start time.

On the other hand, in the case of performing the assignment by rear-justification, the process jobs are sequentially assigned to the idle time from the lower process of the target order job (step 308), and the constraint queue is assigned.
Is checked (step 309), and if not, it is reassigned to the free time in the forward direction so as to satisfy the constraint (step 31).
0).

Next, it is checked whether or not all the process jobs have been allocated (step 311). If all the process jobs have been allocated, the real allocation processing of one order job is completed, and if not, the next higher process is performed. Step 30
Repeat the processing after step 8. In the case of a previous process job, the start time of the subsequent process job is set as the end time, and when the job is moved under the constraint condition, the constraint condition is checked back to the lower process. If all the constraints cannot be cleared, they are removed from the constraint queue in the order of the weaker constraints so that the allocation is successful.

Summarizing the operation of the product production planning system of FIG.
The name of the device used in each process, the occupation time of the device in each process, attribute data, etc. are stored in advance in the product master storage unit 11 in correspondence with the product, and when an order is given. The job generation unit 12 generates a job for each device used in each process for manufacturing the product specified by the order, and determines the device occupation time and the input time of the job.

The job developing unit 13 arranges each job in a two-dimensional space composed of a device name and a period spanned by a predetermined time width in consideration of a device to be used and an input timing, and performs a load tape.
The bull 14 is created. The operation rate monitoring unit 15 obtains an operation rate which is a ratio between the total occupation time of all jobs arranged at a predetermined position in the two-dimensional space and the maximum operable time of the apparatus at the position, and the relocation unit 16 sets the operation rate. A predetermined job among the jobs arranged in the two-dimensional space position equal to or larger than the value is rearranged in another space position to reduce the operation rate to a set value or less. ... Temporary assignment

When the provisional assignment is completed, the production plan determining unit 17
Assigns process jobs for manufacturing the ordered products on a Gantt-chart in the order of early inputting while placing importance on the temporary allocation position of the load table, and performs product production planning in a batch plant. To determine.
... More than this

[0038]

As described above, according to the present invention, a comparatively rough production plan is made in units of periods spanned by a predetermined time width, and a fine production plan is made in units of days based on the production plan. Therefore, it is not necessary to rely on an expert, and the production planning can be performed up to the production sequence, and further, the number of man-hours for constructing the system can be reduced.

Further, according to the present invention, since the process jobs of the respective products are arranged on the Gantt chart in such a manner that the constraint conditions are satisfied in the order of products input earlier in the load table, the accuracy of the accuracy is improved. High product production planning can be performed.

Further, according to the present invention, it is possible to plan a feasible schedule plan in a short time for a problem having complicated processes such as a batch plant and severe restrictions. In addition, if the user's restrictions are increased, a system with more severe restrictions and a planning result with more user's know-how can be constructed.

[Brief description of the drawings]

FIG. 1 is a diagram illustrating the principle of the present invention.

FIG. 2 is a configuration diagram of an embodiment of the present invention.

FIG. 3 is a data configuration diagram of a product master.

FIG. 4 is an explanatory diagram of a job.

FIG. 5 is an explanatory diagram of a two-dimensional space of a load table.

FIG. 6 is an explanatory diagram of a load table.

FIG. 7 is a flowchart of a relocation process.

FIG. 8 is a flowchart of a production plan determination process.

FIG. 9 is an explanatory diagram of a job queue.

FIG. 10 is an explanatory diagram of a constraint queue.

FIG. 11 is a flowchart of an allocation process.

FIG. 12 is a relationship diagram between a Gantt chart and a free time list.

FIG. 13 is a process explanatory view of a batch plant.

[Explanation of symbols]

 11. Product master storage unit 12. Job generation unit 13. Job development unit 14. Load table 15. Operation rate monitoring unit 16. Relocation unit 17. Production plan determination unit 18. Gantt chart

──────────────────────────────────────────────────続 き Continuation of the front page (72) Inventor Kenichi Ishikawa 2-6-1 Marunouchi, Chiyoda-ku, Tokyo Within Zeon Corporation (72) Inventor Minoru Inuzuka 1-2-1 Yakko, Kawasaki-ku, Kawasaki-ku, Kawasaki, Kanagawa Prefecture Inside Zeon Corporation (72) Inventor Kenji Aragaki 1015 Uedanaka, Nakahara-ku, Kawasaki City, Kanagawa Prefecture Inside Fujitsu Corporation (56) References JP-A-3-104544 (JP, A) JP-A-1-183345 ( JP, A) (58) Fields investigated (Int. Cl. ⁷ , DB name) G06F 17/60 B23Q 41/08

Claims (3)

(57) [Claims] In a product production planning device in a batch plant that manufactures a product through a plurality of processes, the name of the device used in each process and the occupation time of the device in each process are stored in correspondence with the product. Hand
A job is generated for each device used in each step in order to manufacture the product specified by the order and the order, and the job input timing is determined based on the occupation time of the device and the delivery date of the order. to means, the device name in one direction, means for positioning in consideration of the closing timing of each job and its use device in a two-dimensional space formed by arranging the period spanned by a predetermined time width in the other direction, a predetermined Means for obtaining a two-dimensional space position where an operation rate, which is a ratio of the total occupation time of all the jobs arranged at the position and the maximum operable time of the apparatus at the position, is equal to or more than a set value; jobs arranged at the two-dimensional space position means below a set value rearrangement to operating rate a predetermined job to another spatial location of the formed by rearranged load Te - means, for determining a product production plan in a batch plant based on the table Specially to have Products in the batch plant to
Production planning equipment . 2. The means for determining a product production plan determines an allocation order in an order of earlier input timing using a load table, and a job for manufacturing a product of each order in accordance with the order. 2. The product production planning device in a batch plant according to claim 1, wherein the product production plan is determined by allocating the product production plan to a Gantt chart. 3. The product production plan determining means stores product attributes in association with each product, defines constraints on product manufacturing in accordance with the attributes, and satisfies the constraints. in the job Gantocha - product manufacturing planning system in a batch plant according to claim 2, wherein the allocating on bets.