JP4941053B2 - Steel product production planning method and manufacturing method - Google Patents

Description

  The present invention relates to a production planning method for a steel bar product and a manufacturing method thereof.

For example, the following has been proposed as a conventional method for manufacturing a steel product (see, for example, Patent Document 1).
(A) First, the steel pieces are arranged in the rolling order so as to comply with the rolling restrictions. Next, a plurality of orders are linked to each steel piece.
(B) Make primary sawing plan, brush up with secondary and tertiary (change the order of sawing in steel pieces, change order between steel pieces).
(C) The tying / saw cutting order determination is repeated based on the following evaluation formula.
-Yield: Rolling yield, order digestion ratio-Production capacity: Number of sawing passes, number of cooling floor take-in rows, roller straightener short length concentration ratio, roller
Number of table transports, pile reduction rate, cart load, double material sampling interval, warehouse
Concentration ratio of products in a single warehouse ・ Labor productivity: Pallet loading cycle, Pile reduction rate

JP 2000-71119 A

  The conventional production planning method associates an order group after determining a billet and a rolling order in advance, and is excellent in feasibility. However, if there is a variation in the size and number of orders to be manufactured, it is very difficult to eliminate the generation of surplus parts in the process of assigning multiple orders to a billet of a predetermined length. It can be said that it is a method that incorporates the risk of decline.

  The present invention solves the above-mentioned problems, and provides a production plan method for a bar product and a production method thereof capable of simultaneously improving the production plan, yield, and other evaluation indexes satisfying the production constraints. With the goal.

The production plan method for steel products according to the present invention reads out a plurality of orders with different dimensions stored in a storage device and puts them on a billet, and designs a combination of a plurality of billets necessary for all orders. A steel slab design process to be stored in a storage device, and a production plan creation process to create a manufacturing plan for a plurality of steel slabs designed in the steel slab design process and stored in the storage device. In the method, when the billet design process designs the order group returned from the production plan creation process, the assembling length of the order group, the number of billets that can be collected in the same pattern of assembling the billet, and the steel a use-up orders in assortment of pieces and the evaluation index, while the assortment of steel pieces of the evaluation index is higher pattern and adoption candidates, with reference to the billet length type upper, billet number does not increase As a series of work, the design of the steel slab is performed by resetting a value smaller than the initial steel slab length upper limit so that the surplus weight becomes smaller, and the above work is repeated a plurality of times until all orders are taken out. Repeat and adopt the result as the solution.

In the production plan method for steel products according to the present invention, the manufacturing plan creation step is caused by aggregation when the lengths of the plurality of billets designed in the billet design step are aggregated to the billet length type upper limit or less. To determine whether or not the surplus weight is within a predetermined value, and for the order group that constitutes the non-adopted steel slab group, as a series of operations, the above-mentioned work is carried out as a series of operations. Is repeated several times until all orders are taken out, and the result is adopted as a solution.

  Moreover, the manufacturing method of the steel bar product which concerns on this invention manufactures a several steel piece based on the manufacturing plan of the steel piece employ | adopted by said production plan method of a steel bar product.

  According to the present invention, since the orders are sequentially arranged so as to guarantee the upper limit of the length of the billet, it is possible to create a manufacturable production plan that satisfies the production constraints. Since the design is made so that the surplus weight is kept within a predetermined value without increasing the number of steel pieces, the yield and other evaluation indexes can be improved at the same time.

  FIG. 1 is a system configuration diagram for carrying out the first embodiment of the present invention. This system includes a billet design and production instruction computer (hereinafter referred to as a computer) 10, a database 11, a terminal 12, and a production facility 13. Various kinds of order information from the terminal 12 are input to the computer 11 and temporarily stored in the database 11. The database 11 includes an order file 21, a billet assembling file 22, and a billet production plan file 23 (see FIG. 2). The order file 21 stores various kinds of order information from the terminal 12.

