JP4232386B2 - Production plan creation system and production plan creation method - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a production plan creation system and a production plan creation method for creating a production plan when a product is produced in a district with a production facility having a plurality of manufacturing processes such as steel products.
[0002]
[Prior art]
For example, in an industry that performs mass production of tens of thousands of products per month, represented by steel products, etc., it responds to different customer product orders such as product types and dimensions such as steel grades, and production by delivery date. In order to complete the process, the work in progress and the newly manufactured product are combined, and a rough production plan such as a monthly unit is created with the aid of a computer.
[0003]
As a conventional production plan creation method, for example, a method described in JP-A-9-183044 is known.
In this conventional example, there are a first process for presetting basic constraint conditions for each unit process set at a fine predetermined time, and a schedule table for the target unit process so that the schedule evaluation scale becomes a limit value. A second process for allocating the processing time of the job, and a third process for transferring the allocation target to the next unit process subsequent to the target unit process. The second and third processes are preset. A production plan creation method is disclosed in which a schedule table in which the processing time of each job is assigned for each unit process is created repeatedly for the number of times performed.
[0004]
[Problems to be solved by the invention]
However, in the conventional production plan creation method, since the production time zone in the unit production process is set finely for each job, fine job assignment can be performed. It is not suitable for handling a structural unit called a cycle that continuously manufactures a number of products (jobs) of the product, and the constraint conditions of recent cycles are relaxed, that is, if they are not the same, they are somewhat similar types Even if the products are of different types and products with similar manufacturing conditions, it is not possible to meet the demand for manufacturing in the same cycle.
[0005]
For example, if a manufacturing time frame (a time bucket, hereinafter simply referred to as a bucket) of a product group to be manufactured in a certain process is set to one day, a part of a plurality of types of product manufacturing time zones that can be manufactured in the same cycle If they overlap and some do not overlap, the production capacity of the production equipment in that process may be judged to be manufacturable even when it is not manufacturable, making it difficult to predict the production time zone of each product. There is a problem that will occur. That is, as shown in FIG. 17, it is possible to manufacture in the manufacturing process called cold rolling of the tinning cycle from 18:00 on the i-1th day to 18:00 on the ith day. Manufacturing process of cold rolling when the cold rolling of the blank plate that can be cold rolled in the same cycle is possible from 6:00 on the i-th to 6 o'clock on the i + 1th Is set to the 1st time zone from 0 o'clock to 24:00 on the i-th day, it is possible to simultaneously assign the production time zone of each product of the tinplate and the tinplate original plate to this one-day bucket. As a result, the production capacity of the cold rolling equipment may be exceeded. Even if this point is improved and the production timing of the product in the over portion is advanced or delayed, this time, in fact, the hatching is not shown between 0 o'clock and 6 o'clock on the i-th shown in the figure. Although it is judged that the tin plate cannot be assigned, it is determined that the tin plate can be assigned, and similarly, the tin plate cannot be assigned from 18:00 to 24:00 on the i-th day shown in the hatching. It will be judged that it is possible to assign the splash, and the production time of each product will be confused.
[0006]
Therefore, the present invention has been made paying attention to the problems associated with the conventional example as described above, and the production time zone of the product group that can be produced in the same cycle of the same process is manufactured in the manufacture of the equipment in that process. It is an object of the present invention to provide a production plan creation system and a production plan creation method having a scheduling function that can be accurately assigned to buckets without exceeding capacity.
[0007]
[Means for Solving the Problems]
In order to achieve the above object, a production plan creation system according to claim 1 is a production plan creation system for creating a production plan in the case of sequentially producing products in a plurality of production facilities having a plurality of manufacturing steps. A cycle calendar creating means for creating a cycle calendar that sets the production time of the product in each production facility, the cycle calendar creating means has a daily time bucket set in units of days for each of the manufacturing processes, The daily time bucket is configured by a set of variable length time buckets that can set a cycle type representing a group of products that can be manufactured with the same cycle chance for each manufacturing process, and set a time zone dedicated to the production equipment of the cycle chance. Is The time bucket length of the variable length time bucket is set so that the time bucket changes when the different cycle types overlap in a manufacturing process. It is characterized by that.
[0008]
And claims 2 The production plan creation method according to the production plan creation method for creating a production plan in the case of sequentially producing products in a plurality of production facilities having a plurality of manufacturing processes, sets the production time of the product in each production facility When creating a cycle calendar, a daily time bucket set for each manufacturing process is set, and the daily time bucket is set. Is A cycle type that represents a group of products that can be manufactured with the same cycle chance for each manufacturing process can be set, and consists of a set of variable-length time buckets that set a time zone that occupies the production equipment of the cycle chance, The variable-length time bucket has a time bucket length set so that when a different cycle type overlaps in a certain manufacturing process, the time bucket boundary is set as the time bucket boundary. It is characterized by verifying the manufacturing capacity of equipment based on variable-length time buckets.
[0009]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, embodiments of the present invention will be described with reference to the drawings.
FIG. 1 is a configuration diagram showing a schematic configuration of the present invention, in which a host computer 1 and a server 2 constituted by, for example, an engineering workstation are connected, and the server 2 is arranged in a number of production processes at a steel works. An information processing terminal 3 composed of, for example, a personal computer is connected via a local area network 4.
[0010]
The host computer 1 is provided with a series order database DB for managing order data for each series. Product orders received in the order database DB by series are processed by a steel plate, hot rolling (hot rolling). ) Order files F1 to F8 by classifying into types such as orders, cold rolling (cold rolling) orders, electromagnetic steel orders, large steel orders, medium steel orders, slab orders, wire rod steel orders, etc. The current work-in-progress order and a planned order to be newly produced are extracted from each series order stored in the order file, and the extracted order data by series is transmitted to the server 2.
