JP6703836B2 - Neck process specifying device and method - Google Patents

Description

The present invention relates to a neck process specifying device and a neck process specifying method for specifying a neck process in a production process for producing a wide variety of products by using a plurality of facilities including a facility for performing setup change according to a lot even in the same process. Regarding

Products are generally manufactured through a plurality of processes (operations). Each process is carried out using various equipment suitable for the process, and the usage of each of these equipment depends on how the manufacturing target during manufacturing flows through each equipment in the factory (shop). It is roughly divided into a shop type and a flow shop type. The job shop type refers to a case where the order of steps required to manufacture a product is determined for each product (product type). The flow shop type refers to a case in which all products (variety) have the same process sequence. Therefore, when a plurality of facilities for performing each process are arranged in a line (straight line) in the factory, the manufacturing target does not always flow from the upstream side to the downstream side in the job shop type. The equipment may be skipped or returned from the equipment on the downstream side to the equipment on the upstream side, but in the flow shop type, the manufacturing object sequentially flows from the upstream side to the downstream side.

Such a flow shop type is suitable for a factory with a line arrangement in which a plurality of facilities are arranged in a line, but in the case of producing a large number of products, it is necessary to change the setup according to the lot even in the same process. For example, when the A process (for example, heat treatment process or painting process) in the production process consisting of a plurality of processes is carried out by the A facility (for example, heat treatment facility or painting facility), the A facility is under the A condition in the production of A lot. (For example, heat treatment at 400° C. or red coating etc. is carried out to perform the A step, and in production of the B lot, the A facility is different from the A condition in the B condition (for example, heat treatment at 600° C. or blue coating). Etc.), the process A is carried out. Therefore, when the production of the A lot is switched to the production of the B lot, it is necessary to change the setup of the A facility from the A condition to the B condition. For this reason, in a flow shop type production line, an unexpected load may be applied to a specific process (equipment), a production target may be stagnant, or an empty state of equipment may occur. The productivity of the entire production line will decrease. As one of the measures, the process with the lowest productivity (bottleneck process) is specified in the production process, and the productivity of the specified bottleneck process is improved, thereby improving the productivity of the entire manufacturing line. (For example, TOC (Theory Of Constraints) theory). To implement this measure, it is necessary to identify the bottleneck process. Techniques for specifying such a bottleneck process are proposed in, for example, Patent Document 1 and Patent Document 2.

In Patent Document 1, a bottleneck device in which the production capacity required for the manufacturing apparatus exceeds the processable production capacity of the apparatus is extracted by the occurrence prediction processing. The occurrence prediction process includes the production plan in the evaluation target period, in-process lot information of the semiconductor device manufacturing line, inter-process TAT of each product/process, wafer processing time, startable manufacturing device information, product/process/ A process for obtaining the wafer processing time for each manufacturing apparatus, a process for calculating the required number of processed wafers for each product/process by using the acquired information, and a required number of processed wafers for each product/process for each day And a bottleneck device extraction process by comparing the required number of processed wafers for each manufacturing device for each day calculated by the process of allocating the number of available wafers to the available manufacturing devices in the corresponding product/process.

In Patent Document 2, the bottleneck process having the longest total processing time of all base materials is obtained based on the base material processing time in each process corresponding to each order information. The processing time of the member in each process is obtained by referring to the process equipment specification information of each process (for example, see the paragraph [0033]), and the equipment specification information is information about the processing capacity of the equipment (for example, [0026]. ] Paragraph). Specifically, the equipment specification information of the rolling process P1 includes the range of the dimensions (thickness, width, length) of the base material that can be rolled by the rolling mill and the processing time thereof, and the base material dimension range ( (Thickness, width, length) and rolling treatment time. The equipment specification information of the cutting 1 step P2 and the cutting 2 step P3 includes information on the processing time for the base material that can be cut by the cutting machine, and the number of times the base material is cut, the fixed processing time, and the cutting processing time are included. Including. The equipment specification information of the inspection process P4 has information on the processing time in the inspection machine, and includes the presence/absence of the inspection, the fixed processing time, and the inspection processing time (for example, see the paragraph [0026]).

JP, 2005-190031, A JP, 2015-14894, A

By the way, in Patent Document 1, the bottleneck device includes a production plan in an evaluation target period, in-process lot information of a semiconductor device manufacturing line, inter-process TAT for each product/process, wafer processing time, startable manufacturing device information, and It is specified based on the processing time of the wafer for each product/process/manufacturing apparatus. In Patent Document 2, the bottleneck process is specified based on the processing time of each process. However, the factors that reduce the productivity of the process are not limited to these, and there is room for improvement in identifying the bottleneck process. For example, the average processing time is the shortest in all processes, but when the time required for setup change (setup time) performed according to lot in the same process is the longest in all processes, it depends on the product mix (combination of products). If the number of setup changes increases, a process with a short processing time may become a bottleneck process.

The present invention has been made in view of the above circumstances, and an object thereof is to produce a wide variety of products by using a plurality of facilities including a facility for performing setup change according to a lot even in the same process in a flow shop type. A neck process specifying device and a neck process specifying method capable of specifying a neck process in a production process more accurately.

As a result of various studies, the present inventor has found that the above object can be achieved by the present invention described below. That is, a neck process identification device according to one aspect of the present invention is a neck process identification device that identifies a neck process in a production process for producing a wide variety of products by using a plurality of facilities in a flow shop type. Is a constraint condition relating to the execution of the process performed by the equipment for performing the setup change including equipment for performing the setup change according to the lot in the same process, and the setup change set in advance for each lot. A constraint condition information storage unit that stores the constraint condition including at least the setup condition that is a condition to be performed in association with the process performed in the equipment that performs the setup change, and processes each of the plurality of processes in the production process. An arrival sequence creation unit that creates an arrival sequence to the process in a plurality of target jobs, and a plurality of arrivals in which the plurality of jobs are arranged according to the arrival sequence created by the arrival sequence creation unit for each of the plurality of processes. An arrival order matrix storage unit that stores an order matrix in association with each of the plurality of processes, and an arrival order matrix corresponding to each process stored in the arrival order matrix storage unit for each of the plurality of processes. And a rearrangement arrival order matrix creating unit that rearranges a plurality of jobs to create a rearrangement arrival order matrix based on the constraint condition corresponding to the process stored in the constraint condition information storage unit, For each of the plurality of processes, the productivity of the process is defined by the rearrangement arrival sequence matrix of the process created by the rearrangement arrival sequence matrix creating unit, the setup change time of the setup corresponding to the predetermined process, and A productivity calculating unit that is determined based on a processing time of a job corresponding to a predetermined process, and a plurality of productivity corresponding to each of the plurality of processes determined by the productivity calculating unit, And a neck process specifying unit that specifies a neck process in the production process. The productivity refers to the amount that can be processed per unit time in each of the plurality of steps in the production step. The neck process refers to a process in which productivity is equal to or lower than a preset threshold value among a plurality of processes in the production process, and includes a bottleneck process. The bottleneck process is a process having the lowest productivity among the plurality of processes in the production process.