FIG. 2 is a flowchart showing the process of the system shown in FIG.
(A) First, design conditions and facility operation conditions are input / referenced / changed at the terminal 12 and stored in the order file 21. The computer 10 reads the information of the order file 21, determines the billet assembling based on the flowchart of FIG. 3 to be described later while referring to the design condition and the equipment operation condition, and stores it in the billet assembling file 22 ( Billet design process).
(B) Next, the computer 10 creates a manufacturing plan based on the flowchart of FIG. 4 described later based on the information of the steel piece assembling file 22, and stores it in the steel piece manufacturing plan file 23 (manufacturing plan). Creation process).
(C) The computer 10 supplies the manufacturing plan information stored in the billet manufacturing plan file 23 to the manufacturing equipment 13, and the manufacturing equipment 13 operates the equipment based on the manufacturing plan information, and the steel is produced according to the production plan. Manufacture pieces.

Table 1 shows an example of an order group stored in the order file 21 (here, a simple case is shown for convenience of explanation). In the present embodiment, six types of order groups are set, and the total length is 613 m. In this embodiment, when the steel bill assembling length is set to, for example, Max 70 m, an order group with a total length of 613 m is created with a maximum billet length of 70 m,
613m ÷ 70m = 8.8 (book)
It can be seen that it can be manufactured with a minimum of 9 steel pieces.

  Table 2 is an example of the refinement processing group classification. In this example, classification is made into three types of A (small), B (medium), and C (large) according to the order length. Here, the finishing equipment refers to a piling device. The piling apparatus creates a transport lot (pile) by stacking a plurality of products of the same length received one by one from the upstream. A transport lot is a unit that can be handled in a lump with a crane or the like, and it is desirable to reduce the number in order to improve workability.

  Table 3 shows an example of the billet length constraint. In this example, a maximum of two types of constraints are provided.

  FIG. 3 is a flowchart showing details of the above-described billet design process, and the computer 10 performs various arithmetic processes according to the flowchart.

(S11) The order data (see Table 1) is fetched from the order file 21.
(S12) The order data (see Table 1) is classified according to the groups (A to C) in Table 2. That is, the group to which each order belongs is classified.
(S13) An assembling pattern for the order data classified as described above is created.
(S14) The assembling length range is read from the order file 21. In this example, the assembling length range is set to 70 m as described above.
(S15) Next, the following processing is performed to create the first pattern. A combination of all orders of the group (A to C) is tried. In other words, orders are appropriately extracted from each group and combined. In that case, the number from each group includes 0, 1 or 2 or more. Then, an evaluation index is calculated for the combination.

Here, the evaluation index is based on the following (1) to (3).
(1) Assortment length The closer to the MAX assembling length, the better. In the billet design problem, there is a restriction that the entire order group can be taken out. Therefore, it is highly possible that the billet number can be reduced as the assembling length increases. Since a rounded part is always generated for each steel slab and the yield decreases, the number of steel slabs and the yield are inversely proportional.
(2) Number of pieces of steel that can be collected in the same pattern. When combined with the above (1), it is convenient in terms of yield and the number of types of steel slabs in that many steel slabs can be designed as long as possible. Although the number of types of billet length will be described later, it is a limitation when casting a billet in the upstream process of strip production, and it is better to have a smaller number of types, so it matches this evaluation index.
(3) Use up of orders It is desirable to use up the contained orders by adopting this pattern. If the order cannot be used up, there is a restriction that it can be used continuously when creating the next pattern.

(S16) The evaluation indexes are sorted in descending order of the evaluation indexes. Specifically, first, sorting is performed according to the “(1) assembling length”, and then the sorted one is sorted according to the “(2) number of steel pieces that can be collected in the same pattern”. Finally, the sorted items are sorted in three stages, ie, sorted according to the above-mentioned “(3) Order use up”. Of course, the sorting method is not limited to the above-mentioned example, and it goes without saying that it can be appropriately changed as necessary. For example, the above (1) to (3) are assigned evaluation points. You may make it sort by it. Table 4 shows the result of sorting as described above. In Table 4, the top eight of the sorted combinations are shown. Table 4 shows a state after sorting the results of the total length of 70 m on the basis of the above three evaluation indexes, and adopts a pattern having the maximum number of steel pieces that can be collected in the same pattern.

