JP6215173B2 - Manufacturing management system, manufacturing management method, and manufacturing management program - Google Patents

Description

  Embodiments described herein relate generally to a manufacturing management system, a manufacturing management method, and a manufacturing management program.

  In a production site, a plurality of production lines each having a plurality of processes are often provided. In this case, the product is manufactured through a plurality of processes included in each manufacturing line. In the production line, it is ideal that the processing time of each process is the same in order not to generate a product waiting for processing. However, it is not easy to actually construct such a production line. Therefore, in an actual production site, there may be a process in which a stock waiting to be processed is generated and a process in which a stock to be processed is insufficient. If there is a process in which inventory is waiting to be processed or a process in which inventory to be processed is insufficient, production efficiency decreases. For this reason, development of a technique for improving such a situation has been desired at the production site.

JP 2004-295192 A

  The problem to be solved by the present invention is to provide a manufacturing management system, a manufacturing management method, and a manufacturing management program capable of improving production efficiency.

  The manufacturing management system according to the embodiment manages a plurality of manufacturing lines, each consisting of a plurality of processes. The manufacturing management system includes a detection unit, a history acquisition unit, a setting unit, an upper limit comparison unit, a lower limit comparison unit, and a determination unit. The detection unit detects the number of stocks at a reference time for each of the processes in the plurality of production lines. The history acquisition unit acquires a conveyance status of the inventory between the plurality of production lines before the reference time. The setting unit sets a lower limit value and an upper limit value of the number of the inventory at the reference time for each of the steps. The setting unit determines the upper limit value by using the lower limit value and the time required for transporting the inventory acquired by the history acquisition unit. The upper limit comparison unit compares the number of stocks and the upper limit value in each of the processes, and extracts an excess process in which the number of stocks exceeds the upper limit value. The lower limit comparison unit compares the number of stocks in each of the steps with the lower limit value, and extracts an insufficient process in which the number of stocks is below the lower limit value. The determination unit determines whether the excess process and the insufficient process are processes in which the stock can be delivered. The determination unit determines conveyance of the inventory from at least one excess process to at least one insufficient process capable of delivering the inventory.

1 is a block diagram illustrating a manufacturing management system according to a first embodiment. The block diagram showing the relationship between the manufacturing management system which concerns on 1st Embodiment, a manufacturing line, and a conveyance part. The flowchart of the manufacturing management program which concerns on 1st Embodiment. The block diagram showing the manufacture management system concerning a 2nd embodiment. The flowchart of the manufacturing management program which concerns on 2nd Embodiment. The block diagram showing the relationship between the manufacturing management system which concerns on 3rd Embodiment, a manufacturing line, and a conveyance part.

Hereinafter, embodiments will be illustrated with reference to the drawings. In addition, in each drawing, the same code | symbol is attached | subjected to the same component and detailed description is abbreviate | omitted suitably.
In this specification, the final product and the semi-finished product are collectively referred to as a product. A semi-finished product is a product in a manufacturing process that has been processed in process units but has not yet reached a final product. In each process, a product waiting for processing to start is referred to as inventory.

(First embodiment)
A manufacturing management system 10 according to the first embodiment will be described with reference to FIGS. 1 and 2.
FIG. 1 is a block diagram showing a manufacturing management system 10 according to the first embodiment.
FIG. 2 is a block diagram showing the relationship between the manufacturing management system 10, the manufacturing line 20, and the transport unit 30 according to the first embodiment.
The production management system 10 manages a plurality of production lines 20.

As illustrated in FIG. 1, the manufacturing management system 10 includes a detection unit 1, a history acquisition unit 2, a setting unit 3, an upper limit comparison unit 4, a lower limit comparison unit 5, and a determination unit 6.
As shown in FIG. 2, the production management system 10 is connected to a plurality of production lines 20 (20a, 20b, and 20c) and a plurality of transfer units 30 (30a, 30b, and 30c).
In FIG. 2, as an example, the case where the manufacturing management system 10 is connected to three manufacturing lines and three transport units is shown. The production management system 10 may be connected to more production lines and conveyance units.

  Each production line 20 includes a plurality of processes. For example, the production line 20a includes steps 20a1, 20a2, 20a3,. In each production line 20, products are exchanged between the plurality of steps, and predetermined processes are sequentially performed on the products.

  The conveyance unit 30 transfers stock between the plurality of production lines 20. For example, delivery of inventory is performed between the production lines 20a and 20b by the transport unit 30a.

The detection unit 1 detects the number of stocks at each reference time for each process. The detection unit 1 outputs the detected stock quantity to the upper limit comparison unit 4 and the lower limit comparison unit 5.
First, as an example, a case where the reference time is the current time will be described.

  The history acquisition unit 2 acquires the conveyance status of inventory by the conveyance unit 30 before the reference time. The history acquisition unit 2 outputs to the setting unit 3 the time required for the conveyance of the inventory in the conveyance unit 30. For example, the history acquisition unit 2 extracts the latest conveyance time with respect to the reference time, and outputs the extracted conveyance time information to the setting unit 3. Alternatively, the history acquisition unit 2 may output an average conveyance time by the conveyance unit 30 before the reference time to the setting unit 3.

  The setting unit 3 sets a lower limit value and an upper limit value at the reference time for each process with respect to the number of stocks.

  The lower limit of inventory in each process can be determined by various methods. The lower limit value is, for example, the number of products processed per unit time in each process. When a plurality of devices are provided for one process, the total number of products processed per unit time by the plurality of devices can be obtained. The number of processed products per unit time may be calculated in consideration of the operation status of the apparatus that changes from time to time, such as periodic cleaning and maintenance of the apparatus and failure of the apparatus.

