JP3290482B2 - Operation schedule creation device for product processing equipment - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention is directed to, for example, performing a predetermined process on each product from a first buffer facility for storing a plurality of types of products for each product and dispensing the processed product to a subsequent second buffer facility, for example, product filling. The present invention relates to an operation schedule creation device that creates an operation schedule of a product processing facility such as a facility.

[0002]

2. Description of the Related Art Heretofore, an apparatus for creating an operation schedule for a product processing facility having a buffer facility at a preceding or subsequent stage of the facility has been proposed and applied by the present inventors and disclosed in Japanese Patent Application Laid-Open No. 3-104544. Is mentioned. In the operation schedule creation device disclosed above, based on the product storage amount of one buffer facility provided before or after the product processing equipment typified by a filling facility or the like, or a preset shipping plan quantity for each product, An operation schedule plan for the product processing equipment is created. The above-mentioned operation schedule plan can be represented as, for example, a Gantt chart in which the product processing time by the product processing equipment is assigned to each product. At the same time, the respective cumulative curves in the schedule target period for each are created from the incoming and outgoing quantities of each product in the buffer facility. Each cumulative curve is created based on both the product processing time and the product processing amount on the operation schedule. With respect to the respective cumulative curves of the incoming and outgoing quantities for each product created in this way and the proposed operation schedule of the product processing equipment, the schedule calculation time t
In the above, the cumulative incoming value f (t) and the cumulative outgoing value g (t) of the buffer equipment in the above-mentioned buffer equipment are calculated as V (t ₀ ) (t ₀ : initial time of the schedule calculation). Assuming that the stock amount at the time t is V (t) and the relationship expressed by the following equation is satisfied, it is possible to avoid a product stock breakage in the buffer facility. V (t) = V (t ₀ ) + f (t) −g (t) ≧ 0 (1) Therefore, the incoming amount f (t) or the outgoing amount g (t) determined by the above-mentioned operation schedule plan. Is appropriately corrected and determined so that the formula (1) always satisfies the relationship of equation (1).

[0003]

As described above, the conventional operation schedule creating apparatus uses the above-described product processing method for one buffer facility so that the stock amount for each product satisfies the constraint condition (formula (1)). The draft of the equipment operation schedule was created. By the way, considering a configuration in which buffer facilities are respectively provided in both the former stage and the latter stage, the product processing equipment is set so that the relationship between the incoming and outgoing quantities for each product in each buffer equipment satisfies the above equation (1). It is necessary to determine the operation schedule of each of the buffer facilities in an organically linked manner with the change in the amount of storage and retrieval at each buffer facility. For example, as an example of a filling facility that has a product silo in the first stage and a product warehouse in the second stage, if the inventory of products in the above-mentioned product warehouse becomes excessive, the amount of product filling by the above-mentioned filling facility will be reduced or extended. In addition, it is necessary to change or modify the operation schedule to stop the operation of the filling equipment. Then, according to the operation schedule thus modified, the outgoing amount of each product paid out from the product silo to the filling facility must be reduced accordingly. As described above, for example, the planner attempts to create an operation schedule of the above-mentioned product processing equipment so that the stock quantity of each product in both the buffer equipment before and after the equipment which is mutually affected is kept within an appropriate range. Then, an extremely large amount of labor and time is required for the operation of correcting the operation schedule plan. In particular,
If the types of products to be handled and the types of processing by the product processing equipment are extremely large, or if the schedule target period is extremely long, it is practically almost impossible to manually determine an appropriate operation schedule. SUMMARY OF THE INVENTION Accordingly, an object of the present invention is to provide an operation schedule creation device for a product processing facility capable of creating an appropriate operation schedule corresponding to the situation of each product in both buffer facilities provided before and after the facility. .

[0004]

The main means adopted by the present invention to achieve the above-mentioned object is that the main point is that each product from a first buffer facility for storing a plurality of types of products for each product. And an operation schedule creation device for creating an operation schedule of the product processing equipment to be paid out to the subsequent second buffer equipment after the predetermined processing is performed, the product being delivered from the product processing equipment to the second buffer equipment within the schedule target period. The cumulative curve of the second buffer storage volume for each product is set within a range exceeding the preset cumulative total of the planned storage volume for each product released from the second buffer facility, and the storage timing of each product into the second buffer facility and Means for creating a second buffer accumulated amount curve, which is created by setting an incoming amount, and receiving data to the first buffer facility during the schedule period. To set the storage time and storage amount of each product into the first buffer equipment within a range that exceeds the curve based on the created second buffer storage amount cumulative curve for each product. From the first buffer cumulative total curve and the first buffer cumulative total curve created by the first buffer cumulative volume curve generating means, and the schedule object of the second buffer facility and the first buffer facility from the generated second buffer cumulative volume curve and the first buffer cumulative cumulative curve. Inventory status determining means for determining at least the inventory status of each product during the period;
Setting and changing the storage timing and storage amount of each product into the second buffer facility and / or the first buffer facility according to at least the stock status of each product of the second buffer facility and the first buffer facility determined above. And a schedule changing means for changing the operation schedule of the product processing facility. As a schedule changing means of the main means, an expert system, for example, in which a rule describing the processing content of the product processing equipment is applied to inference processing, can be used. The priority for properly creating an operation schedule is set at least in the inventory status of each product within the schedule target period of the second buffer equipment and the first buffer equipment calculated by the inventory status determination means of the main means. It is also possible to attach.

