JP4177234B2 - Production planning device and production planning method - Google Patents

Description

  The present invention is an auto parts manufacturer, a part manufacturing process within an auto manufacturer, such as a delivery period from a car assembly line, a manufacturing activity that is based on orders with strong delivery restrictions such as delivery order, The present invention relates to a production plan planning apparatus and a production plan planning method for a manufacturing industry of a build-to-order manufacturing type having a strong delivery constraint that satisfies a constraint on delivery order, a constraint on equipment, and a lot-sizing constraint for obtaining manufacturing efficiency.

  In the auto parts manufacturer and auto parts manufacturing process, production activities are performed based on the delivery time, the order of pallet delivery, the order specified in the order of mixed loading in the pallet, and order information. In the auto parts manufacturer and auto parts manufacturing process, the order information from the auto manufacturer is one by one order that does not consider manufacturing efficiency at all. Has been decided. The lot size is determined by summarizing the current product stock section and the specified order group, and rounding up the shortage that cannot be allocated to the production lot size. This lot sizing process usually relies on manpower. This is because an attempt to perform lot size determination processing by computer processing results in an explosion of combinations, and it is not possible to obtain a plan allocated with time for facilities of lots that are put together in practical lots in real time. If the lot size is determined in advance, the order of the lots can be determined by means of optimization such as mathematical programming, genetic algorithm, or simulated annealing. However, determining the lot size is the stress of the current planner. It has become.

  Patent Document 1 discloses an input unit for inputting vehicle information to be manufactured, a calculation unit for determining an optimal loading order based on the vehicle information input to the input unit, and a loading order plan obtained by the calculation unit. In the vehicle production line input order planning apparatus having an output unit for outputting the output to the outside, the calculation unit creates the vehicle input order and based on the constraint condition at the time of work input input from the input unit , To determine the degree of dissatisfaction of the created order as a penalty value, while creating multiple order of order, determine the penalty value for the constraint condition for each order of order, and find the order of input that minimizes the penalty. An input order planning device is described.

  In Patent Document 2, in a factory that performs processing having a plurality of processes, basic data relating to matters necessary for planning an object production plan and an arrangement of apparatuses in the process of producing an object, Equipment capacity data related to the time required for processing, machine-to-machine time data related to the movement time of products from the previous process production equipment to the next process production equipment, and equipment used for successive production processes. A detailed planning procedure for determining a production device and a production time for a predetermined number of product lots from the data of the allocation rule that describes in which order the product is allocated to which device, the basic data, and each Apply the procedure specified in advance for each process using the process time data on the time required for production in the process and the transition calculation procedure to calculate the production time of the lot. Production planning how to create a plant-wide production plan have been described.

  Patent Document 3 discloses a manufacturing process production plan planning method in which a production plan is drafted or changed from basic data of a factory necessary for drafting a production plan at a processing factory and operation data such as an order, inventory, and production plan. In order to respond to changes in orders due to an increase in determinism with minimal changes, the machining process has a production order creation step that creates production orders by assigning orders, finished product inventory, and production plans before the change. A production planning method is described.

  Patent Document 4 includes a job creation step for creating a plurality of jobs by combining an appropriate number of lots into one job according to production request data including delivery date and production quantity for each lot to be produced. The job creation step allocates the delivery date and the number of production for each lot included in the input data as a required amount for each fixed time unit on the time axis. At the same time, the first step of assigning the production capacity for each fixed time unit on the same time axis, and the presence or absence of the requested quantity is searched while going back from the search start point on the time axis, and the requested quantity is assigned. The second step of setting the point in time as the calculation start point, and adding the requested amount and production capacity for each fixed time unit while going back on the time axis from the calculation start point Each cumulative value is calculated, a time point at which the difference between the two cumulative values is greater than a predetermined value is detected, the time point is set as a calculation end point, and the time point immediately before is set as a new search start point. A production planning method having three steps and a fourth step of combining one or a plurality of lots included in the period from the calculation start point to the end point into one job is described.

JP 2003-271223 A JP-A-11-320343 JP-A-9-153090 JP-A-7-114599

  In the manufacturing industry such as auto parts manufacturers with strong delivery restrictions, orders from auto makers are generated in units of several hours by specifying the delivery time. This order is not in the lot unit expected by the manufacturing industry due to the necessity of delivery in the assembly order of the automobile. Conventionally, it has been attempted to cope with this problem by determining the lot size in advance and optimizing the order of lots. However, if the lot size cannot be determined dynamically at an appropriate size, there are problems such as an increase in product inventory, a long manufacturing time, and a failure to satisfy the delivery date.