  The lower limit value is input to the setting unit 3 by an administrator, for example, and the lower limit value is set in the setting unit 3. Alternatively, the setting unit 3 may calculate the number of processes per unit time with reference to the past operation status of the apparatus. The lower limit value set by the setting unit 3 is output to the lower limit value comparison unit 5.

  The upper limit value of inventory in each process is determined using information output from the history acquisition unit 2. The upper limit value is obtained by, for example, multiplying the number of products processed per unit time in each process by the time required for inventory transport in the transport unit 30 output from the history acquisition unit 2, and adding the lower limit value to the value. Can be obtained. When a plurality of devices are provided for one process, the total number of products processed per unit time by the plurality of devices can be obtained. The number of products processed per unit time may be calculated in consideration of the operation status of the apparatus, which changes from moment to moment, such as in-apparatus cleaning, apparatus maintenance, and apparatus failure.

By using the sum of the product of the number of processed products per unit time and the transport time as the upper limit value and the lower limit value, it is possible to deliver the stock in consideration of the transport time.
As for the upper limit value, for example, the lower limit value is input to the setting unit 3 by the administrator. In the setting unit 3, the lower limit value includes the transport time from the history acquisition unit 2 and the number of products processed per unit time in each process. The product is added and determined. The upper limit value set by the setting unit 3 is output to the upper limit value comparison unit 4.

  Depending on the production line, a plurality of devices are provided for one process, and the performance of each device is different, so the conditions of processing performed by each device may be different. In addition, the stock that can be processed by each device may be different. In such a case, it is preferable that an upper limit value and a lower limit value are set for each apparatus. This is because even if the number of requests is extracted with a plurality of devices as a unit, depending on the stock received, there may be no device available to process the stock.

  In the present embodiment, in such a case, the processing performed in each device may be handled as one process. In other words, when the upper limit and lower limit are set individually for each device, the processing for each device is handled as one process, the number of requests and the number of supplies in each device are extracted, and the inventory is transferred between the devices. May be performed.

  In the setting of the upper limit value, the upper limit value is substantially determined even if the upper limit value is determined using the number of processed products per unit time and the transport time output from the history acquisition unit 2 without quoting the lower limit value. This can only be done using the lower limit. That is, in the setting of the upper limit value, the product processing number per unit time in each process is multiplied by the transport time output from the history acquisition unit 2, and the product processing number per unit time in each step is added. The setting unit 3 may function.

  For the shortage process, the stock continues to be supplied from the process upstream of the shortage process even while the inventory is being transferred from the excess process to the shortage process. For this reason, the number of stocks that are deficient in the shortage process may be different at the time when the conveyance of the stock is completed. In this regard, by determining the upper limit value in consideration of the time required for conveyance, it becomes possible to suppress conveyance of excess inventory to the shortage process, and it is possible to suitably improve production efficiency. .

  The upper limit comparison unit 4 compares the number of stocks with the upper limit at the reference time set for each process. Then, the upper limit comparison unit 4 extracts a process in which the number of stocks exceeds the upper limit as an excess process and outputs it to the determination unit 6. At the same time, the upper limit comparison unit 4 calculates the number of stocks that exceed the upper limit, and outputs the number to the determination unit 6 as the number of supplies to the shortage process.

  The lower limit comparison unit 5 compares the number of stocks with the lower limit at the reference time set for each process. Then, the lower limit comparison unit 5 extracts a process in which the number of stocks is lower than the lower limit as an insufficient process and outputs it to the determination unit 6. At the same time, the lower limit comparison unit 5 calculates the number of stocks that are insufficient for the lower limit, and outputs the number to the determination unit 6 as the number of requests for excess processes.

Depending on the process, a process for a product can be executed instead of a predetermined process in another production line. The determination unit 6 determines whether there is a process capable of delivering stock among the shortage process and the excessive process extracted by the upper limit comparison unit 4 and the lower limit comparison unit 5. For example, the determination unit 6 stores in advance processes that allow delivery of stock. When there are an insufficient process and an excess process in which inventory can be delivered, the determination unit 6 determines conveyance of the inventory from at least one excess process to at least one insufficient process. At the same time, the determination unit 6 compares the number of requests from the lower limit comparison unit 5 with the supply number from the upper limit comparison unit 4 and determines the number of stocks to be transported. For example, the number of conveyance is equal to or greater than the smaller one of the supply number and the request number, and is equal to or less than the larger number of the supply number and the request number.
The determination unit 6 outputs information on the process of carrying and the number of conveyances to the production line 20 and the conveyance unit 30.

When there are two or more insufficient processes in which the number of stocks is less than one excess process, the inventory may be transferred from one excess process to two or more insufficient processes.
If the number of supplies from one excess process is equal to or greater than the total number of requests from two or more insufficient processes, the required number may be transferred from the excess process to each of the insufficient processes. Alternatively, the supply number may be distributed in a ratio corresponding to the number of requests for each shortage process, and the distributed supply number may be conveyed to each shortage process.

  If the number of supplies from one excess process is less than the total number of requests from two or more insufficient processes, the supply number is allocated to the ratio according to the number of requests for each insufficient process. The allocated supply number is transferred to each shortage process. Or when the priority mentioned later is set to each process, you may supply inventory preferentially to a process with high priority.

When there are two or more excess processes in which the number of stocks exceeds one short process, the stock may be conveyed from a plurality of excessive processes to one short process.
When the number of requests from one insufficient process is equal to or less than the total number of supplies from two or more excess processes, each supply number may be transferred from each excess process to the insufficient process. Alternatively, the number of requests may be allocated to a ratio corresponding to the number of supplies from each excess process, and the allocated request number may be conveyed from each excess process.

  If the number of requests from one insufficient process is less than the total number of supplies from two or more excess processes, allocate the number of requests to a ratio corresponding to the number of supplies of each excess process, The allocated number of requests is conveyed from each excess process. Or when the priority mentioned later is set to each process, you may supply stock preferentially from the process with low priority.

