JP5234813B2 - Production plan creation apparatus and method - Google Patents

Description

  The present invention relates to a production plan creation apparatus and a production plan creation method for creating a production plan in consideration of setup change.

  Typically, manufacturing companies plan production plans (production schedules, schedules) to maximize productivity of production equipment, comply with delivery dates of orders, minimize inventory (in-process), and minimize costs. I'm working hard. In addition, sudden events such as sudden breakdowns of production facilities and unexpected orders occur, which necessitates a review of the production plan. In the past, such production plans have been relied on by hand based on empirical intuition, but in recent years, methods and apparatus for producing production plans using computers have been researched and developed, and various proposals have been made. It has been done. As a technique related to such a production plan, for example, Patent Document 1 can be cited.

  The manufacturing process management device disclosed in Patent Document 1 includes a process order table in which necessary processes for each product type and an execution order thereof are registered, and an interlock condition table for determining an execution condition of each process. It operates according to the production schedule, determines the next execution process according to the process sequence table, checks the execution condition of each process using the interlock condition table, and activates the corresponding process. According to this configuration, it is described in the paragraph [0041] that the process of changing the logic of the program relating to the addition of the product type and the change of the process interlock is not necessary and the interlock condition can be accurately set.

  On the other hand, there are products (including semi-finished products) having a predetermined composition (components and their ratios, component compositions, specifications) in which a plurality of components are mixed, such as alloys such as aluminum alloys and copper alloys. . In order to produce an alloy having a predetermined composition, such a product is produced by putting a main component pure material such as pure aluminum or pure copper and a small amount of additive material such as other elements into a melting furnace. And when products of the same kind (same composition) are manufactured in the same melting furnace, it is not so necessary, but when products of different kinds (different compositions) are manufactured in the same melting furnace, When switching from the production of a product of a variety (single treatment or charge) to the production of a product of the next different variety, due to the difference in composition in each variety, There is a case where a process of changing the setup, which is a preparation work for switching to manufacturing, is required. That is, in the melting furnace, the manufacture (melting) of a certain kind of product is completed, and the hot water (melted metal (including alloy)) in the melting furnace is dispensed to manufacture the next different kind of product. However, due to the structure of the melting furnace, a certain amount of hot water usually remains in the melting furnace as a residue. Therefore, when a product of the next product type is manufactured as it is, this residue affects the component composition of the next product, so that the next product does not have a predetermined composition. For this reason, when products of different varieties are continuously melted in one melting furnace, a setup change process is required depending on the combination of the varieties before and after that. For example, in the case of this melting furnace, a process of diluting the residue is performed by putting a pure metal material such as aluminum or copper into the melting furnace, for example. When the production facility is a batch facility that processes charges, it is called buffer charge. Therefore, when making a production plan, it is necessary to make a production plan that takes this setup change into consideration. In this way, when products of different varieties are manufactured in one production facility, if the result of manufacturing the product of the previous varieties affects the manufacture of products of the subsequent varieties, A setup change process (preparation work) is required for proper production.

  When planning a production plan that takes this setup change into account, in a conventional production plan creation apparatus (schedule creation apparatus), the setup change generation condition is defined as a setup change master and stored in advance. In the setup change master, the presence / absence of setup change and the time required for setup change are registered for the combination of the preceding and succeeding types. As a result, in the process of planning a production plan, the presence or absence of setup change is determined by referring to the previous and subsequent processes, and when setup change is necessary, the required time is obtained, and the planning of the production plan considering setup change is made. It becomes possible. For example, in a production plan creation device that manufactures an alloy such as an aluminum alloy or a copper alloy in a melting furnace, the presence or absence of furnace washing (buffer charge) for the types of preceding and following alloys is registered in a table format in the setup change master, The time required for the setup change is registered.

  As a scheduling method considering such a setup change, for example, Patent Document 2 can be cited. In the scheduling method in consideration of the setup change disclosed in Patent Document 2, a step of planning a product production schedule in the production facility according to time series, and whether the setup change in the production facility is necessary based on the production schedule. A step for determining whether or not a setup change is necessary, a judgment step for determining whether or not an external setup is possible, a setup change in a production facility is necessary, and A scheduling method that takes into account setup changes, including the steps of formulating a schedule for setup operations when the external setup can be executed, and the step of formulating a production schedule for products based on the schedule of the planned setup operations It is. Then, according to the description of the paragraph [0020], in the step of determining whether or not the setup change is necessary, the determination is performed based on information stored in advance in the equipment management computer 600 (S120). In addition, according to the description of the paragraph [0027], in the step of planning the setup work, the scheduling target time is traced back to the start of work of the same kind of the previous process (S140), and the necessary resources ( Scheduling is performed only for the set-up work for the product B in consideration of the tool, personnel, materials, etc.) and conditions (S140). With such a configuration, in the scheduling method considering the setup change disclosed in Patent Document 2, preparation for setup change is scheduled in the form of external setup. That is, as shown in FIG. 4 of Patent Document 2, preparation for setup change is scheduled in the form of external setup so that setup work for product B is performed outside while product A is being produced. .

JP 2000-099109 A JP 2005-031794 A

  In a conventional production plan creation device, when planning a production plan in consideration of setup change, it is necessary to store setup change conditions in advance for the combination of the preceding and succeeding types as described above.

  For this reason, first of all, when there are many varieties, the number of combinations increases exponentially. As a result, when the operating conditions for manufacturing products at the production facility are changed, the condition of the setup change is changed each time. It takes a lot of time to correct. Second, each time a new product type is added, it becomes necessary to correct the condition of the setup change, which takes time. In particular, it becomes a serious problem when the addition of varieties frequently occurs. Thirdly, it becomes necessary to manually maintain the setup change conditions, and at that time, the setup change conditions may be erroneously registered in the setup change master.

  In the technique disclosed in Patent Document 1, setup change is not considered, and if setup change is considered, setup change is registered in the process order table in advance, and the above-described inconvenience occurs. In the technique disclosed in Patent Document 2, referring to the description of the paragraphs [0020] and [0027], information for that is also stored in advance in order to perform scheduling considering the setup change. This is necessary and causes the above-mentioned disadvantages. Further, in Patent Document 2, preparation for setup change is scheduled in the form of external setup.

  The present invention has been made in view of the above circumstances, and its purpose is to consider setup change even when the number of varieties is large, when varieties are added, or when maintenance is performed manually. It is to provide a production plan creation device and a production plan creation method capable of executing the production plan created by a relatively simple process.

As a result of various studies, the present inventor has found that the above object is achieved by the present invention described below. That is, in one aspect according to the present invention, in the production plan creation device for creating a production plan for a plurality of operations for manufacturing a plurality of products for one production facility, the plurality of products have a composition. Including at least products of different varieties due to different, the plurality of operations are given a processing order in advance, and between one operation in the plurality of operations and another operation following the operation, Based on the composition of the residue remaining in the production facility after the completion of one operation and the composition of the product manufactured by the other operation, the residue is formed with the main component of the product manufactured by the other operation. A determination unit that determines whether or not a setup change process for dilution is necessary; and when the setup change process is required by the determination unit, a transition is made between the one operation and the other operation. By placing the setup change process of performing the setup change process characterized by comprising a creation unit for creating a production plan for the plurality of work.

  In the production plan creation device having such a configuration, the composition of the residue remaining in the production facility after the completion of one work and the other work between one work in a plurality of work and the other work following it. Based on the composition of the product to be manufactured, it is determined whether a changeover process for diluting the residue with the main component of the product manufactured in another operation is necessary, and the changeover process is required. If it is determined, a production plan for a plurality of operations is created by inserting a setup change process between one operation and another operation. For this reason, the production plan creation apparatus having such a configuration does not need to memorize the setup change conditions in advance for the combination of preceding and succeeding types, so that even when the number of types is large, additional types are added. Whether or not maintenance is performed manually, it is possible to create a production plan in consideration of setup change by a relatively simple process.

  Further, in the above-described production plan creation device, the dilution amount in the setup change process is a fixed amount set in advance, and when the setup change process is necessary by the determination unit, it is manufactured in the other operation. A diluted composition calculator that obtains the composition of the diluted residue obtained by diluting the residue by a certain amount with a main component of the product to be obtained, and the determination unit uses the diluted residue as the residue, Until it is determined that the setup change process is not necessary, it is determined whether or not the setup change process is necessary, and the creation unit determines that the setup change process is necessary by the determination unit. It is characterized in that a production plan for the plurality of operations is created by inserting a setup change process according to the number of times between the one operation and the other operation.

  According to this configuration, it is possible to determine the number of dilutions according to the number of determinations, and it is possible to create a production plan in the setup change process according to the number of determinations. Then, by obtaining the minimum necessary number of dilutions according to the number of judgments, it becomes possible to create a production plan in the setup change process with the minimum necessary number of dilutions, and a more appropriate production plan is created.

