JP5613919B2 - Production line simulation apparatus and program - Google Patents

Description

  The present invention relates to a technique for simulating a product production line.

  In recent years, IT has been promoted in every situation, and production management systems are being developed in order to improve production efficiency even at production sites of products. In some manufacturing sites, a model of an existing production line is built on a computer and simulation is performed, which is useful for verifying the performance of the production line.

  For example, in Patent Document 1, operating state data in each process of a production line is collected, a production simulation model incorporating a probability model is generated based on the operating state data, and parameters are input to this model to execute a simulation. An apparatus is disclosed.

JP 2007-148827 A

  Many of the existing production line simulation apparatuses manually input parameters of each apparatus constituting the production line into a spreadsheet and input production management data. However, as the production line becomes larger and complicated, there is a problem that the operation of inputting production management data into a spreadsheet becomes very complicated.

  The present invention has been made in view of such a current situation, and an object thereof is to provide a process editor function for easily inputting production management data in a production line simulation apparatus.

  In order to solve the above-described problems, a production line simulation apparatus according to an aspect of the present invention is a production line simulation apparatus for calculating product production time and production capacity in a production line composed of a plurality of processes. A process editor for creating production management data that includes at least the input material data related to the material input to the process, the discharged material data related to the material discharged from the process, and the time required for the process for each process required until the end. Prepare. The process editor unit creates a process cell object displaying at least a part of the production management data for each process.

  It should be noted that any combination of the above-described constituent elements and a representation of the present invention converted between a method, an apparatus, a system, etc. are also effective as an aspect of the present invention.

  According to the present invention, production management data can be easily input in a production line simulation apparatus.

It is a figure which shows the structure of the production management system containing the production line simulation apparatus which concerns on one Embodiment of this invention. It is a figure which shows the whole process sequence of a production line simulation apparatus. It is a figure which shows the structure of a production line simulation apparatus. It is a figure which shows an example of the layout editor screen displayed on the display of a user terminal by a layout editor display part. (A) is a figure which shows an example of the table where an equipment parameter is stored, (b) is a figure which shows an example of the table where a physical distribution equipment parameter is stored. It is a figure which shows an example of the input form screen for setting a distribution equipment parameter. It is a figure which shows an example of the production management data sheet used with the conventional process editor. It is a figure which shows the process cell which concerns on one Embodiment of this invention. It is a figure which shows the state by which the process setting tab was selected in the input form screen. It is a figure which shows the state by which the use equipment setting tab was selected in the input form screen. It is a figure which shows the example of a process editor screen in the case of inputting the production management data of the production line of an bread and cream bread. It is a figure which shows the example of a process editor screen in the case of inputting the production management data of the production line of an bread and cream bread. It is a flowchart which shows the flow of the process in a production line simulation apparatus. It is a figure which shows the production line of a virtual example. It is a table | surface of the simulation result based on a virtual example. It is a setting screen of a factory CO ₂ emission factor. It is a graph of the CO ₂ emission amount result. It is a figure which shows an example of the list which displays the evaluation value about a some simulation result.

  One embodiment of the present invention simulates the production of a product on a production line in a factory, reflecting the actual layout of the devices constituting the line, the processing capacity and processing time of each device, the movement time between devices, and the like. The present invention relates to a production line simulation apparatus. The user constructs a virtual production line on the screen by using the layout editor function provided by the device, and inputs a process of the device on the production line by using the process editor function. It is possible to simulate the production quantity and production time of a product that is completed after that.

  In this specification, “Production line” is the connection of multiple processes to obtain a certain final product, and “Equipment” is the function of each facility, such as machinery and equipment. Input materials, parts, and assemblies are referred to as “input materials”, materials, parts, and assemblies that are discharged from each process are referred to as “exhaust materials”, and handling units of input materials or exhaust materials are referred to as “lots”. Call.

  FIG. 1 shows a configuration of a production management system 100 including a production line simulation apparatus 10 according to an embodiment of the present invention. The production management system 100 includes terminals 20a to 20d that are examples of production management apparatuses, a production line simulation apparatus 10, and a network 12 that connects them.

FIG. 2 is a diagram illustrating an overall processing procedure of the production line simulation apparatus 10 according to the present embodiment. In the production line simulation apparatus 10, first, a layout of a factory where the production line is installed is created using a layout editor (S10). Subsequently, details of each process such as processing, assembly, and packing in the production line are set using the process editor (S12). Next, a simulation simulating an actual production line is executed using the created layout and process flow (S14). When the simulation result is obtained, post-processing such as CO ₂ emission calculation using the result is executed, or the simulation result or calculation result is output to the user terminal in a graph or table format (S16).

