JP3336732B2 - Production plan evaluation device - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an apparatus for objectively and quantitatively evaluating a production plan designed to operate a production line for producing a plurality of types of products.

[0002]

2. Description of the Related Art Conventionally, at present, a skilled person makes experience planning and evaluation of a production plan for operating a production line for producing a plurality of types of products. That is, drafting a production plan for operating a production line that produces a plurality of types of products is to select one optimal combination from a very large number of combinations, and then consider many conditions. The need for it requires very sophisticated and complex work. In addition, the work of evaluating a planned production plan cannot be uniquely quantified due to the presence of many evaluation functions, as in the case of planning. Therefore, a very sophisticated and complicated work is required. Therefore, conventionally, a skilled person familiar with the production process drafts a production plan. Also, the evaluation of the production plan was performed by a skilled person thoroughly examining the drafted production plan in the form of a diagram or table and comparing it with the order information.

However, the planning and evaluation by a person is not quantitative and is difficult for a third party to understand. For this reason, it was difficult to judge the validity, and there was a risk that customs would make the production plan inefficient. Furthermore, in general,
In many cases, the person who makes the production plan and the person who evaluates are the same person, and there is a problem that an objective evaluation cannot be made.

On the other hand, in general, the evaluation of a production plan is as follows:
The evaluation of the production planning system design itself, which is performed by evaluating the production plan created by the production planning system, and (B) whether the results of the production plan formulated during daily operation after the system introduction are appropriate. The evaluation is performed in two stages. However, in either case (A) or (B), there is a problem that the evaluation by a person is not quantitative, so it is difficult for a third party to understand and it is difficult to judge the validity of the evaluation. . Further, in the case of (B), there is a problem that a person who confirms the production plan is required to be a sufficiently skilled person, and the man-hour of the person is increased.

In order to solve the above-mentioned problem, for example, in Japanese Patent Application Laid-Open No. 1-109060, by inputting a product type and a production quantity, a plurality of input types are determined in accordance with expert rules stored in advance with respect to an input order determination algorithm. A production schedule creation device has been proposed which formulates an input schedule, calculates an evaluation value for each schedule based on an evaluation function given in advance, and reports the best schedule. Here, as the evaluation function, a function obtained by multiplying each of the manufacturing lead time, the delivery deadline, and the equipment operation rate by a constant is added. According to this production schedule creation device, many factors related to production are simultaneously considered, and the knowledge base is used to incorporate the know-how of experienced schedule creators. However, it is described that there is an effect that it can be performed in a short time.

[0006]

However, regarding the evaluation of a production plan, Japanese Patent Laid-Open Publication No. 1-109060 discloses an evaluation formula for adding a product obtained by multiplying each of a production lead time, a delivery margin, and a facility operation rate by a constant. Was disclosed only, and no level could be applied to the evaluation of sophisticated and complex real-world production plans. In other words, there is a problem that only a general evaluation of the production plan itself is performed, and a specific evaluation cannot be performed from the viewpoint of a production-related party such as a producer or an orderer.

[0007] Even if the evaluation is performed on the producer side, there are various evaluation factors such as the evaluation of the load of the person, the production yield, and the delivery date. There is a problem that the evaluation of the production plan is unilateral because the evaluation of the entire plan is to be evaluated by one numerical value. Further, even when the evaluation is performed on the producer side, there are various evaluation factors such as a load state of a person, a production yield, and a margin for a delivery date. On the other hand, the conventional evaluation method expresses the evaluation of the entire production plan with one numerical value, so it is unclear what kind of factor is good or bad quantitatively. There was a problem. Further, when evaluating a drafted production plan, the importance of a specific evaluation item such as a load state of a person may change. Even in such a case, there has been a problem that the production plan evaluation device cannot be made to respond quickly to the change in the importance of the evaluation item because it has been extremely complicated since the conventional method had only to change the entire original evaluation function. .

[0008] The production plan evaluation apparatus of the present invention solves the above-mentioned problem, and converts a production plan drafted to operate a production line for producing a plurality of types of products from both the orderer side and the producer side. And a device for objectively and quantitatively calculating an evaluation value for each evaluation item.

[0009]

SUMMARY OF THE INVENTION A production plan evaluation device according to the present invention is a production plan evaluation system designed to operate a production line for producing a plurality of types of products according to an order in which a type, a number and a delivery date are specified. a production plan evaluation device for evaluating the plan, and the production planning situation storage means for storing a production plan that has been standing proposed a master memory means for storing basic data relating to facilities of production lines, the production planning situation With respect to the production plan stored in the storage means, the basic data stored in the master storage means is used to respond to a request from the orderer.
And a buyer satisfaction calculation means for calculating that achievement, raw
Production planning status storage means or master storage means
On the other hand, the number of days of delivery delay and order type for delivery delay
First table data showing the degree of satisfaction of the delivery delay by type
Second, indicating the quantity satisfaction from the number of orders delayed in delivery
Memorize the table data and fulfill the orderer
The calculation means calculates (1) the number of days late for delivery
First table data from the number of days
Read the type of delivery delay satisfaction based on the data
(2) Orders with late delivery
Number satisfaction based on the second table data
Means for reading the number of users who read the data, (3) Delivery delay by type
Satisfaction Calculator that calculates the product of the customer satisfaction and the number satisfaction
Dan, (4) above-mentioned (1) to all delivery delays
(3) is calculated, satisfaction accumulation means for calculating their product
And the degree of satisfaction of the orderer on the delivery deadline is calculated .