[0005]

In the operation schedule creation device for the product processing equipment according to the present invention, first, the cumulative curve of the second buffer storage quantity for each product to be paid out from the product processing equipment to the second buffer equipment during the schedule target period is obtained. It is created, for example, by setting an operation schedule plan of the product processing equipment within a range that does not cause the second buffer equipment to run out of stock due to each delivery. Similarly, the cumulative curve of the first buffer storage amount for each product stored in the first buffer equipment is also within a range that does not cause the stockout in the first buffer equipment based on the created cumulative curve of the second buffer storage quantity. , Are created by setting a proposed operation schedule for the product processing equipment. Then, the stock status such as the stock quantity and the stock quantity for each product of the second buffer equipment and the first buffer equipment is determined from the created second buffer stock quantity cumulative curve and the first buffer stock quantity cumulative curve. Is done. In this way, the operation schedule of the product processing equipment is determined by the second status determined by the inventory status determining means.
By changing the setting of the storage time and the storage amount for each product in the second buffer equipment and / or the first buffer equipment according to at least the stock status of each product of the buffer equipment and the first buffer equipment, Changed appropriately.

[0006]

Embodiments of the present invention will be described below with reference to the accompanying drawings to provide an understanding of the present invention. The following embodiment is an example embodying the present invention and is not intended to limit the technical scope of the present invention. Here, FIG. 1 is a block diagram showing a schematic configuration of an operation schedule creation device according to one embodiment of the present invention, FIG. 2 is a schematic configuration diagram showing a filling facility to which the operation schedule creation device is applied and peripheral equipment thereof, FIG. 3 is a graph showing the accumulation curves of the incoming and outgoing quantities at the warehouse, FIG. 4 is a graph showing the respective accumulating curves of the incoming and outgoing quantities at the silo, and FIG. 5 is for improving the stock status and the like in the silos. FIG. 6 is an explanatory diagram showing the rule contents for improving the stock situation in the warehouse, and FIG. 7 is a rule content for determining the setting order of the filling job. FIG. 8B is an explanatory diagram when the urgency rank at that time is higher, FIG. 8B is an explanatory diagram when the urgency rank at that time is lower, and FIG. 8 is an operation schedule of the filling facility. 9 is a flowchart showing a basic procedure of a process of correcting / changing the data, FIG. 9 shows a detailed procedure of each step in FIG. 8, (a) is a flowchart showing a procedure of step S100, and (b) is a process of step S200. A flowchart showing the procedure, (c) is a flowchart showing the processing procedure of step S300, FIG. 10 is a flowchart showing a detailed processing procedure of step S201 (pre-inference processing section) of FIG. 9 (b), and FIG. FIG. 12B is a flowchart showing a detailed processing procedure of step S202 (planning processing preprocessing unit), and FIG. 12 is a flowchart showing step S2 of FIG. 9B.
FIG. 13 is a flowchart showing a detailed processing procedure of 03 (the most recent day detailed planning section), and FIG. 13 is step S20 in FIG.
FIG. 14 is a flowchart showing the detailed processing procedure of Step 4 (normal planning section), and FIG. 14 is a flowchart showing the detailed processing procedure of step S205 (processing section after planning processing) in FIG. 9B.

As shown in FIG. 1, an operation schedule creating apparatus 1 according to this embodiment has a central processing unit (CPU:
(Not shown).
A computing unit 2 for computing / creating an operation schedule of a filling facility 10 (an example of a first buffer facility) and a filling facility 10 (an example of a product processing facility: see FIG. 2) in which a warehouse 12 (an example of a second buffer facility) is provided. , Schedule target period, estimated shipment amount for each product shipped from the filling equipment 10 or warehouse 12, filling equipment 10, silo 11, warehouse 12, and other equipment data, initial stock amount for each product in the silo 11 or warehouse 12. And the like, and an input section 6 for preliminarily setting and inputting an operation schedule before the operation schedule is created, an operation schedule calculated and created by the arithmetic section 2, and each accumulation curve (abbreviated as ACC) relating to the silo 11 and the warehouse 12. (To be described later) and the like, and various programs, input data input from the input unit 6, and the arithmetic unit 2. A storage unit 5 for storing the calculated data and the like, a stock amount of each product in the silo 11 and the warehouse 12, a production state of the product in the production facility 13, and a schedule target period of the product to be stored in the silo 11 or the warehouse 12. The condition, such as the product type and packing condition (generally equivalent to "at least inventory status"), is used as a condition part, and the entry timing and quantity of each product into the silo 11 and the warehouse 12 are changed according to the contents of the condition part. By doing so, a rule base 4 (an example of a rule storage unit) that stores a rule that has a schedule change action for changing the operation schedule of the filling facility 10 as a conclusion part, and a calculation unit 2 calculates at each schedule calculation time t. -The rules that at least match the determined stock status are extracted from the rule base 4 by inference processing. Reschedule the action described in the conclusion part of a rule issued has been an inference unit 3 for outputting the arithmetic unit 2.
The operation unit 2 of the operation schedule creation device 1 is
It is communicably connected to an external host computer 8. As a result, data such as the amount of each safety stock in the silo 11 and the warehouse 12, the filling capacity of the filling equipment 10, the command for assigning the type to each silo 11, and the like are directly input from the host computer 8 to the arithmetic unit 2, or conversely. The operation schedule finally determined by the operation schedule creation device 1 is transmitted to the host computer 8.