  FIG. 3 shows a configuration of the production line simulation apparatus 10. The production line simulation apparatus 10 mainly includes a layout editor unit 30, a process editor unit 40, a simulation execution unit 50, a post-processing unit 60, a display control unit 80, and an import / export unit 82. Each block shown here can be realized in terms of hardware by elements such as a CPU and a memory of a computer, and in terms of software, it can be realized by a computer program or the like loaded in the memory. It is drawn as functional blocks realized by cooperation. Therefore, those skilled in the art will understand that these functional blocks can be realized in various forms by a combination of hardware and software.

  The user can input data necessary for the simulation or browse the output result via the user terminal 20 connected to the production line simulation apparatus 10. The user terminal 20 is typically a personal computer, and includes a mouse and a keyboard as input devices, a display as an output device, a hard disk drive as a recording device, a recording medium reading device, and the like.

  The layout editor unit 30 provides the user terminal 20 with a layout editor screen for creating a layout of equipment, personnel, transportation means, etc. in a factory or the like that is the target of a production line simulation. In addition, the layout editor unit 30 also provides the user terminal 20 with an input form screen for setting detailed information of equipment constituting the layout. The layout created by the layout editor unit 30 is sent to the simulation execution unit 50.

  The process editor unit 40 sets detailed information of each process constituting the production line and provides the user terminal 20 with a process editor screen for creating a process flow diagram expressing the connection between the processes. The process flow created by the process editor unit 40 is sent to the simulation execution unit 50.

  The simulation execution unit 50 executes a simulation simulating an actual production line based on the created layout and process flow.

The post-processing unit 60 calculates a CO ₂ emission amount based on the simulation result, and calculates an evaluation value for determining superiority or inferiority between the simulation results.

  The display control unit 80 outputs a layout editor screen, a process editor screen, or a simulation result graph or table created by the layout editor unit 30, the process editor unit 40, and the post-processing unit 60 to the user terminal 20.

  The import / export unit 82 imports data such as production management data, layout sheets, and various parameters that have already been used for simulation, or the data created by the production line simulation device 10 to the user terminal 20. Or export. The import / export unit 82 may have a function of converting these data into a data format that can be read by the production line simulation apparatus 10.

  Further detailed configurations and functions of the layout editor unit 30, the process editor unit 40, the simulation execution unit 50, and the post-processing unit 60 will be described later with reference to related drawings.

  Next, details of the layout editor unit 30 will be described. As shown in FIG. 3, the layout editor unit 30 includes a layout editor display unit 32, an input form control unit 34, a layout sheet holding unit 36, a layer holding unit 38, and a parameter holding unit 39.

  The layout editor display unit 32 displays a layout editor for constructing a production line model on the display of the user terminal 20. The layout sheet holding unit 36 holds a layout sheet that defines a production line model. The layer holding unit 38 holds a layer that defines a flow line of a material between processes on the production line by overlapping the layout sheet.

  The input form control unit 34 displays an input form for allowing the user to input various data necessary for the simulation on the layout editor. As the input form, there are an equipment parameter input form, a logistics equipment parameter input form (FIG. 6), and the like. The parameter holding unit 39 holds equipment parameters that define the performance of equipment in each process, logistics equipment parameters that define the performance of logistics equipment that transports materials, and the like set in the input form.

  FIG. 4 shows an example of the layout editor screen 150 displayed on the display of the user terminal 20 by the layout editor display unit 32. The user can use the layout editor to build a model of a real or virtual factory production line on the computer.

  The layout editor screen 150 is composed of three areas. The floor area 110 is an area in which a floor image 112, which is a reduced image of a production line layout sheet, is displayed corresponding to the number of floors. Any one of the floor images 112 is highlighted by the user's selection, and the layout sheet of the selected floor is displayed in the layout area 130. Although only three floor images are shown in this figure, the number of floor images can be increased or decreased in accordance with the actual number of floors on which a layout sheet is created. A plurality of floor images may be set corresponding to the production lines on each floor of the factory, or a plurality of floor images may be set corresponding to the separate production lines of different factories. The floor images can be associated by defining movement between floors. For example, if the floor image corresponds to the production line on each floor of the factory, the elevator should be placed at the same position on the layout sheet of each floor to represent one production line that moves the material between floors. Can do. When each floor image corresponds to a separate production line, it can be related by defining that the end of one production line and the start of the other production line are connected by truck delivery.