(S17) A plurality of patterns in Table 4 are stored in the steel piece assembling file 22. In this example, for example, an example of the top three combinations is stored. These three patterns are respectively adopted as the first pattern (first type) as described later.
(S18) The top one in Table 4 is extracted and determined as the first pattern (first type). Here, 21 × 2 × 3 (= 6) and 15 × 4 × 3 (12) are used. FIG. 5A shows a state in which the first pattern thus formed is employed.
(S19) When the top one in the above Table 4 is extracted as the first pattern, as shown in “Remaining” in FIG. 5B, the remaining order is 8-6 = 2 in 21m. , 18m is 5, 14.5m is 6, 13m is 7, 9m is 8, and 7m is 15-12 = 3. Based on the remaining order data, it is determined whether or not there is an in-group continuous order after the second pattern. In this example, since there is an in-group continuation order (see “continuation” in FIG. 5B), it is determined that there is an in-group continuation order.

(S20) Then, all combinations of continuous orders within the group are tried.
(S21) If it is determined that there is no in-group continuous order, all combinations of all remaining orders in the group and other group continuous orders are tried.
(S22) Next, it is determined whether or not there is an order cancellation and an in-group remaining order for the tried combination, and if the determination is YES, the process proceeds to processing (S23), and if NO, The process proceeds to processing (S25).
(S23) The following one type is added from the group and the arrangement is tried (see FIG. 5C).
(S24) It is determined whether or not the combination is within the assembling length range. If it is not within the assembling length range, the process returns to the above-described process (S23) and the process is repeated.
(S25) When it is determined in the above determination (S24) that it is the assembling length range and when it is determined NO in the above determination (S22), the result of the combination so far is used as the above evaluation index. Sort in descending order. FIG. 5D shows what is sorted in this way.

(S26) Of the sorted combinations, the highest one is stored in the steel piece assembling file 22 as a solution candidate. As a result, a combination of, for example, the second pattern (second type) in Table 5 described later is determined.
(S27) Next, it is determined whether there is a remaining order.
(S28) If the remaining order still remains, the remaining order number is updated. The remaining order number at this time is as shown in FIG. Thereafter, similarly to the above example, the processes (S18) to (S28) are repeated, and when there is no remaining order, the process proceeds to the process (S29).
(S29) Here, it is determined whether or not the above processing (S19) is processing from (1) in FIG. 4, and if it is not processing from (1) in FIG. 4, processing in FIG. The process proceeds to (S31).

  Table 5 is an example of assortment generated by the process up to the above process (S27), and this is stored in the steel piece assembling file 22. In this example, there are four types of steel slab length (70 m, 69 m, 68, 5 m, 58 m). Table 5 shows the result of designing the first pattern (first type) as the topmost pattern in Table 4 above, and designing the second pattern (second type) and thereafter from that as the starting point (Table 5 will be described later). (The result is sorted by the process (S30b).) The processing after the second pattern (second type) in Table 5 employs the top one after sorting the pattern candidates in descending order of the evaluation index (S26), and as described above, for each length group It is executed under the restriction that the design of another billet is started for the first time after all orders that have been designed from the previous pattern are used. For this reason, for example, in the second pattern (second type) design, the total length is 70 m. There is an effect that the design does not exist. As a result, the maximum total length of the second pattern is 69 m.

FIG. 4 is a flowchart showing details of the billet production planning process.
(S31) The above billet design result data is input. That is, the data of the steel piece assembling file 22 (in the above example, the data shown in Table 5) is fetched.
(S32) The number of types of billets in the billet design result data is calculated. In this example, there are four types (70 m, 69 m, 68.5 m, 58 m) as described above.
(S33) The number of types of steel slabs and the upper limit of the number of types (2 in this example) are compared to determine whether the number of types of steel slabs> the upper limit of the number of types. In this example (four types), there are more than two types as described above.
(S33a) If it is determined that the number of types of billets is smaller than the upper limit of the number of types (for example, two types), the billet design result data at that time is stored in the billet production plan file 23.