  In the above production plan creation device, the dilution time obtained by multiplying the time required for one dilution set in advance by the number of determinations determined by the determination unit that the setup change processing is necessary A setup change time calculation unit for obtaining setup change processing time including the changeover processing time of the setup change processing time obtained by the setup change time calculation unit, the creation unit A production plan for the plurality of operations is created by putting it between the operations.

  According to this configuration, it is possible to obtain the setup change processing time corresponding to the number of dilutions, and it is possible to create a production plan in the setup change processing step of this setup change processing time.

  Further, in the above-described production plan creation devices, the setup change time calculation unit is a component that needs to be added to the diluted residue after being diluted by the number of times determined that the setup change process is necessary. The component addition time required to add this component is calculated, and the creation unit calculates the time obtained by adding the dilution time calculated by the setup change time calculation unit and the component addition time. As the setup change processing time, a production plan is created for the plurality of operations.

  According to this configuration, it is possible to obtain not only the time required for dilution but also the time for adding components, and a production plan can be created by the setup change process of the setup change processing time including these.

  In the above-described production plan creation device, the component master storage unit that stores the composition of the product in advance, the processing amount to be processed in one operation in the production facility, and the amount remaining after the end of one operation And a facility master storage unit for preliminarily storing a residual amount that is also an amount remaining after the completion of one dilution, a processing time required for one work process, and a dilution time required for one dilution. It is characterized by providing.

  According to this configuration, the composition of the varieties is stored in advance in the component master storage unit, and the processing amount (unit processing amount) processed in one operation in the production facility is the amount remaining after the end of one operation. Residual amount (unit residual amount), which is also the amount remaining after the end of one dilution, processing time (unit processing time) required for one work process, and dilution time (unit dilution) required for one dilution Time) is stored in advance in the equipment master storage unit. Therefore, it is not necessary to input each data to the production plan creation device in advance, and it is not necessary to input each data to the production plan creation device every time a production plan is created. Can be executed with simpler processing. Further, even when a product type is added, it is possible to automatically reflect the composition of the additional product type in the creation of the production plan only by additionally registering it in the component master storage unit.

  Further, in the above-described production plan creation device, the composition of the residue after dilution is obtained by diluting the residue by adding the main component of the product manufactured in the other operation by an amount corresponding to the capacity of the production facility. A dilution composition calculation unit to be obtained, wherein the determination unit calculates the dilution obtained by dividing the concentration of the component contained in the diluted residue by the concentration of the component contained in the product manufactured in the other operation. Calculate all the components contained in the post-residue, and determine that the setup change process is necessary when the dilutions of each component exceed a preset specified dilution. It is characterized by that.

  According to this configuration, it is possible to determine whether or not the setup change process is necessary based on whether or not the dilution of each component contained in the residue after dilution exceeds a preset specified dilution. Here, the residue is diluted by adding the main component in an amount corresponding to the capacity of the production equipment, and this diluted residue is used as a reference when moving to another operation after the end of one operation. In this case, the main component of the product manufactured in the other work is always charged to the extent that the capacity of the production facility is satisfied, so whether further dilution is necessary based on the residue after dilution after charging. This is because it is necessary to determine whether or not. The dilution obtained by dividing the concentration of each component contained in the residue after dilution by the concentration (target concentration) of the component contained in a product manufactured in another operation exceeds a preset specified dilution. Sometimes it can be determined that a setup change process is necessary. The specified dilution is set to “1” assuming that no tolerance is set for the dilution, but a predetermined tolerance is set for the normal dilution (concentration of each component). Therefore, there may be a value other than 1. The specified dilution can be set in common for each component, but can also be set individually for each component.

  In the above-described production plan creation apparatuses, the production plan creation device further includes a setup change time calculation unit that calculates a setup change processing time required for the setup change processing based on the dilution of each component, and the creation unit includes the setup change time. A production plan for the plurality of operations is created by inserting a setup change processing step of the setup change processing time obtained by the calculation unit between the one operation and the other operation. .

  According to this configuration, it becomes possible to obtain the setup change processing time, and a production plan can be created in the setup change processing step of this setup change processing time.

  In the above-described production plan creation devices, the setup change time calculation unit calculates a dilution time required for a dilution process for setting the largest maximum dilution among the dilutions of each component to the specified dilution. It is characterized by including a calculation part.

  According to this configuration, by calculating the dilution time for setting the maximum dilution to the specified dilution, it is possible to specify the time for making the dilution of all the components equal to or less than the specified dilution. This is because if the highest dilution among the dilutions of each component is diluted to the specified dilution, the dilutions of the other components are inevitably diluted below the specified dilution. Therefore, according to this configuration, it is possible to calculate the time for making the dilution of all the components equal to or less than the specified dilution as the setup change processing time. “Making the maximum dilution to the specified dilution” includes, when a predetermined tolerance range is set for the specified dilution, including the maximum dilution within the tolerance range. The purpose.

  In the above-described production plan creation devices, the setup change time calculation unit is a component required for the process of adding a component whose dilution is less than the specified dilution when the maximum dilution is diluted to the specified dilution. It further includes a component addition time calculation unit for calculating an additional time, and the creation unit sets a time obtained by adding the dilution time calculated by the setup change time calculation unit and the component addition time as the setup change processing time. A production plan is created for the plurality of operations.

  According to this configuration, it is possible to calculate the setup change processing time taking into account the component addition time required for the additional processing of the component required when shifting from one work to another work, so a more accurate production plan can be created can do.

  In these production plan preparation devices, the component master storage unit that stores the composition of the product in advance, the processing amount processed in one operation in the production facility, and the amount remaining after the end of one operation. And an equipment master storage unit for preliminarily storing a residual amount that is also an amount remaining after the end of one dilution and a processing time required for one work process.

  According to this configuration, the data stored in the storage unit is simply given to the production plan creation device in advance, and it is not necessary to input each data to the production plan creation device every time the production plan is created. It becomes possible to create a production plan considering replacement with a simpler process. Even when a product type is added, it is possible to automatically reflect the composition of the additional product type in the creation of the production plan only by additionally registering it in the component master storage unit.

  Further, in the above-described production plan creation device, the apparatus further includes a processing order storage unit that stores a processing order in a plurality of operations, and the processing order in the plurality of operations is stored in the processing order storage unit in advance. A processing order in a plurality of operations is given in advance.

  According to this configuration, the processing order in a plurality of operations is stored in advance in the processing order storage unit. For this reason, it is not necessary to input the processing sequence to the production plan creation device every time a production plan is created, and it is possible to reduce labor, and it is easier to create a production plan that takes into account setup changes. Can be executed.

And in another aspect of the present invention, in the production plan creation method for creating a production plan for a plurality of operations for producing a plurality of products for one production facility, the plurality of products are: The product includes at least products having different varieties due to different compositions, and the plurality of operations are given a processing order in advance, and between one operation in the plurality of operations and another operation following the operation, Based on the composition of the residue remaining in the production facility after the end of the one operation and the composition of the product manufactured by the other operation, the residue is a main component of the product manufactured by the other operation. A determination step for determining whether or not a setup change process for diluting is necessary, and when the setup change process is required in the determination step, the one operation and the other operation By the put setup change processing step of performing a setup change process between, characterized by comprising a generating step of generating a production plan for the plurality of work.

  In the production plan creation method having such a configuration, the composition of the residue remaining in the production facility after the completion of one work and the other work between one work in a plurality of work and the other work following the work. Based on the composition of the product to be manufactured, it is determined whether a changeover process for diluting the residue with the main component of the product manufactured in another operation is necessary, and the changeover process is required. If it is determined, a production plan for a plurality of operations is created by inserting a setup change process between one operation and another operation. For this reason, the production plan creation method having such a configuration does not need to store the condition of the setup change in advance for the combination of preceding and succeeding varieties. Whether or not maintenance is performed manually, it is possible to create a production plan in consideration of setup change by a relatively simple process.

  The production plan creation device and the production plan creation method according to the present invention can create a production plan that takes into account setup changes even when the number of types is large, when types are added, or when maintenance is performed manually. It is possible to execute with relatively simple processing.

