JP5300708B2 - Production management apparatus, production management method and program - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To allow production planning and management employing a production number management method to facilitate delivery period management or the like, with production efficiency improved, in primary materials type industry. <P>SOLUTION: An aggregation part 101 aggregates pieces of received order information to which production specifications of products are common, out of a plurality of pieces of input received order information as the same type of received order information. A production number giving part 102 gives one unique production management number of the same type of received order information aggregated by the aggregation part 101 and gives one unique production management number to each piece of the other received order information. A step development part 104 schedules respective production steps for pertinent products per manufacturing management number given by the production number giving part 102. <P>COPYRIGHT: (C)2011,JPO&amp;INPIT

Description

  The present invention relates to a technique for managing product production in a material-type manufacturing industry.

  In the manufacturing industry, production management is performed using methods such as MRP (Material Requirements Planning) and production number management. MRP performs everything from parts arrangement to inventory management based on the amount of parts required for a finished product, and is generally suitable for production management of standard products that are mass-produced (for example, patents). Reference 1). In order to avoid a shortage, there are many parts and product inventory, and lead time can be shortened with respect to orders from customers, but there is a drawback of having inventory.

  On the other hand, production number management is a method in which one production management number (manufacture number) is assigned to one order, and production management is consistently performed with this production number, including parts incorporated into the product. Yes (see, for example, Patent Document 2). This method has the advantage of reducing inventory, and can be said to be a production management system suitable for manufacturing by individual orders for high-mix low-volume production. For example, when an order is received for a custom-made product, all plans can be managed with the product number from the date of shipment to production and design, so that even a custom-made product that does not have a standard specification or process can be easily kept in time.

JP-A-8-339406 JP 2003-58225 A

  By the way, production number management is a production management technique applied in a manufacturing industry (process assembly type manufacturing industry) in which a plurality of parts and materials are used for assembly. On the other hand, the manufacturing industry (material manufacturing industry) that develops into a plurality of different products based on a certain material, such as steel, non-ferrous metals, petroleum and chemicals, also has production based on individual orders.

  In the material-type manufacturing industry, the same kind of products are often processed together even in separate orders. For example, in the case of a rolling process in the steel industry, it is necessary to set the roller size and interval of the rolling mill each time according to the size of the product. Since this setting requires time and other costs, it is desirable to reduce the number of times as much as possible. Accordingly, there is a demand for planning a process in units (management units) collected as much as possible when processing similar products (orders). In each process, work scheduling is often performed in this management unit.

  Here, by applying the production number management method to such a material-type manufacturing industry, we can expect effects such as inventory reduction and delivery date management. It could not be applied to the material manufacturing industry.

  That is, in the conventional production number management, the shipping date is determined for each individual order, and material procurement and manufacturing plans are determined retroactively from the shipping date. Accordingly, as described above, it is not envisaged that, in the material-type manufacturing industry, processing is performed together in the manufacturing process in a unit of management although they are separate orders. Therefore, if the production number management technique is directly adopted in the material type manufacturing industry, only the plans for individual orders are prioritized and cannot be aggregated, resulting in a decrease in production efficiency.

  Therefore, an object of the present invention is to enable production planning and management in which a production number management technique is introduced in the material type manufacturing industry, and to facilitate delivery time management and the like while improving production efficiency.

The production management apparatus according to the present invention includes an aggregation unit that aggregates, as the same type of order information, order information that has a common product manufacturing specification among a plurality of input order information, and the same type of order information that is aggregated by the aggregation unit. For each of the production management numbers assigned by the granting means, the granting means for assigning one unique production management number to the other order information and assigning one unique manufacturing management number to the other order information, And scheduling means for performing scheduling in each manufacturing process of the corresponding product.

  In the present invention, among the plurality of input order information, the order information having the same product manufacturing specifications is aggregated as the same kind of order information and given a unique manufacturing control number, and the other order information Each is assigned a unique production control number, and for each assigned production management number, scheduling of each manufacturing process of the corresponding product is performed. Therefore, in the material type manufacturing industry, it is possible to perform production planning and management that introduces a production number management technique, and to improve delivery efficiency and facilitate delivery date management.