  For this reason, after a person performs the lot size generation part first, the computer determines only the part for determining the input order. If this is attempted to be executed by a computer, a combination explosion occurs, and there is a problem that an optimum lot size cannot be created within a finite time. An object of the present invention is to create a production process delivery schedule that can produce an optimum lot size by a computer within a finite time, prevents an increase in product inventory, and can satisfy a delivery date for a strict order. To do.

  The present invention includes an input unit that inputs order information for a plurality of lots for which at least a delivery time, a delivery order, a quantity, and a mixed loading order are specified, a calculation unit that creates a production plan based on the input order information, and the In a production facility production plan planning device having an output unit for outputting a production plan generated by a calculation unit, the calculation unit includes a time allocation unit for assigning a time for completing production in the production facility for a lot included in the order information; Set the lot unit for each lot, add the number of additional lots consisting of the number of steps to the lot unit, determine the lot size temporarily, and determine the order of input to the production equipment for each lot. Lot size, time allocation, lot unit and time required for production of each step, whether the lot production of the tentatively determined lot size With reference to the setup time required for lot production of the lot size provisionally determined in the next order, by the assigned time, work and setup by assigning the setup time for each lot and the provisionally determined lot size When there is a work / setup time and assignment execution unit to be executed, and a delivery delay determination unit that determines whether production is completed for each lot by the assigned time, and production is not completed by the assigned time In addition, a production facility planning apparatus for a production facility is provided in which the lot size and the number of steps are changed, the lot size is temporarily determined again, and whether to complete the production for each lot by the assigned time is repeatedly processed.

  According to the present invention, in a production plan that involves determination of a lot size, anyone can obtain an equivalent production plan in a short time without the need for know-how. Satisfying customer delivery times can improve CS (customer satisfaction) and improve shelf assets by reducing product inventory.

  According to the present invention, since an optimized lot size for production up to the assigned time is determined, a production plan that eliminates delays in delivery can be found. In other words, a satisfactory scheduling can be set even when the restrictions are severe. In addition, since it is not necessary for the planner to determine the lot size in advance, anyone can obtain the same production plan result. By eliminating the work time for determining the lot size, it is possible to reflect the change in the order such as the jump-in order and the production status in the latest. Depending on the actual work progressed during the production plan creation time, a newly created production plan may not be used.

  From the input order information, the transportation time from the company to the orderer is subtracted, and the shipping time within the company, that is, the delivery time until the completion of production is obtained. Shipment is performed in a mixed form of orders designated by trucks or the like. Even if this shipment is simultaneous shipment, it has strong delivery time and delivery restrictions that are specified up to the mixed loading order on the pallet (loading order in the pallet) and delivery order.

  The delivery restrictions of the delivery order and the mixed order are replaced as they are in the order of production, and temporary allocation is performed as the work order of the equipment. At the time of this temporary allocation, it is handled as production order information without considering production tact. Next, inventory is reserved from the production order information, and only production necessary orders are extracted. This provides the necessary manufacturing priority that cannot be covered by inventory. The difference between the product with the highest manufacturing priority and the preceding lot at the end of the previous plan is examined, and if the types are different, it is understood that the setup time must be set before the manufacturing timing of the product with the highest priority. The minimum lot size is obtained from the lot summarizing conditions of the product with the highest manufacturing priority, a temporary lot size is generated, and the production position of the corresponding lot is determined in consideration of the connection cross section with the preceding lot at the end of the previous plan. Vacant seats will be generated after the previous batch of the same product has been put forward so that the same product can be produced first. Also, it is checked whether there is an empty time between the preceding lot end time at the end of the previous plan and the setup start time of the corresponding lot. If there is an empty space, the subsequent product is checked for an order of the same product as the preceding lot, and if there is a corresponding order, the production possible frame is advanced. As a result, the number of vacant seats will increase. Next, refer to the subsequent provisional allocation information to extract the products that must be preferentially produced, secure the setup time from the end of the allocation, determine the production allocation start time, and Temporary allocation is performed at the minimum lot size, and advancement is performed from the succeeding temporary allocation in the same manner as described above. Repeat this. When there is no provisional order, the satisfaction of the delivery date of each order is checked. If there is no delay in delivery time, it is checked whether the same product appears multiple times in the manufacturing position, and replacement is performed in a lump, and examination is made to collect lots. In this replacement, only the product linked to the order is moved. The part that is not tied to the order is deleted. If there is a delay in the delivery date, the individual product lots are examined, and products that are not linked to the order are deleted one by one from before the time, and an operation for checking the cancellation of the delivery date delay is performed. This operation makes it possible to create a plan that does not satisfy the proper manufacturing lot size but can meet the delivery date and prevent the occurrence of excess inventory. In this way, it is possible to easily find a production plan that easily satisfies the lot grouping restrictions and the delivery date.