It is a block diagram which shows the structure of the production plan preparation apparatus in embodiment. It is a figure which shows the structure of the component master table in the production plan preparation apparatus of embodiment. It is a figure which shows the structure of the equipment master table in the production plan preparation apparatus of embodiment. It is a flowchart which shows operation | movement of the production plan preparation apparatus in embodiment. It is a figure for demonstrating the processing order of each operation | work with respect to the some operation | work for producing the some product which is the object of a production plan. It is a figure for demonstrating the determination process of the furnace washing process in the case of manufacturing the kind 5 and the kind 1 in order with one melting furnace. It is a figure for demonstrating the furnace washing process between each operation | work in the processing order of each operation | work shown in FIG. It is a Gantt chart showing the schedule which considered the furnace washing process. It is a block diagram which shows the structure of the production plan preparation apparatus in other embodiment. It is a figure which shows the structure of the component master table in the production plan preparation apparatus of FIG. It is a figure which shows the structure of the equipment master table in the production plan preparation apparatus of FIG. It is a flowchart which shows operation | movement of the production plan preparation apparatus in this embodiment. It is a figure for demonstrating the processing order of each operation | work with respect to the some operation | work for producing the some product which is the object of a production plan. It is a figure which shows the dilution for every element at the time of performing one operation | work and the other operation | work following this, the maximum dilution, and the number of elements to add. It is a figure for demonstrating the setup change process between each work in the processing order of each work shown in FIG. It is a Gantt chart showing the schedule which considered the setup change process.

  Hereinafter, an embodiment according to the present invention will be described with reference to the drawings. In addition, the structure which attached | subjected the same code | symbol in each figure shows that it is the same structure, The description is abbreviate | omitted suitably.

  FIG. 1 is a block diagram illustrating a configuration of a production plan creation apparatus according to the embodiment. FIG. 2 is a diagram illustrating a configuration of a component master table in the production plan creation apparatus according to the embodiment. Drawing 3 is a figure showing the composition of the equipment master table in the production plan creation device of an embodiment.

The production plan creation apparatus S of the embodiment is an apparatus that creates a production plan for a plurality of operations for manufacturing a plurality of products for one production facility. For example, as shown in FIG. 1, such a production plan creation apparatus S includes a processing order determination unit 1, a processing order storage unit 2, a diluted composition calculation unit 3, a setup change condition determination unit 4, and a setup. Change count determination unit 5, setup change time calculation unit 6, schedule creation unit 7, schedule storage unit 8, input unit 11, output unit 12, component master storage unit 21, equipment master storage unit 31 It is configured with.

  The input unit 11 creates various production commands such as a command for starting a production plan creation program for creating a production plan that takes into account the setup change process, and various data necessary for creating (planning) the production plan. A device that inputs to the device S, such as a keyboard or a mouse. The output unit 12 is a device that presents (outputs) the command and data input from the input unit 11 and the production plan created by the production plan creation device S. For example, a CRT display, LCD, organic EL display, A display device such as a plasma display or a printing device such as a printer. The schedule (production plan) is displayed on the output unit 12 in a Gantt chart, for example. This Gantt chart takes time on the horizontal axis and the production equipment on the vertical axis, and each work in the production of a plurality of products is started from its start time for each processing (work) unit in the production equipment. A tile represented by a rectangular frame (job frame) corresponding to the time width until the end time is drawn on the display.

  The processing order determination unit 1 performs the order of performing each of the plurality of operations for manufacturing a plurality of products that are the targets of the production plan (schedule) without considering the setup change processing step (processing sequence). ). The plurality of products to be produced (planned) includes at least products having different varieties due to different compositions. That is, the plurality of products targeted for production planning may all be of different varieties, and may include products of the same product as long as at least two types of products are included. The determination of the processing order for a plurality of operations is not particularly limited, and known conventional means are used, for example, a so-called delivery order processing determination method for determining the order of executing the work of products in the order of delivery of the products, Alternatively, for example, a human operator may specify (determine) the processing order. In the present embodiment, the product is an alloy using a melting furnace, and the changeover process is performed by introducing a pure metal material (principal component pure raw material) into the melting furnace to obtain a residue (variety produced in the previous operation). This is a furnace washing process that dilutes the alloy. Therefore, the processing order determination unit 1 determines the order of performing each of the plurality of operations for manufacturing the plurality of alloys that are the targets of the production plan without considering the furnace washing process. is there.

  The processing order storage unit 2 stores the processing order of each of a plurality of operations for manufacturing a plurality of products (alloys in this example) that are targets of production planning. The processing order storage unit 2 stores processing orders for a plurality of tasks determined by the processing order determination unit 1. As described above, in this embodiment, the processing order in a plurality of operations is stored (stored) in advance in the processing order storage unit 2 before creating the production plan in consideration of the setup change processing. The processing order is given in advance to the production plan creation device S.

The component master storage unit 21 is a device that stores basic product information necessary for creating (planning) a production plan, and stores product master data that is data related to product specifications including at least the product composition. The rewritable nonvolatile storage element is an EEPROM, a hard disk device, or the like. More specifically, the component master storage unit 21 stores the composition of the product type for each of a plurality of product types. For example, as shown in FIG. 2, the component master storage unit 21 stores the composition (components and their proportions) of each of a plurality of varieties as a component master table 22 in a table format. In the present embodiment, the alloy is a metal having a predetermined component composition generated by adding seven types of elements to a pure metal material (main component pure raw material) serving as a base. In the component master table 22, In the example shown in FIG. 2, the composition of seven kinds of additive raw materials from element A to element G is registered in% (percentage) for each of ten kinds from kind 1 to kind 10. For example, in the cultivar 1, the element A is 0.010%, the element B is 0.100%, the element C is 0.030%, the element D is 0.030%, and the element E is 0. 0.050%, element F is 0.050%, and element G is 0.010%. Further, for example, in the cultivar 5, the element A is 0.010%, the element B is 0.100%, the element C is 2.000%, the element D is 0.200%, and the element E is 0.050%, element F is 0.050%, and element G is 0.005%. Note that the main component pure raw material (base metal) is omitted from the component master table 22.

The equipment master storage unit 31 is basic information necessary for creating (drafting) a production plan, and is data relating to specifications of the production equipment including at least a unit processing amount, a unit residual amount, a unit processing time, and a unit dilution time. In the same manner as the component master storage unit 21 , for example, an EEPROM, a hard disk device, or the like, which is a rewritable nonvolatile storage element, is configured. The unit processing amount is a processing amount processed in one operation at the production facility, and the unit residual amount is an amount remaining after completion of one operation at the production facility. In this embodiment, this unit residual amount The amount is also the amount remaining after completion of one dilution at the production facility, the unit processing time is the processing time required for processing one operation at the production facility, and the unit dilution time is This is the dilution time required for one dilution in the production facility. More specifically, as shown in FIG. 3, the equipment master storage unit 31 has a furnace capacity of a melting furnace as an example of the unit processing amount, a residual amount as an example of the unit residual amount, and an example of the unit processing time. As an example of the processing time required for melting the alloy material and the unit dilution time, the furnace cleaning time required for the furnace cleaning processing is stored in a table format. In the example of the equipment master table 32 shown in FIG. 3, the furnace capacity is 25 tons (ton) per time, the residual amount is 5 tons (ton) per time, and the processing time is per time. 6 hours and the furnace wash time is 4 hours per time.

  The post-dilution composition calculation unit 3 obtains the composition of the diluted residue (residue after dilution) by performing a setup change process (furnace washing process in this example) for the residue before dilution. It is. For example, the residue is diluted with the furnace capacity by the main component of the product produced in the subsequent operation. That is, in the present embodiment, the dilution amount is a fixed amount set in advance.

  The changeover condition judgment unit 4 determines the composition of the residue remaining in the production facility (melting furnace) and the other between one operation in a plurality of operations and the other operation following this operation. Based on the composition of the product manufactured in the operation, it is determined whether or not a changeover process (furnace washing process in this example) is required to dilute the residue with the main component of the product manufactured in the other operation. To do. In the present embodiment, as described above, the dilution amount in the setup change process is a predetermined amount (furnace capacity in the present example), so that one setup process follows one process step. It may not be possible to produce a proper product in other processing steps. For this reason, in the present embodiment, the setup change condition determination unit 4 uses the diluted residue as a new residue, and determines that the setup change process (furnace washing process in this example) is not necessary. It is determined whether or not a replacement process is necessary.

  The setup change frequency determination unit 5 determines the number of setup change processes (furnace washing process in this example) based on the calculation result of the diluted composition calculation unit 3 and the determination result of the setup change condition determination unit 4. More specifically, the setup change frequency determination unit 5 counts the number of determinations determined by the setup change condition determination unit 4 that the setup change process is necessary, for example, to change the setup change process (in this example, the furnace The number of times of washing processing is obtained.

The setup change time calculation unit 6 is based on the setup change time (unit dilution time in this example) stored in the equipment master storage unit 31 and the number of setup changes obtained by the setup change number determination unit 5. The setup change processing time is calculated. More specifically, the setup change time calculation unit 6 performs setup change by the setup change condition determination unit 4 at the setup change time per unit (in this example, unit dilution time) stored in the equipment master storage unit 31. The setup change processing time (furnace washing time in this example) is obtained by multiplying the number of times determined that processing is necessary.