  The transport unit 30 transports the stock determined to be transported by the determination unit 6 from the at least one excess process to the at least one short process among the plurality of production lines 20. The transport unit 30 includes, for example, a stacking unit provided in each production line 20 and a transport path through which stock is transported between the stacking units. The stock transported from the excess process to the shortage process is collected in a stacking unit provided in each production line. Then, stock is delivered between the stacking units of each production line 20 through the conveyance path. The stock transferred to the stacking unit of the other production line 20 is transferred to the shortage process.

  The history acquisition unit 2 may output the time required for conveyance to the setting unit 3 between each production line 20. In an actual production site, the time required for delivery of inventory is rarely equal among all the production lines 20. For this reason, the history acquisition unit 2 outputs the time required for conveyance between the respective production lines 20 to the setting unit 3, and the setting unit 3 performs each process included in a certain production line, It is preferable to set an upper limit for each other production line.

For example, in the example shown in FIG. 2, a transport unit 30 a that delivers stock between the production line 20 a and the production line 20 b and a transport unit 30 c that delivers stock between the production line 20 a and the production line 20 c. And, the time required for conveyance is different. The history acquisition unit 2 sets an upper limit value for the production line 20b in consideration of the time required for conveyance by the conveyance unit 30a for the processes included in the production line 20a, and is necessary for conveyance by the conveyance unit 30c. You may set the upper limit with respect to the manufacturing line 20c in consideration of the time which is set.
By doing so, it becomes possible to more efficiently supply the stock to the shortage process, and it becomes possible to further improve the production efficiency.

  The determination unit 6 may total the number of stocks determined to be transported between the production lines 20. In this case, the determination unit 6 compares the total number of conveyances between the predetermined production lines 20 with the number that can be conveyed within a predetermined time by the conveyance unit 30 between the production lines 20. When the total number of conveyances exceeds the number of conveyance units 30 that can be conveyed within a predetermined time, the determination unit 6 outputs the result to the setting unit 3, and the setting unit 3 increases the upper limit value and the lower limit value. At least one of the values is decreased.

  For example, the determination unit 6 compares the total number of stocks delivered between the production lines 20a and 20b with the number of stocks that can be transported within a predetermined time by the transport unit 30a. When the total number of stocks delivered is larger than the number of stocks that can be transported within a predetermined time by the transport unit 30a, at least one of an increase in the upper limit value and a decrease in the lower limit value in each process of the production lines 20a and 20b. Is done.

  The upper limit comparison unit 4 and the lower limit comparison unit 5 extract the excess process and the insufficient process, and calculate the supply number and the request number based on the newly set upper limit value and lower limit value.

The determination unit 6 calculates the number of conveyances based on the newly calculated supply number and request number. The setting unit 3 repeats the change of at least one of the upper limit value and the lower limit value until the total number of conveyances in all the processes becomes equal to or less than the number that can be conveyed within a predetermined time.
When the total number of conveyances between the predetermined production lines 20 is equal to or less than the number that can be conveyed within the predetermined time between the production lines 20, the determination unit 6 determines whether the inventory from the excess process to the shortage process. Determine the transport.
The predetermined time described above is determined, for example, by inputting an arbitrary time to the determination unit 6 by the administrator.

If excessive stock is transported from an excess process to a shortage process beyond the transport capability of the transport unit 30, stock stagnation may occur in the transport unit 30 and production efficiency may not be improved favorably.
Since the determination unit 6 has the above-described function, it is possible to suppress the stagnation of the stock in the transport unit 30 and suitably improve the production efficiency while carrying the stock from the excess process to the short process. Become.

  A priority may be set for each process. With regard to the inventory determined to be transported by the determination unit 6, the stock transported to the process with higher priority is transported with priority over other stocks. The priority may be set for each process, or may be set for a plurality of processes for each production line 20 in a lump.

The priority may be changed during operation of the production line 20. For example, a first priority value is set in advance for each process, and a value corresponding to the time that has elapsed since it was determined that the stock is supplied to the insufficient process is set to the second priority value. It may be added as a priority value. At this time, the second priority value becomes higher as the product has a longer elapsed time since it is determined that the stock is supplied.
If only the first priority value is set, it may be difficult to carry stock for a process with a low first priority value. In order to improve such a state, a method of determining the priority using the first priority value and the second priority value is effective.

  The detection unit 1 may detect the number of stocks of each process at a future reference time in addition to the current time.

  For example, the detection unit 1 stores a change in inventory in each past process, and the detection unit 1 executes a simulation for predicting a future change based on the past change tendency. Furthermore, the detection unit 1 may store a schedule for increasing the processing capacity of a specific process, a maintenance schedule for an apparatus related to the specific process, and the like. In this case, the detection unit 1 adds such information and executes a simulation for predicting future inventory fluctuations. Or the result of the simulation which predicted the fluctuation | variation in the future is output with respect to the detection part 1. FIG.

  The detection unit 1 detects the number of stocks of each process at a future reference time by simulation and outputs the detected number to the lower limit comparison unit 5 and the upper limit comparison unit 4.

  For example, the history acquisition unit 2 extracts the latest conveyance time with respect to the current time, and outputs the extracted conveyance time information to the setting unit 3.

  The setting unit 3 sets a lower limit value and an upper limit value for the number of stocks at a future reference time for each process. The setting unit 3 outputs the set upper limit value to the upper limit value comparison unit 4 and outputs the set lower limit value to the lower limit value comparison unit 5.

  The upper limit comparison unit 4 compares the number of stocks at the future reference time with the upper limit set for each process. Then, the upper limit comparison unit 4 extracts a process in which the number of stocks exceeds the upper limit as an excess process and outputs it to the determination unit 6.