[0008] filling facility 10 where the operation schedule creation device 1 is applied, as shown in FIG. 2, and Raleigh filling machine 10 _d to be filled, for example, in Lowry to ship products each product type directly, the flexible container of the above product (Hereinafter F
2) FC filling machine 1
0 and _a, 10 _b, the product paperback: has and a PB filling machine 10 _c that bagging the (bag hereinafter abbreviated as PB). Incidentally, it is intended to fill the product into FC filling machine 10 _b for refilling the product in FC Raleigh or PB if the FC filling machine 10 _b need. On the upstream side of the filling facility 10, a plurality of silos 11 for storing products from the production facility 13 for producing a plurality of kinds of products for each product type are arranged in parallel.
On the other hand, on the downstream side of the filling equipment 10, an FC filling machine 10
(The Packing in this case, FC or PB can be mentioned) varieties, Nisugatabetsu from _a or PB filling machine 10 _c warehouse 12 for storing products are deployed. The products (lorries in the form of packing ₎ from the lorry filling machine 10d are directly shipped by lorries without going through the warehouse 12. In the silo 11, most kinds of products may be stored in any one of the silos 11 until the filling time of the product comes. However, the products of the special kind are once stored in the silo 11, and then all of the products are immediately stored in the filling facility 1 in preparation for the next storage from the production facility 13.
It has the constraint that the silo 11 must be emptied by filling it with zeros. On the other hand, the production of products by the production equipment 13 is performed 24 hours a day. On the other hand, the operation and shipping work of the filling equipment 10 are performed only in the daytime in principle, and are not performed at night on weekdays and on weekends and holidays. The total number of workers involved in the operation of the filling facility 10 is determined. In addition, these total workers are appropriately allocated according to the operation status of each of the filling machines 10 _a to 10 _d of the filling equipment 10. However, each filling machine has a minimum required number of workers.

The operation schedule creating apparatus 1 of this embodiment, a filling facility 10 to which the apparatus is applied, and its peripheral facilities 11 to 11
13 is configured as described above. The operation of creating an operation schedule of the filling facility 10 by the operation schedule creation device 1 will be described below. First,
An accumulation curve (an example of a first buffer accumulated amount curve; hereinafter abbreviated as a first buffer ACC) for each type of product to be stored in the silo 11 from the production facility 13 and a product to be discharged from the filling facility 10 to the warehouse 12 A procedure for creating an accumulation curve (an example of a second buffer accumulated amount cumulative curve; hereinafter abbreviated as a second buffer ACC) for each product type and packing style will be described below. ACC Model of Product by Product Type / Package in Warehouse 12 For example, if the above product is product A / package X (= Y), the change in stock quantity of product of product type / package Y in warehouse 12 is expressed by the following equation. It is described in the ACC model. V _WX (t) = V _WX (t ₀ ) + f _WX (t) −g _WX (t) (2) V _WX min ≦ V _WX (t) ≦ V _WX max (3) where , V _WX (t): Warehouse stock quantity of “Y” V _WX (t ₀ ): Warehouse initial stock quantity of “Y” f _WX (t): Cumulative value of incoming quantity (filled quantity) of “Y” g _WX ( t): Cumulative value of outgoing quantity (shipping quantity) of “Y” The cumulative value of incoming quantity f _WX (t) in the above equation (2) is the product type / packing style Y
Corresponds to the filling amount of the filling equipment 10 for the product of the above. Therefore, the cumulative storage amount value f _WX (t) can be expressed by the following equation as the sum of the filling amounts of the products of the type / package Y from the schedule start time t ₀ to the schedule calculation time t.

(Equation 1) Here, m = min (i: i∈I) -1 (5) where i represents the order of work, t _XSi is the i-th work start time, and I is t <t _XSi Is a set of i that satisfies When t _XSm ≦ t ≦ t _XEm (during filling), t _X ^* = t (6) When t> t _XEm (after filling), t _X ^* = t _XEm (7) It is. Here, ν represents the filling speed, and suffixes S and E
Indicates the start date and time and the end date and time of the filling operation.