[0011]
Here, as shown in FIG. 2, demand order data in which product name, dimension, quantity, and customer name representing product types such as demand order name, delivery date, and material are registered in the order database DB by series. The demand order registration file 11, the production order association file 12 that stores the production order association data representing the association between the demand order name and the production order name, and the demand order registration file 11 are converted by the production order association data, and the in-process inventory A production order data registration file 13 for storing production order data in which production order names, process order names, product names, dimensions, and quantities are registered in units of information, and a production order name, process name, pre-process in-process state, In-process inventory information file that stores in-process inventory information with registered quantity, post-process in-process status, quantity, etc. And a 4. It should be noted that by having this work-in-progress information, products that have a necessary quantity of work-in-process that can be applied to the current demand order are not newly manufactured. That is, the required production quantity can be determined from the quantity of work in progress and the quantity of demand orders.
[0012]
The server 2 is provided with a production plan management system 2A that creates a production plan based on the current work-in-progress order and production schedule order transmitted from the host computer 1.
Then, the data calculation processing unit 20a provided in the production plan management system 2A refers to the standard table 20b, the process table 20c, and the cycle calendar file 20d according to each facility capability of a plurality of manufacturing processes for manufacturing each product. A production plan creation process for creating a production plan is performed, the production plan information is stored in the production plan file 20e, and the production plan information is displayed on the display 20f.
[0013]
In the cycle calendar file 20d, there is a bucket that defines an allocation time zone of a production chance (hereinafter referred to as a cycle chance) of a cycle in which one or a plurality of products can be produced for each production process for each product (cycle) type. Stores the arranged cycle calendar. As shown in FIG. 3, this cycle calendar is, for example, the rolling (manufacturing) of tinplate in the tandem cold mill TCM, which is a cold rolling facility, from the evening of the i-1th day to the evening of the ith day. Assuming that it is possible until 18:00, set a cycle CY1 corresponding to this, and between similar morning tin plates, from 6am on the i-th to 6am on the i + 1th When manufacturing is possible, the cycle CY2 of the tin plate corresponding to this is set.
[0014]
At this time, in the present invention, for each set cycle CY1 and CY2, a one-day bucket BKi is formed at the date boundary position, and this one-day bucket BKi changes the overlapping state of cycles CY1 and CY2. It is composed of a set of variable-length buckets VBKi1, VBKi2, and VBKi3 divided by a position, that is, the morning of 6:00 on the i day and the evening of 18:00 on the i day.
[0015]
In this way, by configuring the daily bucket BKi with the variable-length buckets VBKi1 to VBKi3 divided at the positions where the overlapping state changes, the variable-length bucket VBKi1 becomes a tin cycle opportunity that can be cold-rolled only for tinplate and is variable. The long bucket VBKi2 has a cycle chance for tinplate and tinplate that can be cold-rolled, and the variable-length bucket VBKi3 has a cycle chance for tinplate that can be cold-rolled only for the tinplate. It can be.
[0016]
And, for each of the formed variable length buckets VBKi1 to VBKi3, the processing times TA, TB, TC or tinplate original plates D, E, F of the tin plates A, B, C that are actually scheduled for cold rolling As shown in FIG. 3, cold rolling of tinplate B is applied to variable length bucket VBKi1, and cold rolling of tinplate C and tinplate original plate D is applied to variable length bucket VBKi2, as shown in FIG. The variable length bucket VBKi3 is assigned cold rolling of the tin plate E.
[0017]
In this way, by assigning cold rolling to each of the variable length baskets VBKi1 to VBKi3, the filling ratios Fi1 to Fi3 of each of the variable length baskets VBKi1 to VBKi3 are set in the time zones of the respective variable length buckets VBKi1 to VBKi3. If the lengths are TSi1 to TSi3, respectively, they can be expressed by the following formulas (1) to (3).
Fi1 = TB / TSi1 × 100 (%) (1)
Fi2 = (TC + TD) / TSi2 × 100 (%) (2)
Fi3 = TE / TSi3 × 100 (%) (3)
Here, TB, TC, TD, and TE represent the time (hr) required for cold rolling of A, B, C, D, and E, respectively.
[0018]
Moreover, the filling rate Fi0 of the daily unit bucket BKi can be expressed by the following equation (4).
Fi0 = (TB + TC + TD + TE) / 24 (4)
Based on the filling rate Fi0 of the daily unit bucket BKi and the filling rates Fi1 to Fi3 of the variable length buckets VBKi1 to VBKi3, it is possible to accurately verify whether the manufacturing capacity of the facility is exceeded.
[0019]
That is, when any one of the filling rates Fi0, Fi1 to Fi3 of each bucket BKi, VBKi1 to VBKi3 exceeds 100%, it means that a time zone exceeding the facility capacity occurs, and the filling rate is 100%. In some cases, it represents a full operation state, and when the filling rate is less than 100%, it means that the production capacity of the facility is still sufficient.
[0020]
In order to create a cycle calendar in this way, each information processing terminal 3 accesses the data calculation processing unit 20a of the production plan management system 2A and executes the cycle calendar creation process shown in FIG.
In the cycle calendar creation process, first, in step S1, the currently stored and stored cycle calendar is read from the cycle calendar file 20d, and the read cycle calendar is displayed on the display 3b. Then, the process proceeds to step S2.
[0021]
In step S2, it is determined whether or not cycle setting is performed. This determination is performed, for example, by determining whether or not the cycle setting key assigned in the function key of the keyboard 3c is pressed. When it is determined that the cycle setting key is not pressed, it is determined that the cycle setting is not performed. Then, the process proceeds to step S3, where it is similarly determined whether or not the end key assigned in the function key has been pressed. When the end key is pressed, the cycle calendar creation process is terminated, and the end key is pressed. If not, the process returns to step S1.