[0010]

Production planning situation storage means production plan evaluating means of the present invention, the type, depending on the orders number and delivery is specified, to run the production line for manufacturing a plurality of types of products with [action] above Symbol Configuration I remember the production plan that was planned for. The master storage unit stores various basic data relating to production and weights for different evaluation items. The orderer satisfaction degree calculating means calculates the degree of achievement of the orderer's request with respect to the production plan stored in the production plan drafting state storage means, using the basic data stored in the master storage means. On the other hand, the producer satisfaction calculating means calculates the degree of achievement with respect to the producer's goal, using the production plan stored in the production planning situation storage means as basic data stored in the master storage means.

The orderer satisfaction calculation means for delivery delay included in the orderer satisfaction calculation means calculates the orderer's satisfaction based on the delivery delay for the delivery date specified by the orderer. The first table data stores data indicating the number of days of delivery delay with respect to the delivery delay and the relationship between the order type and the type of delivery delay satisfaction. Further, the second table data stores data indicating a relationship between the number of orders with delayed delivery and the number satisfaction. Next, a specific operation of the orderer satisfaction calculating means for the delivery delay will be described in order. (1) Type delivery delay orderer satisfaction degree reading means,
The number of days of delivery delay is calculated, and the degree of satisfaction of delay of delivery is read out based on the first table data from the calculated number of days of delivery delay and order type. (2) The number satisfaction reading means reads the number satisfaction based on the second table data from the number of orders whose delivery date is delayed. (3) Satisfaction calculating means calculates the product of the type of delivery delay satisfaction and the number satisfaction. (4) The satisfaction accumulating means calculates (1) to (3) for all delivery delays, and calculates their product.

[0012] Further, 2 included in the producer satisfaction calculating means.
Each of the above item-by-item satisfaction degree calculation means calculates the degree of achievement with respect to the target on the producer side for different items. The producer-side total satisfaction calculating means calculates the product of the item-specific satisfaction calculated by the item-specific satisfaction calculating means and the corresponding weight, calculates the sum of those products, and calculates the sum of the products. Assume total satisfaction. The display means displays the producer's total satisfaction and the item-specific satisfaction.

[0013]

Embodiments of the present invention will be described below with reference to the drawings. FIG. 1 is a block diagram showing the overall configuration of the production plan evaluation device of this embodiment. The production plan evaluation device of this embodiment is a device for evaluating a production plan of a production line that produces a prototype of an automobile part. Because it is a prototype, it is a production line on which various types of products are produced. The main part of the production plan evaluation device is constituted by an evaluation program stored in a personal computer. The order information storage unit 1 is connected to the planning result evaluation calculation means 5. As shown in FIG. 20, the order information storage unit 1 stores a product number to be delivered, a delivery date, a production quantity, an order type, and the like input from an input device such as a keyboard. Here, the order type is the priority of production, and A, B, and
It is described in seven stages of C, D, E, G, and F.

A production plan drafting status storage unit 2 is connected to the order information storage unit 1. Production planning situation storage unit 2
Stores the production plan 29 and the human load 28 that are to be evaluated by the production plan evaluation device. As shown in FIG. 10, the production plan 29 includes a production plan number, a product number, a scheduled production start date, a scheduled completion date, a scheduled neck process start date, a scheduled neck process end date, a neck process equipment number, a corresponding order number, and an evaluation plan. Contains segment information. Here, in the corresponding order number, a plurality of order numbers of order information corresponding to the production plan are described. In the evaluation plan category, a flag indicating whether or not the current evaluation target plan is stored. For example, if the system needs to evaluate a plan that has been drafted for the first time, 1 is entered. If the plan is not to be evaluated, 0 is entered. The corresponding order number stores a string indicating which order information corresponds to the production plan.

The master storage unit 3 is connected to the planning result evaluation calculation means 5. The master storage unit 3 stores various types of master information that can be changed by a user and that is necessary for performing an evaluation. Next, information stored in the master storage unit 3 will be described. As shown in FIG. 12, a part number master 9 that stores master information in units of part numbers is stored. The item number master 9 stores an item number, a group category to which the item number belongs, and a margin date.
In addition, as shown in FIG. 13, a human ability calendar 17 for storing daily human ability is stored. FIG.
As shown in FIG. 4, an operating day calendar 18 that describes whether or not it is an operating day on a daily basis is stored. Here, in the operating day section, a flag of 1 is set if the operating day is set, and 0 is stored if the operating day is not an operating day.