Here, as shown in FIG. 3, the second buffer ACC for each type / package Y delivered from the filling facility 10 to the warehouse 12 during the schedule period is a preset delivery planned amount g _WX In a range exceeding the cumulative curve of (t) (that is, a range in which the stock of the product in the warehouse 12 does not occur), the time of filling the product into the warehouse 12 (an example of the time of stocking) and the amount of filling (the amount of Example) is uniquely created by being set on the Gantt chart by the arithmetic unit 2. That is, the calculation unit 2 is an example of the second buffer cumulative amount curve creation means according to the present invention. Note that the upper limit value V _WX max of the inventory amount in the warehouse 12 is not set individually for each product type / packing type, but is set for the total inventory amount of products for all product types / packing types. Is represented by

(Equation 2) In addition, the upper limit value V of the inventory amount of the product for every product type / package Y
_WX max varies depending on the combination of the product type and the packaging style, and can be increased by renting an external warehouse, for example. Therefore, the upper limit value V _WX max of the stock amount is not treated as a constraint condition here. That is, equation (3) is modified as follows. _{V WX min ≦ V WX (t} ) ··· (3 a) If there is no product receipts from more filling stations 10, from at least the time such below safety stock quantity V _WX min product in a warehouse 12 The time LST at which the filling operation must be performed before the product is stored in the warehouse is the time t 'at which the following equation is satisfied when f _WX (t) = 0 in the equation (2). . V _WX (t ′) = V _WX (t ₀ ) −g _WX (t ′) = V _WX min (9) Therefore, before the time LST, the product of the product type / package Y Filling work must be performed. Accumulation Curve Model in Silo 11 Here, the change of the stock amount in the silo 11 of the type A is described by the ACC model of the following equation. _{V HA (t) = V HA} (t 0) + f HA (t) -g HA (t) -R A (t) ··· (10) V HA min ≦ V HA (t) ≦ V HA max ··・ (11) Here, V _HA (t): the amount of silo stock of “A” V _HA (t ₀ ): the initial amount of silo stock of “A” f _HA (t): the amount of stock of “A” (production equipment) Production amount) Cumulative value g _HA (t): Cumulative value of shipping volume (filled amount) excluding the lorry shipment of "A" _RA (t): Cumulative value of lorry shipment of "A"

In equation (10), as shown in FIG. 4, the cumulative value of the delivery amount from the silo 11 is the cumulative value g _HA (t) of the product for the warehouse 12 and the cumulative value R of the lorry shipment.
_A (t). That is, the cumulative value g _HA (t)
Is equivalent to the total value of the total filling amount of the product in all the packing styles of the product type A, and can be expressed by the following equation.

(Equation 3) However, m, t _A ^* is calculated by the equations (5) to (7) for each package. On the other hand, the cumulative value f _HA (t) of the storage amount into the silo 11 is calculated by the following equation as the sum of the production amounts of the type A in the production facility 13 that manufactures a plurality of types.

(Equation 4) Here, n = min (i: i∈I) -1 (14) where t _DSi is the start time of the i-th work, and I is a set of i satisfying t <t _DSi. . When t _DSn ≤ t ≤ t _DEn (during production), t _D ^* = t ... (15) When t> t _DEn (after production end), t _D ^* = t _DEn ... (16) Here, q represents the production speed of the product of the production facility 13, and the suffixes S and E represent the production start date and time and the end date and time of a lot of the product at the production facility 13. However, the production speed q in the production facility 13 was constant here. Therefore, under the condition that the total lorry shipment value R _A (t) is known for each product type, (1
(1) within a range satisfying the expressions (0), (11), and (13).
_{Determining the} cumulative value g _HA (t) of the filling amount by the equation (2) is nothing but planning a filling schedule of products of all kinds of a certain kind for the warehouse 12. However, at this time, the expressions (2) and ( _3a ) relating to the warehouse 12 must be satisfied at the same time. That is, from the equation (12), the above-described cumulative filling amount g _HA (t) can be expressed as the following equation.

(Equation 5) Here, f _WAXj (t) indicates the cumulative value of the filling amount for the product of the type “A” and the packing form “X _j ”. On the other hand, this silo 11
The time LST obtained from the ACC model in the above is the time t ″ where the following equation is satisfied when g _HA (t) = 0 in equation (10): V _HA (t ″) = V _HA (t ₀ ) + F _HA (t ″) − R _A (t ″) = V _HA max (18) Note that the second buffer ACC shown in FIG. However, the ACC represented by the cumulative filling value g _HA (t) shown in FIG. 4 is obtained by summing the cumulative filling values of all the packaging forms except the lorry for the common type A. Therefore, in the case of the above-mentioned cumulative lorry shipment value R _A (t) = 0, the ACC formed by the cumulative filling amount g _HA (t) naturally corresponds to the ACC of the cumulative delivery amount from the silo 11.