(S34) When the number of steel slab types> the upper limit of the number of types, the second to the last steel slab are read one by one. Here, the second pattern is read first.
(S35) Then, it is determined whether or not the condition of steel slab length ≧ steel slab maximum length−threshold is satisfied. In this example, the threshold is set to 1 m, for example.
(S36) If the above condition is satisfied, the pattern length is set to the previous pattern length. For example, in this example, 69 m is set to 70 m. This rounds the length of the steel piece. That is, in the case of a deviation within a threshold with respect to the maximum billet length, a process for reducing the billet length type is performed by allowing a surplus (surplus length). In the example in Table 5, the length of the second and fourth steel pieces 69m is set to 70m, and a total length of 2m is generated for each 1m. However, all the steel pieces up to the fourth kind are unified to the maximum length of 70m. The

(S37) When the condition is not satisfied in the above process (S35), or after the above process (S36), it is determined whether or not the above process is finished up to the final billet, and the final billet is not reached The process returns to the above process (S35), and the processes (S35) to (S37) are repeated.
(S38) After the above processing, the number of types of billets is recalculated. In this example, since 69 m was rounded to 70 m, the number of types of steel slabs was reduced to 3 (70 m, 68.5 m, 58 m).
(S38a) Next, the number of types of steel slabs and the upper limit of the number of types (2 in this example) are compared to determine whether the number of types of steel slabs> the upper limit of the number of types. In this example, since 69 m is rounded to 70 m, the number of types of steel slab is reduced to 3, but since the number of types is still exceeding the upper limit (2), the process proceeds to the next process (S39). When it is determined that the number of types of billets is smaller than the upper limit of the number of types, the billet design result data at that time is stored (S33a).

(S39) Here, in order to further reduce the number of types of billets, the type of billets N (for example, two pieces) is not adopted retroactively from the final pattern (this portion will be redone). Specifically, a total of three of the sixth type 58m × 1 and the fifth type 68.5m × 2 are not adopted. Six pieces of steel were adopted.
(S40) The remaining number of orders whose combination is not determined by (S39) is updated. In this example, the remaining number after combining up to the fourth pattern in Table 5 is the number of remaining orders. In this example, as shown in Table 6, 18 m × 2, 14.5 m × 6, 9 m × 8 are the remaining orders. Redesign is performed for the rejected order group.

(S41) The slab length allocatable number that can be further adopted is obtained from the number of steel slab length allocatable numbers = the upper limit of the number of types—the number of adopted steel slab lengths. In this example, since the upper limit of the number of types = 2 and the number of employed steel slab lengths = 1, the number of steel slab lengths that can be allocated = 1.
(S42) Next, it is determined whether the number of billet length allocatable is one. In this example, the steel piece length allocatable number is 1, and the process proceeds to the next process (S43).
(S43) Here, a new steel piece maximum length is obtained. The total length of the rejected orders is 195 m, the number of billet length allocatable is 1, and the remaining one type of billet length is set. The maximum billet length is
Maximum length of steel slab = {Remaining order length ÷ (Minimum required number of slabs-Number of slabs adopted)}
= {195m ÷ (9-6)} = 65m
Ask for. If all the remaining steel slabs can be designed with 65 m, this means that it is not necessary to increase the number of steel slabs.

(S44) In the above processing (S42), when it is determined that the number of billet length allocatable is not 1,
Order remaining length ÷ (Adopted steel slab length-renewal length)> (Minimum required number of slabs-Adopted steel slabs)
Whether or not is satisfied is determined. The update length is set to 2 m or 3 m, for example, and means that the steel piece length to be adopted is cut down. For example, if the update length is set to 3 m, the adopted steel piece length is 70 m. This means that the steel piece length to be adopted in the future will be 67 m. If the above condition is not satisfied, the process proceeds to the process (S45). If the above condition is satisfied, the process proceeds to the process (S46) on the assumption that there is room for further examination.

(S45) Here, the minimum length of the adopted steel slab is applied to the remaining steel slab, and the result is stored (S33a).
(S46) Further, the maximum length of steel slab is set as adopted steel slab length−updated length, and in the subsequent processing, the maximum length of steel slab is set shorter than the conventional length.
(S47) The slab design for the remaining number of orders is continued. When continuing, the process returns to the process (S19) of FIG. 3 and the processes (S19) to (S28) are repeated. Note that the determination whether or not there is an in-group continuation order after the next pattern of the process (S19) is for a pattern that has been rejected, and in this example, is there an in-group continuation order after the fifth pattern? Judge whether or not. In the process (S29), since it is determined that the process starts from the above (1), the process proceeds to the process (S30).