  The schedule creation unit 7 performs a setup change process (furnace washing process in this example) with respect to the process order in a plurality of operations stored in the process order storage unit 2 as necessary, that is, by the setup change condition determination unit 4. Is necessary, a production plan for a plurality of operations is created by inserting a setup change processing step between one work determined by the setup change condition determination unit 4 and another work. . In the present embodiment, the setup change process is inserted between the one work and the other work according to the number of times the setup change condition determination unit 4 determines that the setup change process is necessary. More specifically, in the present embodiment, the setup change processing step is inserted between the one work and the other work in the setup change processing time obtained by the setup change time calculation unit 6. In other words, in the present embodiment, the schedule creation unit 7 performs the setup change process calculated by the setup change time calculation unit 6 as necessary for the processing order in a plurality of operations stored in the processing order storage unit 2. By inserting a time change process (furnace washing process in this example), a production plan (schedule) for a plurality of operations in a plurality of products considering the change process is created.

  The schedule storage unit 8 stores production plans (schedules) for a plurality of operations in a plurality of products. The schedule storage unit 8 stores the schedule created by the schedule creation unit 7. More specifically, the schedule storage unit 8 is a product identifier (product ID) for identifying and identifying a product and an identifier for identifying and identifying a production facility for each of a plurality of products. The production facility identifier (equipment ID) of the production facility to be produced, the product type, and the start / end information related to the start time and end time of the work for the product are stored. In the initial state, the schedule of the initial plan stored in the processing order storage unit 2 is stored in the schedule storage unit 8, and when the schedule of the initial plan is corrected and created by the schedule creation unit 7, the schedule creation unit 7 The corrected schedule created by the above is stored in the schedule storage unit 8.

  The production plan creation apparatus S having such a configuration can be configured by, for example, a computer, more specifically, a server computer, a personal computer, or the like. These processing order determination unit 1, post-dilution composition calculation unit 3, setup change conditions The determination unit 4, the setup change frequency determination unit 5, the setup change time calculation unit 6 and the schedule creation unit 7 can be functionally configured in an information processing unit configured to include, for example, a microprocessor and its peripheral circuits. The processing order storage unit 2, the schedule storage unit 8, the component master storage unit 21, and the equipment master storage unit 31 are functionally configured in a storage device that includes a storage element (memory), a hard disk device, and the like, for example. Is possible. Further, for example, the component master storage unit 21 and the equipment master storage unit 31 may be configured with a server computer. When the production plan creation device S is configured by a plurality of server computers, the server computers are connected to each other via a communication network (network).

Note that the production plan creation device S may further include an external storage device (not shown) as necessary. External storage device, for example, a flexible disk, CD-ROM (Compact Disc Read Only Memory), CD-R (Compact Disc Recordable), DVD-R (Digital Versatile Dis c R ecordable) and Blu-ray disc (Blu-ray Disc) For example, a flexible disk drive, a CD-ROM drive, a CD-R drive, a DVD-R drive, a Blu-ray disk drive, and the like are devices that read data from and / or write data to / from a recording medium.

  Here, the production plan creation device S does not store a production plan creation program for creating a schedule (production plan) considering the setup change process, master information such as a component master and an equipment master, etc. It may be configured to be installed (stored) in each device via the external storage device from a recording medium that records these programs, master information, and the like. Alternatively, the production plan creation device S may be configured such that the created schedule data is recorded on a recording medium via the external storage device.

  Next, the operation of this embodiment will be described. FIG. 4 is a flowchart illustrating the operation of the production plan creation apparatus according to the embodiment. FIG. 5 is a diagram for explaining the processing order of each of a plurality of operations for producing a plurality of products that are the targets of the production plan. FIG. 6 is a diagram for explaining the determination process of the furnace washing process in the case where the product type 5 and the product type 1 are sequentially manufactured in one melting furnace. FIG. 7 is a diagram for explaining the furnace washing process between the operations in the processing order of the operations illustrated in FIG. 5. FIG. 8 is a Gantt chart showing a schedule considering the furnace washing process.

  In FIG. 4, first, in step S <b> 11, the processing order determination unit 1 performs a plurality of operations for manufacturing a plurality of products that are targets of a production plan (schedule) without considering the setup change processing step. The processing order for performing each of these tasks is determined, and the determined processing order of each task is stored in the processing sequence storage unit 2. In the processing order storage unit 2, for example, as shown in FIG. 5, the processing order that is the processing order number, the product number (product No.) corresponding to the product manufactured by the work in the processing order, The product types manufactured in the processing sequence are associated with each other and stored in a table format. Product No. Is an example of the product ID. In the example shown in FIG. 5, for example, the first processing order is the product number. This is an operation for manufacturing a product of type 5 of C1. This is an operation for manufacturing a product of type 1 of C2. This is an operation for manufacturing a product of C1 type 1.

  Subsequently, in step S12, the composition calculation unit 3 after dilution arbitrarily sets a set of one operation from the plurality of operations stored in the processing order storage unit 2 and other subsequent operations (previous and subsequent processes). One set is extracted. This extraction method may be any method. For example, in this embodiment, one set is extracted in order from the beginning of the processing order. For example, in the example shown in FIG. The work of manufacturing the product of C1 type 5 (one work, the previous process) and the product No. in the second processing order. A combination with a work for manufacturing a product of C1 type 1 (other work, post-process) is extracted.

  Subsequently, in step S13, the composition corresponding to the product type (previous product type) manufactured in one operation in the set extracted in step S12 by the diluted composition calculation unit 3 and the product manufactured in another operation The composition (the composition of the previous product and the subsequent product) corresponding to the product (the subsequent product) is acquired from the component master storage unit 21. In the present embodiment, the standard composition is registered in the component master table 22. For example, in the example shown in FIG. The composition corresponding to the product type 5 of C1 and the product No. manufactured by other operations The composition corresponding to the type 1 of C2 is acquired from the component master table 22 shown in FIG.

  Subsequently, in step S14, a variable N indicating the number of times of changeover processing is initialized to 0 (N = 0) by the changeover frequency determination unit 5 and initialization of the variable N is executed.

  Subsequently, in step S15, the composition of the residue (residue after dilution) is obtained by the post-dilution composition calculation unit 3 after N times of setup change processing.

  Here, in the present embodiment, when one operation is completed, only the residual amount is obtained once, so that one furnace washing process is performed on the residue, and the number of changeover processes N When = 0, the composition of the residue after the default one furnace washing process is obtained by the after-dilution composition calculation unit 3. For example, in the example shown in FIG. When a product of C1 type 5 is manufactured, one furnace washing process is executed by default, and the residue is the main component of the product (main component pure raw material, base metal raw material) manufactured in other operations. Is diluted. This dilution is performed by filling the main component pure raw material in the production facility, that is, in this example, the furnace capacity of the melting furnace. Therefore, in this case, the dilution rate is a value obtained by dividing the residual amount by the furnace capacity (= residual amount / furnace capacity). Then, the composition of the residue after the default one furnace washing is obtained by multiplying the composition of the residue before the default one furnace washing by the dilution rate by the after-dilution composition calculation unit 3. That is, by multiplying by the k-th dilution rate, the composition ratio of each component after k-th dilution is obtained. In the example shown in FIG. 3, the dilution rate is 0.2 (= 5 ton / 25 ton). Therefore, in the above example, the composition of the initial residue is that element A is 0.00200 (= 0.010 × 0.2)% and element B is 0.0200 (= 0.100 × 0.2). %, Element C is 0.40000 (= 2.000 × 0.2)%, element D is 0.04000 (= 0.200 × 0.2)%, and element E is 0.01000. (= 0.050 × 0.2)%, element F is 0.01000 (= 0.050 × 0.2)%, and element G is 0.00100 (= 0.005 × 0. 2)%. In FIG. 6, the results are collectively shown in the column “No furnace cleaning (%)”. In the example shown in FIG. 2, the main components of the types 1 to 10 are the same. Further, in this example, the processing time in the equipment master table 32 shown in FIG. 3 includes this default one-time furnace washing processing time.