  In the layout area 130, a layout sheet editing screen for the floor highlighted in the floor area 110 is displayed. Although it is desirable that a grid corresponding to a predetermined dimension (for example, 50 cm × 50 cm) of an actual factory is displayed on the layout sheet, the grid is omitted in this figure for easy viewing. doing. On the layout sheet editing screen, the user selects and arranges icons 132 corresponding to each process of the production line, and creates a layout sheet in which the actual line is reduced. For example, an icon corresponding to a desired process can be selected from an icon menu superimposed on the screen by selecting a toolbar (not shown) displayed at the top of the layout sheet editing screen or by right-clicking. The icon 132 may be an illustration corresponding to the process, or may be a text with a description in a square frame as shown in the figure. As an example, in the icon 132 in the figure, “ELV” represents an elevator, “ISP” represents an inspection process, “MC” represents a machining process, and “ASM” represents an assembly process.

  The layout sheet is created so that the positional relationship between icons corresponds to the actual positional relationship between each process. For example, when the distance between the process “ISP1” and the process “MC2” is 1 m, the respective icons are arranged apart from each other by two grids.

  The layer area 120 is an area for displaying layers 122 to 128 that define a transport route between processes for each physical distribution equipment. In the example of FIG. 3, the layer 122 defines a transport route on which an automated guided vehicle (AGV) travels, the layer 124 defines a transport route on which a forklift travels, and the layers 126 and 128 are used by a worker on a carriage. The route to carry is defined by. Black dots in each layer are displayed corresponding to process icons in the layout editing screen.

  A layer is defined for each logistics equipment. The user, for example, calls a layer editing screen (not shown) by clicking any layer in the layer area 120, and defines the transportation route for each physical distribution equipment by connecting the black dots corresponding to the processes with line segments. can do. For example, the layer 122 represents that the AGV carries between the processes “MC2” and “ASM1” and between the processes “ISP3” and “ISP4”. In this example, the transport route is a straight line, but the transport route may be defined by a curved line or a bent line. A production line model is expressed by superimposing all the layers created in this way on the layout sheet.

  As will be described later, the production line simulation apparatus 10 recognizes which physical distribution equipment is used by referring to a layer when calculating a material conveyance time between processes. Therefore, by defining a transport route using a plurality of layers as described above, it is possible to create a layout sheet in which different logistics equipments are mixed in one production line. In addition, by defining the movement speed and the transportable amount of each physical distribution equipment in the physical distribution equipment parameters described later, it is possible to simulate a complex production line with different movement times and transport amounts between processes.

FIG. 5A shows an example of a table 300 in which equipment parameters are stored. In the present embodiment, one piece of equipment corresponds to each process. The equipment includes mechanical equipment such as lathes, mixers, and packaging machines, and manual work such as packing.
The equipment name 302 represents the name of the equipment corresponding to each process. A type 304 represents a type name such as processing, inspection, and assembly. The failure rate 306 and the recovery time 308 represent the failure rate of each equipment and the recovery time at the time of failure. The defect rate 310 represents the rate of occurrence of defective products when materials are processed with each equipment. The buffer number 312 represents the upper limit number of materials that can be held in the equipment before processing, inspection, assembly, or the like in each equipment. The failure rate, recovery time, and failure rate may be set using the statistical data of the various devices that make up the production line if the production line already exists, and new installations, changes, and expansions of the production line are considered. In that case, a prospective value may be set.

FIG. 5B shows an example of a table 500 in which logistics equipment parameters are stored. As the logistics equipment name 502, a name corresponding to the logistics equipment defined in the layer of FIG. 3 is set. The failure rate 504 and the recovery time 506 represent the failure rate of each physical distribution equipment and the recovery time at the time of failure. A speed 508 represents a moving speed of the AGV, forklift, worker, and the like. The load time 510 represents the time required for each logistics equipment to be transported. These values may be set using statistical data of various devices that make up the production line if the production line already exists, and are expected when considering the establishment, change, or expansion of the production line. A value may be set. In this way, by individually setting parameters for each logistics equipment, a plurality of logistics equipment can be verified in a mixed manner in the production line to be simulated.

As described above, the equipment parameters and the logistics equipment parameters can be set through the input form screen provided by the input form control unit 34. FIG. 6 is an example of such an input form screen, and shows a screen 400 for setting the logistics equipment parameters shown in the table of FIG. As illustrated, the input form screen 400 includes input areas for a logistics equipment name 402, a failure rate 404, a recovery time 406, a speed 408, and a load time 410. These correspond to items 502 to 510 in FIG. Input form screen 400 further input region of each distribution equipment can transport lot size 412, number 414 logistics equipment, CO ₂ emissions 416 logistics equipped moving, CO ₂ emissions 418 in the physical distribution equipment is stopped including. The input form screen 400 may include input areas for items other than those described above, or may not include input areas for some of the above items.

Although not shown, the input form screen for setting the equipment parameters also has the same configuration as FIG. 6 except that the item names are different. However, in order to perform the calculation of the CO ₂ emissions, which will be described later, the input area for setting the CO ₂ emissions stopped and CO ₂ emissions in operation for each equipment is provided.