Such a neck process identification device rearranges, for each of a plurality of processes in a production process, a plurality of jobs arranged in an arrival sequence matrix corresponding to the process, based on a constraint condition corresponding to the process. A rearrangement arrival sequence matrix is created using the rearrangement arrival sequence matrix for each of the plurality of processes, the rearrangement arrival sequence matrix for the relevant process, the preset setup change time corresponding to the process, and the predetermined productivity. The neck process is identified based on the processing time of the job corresponding to the obtained process, and the neck process is identified based on the productivity of each of the obtained processes. In this way, since the neck process is specified in consideration of the constraint condition including at least the setup condition, the neck process specifying device is a flow shop type in which the plurality of facilities including the equipment for performing the setup change according to the lot even in the same process are used. A neck process in a production process for producing a wide variety of products can be specified more accurately.

In another aspect, in the above-described neck process specifying device, the arrival order creation unit creates a plurality of arrival orders of the process, and the rearrangement arrival order matrix creation unit creates a plurality of arrival orders in the process. The matrix is rearranged to create a plurality of rearrangement arrival order matrices, and the productivity calculating unit obtains the productivity of the process by obtaining the average productivity of the plurality of rearrangement arrival sequence matrices in the process. It is characterized by

Such a neck process identification device creates a plurality of arrival orders, that is, a plurality of arrival order matrices for one process, and a plurality of rearranged arrival order matrices based on the plurality of arrival orders (arrival order matrices). Is calculated, and the average productivity of the plurality of rearrangement arrival order matrices is obtained as the productivity. Since the productivity is obtained by performing a plurality of trials (simulations) in this way, the neck process identification device can obtain the productivity more accurately, and thus can identify the neck process more accurately.

In another aspect, in the above-described neck process specifying device, the rearrangement arrival order matrix creating unit replaces the arrival order matrix by the setup condition further corresponding to the lot corresponding to the job. , An arrival sequence matrix conversion unit for converting a plurality of setup conditions into a setup condition arrival sequence matrix, and a setup range for the setup conditions from the head to a predetermined number of the setup condition arrival sequence matrix A selection unit that selects one setup condition from the search range according to a predetermined selection rule, a rearrangement arrival sequence matrix storage unit that stores the setup condition selected by the selection unit in the selection order, and the setup condition is selected. Each time, the order of the setup conditions in the setup condition arrival order matrix is updated, and an arrival order matrix update unit that causes the selection unit to select 1 setup condition until there is no setup condition in the setup condition arrival order matrix. It is characterized by including.

Such a neck process specifying device converts the arrival sequence matrix into a setup condition arrival sequence matrix in which a plurality of setup conditions are arranged by replacing the lot corresponding to the job with the setup condition, and then, within the search range. Since the setup condition of 1 is selected by a predetermined selection rule and the rearrangement arrival sequence matrix is created in this selection order, the productivity that appropriately reflects the setup condition can be obtained.

Further, in another aspect, in the above-described neck process identification device, the constraint condition includes a storage space size that is a size of a storage space in which the job is stored, preset for each process, and the rearrangement arrival order matrix The creating unit is characterized in that the search range is set to a range based on the storage size corresponding to the process.

The storage size is the size of the storage space for jobs (work-in-process) to be processed in the process. For this reason, the larger the storage size, the wider the choice of jobs to be processed in the process, so that it becomes easier to combine more jobs into one larger lot, and the number of setup changes can be reduced. You can improve the property. Since the neck process specifying device sets the search range to a range based on the storage size of the process, it is possible to obtain the productivity that appropriately reflects the storage size as one of the constraint conditions.

Further, in another aspect, in the above-described neck process identification device, the constraint condition includes an inventory amount preset for each process, and the rearrangement arrival sequence matrix creation unit sets the search range to the process. It is characterized by setting the range based on the corresponding stock amount.

Since such a neck process identification device sets the search range to a range based on the inventory amount (amount of work in progress) of the relevant process, one of the constraint conditions is to obtain the productivity that appropriately reflects the inventory amount. You can

In addition, in another aspect, in the above-described neck process specifying device, the setup condition includes a setup condition common to a plurality of lots.

Such a neck process specifying device can reduce the number of setup changes corresponding to lots by improving the productivity by collecting lots having common setup conditions even if the lots are different.

Further, a neck process specifying method according to another aspect of the present invention is a neck process specifying method for specifying a neck process in a production process for producing a large variety of products by using a plurality of equipment in a flow shop type, The equipment of includes a facility for performing setup change according to lots in the same process, is a constraint condition related to the implementation of the process performed by the equipment for performing the setup change, and is preset for each lot. A constraint condition information storing step of storing the constraint condition including at least a setup condition that is a condition for performing a replacement in a constraint condition information storage unit in association with the process performed in the facility for performing the changeover, and the production process. For each of the plurality of processes in step A, an arrival sequence creating process for creating an arrival sequence to the process in a plurality of jobs to be processed, and for each of the plurality of processes, the plurality of processes according to the arrival order created in the arrival sequence creating process. An arrival order matrix storing step of storing a plurality of arrival order matrices in which the jobs of (1) are arranged in the arrival order matrix storing section in association with each of the plurality of steps, and the arrival order matrix storing section for each of the plurality of steps. The plurality of jobs arranged in the stored arrival order matrix corresponding to the process is rearranged based on the constraint condition corresponding to the process stored in the constraint condition information storage unit to be rearranged in the arrival order. For each of the plurality of steps, a rearrangement arrival order matrix creating step for creating a matrix, and for each of the plurality of steps, the rearrangement arrival order matrix of the corresponding step created in the rearrangement arrival order matrix creating step is determined in advance. The setup change time of the setup change corresponding to the process concerned, and the productivity calculation step obtained based on the processing time of the job corresponding to the predetermined process, and the plurality of productivity calculation steps obtained in the productivity calculation step. A neck process specifying process for specifying a neck process in the production process based on a plurality of productivity corresponding to each process.

Such a neck process specifying method rearranges, for each of a plurality of processes in a production process, a plurality of jobs arranged in an arrival sequence matrix corresponding to the process based on a constraint condition corresponding to the process. A rearrangement arrival sequence matrix is created using the rearrangement arrival sequence matrix for each of the plurality of processes, the rearrangement arrival sequence matrix for the relevant process, the preset setup change time corresponding to the process, and the predetermined productivity. The neck process is identified based on the processing time of the job corresponding to the obtained process, and the neck process is identified based on the productivity of each of the obtained processes. In this way, since the neck process is specified in consideration of the constraint condition including at least the setup condition, the neck process specifying method is a flow shop type in which a plurality of facilities including a facility for performing the setup change according to the lot even in the same process are used. A neck process in a production process for producing a wide variety of products can be specified more accurately.

The neck process identification device and the neck process identification method according to the present invention, the neck process in the production process for producing a large variety of products by using a plurality of facilities including a facility for performing setup change according to lot even in the same process. It can be specified more accurately.