Further, as shown in FIG. 15, a similarity score master 19 in which scores to be added are described according to the type of step change is stored. That is, when the product produced before and the product produced next are similar, the similarity A
And the score is stored as 30. This is because a high degree of similarity means that the time required for the step change operation is relatively short. If the product produced before and the product produced next are not similar, a score of 10 is stored as the similarity C. This is because a low degree of similarity means that the time required for the step change operation is relatively long. The similarity B indicates an intermediate point between the similarity A and the similarity C. Further, as shown in FIG. 16, an ideal average daily volume 20 used in the calculation of the degree of satisfaction of the volume is stored. This indicates the daily turnover when the production line operates smoothly. Further, as shown in FIG. 17, the processing period 21 of the standard neck process used in the calculation of the work satisfaction is stored. Although the neck step will be described later, in the present embodiment, machining by a machining center is the neck step. Also,
As shown in FIG. 18, the number of neck process facilities 22 used in the calculation of the degree of satisfaction of the work volume is stored. In the present embodiment, six, which is the number of machining centers installed on the production line, is stored.

As shown in FIG. 19, a weight master 23 describing the weight of each item is stored in order to comprehensively determine various degrees of satisfaction. The weight master 23 describes weighting according to how much the various degrees of satisfaction affect the total satisfaction or how much the degree of satisfaction is to be evaluated. In this embodiment, the producer satisfaction is (1) the producer's satisfaction with respect to the human load of the planning result, (2) the producer's satisfaction with the variation of the human load with respect to the planning result, and (3) the planning result. (4) Producer's satisfaction with the volume of the planning result, (5) Producer's satisfaction with the safety of the planning result inventory and delivery date Degree. Here, if a certain degree of satisfaction can be ignored, the weight may be set to 0.

In this embodiment, the weight of the producer's satisfaction with respect to the load of the person who wants to evaluate the most important points (1) is 0.4
(3) Producer's satisfaction with the changeover is 0.3, which is an item that people struggle with when planning, and (5) Inventory and delivery time are the next items to be evaluated. Assuming that the producer's satisfaction is 0.15, (2) the producer's satisfaction with respect to variations in human load with respect to the planning result is 0.1, and (4) the producer's satisfaction with the volume of the planning result. It is set to 0.05. This weight is a numerical value to be adjusted or changed when the importance of each item changes, and can be changed by inputting from a keyboard.

The evaluation result storage unit 4 is connected to the planning result evaluation calculation means 5. The evaluation result storage unit 4 displays the result evaluated by the planning result evaluation calculation unit 5 on the display unit 2.
Tell 6 Here, as shown in FIG. 21, the evaluation result storage unit 4 stores (A) customer satisfaction with the planning result,
(B) The producer's satisfaction with the planning result is stored. The customer satisfaction is the orderer satisfaction. Further, planning the producer side satisfaction itemized satisfaction for the result, (1) the producer side satisfaction with the load of human planning results (2) producer side against the Baratsu key load of a person planning results Satisfaction, (3) Producer's satisfaction with the change of the planning result, (4) Producer's satisfaction with the volume of the planning result, and (5) Safety with respect to the stock and delivery date of the planning result Is stored.

Further, there is a planning result evaluation calculating means 5 connected to the order receiving information storage unit 1, the production planning situation storage unit 2, the master storage unit 3, and the evaluation result storage unit 4. The planning result evaluation calculation means 5 reads the production plan 29 and the human load 28 from the production plan drafting status storage unit 2 and reads the order information storage unit 1.
The production plan is evaluated with reference to the order information and the master information in the master storage unit 3, and the result is written in the evaluation result storage unit 4. The planning result evaluation calculation means 5 includes FIG.
As shown in (a), the customer satisfaction calculation means 8 of the planning result and the producer satisfaction calculation means 7 of the planning result (B)
And are included. Further, the customer satisfaction calculation means 8 for the planning result is connected to a customer satisfaction calculation means 10 for the delay in the delivery of the planning result.

On the other hand, the producer-satisfaction calculating means 7 of the planning result reads the human load and calculates the degree of satisfaction based on whether the load is overload or not. It is included. Further, a producer-satisfaction calculation unit 12 for calculating the degree of satisfaction with respect to the variation in the load of the person as a result of drafting the load of the person and calculating the degree of satisfaction with the variation in the load of the person.
It is included. Also included is a producer side satisfaction degree calculation means 13 for reading the production plan 29 and calculating the degree of satisfaction in accordance with the number of step changes. Also included is a producer-side satisfaction calculation means 14 for reading the production plan 29 and calculating the degree of satisfaction based on how many products can be produced. In addition, the production plan 29 is read, the order information is referred to, and the degree of completion is calculated according to how much the scheduled completion date can be with respect to the delivery date and how soon the product can be completed. Is included in the producer-satisfaction calculating means 15 which has seen the above.

Further, the user interface unit 6
It is connected to a production plan drafting status storage unit 2, a master storage unit 3, and an evaluation result storage unit 4. The user interface unit 6 includes a master editing unit 2 for changing various types of master information stored in the master storage unit 3.
4 are included. In addition, the user can view the production plan 29 and the human load 28 in the production plan drafting status storage unit 2, and check the evaluation result storage unit 4.
And a display means 26 for viewing the evaluation result of the production plan stored in the storage means. Further, it includes a production plan editing means 27 for editing the production plan 29 of the production plan drafting status storage unit 2.