  The production equipment production planning device and production planning method consists of a time allocation unit that assigns the time to complete production at the production equipment for the lots included in the order information, and sets the lot unit for each lot, and the number of steps per lot. The lot size determination unit that provisionally determines the lot size by adding the number of additional lots, and the order of input to the production equipment for each lot is determined, and the lot size, time allocation, lot unit and each step described above are determined. Refer to the time required for production and the setup time required for lot production of the tentatively determined lot size to lot production of the tentatively determined lot size in the next order. Work by assigning the time and provisionally determined lot size, work to perform setup, setup time and actual assignment A lot unit, and when determining that production is not completed by the allocated time, by the calculation unit having a delivery date delay determination unit for determining whether to complete production for each lot by the allocated time The lot size is changed and the lot size is temporarily determined again, and it is repeatedly processed whether production is completed for each lot by the assigned time, and the lot size that completes production for each lot by the assigned time is manufactured. It is determined as a lot size for delivery date scheduling.

  Then, when determining the lot to be produced at the beginning of the day, the loading order determination unit gives priority to the lot produced at the end of the previous day.

When a blank time without lot production occurs between lot productions based on the determined lot size, the arithmetic unit inputs production of a dummy lot during the blank time.
The calculation unit sets the lot summarizing conditions, inputs the order information, and goes back in time based on the delivery time of the lot to be produced at the production facility based on the order information. Add one or more single lots that make up a lot unit (however, it is desirable to make it less than or equal to a single lot that makes up a lot unit) and perform lot size determination processing and production time allocation of the determined lot size The production process delivery schedule to be performed at the same time is generated.

Hereinafter, the configuration and operation of a production planning device for a manufacturing industry with strong delivery restrictions according to an embodiment of the present invention will be described with reference to FIGS.
First, referring to FIG. 1, the overall configuration of a production planning apparatus for a manufacturing industry with strong delivery restrictions will be described.

FIG. 1 is a system block diagram showing the overall configuration of a production plan planning apparatus for a manufacturing industry with strong delivery restrictions according to an embodiment of the present invention.
As shown in FIG. 1, the production plan planning apparatus for a manufacturing industry with strong delivery restrictions according to the present embodiment includes an input unit 1, an arithmetic unit 3, and an output unit 5, and memories 2 and 6 as storage devices. It is configured.

  The input unit 1 includes a LAN device 1a, a keyboard 1b, a display device 1c, and an input storage unit 1d. Information input using the keyboard 1b and the display device 1c and information input from other external devices through a communication procedure such as the LAN device 1a are stored in the input device 1d.

As information input from the input unit 1,
1) Order information that is order information from customers such as automobile manufacturers,
2) Information on the quantity of finished product inventory of products that are production items,
3) Calendar information as equipment operation timetable information taking into account operation and non-operation,
4) Product manufacturing capacity information indicating the product production capacity determined by the combination of the product and equipment.
5) Setup time information indicating the setup work time that occurs when the product is switched at the facility.
6) Packing lead time information indicating the work time in the packing process for each product,
7) Inter-process lead time information indicating the transfer time between the process equipment and the post-process equipment,
8) Work result information as a result of working on site based on the production plan output last time,
9) Product production lot unit information indicating the minimum lot size, number of steps, and maximum lot size as the production unit for each product,
10) Equipment specification information, which is basic information such as equipment capacity and production conditions,
Etc. These pieces of information input from the LAN device 1a or the keyboard 1b are stored in the input storage unit 1d. The input information stored in the input storage unit 1 d is taken over by the calculation unit 3 via the memory 2.

  Based on the input information from the input unit 1, the calculation unit 3 creates a production plan that is in the order of product introduction. The memory 6 stores a program group executed by the calculation unit 3. The memory 6 may be a storage medium such as a magnetic disk device. The calculation unit 3 executes processing based on the program group stored in the memory 6. As will be described later, order information is stored in the memory 2, and a lot uniting condition having a number of steps (values) set between lot units and lot units produced by the production facility is stored in the memory 6. The memory 2 and the memory 6 may be integrated. The calculation unit 3 includes a production plan creation unit 3a. The production plan creation unit 3a creates a production plan as a lot input sequence for each process based on the input information. The produced production plan information is stored in the memory 6. The output unit 5 includes a printer 5a, a display device 5b, a plan storage unit 5c, and a LAN device 5d, and can output information stored in the memory 6. It is connected to other devices via the LAN device 5d. The output is published as a work instruction and on the Web, and is used as equipment work order information and manufacturing lot size information.