It is a block diagram showing composition of a neck process specific device in an embodiment. FIG. 2 is a block diagram mainly showing a configuration of a rearrangement arrival sequence matrix creating unit of the neck process specifying device shown in FIG. 1. It is a figure which shows the structure of the job information table memorize|stored in the neck process specific|specification apparatus shown in FIG. It is a figure which shows the structure of the constraint condition information table memorize|stored in the neck process specific|specification apparatus shown in FIG. It is a figure which shows the structure of the process information table memorize|stored in the neck process specific|specification apparatus shown in FIG. 3 is a flowchart showing the operation of the neck process identification device shown in FIG. 1. FIG. 3 is a diagram for explaining a method of creating a rearrangement arrival order matrix in the neck process specifying device shown in FIG. 1. FIG. 8 is a diagram showing a job information table stored in the neck process specifying device shown in FIG. 1 in the first embodiment. In 1st Example, it is a figure which shows the constraint condition information table memorize|stored in the neck process specific|specification apparatus shown in FIG. In 1st Example, it is a figure which shows the process information table memorize|stored in the neck process specific|specification apparatus shown in FIG. FIG. 9 is a diagram showing a job information table stored in the neck process specifying device shown in FIG. 1 in the second embodiment. In 2nd Example, it is a figure which shows the constraint condition information table memorize|stored in the neck process specific|specification apparatus shown in FIG. In 2nd Example, it is a figure which shows the process information table memorize|stored in the neck process specific|specification apparatus shown in FIG.

An embodiment of the present invention will be described below with reference to the drawings. It should be noted that in each of the drawings, the components denoted by the same reference numerals indicate the same components, and the description thereof will be appropriately omitted. In the present specification, reference numerals without suffixes are used for generic names, and reference numerals with suffixes are used when referring to individual components.

(Structure of neck process identification device)
FIG. 1 is a block diagram showing a configuration of a neck process identifying device according to an embodiment. FIG. 2 is a block diagram mainly showing the configuration of the rearrangement arrival sequence matrix creating unit of the neck process identifying apparatus shown in FIG. FIG. 3 is a diagram showing a configuration of a job information table stored in the neck process identifying apparatus shown in FIG. FIG. 4 is a diagram showing a configuration of a constraint condition information table stored in the neck process specifying device shown in FIG. FIG. 4A shows the first constraint condition information table, and FIG. 4B shows the second constraint condition information table. FIG. 5 is a diagram showing a structure of a process information table stored in the neck process specifying device shown in FIG.

The neck process identification device M according to the embodiment includes, for example, as shown in FIG. 1, a job information storage unit 1, an arrival order creation unit 2, an arrival order matrix storage unit 3, a constraint condition information storage unit 4, and a process. The information storage unit 5, the rearrangement arrival order matrix creation unit 6, the rearrangement arrival order matrix storage unit 7, the productivity calculation unit 8, the productivity storage unit 9, and the neck process identification unit 10 are provided.

The neck process specifying device M including such units 1 to 10 is configured by, for example, an information processing device. The information processing apparatus includes, for example, a computer including a CPU (Central Processing Unit), a ROM (Read Only Memory), a RAM (Random Access Memory), and an auxiliary storage device, a display (an example of an output unit that outputs data), and an operation. A device (an example of an input unit for inputting data). As such an information processing device, for example, a stationary information processing device such as a desktop computer may be adopted, or a portable information processing device such as a tablet terminal or a smartphone may be adopted.

Each block shown in FIG. 1 is realized, for example, by the CPU executing a program (neck process specifying program) stored in an auxiliary storage device and causing a computer to function as a neck process specifying device. In FIG. 1, blocks shown by squares are functionally realized mainly by a CPU, and blocks shown by cylinders are mainly realized functionally by a storage device including a ROM, a RAM, an auxiliary storage device, and the like. It

The neck process identification device M identifies a neck process in a production process for producing a wide variety of products by using a plurality of facilities including a facility for performing setup change according to a lot even in the same process in a flow shop type.

The “lot” generally refers to a product unit in production management, but in the present embodiment, it represents a unit of a job that can be put together. For this reason, the same process (for example, a process of using the same equipment under the same conditions such as coating with the same color or heat treatment at the same temperature) can be used in different types of products in one process. In this case, they may be combined into one lot and belong to the same lot.

“Setup change” refers to setup work (preparation work of equipment) that occurs when the type of product to be processed or the process contents change in equipment. The work (setup work) carried out during the setup change depends on the type of equipment. For example, replacement of jigs and tools such as press dies, standard adjustment of precision cutting equipment or chemical equipment, change of standard and switching of assembly parts or members accompanying it, and confirmation of work contents before manufacturing etc. Corresponds to. "Perform setup change according to lot" means that setup work occurs when the lot to be processed is switched in equipment. Therefore, in the present embodiment, the larger the lot size, the smaller the number of setup changes (setup times) and the time required for that (the total setup time, which is the sum of the setup times), and therefore the productivity is improved. The "equipment" corresponds to a processing device or the like that processes a product. “Processing” corresponds to manufacturing or processing of a work. One piece of equipment usually carries out one process, but one piece of equipment may carry out a plurality of steps.

In the present embodiment, the “neck process” refers to a process in which productivity is equal to or lower than a predetermined threshold value set in advance in the plurality of processes in the production process, and particularly, in the plurality of processes in the production process. The process with the lowest productivity is called the "bottleneck process". Therefore, the neck process includes a bottleneck process. Since the productivity of the whole production process can be effectively improved by improving the productivity of the neck process whose productivity is equal to or less than a predetermined threshold value, the identification of this neck process is important. In particular, improving the productivity of the bottleneck process is more effective for improving the productivity of the entire production process.

The job information storage unit 1 stores in advance information of a plurality of jobs to be processed (job information). The “job” refers to one unit of a processing target processed by equipment, and corresponds to, for example, a work. The “workpiece” is an object to be processed in a machine tool. In the present embodiment, each of the plurality of jobs is pre-assigned to any one of the plurality of types.

More specifically, the job information storage unit 1 stores the job information in a table format, for example. The job information table JT for registering this job information registers, for example, as shown in FIG. 3, a product type field 11 for registering the product type of a job and the number of works (the number of jobs) of the product type registered in the product type field 11. A work number field 12 is provided, and a record is provided for each product type.

The arrival order creation unit 2 creates, for each of a plurality of processes in the production process, an arrival order to the process in a plurality of jobs to be processed. More specifically, the arrival order creation unit 2 arranges all the jobs to be processed stored in the job information storage unit 1 in a random (random) order for each of the plurality of processes. This creates the order of arrival at the process. The arrival order creation unit 2 creates a plurality of arrival orders having different arrangement patterns (job arrangement order) for one process by repeating this a plurality of times.