Next, the contents of the customer satisfaction calculation means 10 for the delay in the delivery date of the planning result will be described in detail. From the production plan drafting status, the production plan 29 in which the flag of 1 is set in the evaluation plan section is taken out. And each production plan 2
For 9, calculate the following number: That is, the number of days delayed for delivery is determined as the difference between the delivery date and the scheduled completion date. At this time, the number of days late for delivery is calculated on a working day basis using the working day calendar of the customer. The problem with late delivery is that
This is because it has nothing to do with the working day of the producer and should be calculated using the working day calendar of the customer where the customer is operating. For example, the difference between November 1 and November 5 is two days if November 2 and November 3 are non-operating days of the customer.

Using the customer satisfaction graph for the delivery delay of the order type shown in FIG. 2 based on the order type and the number of days of the delivery delay, the customer satisfaction for the delivery delay of the order type of the order is shown. Dki (di) is obtained. 2 is stored in the master storage unit 3 or the planning result evaluation calculation unit 5. Depending on the type of the ordered product, the orderer's requirement for the delivery date differs, and naturally the orderer's satisfaction with the delivery date also differs. Therefore, the type of the product is input in order to determine the degree of urgency required when receiving an order. In the production line of the prototype of the automotive parts of the present embodiment, the order type A is an urgent limited express product,
Order type B is a test sample that is a test product before mass production, order type C is a normal prototype with a large production quantity,
The order type D is a normal prototype with a small production quantity, the order type E is a trial prototype for use in engine unit tests, etc., and the order type F is a spare part that can be used even if the delivery date is delayed. G is a prototype at the development stage. In the case of the order type A, as shown in FIG. 2, the satisfaction level decreases to almost 0 within one day, whereas in the order type F,
Even if the delivery date is delayed by six days, the drop in satisfaction is small.

Next, the customer satisfaction N (ji) based on the quantity of the order is obtained from the quantity of the order by using the customer satisfaction graph based on the quantity shown in FIG. The customer satisfaction graph based on the quantity shown in FIG. 3 is stored in the master storage unit 3 or the planning result evaluation calculation unit 5. Then, Dki (di) * N (ji) is calculated as the customer satisfaction of the order. The reason for taking into account customer satisfaction based on the quantity of orders is to give priority to the production of products ordered in large quantities. The reason is that a large quantity means that there is a high possibility that the number of customers is large. By performing this calculation for all the production plans 29 with the evaluation plan category of 1, the customer satisfaction of the corresponding order with respect to all the orders with the deadline is calculated, and the product of all of them is calculated. , And the customer satisfaction Sc for the delay in delivery of the planning result. Here, all products are calculated because the demand level of the contractor's delivery date is the most important evaluation factor in the production plan, and it is a big problem that multiple occurrences occur.
This is because the customer satisfaction Sc is sharply reduced when a plurality of delivery delays occur by taking the product.

To summarize the above description with equations, the customer satisfaction Sc is expressed by the following equation (1).

(Equation 1) Here, n is the number of orders with late delivery, i is the order with late delivery, ki is the order type of order i, di is the number of days of delay in order i, ji is the quantity of order i, and Dki (di) is the quantity of order i. Customer satisfaction with order type ki of order i, delivery delay di,
N (ji) represents the customer satisfaction by the quantity ji of the order i.

The result calculated by the formula (1) by the customer satisfaction calculation means 10 for the delay in the delivery of the planning result is sent to the customer satisfaction calculation means 8 for the planning result, where the weight of the customer satisfaction for the delay in the delivery is calculated. Is read from the weight master 23 of the master storage unit 3, the product of the two is calculated, and the result is used as the customer satisfaction of the planning result as the evaluation result storage unit 4.
Sent to and stored. In the present embodiment, the weight of the customer satisfaction with respect to the delivery delay is set to 1.0 because there is only one of the satisfactions constituting the customer satisfaction with respect to the delivery delay.

Next, a method of calculating the degree of satisfaction of the producer on the basis of the planning result will be described in detail. Five satisfaction levels constituting the producer-side satisfaction level of the planning result are calculated by calculation means described below. First, a description will be given of the producer-side satisfaction calculating means 11 with respect to the human load resulting from the planning. All dates and loads are read from the human load 28 in the production plan drafting status storage unit 2, and the capability corresponding to the date is read from the human capability calendar 17 in the master storage unit 3. That is, it reads out how many workers can operate on that date. Then, the next quantity is obtained for the date when the load exceeds the capacity. First, (load / capacity) * 100 is calculated to determine what percentage of the load is relative to the capacity. Then, using the producer satisfaction graph with respect to the human load shown in FIG. 4, the producer satisfaction with respect to the human load for each overload date is obtained, and all the products are set as the producer satisfaction with respect to the human load as a planning result. Calculate as degree S1. This can be summarized by an equation, and the producer's satisfaction S1 with respect to the human load as a result of the planning can be obtained by the following equation (2).

(Equation 2) Here, i is the day of the overload, li is (load / capacity) * 100 of the day i of the overload, and M (li) represents the producer's satisfaction with the day i of the overload. The reason why overload is a problem in the degree of producer satisfaction is that a production target cannot be achieved due to overload.