Next, the description returns to the flowchart of FIG.
(S30) Here, it is determined whether or not a predetermined number of designs have been completed, and if not completed, the process proceeds to processing (30a). In addition, this process (S30) transfers not only from a process (S29) but from the process (S33a) of FIG. 4 similarly. In the description so far, the topmost pattern in Table 4 is adopted as the first pattern, and the combination of steel slabs after the second pattern has been designed based on that pattern, but here it is finished, Next, the 2nd pattern of Table 4 is employ | adopted as a 1st pattern, and in order to design the combination of the steel slab after the 2nd pattern which is the next pattern, it transfers to a process (S30a).
(S30a) In order to design the next new combination pattern, the remaining number of orders is initialized, the process proceeds to the above process (S18), and the same process is repeated. The above process is repeated three times in this example.
(30b) The above design results are sorted in descending order of evaluation index.
(30c) The best solution is saved in the billet production plan file 23 based on the sorted result, and the process is terminated.

  Table 7 below shows examples of combination patterns designed as described above. In this example, the top combination in Table 4 is adopted as the first pattern (first type). In the present embodiment, three such tables are created. In addition, since the 5th type and the 6th type of Table 7 could be designed with a steel piece length of 65 m, the result of satisfying the steel piece length upper limit of 2 types was obtained while maintaining the extra length of 2 m generated by the rounding.

  Table 8 shows the result of simple rounding of the steel pieces to explain the effect of the present embodiment. If the length of the second steel piece is set to 68.5 m, the final surplus length will be 12.5 m.

As described above, according to the present embodiment, it is possible to create a manufacturable production plan that guarantees the upper limit of the billet length type while satisfying the refinement processing group constraint, and the surplus weight is within a predetermined value without increasing the number of billets. Therefore, the yield and other evaluation indexes can be improved at the same time.
In addition, although the above specific example showed a small assembling example for easy understanding of the explanation, when the upper limit of the number of types of billets is large, the billet design is repeated while reducing the billet maximum length by the updated length. , You will be searching for the best results. When the steel piece length upper limit is reached such that the number of steel pieces increases, the search process is terminated, and the best result so far can be adopted. Then, the adopted production plan can be stored and reflected in the production order output to the production facility.

It is a system block diagram for enforcing the production method of the steel bar product concerning Embodiment 1 of the present invention. It is the flowchart which showed the outline | summary of the production method of the steel bar product concerning Embodiment 1 of this invention. It is the flowchart which showed the detail of the steel piece design process of FIG. It is the flowchart which showed the detail of the billet production plan preparation process of FIG. It is explanatory drawing of the process of FIG.

Explanation of symbols

  10 computers, 11 databases, 12 terminals, 13 manufacturing equipment, 21 order file, 22 billet assembling file, 23 billet manufacturing plan file.

Claims (3)

A billet design process in which a plurality of orders with different dimensions stored in a storage device are read out and assembled on a billet, a combination of billets required for all orders is designed and stored in the storage device,
In the production plan method of the steel bar product, which is designed in the billet design step and has a production plan creation step of creating a production plan of a plurality of billets stored in the storage device,
The billet design process includes:
When designing the order group returned from the manufacturing plan creation process , the evaluation index is the assembling length of the order group, the number of bills that can be collected in the same pattern of the billet assembling, and the order use up in the billet assembling. The combination of steel slabs with a pattern with a high evaluation index is adopted as a candidate for adoption, and the upper limit of the initial steel slab length is set so that the excess weight is reduced within a range in which the number of steel slabs does not increase with reference to the upper limit of the type of steel slab It is a series of work to design a billet by resetting a smaller value, repeat the work several times until all orders are taken, and adopt the result as a solution Product production planning method. The production plan creation process includes:
When integrating the length of a plurality of steel slabs designed in the steel slab design process below the upper limit of the steel slab length type, it is determined whether the surplus weight generated by the aggregation is within a predetermined value, and is not adopted. As for the order group constituting the billet group, the reversal to the billet design process is a series of work, and the work is repeated several times until all orders are removed, and the result is taken as a solution. The method for planning production of a long bar product according to claim 1, which is adopted.   A method for manufacturing a steel bar product, comprising manufacturing a plurality of steel slabs based on a steel slab manufacturing plan adopted by the method for manufacturing a steel bar product according to claim 1 or 2.

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