For example, in the example shown in FIG. 3, since the type a is the XW workpieces, the type b is the YW workpieces, and the type c is the ZW workpieces, the arrival sequence creation unit 2 For the first first process PR1 in the process, these (XW+YW+ZW) works are randomly arranged to form one arrival order. Then, the arrival order creation unit 2 creates a plurality of arrival orders with different array patterns by repeating this for the first step PR1. Further, the arrival order creation unit 2 creates a plurality of arrival orders having different arrangement patterns for the next second process PR2 by the same process as the first process PR1. Then, the arrival order creation unit 2 repeats such a process until the final process PRn in the production process. As a result, a plurality of arrival sequences are created for each of the n processes in the production process.

The arrival order matrix storage unit 3 corresponds a plurality of arrival order matrices in which the plurality of jobs are arranged according to the arrival order created by the arrival order creation unit 2 for each of the plurality of processes in the production process, to each of the plurality of processes. It is attached and memorized. For example, the arrival order matrix storage unit 3 receives the jobs randomly selected by the arrival order creation unit 2 from the plurality of jobs one by one and stores them in a first-in first-out method until there are no more jobs to be selected. Stores one arrival order matrix by.

The constraint condition information storage unit 4 stores the constraint condition relating to the execution of the process performed in the equipment for performing the setup change in association with the process performed in the equipment for performing the setup change. The constraint condition includes at least a setup condition that is a condition for performing the setup change set in advance for each lot. The constraint conditions may include appropriate conditions according to the characteristics of the process in addition to the above-mentioned setup conditions. For example, a preset condition for each process may be a place for placing a job (work-in-progress) to be processed in the process. It may include a storage space size, which is a size, and may include, for example, a preset inventory amount (amount of work-in-progress) for each process. The setup condition may be an appropriate condition depending on the type of equipment and the content of the process, for example, the type of roll around which the steel material is wound in the rolling process, and, for example, the heat treatment temperature in the heat treatment process, For example, in the painting process, the painting color.

More specifically, the constraint condition information storage unit 4 stores the constraint conditions in a table format, for example. In the present embodiment, the two first and second constraint condition information tables LT and AT are stored in the constraint condition information storage unit 4. As shown in FIG. 4A, the first constraint condition information table LT for registering the setup condition as the constraint condition includes, for example, as shown in FIG. 4A, a product type field 41 for registering the job product type and a product type field 41 for registering the product type. A constraint condition field 42 for registering constraint conditions (setup conditions) is provided, and a record is provided for each product type. The first constraint condition information table LT as described above is provided in association with the process performed by the equipment for performing the setup change. In the example illustrated in FIG. 4A, the constraint condition information storage unit 4 includes a plurality of constraint condition information tables LT-1, LT-2, LT-3,... Corresponding to the plurality of processes in the production process. Remembered in. The second constraint condition information table ST in which the storage size, the stock amount, and the like are registered as the constraint conditions includes the process name field 43 in which the process name is registered, and the constraint condition of the process having the process name registered in the process name field 43 ( A constraint condition field 44 for registering a storage space size, an inventory amount, etc. is provided, and a record is provided for each process name of a process performed by the equipment for performing the setup change.

The process information storage unit 5 stores process information, which is information necessary for obtaining productivity. The process information includes, for example, a processing time required to perform the process, a setup time required to perform a setup change (setup work), and the like. More specifically, the process information storage unit 5 stores the process information in a table format. For example, as shown in FIG. 5, the process information table PT for registering the process information items shows a process name field 51 for registering a process name and a processing time of a process having a process name registered in the process name field 51. A processing time field 52 to be registered, a setup time field 53 to register setup time of a process having a process name registered in the process name field 51, and a record is provided for each process (process name).

The above-mentioned job information, constraint condition information, and process information are stored in advance in the job information storage unit 1, the constraint condition information storage unit 4, and the process information storage unit 5, respectively, before information processing for determining a neck process. ..

The rearrangement arrival sequence matrix creating unit 6 sets, for each of the plurality of processes in the production process, a plurality of jobs arranged in the arrival sequence matrix corresponding to the process stored in the arrival sequence matrix storage unit 3 as a constraint condition. Based on the constraint condition corresponding to the process stored in the information storage unit 4, rearrangement is performed to create a rearrangement arrival sequence matrix. As described above, since one process has a plurality of arrival order rows having mutually different job arrangement patterns, the rearrangement arrival order matrix creating unit 6 relates to each of the plurality of steps in the production process. The plurality of arrival order matrices in the process are rearranged to create a plurality of rearranged arrival order matrices. The rearrangement arrival order matrix storage unit 7 stores the plurality of rearrangement arrival order matrices created by the rearrangement arrival order matrix creation unit 6 for each of the plurality of processes in the production process in association with each of the plurality of processes. To do.

The rearrangement arrival order matrix creation unit 6 as described above includes, for example, as shown in FIG. 2, an arrival order matrix conversion unit 61, a selection unit 62, and an arrival order matrix update unit 63.

The arrival sequence matrix conversion unit 61 converts the arrival sequence matrix into a setup condition arrival sequence matrix in which a plurality of setup conditions are arranged, by replacing the lot corresponding to the job with the setup condition. In the present embodiment, the lots are grouped for each product type, and the setup conditions are associated with the product types. Therefore, the arrival order matrix conversion unit 61 replaces the lots with the setup conditions corresponding to the product type corresponding to the job. To convert the arrival order matrix into the setup condition arrival order matrix.

The selection unit 62 sets a search range for the setup conditions from the top to a predetermined number of the setup condition arrival sequence matrix, and selects one setup condition from the set search range according to a predetermined selection rule, The selected setup condition is output to the rearrangement arrival order matrix storage unit 7. The rearrangement arrival order matrix storage unit 7 stores the setup conditions selected by the selection unit 62 in the selection order in a first-in first-out method. As a result, the setup condition arrival order matrix is rearranged into a rearrangement arrival order matrix and stored in the rearrangement arrival order matrix storage unit 7. The predetermined selection rule can adopt a condition for grouping in the same lot in order to reduce setup change. Therefore, the same setup condition as the setup condition selected immediately before is preferentially selected from the search range. When the same setup condition as the setup condition selected immediately before is not within the search range, an appropriate setup condition within the search range is selected. For example, as a result of selection by the selection unit 62, the largest number of setup conditions are selected within the search range in the remaining residual setup condition arrival sequence matrix. Further, for example, as a result of selection by the selection unit 62, the setup condition arranged at the head of the remaining remaining setup condition arrival sequence matrix is selected.

The arrival order matrix updating unit 63 updates the order of the setup conditions in the setup condition arrival order matrix by MSB every time the setup condition is selected, and selects until the setup conditions of the setup condition arrival order matrix disappear. The section 62 allows the setup condition of 1 to be selected.