Next, the configuration of the production plan creation unit 3a included in the calculation unit 3 of FIG. 2 will be described in detail.
As described above, the memory 2 records information on orders, lot units, inventory, plan parameters, work results, and previous plans for at least a plurality of lots for which delivery time, delivery order, quantity, and mixed order are specified. ing.

  The production plan creation unit 3a of the calculation unit 3 includes an input information capture unit 31, an inventory allocation production amount extraction unit 311, a time plan correction unit 32 for a previous plan based on actual results, a plan target process setting unit 321, and a process ( Temporary) time allocation unit 33, lot size provisional determination / review unit 331 (consisting of a lot size temporary determination unit and a review unit), work / setup time and allocation execution unit 34, delivery date delay presence / absence determination unit 341, plan An end determination unit 342, a production plan propagation unit 35 to the previous process, a planning target process change unit 351, an overall production plan / time allocation result storage unit 37, and an optimization unit 38 are provided.

  The input information capturing unit 31 captures order information from the memory 2. The inventory allocation production amount extraction unit 311 extracts the production amount from the inventory information and the order information.

  The time correction unit 32 of the previous plan based on the actual results corrects the time of the previous plan from the extracted manufacturing amount, the actual operation results, and the previous plan information. The planning target process setting unit 321 sets the final process with reference to the corrected time of the previous plan.

  The time allocation unit 33 of the corresponding process of the order information inputs the set final process and the production amount, and performs temporary time allocation of the corresponding process. The lot size tentative determination / review unit 331 inputs the order information, the production amount, and the allocated time, sets the lot unit (number of units) for each lot, and includes the number of steps (the number of sets of steps) for each lot. The lot size is determined by adding the number of additional lots.

  The work / setup time and allocation execution unit 34 receives the information from the lot size provisional determination / review unit 331, inputs the plan parameter information, determines the order of input of each lot into the production facility, and Refer to the lot size, time allocation, and the time required for the production of each lot unit and each step, the setup time required from the lot production of the tentatively decided lot size to the lot production of the tentatively decided lot size in the next order Thus, by the assigned time, the work and setup by the assignment of the setup time for each lot and the provisionally determined lot size are executed.

The delivery delay determination unit 341 receives the work / setup time and the information from the allocation execution unit 34, and determines whether production is completed for each lot by the allocated time. If it is determined that there is a delay in delivery, the lot size tentative decision is reviewed, the lot size is tentatively decided again, and finally the lot size is decided. Accordingly, the work / setup time and allocation execution unit 34 determines the lot size and the order of loading, and gives the time. This completes the manufacturing delivery schedule for the overall production plan. If there is no delay in delivery, the plan end determination unit determines whether it is incomplete or complete. When it is determined that the production plan is incomplete, the production plan propagation (reflection) unit 35 to the previous process inputs the order information and propagates the production plan to the previous process. The plan target process changing unit 351 changes the plan target process in the immediately preceding process, and transmits the changed plan target process information to the time allocation unit 33 of the corresponding process in the order information. When it is determined that the process is finished, the overall production plan / time allocation result storage unit 37 stores the overall production plan and the time allocation result. These results are sent to the optimization unit 38 and stored in the memory 4 as an optimization plan.
Further, the above result is stored in the memory 6 as a plan result.

Here, the processing operation of the production plan creation unit 3a in the production plan planning apparatus of the manufacturing industry with strong delivery restrictions according to the present embodiment will be described with reference to FIG.
In step S <b> 10, the input information capturing unit 31 reads information from the input storage unit 1 d of the input unit 1 to the memory 2.

  Next, in step S15, the time correction unit 32 of the previous plan based on the actual results extracts the lot that has not started work in the production plan range output last time, and determines the time from the end time of the lot in which the work was actually performed. The allocation unit 33 corrects and fixes the planned time of the unworked lot so that the order is not changed.

  In step S20, the time assigning unit 33 subtracts the transport lead time from the customer delivery time of the order information as necessary, and corrects it to the shipping time of the own factory. If the departure time of the shipping flight is determined, it is corrected again to the previous shipping flight time. Further, the packing lead time as input information is subtracted from the correction time, and the time required for completion as a production line is set for each order. If it is not necessary to correct the time constraints of shipping flights and the lead time of packing work, there is no functional problem with the order time.