It is a block diagram which shows the functional structure of the production management apparatus which concerns on embodiment of this invention. It is a figure which shows the hardware constitutions of the production management apparatus which concerns on embodiment of this invention. It is a flowchart which shows the flow of the main processes of the production management apparatus which concerns on embodiment of this invention. It is a flowchart which shows the detail of the allocation process of the base material in step S305 of FIG. It is a figure which shows notionally the allocation process of the base material demonstrated using FIG. It is a flowchart which shows the detail of the scheduling process of step S307 of FIG. It is a figure which shows the specific example of the master information which stored the processing capacity in each process, the yield rate, and the conveyance time to the following process. It is a figure for demonstrating the scheduling process by a process expansion | deployment part concretely. It is a figure which shows the specific example of an order information management table and a manufacture management table.

  DESCRIPTION OF EXEMPLARY EMBODIMENTS Hereinafter, preferred embodiments to which the invention is applied will be described in detail with reference to the accompanying drawings. In the present embodiment, the production management of the steel industry will be described as an example of the manufacturing industry (material type manufacturing industry) that develops into a plurality of different products based on a certain material. However, the present invention is not limited to iron making, and the present invention can also be applied to non-ferrous metals, petroleum, chemicals, and the like.

FIG. 1 is a block diagram showing a functional configuration of a production management apparatus according to an embodiment of the present invention.
In FIG. 1, reference numeral 101 denotes an aggregating unit, which inputs a plurality of order information of products from customers by operating means such as a keyboard and a mouse or via a communication line such as the Internet (in the example of FIG. (Enter (1) to (6)), analyze the components and dimensions of the ordered product from the input order information and the transit process when manufacturing the product, etc. Collect order information. In the example of FIG. 1, the order information (1) to (3) is the same kind of order information and represents that they are aggregated. Reference numeral 102 denotes a product number assigning unit that assigns product numbers in units aggregated by the consolidating unit 101. Although details will be described later, the manufacturing specification number is determined from the item information included in the order information. Order information having the same manufacturing specification number is collected as the same type, and order information having different manufacturing specification numbers is not collected. The manufacturing process and manufacturing conditions are determined by the manufacturing specification number. In the present embodiment, the product ordered by the order information (1) to (3) is manufactured through the process 1 → the process 2 → the process 3 → the process 4, and the product ordered by the order information (4) is the process 1 → The product manufactured through the process 2 → the process 4 and received the order by the order information (5) is manufactured through the process 1 → the process 3 → the process 4 and the product ordered by the order information (6) is the process 1 → the process 2 → It is determined that it is manufactured through step 3 → step 4. However, the product ordered by the order information (1) to (3) and the product ordered by the order information (6) are manufactured through the same process, but manufactured under different manufacturing conditions. Accordingly, the order information (1) to (3) is aggregated and assigned a production number ABC123, a production number ABC004 is assigned to the order information (4), and a production number ABC005 is assigned to the order information (5). Is given, and the production number ABC006 is assigned to the order information (6). Each assigned product number is unique information. The product number is an abbreviation for manufacturing control number.

  Reference numeral 103 denotes a base material assigning unit that assigns a base material to each product number assigned by the product number assigning unit 102. The “base material” corresponds to the above “material”, and various products are manufactured based on the “base material”. For example, if the product (final product) is a thin plate or steel pipe, the base material is pig iron or slab, and if the product is gasoline or heavy oil, the base material is crude oil. Reference numeral 104 denotes a process development unit, which assigns each product number assigned by the product number assigning unit 102 to a work lot, and determines the processing order of the product number in each work lot. Here, the production numbers having common production conditions are processed into the same work lot. In the example of FIG. 1, the production number ABC123, the production number ABC004, and the production number ABC005 are collectively assigned to the work lot 1- (1) in the process 1, and the production number ABC006 is assigned to the work lot 1- (2). Yes. In step 2, the product numbers ABC123 and ABC004 are collectively assigned to work lot 2- (1), and the product number ABC006 is assigned to work lot 2- (2). In step 3, the production number ABC123 is assigned to the work lot 3- (2), the production number ABC005 is assigned to the work lot 3- (1), and the production number ABC006 is assigned to the work lot 3- (3). In step 4, the product numbers ABC123 and ABC004 are collectively assigned to the work lot 4- (1), and the product numbers ABC005 and ABC006 are collectively assigned to the work lot 4- (2). By collecting work lots in this way, even if the specifications of the final product are different, it is possible to work together in the middle of the process, making it possible to use equipment capacity effectively and reduce work time. .