  Next, the process editor unit 40 will be described. As shown in FIG. 3, the process editor unit 40 includes a process editor display unit 42 and a production management data holding unit 46.

  The process editor display unit 42 sets, on the display of the user terminal 20, data related to each process constituting the production line, and displays a process editor for setting a connection between processes.

  The production management data holding unit 46 holds production management data in which data relating to input materials and data relating to discharged materials are set for each process required from the start to the end of product production, which is set in the process editor.

  FIG. 7 shows an example of a production management data sheet 200 used in a conventional process editor. This production management data sheet 200 is created for an ampan and cream bread production line. The production management data sheet 200 is created in a spreadsheet format such as Excel or a text format such as CSV.

  The “product name” column 202 represents the names of products produced on the production line. The “flow number” column 204 represents a flow number indicating a connection before and after the process. A “flow name” column 206 represents a name for each flow. The “process” column 208 includes a column representing the order, number, name, and step number of each process. The “process” column 208 also includes a “type” column 209 indicating that there is a merge or division between lines, which will be described later. The “merging / dividing” column 210 defines the merging destination of the line or the dividing destination of the line indicated by the type column 209 by the flow number. The “input material information” column 212 includes columns indicating the name, lot size, lot unit, and lot number of materials input to each process. Similarly, the “discharge material information” column 214 includes columns representing the name, lot size, lot unit, and lot number of materials discharged from each process. A “required time” column 216 represents a time required for processing the material.

  In this specification, “join” means that a plurality of lines are integrated into one line. For example, it corresponds to processes such as assembling a plurality of parts processed in different sublines, mixing a plurality of materials, and wrapping one part with another part. It is also possible to join two or more sublines simultaneously to one main line. The merging process corresponds to providing a plurality of distribution equipment routes that proceed to a predetermined process on the layer on the layout editor screen of FIG.

  “Division” means that one line is divided into a plurality of lines. For example, it corresponds to a process of continuously processing a part cut in a certain process on separate lines or subdividing a material. It is also possible to merge the divided line with another line, further divide the line into a plurality of lines, or rejoin the divided line. The division process corresponds to providing a plurality of distribution equipment routes that advance from a predetermined process to another process on a layer on the layout editor screen of FIG.

  When such a conventional production management data sheet 200 is used, the user imports a production management data sheet prepared in advance in the user terminal into the production line simulation apparatus, or a production management data sheet provided by the simulation apparatus. The necessary data was entered on the input form.

  However, in the production management data sheet as shown in FIG. 7, it is difficult to express the connection between the processes because each process is arranged in a line. In particular, when processes are merged or processes are divided, they must be defined using the “Type” column 209 in the data sheet, so it is possible to visually grasp the process flow. It becomes difficult. This tendency becomes more pronounced in production lines with hundreds of processes, complex merges and divisions.

  Therefore, in the present embodiment, a process editor function is provided that can easily edit the production management data sheet and can visually grasp the connection between the processes.

  The process editor display unit 42 prompts the user to input production management data using a “process cell” object 600 as shown in FIG. One process constituting the production line corresponds to one process cell 600. As an example, the process cell 600 has a shape in which a large rectangular region 601 is sandwiched between two small rectangular regions 602 and 604. The process cell 600 is displayed on the editor screen by selecting a predetermined menu item, clicking a button, or dragging and dropping an icon on the process editor screen displayed on the display of the user terminal 20. You can create any number.

  An upper rectangular area (hereinafter referred to as “input lot area”) 602 represents the number of input lots for the process. A lower rectangular area (hereinafter referred to as “discharge lot area”) 604 represents the number of discharged lots from the process. In FIG. 8, the number of input lots and the number of discharged lots are both “1”. In other words, this process corresponding to the process cell 600 indicates that one lot is discharged after some processing or processing is performed on one lot. In the case where there are a plurality of processes serving as input lot carry-in sources or discharge lot transfer destinations, a corresponding number of rectangular regions 602 or 604 are created.

  A central rectangular area 601 represents the contents of processing performed in this step. As shown in the figure, the rectangular area 601 includes “process name” 610, “process time” 612, “process division availability” 614, “start time setting availability” 616, “entry process setting availability” 618, “available equipment”. Number of units ”620 and“ Process ID ”622 are included. “Process name” is the name of the process. “Process time” is an operation time required for the process. “Presence / absence of process division” is a flag indicating whether or not the process can be divided. “Start time setting presence / absence” is a flag indicating whether or not a time for starting the process is set. “Incoming / outgoing process setting presence / absence” is a flag indicating whether or not the process is an incoming process. “Available equipment” indicates the number of equipment that can be used in the process. “Process ID” is an ID assigned to the process.