  The time required to complete the production line is assigned to the production facility in the final process as the production order without changing the order. A production-capable facility can be determined by whether or not the product manufacturing capability information in the input information is defined.

  Next, in step S25, the time allocation unit 33 checks the presence / absence of the product inventory, and makes an allocation for shipping with the inventory product from the head of the corrected order. Only the necessary production order is obtained by the allocation. When the necessary production order as a result of the inventory allocation is examined, the order of products necessary for production is obtained.

  Next, in step S30, the lot size tentative determination / review unit 331 obtains information on the minimum lot size, the maximum lot size, and the number of steps from the product manufacturing lot unit information that is the input information, and the minimum lot in the order of the production necessary orders. Lot summary by size. As a result of this lot summarization, the subsequent order of the production necessary order is examined, and the same product is moved within the range of the lot summarization. You may fill the vacant seats of the move source in front, but leave the seats vacant. In turn, the necessary production orders are checked backwards and lots are collected.

  Next, in step S35, the work / setup time and allocation execution unit 34 sequentially allocates the lot summary result, the last product of the takeover information from the previous production plan obtained in S20, and the production completion time. It should be noted here that the first lot of the lot-sizing result is assigned to the time zone that is in time for itself without completely leading. At the time of this allocation, if the product of the preceding lot and the product type are different, the setup time from the setup time information is assigned before the production time. By this operation, if there is a blank time zone between the completion time at the end of the previous plan and the first lot assigned this time, the same product as the product at the end of the previous plan process is searched for from the lot summary information as a dummy lot. Perform an operation to fill the blank time zone as much as possible. If there is no production requirement order that can perform this pre-packing operation, the pre-packing is terminated there. Here, it is checked whether or not the conditions of the minimum lot size and the number of steps are satisfied, and if the number of steps is not satisfied, a product not tied to the order is filled. The quantity not linked to this order is stored. Thereafter, the lot summary results of the production necessary orders are assigned to the equipment while ensuring the setup time and the lot size.

  Next, in step S40, the delivery date delay presence / absence determination unit 341 checks whether the delivery date delay has occurred with respect to the production completion required time based on the result of the equipment assignment. If there is a delivery delay, step S45 is executed. If there is no delivery delay, the process proceeds to step S50.

  Next, in step S45, the process returns to the lot size provisional decision / review unit 331 to review the lot size. In this review, the minimum lot size and the number of ticks are sequentially broken and reviewed. First, products that are not tied to an order are deleted within the range assigned this time. Each piece is deleted in order from the earliest time, and the time reassignment is performed in cooperation with the time assigning unit 33 to check the cancellation of the delivery delay. If there is no delay in delivery time, the process proceeds to step S50.

  Next, in step S50, the presence or absence of a retroactive process is checked. If the allocation is completed up to the first process and the production plan has been created, the process ends. If there is still an unallocated process, step S55 is performed.

  In step S55, the plan propagation unit 35 for the previous process goes back the production lot part of the production plan result of the most recently created process according to the inter-process lead time information which is input information, and temporarily allocates the previous process. Do. The process is repeated from step S30. The repetitive processing from step S30 is performed by the planning target process changing unit 351 to distinguish it from the final process. If the processes of steps S20 and S25 can be distinguished by processes, they may be treated as the same process.

  Next, when production plans for all processes are completed, the overall production plan / time allocation result storage unit 37 stores the plans. The result is stored in the memory 6. Although the process may be terminated here, the optimization unit 38 executes a process of optimizing the lot insertion order within a range where the lot size is not changed. In this optimization process, optimization is performed using an optimization means based on knowledge processing such as a genetic algorithm and simulated annealing. The optimization result is updated and stored in the memory 4.

  As described above, the calculation unit 3 (FIG. 1) sets the lot grouping conditions and performs the following processing. In other words, the lot condition is satisfied for each lot in the form of satisfying the lot conditions when the setting is changed and performing time retrogression based on the delivery time of the lot produced at the target production facility according to the order information. The lot size determination process is performed by adding one or a plurality of single lots constituting the number of steps. Also, the production time allocation of the determined lot size is performed at the same time. In this way, the manufacturing process delivery date is generated by the calculation unit 3. Next, a specific example will be described in detail.