The productivity calculating unit 8 calculates the productivity of the process for each of the plurality of processes in the production process by the rearrangement arrival sequence matrix of the process created by the rearrangement arrival sequence matrix creating unit 6 (in the present embodiment, the setup sequence). It is obtained based on a matrix obtained by rearranging the conditional arrival sequence matrix), a setup time for setup change corresponding to the predetermined process, and a processing time of a job corresponding to the predetermined process. In the present embodiment, since a plurality of arrival order rows exist in one process and therefore a plurality of rearrangement arrival order matrices exist, the productivity computing unit 8 determines that the plurality of rearrangement orders in the process. The productivity of the process is calculated by calculating the average productivity of the arrival sequence matrix. The productivity refers to the amount that can be processed per unit time in each of the plurality of steps in the production step. Although the productivity is represented by the number of jobs in the present embodiment, the productivity is not limited to this and may be represented by an arbitrary unit such as weight or length.

The productivity storage unit 9 stores the plurality of productivity calculated by the productivity calculation unit 8 for each of the plurality of processes in the production process in association with each of the plurality of processes.

The neck process identification unit 10 identifies a neck process in the production process based on a plurality of productivity corresponding to each of the plurality of processes obtained by the productivity calculation unit 8. More specifically, the neck process identification unit 10 obtains, for example, a process having a productivity equal to or lower than a predetermined threshold among a plurality of processes in the production process as a neck process. Further, for example, the neck process identification unit 10 obtains the process having the lowest productivity among the plurality of processes in the production process as the neck process, that is, the bottleneck process.

(Operation of neck process identification device)
Next, the operation of this embodiment will be described. FIG. 6 is a flowchart showing the operation of the neck process identifying device shown in FIG. FIG. 7 is a diagram for explaining a method of creating a rearrangement arrival sequence matrix in the neck process specifying device shown in FIG. 1.

In such a neck process specifying apparatus M, in FIG. 6, first, the arrival order creation unit 2 reads the job information of a plurality of jobs to be processed from the job information storage unit 1 and all the first process PR1. The jobs of (1) are arranged in a line in a random (random) order to create an arrival order to the process, and are stored in the arrival order matrix storage unit 3 as an arrival order matrix in association with the first process PR1. More specifically, the arrival order creation unit 2 randomly selects one job from the plurality of jobs and outputs it to the arrival order matrix storage unit 3 until there are no more jobs to be selected. The unit 3 receives the jobs one by one from the arrival order creation unit 2 and stores them in a first-in first-out manner in association with the first process PR1. As a result, one arrival order matrix is created by the arrival order creation unit 2 and stored in the arrival order matrix storage unit 3. For example, when the job information storage unit 1 stores job information in which there are four jobs of type a, five jobs of type b, and five jobs of type c, The arrival order creation unit 2 creates the arrival order illustrated in FIG. 7A by arranging these three types of 14 jobs in a line in a random order, and the arrival order matrix storage unit 3 stores the arrival order illustrated in FIG. As shown in (A), an arrival order matrix in which a plurality of jobs are arranged is stored in association with the first process PR1. In FIG. 7A, one ellipse indicates one job. In FIG. 7A, the difference in product type is shown by the difference in color. Here, the black ellipse represents the job of product a, and the gray ellipse (ellipse hatched with diagonal lines) is product b. Job, and the white ellipse indicates the job of the product type c. Then, the arrival order creation unit 2 creates a plurality of arrival orders with different array patterns (job arrangement order) for the first step PR1 by repeating this a plurality of times, and the arrival order matrix storage unit 3 A plurality of arrival order matrices corresponding to the plurality of arrival orders are stored in association with the first step PR1 (S1).

Next, the rearrangement arrival order matrix creating unit 6 reads a plurality of arrival order matrices from the arrival order matrix storage unit 3 for the first step PR1, and the constraint condition information storage unit 4 for each of the plurality of arrival order matrices. The rearrangement arrival order matrix is rearranged to create a rearrangement arrival order matrix based on the constraint condition corresponding to the first process PR1 stored in step S1, and the rearrangement arrival order matrix storage unit 7 is created for each of these plurality of arrival order matrices. The plurality of rearranged arrival order matrices are stored in association with the first step PR1 (S2).

More specifically, first, the arrival order matrix conversion unit 61 replaces each of the plurality of arrival order matrices with the setup condition that further corresponds to the lot corresponding to the job, thereby making the arrival order matrix into a plurality of arrival order matrices. The setup conditions are converted into a setup condition arrival sequence matrix. For example, in the constraint condition information storage unit 4, the constraint condition information that the constraint condition of the product type a is the setup condition A, the constraint condition of the product type b is the setup condition B, and the constraint condition of the product type c is the setup condition C. , The arrival order matrix conversion unit 61 replaces the job of type a in the arrival order matrix with the setup condition A, replaces the job of type b of the arrival order matrix with the setup condition B, and The job of type c is replaced with the setup condition C. For example, the arrival order matrix shown in FIG. 7A is converted into the setup condition arrival order matrix shown in FIG. 7B by such replacement processing. In FIG. 7B, one ellipse indicates one setup condition (job having the setup condition). In FIG. 7B, the difference in the setup conditions is indicated by the difference in color. Here, the black ellipse indicates the setup condition A (job having the setup condition A), and the gray ellipse (hatched diagonal lines). The ellipse marked with () indicates the setup condition B (job having the setup condition B), and the white ellipse indicates the setup condition C (job having the setup condition C). The same applies to FIGS. 7C to 7E.

Next, the selection unit 62 sets a search range for the setup conditions from the top of the setup condition arrival sequence matrix to a predetermined number, and selects one setup condition from the set search range according to a predetermined selection rule. The selected setup condition is output to the rearrangement arrival order matrix storage unit 7. The search range is set to, for example, a range based on the constraint condition associated with the first step PR1. More specifically, the search range is set to, for example, a range based on the storage size associated with the first process PR1. Further, for example, the search range may be set to a range based on the stock amount associated with the first process PR1, for example. The predetermined selection rule is a condition for grouping in the same lot in order to reduce setup change. More specifically, in the first selection, the setup condition with the largest number is selected within the search range in the setup condition arrival sequence matrix. For example, in the setup condition arrival sequence matrix shown in FIG. 7B, the search range is set in a range based on five storage sizes, and the setup condition with the largest number (setup condition with the largest number in this search range is set. Setup condition A, which is the job) is selected. In the setup condition arrival sequence matrix shown in FIG. 7B, the setup condition C is also the setup condition with the largest number in the search range, like the setup condition A. Therefore, instead of the setup condition A, the setup condition A C may be selected. When there are a plurality of setup conditions with the largest number in the search range, the setup condition closest to the head in the setup condition arrival sequence matrix may be selected. The setup condition A thus selected is stored in the rearrangement arrival order matrix storage unit 7. In FIG. 7B, the setup condition on the right side, which is described as “step”, is the setup condition stored in the rearrangement arrival order matrix storage unit 7.