  Note that items other than the above may be included in the process cell, or some of the above items may not be included. Further, the shape of the process cell is not limited to that shown in FIG.

  A plurality of process cells 600 are connected by links 606 and 608. The upper link 606 is connected to the process cell of the input lot, and the lower link 608 is connected to the process cell of the discharge lot. As will be described later, the link can be easily created on the process editor using a mouse or the like.

  Input of data to the process cell 600 is performed via an input form screen 700 shown in FIGS. The input form screen 700 is displayed by, for example, double-clicking a process cell on the process editor displayed on the display of the user terminal 20 or selecting a predetermined menu item. The input form screen 700 includes a process setting tab 702, a process detail setting tab 704, a used equipment setting tab 706, and an operator setting tab 708. By selecting these tags, data input items can be switched.

  FIG. 9 shows a state where the process setting tab 702 is selected. Here, process ID 710, process name 712, work time 714, input lot information 716 and discharge lot information 718 can be set. These correspond to the number of the process 208, the name of the process 208, the required time 216, the input material information 212, and the discharge material information 214, respectively, in the conventional production management data sheet 200 shown in FIG.

  FIG. 10 shows a state where the use equipment setting tab 706 is selected. Here, equipment to be assigned to each process can be selected from the list 730. This list is created by the process editor display unit 42 using the equipment parameters set in the layout editor unit 30. Select the equipment to be assigned from the candidate list 738 on the right side and press the “Add” button 732 to add it to the left side list 730, or select the unnecessary equipment from the left side list 730 and press the “Delete” button 734 to delete it. can do. The equipment to be allocated may be displayed in the list 730 for each layer stored in the layer holding unit 38. In this case, a “layer selection” button 736 may be pressed to select a desired layer.

  In this way, data is input for each process using the input form, and the contents are collectively displayed in the process cell. Therefore, it is easy to grasp the process that is inputting data, and each process can be easily identified at a glance. Therefore, the burden on the user who inputs data is reduced.

  FIG. 11 and FIG. 12 show an example of a process editor screen when inputting production management data of an bread and cream bread production line using the process editor of the present embodiment.

  The user creates a process cell for each process constituting the production line on the process editor screen provided by the simulation apparatus. At this stage, there is no need to consider the order or connection between the processes. FIG. 11 shows a state where the process cells P602, P405, P406, P104, P505, and P606 corresponding to some processes in the bread production line have been input. The process cell number corresponds to the process number in the production management data sheet 200 of FIG.

  FIG. 12 shows a state in which processes are connected by a link corresponding to an actual production line. The process editor sets a pointer (not shown) for each of the rectangular areas above and below the created process cell (that is, each of the input lot area and the discharged lot area. By clicking the pointer with a mouse or the like, a link can be easily set between two process cells.

  As shown by process cells P405 and P505 in FIG. 12, a process cell in which two or more input lots are set represents that a plurality of sublines are merged in the process. For this reason, each input lot is connected to a discharge lot of a different process cell by a link. Further, as indicated by the process cell P104, the process cell in which two or more discharge lots are set represents that it is divided into a plurality of sublines in the process. For this reason, each discharge lot is connected to the input lot of a different process cell by a link.

  Further, the standby state of each process can be expressed by adjusting the number of discharged lots and input lots connected by links. For example, in the process cell 405, two input lots are both “100” and one discharge lot is “100”. This represents that, in the corresponding process, the cream for 100 cream breads and the dough for 100 creams are received and the bread containing 100 creams is discharged. In other words, in this process, the processing is not started until 100 creams and bread dough arrive.

  In this way, a process flow representing the flow of the process of the production line to be simulated can be created on the process editor.

  The created process flow may be converted into a conventional spreadsheet format as shown in FIG. 7 by a conversion unit (not shown) and stored in the production management data holding unit 46. The stored sheet may be exported to the user terminal 20 as a production management sheet via the import / export unit 82. Conversely, the process editor display unit 42 may operate to analyze the production management sheet imported by the import / export unit 82 and display it on the process editor as a process cell format as shown in FIG. Thereby, when simulating a similar production line, an existing production management sheet can be utilized.

  As described above, in the process editor of this embodiment, the process management data can be easily input and edited by adopting the process cell. Moreover, the connection between processes can be expressed only by rearranging the process cells on the screen on the process editor and connecting them with links. In addition, the process flow can be visually grasped on the editor. In addition, since the connection between processes can be easily changed, it is easy to study the optimum material flow line.

  A plurality of lines arranged in parallel can be created on one screen, and different colors may be set for each line. This facilitates comparison between lines.