[0022]
If the determination result in step S2 determines that the cycle setting key has been pressed, it is determined that cycle setting is to be performed, the process proceeds to step S4, and an input screen for cycle input data is displayed on the display 3b. This input screen is provided with input fields for inputting at least the cycle type, the cycle start date and time, and the cycle end date and time, and predetermined items are input to these input fields. The input data is also reflected in the cycle calendar display.
[0023]
Next, the process proceeds to step S5, and it is determined whether or not the input of cycle input data is completed. This determination is performed, for example, by determining whether or not the end button formed in the input screen of the cycle input data displayed on the display 3b is selected by clicking the mouse 3d, for example, and the end button is clicked. If it is determined that it is not, the process proceeds to step S4. If it is determined that the end button is selected, the process proceeds to step S6.
[0024]
In this step S6, it is determined whether or not the variable length bucket formed between the input cycle start date and time and the cycle end date and time straddles the date boundary. If the date boundary is straddled, the process proceeds to step S7. Then, after newly forming a plurality of variable-length buckets divided at the date boundary position, the process proceeds to step S9. When the date boundary is not crossed, the process proceeds to step S8, from the cycle start date to the cycle end date. After one new variable length bucket is formed, the process proceeds to step S9.
[0025]
In this step S9, it is determined whether or not there is an existing variable length bucket that overlaps with a newly formed variable length bucket, and if there is no overlapping existing variable length bucket, the process proceeds to step S10. The newly created variable-length bucket is set as an existing variable-length bucket, and then the process proceeds to step S11, and the cycle calendar including the set existing variable-length bucket is displayed again on the display 3b, and then the process proceeds to step S12. Then, it is determined whether or not the end key is pressed, and when it is determined that the end key is not pressed, step S is performed. When it is determined that the end key is pressed, the process proceeds to step S13, and the updated cycle calendar is overwritten and stored in the cycle calendar file 20d, and then the cycle calendar creation process is terminated.
[0026]
If there is an existing variable-length bucket that overlaps a part of the newly formed variable-length bucket and part of the time zone in step S9, the process proceeds to step S14, and the existing variable-length bucket is overlapped. After forming a new split variable length bucket with the position where the change occurs as a boundary, the process proceeds to step S11.
The process of FIG. 4 corresponds to the cycle calendar creation means.
[0027]
When the variable length buckets constituting the daily unit bucket are continuous as in the example of 3TCM shown in FIG. 5, the cycle calendar created in this way has two stages such as G, H, and I. It is displayed separately. Even when different cycles with similar product types are integrated and manufactured in the same cycle, these are displayed in two or more stages, for example, Q and R. When a cycle type corresponding to the type of product to be manufactured is assigned to the variable-length bucket in the stacking process described later, the filling rate is calculated in units of variable-length buckets, and this variable is variable when the filling rate exceeds 100%. By displaying the long bucket as a solid fill and displaying the hatching according to the filling rate when it is 100% or less, it is possible to easily grasp the neck process exceeding the filling rate of 100% (operating rate of 100% for equipment). Then, the mountain climbing process described later can be performed. Alternatively, the charge rate can be displayed on a daily basis.
[0028]
Each information processing terminal 3 accesses the data operation processing unit 20a of the production plan management system 2A and executes the production plan creation process shown in FIG.
As shown in FIG. 6, in the production plan creation process, first, in step S21, a thick plate order, a hot rolling (hot rolling) order, and a cold rolling (cold rolling) are performed from the order database DB by series of the host computer 1. Read in-process orders and new orders for products stored in the order files F1 to F8, classified into orders, electromagnetic steel orders, large steel orders, medium steel orders, billet orders, wire bar steel orders, etc. . Here, as shown in FIG. 2, the product name, dimensions, quantity, and delivery date are set in the production order, and the delivery date is the number of days required for transportation if it is transported to logistics such as customers by ship. It is preferable that the value is set in consideration of the shipping timing and the like by ship.
[0029]
Next, the process proceeds to step S22, and the passing process is determined by referring to the standard obtained by referring to the standard table 20b based on the product name and dimensions of each manufacturing order and further to the standard table 20C. To do. Here, as shown in FIG. 7, the process table registers the part data definition file 21 in which the standard, quantity, process order, raw material name, and quantity are registered, and the part name (raw material) and part type (purchased product). The part list definition file 22 to be registered, the process order, the process name, the equipment name (specific passing equipment name of the corresponding process), the manufacturing process order list file 23 in which the required time is registered, and the relationship between the equipment and the installation location are registered. An equipment list definition file 24, an alternative equipment setting definition file 25 in which the process order, process name, equipment name, and required time (time ratio with respect to the time required to pass through the equipment originally intended to pass) are registered; The cycle process order setting definition file 26 in which the cycle name representing the order, process name, and product type is registered, and the relationship between the product type corresponding to the cycle name and the equipment through which it can pass are registered. And a Le facilities set definition file 27.
[0030]
Then, for each manufacturing order, the manufacturing process to be passed with reference to the manufacturing process list file 23 and the passing order to pass through them are obtained (in FIG. 7, for example, BF for the process order indicated by AAAA) Pass through each facility (process) in the order of passage: → CC_4 → HM → CM_1 → CAL_2.)
In addition, by having the alternative equipment setting definition file 25, when production concentrates on a specific process, it can be used to determine whether or not transfer to another alternative equipment is possible.
[0031]
In addition, by having a cycle facility setting definition file 27 in which the correspondence relationship between the type of product corresponding to the cycle name and the name of the facility through which it can pass (for example, shape steel, plating (COAT), etc.) is registered, When creating a production plan by accumulating the processing time for each equipment and for each process, the production capacity for each equipment and each process is referenced by referring to the required time registered in the manufacturing process order list file 23. It is possible to determine whether or not the upper limit is exceeded, so that it is possible to create a highly accurate production plan.