  FIG. 3 shows the equipment and process configuration of the press industry, which is one working mode to which the present invention is applied. The press industry manufactures everything from car bodies, bonnets and trunks to detailed parts such as internal gears. The plan becomes very complicated if there are many types of products to be handled. Blanking is a process of cutting a sheet-shaped steel sheet, which is an input material for a press, from a coil on a roll. The pressing is a process of forming a steel sheet using a die called a die by a press machine. Hem is a process of incorporating a reinforcing material that bends and sticks the outer periphery to the inside in order to reinforce the pressed steel sheet. Packing is a process of loading on a delivery pallet in the specified order according to the shipping conditions.

  FIG. 4 shows an example of an order in the press industry, which is one work form to be solved by the present invention. The car assembly manufacturer and the process are instructed to deliver the specified mixed product by the designated time. The five clusters in FIG. 4 show examples of mixed loading units. The five clusters have the order used from left to right.

  FIG. 5 shows an example in which the number of steps in the lot summary condition is severe. The minimum lot size is a constraint value that the equipment efficiency is lowered unless a lot, that is, a set of lot units is grouped into 10 or more when the equipment is assigned.

  FIG. 6 shows an example of a conventional method for generating a replenishment lot by giving initial stock conditions to the order example shown in FIG. The order quantity column in FIG. 4 summarizes the quantity for each product within the delivery time zone. The remaining inventory is a column indicating a numerical value obtained by subtracting the number of orders for each time zone from the number of products in stock and tracking the number of inventory. Here, when the remaining inventory becomes a negative number, the inventory tracking numerical value is corrected on the assumption that replenishment is performed in the corresponding time zone.

  In general, there is a case where a method of determining the total number of replenishments by tracking to the end without correcting with the number of replenishments in the middle may be adopted, but in this example, replenishment is required every time because it targets processes with strong time constraints. This will be explained using the method of raising a lot. In the replenishment number column, the quantity to be replenished is generated with the minimum lot size shown in FIG. Strictly speaking, the replenishment needs to be completed before the time when the stock becomes negative. Taking product A as an example, the initial inventory is four. If two shipments with a delivery time of 8 o'clock are performed, the remaining inventory becomes 2 at 8 o'clock. If 5 units are shipped at 9 o'clock, the remaining inventory will be -3 units, making it impossible to ship. For this reason, replenishment with the minimum lot size of 10 is performed so that the remaining inventory becomes 7 at 9 o'clock. This is carried out to the end with respect to the time axis, and the same examination is performed for all products. In this way, in the conventional method, inventory tracking is performed and the method of generating replenishment lots is taken with the timing of shortage or falling below safety stock, but when there are many product types or when the numerical value to be calculated is large, The work time is long and a heavy burden.

FIG. 7 shows an equipment configuration for explaining one embodiment of the present invention.
Since the distribution of products that can be produced with respect to equipment is not related to the present invention, the explanation will be made with one equipment. Although one product can be produced by a plurality of facilities, it can be dealt with on the extension line of the result of the embodiment of the present invention, so that the description will be made with one facility.

  FIG. 8 shows an example in which the production allocation is performed by the conventional method with the order of FIG. 4 and the replenishment lot of FIG. 6 in the equipment configuration of FIG. The first level is assigned in the order of the supplement products generated in FIG. The underlined part of the product indicates a delay in delivery. For convenience of explanation of the present invention, the setup time is 30 minutes every time the product is switched, and the production time of each product is 3 minutes. Usually, the production time is obtained by calculation according to product manufacturing capability information which is input information. The product manufacturing capacity is called a standard construction period (ST) and is given by the processing time per unit, the number of processings per unit time, and the like. In the former ST, the time can be calculated by integrating the production quantity. In the latter case, the time can be calculated by dividing the production quantity by ST. The second stage and the third stage show the plan results obtained by the optimization means for determining the lot insertion order. The delivery delay cannot be resolved.

FIG. 9 shows an example in which the number of steps in the lot summarizing condition is moderate.
Even if this gradual condition is given, it is clear that the delay in delivery date cannot be solved by the conventional method because the lot size is fixed in advance.

  FIG. 10 shows provisional allocation and product inventory allocation status as an embodiment of the present invention in the order of FIG. 4 in the equipment configuration of FIG. The order surrounded by ○ indicates an order in which inventory is allocated.

  FIG. 11 shows a situation in which the inventory allocation order in FIG. 10 is deleted and only the production necessary orders are narrowed down. The arrows indicate the first appearance position of the production required orders for the products A, B, C, and D.

  FIG. 12 shows an example of the result of provisional assignment of the production required order of FIG. 11 along the time axis. Here, the production time per piece is not so important, and it is important that the production required order for the lot exists in the time zone, and the vacant seat where the production necessary order does not exist is generated. That is, only the order is important here. The necessity of producing the product A first can be understood from this order information. If the product B has the next priority to be produced, the priority can be easily read.