Next, a description will be given of the producer-side satisfaction calculating means 12 with respect to the variation in the load of the person as a result of the planning. All dates and loads are read from the human load 28 in the production plan drafting status storage unit 2 and sorted in chronological order. Then, the number n of the dates is obtained. From the first date to the last date, the sum of the squares of the difference between the loads on the day and the next day is divided by (n−2) to obtain the square root. As a result, the variation in the load of the person can be obtained as a standard deviation which is a statistic.

This can be summarized by the following formula. The producer's satisfaction S2 with respect to the variation in the load of the person as a result of the planning is given by
It is obtained by the formula.

(Equation 3) Here, B (x) is the producer's degree of satisfaction with respect to the variation x in the human load, and the variation x in the human load is obtained by the following equation (4).

(Equation 4) Here, i is the date after sorting, xi is the load of date i, n
Represents the number of dates i. The reason that the variation in the load of the person on the producer side becomes a problem is that it is difficult to treat the person if the variation of the person is large. That is,
This is because it is easier for people who are used to work to secure people who have less variation.

Next, a description will be given of the means 13 for calculating the degree of satisfaction of the producer with respect to the change of the planning result. In this embodiment,
A line as shown in FIG. 7 is assumed as a production process. That is, this is a line in which a neck process in which a plurality of facilities are arranged in parallel in the middle of the process. In the neck process, a plurality of facilities are arranged in parallel because the production quantity per machine is small, and the production volume of the production line is determined by the processing quantity of the neck process. The steps arranged in parallel in this embodiment are processing steps by a machining center. Machining centers use a single machine to process processes previously handled by multiple equipment.
Since processing takes a long time, it is called a neck step, and a plurality of machining centers are arranged in parallel.
On the upstream and downstream sides of the machining center, buffers for compensating continuous operation of other processes are arranged. In a line having such a configuration, a production plan is set so that production is efficiently performed in a normal neck process.
By doing so, the output can be maximized.

The producer's degree of satisfaction S3 for the step change obtained here is calculated based on whether the number of step changes in the neck process is large or small. First, a production plan 29 whose evaluation plan category is 1 is read from the production plan drafting status storage unit 2, and a production plan is allocated to each equipment of a neck process as shown in a Gantt chart shown in FIG. With this, it is possible to know how the part numbers to be processed change in which equipment. In this embodiment, since four machining centers are arranged in parallel,
Four units are listed vertically on the Gantt chart. According to this Gantt chart, production plan 2 whose production plan category is 1
Regarding the plan 9, the previous plan b on the same equipment as the plan a is examined. Then, using the product numbers of the plans a and b as keys, the respective group divisions are read from the product number master 9 of the master storage unit 3. The group division is based on the fact that machining of the machining center is common. It is determined which of the following three similarities between the two plans is based on the product numbers and the group divisions of the two plans. (1) When the product numbers of two plans are the same, the similarity A
And (2) When two plans have different part numbers but the same group division, the similarity B is set. (3) When the group divisions of the two plans are different, the similarity C is set.

After the similarity is obtained, the similarity score is obtained from the similarity score master 19 in the master storage unit 3.
This is done for all plans and their similarity score P
Calculate the sum ｉP (i) of (i). Here, when the immediately preceding plan b does not exist, the similarity is calculated as C. The product P1 * n of the score P1 of the similarity A and the number n of the production plans whose evaluation plan category is 1 is obtained. And the sum of similarity score Σ
The value obtained by dividing P (i) by P1 * n is calculated as the producer's satisfaction with the change of the planning plan. The reason that the changeover is a problem in terms of the producer's satisfaction is that the production is not performed at the time of the changeover, so that it is desirable to reduce the time required for the changeover. When this is summarized by an equation, the degree of satisfaction S3 on the producer side with respect to the change of the planning result is obtained by the following equation (5). In Equation 5, the step change is evaluated based on P1 * n.

(Equation 5) Here, i is a production plan with an evaluation plan category of 1, n is the number of plans i with an evaluation plan category of 1, P1 is a score of similarity A, P2
Represents the score of the similarity B, P3 represents the score of the similarity C, and P (i) represents the score of the plan i.

Next, a description will be given of the means 14 for calculating the degree of satisfaction of the producer with respect to the volume of the planning result. Here, the line configuration shown in FIG. 7 is also assumed, similarly to the producer side satisfaction degree calculating means 13 for the change of the planning result. First, the production plan 29 whose neck process date is today or later is read out from the production plan drafting status storage unit 2, and the sum of the production quantities of each plan is obtained. Next, by calculating the difference between the scheduled end date of the neck process machining and the scheduled start date of the neck process machining for all the production plans for which the scheduled end date of the neck process is today or later, and calculating the sum thereof, The sum Σti of the neck process processing periods is obtained.