[0032]
By the way, a cycle is a name that refers to the simple construction of a united quantity because it is common to manufacture a number of products of the same type in a single facility. However, it is named because it has a chance to manufacture the same type of cycle periodically, such as once every few days.
Next, the process proceeds to step S23, and the processing time in each process is previously set in advance in the process table 20C with reference to the process table 20C based on the passing process for each manufacturing order. In addition to reading the shortest time required to carry the product between the processes not to be read, several cycle chances (hereinafter referred to as cycle chances) of the corresponding product type in the cycle calendar are read from the cycle calendar file 20d, and manufacturing is performed at any one of these manufacturing opportunities. Based on this assumption, a reference time is calculated, and based on the calculated reference time, a cycle setting line is obtained in which the passage timings of the passage steps are connected as shown in FIG. Here, the lead time is a generic term for the time required for manufacturing each product in each manufacturing process, the time required for transporting between processes, or the total and the total required time.
[0033]
Next, the process proceeds to step S24, and a stacking process for accumulating the processing time of each production order scheduled to pass is performed for each process, for example, on a daily basis based on the obtained cycle setting line for each production order (that is, Several types of cycles may be scheduled separately and consecutively during the day).
Next, the process proceeds to step S25, and whether or not there is an overcapability process (neck process) in which the obtained facility capacity exceeds 100% (in the case of the above-mentioned daily unit, the synthesis of the processing time) If there is no overcapacity process, the cycle chance of each product type in the cycle calendar read in step S23 is stored in the production plan file 20e as it is. When the excess process exists, the process proceeds to step S26.
[0034]
In this step S26, an adjustment process called mountain break is automatically performed for the overcapability process. This devastating process uses other alternative equipment in the same process for production orders that lead to overcapacity, or moves the processing timing in that process one cycle earlier or one later to another cycle opportunity of the same product type, This is to create a production plan that is corrected by leveling so that the operation rate of the over-capacity process becomes 100% or less.
[0035]
Next, the process proceeds to step S27, and after performing the pile processing for accumulating the processing time for each process again, reflecting the corrected production plan for each production order after the mountain collapse, the process returns to step S25.
On the other hand, the reference time calculated in step S23 of FIG. 6 will now be described in detail. Here, the reference time is a generic name for the earliest startable time and the latest startable time described below. The horizontal axis shown in FIG. 8 takes time, and the vertical axis shows continuous casting process CC, hot rolling process HOT, pickling process PIC, cold rolling process COLD, continuous annealing process CAL, plating process COAT, etc. As shown in the chart of the steps, first, when the work start point P10 is set in the continuous casting process CC that is the initial process at the calculation start time t1, the hot rolling process HOT that is a process downstream from the work start point P10. -The earliest possible start time for each process is sequentially set with a preset minimum lead time for the plating process and the like. By connecting the work start points P10 to P15 representing the earliest possible start time for each process, a line L1 shown by a broken line in FIG. 8 can be represented.
[0036]
And the time which considered the restriction | limiting of the cycle chance of the installation in the passage process with respect to this earliest start possible time is set as restrictions earliest possible start time. That is, as shown in FIG. 8, if the cycle chance C31 represented by a rectangle as a cold rolling process (COLD) is set to a time later than the work start point P13 representing the earliest possible start time, this cycle The work start point P13 of the earliest possible start time is changed to the start point P23 in the cycle chance C31 due to the restriction of the chance C31, and the work start points P14 and P15 representing the earliest possible start time on the downstream side are accordingly changed. It is shifted to work start points P24 and P25 representing the earliest possible start time considering the constraints. This is because, if there is no cycle chance of the product type corresponding to the earliest possible start time for the product to be passed, the product must pass through the process until there is a cycle chance. By connecting the work start points P23 to P25 representing the earliest possible start time in consideration of the constraints, the line L2 shown by the alternate long and short dash line in FIG. 8 can be represented.
[0037]
Further, the latest possible start time for each process is sequentially set with the shortest lead time set in advance for each process upstream from the delivery date. By connecting the work start points P30 to P35 representing the latest possible start time LPST for each process, the thin line L3 shown in FIG. 8 can be represented.
A time considering the restriction of the cycle chance of the equipment in the passing process with respect to the latest possible start time is set as the latest possible start time considering the restriction. That is, assuming that the cycle chance C32 represented by a rectangle in the cold rolling process (COLD) is set at a time earlier than the work start point P33 representing the latest possible start time as shown in FIG. The work start point P33 at the latest possible start time is changed to the work start point P43 in the cycle chance C32 due to the restriction of the chance C32, and the work start point P32 indicating the latest latest possible start time is changed accordingly. , P31, and P30 are also shifted to work start points P42, P41, and P40 that represent the latest possible delay start time. By connecting the work start points P40 to P45 representing the latest possible start time in consideration of the restriction, the thick line L4 shown in FIG. 8 can be represented.
[0038]
Therefore, in FIG. 8, in each facility, the delivery date can be achieved by assigning the work start time between the line L2 representing the earliest possible start time considering the constraint and the line L4 representing the latest possible start time considering the constraint. A production order that cannot be assigned is a material that cannot be properly placed, and the latest startable time is assigned for convenience.
The constraint start and the earliest possible start time are used as the source of the earliest constraint condition when stacking, the allocation constraint condition when landslide, and the provisional constraint consideration earliest start possible time when the lock position is set. The latest possible start time is used as the latest constraint condition at the time of landslide described later.