  FIG. 13 shows an example of the result of simple assignment of FIG. 12 under the lot grouping conditions of FIG. A minimum lot size of 10 is generated for products A1 to A3 to be produced by 9 o'clock. As a result, subsequent A4 to A10 are produced at the same timing. Since it is sufficient that the production of the lots A1 to A10 is finished by 9:00, it can be seen that the lots may be produced from 7:30. Since the last plan ends with product B, it is understood that setup is always necessary, and it is necessary to secure the setup for 30 minutes before 7:30, and the setup is assigned from 7:00. Since a blank for 30 minutes has occurred from 6:30 to 7:00, it is considered to fill the blank. That is, there are 10 vacant seats with 3 minutes as one vacant seat. Since it is impossible to perform the setup and produce the minimum lot size by examining the product manufacturing capability information, the candidates are narrowed down to the same products as the products at the end of the previous day. Setup time is not required for the same product. As a result, the lot of the product B including B1 to B4 of the product B (B1 to B4 are unit lots, respectively) can be assigned. After that, the results are assigned as they are according to the priority order of production. Products that do not have a numerical value after the product symbol indicate that the order is not linked.

  FIG. 14 shows an example of the result of assignment from the simple assignment of FIG. 13 by the optimization means of the conventional method. Although it is the same result as FIG. 8, the existence of the product which is not tied to an order is understood well. It can also be seen that only one of A11 does not satisfy the delivery date.

FIG. 15 shows an output result in one embodiment of the present invention based on the lot summarizing conditions of FIG. 9 and the production necessary orders of FIG.
This is the result of maximal examination that does not cause product inventory. Compared to FIG. 14, it can be seen that there are few products that are not tied to orders.

  In the embodiment of the present invention, from the state shown in FIG. 14, a check is performed in the time axis direction from the B1 point assigned this time, a product that is not associated with an order is searched, and each product is deleted, and the operation of simulating the cancellation of the delivery date is repeated. This will give you the best results. The delivery delay is eliminated by deleting one B assigned at 6:39, and the whole shifts 3 minutes ago.

Even when processing under the strict lot summarization conditions of FIG. 5, if the cancellation of the delivery date delay is designated with the highest priority, the delivery date delay is solved by performing a simulation of the delivery date delay cancellation by reducing the lot size.
It is also possible to abort the process when the delivery delay is resolved.

  As described above, the production planning apparatus according to the present embodiment inputs order information for a plurality of lots with delivery restrictions that are designated with delivery times, delivery orders, mixed loading orders, and quantities for which delivery times are designated. Input unit, order of lots produced for production equipment based on order information input to the input unit, arithmetic unit for creating a production plan as a production amount, and output unit for outputting a production plan generated by the arithmetic unit It is configured as a production planning device for a production facility having

  The production planning apparatus includes a storage device that stores order information and batch conditions for batch production of lots produced by the production facility and a batch condition having a number of steps set between the lot units.

The calculation unit sets the lot summarizing conditions, inputs the order information, and goes back in time based on the delivery time of the lot to be produced at the production facility based on the order information. One or more single lots constituting a lot unit (however, a single lot constituting a lot unit or less) is added, and the production process time schedule scheduling that simultaneously performs the lot size determination process and the production time allocation of the determined lot size To generate.
The production order of the lot is determined according to the delivery order and the mixed loading order specified for the lot.

  The storage device stores the amount of production stock for each lot, and the calculation unit allocates the amount of product stock from the order information and performs the process of determining the lot size.

  The arithmetic unit preferentially adds one or a plurality of single lots for the same lot to the lot of the last manufacturing process on the previous day.

  The calculation unit assigns the production of the same lot as the previous process, which is a lot that is not linked to the order during the blank time allowed by the lot summary condition between the processes set by the lot size determination process.

  The calculation unit performs a simulation on the manufacturing process delivery date by changing the setting of the lot summarizing conditions, determines whether there is an order that is delayed in delivery date, and if there is, searches for a lot that is not associated with the order and deletes it.