As described above, the production facility 13 sends the silo 11
The first buffer ACC for each product type to be stored in the product is the sum (g _HA) of all the packing forms of the second buffer ACC created above.
(T)) and the lorry shipment volume cumulative curve, and is stored in the silo 11 in a range exceeding a cumulative curve (that is, a curve based on the second buffer ACC) and not exceeding the silo capacity upper limit V _HAmax. The product is created by the calculation unit 2 by setting a production time (an example of a storage time) and a production amount (an example of a storage amount) in the production facility 13 of a product. That is, the calculation unit 2 is an example of a first buffer storage volume cumulative curve creation unit according to the present invention. However, in the above-described model, one type of product is stored in one silo for easy understanding. That is, it is assumed that, for convenience, there is one silo of a plurality of silos 11 that can store one kind of product, the capacity of which is the sum of the storage capacities of the silos 11. Then, the arithmetic unit 2 calculates, based on the second buffer ACC and the first buffer ACC created as described above, the schedule target period of the product for each product type or product / package type in the warehouse 12 and the silo 11. Of the product in the production facility 13 is determined. For example, whether the stock quantity of the product in the warehouse 12 or the silo 11 is not too large over the entire period, or whether there is a time when the stock quantity temporarily increases, (t)
It is determined whether or not the stock amounts V _WX (t) and V _HA (t) at the time are smaller than the respective safety stock amounts V _WX min and V _HA min. That is, the calculation unit 2 is an example of the stock status determination unit according to the present invention.

In the operation schedule creating apparatus 1 of this embodiment, in particular, rules having the contents shown in FIGS. 5 and 6 are set in advance through the input unit 6 and stored in the rule base 4. For example, the rules shown in FIGS. 5 and 6 are rules for improving the stock status of products in the silo 11 and the warehouse 12, and the like. In the condition part of these rules, as a result of judging the operation schedule of the filling equipment 10 created as described above, the stock status of the product in the silo 11 or the warehouse 12 on the next day or two days after the schedule correction target date and the production equipment 13 (hereinafter referred to as “urgency status”) and the like. An urgency rank (an example of priority; an integer from 0 to 9) according to the content of the urgency status is assigned to the urgency status. The urgency rank is set to give priority to the time of entry of products into the warehouse 12 or the silo 11 for each product type / packing type or product type in accordance with the urgency situation. The urgency rank indicates the manufacturing process of the production facility 13,
In the final step of the production facility 13, the type is being set in advance based on the type of product being manufactured and the time LST calculated from the first buffer ACC or the second buffer ACC. In the conclusion part of the above rule, the operation schedule of the filling equipment 10 is modified / changed so that the stock amount of the product in the silo 11 or the warehouse 12 is kept within an appropriate range according to the urgency rank of the above condition part. (An example of a schedule change action) is described. And
The target part of the urgency rank which improves the urgency situation of the silo 11 or the warehouse 12 at that time according to the operation schedule modified / changed by executing the action of the conclusion part is included in the condition part of each rule. Is also set. Therefore, the next step when the urgency rank of the urgency situation determined at that time does not reach the target rank as a result of correcting or changing the operation schedule of the filling facility 10 by executing the action of the conclusion part of a certain rule. Is also set as a secondary action. In the condition part of the rule shown in FIG. 6, "many plan remaining" refers to a relation of "standard filling amount x days available for filling <remaining plan" for a standard filling amount preset for each product type and packing style. And “the remaining plan is appropriate” means the relationship of “standard filling amount × number of days that can be filled> remaining plan”. The “next day” is the next day excluding a day on which the filling operation is not performed, such as a weekend, a national holiday, or the like, and refers to a day on which the next filling operation is possible. The “same day” is the day until the next day, and may be multiple days. The “standard filling amount” refers to a standard filling operation amount set in advance based on the operation time specified for each product type and packing style. And the "forced filling instruction"
For example, when the silo 11 is forcibly instructed to perform a filling operation irrespective of the stock status of the silo 11, such as when the silo 11 is repaired or when a low-quality product is generated in the production facility 13. As shown in FIGS. 5 and 6, in each of the silo 11 and the warehouse 12, the respective urgency status is determined from the operation schedule plan of the filling equipment 10 set at that time, and accordingly, the respective urgency ranks are determined. However, when modifying or changing the above operation schedule, it is necessary to select an action of one of the rules.

FIG. 7 shows a rule for selecting a filling job according to the respective urgency ranks determined for the silo 11 or the warehouse 12. In this case, FIG.
(A) shows a case where each urgency rank is higher (for example, 5 or more), and (b) shows a case where each urgency rank is lower (for example, 4 or less). Here, the “filling job” refers to one filling work unit that is continuously performed.
When selecting the filling job and allocating the filling job on the Gantt chart according to the urgency rank of the rules shown in FIGS. 5 to 7, it is necessary to consider the following constraint conditions. Equipment restrictions-Other equipment restrictions, such as limited filling machines that can be used for each product type. Inventory restrictions ・ The safe stock amount of the product for each product type and packing style is set in the warehouse 12, and the filling equipment 1 which is less than this safety stock amount is set.
Do not create a zero operation schedule. -Each silo 11 has an upper limit of product inventory for each product type.・ Some silos 11 have a safety stock amount set. In this case, the operation schedule draft must be created so that the stock amount of the product for each type falls between the safety stock amount and the stock upper limit. Must. (Satisfying this constraint condition is equivalent to conforming to the production plan of the product in the production facility 13.) Restriction of workers • There is an upper limit on the total number of workers who perform the filling operation. The number of workers involved in the filling operation for each filling machine is specified in advance,
It is preferable that the number of members be as small as possible. Work time restrictions-Filling work is generally performed only during the daytime on weekdays. However, in order to fulfill the filling job corresponding to the higher urgency rank, overtime and holiday work are not stopped. Special Product Restriction The order of switching the filling job of a product of a special product follows the production sequence of the product in the production facility 13.・ Products of special varieties once stored in a certain silo 11
The entire amount must be dispensed from this silo 11 by one filling job. Delivery time constraints In this case, since the production facility 13 is basically a make-to-stock production process corresponding to the planned shipment quantity, if the stock quantity constraints in the warehouse 12 and the silo 11 are satisfied, the type and packing style The expected delivery date of each product is also respected.