  Next, the function of the simulation execution unit will be described. As shown in FIG. 3, the simulation execution unit includes a calculation unit 54 and a result holding unit 56.

  The computing unit 54 refers to the process flow created by the process editor unit 40 and the layout sheet, layer, and various parameters created by the layout editor unit 30, and the processing quantity and processing time of the material in each process of the production line And so on. Furthermore, based on the calculation results, the number of final products produced, production time, and the like are calculated. The simulation result is stored in the result holding unit 56.

  More specifically, when the process flow as shown in FIG. 12 is created by the process editor unit 40, the calculation unit 54 refers to the input material data for the process at the head of the line and the equipment parameters for the process. Then, the time required for processing in the process is calculated. Thereafter, referring to the discharged material data, the transport route to the next process, and the distribution equipment parameters, the time required for transport to the next process is calculated. For example, the transfer time can be calculated from the number of grids between processes on the layout sheet and the speed of the logistics equipment parameter corresponding to the layer that defines the transfer route between the processes. After the material is discharged, the process calculates the processing time for the next input material. In this way, by calculating the processing time and processing unit of materials in each process, and the transfer time between processes, it is possible to achieve the number of final products produced within the operating time or the predetermined number of products produced. The required production time can be obtained.

  In addition, since the simulation method itself which calculates such a production number and production time is well-known, the detailed description beyond this is abbreviate | omitted in this specification.

  The calculation unit 54 may record a log of calculation (for example, production start time, required production time, etc.) performed for each lot in each process. By referring to this log, it is possible to easily grasp in which process an in-process has occurred, which part of the line is a bottleneck, and whether the input timing of the material is appropriate.

  In addition, based on the failure rate and recovery time set in the equipment parameters, the calculation unit 54 performs the above calculation in consideration of the probability of failure occurring in the equipment, so that the actual production line operation status Can be more accurately reflected in the simulation. This makes it possible to determine whether equipment with a high failure rate should be replaced and the cost-effectiveness of replacement based on the rate of increase in the number of products produced.

FIG. 13 is a flowchart showing the flow of processing in the production line simulation apparatus according to the present embodiment.
First, on the layout screen provided by the layout editor display unit 32, the user creates a layout sheet expressing a production line to be simulated and a layer defining logistics equipment between processes (S30). The created layout sheet and layer are stored in the layout sheet holding unit 36 and the layer holding unit 38, respectively. In addition, on the input form screen provided by the input form control unit 34, the user creates equipment parameters that define the performance of equipment in each process and logistics equipment parameters that define the performance of each physical equipment (S32). . The created parameter is stored in the parameter holding unit 39.

  Further, the user creates a process flow expressing the flow between steps on the process editor screen provided by the process editor display unit 42 (S34). The created process flow is converted into production management data and stored in the production management data holding unit 46. Further, the user sets the operation time of the production line (S36). Note that the order of S30 to S36 can be arbitrarily changed.

  The calculation unit 54 refers to the production management data, layout sheet, layer, and various parameters, and calculates the production time, the number of products, etc. of the product in a given production line (S38). The simulation result is stored in the result holding unit 56. (S40).

  The user refers to the simulation results, repeats the simulation after taking measures such as rearranging the production line on the layout sheet, replacing a part of the equipment with another equipment, and changing the logistics equipment. It is possible to check whether the production number can be increased or whether the planned number can be produced within a desired period.

  As described above, a model of a production line composed of the same processes as an actual production line in a factory can be configured on a computer and a simulation can be executed. This makes it possible to predict delivery times when processing conditions are changed, plan production plans, verify factory designs, verify production process improvements, verify equipment and personnel placement, analyze proximity, detect and respond to bottlenecks, and equipment It can be used to judge the situation.

  In addition, by defining a transport route between processes using layers, movement by a plurality of logistics equipment having different transport capabilities can be mixed in a production line to be simulated. Changes in production efficiency due to differences in logistics equipment can be easily calculated by exchanging layers.

  Further, by creating a process flow diagram on the process editor screen, it is possible to perform a simulation by expressing a production line including complicated processes such as merging and dividing between lines. Thereby, a production line simulation apparatus can be applied to a wide range of industries. As an example, the production line simulation apparatus according to the present invention appropriately creates materials, equipment parameters, and the like in production management data in accordance with the actual production line, thereby enabling the automobile industry, precision parts industry, electrical / electronic parts industry, semiconductors. Applicable to any manufacturing industry such as industry, pharmaceutical industry and food industry.

Subsequently, the function of the post-processing unit 60 will be described. The post-processing unit 60 includes a CO ₂ emission calculation unit 70 and an evaluation unit 62.