[0039]
Now, it returns to description after step S22 again and shifts to description of a mountain climbing process. The stacking process of step S24 and step S27 in FIG. 6 is a process of stacking the order rods with a standard lead time that assigns the processing timing in each process of each manufacturing order while taking into account the constraint of the cycle chance, going back from the delivery date. By setting an appropriate lead time based on the order delivery date, each production order is assigned to the corresponding cycle chance of each process. Specifically, as shown by the thick line L5 in FIG. 9, the cycle chance constraint is considered retroactively from the delivery date, and the standard lead time is used to allocate from the downstream process to the upstream process. is there. Here, ◎ represents a reference time that is a manufacturing start time in each facility. Then, for example, the daily production orders of the third tandem cord mill 3TCM, which is equipment for the cold rolling (COLD) process, are stacked as shown in FIG. 9, so that the third tandem cold mill 3TCM on the Nth day If the operating rate exceeds 100%, mountain climbing will occur. However, if adjustment of cycle chances is not performed, the latest start taking into account the constraints set by the standard lead time considering cycle opportunities will be traced back from the delivery date. The period within the cycle chance C32 through which the line L4 shown by a thin solid line representing the possible time passes and the period within the previous cycle chance C31 is the adjustable range A1 due to the landslide.
[0040]
When adjusting the cycle chance, the cycle chance C31 is expanded on the horizontal line L5 on the past side of the cycle chance C31, or the end of the next cycle chance C32 on the future side of the cycle chance C31, that is, It is possible to extend the cycle chance until the latest possible start time in consideration of the constraint by the operator in charge dragging the start end of the cycle chance display on the display with the mouse. As described above, the adjustable range A2 by the mountain break including the cycle calendar adjustment can be made longer than the mountain break adjustable range A1 when the cycle calendar adjustment is not performed.
Now, the operation of the production planning system according to the present invention will be described in more detail based on the above embodiment.
[0041]
In the host computer 1, the received product order is input, the in-process status of the in-process product order is input, and the product order that can be ordered can be input.
In normal operations, there are two types of cases: creating an actual production plan based on a newly ordered product order, and providing sales expansion order support that selects a product order that can be ordered and absorbs fluctuations in production capacity. It is done.
[0042]
When creating a production plan based on a newly ordered product order, the newly ordered product order is input to the host computer 1. For this product order, a demand order name, delivery date, product name, dimensions, quantity, and customer name are input. The in-process inventory information file is not created for the newly ordered product order, so the current in-process status is registered in the in-process inventory information file 14 for the previously ordered product order.
[0043]
In other words, as shown in FIG. 2, assuming that product orders with two demand order names S145-XXXXX-XX and S145-YYYYY-YY with quantities of 50000 kg and 150,000 kg have been previously received, AAAA and BBBB, as shown in FIG. 7, as for the product name AAAA, slabs are formed by continuously casting the molten iron extracted from the blast furnace (BF) from the molten steel refined at the steelmaking plant with a continuous casting machine (CC), This slab is hot-rolled (HM), pickled (PIC), cold-rolled (CM), continuously annealed (CAL), and then shipped as a product. The steel smelted and refined is continuously cast with a continuous casting machine (CC) to form a slab, this slab is hot-rolled (HM), pickled (PIC), cold-rolled (CM), Furthermore, it shall be shipped as a product after plating (COAT).
[0044]
In addition, products handled at steelworks are not limited to the above products, but products that are shipped after rolling a slab formed by continuous casting after thick plate rolling, as a product by hot rolling the slab Products to be shipped, products that have been cold-rolled and then annealed and then electroplated, and are processed as a coating and then shipped as a product, those that are shipped after other plating such as hot dipping instead of electroplating, etc. There are a wide variety of product forms such as processing products purchased from other manufacturers and shipping them as products.
[0045]
Returning to FIG. 2 again, both of these demand orders are not new orders, but are in units of in-process inventory information. For one demand order, production orders S145-XXXXX-XX-AA and S145-XXXXX-XX for 20000 kg and 30000 kg. -BB is divided into 2 parts, and the other demand order is divided into 5 parts into 30000kg production orders S145-YYYYY-YY-AA to S145-YYYYY-YY-EE, and a production order is generated for each of these production orders. A data registration file 13 is formed.
[0046]
The production order S145-XXXXX-XX-AA is in the pre-process state of hot rolling (HM), and the production order S145-XXXXX-XX-BB is in the post-process state of hot rolling (HM). Yes, the production order S145-YYYYY-YY-AA is in the pre-process state of cold rolling (CM), and these are stored in the in-process inventory information file 14.
Then, a cycle calendar is created that represents the processable status for each cycle type in each processing facility in terms of weeks and / or months. This cycle calendar may be reflected in consideration of the construction period including the periodic repair work of the processing equipment and the manufacturing order status.
[0047]
As described above, the cycle calendar is created as shown in FIG. 10 for a plurality of, for example, three cycle types 1 to 3 that can be processed within the same cycle with the same processing equipment such as the tin plate and the tin plate. For a certain processing facility, for cycle type 1 (illustrated as (a)), from 19:00 on the i-1 day to 19:00 on the i day and from 14:00 on the i + 1 day to 3 o'clock on the i + 2 day. For cycle type 2 (illustrated as (b)) from 5 o'clock on the i-th day to 15:00 on the i + 1-th day, for cycle type 3 (illustrated as (C)) from 14:00 on the i-th day to i + 1-th day The case of setting until 14:00 will be described.
[0048]
When the cycle type 1 is set first, the cycle calendar stored in the cycle calendar file 20d is read and displayed on the display 3b (step S1). At this time, if there is no other existing bucket in the time zone in which the cycle type 1 is set, a cycle calendar in which no bucket is displayed in the corresponding time zone is displayed on the display 3b.
[0049]
In this state, when the setting key of the keyboard 3c is pressed, the setting process is started. First, an input screen for inputting cycle input data is displayed on the display. In this input screen, the cycle type, cycle start date and time, It is determined that the data input has been completed by inputting essential items such as the cycle end date and time by operating the keyboard 3c and then selecting the end button displayed on the input screen with the mouse (step S5).