Next, the arrival order matrix updating unit 63 updates the order of the setup conditions in the setup condition arrival order matrix with MSB justification each time a setup condition is selected. In the setup condition arrival sequence matrix shown in FIG. 7(B), as described above, when the setup condition A near the beginning is selected, the order is updated justified, and after the selection shown in FIG. 7(C). Setup condition Arrival order matrix. Then, the arrival order matrix updating unit 63 causes the selection unit 62 to select one setup condition until the setup condition of the setup condition arrival order matrix is exhausted, and the selected setup condition is stored in the rearrangement arrival order matrix storage unit 7. Remember. In the second and subsequent selections, the same setup condition as the setup condition selected immediately before is preferentially selected from the search range, and the setup condition that is the same as the setup condition selected immediately before is not within the search range. As in the case of the first selection, as a result of the selection by the selection unit 62, the setup condition with the largest number is selected within the search range in the remaining setup condition arrival sequence matrix. In the setup condition arrival sequence matrix shown in FIG. 7B, in the second selection, as shown in FIG. 7C, the same setup condition as the setup condition A selected immediately before is preferentially selected from within the search range. Is selected and stored in the rearrangement arrival order matrix storage unit 7, and the order is forward-justified and updated as shown in FIG. 7(D). In the third selection, since the same setup condition as the setup condition A selected immediately before is not within the search range, as shown in FIG. 7D, the search range in the remaining remaining setup condition arrival sequence matrix is shown. Among them, the setup condition C having the largest number is selected, stored in the rearrangement arrival order matrix storage unit 7, and the order is justified. Similarly, selection, storage, and update are performed thereafter, and the rearrangement arrival order matrix shown in FIG. 7E is generated.

Returning to FIG. 6, next, the productivity calculating unit 8 rearranges the plurality of rearrangement arrival order matrices created by the rearrangement arrival order matrix creating unit 6 (in the present embodiment, the setup condition arrival order matrix is rearranged). Matrix) for each of the productivity of the first process PR1 to the rearrangement arrival sequence matrix, the setup time of the setup change corresponding to the predetermined first process PR1, and the predetermined first process PR1. The average productivity is calculated based on the processing time of the corresponding job, and the calculated productivity of the first process PR1 (here, the average productivity) is stored in the productivity storage unit 9 in association with the first process PR1. More specifically, the productivity calculation unit 8 counts the number of setup changes of the rearrangement arrival order matrix for each of the plurality of rearrangement arrival order matrices, and the process information is added to the counted total number of setup changes. By multiplying the setup time (min/time) of the first process PR1 stored in the storage unit 5, the total setup time required for setup change is obtained, and the number of works in the rearrangement arrival sequence matrix is counted, and this count is performed. By multiplying the total number of workpieces by the processing time (min/work) of the first process PR1 stored in the process information storage unit 5, the total processing time required to process the workpieces is obtained, and the total setup time and the total processing time are calculated. The total time of the first step is obtained by calculating the sum of the time and the operation time of one month (min, for example, 43200 minutes when the operation time of one month is 720 hours) is multiplied by the total number of workpieces. The productivity of the rearrangement arrival order matrix is obtained by dividing by the total time of the first process (productivity (work/month)=(43200 (min)×total number of works)/(total time of the first process) ), total time of the first step=total setup time+total processing time). Then, the productivity calculating unit 8 obtains the average productivity for the plurality of productivity obtained for each of the plurality of rearrangement arrival order matrices, and sets it as the final productivity of the first step PR1, and this is the productivity storage unit 9 Is stored in association with the first step PR1. The operating rate of the facility may be taken into consideration in the operating time. For example, when the operating rate is 80%, the multiplication result is the result obtained by multiplying the operating rate for one month by the operating rate and the total number of workpieces (for example, if the operating time for one month is 720 hours, 43200 (minutes)). )×0.8×(total number of works)).

Next, the neck process identification unit 10 determines whether or not the processes S1 to S3 have been executed for all the processes in the production process. That is, the neck process identification unit 10 determines whether or not each productivity (here, each average productivity) has been obtained for all the processes in the production process (S4). As a result of this determination, if the processes of the processes S1 to S3 have not been executed for all the processes, that is, if the productivity is not required for all the processes (No), the process proceeds to the process S1. On the other hand, as a result of the determination, when the processes S1 to S3 are executed for all the processes, that is, when the productivity is required for all the processes (Yes), The next process S5 is executed.

In this process S5, the neck process identification unit 10 identifies the neck process in the production process based on the plurality of productivity corresponding to each of the plurality of processes obtained by the productivity calculation unit 8. More specifically, the neck process identification unit 10 obtains, for example, a process having a productivity equal to or lower than a predetermined threshold among a plurality of processes in the production process as a neck process. The neck process identification unit 10 may obtain the bottleneck process having the lowest productivity among the plurality of processes in the production process.

Then, the neck process specifying unit 10 outputs the obtained neck process (S6), and ends the present process. For example, the neck process identification unit 10 displays the neck process on the display device. Further, for example, the neck process specifying unit 10 outputs the neck process to an external device via an interface circuit such as a USB (Universal Serial Bus) interface circuit or a communication circuit such as a LAN (Local Area Network) card.

As described above, the neck process identification device and the neck process identification method implemented therein according to the present embodiment include, for each of a plurality of processes in the production process, a plurality of arrival sequence matrices arranged in the arrival sequence matrix corresponding to the process. The jobs are rearranged based on the constraint condition corresponding to the process to create a rearrangement arrival order matrix, and for each of the plurality of processes, the productivity of the process is determined by the rearrangement arrival order matrix of the process, Obtained based on the preset setup change time corresponding to the process and the job processing time corresponding to the preset process, and the neck process is specified based on each of the obtained productivity of each process. .. As described above, since the neck process is specified in consideration of the constraint condition including at least the setup condition, the neck process specifying device and the method can flow a plurality of equipment including the equipment for performing the setup change according to the lot even in the same process. It is possible to more accurately specify the neck process in the production process that uses a shop type to produce a wide variety of products.

As a result, flexible and accurate operation determination can be connected. For example, it is possible to detect in advance the possibility that the neck process will change for each one-month production plan, and it is possible to start early the operation judgment and response that will lead to the productivity improvement of the true neck process. In addition, it is possible to prevent erroneous investment decisions. Normally, the investment for improving the productivity of the entire factory is made for the neck process based on the TOC theory, but if the neck process is incorrectly specified, there is a possibility of making capital investment that does not lead to productivity improvement. is there. However, in this embodiment, since the neck process can be specified more accurately, such an incorrect investment decision can be prevented.

Further, the neck process identifying apparatus and the method create a plurality of arrival orders, that is, a plurality of arrival order matrices for one process, and perform a plurality of rearrangements based on the plurality of arrival orders (arrival order matrices). An arrival order matrix is created, and the average productivity of the plurality of rearranged arrival order matrices is calculated as the productivity. Since the productivity is obtained by performing a plurality of trials (simulations) as described above, the neck step identifying apparatus and the method can more accurately obtain the productivity, and thus more accurately identify the neck step. it can.