It is a system block diagram which shows the whole structure of the production plan planning apparatus of the manufacturing industry with strong delivery restrictions of one Embodiment of this invention. It is a flowchart figure which shows the process of the production plan preparation part 3a in the production plan planning apparatus of the manufacturing industry with strong delivery restrictions by one Embodiment shown in FIG. It is a figure which shows the equipment and process structure of the press industry which are one working form to which this invention is applied. It is a figure which shows the example of an order of the press industry which is one working form which this invention tends to solve. It is a figure which shows an example with a severe | strict number of steps of lot summary conditions. It is a figure which shows the example of the conventional production | generation method of a replenishment lot, giving the conditions of initial stock to the order example shown in FIG. It is a figure which shows the installation structure explaining one Example of this invention. FIG. 8 is a diagram illustrating an example in which production allocation is performed by the conventional method for the order of FIG. 4 and the replenishment lot of FIG. 6 in the facility configuration of FIG. 7. It is a figure which shows an example with a loose | interval of the number of steps of lot summary conditions. FIG. 8 is a diagram illustrating provisional allocation and product inventory allocation status as an embodiment of the present invention with the order of FIG. 4 in the facility configuration of FIG. 7. It is a figure which shows the condition of the production required order which remained by the inventory allocation result in FIG. It is a figure which shows the example of the result of having temporarily allocated the production required order of FIG. 11 along the time axis. It is a figure which shows the example of the result of having simply allocated | assigned FIG. 12 on the lot summary conditions of FIG. It is a figure which shows the example of the result allocated by the optimization means of the conventional method from the simple allocation of FIG. It is a figure which shows the output result in one Embodiment of this invention based on the lot summarizing conditions of FIG. 9, and the production required order of FIG.

Explanation of symbols

  DESCRIPTION OF SYMBOLS 1 ... Input part, 2, 4, 6 ... Memory, 3 ... Operation part, 3a ... Production plan preparation part, 5 ... Output part, 31 ... Input information taking-in part, 32 ... Previous plan results correction part, 33 ... Final process production A plan creation unit, 34 ... a time allocation unit, 35 ... a plan propagation (reflection) unit to the previous process, 36 ... a previous process production plan creation unit, 37 ... an overall production plan / time allocation plan storage unit, 38 ... an optimization unit.

Claims (4)

An input unit that inputs order information for a plurality of lots for which at least delivery time, delivery order, quantity, and mixed order are specified, a calculation unit that creates a production plan based on the input order information, and generated by the calculation unit In a production facility planning device for a production facility having an output unit for outputting a production plan,
The calculation unit sets a lot unit for each lot and assigns an additional lot number consisting of increments to each lot, assigning a time to complete production at the production facility for the lot included in the order information. The lot size determination unit that provisionally determines the lot size and the order of input for each lot into the production facility are determined, and the lot size, time allocation, and the time required for production in each lot and each step are provisionally determined. Referring to the setup time required from the lot production of the lot size to the lot production of the lot size provisionally determined in the next order, the setup time and the provisionally determined lot size of each lot by the assigned time Work by assignment, work to perform setup, setup time and assignment execution section, and each lot by the assigned time A delivery delay determination unit that determines whether to complete the production, and if the production is not completed by the assigned time, the lot size is changed and the lot size is provisionally determined again, A production facility planning system for production equipment that repeatedly processes whether production is completed for each lot by the assigned time.   2. The production plan planning apparatus for a production facility according to claim 1, wherein, in determining a lot to be produced at the beginning of the day, the input order determination unit gives priority to the lot produced at the end of the previous day.   2. The production according to claim 1, wherein the calculation unit inputs production of a dummy lot during the blank time when a blank time without lot production occurs between lot productions according to the determined lot size. Equipment production planning device. An input unit that inputs order information for a plurality of lots for which at least delivery time, delivery order, quantity, and mixed order are specified, a calculation unit that creates a production plan based on the input order information, and generated by the calculation unit In the production plan planning method by the production plan planning device of the production facility having the output unit for outputting the produced production plan,
A time allocation unit that assigns the time to complete production at the production equipment for the lots included in the order information, and a lot unit for each lot is set, and an additional lot number consisting of ticks is added to the lot unit to temporarily determine the lot size. Lot size determination unit to determine, the order of input to each production facility for each lot, the lot size, time allocation, lot unit and time required for production of each step, lot production of the provisionally determined lot size Refer to the setup time required for lot production of the lot size tentatively decided from the next to the next order, and by the assigned time, work and setup by assigning the setup time and tentatively decided lot size for each lot Complete the production for each lot by the time and time assigned to the work / setup time and assignment execution section When it is determined that the production unit does not complete production by the assigned time, the lot size is changed again and the lot size is temporarily determined again by the operation unit having It is characterized by repeatedly determining whether to complete production for each lot by the assigned time, and determining the lot size for completing production for each lot by the assigned time as the lot size for manufacturing process delivery schedule scheduling. Production planning method for production equipment.

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