The post-processing unit 60 refers to the simulation result stored in the result holding unit 56, and calculates an amount of CO ₂ discharged from the entire factory when the production line to be simulated is started up; And a coefficient setting unit 74 that outputs a coefficient setting screen necessary for calculating the CO ₂ emission amount to the user terminal 20.

Hereinafter, calculation of the CO ₂ emission amount in the present embodiment will be described based on a virtual case. FIG. 14 shows a production line for virtual cases. In the figure, squares indicate equipment and solid lines indicate transport routes. Here, it is assumed that two types of simulations in which the speed of logistics equipment is changed are executed. In “Verification 1”, the speed of logistics equipment was set to 20 m / min, and in “Verification 2”, the speed of logistics equipment was set to 30 m / min.

  FIG. 15 is a table 900 of simulation results by the simulation execution unit based on virtual cases. As shown in the simulation result 904, the simulation execution unit calculates equipment movement time, equipment standby time, physical distribution equipment movement time, physical distribution equipment standby time, factory operation time, and factory stop time.

FIG. 16 shows a setting screen 950 for the factory CO ₂ emission factor. As shown in the drawing, it is possible to set a CO ₂ emission amount 952 per unit area / unit time when the factory is operating and a CO ₂ emission amount 954 per unit area / unit time when the factory is stopped. The CO ₂ emission amount per unit time during operation and stoppage of equipment and logistics equipment can be set in each parameter input form as shown in FIG. These CO ₂ emission amounts may be based on actual measurements or may be virtual values.

The computing unit 72 calculates the CO ₂ emission amount based on the simulation result 904 of FIG. In this embodiment, the calculating part 72 calculates the CO ₂ emission amount of equipment and physical distribution equipment separately. For these, the CO ₂ emissions are calculated respectively during operation and during standby. In addition, the amount of CO ₂ emitted by factories that are not included in the production line, such as air conditioning and lighting, is also calculated.

Specifically, the following E1 to E6 are calculated using the simulation result 904.
-CO ₂ emissions during equipment operation: E1 = Σ {CO ₂ emissions during equipment operation (kg / hour) x equipment operation time (hours)}
・ CO ₂ emissions during equipment standby: E2 = Σ {CO ₂ emissions during equipment standby (kg / hour) x equipment standby time (hours)}
-CO ₂ emissions during logistics equipment operation: E3 = Σ {(CO ₂ emissions during logistics equipment operation (kg / hour) x logistics equipment operation time (hours))
-CO ₂ emissions during logistics equipment standby: E4 = Σ {(CO ₂ emissions during logistics equipment standby (kg / hour) x logistics standby time (hours))}
・ CO ₂ emissions during factory operation: E5 = {CO ₂ emissions during factory operation (kg / hour / m ² ) × factory area (m ² ) × factory operation time (hours)}
-CO ₂ emissions during factory shutdown: E6 = {CO ₂ emissions during factory shutdown (kg / hour / m ² ) × factory area (m ² ) × factory shutdown time (hours)}

In addition, since a plurality of equipment and logistics equipment are included in the production line, the above E1 to E4 calculate the CO ₂ emission amount for each equipment or logistics equipment when it is in operation and in standby, respectively. It is calculated by summing up logistics equipment. On the other hand, E5 and E6 are calculated one by one for the whole factory.

Finally, the CO ₂ emission amount E discharged from the entire factory is calculated by the following equation.
E = E1 + E2 + E3 + E4 + E5 + E6

The CO ₂ emission result 906 in FIG. 15 shows E1 to E6 and E calculated as described above. From these results, it is possible to calculate the discharge amount per unit equipment, the discharge amount per unit area, and the discharge amount per unit process.

FIG. 17 shows a state 980 in which the calculation unit 72 graphs verification 1 and verification 2 based on the CO ₂ emission result 906 of FIG. 15. As illustrated, each item of the CO ₂ emission result 906 is displayed in a graph with a different color. In the figure, the bold line graph at the top represents the emission amount E of the entire factory. This graph makes it possible to visually grasp the CO ₂ emission amount in each verification.

Generally, on the production line site, unexpected situations such as equipment failures, equipment capacity differences, and production quantity changes frequently occur. In the present embodiment, it is possible to execute the production simulation in consideration of the above-described events a plurality of times after virtually constructing the same process as the site using the layout editor and the process editor. Since the CO ₂ emission amount is calculated for each simulation result, changes in various events can be immediately reflected in the CO ₂ emission amount.

Further, by calculating the emission amount based on the result of the production simulation, the number of products produced and the CO ₂ emission amount can be obtained at one time. For this reason, for example, the CO ₂ emission amount per product can be accurately calculated.