Further, the neck process identifying apparatus and the method convert the arrival sequence matrix into a setup condition arrival sequence matrix in which a plurality of setup conditions are arranged by replacing the lot corresponding to the job with the setup condition. Since one setup condition is selected from the range by a predetermined selection rule and the rearrangement arrival order matrix is created in this selection order, the productivity that appropriately reflects the setup condition can be obtained.

The larger the storage size, the wider the choice of jobs to be processed in the process. Therefore, it is easier to combine more jobs into one larger lot, which reduces the number of setup changes and improves productivity. it can. Therefore, when the search range is set to a range based on the storage size of the process, the neck process specifying device and the method can obtain the productivity that appropriately reflects the storage size as one of the constraint conditions. In particular, when the search range is set equal to the value of the storage size, a job to be processed using the maximum storage size is selected, so that the maximum productivity of the target process can be assumed.

Further, when the search range is set to a range based on the stock amount (the amount of work-in-progress) of the process, the neck process specifying device and the method appropriately reflect the stock amount as one of the constraint conditions. You can ask for sex. In particular, in actual operation, since there are obsolete stocks, safety stocks, etc., it is preferable to set the stock quantity that can be actually used in the process.

In the above embodiment, the setup conditions may include setup conditions common to a plurality of lots. According to this, the neck process specifying apparatus M and the method can reduce the number of setup changes corresponding to lots by collecting lots having common setup conditions even if the lots are different, and productivity can be improved.

Further, in the above-described embodiment, the setup time is set to one time for one process, but a different time may be set depending on the product before and after the setup change.

Further, in the above-described embodiment, the average productivity is used as the final productivity, but the productivity of another representative value such as the median value may be used as the final productivity.

Next, examples using more specific numerical examples will be described.

(First embodiment)
FIG. 8 is a diagram showing a job information table stored in the neck process identifying apparatus shown in FIG. 1 in the first embodiment. FIG. 9 is a diagram showing a constraint condition information table stored in the neck process specifying device shown in FIG. 1 in the first embodiment. 9A shows the first constraint condition information table LT-A1 in the rolling process PR-A of the first process, and FIG. 9B shows the first constraint condition in the heat treatment process PR-B of the second process. 9C shows the information table LT-B1, and FIG. 9C shows the second constraint condition information table ST-1 of the rolling process PR-A and the heat treatment process PR-B. FIG. 10 is a diagram showing a process information table stored in the neck process specifying device shown in FIG. 1 in the first embodiment.

In this first embodiment, the production process includes a first rolling process PR-A and a second heat treatment process PR-B. The job information storage unit 1 stores a job information table JT-1 shown in FIG. 8 as job information. That is, for each of the five product types a to e, the number of each work is 100, and the total number of works is 100×5=500. The first constraint condition information table LT-A1 in the rolling process PR-A of the first process shown in FIG. 9A is stored in the constraint condition information storage unit 4 as one of the constraint conditions, and other constraint conditions are stored. 9B, the first constraint condition information table LT-B1 in the heat treatment process PR-B of the second process shown in FIG. 9B is stored. As another one of the constraint conditions, FIG. The second constraint condition information table ST-1 of the rolling process PR-A and the heat treatment process PR-B shown is stored. That is, in the rolling process PR-A, the setup conditions for the α rolls or the ε rolls are set for the product types a to e, respectively, and in the heat treatment process PR-B, the temperature TA° C. to the temperature for the product types a to e. The setup conditions for each TE° C. are set, the storage size 30 (work) is set in the rolling process PR-A, and the storage size 10 (work) is set in the heat treatment process PR-B. Then, the process information storage unit 5 stores the process information table PT-1 shown in FIG. 10 as the process information. That is, the processing time of the rolling process PR-A is 100 (min/work), and the setup time thereof is 100 (min/time). The processing time of the heat treatment step PR-B is 70 (min/work), and the setup time thereof is 300 (min/time).

With respect to the first example of such numerical examples, the neck process specifying device M obtains the results shown in Table 1 by executing the processes S1 to S6 shown in FIG. Here, the number of trials is 10. That is, in the process S1, ten arrival orders are generated, in the process S2, ten rearranged arrival order matrices are generated for the arrival order matrices corresponding to these ten arrival orders, and in the process S3, The 10 productivity averages for these 10 rearranged arrival order matrices are determined.

As can be seen from Table 1, the average productivity of the rolling process PR-A is 404.6 (work/month), and the average productivity of the heat treatment process PR-B is 347.1 (work/month). .. Therefore, when the bottleneck process is obtained, it can be seen that the heat treatment process PR-B is the bottleneck process. This is because the heat treatment process PR-B has a higher process capability (process time per work piece) than the rolling process PR-A, but since the storage space size is small, setup change is likely to occur, and one more time is required. This is because the setup time per hit also takes a significantly long time. Therefore, in the first embodiment, if an attempt is made to identify the neck process only by the process capability, there is a possibility that an erroneous conclusion will be drawn (the rolling process PR-A will be regarded as a bottleneck process).

(Second embodiment)
FIG. 11 is a diagram showing a job information table stored in the neck process identifying apparatus shown in FIG. 1 in the second embodiment. FIG. 12 is a diagram showing a constraint condition information table stored in the neck process specifying device shown in FIG. 1 in the second embodiment. 12A shows the first constraint condition information table LT-C2 in the rolling process PR-C of the first process, and FIG. 12B shows the first constraint condition in the heat treatment process PR-D of the second process. 12C shows the information table LT-D2, and FIG. 12C shows the second constraint condition information table ST-2 of the rolling process PR-C and the heat treatment process PR-D. FIG. 13 is a diagram showing a process information table stored in the neck process specifying device shown in FIG. 1 in the second embodiment.

In the second embodiment, the production process includes a rolling process PR-C of the first process and a heat treatment process PR-D of the second process. The job information storage unit 1 stores the job information table JT-2 shown in FIG. 11 as the job information. That is, the number of works of the product type a is 60, the number of works of the product type b is 50, the number of works of the product type c is 40, the number of works of the product type d is 30, The number of works of the product type e is 20, and the total number of works is 60+50+40+30+20=200. As one of the constraint conditions, the constraint condition information storage unit 4 stores the first constraint condition information table LT-C2 in the rolling process PR-C of the first process shown in FIG. 12B, the first constraint condition information table LT-D2 in the heat treatment step PR-D of the second step shown in FIG. 12B is stored, and as another one of the constraint conditions, FIG. The second constraint condition information table ST-2 of the rolling process PR-C and the heat treatment process PR-D shown is stored. That is, in the rolling process PR-C, the setup conditions for the product type a are α rolls, the setup conditions for the product types b and c are β rolls, and the setup conditions for the product types d and e are δ rolls. Is. Therefore, setup conditions common to a plurality of types (one example of lot) are included. In the heat treatment process PR-D, the setup conditions of the temperature TA° C. to the temperature TE° C. are set for the product types a to e, respectively, and the storage size 10 (workpiece) is set to the rolling process PR-C. A storage size of 10 (work) is set in -D. Therefore, the storage size of the rolling process PR-C and the storage size of the heat treatment process have the same value (the search range is the same). Then, the process information storage unit 5 stores the process information table PT-2 shown in FIG. 13 as the process information. That is, the processing time of the rolling process PR-C is 80 (min/work), and the setup time thereof is 120 (min/cycle). The processing time of the heat treatment process PR-D is 75 (min/work), and the setup time thereof is 115 (min/time).