A procedure for creating an operation schedule of the filling facility 10 by the inference process using the above-described rules in the operation schedule creation apparatus 1 of the present embodiment will be described below. As shown in FIG. 8, the basic procedure of the process of creating the operation schedule is roughly divided into three steps (S100 to S300). For example, in step S100, input data input to the inference unit 3 is set in the calculation unit 2. Then, step S20
In the case of 0, inference processing is executed by the inference unit 3 based on the input data, and an operation schedule draft of the filling facility 10 is created. Further, in step S300, the schedule draft created by the inference unit 3 is evaluated, and the adoption / non-adoption of this schedule draft is determined based on each of the above-described constraints. Then, an operation schedule draft that satisfies all the above constraints is adopted and transferred to the host computer 8. First, in step S100, as shown in FIG. 9A, the production schedule plan data of the production facility 13 and the silo 11
In addition, the initial stock amount data of the product for each product type / product type / package in the warehouse 12 and the shipping schedule data (shipping amount and shipping time) from the warehouse 12 and the lorry are received from the host computer 8 (host computer) ( S101). Each of the received data is set and stored in the data table of the memory 5 (S102 to S104). Other basic data such as the capacity of each facility and the amount of safety stock of the silo 11 and the warehouse 12 are set in advance in the data table of the memory 5, and the input unit 6 is used only when the contents of each are changed. It is rewritten and updated from outside via. Next, in step S200, an operation schedule draft is created by inference processing using the rule with the urgency rank. As shown in FIG. 9B, the inference process performed by the inference unit 3 is a pre-inference start processing unit (S2).
01) and a filling plan drafting processing unit for executing inference processing.

First, the pre-inference start processing unit in step S201 creates a knowledge base having contents that should be originally prepared prior to execution of the inference processing. Here, the contents of the knowledge base that should be originally prepared include knowledge of resource relationships (resources of interest, occupied resources, and consumed resources). Here, the resources of interest are the equipment that is the target of the operation schedule (specifically, the filling equipment). Occupied resources are resources occupied during execution of a certain filling operation (here, workers, etc.), and consumed resources are obtained by executing the filling operation. It is a resource that decreases or increases (in this case, the stock amount in the silo 11 and the warehouse 12). Knowledge of standards (product manufacturing standards in the production facility 13, switching standards and stoppage standards in the filling machine of the filling facility 10), process information of the production facility 13, and the like. These are previously registered as knowledge bases in the data table of the memory 5 as described above, but as shown in FIG. 10, only when the setting needs to be changed (S1, YES), a new The data is read, and the contents of the knowledge base are rewritten, updated or added in step S201 (S2).
Subsequently, a pre-planning processing section (S2
In 02), as shown in FIG. 11, an operation day calendar for the filling facility 10 is set (S3). Then, for each silo 11, the stock upper limit of the silo 11 is set based on the type of the product to be stored and the bulk specific gravity of the product (S4). Further, a production schedule plan in the final process of the production facility 13 is set (S5). Here, for example, the initial stock amount of the product for each type of the silo 11 is also set, so that the initial first buffer ACC can be created from the production schedule plan and the initial stock amount. Next, the product stock amount in the warehouse 12 is set (S6). At the same time, the initial stock quantity and the shipping schedule of the product by product type / packing type are set, and based on these, the initial second buffer A
A CC is created. Subsequently, the production amount of the product for each product type / package required in the schedule target period (this production amount is hereinafter referred to as an order) is based on the inventory plan and the sales plan (planned shipping plan) for the warehouse 12 in which the production is set in advance. Is determined (S7). At this point, one filling job (temporary filling job) is temporarily set for one of the determined orders (S8).