  The lower limit comparison unit 5 compares the number of stocks at a future reference time with the lower limit set for each process. Then, the lower limit comparison unit 5 extracts a process in which the number of stocks is lower than the lower limit as an insufficient process and outputs it to the determination unit 6.

  The determination unit 6 determines whether there is a process capable of delivering stock among the insufficient processes and the excessive processes at the future reference time. When there are an insufficient process and an excess process in which inventory can be delivered, the determination unit 6 determines conveyance of the inventory from at least one excess process to at least one insufficient process. The determination unit 6 outputs the information on the inventory that has been determined to be transported to the transport unit 30.

  The transport unit 30 transports the stock determined to be transported by the determination unit 6 from the at least one excess process to the at least one short process among the plurality of production lines 20. At this time, the conveyance by the conveyance unit 30 is performed prior to a future reference time. According to such a system, the flow of inventory from the previous process of each process can be predicted at a future time by simulation, and a process in which an excess of inventory occurs and a process in which an inventory shortage occurs can be predicted. For this reason, it is possible to transport the inventory from a process in which an excess of inventory occurs to a process in which an inventory shortage occurs at a more appropriate timing. As a result, in the shortage process, it is possible to shorten the time when the shortage of inventory occurs, and to improve the production efficiency.

  More preferably, the time at which the detection unit 1 detects the number of stocks in each process is a time obtained by adding the time required for conveyance output from the history acquisition unit 2 to the current time. By doing so, it is possible to transport the inventory from the process that is considered to be excessive to the process that is considered to be insufficient so that the detection unit 1 matches the time when the number of inventory is detected. . For this reason, in a shortage process, the time when the shortage of inventory occurs can be shortened, and the production efficiency can be further improved.

The manufacturing management system 10 may further include a first determination unit 7.
The first determination unit 7 predicts the number of stocks in each process after the transport of the stock is performed by the transport unit 30, and determines whether or not the situation of the shortage process and the excessive process is improved due to the transport of the stock. To do.
As an example, the first determination unit 7 improves the situation by counting the number of insufficient processes after the inventory has been transported and comparing it with the number of insufficient processes before the inventory has been transported. Determine the presence or absence. As another example, in the shortage process, the first determination unit 7 may compare the total number of shortages of inventory (the number of requests) before and after the conveyance to determine whether the situation has improved.
The first determination unit 7 outputs a determination result about whether or not the situation has been improved to the transport unit 30.

At this time, the first determination unit 7 may further output the determination result to the setting unit 3. When it is determined by the first determination unit 7 that there is no improvement in the situation and the result is output to the setting unit 3, the setting unit 3 performs at least one of a decrease in the upper limit value and an increase in the lower limit value in each step. The result is output to the upper limit comparison unit 4 and the lower limit comparison unit 5.
When a new upper limit value is set by the setting unit 3, the upper limit value comparison unit 4 compares the newly set upper limit value with the number of stocks in each process, and extracts excess processes and calculates the number of supplies. I do. Similarly, when a new lower limit value is set by the setting unit 3, the lower limit value comparison unit 5 compares the newly set lower limit value with the number of stocks in each process, and extracts and requests an insufficient process. Calculate the number.

When the manufacturing management system 10 includes the first determination unit 7, the transport unit 30 can improve the situation from the first determination unit 7 even when information is output from the determination unit 6. If the determination result shown is not output, the inventory is not transported. In other words, the manufacturing management system 10 stores the inventory in the transport unit 30 only when the first determination unit 7 determines that there is an improvement in the situation of the insufficient process and the excess process, in addition to the transport determination by the determination unit 6. Let the transport.
It is possible to improve the production efficiency more suitably by determining the presence / absence of improvement of the situation due to the conveyance by the first determination unit 7.

The manufacturing management system 10 described above is applicable not only when a plurality of manufacturing lines 20 are provided in the same building, but also when a plurality of manufacturing lines 20 are provided in different buildings.
In this case, the conveyance unit 30 conveys stock between a plurality of buildings. When carrying stock between a plurality of buildings, the carrying time tends to be longer than when carrying stock within the same building. Therefore, as in this embodiment, it is possible to improve the production efficiency more suitably by setting the upper limit value in consideration of the conveyance time.

Next, the manufacturing management program according to the first embodiment will be described with reference to FIG.
FIG. 3 is a flowchart of the manufacturing management program according to the first embodiment.
3 is executed by a manufacturing management system 10 including a detection unit 1, a history acquisition unit 2, a setting unit 3, an upper limit comparison unit 4, a lower limit comparison unit 5, a determination unit 6, and a first determination unit 7. Represents a manufacturing management program.

  In the flowchart shown in FIG. 3, the detection unit 1 is input with a change history of the number of stocks in each past process and a future stock change prediction (simulation) result based on the change history. To do. It is assumed that a lower limit value for each process is set in the setting unit 3. Further, it is assumed that an upper limit value is set in the setting unit 3 upon receiving information output from the history acquisition unit 2. It is assumed that the lower limit value and the upper limit value in each process are input from the setting unit 3 to the detection unit 1.

The detection unit 1 detects the number of stocks of each process at the reference time X (S101). For example, the reference time X is the current time.
The upper limit comparison unit 4 compares the detected stock quantity with the upper limit for each process (S102).
When there is an excess process in which the detected inventory number exceeds the upper limit value, the process is extracted and the inventory quantity exceeding the upper limit value is calculated as the supply number (S103).

The lower limit comparison unit 5 compares the detected inventory quantity with the lower limit for each process (S104).
When there is a shortage process in which the detected inventory number is below the lower limit value, the process is extracted, and the inventory quantity that is less than the lower limit value is calculated as the requested number (S105).
Note that S104 and S105 may be performed prior to S102 and S103.