FIG. 2 is a diagram illustrating a hardware configuration of the production management apparatus according to the present embodiment.
The CPU 201 comprehensively controls each device and controller connected to the system bus. The ROM 203 or the HD (hard disk) 207 stores a basic input / output system (BIOS) that is a control program for the CPU 201, an operating system program, a program for the processing shown in FIGS. Is remembered.

  In the example of FIG. 2, the HD 207 is configured to be arranged inside the production management apparatus. However, as another embodiment, a configuration corresponding to the HD 207 may be arranged outside the production management apparatus. In addition, the program for performing the processing shown in FIGS. 3, 4, and 6 according to the present embodiment is recorded on a computer-readable recording medium such as a flexible disk (FD) or a CD-ROM, and the recording thereof is performed. It is good also as a structure supplied from a medium, and good also as a structure supplied via communication media, such as the internet.

  The RAM 202 functions as a main memory, work area, and the like for the CPU 201. The CPU 201 implements various operations by loading a program necessary for execution of processing into the RAM 202 and executing the program.

  The HD 207 and the FD 206 function as an external memory. The CPU 201 implements various operations by loading a program necessary for execution of processing into the RAM 202 and executing the program.

  The disk controller 205 controls access to external memories such as the HD 207 and the FD 206. The communication I / F controller 204 is connected to the Internet or a LAN, and controls communication with the outside by, for example, TCP / IP.

  The display controller 208 controls image display on the display 209.

  The KB controller 210 receives an operation input from the KB (keyboard) 211 and transmits it to the CPU 201. Although not shown, in addition to the KB 211, a pointing device such as a mouse can also be applied to the production management apparatus according to this embodiment as a user operation means.

  The aggregation unit 101, the product number assignment unit 102, the base material allocation unit 103, and the process development unit 104 illustrated in FIG. 1 are stored in, for example, the HD 207 and loaded into the RAM 202 as necessary, and the CPU 201 that executes the program. This is a realized configuration.

FIG. 3 is a flowchart showing a main processing flow of the production management apparatus according to the embodiment of the present invention.
First, the aggregating unit 101 receives a plurality of pieces of product order information from customers and inputs them to the order information management table 901 (step S301). Next, the aggregating unit 101 analyzes the product specifications (components, dimensions, route processes, etc. of the ordered product) included in the corresponding received order information for the input order information, obtains the manufacturing specification number, and receives the same type of orders. Information (order information of the same manufacturing specification number) is determined (step S302). Next, the aggregating unit 101 aggregates the order information determined to be the same type (step S303).

  FIG. 9 is a diagram showing a specific example of the order information management table 901 and the manufacturing management table 902. The order information management table 901 is a table for storing the order information input by the aggregation unit 101. That is, the order information management table 901 includes the order number, product item information, product size information, product order weight, and minimum / maximum value (Min / Max) information of the product order weight included in the order information. Stores product delivery date information, product specifications, and the like. The manufacturing management table 902 is a table that stores the result of the product analysis specifications analyzed by the consolidating unit 101 based on the order information. That is, in the manufacturing management table 902, the manufacturing specification number and the transit process are stored in addition to the order number in the order information.