Next, the total number of days of a gap that cannot be allocated is determined by the following procedure. The processing period 21 of the standard neck process is read from the master storage unit 3, and the processing period 21 of the standard neck process is added to the date a for evaluation to be a period b.
Then, a gap is searched for in the period b using the Gantt chart shown in FIG. The gap is the part where nothing is allocated on the Gantt chart. Then, the total number of days c of the gap included in the Gantt chart is obtained. On the other hand, after the period b, from the date after to the date when the plan is at the rightmost end on the Gantt chart, the human load 2
8 and the load on that date and the human ability calendar 17 in the master storage unit 3 to read out the capability on that date, and obtain the total number of days d in the gap when there is a gap on the day of overload. Then, by calculating the sum of the total number of days c and the total number of days d, the total number of days z in the gap of the neck process that cannot be allocated is obtained.

Next, the number of neck process equipments 22 is read from the master storage unit 3, and the sum of machining periods of the neck process Δt
By dividing the numerical value obtained by adding i and the total number of days z of the neck process that cannot be allocated to the number of the neck process facilities 22, the machining period e for all the production plans whose evaluation plan category is 1 is obtained. By dividing the sum of the planned quantities Δm by the processing period e, an average volume E per day is obtained. The average volume E is compared with the ideal average volume R read from the ideal average volume 20 in the master storage unit 3. And 1 if E is greater than or equal to R
When E is smaller than R, E / R is calculated as the producer's satisfaction with the volume of the planning result. Note that the date is calculated based on the working day calendar 18 in the master storage unit 3.

When this is summarized by an equation, the producer's satisfaction S4 with respect to the volume of the planning result is obtained by the following equation (6).

(Equation 6) Here, the average volume E per day is obtained by the following equation (7).

(Equation 7) Here, i is the planned end date of the neck process machining from today onward, n is the planned end date of the neck process machining is the number of plans after today, m is the quantity of the plan, t is the machining period of the neck process, R
Represents an ideal average volume per day, E represents an average volume per day, q represents the number of neck process facilities, and z represents the total number of gaps that cannot be allocated.

Next, a description will be given of the producer satisfaction level calculating means 15 which is safe with respect to the stock and delivery date of the planning result.
The production plan 29 whose evaluation plan category is 1 is read from the production plan drafting status storage unit 2. For each production plan 29, all corresponding orders are read from the order information. Master storage unit 3
The spare date a of the corresponding product number is read from the product number master 9 of the corresponding item, and the spare date a is subtracted from the delivery date of the order using the working day calendar 18 of the master storage unit 3 to obtain an ideal scheduled completion date b. Next, a standard deviation is calculated as to how much the ideal scheduled completion date b differs from the actual scheduled completion date. That is, the difference d between the ideal scheduled completion date b and the actual scheduled completion date is determined using the working day calendar 18. The sum of squares of the difference d is obtained for all corresponding orders, and the square root f of a numerical value obtained by dividing one by one from all corresponding orders is obtained.

Then, using the value f, a production-side satisfaction graph showing the safety of the planned inventory and the delivery date is obtained by using the producer's satisfaction graph with respect to the variation of the expected completion date with respect to the ideal completion date shown in FIG. Calculate the customer satisfaction. The reason for considering the margin for the delivery date and the like in the producer's satisfaction level is that the production side always needs a certain margin because the production plan may be confused due to an accident or the like. On the other hand, if the production is too early for the delivery date, the stock will increase, and an extra warehouse or the like will be required, which is uneconomical.

When this is summarized by an equation, the producer's satisfaction S5, which is safe with respect to the stock and delivery date of the planning result, can be obtained by the following equation (8).

(Equation 8) The variation degree ε of the actual completion schedule with respect to the ideal completion date is obtained by the following equation (9).

(Equation 9) Here, n is the number of corresponding orders of the production plan with the evaluation plan category of 1, i is the corresponding order of the production plan with the evaluation plan category of 1, y is the delivery date of the order i, g is the margin date of the order i, and c is the order received. The ik scheduled completion date, ε represents the degree of variation of the actual completion schedule with respect to the ideal scheduled completion date, and ρ represents the degree of satisfaction of the producer with respect to the variation of the actual completion schedule with respect to the ideal scheduled completion date.

Next, the operation of the production plan evaluation device described in detail above will be described. FIG. 21 shows production plan numbers 0001 to
FIG. 2 shows a diagram showing production schedules of 14 lots of 0014. The equipment numbers shown at the left end indicate the numbers of the six machining centers, and indicate which machining center processes the lot with the production plan number. The quantity is
The production plan number indicates the number of products to be produced. The corresponding order of priority is indicated by A to G. N black triangles indicate delivery dates. Also, in the load column,
The person load is indicated by person * hour. The capacity column indicates the number of workers who can work on the production line * hours, and the capacity of each person.

The result of evaluating the production plan 29 shown in FIG. 21 by the production plan evaluation device of the present invention will be described. The evaluation is performed in the initial state in which the production plan is made, and changes i to l during operation.
Are performed for each of the four states after the addition of. First, the evaluation result of the initial state will be described. The characteristics of the production plan in the initial state are as follows. That is, (1) Regarding the human load, there is variation, but there is no day when the load is overloaded. (2) There is no step change because each facility has only one part number for processing assignment. (3) The delivery date of each lot is not too long and not too short with respect to the delivery date, and has a proper margin. (4) The volume is sufficient.