It is determined whether there is a process capable of delivering stock among the extracted excess processes and insufficient processes (S106).
If there are an excess process and an insufficiency process in which inventory can be delivered, the supply number of the excess process is compared with the required number of the insufficiency process to calculate the number of conveyances (S107).
It is determined whether or not there is data at the reference time X + 1 in the simulation result (S108). For example, the time X + 1 is 15 minutes after the time X, and it is determined whether the simulation result after 15 minutes exists in the detection unit 1.
When there is no data at the reference time X + 1 in the simulation result, it is determined whether or not the situation is improved when the inventory is transferred from the excess process to the insufficient process (S109).

When it is determined that there is an improvement in the situation due to the conveyance of inventory from the excess process to the shortage process, the number of inventory to be conveyed is added up. Then, it is determined whether or not the number of stocks to be transported is equal to or less than the number that can be transported within a predetermined time (S110).
When the number of stocks to be transported can be transported within a predetermined time, the transport unit 30 starts transporting stocks (S111).

In S102, when the number of detected stocks is below the upper limit value in all steps, the program operation at the reference time X is terminated. Then, the detection unit 1 determines whether or not there is data at the reference time X + 1 (S112).
If there is no data at the reference time X + 1, the program operation is terminated (S113).
If there is data of the reference time X + 1, the reference time X is replaced with X + 1 (S114).
After replacing the reference time with X + 1, the program operation is performed again from S101.

  In S104, if the number of detected stocks exceeds the lower limit in all processes, and if there are no excess process and insufficient process in which inventory can be delivered in S106, the process similarly proceeds to S112.

In S108, when the simulation result includes data of the reference time X + 1, the reference time X is replaced with X + 1 (S115).
The stock quantity of each process at the reference time X is detected (S116).
The number of conveyances is subtracted or added to the detected number of inventory from the excess process or the insufficient process for which inventory conveyance is determined (S117). That is, it is possible to more accurately predict the excess process and the deficient process at the future reference time by re-inspecting the excess process and the deficient process for which the conveyance of the inventory is determined by considering the number of conveyance. Become.
S102 is performed again for the number of stocks for which the conveyance number has been subtracted or added.

In S109, when it is determined that there is no situation improvement when the inventory is transferred from the excess process to the shortage process, the setting unit 3 corrects the upper limit value and the lower limit value (S118).
Based on the corrected upper limit value and lower limit value, S102 is performed again.

In S110, when the number of stocks to be transported exceeds the number that can be transported within a predetermined time, the upper limit value and the lower limit value are corrected (S118).
Based on the corrected upper limit value and lower limit value, S102 is performed again.

(Second Embodiment)
A manufacturing management system 50 according to the second embodiment will be described with reference to FIG.
This embodiment is different from the first embodiment in that it further includes a second determination unit 8. The second determination unit 8 determines whether there is an improvement in the situation due to the conveyance of the inventory in consideration of the carry-in of the inventory to the insufficient process from the previous process of the insufficient process.
More specifically, the 2nd determination part 8 is supplied to the said shortage process from the process immediately before a target shortage process about the shortage process in which supply of inventory is performed during the latest conveyance time. Calculate the number of inventory.

Below, the function of the 2nd determination part 8 which concerns on this embodiment is explained in full detail.
First, as in the first embodiment, the supply number and the requested number of inventory are output from the upper limit comparison unit 4 and the lower limit comparison unit 5 to the determination unit 6, and the determination unit 6 determines whether or not inventory delivery is possible. Is done.
Thereafter, the determination unit 6 outputs information on the shortage process for which supply of stock is determined to the second determination unit 8. In addition, the latest determination unit 8 receives the latest transport time from the history acquisition unit 2 with respect to the reference time X.

  The second determination unit 8 completes the process in the process immediately before the target shortage process during the latest transfer time for the shortage process for which supply of stock has been determined, and the number of stocks transferred to the shortage process Is calculated. The calculation of the number of inventory conveyed from the immediately preceding process is performed using the inventory number of the process before the insufficient process at the reference time X detected by the detection unit 1.

  Specifically, first, the inventory quantity of each process at the reference time X is output from the detection unit 1 to the second determination unit 8. And the 2nd determination part 8 calculates the number of the stocks which a process completes in the latest conveyance time in the process before the target insufficient process. As a result, the number of stocks carried into the shortage process is calculated. The number of stocks for which processing is completed during the transport time can be obtained, for example, by dividing the transport time by the time required for the manufacturing apparatus in the previous step to process one stock.

If the number of stocks completed in the previous process during the transport time obtained as a result of the calculation exceeds the number of stocks in the previous process at the reference time X, the inventory at the reference time X The number of inventory in the previous process may be output as the number of inventory transported to the insufficient process.
Alternatively, while the inventory processing in the previous process is being performed, the inventory transferred from the previous process is also taken into consideration, and the inventory that is completed in the previous process during the transfer time A number may be calculated.

  Further, the detection unit 1 may store information related to fluctuations in production capacity such as a schedule for increasing the processing capacity of a specific process and a schedule for maintenance of an apparatus related to the specific process. In the case where information related to fluctuations in production capacity is stored for the process before the shortage process, the detection unit 1 may output this information to the second determination unit 8 in addition to the inventory quantity of each process. Good. In this case, the second determination unit 8 can calculate the number of stocks transferred to the shortage process from the process before the target shortage process, using the information regarding the fluctuation of the production capacity.

  Next, the second determination unit 8 adds the number of inventory conveyances determined by the determination unit 6 to the inventory number of the shortage process that is the inventory conveyance target, and adds the conveyance time to the reference time X. The number of stocks waiting for processing in the shortage process is calculated.