  The analysis process of the aggregating unit 101 will be described in detail. The aggregating unit 101 uses a manufacturing condition information table (not shown) using information such as items and sizes in the order information input to the order information management table 901 as search conditions. ) To extract the manufacturing specification number that matches the order information. As the search condition, an arbitrary number of arbitrary items in the order information may be adopted, and set according to a unit to be aggregated. Then, the order numbers from which the same production specification numbers are extracted are collected and transmitted to the product number assigning unit 102. The production specification information table stores production specification numbers and specifications such as product components and dimensions in association with each other. This analysis process is an example. As another method, for example, when a manufacturing specification number is input as a search key, an order that matches the product specification corresponding to the manufacturing specification number is extracted from the order information management table 901. It is also possible to specify order numbers to be aggregated.

  Next, the product number assigning unit 102 assigns a unique product number to a plurality of pieces of order information aggregated by the aggregating unit 101, and individually assigns a unique product number to order information that is not aggregated. One by one is provided (step S304). In the example of FIG. 1, the order information (1) to (3) is collected as the same kind of order information, and the order number information (4), (5), (6) that is assigned with the production number ABC123 and is not aggregated. Are given the product number ABC004, the product number ABC005, and the product number ABC006. The product number information may be stored in the order information management table 901 as additional information of each order information, or may be stored separately by a table for managing the correspondence between the order information and the product number. good. Thereby, the order number, the product number, and the manufacturing specification number can be related between the tables.

  Next, the base material assignment unit 103 assigns a base material to each product number (step S305). Here, the base material indicates some unit of the material. For example, if the base material is a slab, it is one (one) slab, and if the base material is liquid such as pig iron or crude oil, it is assumed that it is one container containing the liquid. . However, the number is not necessarily one, and may be changed according to the application model.

FIG. 4 is a flowchart showing details of the base material assignment processing in step S305 of FIG.
First, the base material allocation unit 103 extracts one product number (step S401). As described above, the product number is stored in the order information management table 901 or a table that separately manages the correspondence between the order information and the product number. Next, the base material allocation unit 103 determines the quality characteristics of the base material to be used from the manufacturing specification number corresponding to the manufacturing number with reference to the manufacturing specification information table, and the base material having the determined quality characteristics exists as stock. It is determined whether or not to perform (step S402). In addition, the presence or absence of the stock of the base material of each quality characteristic is separately managed in the database, and is determined by referring to it. When the base material having the quality characteristics to be used exists as stock, the base material assignment unit 103 assigns one or more relevant quality-specific base materials to the product number, and stores correspondence information in the database ( Step S403). By the way, the “inventory” referred to here is not limited to what is actually present, but also includes future inventory that will be produced in the future or obtained from the outside.

  When it is determined in step S402 that the base material having the quality characteristic corresponding to the product number is insufficient, the base material assignment unit 103 specifies the base material having the quality characteristic corresponding to the product number, and the Internet. The process of ordering through the process etc. is performed (step S404). Next, the base material allocating unit 103 acquires base material manufacturing progress information and arrival status information through communication with the base material ordering party, and manages the stock in the database (step S405). Next, the base material assigning unit 103 assigns the base material scheduled to be received to the product number (step S403).

  FIG. 5 is a diagram conceptually illustrating the base material assignment process described with reference to FIG. 4. Reference numeral 501 denotes a product number assignment process in step S304 of FIG. Here, first, the production number XYZ001 is assigned to the order information (1). Next, a base material is assigned to the production number XYZ001 (502 in FIG. 5). Here, it is assumed that the base material A and the base material B exist for 40 t. Base material A and base material B have the same quality characteristics. The order quantity of the order information (1) given the production number XYZ001 is 50t. Therefore, the base material A and the base material B are assigned to the production number XYZ001. That is, the base material A is assigned 40t and the base material B is assigned 10t to the production number XYZ001. As for the order information (2), the same manufacturing specification number as the order information (1) is obtained from the order information (2), and the base material B is assigned to the production number XYZ002 given to the order information (2) for 20t. It will be. Note that the base material B is obtained by the order process (step 503 in FIG. 5) executed in step S404 that is executed when it is determined in step S402 in FIG. 4 that the base material A is insufficient. As described above, since the assignment of the base material to the product number is performed according to the amount of the base material required for the product number, one base material may be assigned to a plurality of product numbers.