In the second example of such numerical examples, the neck process specifying device M executes the processes S1 to S6 shown in FIG. 6 to obtain the results shown in Table 2. Here, the number of trials is 10.

As can be seen from Table 2, the average productivity of the rolling process PR-C is 472.0 (work/month), and the average productivity of the heat treatment process PR-D is 448.8 (work/month). .. Therefore, when the bottleneck process is obtained, it can be seen that the heat treatment process PR-D is the bottleneck process. Regarding the processing time and the setup time, although the rolling process PR-C has a lower production capacity, the heat treatment process PR-D is specified to be the bottleneck process. This is because the rolling process PR-C has three setup conditions of α roll, β roll and δ roll, and the heat treatment process PR-D has five setup conditions of temperature TA° C. to temperature TE° C. This is because the rolling process PR-C has less setup conditions than the heat treatment process PR-D, and thus the rolling process PR-A is easier to be grouped in the same lot than the heat treatment process PR-D.

In order to represent the present invention, the present invention has been described above appropriately and sufficiently through the embodiments with reference to the drawings, but those skilled in the art can easily modify and/or improve the above embodiments. It should be recognized that this is possible. Therefore, unless a modification or improvement performed by a person skilled in the art is at a level that departs from the scope of rights of the claims recited in the claims, the modification or the improvement is covered by the scope of rights of the claims. Is understood to be included in.

M neck process identification device 1 job information storage unit 2 arrival order creation unit 3 arrival order matrix storage unit 4 constraint condition information storage unit 5 process information storage unit 6 rearrangement arrival order matrix creation unit 7 rearrangement arrival order matrix storage unit 8 production Sex calculation unit 9 productivity storage unit 10 neck process identification unit 61 arrival sequence matrix conversion unit 62 selection unit 63 arrival sequence matrix update unit

Claims (7)

A neck process identification device for identifying a neck process in a production process for producing a wide variety of products by using a plurality of facilities in a flow shop type,
The plurality of equipment includes equipment for performing setup change according to lots in the same process,
The constraint conditions relating to the execution of the process performed in the equipment for performing the setup change, and the constraint conditions that are preset for each lot and include at least the setup conditions that are the conditions for performing the setup change, A constraint condition information storage unit that stores the information in association with the process performed in the facility that performs,
For each of the plurality of steps in the production process, an arrival order creation unit that creates an arrival order at the step in a plurality of jobs to be processed,
An arrival order matrix storage unit that stores a plurality of arrival order matrices in which the plurality of jobs are arranged according to the arrival order created by the arrival order creation unit for each of the plurality of processes, in association with each of the plurality of processes,
For each of the plurality of processes, a plurality of jobs arranged in the arrival order matrix corresponding to the process stored in the arrival order matrix storage unit corresponds to the process stored in the constraint condition information storage unit. A rearrangement arrival order matrix creating unit that rearranges and creates a rearrangement arrival order matrix based on the constraint condition,
For each of the plurality of processes, the productivity of the process, the rearrangement arrival sequence matrix of the process created by the rearrangement arrival sequence matrix creating unit, the setup time of the setup change corresponding to the predetermined process, And a productivity calculation unit that is determined based on the processing time of a job corresponding to a predetermined process,
A neck process specifying device for specifying a neck process in the production process based on a plurality of productivity corresponding to each of the plurality of processes obtained by the productivity calculating unit. .. The arrival order creation unit creates a plurality of arrival orders for the process,
The rearrangement arrival order matrix creating unit rearranges a plurality of arrival order matrices in the process to create a plurality of rearrangement arrival order matrices,
The neck process specifying device according to claim 1, wherein the productivity calculating unit calculates the productivity of the process by calculating an average productivity of a plurality of rearrangement arrival order matrices in the process. The rearrangement arrival order matrix creating unit,
An arrival order matrix conversion unit that converts the arrival order matrix into a setup condition arrival order matrix in which a plurality of setup conditions are arranged by replacing the lot corresponding to the job with the setup condition.
A selection unit that sets a search range for the setup conditions from the beginning to a predetermined number of the setup condition arrival sequence matrix, and selects one setup condition from the set search range according to a predetermined selection rule;
A rearrangement arrival order matrix storage unit that stores the setup conditions selected by the selection unit in the order of selection,
Each time the setup condition is selected, the order of the setup conditions in the setup condition arrival order matrix is updated, and the selection unit selects one setup condition until the setup conditions in the setup condition arrival order matrix are exhausted. An arrival sequence matrix updating unit is provided. The neck process specifying device according to claim 1 or 2, further comprising: The constraint condition includes a storage space size that is preset for each process and is a storage space for storing the job,
The neck process specifying device according to claim 3, wherein the rearrangement arrival order matrix creating unit sets the search range to a range based on a storage size corresponding to the process. The constraint condition includes an inventory amount preset for each process,
The neck process specifying device according to claim 3, wherein the rearrangement arrival sequence matrix creating unit sets the search range to a range based on an inventory amount corresponding to the process. The neck process specifying device according to any one of claims 3 to 5, wherein the setup conditions include setup conditions common to a plurality of lots. A neck process identification method for identifying a neck process in a production process for producing a wide variety of products by using a plurality of facilities in a flow shop type,
The plurality of equipment includes equipment for performing setup change according to lots in the same process,
The constraint conditions relating to the execution of the process performed in the equipment for performing the setup change, and the constraint conditions that are preset for each lot and include at least the setup conditions that are the conditions for performing the setup change, A constraint condition information storage step of storing the constraint condition information storage unit in association with the process performed by the equipment that performs
An arrival order creating step of creating an arrival order to the process in a plurality of jobs to be processed for each of the plurality of processes in the production process;
Arrival in which a plurality of arrival order matrices in which the plurality of jobs are arranged according to the arrival order created in the arrival order creating step for each of the plurality of steps are stored in the arrival order matrix storage unit in association with each of the plurality of steps. An ordinal matrix storage step,
For each of the plurality of processes, a plurality of jobs arranged in the arrival order matrix corresponding to the process stored in the arrival order matrix storage unit corresponds to the process stored in the constraint condition information storage unit. A rearrangement arrival order matrix creating step of rearranging and creating a rearrangement arrival order matrix based on the constraint condition;
For each of the plurality of processes, the productivity of the process, the rearrangement arrival sequence matrix of the process created in the rearrangement arrival sequence matrix creating process, the setup time of the setup change corresponding to the predetermined process, And a productivity calculation step obtained based on the processing time of the job corresponding to the predetermined step,
A neck step specifying step for specifying a neck step in the production step based on a plurality of productivity corresponding to each of the plurality of steps obtained in the productivity calculating step. .

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