  Next, the second determination unit 8 performs a simulation for calculating the time (processing waiting time) required for processing the inventory for the inventory determined to be transferred from the excess process to the insufficient process.

  Specifically, the second determination unit waits for the processing of the inventory to be transferred (first time) in the excess process at the transfer source when the inventory is not transferred from the excess process to the insufficient process. Is calculated. The second determination unit further calculates a processing waiting time (second time) of the stock to be transferred in the shortage process of the transfer destination when the stock is transferred from the excess process to the shortage process.

At this time, for the calculation of the processing waiting time for the stock to be transported, the transport of the stock from the process immediately before the shortage process described above is taken into consideration. In addition, the stock to be transported is processed after the stock existing in the shortage process at the reference time X and the stock transported from the previous process are processed. Is calculated.
The processing waiting time is obtained, for example, by the product of the number of stocks and the time required for the manufacturing apparatus in the process to process one stock.

  The second determination unit 8 compares the first time and the second time by the above-described simulation. When the second time is shorter than the first time, that is, when the processing waiting time when stock delivery is performed is shorter than the processing waiting time when stock delivery is not performed, the second determination unit 8 affirms the determination of the delivery of the stock input from the determination unit 6. When the second time is longer than the first time, the second determination unit 8 denies the determination of delivery of the stock input from the determination unit 6.

The second determination unit 8 outputs the above determination result to the determination unit 6.
When the determination of the determination unit 6 is affirmed by the second determination unit 8, the determination unit 6 maintains the determination of stock delivery between the excess process and the insufficient process related to the affirmed determination. On the other hand, when the determination of the determination unit 6 is denied by the second determination unit 8, the determination unit 6 cancels the determination of delivery of inventory between the excess process and the insufficient process related to the denied determination.

  Subsequent delivery of inventory between the excess process and the shortage process affirmed by the second determination unit 8 is carried by the carrying unit 30 as in the first embodiment.

The determination unit 6 outputs information on the shortage process for which supply of inventory is determined to the second determination unit 8 and also supplies information on the shortage process and excess process for delivering the stock and information on the number of conveyances. 20 may be output to the second determination unit 8 without being output to the transport unit 30.
In this case, the manufacturing line 20 and the conveyance unit 30 execute delivery of inventory from the excess process to the shortage process only when a result of affirming the determination of the determination unit 6 is input from the second determination unit 8.

  According to this embodiment, while the inventory is supplied to the shortage process, the number of stocks transferred to the shortage process from the process before the shortage process is considered. For this reason, it can suppress that the processing time of the said stock becomes longer as a result of having conveyed the stock to the shortage process. Therefore, the production efficiency can be further improved as compared with the first embodiment.

In the present embodiment, as described in the first embodiment, the detection unit 1 may detect the inventory of each process at the future reference time X. Further, the first determination unit 7 may determine whether or not there is an improvement due to delivery of inventory between the excess process and the insufficient process.
Also in this embodiment, as described in the first embodiment, each step may be given a priority.

Next, a manufacturing management program according to the second embodiment will be described with reference to FIG.
FIG. 5 is a flowchart of the manufacturing management program according to the second embodiment. The flowchart shown in FIG. 5 is a flowchart relating to a manufacturing management system that includes the first determination unit 7 and the second determination unit 8 and detects the number of inventory at the future reference time X in the detection unit 1.
The flowchart shown in FIG. 5 is different from the flowchart shown in FIG. 3 in that it further includes S119. Steps other than S119 are the same as those in the flowchart shown in FIG.

In S107, the manufacturing management program according to the present embodiment executes S119 after determining the number of inventory conveyances from the excess process to the insufficient process.
In S119, it is determined whether or not there is a reduction in the processing waiting time of the inventory conveyed from the excess process to the insufficient process. That is, the above-described comparison between the first time and the second time is performed in S119.

If the second time is shorter than the first time and a positive result is obtained in S119, the process proceeds to S108.
On the other hand, if the second time is longer than the first time and a negative result is obtained in S119, the process proceeds to S112.
The steps after S108 and the steps after S112 are the same as those in the flowchart shown in FIG.

(Third embodiment)
A manufacturing management system 60 according to the third embodiment will be described with reference to FIG.
FIG. 6 is a block diagram illustrating the relationship between the manufacturing management system 60, the manufacturing line 20, and the transport unit 30 according to the third embodiment.
This embodiment is mainly different from the second embodiment in the method for calculating the stock processing waiting time.

In the example shown in FIG. 6, the process 20a1 included in the production line 20a is performed by two production apparatuses 20a11 and 20a12. In this embodiment, when the same process is performed by a plurality of manufacturing apparatuses as described above, these processes are collectively handled as one process.
Similarly, for example, the process 20a2 is performed by four manufacturing apparatuses 20a21, 20a22, 20a23, and 20a24.

In the present embodiment, the second determination unit 8 divides the processing time of one inventory per manufacturing apparatus that performs the process by the number of devices as the processing time per stock in one process. Use the time obtained.
If there are multiple devices that perform the process and the processing time per stock varies depending on the manufacturing device, find the average processing time per stock and divide the average processing time by the number of manufacturing devices. The processing time per stock in the process may be calculated.
Alternatively, the processing time per stock in the process may be calculated by dividing the processing time of the manufacturing device having the longest processing time per stock among the plurality of manufacturing devices by the number of manufacturing devices. .

Here, it demonstrates using a specific example, referring FIG.
For example, a case will be described in which stock is transferred from the process 20a1 which is an excessive process to the process 20b2 which is a shortage process.
At this time, before the delivery of the inventory between the process 20a1 and the process 20b2, the inventory quantity in the process 20a1 is A, the inventory quantity in the process 20b2 is B, and the inventory quantity conveyed from the process 20a1 to the process 20b2 is C. , T is the inventory transport time from step 20a1 to step 20b2.
Then, the processing time of one inventory per manufacturing apparatus in the process 20a1 is α, the processing time of one inventory per manufacturing apparatus in the process 20b1 is β, and one inventory per manufacturing apparatus in the process 20b2. Is the processing time of γ.