Subsequently, in step S16, the changeover condition determination unit 4 determines the composition of the residue remaining in the production facility after the end of one operation between one operation in the plurality of operations and the other operation following this. Based on the composition of the product manufactured in the other operation, it is determined whether or not a changeover process for diluting the residue with the main component of the product manufactured in the other operation is necessary. This determination is based on the fact that the composition ratio (content ratio) of each component excluding the main component of the residue after dilution corresponds to the composition ratio of each component excluding the main component of the product manufactured by other work ( (Content ratio) or less (is there a component that does not meet the standard composition of the subsequent varieties?), Each of the composition ratio (content ratio) of each component excluding the main component of the residue after dilution, If the composition ratio (content ratio) of each component excluding the main components of products manufactured in other operations corresponding to this is less than or equal to this, it is determined that no changeover treatment is necessary, and the residue remains after dilution. Each of the composition ratio (content ratio) of each component excluding the main component of the product is less than the corresponding composition ratio (content ratio) of each component excluding the main component of the product manufactured by other work corresponding to this. If not, it is determined that setup change processing is necessary. It is. That is, at least one of the composition ratios (content ratios) of each component excluding the main component of the residue after dilution, corresponding to each component excluding the main component of the product manufactured by other operations If it is greater than the composition ratio (content ratio), it is determined that a setup change process is necessary. The reason why the determination is made in this way is that the component that is deficient only needs to be supplemented with the added raw material of the component in the other operation following the one operation.

  As a result of this determination, the composition ratio (content ratio) of each component excluding the main component of the residue after dilution is the same for each component excluding the main component of the product manufactured by other work corresponding to this. When it is below the composition ratio (content ratio) (NO), the process of step S18 is executed following the process of step S16. On the other hand, as a result of the determination, all the composition ratios (content ratios) of each component excluding the main component of the residue after dilution are all corresponding components except the main component of products manufactured in other operations. If the composition ratio (content ratio) is not less than (YES), following the process of step S16, the process of step S17 in which the variable N of the number of setup change processes is incremented by one by the setup change number determination unit 5 After (N ← N + 1) is executed, the process of step S15 is executed. That is, after the process of step S16, the process returns to the process of step S15 via the process of step S17. As a result, the setup change condition determination unit 4 takes the diluted residue as a new residue, and the setup change process is necessary until it is determined in step S16 that the setup change process (furnace washing process in this example) is not necessary. It will be judged whether or not.

  For example, in the example shown in FIG. 5, as shown in FIG. 6, in the case of no furnace washing (in the case of a residue after dilution after the default one furnace washing process), the composition ratio of the component of element C is The composition ratio of the component C of the element 1 of 0.4000 is 0.030, the composition ratio of the component of the element D is 0.04000, and the composition ratio of the element D of the element 1 of the variety 1 is Since it is 0.030, in the case of the variable N = 0 of the number of times of setup change processing, each of the composition ratios (content ratios) of each component excluding the main component of the residue after dilution all corresponds to this. If it is not less than the composition ratio (content ratio) of each component excluding the main component of the product manufactured by other work (YES), step S17 is executed and step S15 is executed. The results are collectively shown in the column “in the case of one furnace wash (%)” in FIG. Even in the case of this single furnace washing, as shown in FIG. 6, the composition ratio of the element C component is 0.08000, and the composition ratio of the element C component of the variety 1 is 0.030. In the case of the variable N = 1 of the number of times of setup change processing, each of the composition ratios (content ratios) of each component excluding the main component of the residue after dilution is manufactured by other operations corresponding to this. If it is not less than the composition ratio (content ratio) of each component excluding the main component of the product (YES), step S17 is executed and step S15 is executed. The results are collectively shown in the column “in the case of two furnace washings (%)” in FIG. And in this case of two times of furnace washing, as shown in FIG. 6, each of the composition ratios (content ratios) of the respective components excluding the main component of the residue after dilution all correspond to this. If it is equal to or less than the composition ratio (content ratio) of each component excluding the main component of the product manufactured in (NO), step S18 is executed.

In step S18, the set-up time calculated by the set-up time determining unit 5 and the set-up time per unit change time (unit dilution time in this example) stored in the equipment master storage unit 31 by the set-up time calculating unit 6 Based on the processing number N, the setup change processing time is obtained. More specifically, by multiplying the set-up time per time stored in the equipment master storage unit 31 by the number of determinations determined by the set-up condition determination unit 4 that the set-up process is necessary, That is, the setup change processing time is obtained by multiplying the setup change processing count N counted by the setup change count determining unit 5.

  For example, in the example shown in FIG. 5, since the furnace washing time as the unit dilution time is 4 hours and the number of setup change processings N = 2, the setup change processing time is 8 hours.

  Subsequently, in step S19, all the combinations of one work and the other work following this are extracted from the plurality of works stored in the processing order storage unit 2 by the post-dilution composition calculation unit 3 It is determined whether or not. If the result of this determination is that extraction of all the sets has not been completed (NO), the processing is performed following the processing of step S19 in order to execute the processing of steps S12 to S18 for the next set. The process returns to S12. On the other hand, as a result of the determination, if all sets have been extracted (YES), the process of step S20 is executed following the process of step S19.

  In step S20, a setup change process (furnace washing process in this example) is required by the setup change condition determination unit 4 for the processing order in a plurality of operations stored in the processing order storage unit 2 by the schedule creation unit 7. In some cases, by inserting a setup change processing step (furnace washing processing step in this example) of the setup change processing time calculated by the setup change time calculation unit 6, a plurality of products in a plurality of products considering the setup change processing. A production plan (schedule) for the work is created. The processing time of each work is referred to the equipment master table 32 stored in the equipment master storage unit 31, and the processing time in the equipment master table 32 is used.

  For example, in the example shown in FIG. 5, the results shown in FIG. 7 are obtained by executing the processes shown in FIG. As can be seen from FIG. 7, the product No. in the first processing order. Product No. 2 in the process of manufacturing the product of C1 type 5 and the second processing order. Between the operation of manufacturing the product of C2 type 1, the number of changeover processes (in this example, the number of furnace washing processes) N is 2 and the changeover process time (in this example, the furnace washing process time) is 8 (= 4 hours × 2 times) Time change process (furnace washing process in this example) is inserted, and the product No. Product No. 6 in the work order and processing order of manufacturing the product of C8 type 8 A setup change processing step in which the setup change processing frequency N is 1 and the setup change processing time is 4 (= 4 hours × 1 time) is inserted between the operations for manufacturing the product of C10 type 10 , And the product No. in the seventh processing order. Product No. 8 in the process of manufacturing the product of C10 type 10 and the eighth processing order. A setup change processing step in which the number of setup change processings N is 2 and the setup change processing time is 8 (= 4 hours × 2 times) is inserted between the operations for manufacturing the product of C3 type 3. The

  The production plan created in this way is stored in the schedule storage unit 8 by the schedule creation unit 7 and is output to the output unit 12 as a Gantt chart. For example, in the example shown in FIG. 5, the Gantt chart shown in FIG. 8 is displayed on the output unit 12.

  As described above, in the production plan creation apparatus and the method according to the present embodiment, the composition of the residue remaining in the production facility after the end of one operation between the one operation in the plurality of operations and the other operation following the one operation. And the composition of the product manufactured in the other operation, it is determined whether or not a change-over process for diluting the residue with the main component of the product manufactured in the other operation is necessary. Is determined to be necessary, a production plan for a plurality of operations is created by inserting a setup change process between one operation and another operation. For this reason, the production plan creation apparatus and the method according to the present embodiment do not need to store the setup change conditions in advance for the combination of preceding and succeeding varieties. Even when the system is added or manually maintained, it is possible to create a production plan that takes into account the setup change with a relatively simple process.

  Further, in the production plan creation apparatus and the method according to the present embodiment, the number of times of setup change processing N is counted by the number of times of setup change determination unit 5, and therefore the number of dilutions in the setup change processing can be obtained according to this number N. It becomes possible, and it becomes possible to create a production plan in the setup change process according to the number N of times. Then, by obtaining the minimum necessary number of dilutions in the setup change process according to the number N, it becomes possible to create a production plan in the setup change process with the minimum required number of dilutions, and a more appropriate production plan. Is created.

  Further, in the production plan creation apparatus and the method according to the present embodiment, the setup change processing time is obtained by the setup change time calculation unit 6, so that the production plan is created in the setup change processing step of this setup change processing time. Is possible.

  Further, in the production plan creation apparatus and the method according to the present embodiment, the processing order in a plurality of operations is stored in advance in the processing order storage unit 2. For this reason, it is no longer necessary to input the processing sequence to the production plan creation device S every time a production plan is created, and it is possible to reduce labor, and it is easier to create a production plan in consideration of setup changes. It becomes possible to execute by processing.

  In the production plan creation apparatus and the method according to the present embodiment, the composition of the product type is stored in advance in the component master storage unit 21, and the unit processing amount, the unit residual amount, the unit processing time, and the unit dilution time in the production facility are installed in advance. Stored in the master storage unit 31. For this reason, it is not necessary to input each data to the production plan creation device S in advance, and it is not necessary to input each data to the production plan creation device S every time a production plan is created. Can be executed by a simpler process. In addition, even when a product type is added, it is possible to automatically reflect the composition of the additional product type in creation of a production plan only by additionally registering it in the component master storage unit 21.