[0050]
Then, it is determined whether or not the input cycle crosses the date boundary, and since the input cycle type 1 cycles CY1a and CY1b both cross the date boundary as shown in FIG. Variable length buckets VBK (i-1) 1, VBK (i) 1, VBK (i + 1) 1, and VBK (i + 2) 1 divided at these date boundaries are formed (step S7).
[0051]
Since there are no existing variable length buckets, the new variable length buckets VBK (i-1) 1, VBK (i) 1, VBK (i + 1) 1 and VBK (i + 2) 1 are The existing variable length bucket is set (step S10), and the cycle calendar including these is re-displayed on the display 3b (step S11).
In this state, the end key has not been pressed yet. Next, in order to perform cycle setting of cycle type 2, the process returns to step S1 and the data input process of cycle type 2 can be performed by pressing the setting key again. In this cycle type 2 input, as shown in FIG. 10 (b), the cycle CY2 crosses the date boundary. Therefore, two variable length buckets VBK (i) 2 and VBK (i + 1) divided at the date boundary position are used. ) 2 is formed, and among these, the variable-length bucket VBK (i) 2 includes the existing variable-length bucket VBK (i) 1 having overlapping time zones, so that the i-th day bucket is shown in FIG. ), Variable variable length buckets VBK (i) 11, VBK (i) 12, and VBK (i) 13 divided at 5 o'clock and 19 o'clock, which are times when the overlapping state of buckets changes, are formed and are variable. The long bucket VBK (i + 1) 2 is set as an existing variable-length bucket as it is because there is no overlapping existing variable-length bucket.
[0052]
Thereafter, when data input processing is performed for cycle type 3, as shown in FIG. 10 (c), cycle CY3 crosses the date boundary, so two variable length buckets VBK ( i) 3 and VBK (i + 1) 3 are formed, and the existing variable length buckets VBK are shown in FIG. 10 (d) for both variable length buckets VBK (i) 3 and VBK (i + 1) 3. Since (i) 12 and VBK (i + 1) 2 exist, the existing VBK (i) 12 is changed at 14:00 on the i-th day at 5 o'clock on the i + 1-th time when the overlapping state with these variable length buckets changes. And the new variable length bucket VBK (i + 1) 3 is divided into eight variable length buckets VBK (i-1) 1, VBK (i) 21 to VBK () as shown in FIG. i) 24, VBK (i + 1) 11 to VBK (i + 1) 13, VBK (i + 2) 1 are formed. By pressing the end key in this state, the updated cycle calendar is overwritten on the cycle calendar file.
[0053]
In this state, when the production plan process shown in FIG. 6 is executed by the production plan management system 2A of the server 2, first, in step S21, new order product order information and in-process inventory information stored in the host computer 1 are read. The process proceeds to step S22, and a passing process for each production order is determined with reference to the standard table.
In the example of FIG. 7, the process order AAAA representing the type of slab is continuously cast from the molten steel obtained by refining the hot metal extracted from the blast furnace (BF) at the steelmaking factory using a continuous casting machine (CC) as described above. This slab is hot-rolled (HM), pickled (PIC), cold-rolled (CM), continuously annealed (CAL), and then shipped as a product. The slab is formed by continuously casting the molten steel obtained from the blast furnace from the blast furnace using a continuous casting machine (CC), hot rolling (HM), pickling (PIC), and cold rolling. (CM) and coating process (COAT), and then the process of shipping as a product is determined.
[0054]
Next, the process proceeds to step S23, and each reference time as shown in FIG. When passing through the passing process in order of the shortest lead time (referred to as standard lead time) from the work start point while taking into account the restrictions on cycle chances, each process passing timing and processing time for each manufacturing order, then delivery date to standard The cycle setting line shown in FIG. 9 described above is set by obtaining the process passage timing and processing time for each production order retroactively with the lead time, and the constraint start for each set production order and the earliest possible start time and constraints The production time zone is assigned to the variable length bucket between the cycle setting lines of the latest possible start time.
[0055]
As described above, when the production time zone in each process (equipment) for each production order is assigned to the variable-length bucket, each cycle type as shown in (a), (b) and (c) in FIG. Production time zones in the process (equipment) for each production order are assigned to predetermined variable length buckets 1 to 3. Then, the bucket filling rates fi1 to fin are calculated for each variable-length bucket, and the bucket filling rate fi0 is calculated for each daily bucket.
[0056]
When the calculated bucket filling rates fi1 to fin of variable length buckets exceed 100%, each bucket of the cycle calendar is displayed in a solid display as shown in FIG. 5, and the bucket filling rate is 100% or less. In some cases, the width is indicated by hatching according to the filling rate.
On the other hand, the processing time for each manufacturing order of the daily unit bucket is accumulated for each process, and the operation rate for each process is calculated. The operation rate for each process is as shown in FIG. 11 when the horizontal axis represents time and the vertical axis represents the operation rate.
[0057]
In FIG. 11, in the third tandem cold mill 3TCM, the operation rate exceeds 100%, that is, the facility capacity on the 13th and 15th, and in the third continuous annealing furnace 3CAL, the facility capacity on the 12th, 14th and 16th. Is over. On the other hand, as shown in FIG. 12, in-process inventory amount, the third tandem cold mill 3TCM has a large in-process inventory amount on the 12th and 14th, and the third continuous annealing furnace 3CAL has an in-process inventory amount on the 13th. It is increasing.
[0058]
When the equipment capacity is exceeded, for example, there is no other cycle chance for high-tensile steel in the 3rd tandem cold mill 3TCM in the cycle calendar, and this high-tensile steel product is not properly placed. In the case of accumulating the standard lead time retroactively from the delivery date, due to the restriction of the cycle chance in the 3rd tandem cold mill 3TCM, the production order of high-strength steel concentrates on the cycle chance, and each process of each production order This means that the processing timings in the line are densely overlapped and partly overlapped. In such a case, as shown in FIG. 11, the third tandem cold mill 3TCM exceeds the facility capacity on the 13th.