In the filling plan drafting processing section (see FIG. 9B), the processing of the most recent day detailed planning section (S203) for the first N days of the schedule target period and the (N + 1) day The inference process for drafting the operation schedule is performed by the process of the normal plan drafting unit (S204) for the first and subsequent eyes. All of the processes in these steps are basically executed by using the same method. However, the above-mentioned normal planning unit (S204) is devised so that the constraint conditions are relaxed and the calculation time is reduced. First, as shown in FIG. 12, the latest day detailed planning unit (S203) first calculates the filling work load during the inference period up to the Nth day by rough estimation, and calculates the basic total overtime according to the filling work load. Is determined (S9).
Then, the first day (= 1) is set as the schedule target date M (planning date) (S10, S11). in this case,
Since this is the first calculation and backtracking has not been executed (S12, NO), the processing procedure moves to step S13. At this point, the arithmetic unit 2 uses the second buffer ACC and the first buffer ACC created above to store the stock status of the product for each product type / package / product type during the inference period of the warehouse 12 and the silo 11. Judge and output to the inference unit 3.
Therefore, the inference unit 3 extracts, from the rule base 4, a rule having an urgency status (see FIG. 6) in which the stock status or the like of the warehouse 12 at that time is suitable from the rule base 4 by inference processing. The degree rank is set (S1
3). The urgency rank is set for the silo 11 in the same manner using the rule of FIG. 5 (S14). Then, according to the respective urgency ranks of the warehouse side and the silo side set in this way, the top priority urgent filling job at which the urgent filling work must be performed at this time is selected according to the rule of FIG. (S15). Then, the processing amount of the selected filling job is determined based on the action of the extracted rule (FIGS. 5 and 6) while referring to the filling capacity of the available filling machine, basic overtime, and the like (FIG. 5). S1
6), this filling job is allocated on the Gantt chart based on the action of the rule (S17). When this allocation plan (operation schedule plan) cannot be issued (S1
8, nothing), the process proceeds to step S19, but otherwise usable equipment, workers, silo 11, and warehouse 1
2 is set (S21), and the Gantt chart allocation plan is updated based on the information (S22). Then, when the filling job of the type (5 or more) higher in the urgency rank is not completed (S2
3, YES) or when there is room for the worker load (S24,
In the case of (YES), the processes of steps S15 to S22 described above are repeatedly executed.

When the process proceeds from step S18 to step S19, the fact that the above allocation plan could not be created is as follows.
For example, it is output to a CRT or the like of the output unit 7 and is consulted by an operator. The operator cancels the allocation plan on the planning day and executes backtracking (re-planning) (S19,
(YES), or whether to give up and proceed to the next day (NO) is input through the input unit 6. Thus, for example, when backtracking is performed, the process of step 20 is performed via step S12 (YES) on the same planning date (M = 1). For example, the allocation plan of the filling job is changed, or the priority of the filling machine used for the filling job is changed. Thereby, the allocation plan in step S17 is corrected. Thus, step S1
The processes of 1 to S25 are repeatedly executed every day until the planning date becomes Nth day (S26). That is, the inference unit 3, the rule base 4, and the calculation unit 2 are an example of a schedule changing unit according to the present invention. The remaining filling jobs for which filling processing could not be completed by the Nth day for each product type / package / product type order are processed by the next normal planning unit (S204) (S27). ).
The processing of the normal planning unit (S204) shown in FIG.
This is executed for the period from the (N + 1) th day to the last day of the schedule target period. Note that the processing of the normal planning unit is a processing procedure in which the steps S12, S19 and S20 in the processing of the most recent day detailed planning unit are omitted, that is, a backtrack for canceling and re-planning an operation schedule once prepared. Processing procedure (S
28 to S42). As a result, the operation time can be extremely reduced. The reason for dividing the operation schedule into two planning sections as described above is that the operation schedule for the most recent day until the Nth day is actually used as a work instruction sheet. It is a plan to be performed, but the purpose is to observe the consistency with the production plan in the production facility 13 and to estimate the approximate amount of the filling work load after the (N + 1) th day. Therefore, the operation schedule created by the normal planning unit is re-established as the operation schedule of the detailed planning unit on the most recent day before the actual (N + 1) th day elapses.

Then, in the post-planning processing section (S205, FIG. 9B), as shown in FIG. 14, the most recent day detailed planning section (S203) and the normal planning section (S20)
The operation schedule of the filling facility 10 created in 4) is displayed on the output unit 7 as a Gantt chart (S).
43). It is also possible to display trend information on the stock amount for each product type / product type / packing style in the silo 11 and the warehouse 12 and the worker load. Then, regarding the operation schedule created as described above, the overtime hours, the silo 11
The evaluation is based on the stock amount of the warehouse 12, the number of unprocessed (unallocated) filling jobs, and the like (S44). Thus, the operator determines the final operation schedule by adding and modifying the filling job through the input unit 6 in an interactive manner based on the evaluation result in step S44 (S45). At this time, the PB or F
It is also possible to incorporate a special filling job such as refilling C into the operation schedule. The operation schedule adopted by the operator in this manner is output as a work instruction form from the output unit 7 such as a printer (S46). Regarding the operation schedule created in this way, in step S301 of FIG.
The final decision on rejection is made by the planner. And
The non-adopted operation schedule is discarded (S302), and only the adopted operation schedule is transferred to the host computer 8 (S303), so that the information can be shared with the production schedule plan, sales / shipment plan, and the like for the production equipment 13. Can be
According to the operation schedule creation device 1 of the present embodiment, the operation schedule of the filling facility 10 can be created properly and automatically, and it can be used for products of many kinds and many packages, or for long-term schedules. Even during the period, an appropriate operation schedule can be created. For example, the conventional operation schedule of the filling equipment 10 is a plan up to two to three days ahead.
The operation schedule up to a month ahead can be created relatively accurately. Silo 1 as a buffer facility
It is also possible to keep the product stock quantity in the warehouse 1 and the warehouse 12 within an appropriate range and at the minimum stock quantity.