  In the above-described embodiment, the case where a product is produced for each unit has been described. However, the production according to this embodiment can be performed by treating a charge, which is a group of a plurality of workpieces that are processed at the same time, as the product. The plan creation device can be applied to a device that creates a production plan (schedule) for each processing step of a plurality of charges. In this case, the plurality of charges include at least charges of different varieties. That is, the plurality of charges to be produced may all be of different varieties, and may include the same type of charge as long as at least two types of charge are included. Here, a production facility that simultaneously performs the same kind of processing on a plurality of workpieces is called a batch facility. In this case, the schedule storage unit 8 includes a charge identifier (charge ID) for identifying and identifying a charge for each of a plurality of charges, and an identifier for identifying and identifying a batch facility. The batch equipment identifier (batch ID) of the batch equipment that processes the above, the number of works included in the charge, the type of work included in the charge, and start / end information related to the start time and end time of the charge are stored.

  Moreover, in the above-mentioned embodiment, when there are a plurality of production facilities, a production plan may be created for each production facility using the production plan creation device S of the present embodiment.

  In the above-described embodiment, the production plan stored in the schedule storage unit 8 is displayed on the output unit 12 as a Gantt chart and presented to a user such as an operator, but the production plan stored in the schedule storage unit 8 The handling of is not particularly limited. For example, even if the processing order determination unit 1 or a user such as an operator changes the processing order of a plurality of operations stored in the processing order storage unit 2 and causes the production plan creation device S to create a production plan again. Good. As a result, the production plan can be improved and the best production plan can be found. In addition, for example, the production plan creation device S may be used as a function for evaluating the processing order created during the calculation of a so-called combination optimization program such as SA or GA. The production plan created by the production plan creation device S is used as an index for the evaluation. This optimizes the production plan.

  Hereinafter, other embodiments according to the present invention will be described.

  FIG. 9 is a block diagram illustrating a configuration of a production plan creation apparatus according to another embodiment. FIG. 10 is a diagram showing a configuration of a component master table in the production plan creation apparatus of FIG. FIG. 11 is a diagram showing a configuration of an equipment master table in the production plan creation apparatus of FIG.

  The production plan creation device S2 according to the present embodiment is a device that creates a production plan for one production facility for a plurality of operations for manufacturing a plurality of products. As shown in FIG. 9, the production plan creation device S2 includes a processing order determination unit 41, a processing order storage unit 42, a post-dilution composition calculation unit 43, a setup change condition determination unit 44, and a setup change time. The calculation unit 46, the schedule creation unit 47, the schedule storage unit 48, the input unit 11, the output unit 12, the component master storage unit 49, and the equipment master storage unit 50 are configured.

  Since the input unit 11 and the output unit 12 have the same configuration as that of the above-described embodiment, description thereof is omitted here.

  The processing order determination unit 41 determines the order (processing order) for performing each of the plurality of operations for manufacturing a plurality of products that are the targets of the production plan without considering the setup change processing step. To do. The processing order determination unit 41 is the same as the processing order determination unit 1 in the above-described embodiment. The plurality of products targeted for production planning include at least products having different varieties due to different compositions. That is, the plurality of products targeted for production planning may all be of different varieties, and may include products of the same product as long as at least two types of products are included. In the present embodiment, the product is an alloy using a melting furnace, and the changeover process is performed by introducing a pure metal material (principal component pure raw material) into the melting furnace to obtain a residue (variety produced in the previous operation). This is a furnace washing process that dilutes the alloy.

  The processing order storage unit 42 stores processing orders of a plurality of operations for manufacturing a plurality of products (alloys in this example) that are targets of production planning. The processing order storage unit 42 stores processing orders for a plurality of tasks determined by the processing order determination unit 41.

  Similar to the component master storage unit 21 in the above-described embodiment, the component master storage unit 49 is a device that stores product type master data. Specifically, in the component master storage unit 49, for example, as shown in FIG. 10, the composition (components and their proportions) of each of a plurality of varieties is stored as a component master table 51 in a table format. Yes. In the component master table 51, the main component pure raw material (base metal) is omitted.

  The equipment master storage unit 50 is basic information necessary for creating (drafting) a production plan, and relates to the specifications of the production equipment including at least a unit processing amount, a unit residual amount, a unit processing time, and a one element input time. A device that stores equipment master data that is data, and includes, for example, an EEPROM, a hard disk device, and the like, which are rewritable nonvolatile storage elements. The unit processing amount, the unit residual amount, and the unit processing time are the same as those in the above-described embodiment. The time required to add one element is the time required to add one element (one component) in the production facility. Specifically, in the present embodiment, the time for introducing one element is 10 minutes.

The post-dilution composition calculation unit 43, when shifting from one operation to another operation following this, for the undiluted residue (5 ton: FIG. 11 ) remaining in the production facility at the end of one operation Obtaining the concentration of each residue (concentration after dilution) when the main component of the product produced in another operation is charged in an amount (20 ton) that satisfies the capacity of production equipment (25 ton: Fig. 11 ). It is.

  The setup change condition determination unit 44 performs setup change processing (this example) for diluting a residue with a main component of a product manufactured in another operation between one operation in a plurality of operations and another operation following this operation. Then, it is determined whether or not a furnace washing process is necessary. Specifically, the changeover condition determination unit 44 is preset with a dilution obtained by dividing the diluted concentration by the concentration (referred to as a target concentration) for each element (component) of the product produced in the other operation. If the specified dilution level is exceeded, it is determined that a setup change process is necessary. Here, the specified dilution is “1” when no tolerance is set for the target concentration. That is, when no tolerance is set for the target concentration, it is possible to determine that a component whose dilution degree obtained by dividing the diluted concentration by the target concentration exceeds “1” is a component that requires further dilution. On the contrary, when a tolerance is set for the target concentration, the specified dilution is a value obtained by increasing or decreasing a value corresponding to the tolerance with respect to “1”. In the present embodiment, description will be made assuming that the specified dilution is set to “1”.

The setup change time calculation unit 46 calculates the time required for the setup change process when the setup change condition determination unit 44 determines that the setup change process is necessary. And a component addition time calculation unit 46b. The dilution time calculation unit 46a is required to set the largest dilution factor (maximum dilution factor) among the dilution factors for each element calculated by the setup change condition determination unit 44 as the specified dilution factor (1 in this embodiment). Calculate time. For example, when the specified dilution can be obtained by multiplying the maximum dilution by 1.67 , the dilution time calculation unit 46a sets 0.67 ( see FIG. 11) to 0.67 ( see FIG. 11). 4 hours multiplied by 1.67-1) is calculated as the dilution time. The component addition time calculation unit 46b takes a time required for processing to add a component whose dilution is less than the specified dilution when the residue is diluted at a magnification for setting the maximum dilution to the specified dilution (component addition time). ). Specifically, the component addition time calculation unit 46b first identifies the number of components to be added, and multiplies the number of components by one element input time (see FIG. 11) as the component addition time. calculate.

  The schedule creation unit 47 performs a set-up change process (in this example, a furnace washing process and a set-up process) by the set-up condition determination unit 44 as necessary for the process order in the plurality of operations stored in the process order storage unit 42. When an element addition process is necessary, a production plan for a plurality of operations is created by inserting a setup change processing step between one operation determined by the setup change condition determination unit 44 and another operation. To do. Specifically, the schedule creation unit 47 sets the stage change processing time stage calculated by the stage change time calculation part 46 as needed for the processing order in the plurality of operations stored in the processing order storage unit 42. By inserting a replacement process (furnace washing process and element addition process in this embodiment), a production plan (schedule) is created for a plurality of operations in a plurality of products considering the setup change process.

  The schedule storage unit 48 stores the schedule created by the schedule creation unit 47 in the same manner as the schedule storage unit 8 of the embodiment described above. In the initial state, the schedule of the initial plan stored in the processing order storage unit 42 is stored in the schedule storage unit 48. When the schedule of the initial plan is corrected and created by the schedule creation unit 47, the schedule creation unit 47 The corrected schedule created by the above is stored in the schedule storage unit 48.

Production planning device S 2 with such a configuration, similarly to the production plan creation device S described above, can be configured by a computer or the like, can further comprise an unillustrated external storage device.

  Next, the operation of this embodiment will be described. FIG. 12 is a flowchart showing the operation of the production plan creation apparatus in the present embodiment. FIG. 13 is a diagram for explaining the processing order of each of a plurality of operations for producing a plurality of products that are the targets of the production plan. FIG. 14 is a diagram showing the dilution for each element, the maximum dilution, and the number of elements to be added when performing one operation and another operation following this operation. FIG. 15 is a diagram for explaining a setup change process between each work in the processing order of each work shown in FIG. 13. FIG. 16 is a Gantt chart showing a schedule in consideration of the setup change process.