In response to the above conditions, the production plan evaluation device of the present invention obtains the evaluation results in the initial state as shown in FIG.
The customer satisfaction Sc = 100 and the producer satisfaction = 95 are displayed. Then, regarding the item-specific satisfaction, which is a breakdown of the satisfaction on the producer side, the satisfaction S1 of the human load S1 = 100, the satisfaction S3 of the changeover S3 = 100, the satisfaction S5 of the stock delivery date S5 = 100, and the satisfaction with the variation of the human load. The degree S2 = 46 and the work satisfaction S4 = 100 are displayed. By looking at this value, both the customer satisfaction and the producer's satisfaction show high values, so that it is possible to judge that the overall condition is ideal except for the variation in human load. .

Next, a case where the condition i is changed from the initial state will be described. The content of the condition i is to change the delivery date of the production plan number 0014 from 20 days to 16 days. In this case, since the margin for the delivery date of the production plan number 0014 has been reduced from 5 days before the change to 1 day,
There is no room for delivery. Under this condition, the inventory delivery date satisfaction S5 = 94, and the inventory delivery date satisfaction is reduced by 6 points. However, since the satisfaction level is not so important and the weight is 0.15, the producer side satisfaction level is reduced by only one point, and it can be determined that the production plan has no problem as a whole. .

Next, a case where the condition j is changed from the initial state will be described. The content of the condition j is that the delivery date of the production plan number 0013 is changed from 16 days to 5 days, and at the same time, the delivery date of the production plan number 0014 is changed from 20 days to 8 days. In this case, the two lots are greatly delayed in delivery. For this condition, customer satisfaction Sc =
13, which is a 87 point decrease in customer satisfaction. Regarding the delivery delay, the product is calculated and the score is strictly scored, so the score is extremely low. On the other hand, the inventory delivery date satisfaction S5 = 54, and the inventory delivery date satisfaction is reduced by 40 points. However, the producer's satisfaction is 88, only a decrease of 12 points. By looking at this value, the producer's satisfaction is only a little small, but the customer's satisfaction is very low and it turns out to be a problem. If the condition j is changed, the production plan is redesigned. It turns out that it is necessary.

Next, a case where the condition k is changed from the initial state will be described. The content of the change of the condition k is to reduce the production quantity of the production plan number 0009 from ten to one. In this case, the volume is reduced, and the volume satisfaction is reduced by 19 points. However, since this satisfaction is not so important and has a weight of 0.05, the producer's satisfaction is reduced by only one point, and it can be determined that the production plan has no problem as a whole. .

Next, a case where the condition 1 is changed from the initial state will be described. The content of the change of the condition 1 is to change the product number of the production plan number 0002 from A to G. In this case, a step change occurs in the facility 1. Under this condition, the changeover satisfaction S3 = 86, and the changeover satisfaction is reduced by 14 points. The level change satisfaction is important and its weight = 0.30, so the producer satisfaction is reduced by 5 points. By looking at this numerical value, it can be understood that a problem has occurred with the producer satisfaction, particularly the step change satisfaction as the item-specific satisfaction.

As described in detail above, the production plan evaluation apparatus of this embodiment has the producer-side satisfaction calculating means 7 for planning results and the customer satisfaction calculating means 8 for planning results. Since the evaluation based on the producer and the evaluation based on the orderer are displayed, the evaluation of the production plan can be performed from both the producer and the orderer. In addition, if the value of the producer's satisfaction based on the producer is low, the satisfaction of the overload of the person, the satisfaction of the variation of the person's load, the changeover satisfaction, the satisfaction of the work volume, and the inventory delivery date Since the degree of satisfaction and the like are quantified and displayed for each item, it is possible to easily and accurately grasp what kind of factor is bad quantitatively. Also, when evaluating a production plan,
Even when the importance of a specific evaluation item such as the load state of a person is changing, by changing the weight master 23,
Since there is no need to change the original program, it is possible to respond quickly.

The embodiment of the production plan evaluation apparatus of the present invention has been described above. However, the present invention is not limited to the above embodiment, and various changes can be made without departing from the gist of the present invention. . For example, in this embodiment, only the customer satisfaction calculation means 10 for the delay in the delivery of the planning result is considered as an evaluation item of the customer satisfaction calculation means 8 of the planning result, but other items may be considered. . In this case,
Similar to the producer-side satisfaction calculation means 7 of the planning result, each item is weighted, and the sum of each product is defined as customer satisfaction.
It is also preferable to display a numerical value of satisfaction degree for each item.

For example, in this embodiment, five calculation means are described as the item-specific satisfaction calculation means of the producer-side satisfaction calculation means 7 of the planning result, but other calculation means such as the operation rate of the production line. Items may be considered. Occupancy rate satisfaction δ (r)
May be calculated by the operating rate calculation means as follows. As shown in FIG. 22, when drafting a production plan, it is normal to draft a production plan focusing on orders received in a certain period. This is because even if a production plan is drafted for an earlier order, if the order fluctuates, the production plan must be redrawn. This fixed period is V. In this example, it is 15 days. On the other hand, a standard period (lead time) from the start of the production to the completion is defined as a.