[0020]

The present invention is configured as described above. As a result, it is possible to create an appropriate operation schedule of the product processing equipment corresponding to the stock status of each product in both the buffer equipment provided before and after the equipment.

[Brief description of the drawings]

FIG. 1 is a block diagram showing a schematic configuration of an operation schedule creation device according to an embodiment of the present invention.

FIG. 2 is a schematic configuration diagram showing a filling facility to which the operation schedule creation device is applied and peripheral facilities thereof.

FIG. 3 is a graph showing respective accumulation curves of a storage amount and a storage amount in a warehouse.

FIG. 4 is a graph showing accumulation curves of a storage amount and a storage amount in a silo.

FIG. 5 is an explanatory diagram showing the contents of rules for improving the stock status and the like in a silo.

FIG. 6 is an explanatory diagram showing the contents of rules for improving the stock status and the like in a warehouse.

FIGS. 7A and 7B show the contents of rules for determining the setting order of a filling job, wherein FIG. 7A is an explanatory diagram when the urgency rank at that time is higher, and FIG. FIG.

FIG. 8 is a flowchart showing a basic procedure of a process for correcting and changing the operation schedule of the filling facility.

9 shows a detailed processing procedure of each step in FIG. 8,
(A) is a flowchart showing a processing procedure of step S100, (b) is a flowchart showing a processing procedure of step S200, and (c) is a flowchart showing a processing procedure of step S300.

FIG. 10 is a flowchart showing a detailed processing procedure of step S201 (a pre-inference processing unit) in FIG. 9B;

FIG. 11 is a flowchart illustrating a detailed processing procedure of step S202 (planning processing preprocessing unit) in FIG. 9B;

FIG. 12 is a flowchart showing a detailed processing procedure of step S203 (the latest day detailed planning unit) of FIG. 9B;

FIG. 13 is a flowchart showing a detailed processing procedure of step S204 (normal planning unit) in FIG. 9B;

FIG. 14 is a flowchart showing the detailed processing procedure of step S205 (planning processing post-processing unit) in FIG. 9B;

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 ... Operation schedule preparation apparatus 2 ... Operation part 3 ... Inference part 4 ... Rule base 10 ... Filling equipment (product processing equipment) 11 ... Silo (1st buffer equipment) 12 ... Warehouse (2nd buffer equipment)

Claims (4)

(57) [Claims] 1. A predetermined process is applied to each product from a first buffer facility for storing a plurality of types of products for each product, and a subsequent second process is performed.
In an operation schedule creation device for creating an operation schedule of a product processing facility to be paid to a buffer facility, a cumulative curve of a second buffer storage quantity for each product to be delivered from the product processing facility to the second buffer facility during a schedule target period is calculated. A second storage unit which is created by setting a storage time and a storage amount for each product in the second buffer facility within a range exceeding a preset cumulative release planning amount curve for each product delivered from the second buffer equipment. A two-buffer accumulated amount curve creating means, and a first buffer accumulated amount curve for each product stored in the first buffer facility within the schedule target period, based on the created second buffer accumulated amount curve. The first bar created by setting the storage timing and storage amount for each product in the first buffer facility within the range exceeding the curve. From the second buffer accumulation amount curve and the first buffer accumulation amount curve, for each product in the schedule object period of the second buffer equipment and the first buffer equipment. Inventory status determining means for determining at least the inventory status of the second buffer equipment and / or the first buffer equipment according to at least the inventory status of each product of the second buffer equipment and the first buffer equipment determined above. An operation schedule creation device for a product processing facility, comprising: schedule change means for changing an operation schedule of the product processing facility by changing a setting of a storage timing and a storage quantity for each product. 2. The schedule changing means according to claim 2, wherein
At least the stock status of each product of the buffer equipment and the first buffer equipment is a condition part, and the storage of each product into the second buffer equipment and / or the first buffer equipment according to at least the stock status of each product of the condition part. A rule storage means for storing a rule having a schedule change action for changing the operation schedule of the product processing facility by changing the setting of the timing and the amount of storage; a rule storage means for storing a rule for each product determined by the inventory status determination means; 2. The operation of the product processing equipment according to claim 1, further comprising: inference means for extracting at least a rule that matches the stock status from the rule storage means by inference processing, and executing a schedule change action of the extracted rule. Schedule creation device. 3. The at least inventory status of each of the second buffer equipment and the first buffer equipment determined by the inventory status determination means for each product within the schedule target period, and at least the second inventory status corresponding to the inventory status. 3. An operation schedule creation of a product processing facility according to claim 1, wherein a priority is set for giving priority to a storage timing for each product in the second buffer facility and / or the first buffer facility. apparatus. Wherein said product processing equipment, according to claim 1 to 3 above Filling to each product from the first buffer facility to a plurality of types of packing containers which is paying out filling stations to the second buffer facilities
An operation schedule creation device for a product processing facility according to any one of the above.