  In FIG. 12, first, in step S21, the processing order determination unit 41 does not consider the setup change processing step, and performs a plurality of operations for manufacturing a plurality of products that are targets of a production plan (schedule). The processing order for performing each work is determined, and the determined processing order for each work is stored in the processing order storage unit 42. For example, as illustrated in FIG. 13, the processing order storage unit 42 includes a processing order that is a processing order number, a product number (product No.) corresponding to a product manufactured in the processing order, and the processing. The types of products manufactured by the sequential operations are stored in a table format in association with each other.

  Subsequently, in step S22, the post-dilution composition calculating unit 43 arbitrarily sets one work among the plurality of works stored in the processing order storage unit 42 and another subsequent work (previous and subsequent processes). 1 set) is extracted. This extraction method may be any method. For example, in this embodiment, one set is extracted in order from the beginning of the processing order. For example, in the example shown in FIG. The work of manufacturing the product of C1 type 5 (one work, the previous process) and the product No. in the second processing order. A combination with a work for manufacturing a product of C1 type 1 (other work, post-process) is extracted.

  Subsequently, in step S23, the composition corresponding to the product type (previous product type) manufactured in one operation in the set extracted in step S22 by the diluted composition calculation unit 43 and the product manufactured in another operation. The composition corresponding to the product type (subsequent product type) is acquired from the component master storage unit 49. For example, in the example shown in FIG. The composition corresponding to the product type 5 of C1 and the product No. manufactured by other operations The composition corresponding to the type 1 of C2 is acquired from the component master table 51 shown in FIG.

  Subsequently, in step S24, the degree of dilution for each element is calculated by the after-dilution composition calculation unit 43. First, the post-dilution composition calculation unit 43 is a main component of another work following the one work for the residue (5 ton) after the previous one work is finished and one furnace washing process is finished. Is added by an amount (20 ton) that satisfies the furnace capacity (25 ton) and diluted to calculate the concentration of each element. For example, in the case of the element C of the cultivar 5 in FIG. 10, 0.05 is a value obtained by multiplying the concentration of the element C by 0.25% by (residual amount) / (furnace capacity) of 5/25. Calculate%. Next, the post-dilution composition calculation unit 43 calculates the degree of dilution for making this concentration (0.05%) the concentration of the element C of the cultivar 1 that is the subsequent cultivar (0.03%: see FIG. 10). . Specifically, for the combination of the previous breed 5 and the rear breed 1, the dilution obtained by dividing the concentration of element C in the previous breed 5 (0.05%) by the concentration of element C in the rear breed 1 (0.03%) Calculate the degree (1.67). And as shown in FIG. 14, this dilution degree is calculated about each element AG.

  Subsequently, in step S25, the largest one (maximum dilution) among the dilutions of elements A to G calculated in step S24 is set to a predetermined dilution (in this embodiment, 1 for all elements). It is determined whether or not it exceeds (set). That is, in step S25, in a state where the residue of the previous variety is diluted, it is determined whether or not the concentration of each element contained in the residue dilution exceeds the concentration of each element planned for the subsequent variety. Thus, it is determined whether or not the residue needs to be further diluted. Specifically, for the combination of the previous breed 5 and the rear breed 1 described above, since the dilution degree 1.67 of the element C is the maximum dilution degree, it is determined that the maximum dilution degree is greater than 1. In the example shown in FIG. 14, the maximum dilution of the combination of the previous variety 5 and the subsequent variety 1 and the combination of the previous variety 10 and the subsequent variety 5 exceeds 1, and therefore further dilution is required. Become. In step S25, if it is determined that the maximum dilution exceeds 1, step S26 is executed. If it is determined that the maximum dilution is 1 or less, step S27 is executed.

  In step S26, the dilution time is calculated by the dilution time calculator 46a. That is, the dilution time calculation unit 46a calculates the dilution time based on the maximum dilution and the processing time required for one furnace wash (FIG. 11: 6 hours in the present embodiment). Specifically, for the combination of the previous product type 5 and the rear product type 1, the maximum dilution is 1.67, and further 0.67 times dilution is necessary from the current state, so this is necessary for one furnace wash. About 4 hours obtained by multiplying 6 hours by 0.67 is calculated as the dilution time.

  Subsequently, in step S27, the number of elements to be additionally input is specified. That is, the component addition time calculation unit 46b determines that the dilution of each of the elements A to G is the specified dilution when the residue is diluted so that the maximum dilution becomes the specified dilution (1 in the present embodiment). Identify the number of things that are less than degrees. That is, in the state where the maximum dilution is the specified dilution, it is not necessary to add further elements for which the dilution is equal to or higher than the specified dilution. Here, when the maximum dilution is diluted to the specified dilution, the case where the dilution of other elements does not become less than the specified dilution will be described. Tolerances are set for the concentrations of the elements A to G in each variety. In this case, the specified dilution will be set within a certain range, so that the dilutions of other elements will also be specified in the diluted state so that the maximum dilution is within the specified dilution range. May fall within the range of degrees. However, in the present embodiment in which the specified dilution is set to 1, when the maximum dilution is diluted to the specified dilution, the dilution of other elements inevitably becomes lower than the specified dilution. Specifically, in the group of the previous breed 5 and the rear breed 1 and the group of the previous breed 10 and the rear breed 5 in FIG. 14, all the elements other than the element having the maximum dilution (six elements) should be added. become.

  Subsequently, in step S28, a time (component) for adding each element based on the number of elements specified in step S27 and the one-element loading time (10 minutes in this embodiment) shown in FIG. Add time). Specifically, for the combination of the previous breed 5 and the rear breed 1 in FIG. 14, the number of additional elements to be added is 6, so 60 minutes obtained by multiplying the number of elements 6 by the component addition time 10 minutes is calculated as the component addition time. Is done.

  Subsequently, in step S29, has the composition calculation unit 43 after dilution extracted all the sets of one operation and other subsequent operations from the plurality of operations stored in the processing order storage unit 42? It is determined whether or not. If the result of this determination is that extraction of all the sets has not been completed (NO), the processing is performed following the processing of step S29 in order to execute the processing of steps S22 to S28 for the next set. The process returns to S22. On the other hand, as a result of the determination, if all sets have been extracted (YES), the process of step S30 is executed following the process of step S29.

In step S30, the schedule creation unit 47 performs a setup change process (in this example, a furnace washing process and an element addition process) for the process order in the plurality of operations stored in the process order storage unit 42 by the setup change condition determination unit 44. ) Is necessary, a production plan for a plurality of operations in a plurality of products considering the setup change processing is inserted by inserting a setup change processing step of the setup change processing time calculated by the setup change time calculation unit 46. (Schedule) is created.

  For example, in the example shown in FIG. 13, the results shown in FIG. 15 are obtained by executing the processes shown in FIG. As can be seen from FIG. 15, the product No. in the first processing order. Product No. 2 in the process of manufacturing the product of C1 type 5 and the second processing order. A setup change processing step with a dilution time of 4 (6 hours × 0.67) hours and a component addition time of 1 (6 × 10 minutes) hours is inserted between the operations for manufacturing the product of C1 type 1. The In addition, the product No. in the seventh processing order. Product No. 8 in the process of manufacturing the product of C10 type 10 and the eighth processing order. A setup change process with a dilution time of 4.8 (6 hours × 0.8) hours and a component addition time of 1 (6 × 10 minutes) hours between the production of the C8 type 5 product Inserted.

  Then, a setup change process related to the component addition time is inserted between operations that do not require a dilution process. Specifically, between the work related to the second processing order and the work related to the third processing order, between the work related to the third processing order and the work related to the fourth processing order, and the work related to the fourth processing order. Between the work according to the fifth processing order, between the work according to the fifth processing order and the work according to the sixth processing order, between the work according to the sixth processing order and the work according to the seventh processing order. The component addition time is 1.2 (7 × 10 4) between the work related to the eighth order and the work related to the ninth order, and between the work related to the ninth order and the work related to the tenth order. A changeover process step is inserted which is a minute) time.

  The production plan created in this way is stored in the schedule storage unit 48 by the schedule creation unit 47, and is output to the output unit 12 as a Gantt chart. For example, in the example shown in FIG. 13, the Gantt chart shown in FIG. 16 is displayed on the output unit 12.

  As described above, according to the production plan creation device S2 in the present embodiment, it is determined whether or not the setup change process is necessary depending on whether or not the dilution of each component contained in the residue after dilution exceeds a preset specified dilution. can do. Here, the residue is diluted by adding the main component in an amount corresponding to the capacity of the production facility (in this embodiment, 20 ton), and this diluted residue is used as a reference after the end of one operation. When shifting to this work, the main component of the product manufactured in the other work is always charged to meet the capacity of the production facility. This is because it is necessary to determine whether or not further dilution is necessary as a reference. The dilution obtained by dividing the concentration of each component contained in the residue after dilution by the concentration (target concentration) of the component contained in a product manufactured in another operation exceeds a preset specified dilution. Sometimes it can be determined that a setup change process is necessary.