FIG. 18 shows an example of a list 1000 that is created by the evaluation unit 62 and displays a plurality of simulation results. As shown, the results of the simulation performed are arranged in column 1004. Each item of the simulation result is represented in a row 1002. “Simulation name” is a name given to each simulation. The “total time required” is the time required to complete all processes in a production line to be simulated under given conditions. “Layout” is the name of the layout sheet used in the production line to be simulated. "Total CO ₂ emission amount", calculated by the CO ₂ emission amount calculating unit based on each simulation, a CO ₂ emissions from the entire plant. “Overall equipment availability” and “overall logistics availability” are average values of the availability of all equipment or logistics equipment included in the simulation target production line. The “maximum in-process inventory quantity” and “average in-process inventory quantity” are the maximum value or average value of the in-process inventory quantity generated in the production line. The “maximum number of workers” is the maximum number of workers required to operate the production line. Items other than these are also included in the list.

Further, the evaluation unit 62 can calculate an evaluation score for each simulation result. The evaluation score is calculated as follows, for example. First, for each evaluation item shown in the row 1002 of the table 1000, a ranking (evaluation ranking) is given from a preferable simulation result. For example, if it is “total CO ₂ emission amount”, it is preferable that the value is smaller. Therefore, Sim2 is ranked first, Sim1 is ranked second, and Sim3 is ranked third. Subsequently, the user assigns a weighting order for each evaluation item. That is, the user sets which evaluation item is more important. For each simulation result, (evaluation rank) × (weighting rank) is calculated for all evaluation items, and the sum is obtained. For example, if the evaluation rank is 8th and the weighting is 10th, the evaluation item is 80 points. The obtained value is set as the evaluation value of the simulation result. The smaller the evaluation value, the better the simulation result.

  By referring to this list, it is easy to make a decision of a user who repeatedly executes a simulation for various combinations of layouts and process conditions and selects an optimal combination from the simulations.

  In addition to the above, the post-processing unit 60 may have a function of displaying a Gantt chart, an operation rate graph, a proximity analysis result, and the like as an image based on the simulation result.

  The present invention has been described based on the embodiments. This embodiment is an exemplification, and it will be understood by those skilled in the art that various modifications can be made to combinations of the respective constituent elements and processing processes, and such modifications are also within the scope of the present invention. is there.

DESCRIPTION OF SYMBOLS 10 Production line simulation apparatus, 12 Network, 20 Terminal, 30 Layout editor part, 32 Layout editor display part, 34 Input form control part, 36 Layout sheet holding part, 38 Layer holding part, 40 Process editor part, 42 Process editor display part , 44 input form control unit, 46 production management data holding unit, 48 parameter holding unit, 50 simulation execution unit, 52 line configuration unit, 56 result holding unit, 60 post-processing unit, 62 evaluation unit, 70 CO ₂ emission calculation unit 72 calculation unit, 74 coefficient setting unit, 80 display control unit, 82 import / export unit.

Claims (3)

In a production line simulation device that calculates the production time and production capacity of products in a production line consisting of multiple processes,
For each process required from the start to the end of product production, to create input material data related to materials input to the process, discharged material data related to materials discharged from the process, and production management data including at least the time required for the process With a process editor
The process editor unit creates a process cell object in which at least a part of the production management data is displayed for each process, and sets an input lot area including the number of input materials to each process, and the number of discharged materials from each process. Displaying the lot lot area to be included in the process cell, and by associating the lot lot area and the input lot area with a plurality of process cells, to express the flow between processes,
The process editor unit associates the discharge lot areas of a plurality of process cells with the input lot areas of one process cell to express a merge between production lines, and the discharge lot areas of a plurality of process cells have one process cell. A production line simulation apparatus that waits for processing in the one process cell until processing in the plurality of process cells is completed . Said process editor unit, by associating the discharge lot area of one process cell input lot area of the process cells of multiple production lines simulation according to claim 1, characterized in that to represent the division of the production line apparatus. For each process required from the start to the end of product production, to create input material data related to materials input to the process, discharged material data related to materials discharged from the process, and production management data including at least the time required for the process With the process editor function of
Based on the production management data, a function for calculating the production time and production capacity of a product in a production line consisting of a plurality of processes;
A production line simulation program for realizing a computer
The process editor function creates a process cell object in which at least a part of the production management data is displayed for each process, and sets an input lot area including the number of input materials to each process and the number of discharged materials from each process. Displaying the lot lot area to be included in the process cell, and by associating the lot lot area and the input lot area with a plurality of process cells, to express the flow between processes,
The process editor function associates the discharge lot areas of a plurality of process cells with the input lot areas of one process cell, thereby expressing the merge between production lines, and the discharge lot areas of a plurality of process cells are one process cell. A production line simulation program configured to wait for processing in the one process cell until processing in the plurality of process cells is completed .

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