[0059]
In this way, when the production of a certain facility for a certain production order is concentrated on a certain cycle opportunity, it may not be possible to adjust the process by simply performing a crushed process automatically. That is, one or more time bucket lengths in the cycle calendar are enlarged and reduced for fine adjustment. However, in relation to the same-position stacking process described later, the beginning or end of the variable-length time bucket is dragged with the mouse to expand or contract, and the impossible chance guidance is not displayed because one cycle chance of the downstream process is lost. While confirming, if it is displayed, it will be adjusted sequentially by increasing the cycle chance separately.
[0060]
At this time, the operator in charge adjusts the cycle chance based on the cycle calendar in FIG. 9, the facility capacity in FIG. 11, and the in-process inventory quantity in FIG. That is, in the operation rate verification diagram of FIG. 11, the third tandem cold mill 3TCM and the third continuous annealing furnace 3CAL have almost no production schedules on the 6th and 7th, and the in-process inventory increase trend is also shown in FIG. In addition, the third tandem cold mill 3TCM tends to increase from around 8th, and the 3rd continuous annealing furnace 3CAL tends to increase from around 10th, so the operator in charge of the 3rd tandem cold mill 3TCM is vacant on the 6th, It can be determined that it can be handled by setting a cycle chance for a high-strength steel product that originally did not have a cycle chance on the 7th. Similarly, the 3rd continuous annealing furnace 3CAL also has a cycle chance on the 12th and 13th. It is possible to determine that it is possible to move the cycle chance to 6 to 8 days and 10 and 11 days.
[0061]
Here, as shown in FIG. 13, new cycle chances HT1, HT2 and HT3 for high-tensile steel are formed on the first half of the 5th day, the second half of the 6th day, and the second half of the 7th day in the third tandem cold mill 3TCM. In addition, the non-assignment part of the cycle chance of the product D on the 9th shown in FIG. 5, the non-assignment part of the cycle chance of the product H in the second half of the day, and the non-assignment of the cycle chance of the products K and L in the second half of the 11th day. , The non-assigned part of the cycle chance of the product N and O on the 12th, the non-assigned part of the cycle chance of the product T of the 14th, and the non-assigned part of the cycle chance of the product V of the 15th.
[0062]
Further, in the third continuous annealing furnace 3CAL, as will be described below in comparison with FIG. 5 and FIG. 13, the allocation part of the cycle chances of the 409 series and the 430 series on the 12th and 13th is deleted, and instead, 5 The cycle chance is set in the second half of the day, and the cycle chance of a variety called BB on the 16th is changed to a cycle chance including high-tensile steel and the processing time is shortened.
[0063]
In this way, when the edit result of the cycle calendar is reflected in the cycle calendar, it is determined whether or not there is an appropriately unplaceable material that is not properly placed in the previous cycle calendar. If it does not exist, the reference time is calculated as it is. Further, as shown in FIG. 14, when a line L5 is set by accumulating standard lead times for a certain high-strength steel production order, the high tension in the third tandem cold mill 3TCM of the cycle calendar, for example, is set. If there is a material that cannot be properly placed when the production time zones of many high-strength steel production orders are concentrated there because there are few steel cycle chances, there will be a newly edited cycle chance. Judgment is made on whether or not materials that cannot be properly placed can be manufactured, and if they can be manufactured, the materials that cannot be properly placed are transferred to the cycle opportunity, and rescued as properly placed materials and then piled up and collapsed. Process.
[0064]
Here, when the cycle chance in the desired equipment is adjusted, if the same position as the stacking position before the change of the cycle chance can be secured for the downstream process, the start time is set as much as possible. It is desirable to carry out the same-position stacking process that performs the allocation. That is, as shown in the dashed line in FIG. 9, when the start time of the cycle chance C31 of the cold rolling (COLD) process is extended to the past side, the lead time is shifted to the downstream process with respect to that process. The start time is assigned with the shortest lead time as long as the corresponding cycle chance is not lost, and if the start time before the change of the cycle chance can be maintained for the downstream process, that is, if it is not subject to mountain break, start The time is maintained at the start time before the cycle chance change. On the other hand, as shown by the one-dot chain line in FIG. 9, expanding the cycle chance C32 of the cold rolling (COLD) process to the future side is the corresponding cycle of the continuous annealing (CAL) process on the downstream side. You will lose your chance. In this case, it is preferable to display guidance on the display for adjusting the cycle chance.
[0065]
By performing this same-position stacking process, it is necessary to review the start time for the process upstream of the equipment that adjusted the cycle chance, but the start time for the process downstream of the process that adjusted the cycle chance. This eliminates the need for reviewing and simplifies the mountain climbing process.
By performing the above-described editing process of the cycle calendar, as shown in FIG. 15, the equipment capacity excess of the third tandem cold mill 3TCM on the 13th day is resolved, and this amount is reduced to 5-7 days. As a result of the transfer, excess capacity will be reduced. Similarly, regarding the third continuous annealing furnace 3CAL, the excess of the facility capacity on the 14th is resolved, and this amount is transferred to the 5th to 11th. In addition, as shown in FIG. 16, the in-process inventory amount on the 12th of the third tandem cold mill 3TCM is reduced, and the in-process inventory amount in the third continuous annealing furnace 3CAL is also a large in-process inventory on the 13th. The quantity has been reduced and leveled (there are still days when the production capacity of the equipment has been exceeded, but it can be resolved by further adjustment).