  According to the configuration including the setup change time calculation unit 46 as in the above embodiment, the setup change processing time can be obtained, and a production plan reflecting the setup change processing step of the setup change processing time is created. be able to.

  According to the configuration in which the setup change time calculation unit 46 includes the dilution time calculation unit 46a as in the embodiment, by calculating the dilution time for setting the maximum dilution to the specified dilution, all the components can be calculated. It is possible to specify the time for the dilution to be equal to or less than the specified dilution. This is because if the highest dilution among the dilutions of each component is diluted to the specified dilution, the dilutions of the other components are inevitably diluted below the specified dilution.

  As in the above configuration, according to the configuration in which the setup change time calculation unit 46 includes the component addition time calculation unit 46b, it is necessary for the component addition processing required when shifting from one work to another work following this. Since the setup change processing time including the component addition time can be calculated, a more accurate production plan can be created.

In addition, in the production plan creation apparatus S2 shown in FIGS. 9 to 16 described above, not only the dilution time for diluting the element having the maximum dilution to the specified dilution, but also the component addition time that is the time required for adding the element While calculating the setup change processing time by considering, it may be calculated at least dilutions time not essential for component additional time as setup change processing time.

On the other hand, in the production plan creation device S shown in FIGS. 1 to 8 described above, only the furnace washing time is calculated as the setup change processing time. In this production plan creation device S, the setup change taking into account the component addition time. Processing time can be calculated.

  Specifically, in the production plan creation device S, as shown in FIG. 6, the number N of times of furnace washing for specifying that the concentration of all the elements contained in the residue is lower than the element concentration that is the standard of the subsequent product type is specified. Therefore, after the number of times of furnace washing N, the concentration of all elements is lower than the element concentration of the subsequent varieties, and it is necessary to add all these elements. Therefore, the setup change time calculation unit 6 (see FIG. 1) multiplies the total number of elements (seven elements A to G) by a time (for example, 10 minutes) for adding one element (70 minutes). ) Can be calculated as the component addition time. However, in this case, it is necessary to add the one element insertion time (10 minutes) shown in FIG. 11 as data in the equipment master table 32 shown in FIG. 3 to the equipment master storage unit 31 shown in FIG. .

  Also in the production plan creation device S, tolerances may be set for the concentrations of the elements A to G, which are the specifications of the subsequent varieties shown in FIG. In this case, two or more elements may fall within the tolerance range after N times of furnace washing, so the concentration of each element A to G after N times of furnace washing. Is determined to be less than the concentration of each of the elements A to G, which is the standard for the subsequent varieties, and only the elements having the concentration lower than the concentration are added, and the time required for the additional work is calculated as the component addition time. You can also

  In order to express the present invention, the present invention has been properly and fully described through the embodiments with reference to the drawings. However, those skilled in the art can easily change and / or improve the above-described embodiments. It should be recognized that this is possible. Therefore, unless the modifications or improvements implemented by those skilled in the art are at a level that departs from the scope of the claims recited in the claims, the modifications or improvements are not covered by the claims. To be construed as inclusive.

S, S2 Production plan creation device 1, 41 Processing order determination unit 2, 42 Processing order storage unit 3, 43 Diluted composition calculation unit 4, 44 Setup change condition determination unit 5, Setup change number determination unit 6, 46 Setup change time calculation Unit 7, 47 Schedule creation unit 8, 48 Schedule storage unit 11 Input unit 12 Output unit 21 Component master storage unit 31 Equipment master storage unit 46a Dilution time calculation unit 46b Component addition time calculation unit 49 Component master storage unit 50 Equipment master storage unit

Claims (12)

In a production plan creation device that creates a production plan for a plurality of operations for manufacturing a plurality of products for one production facility,
The plurality of products include at least products having different varieties due to different compositions,
In the plurality of operations, these processing orders are given in advance,
Between one operation in the plurality of operations and another operation following the operation, the composition of the residue remaining in the production facility after the completion of the one operation and the composition of the product manufactured by the other operation A determination unit that determines whether or not a changeover process for diluting the residue with a main component of a product manufactured by the other operation is necessary,
When the setup change process is required by the determination unit, a setup change processing step for performing the setup change process between the one operation and the other operation is performed, thereby producing the plurality of operations. A production plan creation device comprising a creation unit for creating a plan. The dilution amount in the setup change processing step is a predetermined constant amount,
Dilution composition calculation for determining the composition of the residue after dilution by diluting the residue by the predetermined amount with the main component of the product manufactured in the other operation when the determination unit requires the setup change process. Part
The determination unit determines whether or not the setup change process is necessary until it is determined that the setup change process is not necessary, using the diluted residue as the residue.
The creation unit inserts a change-over process step according to the number of determinations that the determination unit determines that the change-over process is necessary, between the one work and the other work, thereby The production plan creation apparatus according to claim 1, wherein a production plan for a plurality of operations is created. A setup change for obtaining a setup change processing time including a dilution time obtained by multiplying a preset time required for one dilution by the number of determinations determined by the determination unit to be necessary for the setup change processing. A time calculation unit,
The creation unit is configured to produce the plurality of operations by inserting a setup change processing step having the setup change processing time obtained by the setup change time calculation unit between the one operation and the other operation. The production plan creation device according to claim 2, wherein a production plan is created. The setup change time calculation unit specifies a component that needs to be added to the residue after dilution after being diluted by the number of times determined that the setup change process is necessary, and adds this component. Calculate the component addition time required for
The creation unit creates a production plan for the plurality of operations using the time obtained by adding the dilution time calculated by the setup change time calculation unit and the component addition time as the setup change processing time. The production plan creation device according to claim 3. A component master storage unit for storing in advance the composition of the variety;
In the production facility, the amount of processing to be processed in one operation, the amount remaining after the end of one operation and the amount remaining after the end of one dilution, and the processing of one operation The production plan creation device according to any one of claims 1 to 4, further comprising: an equipment master storage unit that previously stores a processing time required and a dilution time required for one dilution. . A post-dilution composition calculation unit for determining the composition of the residue after diluting the residue by adding the main component of the product produced in the other operation by an amount corresponding to the capacity of the production facility;
The determination unit includes all the components included in the diluted residue obtained by dividing the dilution obtained by dividing the concentration of the component included in the diluted residue by the concentration of the component included in the product manufactured in the other operation. And determining that the setup change process is necessary when there is a dilution exceeding a predetermined dilution among preset dilutions of the respective components. The production plan creation device described. A setup change time calculation unit for calculating the setup change processing time required for the setup change processing based on the dilution of each component is further provided,
The creation unit is configured to produce the plurality of operations by inserting a setup change processing step having the setup change processing time obtained by the setup change time calculation unit between the one operation and the other operation. The production plan creation device according to claim 6, wherein a production plan is created. The setup change time calculation unit includes a dilution time calculation unit that calculates a dilution time required for a dilution process for setting the largest maximum dilution among the dilutions of each component to the specified dilution. The production plan creation device according to claim 7. The setup change time calculation unit calculates a component addition time for calculating a component addition time required for adding a component having the dilution less than the specified dilution when the maximum dilution is diluted to the specified dilution. Further comprising
The creation unit creates a production plan for the plurality of operations using the time obtained by adding the dilution time calculated by the setup change time calculation unit and the component addition time as the setup change processing time. The production plan creation device according to claim 8. A component master storage unit for storing in advance the composition of the variety;
In the production facility, the amount processed in one operation, the amount remaining after the end of one operation and the amount remaining after the end of one dilution, and the amount of one operation The production plan creation device according to any one of claims 6 to 9, further comprising an equipment master storage unit that stores in advance processing time required for processing. A processing order storage unit for storing processing orders in a plurality of operations;
11. The processing order in the plurality of operations is stored in advance in the processing order storage unit, so that the processing order in the plurality of operations is given in advance. 11. The production plan creation device described. In a production plan creation method for creating a production plan for a plurality of operations for manufacturing a plurality of products for one production facility,
The plurality of products include at least products having different varieties due to different compositions,
In the plurality of operations, these processing orders are given in advance,
Between one operation in the plurality of operations and another operation following the operation, the composition of the residue remaining in the production facility after the completion of the one operation and the composition of the product manufactured by the other operation A determination step for determining whether or not a setup change process for diluting the residue with a main component of a product manufactured by the other operation is necessary,
When the setup change process is required in the determination step, a setup change process step of performing the setup change process between the one work and the other work is performed, thereby producing the plurality of works. A production plan creation method comprising: a creation step for creating a plan.

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