  In this case, α / 2 is calculated as the processing time of one stock in the process 20a1, β / 2 as the processing time of one stock in the process 20b1, and γ / 4 is calculated as the processing time of one stock in the process 20b2. Next, using these calculated times, the processing waiting time of inventory to be delivered is calculated in each step.

When the stock is not transported from the excess process to the shortage process, the processing waiting time of the stock to be transported in the excess process is αA / 2 due to the product of the inventory number A and the processing time α / 2. .
It should be noted that the processing of the inventory determined to be transported in the excess process when the inventory is not transported is treated as processed after all other stocks of the excess process at the reference time X are processed.

  On the other hand, when the inventory is transferred from the excess process to the insufficient process, the number of inventory processed in the process 20b2 is processed by the process 20b1 during the transfer time T to the inventory number B in the original process 20b2. The added inventory quantity is added, and the conveyed inventory quantity C is added. Therefore, the number of inventory processed in the step 20b2 is B + (2T / β) + C. At this time, the processing waiting time for the inventory to be transported in step 20b2 is γ (B + (2T / β) + C) / 4.

Accordingly, the second determination unit 8 affirms the delivery of the inventory determined by the determination unit 6 only when γ (B + (2T / β) + C) / 4 is smaller than αA / 2.
At this time, the fraction after the decimal point may be rounded down for each calculated number of stocks.

In the above description, the calculated first time and second time represent the time until all of the inventory to be transferred from the excess process to the shortage process is processed. However, the present invention is not limited to this, and as the first time and the second time, time until processing of at least one of the stocks to be transported from the excess process to the shortage process may be used. .
When the time until processing of at least one stock is used, the stock processing waiting time in step 20a1 is α (A−C) / 2. The stock processing waiting time in step 20b2 is γ (B + (2T / β)) / 4.
Therefore, in this case, the second determination unit 8 delivers the stock determined by the determination unit 6 only when γ (B + (2T / β)) / 4 is smaller than α (A−C) / 2. Affirm.

  Here, as a comparative example for this embodiment, the same process is performed by a plurality of manufacturing apparatuses, and the processing time of one stock by one manufacturing apparatus is used as the processing time of one stock in the process. Will be described. In this case, according to the example of FIG. 6 described above, the processing time for one stock is α in the step 20a1, β in the step 20b1, and γ in the step 20b2. At this time, when T / β, which is a value obtained by dividing the conveyance time T by the processing time β of one stock in step 20b1, is smaller than 1, the fractional part after the decimal point is rounded down so that the step 20b1 is performed during the conveyance time T. The stock for which processing has been completed is treated as zero.

  However, in an actual production line, it is rare that stock is simultaneously carried into each of a plurality of production apparatuses that perform the same process and processing is started at the same time. That is, in an actual production line, in many cases, processing start times and end times of a plurality of apparatuses that perform the same process are different from each other.

Therefore, in practice, even if the transport time T is less than the processing time of one stock of one device, there is a possibility that the stock is transported from the step 20b1 to the step 20b2.
For this reason, as in the comparative example described above, regardless of the number of devices in each process, the processing time of one stock by one manufacturing apparatus is treated as the processing time of one stock in the process, and is obtained by simulation. The difference between the stock quantity of the process 20b2 at the reference time X + T and the actual stock quantity becomes large.
This difference becomes more remarkable as the number of apparatuses performing one process increases.

  On the other hand, in this embodiment, in consideration of the number of devices that perform the same process, the processing time of one stock in the process is calculated, so that the simulation is executed under conditions closer to the actual production line. Is possible. As a result, the production efficiency can be further improved as compared with the comparative example described above.

  As mentioned above, although several embodiment of this invention was illustrated, these embodiment is shown as an example and is not intending limiting the range of invention. These novel embodiments can be implemented in various other forms, and various omissions, replacements, changes, and the like can be made without departing from the spirit of the invention. These embodiments and modifications thereof are included in the scope and gist of the invention, and are included in the invention described in the claims and equivalents thereof. Further, the above-described embodiments can be implemented in combination with each other.

DESCRIPTION OF SYMBOLS 1 ... Detection part, 2 ... History acquisition part, 3 ... Setting part, 4 ... Upper limit comparison part, 5 ... Lower limit comparison part, 6 ... Determination part, 7 ... 1st determination part, 8 ... 2nd determination part, 10 50 ... 60 Production management system 20 ... Production line 30 ... Conveying unit

Claims (15)