[0066]
In this way, the cycle calendar is composed of daily buckets and the variable-length buckets that make up this daily bucket, so the production capacity of daily equipment is accurately verified with the bucket filling rate of the daily bucket. In addition, the manufacturing capacity of the equipment can be verified on a variable-length bucket basis according to the bucket filling rate of the variable-length bucket, and the manufacturing capacity of the equipment can be verified more precisely. In addition, since the bucket filling rate of variable-length buckets is displayed on the cycle calendar, it is possible to quickly and easily grasp the bottleneck process, suppress excess equipment manufacturing capacity, and level in-process inventory. It is possible to set an optimum cycle chance that can be made and to create an optimum production plan.
[0067]
In the embodiment described above, the present invention has been described for the case where a production plan is made for a steel product. However, the present invention is not limited to this and is applied to a production plan for other products other than steel products. You can also
In the above embodiment, the case where the bucket filling rate of the variable length bucket is displayed in color on the cycle calendar has been described. However, the present invention is not limited to this, and the bucket filling rate may be directly displayed as a numerical value. Good.
[0068]
【The invention's effect】
As described above, according to the invention according to claim 1, when creating a cycle calendar, a daily time bucket set for each manufacturing process is formed, and the daily time bucket is manufactured. Since a cycle representing a product group that can be manufactured with the same cycle chance can be set every time, and it is configured by a set of variable length time buckets that set a time zone that occupies the production equipment of the cycle chance, a variable length bucket It becomes possible to verify the production capacity of equipment on a unit basis, and a more accurate production plan can be created.
[0069]
Claims 1 According to the invention, when the variable-length time bucket has different cycle types in a certain manufacturing process, the time bucket length is set so that the time bucket changes as the time bucket boundary. Therefore, it is possible to form a time bucket in accordance with an actual product production plan, and to create a more accurate production plan.
[0070]
And claims 2 According to the invention according to the present invention, when creating a cycle calendar in which the production time of a product in each production facility is created, a daily time bucket set for each manufacturing process is set, and the daily time bucket is set. A cycle type representing a product group that can be manufactured with the same cycle chance for each manufacturing process, and configured with a set of variable-length time buckets that set a time zone that occupies the production equipment of the cycle chance, The variable-length time bucket has a time bucket length set so that when a different cycle type overlaps in a certain manufacturing process, the time bucket boundary is set as the time bucket boundary. Since the production capacity of the equipment is verified based on the variable-length time bucket, a more accurate production plan can be created.
[Brief description of the drawings]
FIG. 1 is a schematic configuration diagram showing an embodiment of the present invention.
FIG. 2 is an explanatory diagram showing a file configuration in a host computer.
FIG. 3 is an explanatory diagram showing a bucket configuration of a cycle calendar.
FIG. 4 is a flowchart illustrating an example of a cycle calendar creation processing procedure executed by the information processing terminal.
FIG. 5 is an explanatory diagram showing a cycle calendar.
FIG. 6 is a flowchart illustrating an example of a production plan process executed by the information processing terminal.
FIG. 7 is an explanatory diagram showing an example of a standard table used for production plan processing.
FIG. 8 is a diagram for explaining reference time setting processing;
FIG. 9 is a diagram for explaining a stacking process;
FIG. 10 is an explanatory diagram showing a procedure for forming a variable-length bucket in a cycle calendar.
FIG. 11 is an explanatory diagram showing daily facility capacity.
FIG. 12 is an explanatory diagram showing an in-process inventory amount in units of days.
FIG. 13 is a diagram showing a display state of the cycle calendar after editing.
FIG. 14 is a diagram for explaining a stacking process of improperly arranged materials.
FIG. 15 is an explanatory diagram showing the daily facility capacity after editing the cycle calendar.
FIG. 16 is an explanatory diagram showing an in-process inventory amount in daily units after editing the cycle calendar.
FIG. 17 is an explanatory diagram showing a conventional bucket configuration.
[Explanation of symbols]
1 Host computer
2 server
2A Production plan management system
3 Information processing terminal
3a Information processing terminal
3b display
3c keyboard
3d mouse
4 Local area network
11 Demand order registration file
12 Production Order Association File
13 Production order data registration file
14 In-process inventory information file
20a Data processing unit
20b Standard table
20c process table
20d cycle calendar file
20e Production plan file
20f display
21 Parts data definition file
22 Parts list definition file
23 Manufacturing process order list file
24 Equipment list definition file
25 Alternative equipment list definition file
26 Cycle process order setting definition file
27 Cycle equipment setting definition file

Claims (2)

In a production plan creation system for creating a production plan for sequentially producing products in a plurality of production facilities having a plurality of manufacturing processes, a cycle calendar for creating a cycle calendar in which the production time of the product in each production facility is set The cycle calendar creating means includes a daily time bucket set for each manufacturing process in units of days, and the daily time bucket is a product group that can be manufactured with the same cycle chance for each manufacturing process. Can be set, and is composed of a set of variable-length time buckets that set a time zone dedicated to the production equipment of the cycle chance, and the variable-length time bucket overlaps different cycle types in a certain manufacturing process. The time point when the overlap state changes is used as the time bucket boundary. Production planning system which is characterized in Rukoto bucket length is set. In a production plan creation method for creating a production plan in the case of sequentially producing products in a plurality of production facilities having a plurality of production processes, when creating a cycle calendar in which the production time of the product in each production facility is set A daily time bucket set for each manufacturing process is set, and the daily time bucket can set a cycle type representing a product group that can be manufactured with the same cycle chance for each manufacturing process. Of variable length time buckets that set a time zone that occupies the production equipment, and when the variable length time buckets overlap in a certain manufacturing process, the overlapping state changes. the time bucket length is set to be the boundary of the time bucket, the equipment on the basis of the variable length time buckets Production planning method which is characterized in that so as to verify the granulation capacity.

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