  Returning to FIG. 3 again, the process development unit 104 assigns a production lot to a work lot for each process (step S306). Here, a process is performed in which the production numbers having the same production conditions are combined into one work lot in the process. Therefore, even if a product (manufactured product number) follows another manufacturing method as viewed from the whole manufacturing process, it may be processed together as one work lot in a certain process. Next, the process development unit 104 performs production number scheduling for each process (step S307).

  Next, the scheduling process in step S307 in FIG. 3 will be described with reference to FIGS. FIG. 6 is a flowchart showing details of the scheduling process in step S307 of FIG. FIG. 7 is a diagram showing a specific example of the master information that stores the processing capacity, the yield rate, and the transport time up to the next process in each process. FIG. 8 is a diagram for specifically explaining the scheduling processing by the process development unit 104.

  First, the process development unit 104 reads the transit process and delivery date information of the product number ABC 123 from the HD 207 (step S601). The route process is stored in the manufacturing management table 902 of FIG. 9 in association with the order number corresponding to the product number ABC123. The delivery date information is stored in association with the order number corresponding to the product number ABC123 in the order information management table 901 of FIG. Both the order information management table 901 and the manufacturing management table 902 are stored in the HD 207. The master information described above is also stored in the HD 207. The master information stores “conveyance time until the next process”, which is information used to calculate the time required for work between processes. The time required for the work between the actual processes includes the time required for the transfer instruction between the processes and the actual execution instruction of the process after the transfer. Only consider.

  Next, the process development unit 104 reads “accepted amount information (not shown)” and “yield rate” of the material or semi-finished product ABC123 in process 1 from the HD 107, and “accepted amount × yield rate” The “processing amount” in step 1 is calculated (step S602). For example, if 150 t of production number ABC123 is input to process 1, “150t × 94% = 141t” is obtained. This 141t is the “acceptance amount” of the material or semi-finished product in the next process. Next, the process development unit 104 reads “processing capability information” from the HD 107, and calculates “required time” in step 1 from “processing amount / processing capability” (step S603). For example, the “required time” in step 1 of the production number ABC123 is “141 t / (120 t / h) = 1.18 h”.

  Next, the process development unit 104 reads the “conveyance time to the next process” in the process 1 from the HD 107, adds the “conveyance time to the next process” to the calculated “required time”, and starts the next process from the start of the process. Is calculated (step S604). Since the “conveying time to the next process” in the process 1 is 10 h, 11.18 h is required from the start of the process 1 to the start of the next process.

  Next, the process development unit 104 determines whether or not the above processing has been executed up to the final process of the production number (step S605). If it is the final process, the process proceeds to step S606. If it is not the final process, the process returns to step S602. In this way, step S602 to step S604 are repeatedly executed for each process. Thereby, the time from the start of the process to the start of the next process is calculated for each process. FIG. 8 is a diagram illustrating the “required time” of each process, the “conveyance time to the next process” of each process, the “acceptance amount”, and the “processing amount” in each process. As shown in FIG. 8, the “acceptance amount” and the “processing amount” in the step 1 are 150 t and 141 t, respectively, and the “acceptance amount” and the “processing amount” in the step 2 are 141 t and 130 t, respectively. The “acceptance amount” and the “processing amount” at 3 are 130 t and 124 t, respectively, and the “acceptance amount” and the “processing amount” at the step 4 are 124 t and 112 t, respectively. Further, the “required time” of the process 1 is 1.18 h, and the “conveying time to the next process” of the process 1 is 10.00 h. The “required time” of the process 2 is 1.63 h, and the “conveyance time until the next process” of the process 2 is 7.00 h. The “required time” of the process 3 is 2.48 h, and the “conveyance time until the next process” of the process 3 is 6.00 h. The “required time” in step 4 is 3.73 h.