The operation rate is represented by the operation rate of the neck process.
The average operation rate r of the equipment in the neck process is obtained by the following equation (10).

(Equation 10) Here, q is the number of equipment in the neck process, V is the period planned this time, a is the lead time, i is the planned date of the end of the neck process after today, ti is the processing period of the neck process of the plan i,
n represents the number of plans i. Occupancy rate satisfaction δ (r)
Can be obtained from the producer satisfaction degree graph with respect to the average operation rate of the equipment in the neck process in FIG.

[0052]

As is apparent from the above description,
According to the production plan evaluation device of the present invention, since it has a customer satisfaction calculation means standing proposals result, the evaluation which puts Purchase Order side is displayed, the evaluation of the production plan of Purchase Order's From a standpoint .

[Brief description of the drawings]

FIG. 1 is a block diagram showing a configuration of a production plan evaluation device according to an embodiment of the present invention.

FIG. 2 is a diagram showing customer satisfaction with respect to a delivery delay of an order type.

FIG. 3 is a diagram showing customer satisfaction according to the quantity of late delivery.

FIG. 4 is a diagram illustrating a degree of satisfaction of a producer due to a human load.

FIG. 5 is a diagram showing a producer's degree of satisfaction due to variations in human load.

FIG. 6 is a diagram showing a production line without a neck process.

FIG. 7 is a diagram showing a production line having a neck process.

FIG. 8 is a Gantt chart in a neck step.

FIG. 9 is a diagram showing a degree of satisfaction with a variation in a scheduled completion date with respect to a margin date.

FIG. 10 is a diagram showing contents stored in a production plan 29;

FIG. 11 is a diagram showing contents stored by a human load 28;

FIG. 12 is a diagram showing contents stored by a product number master 9;

FIG. 13 is a diagram showing contents stored in a human ability calendar 17;

FIG. 14 is a diagram showing contents stored in an operating day calendar 18.

FIG. 15 is a diagram showing contents stored in a similarity score master 19;

FIG. 16 is a diagram showing contents stored by an ideal average volume per day 20;

FIG. 17 is a diagram showing contents stored in a processing period 21 of a standard neck process.

FIG. 18 is a diagram showing the contents stored by the number of neck process facilities 22;

FIG. 19 is a diagram showing contents stored in a weight master 23;

FIG. 20 is a diagram showing contents of order information stored in an order information storage unit 1;

FIG. 21 is a diagram showing an example of a production plan and its evaluation.

FIG. 22 is an explanatory diagram for explaining a method of calculating an operation rate.

FIG. 23 is a diagram showing the degree of satisfaction of the producer with respect to the average operation rate of the equipment in the neck process.

[Explanation of symbols]

1 Order Information Storage Unit 2 Production Plan Planning Status Storage Unit 3 Master Storage Unit 4 Evaluation Result Storage Unit 5 Planning Result Evaluation Calculation Means 6 User Interface Unit 7 Producer Satisfaction Calculation Means for Planning Results 8 Customer Satisfaction Calculation for Planning Results Means 9 Product Number Master 10 Customer Satisfaction Calculation Means for Delay in Delivery of Planning Results 11 Producer Satisfaction Calculation Means for Human Load in Planning Results 12 Producer Satisfaction Calculation Means for Variations in Human Load in Planning Results 13 Planning Results Means for calculating the degree of satisfaction of the producer on the change of the plan 14 Means for calculating the degree of satisfaction on the producer side with respect to the volume of the planning result 15 Means of calculating the degree of satisfaction with the producer on the basis of the stock and the delivery date of the planning result 17 Ability calendar 18 Working day calendar 19 Master of similarity score 20 Ideal average daily volume 21 Standard neck work Processing period 22 neck process equipment number 23 weight master 24 master editing means 26 display means 27 production plan editing means of

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

Claims (1)

(57) [Claims] 1. A production plan evaluation device for evaluating a production plan designed to operate a production line for producing a plurality of types of products in accordance with an order in which a type, a number, and a delivery date are designated. Production plan planning status storage means for storing the production plan, master storage means for storing basic data relating to the facilities of the production line, etc., and the master storage means for the production plan stored by the production plan planning status storage means. The orderer calculates the degree of achievement for the orderer's request using the stored basic data.
The production plan drafting status storage means or the master storage means.
At least one of the columns is the number of days late for delivery
And the first order showing the degree of satisfaction with the delivery delay
Table data and the number of orders with delayed delivery
And second table data indicating the satisfaction level, and the orderer satisfaction degree calculation means for the delivery delay is: (1)
Calculate the number of days late for delivery and calculate the number of days
And the order type, based on the first table data
Read out the type of delivery delay satisfaction by type
Means to read out the degree, (2) the number of orders that were delayed
Read the number satisfaction degree based on the second table data.
Means for reading out the number of satisfaction levels to be found out;
Satisfaction Calculation for Calculating the Product of Satisfaction and the Number Satisfaction
Means, (4) the above (1) to all delivery delays
Satisfaction accumulation means for calculating (3) and calculating their product
A production plan evaluation device, comprising: calculating the degree of satisfaction of the orderer on the delivery delay .