A production management system for managing a plurality of production lines, each comprising a plurality of processes,
A detector that detects the number of stocks at a reference time for each of the steps in the plurality of production lines;
A history acquisition unit that acquires a conveyance status of the inventory between the plurality of production lines before the reference time;
A setting unit for setting a lower limit value and an upper limit value of the number of the stocks at the reference time in each of the steps, wherein the upper limit value is the lower limit value and the inventory acquired by the history acquisition unit. A setting unit that is determined using the time required for conveyance; and
An upper limit comparing unit that compares the number of stocks in each step and the upper limit, and extracts an excess process in which the number of stocks exceeds the upper limit;
A lower limit comparing unit that compares the number of the stock in each of the steps and the lower limit, and extracts an insufficient process in which the number of stocks is lower than the lower limit;
It is determined whether the excess process and the shortage process are processes capable of delivering the inventory, and the inventory is transferred from at least one excess process to at least one shortage process capable of delivering the inventory. A determination unit that determines conveyance;
Manufacturing management system with In the setting unit, the lower limit is determined by using the processing number of products per unit time in the step, the upper limit is required on the conveyor to the processing number of products per unit time in the step The manufacturing management system according to claim 1, wherein the manufacturing management system is determined using a value obtained by multiplying a predetermined time and the lower limit value. The upper limit comparison unit calculates the number of the inventory that exceeds the upper limit in the excess process as the supply number of the excess process,
The lower limit comparison unit calculates the number of the inventory that is below the lower limit in the shortage process as a required number of the shortage process,
The manufacturing management system according to claim 1, wherein the determination unit calculates the number of conveyances of the inventory based on the supply number and the request number. When the total number of conveyances in all processes calculated by the determination unit exceeds the number that can be conveyed within a predetermined time, the setting unit increases the lower limit value set for each of the processes. And at least one of the reduction of the upper limit value,
The upper limit comparison unit and the lower limit comparison unit extract the excess process and the insufficient process and calculate the supply number and the requested number based on the newly set upper limit value and the lower limit value. ,
The determination unit calculates the transport number for the newly extracted excess process, the insufficient process, and the newly calculated supply number and the requested number,
The said setting part repeats at least one of the increase of the said lower limit value, and the reduction | decrease of the said upper limit value until the sum total of the said conveyance number in all the processes becomes below the number which can be conveyed within predetermined time. Manufacturing management system. About the excess process and the shortage process for which conveyance of the inventory is determined by the determination unit, if the inventory is not transferred from the excess process to the shortage process, the inventory is a transfer target in the excess process. When the inventory is transferred from the excess process to the shortage process for the first time required until the stock processing is performed, the inventory that is the transfer target is processed in the shortage process. A second determination unit that calculates a second time required until the second time is calculated and compares the first time and the second time;
The second determination unit, when the second time shorter than the first time, production management according to claim 3 or 4 for outputting a result of affirmative determination of the determination unit to the determination section system. The second determination unit, during the time required for transporting the inventory to the shortage process acquired by the history acquisition unit, about the shortage process for which the transport of the inventory has been determined by the determination unit, The manufacturing management system according to claim 5, wherein the second time is calculated using a number of inventory conveyed to the shortage process from a process before the shortage process. In the case where the shortage process in which the conveyance of the inventory is determined by the determination unit is performed by a plurality of manufacturing apparatuses, the second determination unit calculates the processing time of the inventory per unit of the manufacturing apparatus. The manufacturing management system according to claim 6, wherein the second time is calculated using a time divided by the number of devices. The second determination unit has the longest inventory processing time among the plurality of manufacturing apparatuses when the shortage process in which the conveyance of the inventory is determined by the determination unit is performed by the plurality of manufacturing apparatuses. The manufacturing management system according to claim 6, wherein the second time is calculated using a time obtained by dividing the processing time of the manufacturing apparatus by the number of the manufacturing apparatuses. Each process has a priority,
The manufacturing management system according to any one of claims 1 to 8, wherein the inventory is transported to the process with the high priority prior to the process with the low priority. The reference time is a future time,
The detection unit detects the number of inventory of each of the processes at the reference time in the future,
The manufacturing management system according to claim 1, wherein the setting unit sets a lower limit value and an upper limit value at the future reference time.   11. The future reference time at which the detection unit detects the number of stocks in each of the processes is a time obtained by adding the time required for the transportation output from the history acquisition unit to the current time. Manufacturing management system. 12. The apparatus according to claim 10, further comprising: a first determination unit that predicts the number of stocks in each of the steps after the transport of the stock is performed, and determines whether the situation is improved due to the transport of the stock. Manufacturing management system. The plurality of production lines are each provided in a different building,
The manufacturing management system according to claim 1, wherein the inventory is transported between the plurality of buildings. A production management method for managing a plurality of production lines, each comprising a plurality of processes,
A detecting step of detecting the number of stocks at a reference time for each of the processes in the plurality of production lines;
A history acquisition step for acquiring the inventory status of the inventory between the plurality of production lines before the reference time;
A setting step of setting a lower limit value and an upper limit value of the number of the stocks at the reference time of each of the steps, wherein the upper limit value is set to the lower limit value and the inventory acquired by the history acquisition step. A setting step that is determined by using the time required for conveyance;
An upper limit comparing step for comparing the number of stocks in each of the processes and the upper limit, and extracting an excess process in which the number of stocks exceeds the upper limit;
A lower limit comparing step for comparing the number of the inventory in each of the processes and the lower limit, and extracting an insufficient process in which the number of the inventory is below the lower limit;
It is determined whether the excess process and the shortage process are processes capable of delivering the inventory, and the inventory is transferred from at least one excess process to at least one shortage process capable of delivering the inventory. A decision step for determining transport;
A manufacturing management method comprising: For computers that manage multiple production lines, each consisting of multiple processes,
A detecting step of detecting the number of stocks at a reference time for each of the processes in the plurality of production lines;
A history acquisition step for acquiring the inventory status of the inventory between the plurality of production lines before the reference time;
A setting step of setting a lower limit value and an upper limit value of the number of the stocks at the reference time of each of the steps, wherein the upper limit value is set to the lower limit value and the inventory acquired by the history acquisition step. A setting step that is determined by using the time required for conveyance;
An upper limit comparing step for comparing the number of stocks in each of the processes and the upper limit, and extracting an excess process in which the number of stocks exceeds the upper limit;
A lower limit comparing step for comparing the number of the inventory in each of the processes and the lower limit, and extracting an insufficient process in which the number of the inventory is below the lower limit;
It is determined whether the excess process and the shortage process are processes capable of delivering the inventory, and the inventory is transferred from at least one excess process to at least one shortage process capable of delivering the inventory. A decision step for determining transport;
Manufacturing management program to execute.

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