  Next, the process development unit 104 sends the delivery date and time indicated by the delivery date information in the order information management table 901 of FIG. 9, the “required time” of each process shown in FIG. 8, and the “transport time to the next process” of each process. , The scheduled start date and time and the scheduled end date and time of each process are obtained (step S606). For example, if the delivery date and time of the production number ABC123 is “2009/08/02 13:00”, it takes 32.02 hours for all the processes, so the scheduled start date and time of the process 1 is “2009/08/01 4:58”. It becomes. Similarly, the scheduled end date / time of step 1, the scheduled start date / time of step 2 to step 3, the scheduled end date / time, and the scheduled start date / time of step 4 are set as “required time” and “transport time to next step” for each step. Calculate retroactively by adding the necessary amount.

  Next, the process development unit 104 determines whether or not the above processing has been executed for all product numbers (step S607). When the process is executed for all the product numbers, the process proceeds to step S608. When the process is not performed for all the product numbers, the process returns to step S601. In this way, the processing from step S601 to S606 is executed for each product number, and the processing order of all product numbers in each step is determined. This uses a so-called optimization technique, and an arbitrary optimization method can be used. For example, for the process 1, the process number processing order is optimized based on information such as the scheduled start date and time of other product numbers in the process 1. The production order ABC123 is assigned a processing order so as to start processing around “2009/08/01 4:58” at the latest. Note that the scheduled start date / time and the scheduled end date / time of all the processes obtained up to step S606 are the shortest processing as viewed from the delivery date / time. For example, when determining the processing order of each product number using the optimization technique in step S608, for example, Start the process ahead of schedule.

  In this embodiment, out of a plurality of input order information, order information that has the same product manufacturing specifications is aggregated as the same type of order information and assigned a unique product number, and other order information Each is given a unique production number. Then, for each assigned manufacturing management number, scheduling of each manufacturing process of the corresponding product is performed. Therefore, according to the present embodiment, in the material type manufacturing industry, it is possible to perform production planning / management that introduces a production number management technique, and it is possible to improve delivery efficiency and facilitate delivery date management.

  In addition, in this embodiment, for each product number, scheduling of the scheduled start time and the scheduled end time of each manufacturing process is performed, so that it is possible to know when and where the material, semi-finished product, and product exist in the future. It becomes possible to grasp the stock.

101: Aggregation unit 102: Product number assignment unit 103: Base material allocation unit 104: Process development unit

Claims (6)

Aggregation means for aggregating the order information that has the same product manufacturing specifications as the same kind of order information among a plurality of input order information,
An assigning unit that assigns a unique manufacturing control number to the same type of order information aggregated by the aggregating unit, and assigns a unique manufacturing management number to other order information,
A production management apparatus comprising scheduling means for performing scheduling in each production process of a corresponding product for each production management number assigned by the assigning means. The scheduling means assigns a manufacturing control number having the same manufacturing condition in each process to one work lot, determines the processing order of the manufacturing control number in each work lot, and performs scheduling. The production management device described. The scheduling means is a manufacturing control number based on at least the received quantity information, processing capacity information, yield rate information, transport time to the next manufacturing process, and product delivery date information of each manufacturing process. production control apparatus according to claim 1 or 2, wherein the scheduling scheduled start time and scheduled end time of each manufacturing process for each. For each production management numbers assigned by said assigning means, according to any one of claims 1 to 3, further comprising an allocation means for determining the allocation of the corresponding at least one base metal Production management device. A production management method using a production management device,
Aggregation step for aggregating the order information with the same product manufacturing specifications as the same kind of order information among the plurality of inputted order information,
An assigning step of assigning a unique manufacturing control number to the same kind of order information aggregated in the aggregating step, and assigning a unique manufacturing control number to the other order information,
A production management method comprising: a scheduling step for performing scheduling in each production process of a corresponding product for each production management number assigned in the assigning step. Aggregation step for aggregating the order information with the same product manufacturing specifications as the same kind of order information among the plurality of inputted order information,
An assigning step of assigning a unique manufacturing control number to the same kind of order information aggregated in the aggregating step, and assigning a unique manufacturing control number to the other order information,
A program for causing a computer to execute a scheduling step for performing scheduling in each manufacturing process of a corresponding product for each manufacturing management number assigned in the assigning step.

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