JP6811703B2 - Production planning support system - Google Patents

Description

The present invention relates to a production planning support system.

When generating a production plan, a bill of materials (BOM) is created for the product to be produced (Patent Documents 1 and 2).

Japanese Unexamined Patent Publication No. 2014-199523 Japanese Unexamined Patent Publication No. 2003-015722

In the prior art, since the parts composition table is created at the time of drafting the production plan, it takes time and effort to create the parts composition table in the case of high-mix low-volume production. Further, in the case of high-mix low-volume production, it may take time for details such as product specifications and production numbers to be determined, or product specifications and production numbers may be suddenly changed. Under such a situation, it takes time and effort to create a parts bill, and the efficiency of the production planning creation work is reduced. In addition, the demands from each process for the production plan are different, and it is difficult to formulate the production plan from the viewpoint of overall optimization.

The present invention has been made in view of the above problems, and an object of the present invention is to provide a production planning support system capable of supporting efficient production planning.

In order to solve the above problems, the production plan planning support system according to the present invention is a production plan planning support system that supports the drafting of a production plan, and manages predetermined basic production information and production capacity used for production management of products. A storage unit that stores production capacity information, and a production basic information selection unit that selects at least one basic production information from the basic production information stored in the storage unit based on input customer request information. Based on the basic production information, production capacity information, and production progress information acquired from the production site, the production planning department that generates a production plan and the production plan generated by the production planning department are produced. It is provided with a production plan reflection unit that reflects the production plan stored in the plan storage unit.

According to the present invention, a production plan can be drafted based on basic production information selected based on customer request information, production capacity information, and production progress information, and can be reflected as a production plan. It does not require the trouble of creating a composition table, and can efficiently support the formulation of production plans.

It is explanatory drawing which shows the outline of the production planning support system which concerns on this embodiment. It is a hardware configuration diagram of the production planning support system. It is explanatory drawing which shows the outline of the production planning model. It is a flowchart of production planning support processing. It is explanatory drawing which shows the example of the method of making a production plan. This is an example of a screen for setting the basic unit code. This is an example of a simulation target selection screen. This is an example of the simulation start screen. This is an example of the simulation result screen. It is explanatory drawing which shows the example of the method of making a production plan in relation to the 2nd Example. This is a configuration example of a database that manages the actual values of standard working hours. It is explanatory drawing which shows the example of the method of making a production plan in relation to the 3rd Example.

Hereinafter, embodiments of the present invention will be described with reference to the drawings. The production planning support system 1 according to the present embodiment prepares basic production information including information on each process required for product production and resource consumption for each resource used in each process for each product model, and uses it as basic production information. Make a production plan based on it.

Therefore, according to the present embodiment, it is not necessary to create a parts composition table. Further, according to the present embodiment, it is possible to make a plan for the production of the ordered product simply by selecting the basic production information of the product model similar to the ordered product, and the production is performed even when the details of the customer request are unknown. You can make a plan.

Further, according to the present embodiment, when the difference in the resource consumption existing between the ordered product and the product model is clear, the planned value can be used instead of the resource consumption specified in the basic production information. .. As a result, it is possible to efficiently formulate a production plan using basic production information, and it is possible to reflect the difference between an actual product and a product model in the production plan, which improves usability.

The first embodiment will be described with reference to FIGS. 1 to 8. FIG. 1 is an explanatory diagram showing an overall outline of the production planning support system 1. The configuration shown in FIG. 1 is merely an example for embodying the present invention, and is not limited to the configuration example shown in FIG. This embodiment is suitably used for high-mix low-volume production of products such as uniform products, customized products, and prototypes. However, this embodiment can also be used for production methods other than high-mix low-volume production.

As will be described later, the production planning support system 1 includes, for example, a production planning planning unit 11, a database storage unit 12, a customer request information acquisition unit 13, a production progress information acquisition unit 14, and a schedule planning information storage unit. 15, selection unit 16, information provision unit 17, production plan reflection unit 18, production plan storage unit 19, load stacking unit 20, correction unit 21, model-specific production basic information automatic generation unit 22, and An automatic setting unit 23 can be provided. The correction unit 21, the model-specific production basic information automatic generation unit 22, and the automatic setting unit 23 have configurations used in other examples described later.

As will be described later, the production planning unit 11 is based on the basic production information selected from the customer request information, the production capacity information of the production site 4 (see FIG. 2), and the production progress information at the production site 4. , Make a production plan. The production plan generated by the production plan planning unit 11 is officially adopted as a production plan with the approval of the user, and is stored in the production plan storage unit 19. Therefore, the production plan before the approval of the user is called a production plan, and may be distinguished from the production plan after the approval of the user. When the customer request information is changed, the production planning unit 11 re-forms the production plan according to the change.

The production planning unit 11 produces a product group that shares various resources such as a designer, a work area of a production site 4, a worker group, equipment, a production line, a test site, and electric power for an arbitrary period specified by a user. Make a production plan so that is optimal for the entire production site 4. A "designer" is a resource that manages the man-hours of a designer who organizes a project for a product to be produced.

The database storage unit 12 as a “storage unit” stores a plurality of predetermined information used for planning a production plan. The database storage unit 12 (hereinafter, also referred to as a storage unit 12) stores, for example, model-specific production basic information 121, production capacity information 122, and product configuration information 123. For the storage unit 12, for example, a non-volatile storage device such as a flash memory device or a hard disk device can be used.

The production basic information 121 for each model is generated for each model of the product, and includes, for example, information on each process required for producing the product and resource consumption for each resource used in each process. Further, the basic production information 121 for each model can include management information such as a basic unit code, a creator name, a creation date, and an update date. In this embodiment, the model-specific production basic information 121 may be referred to as basic unit information 121 or basic unit 121.

The production capacity information 122 is information indicating the production capacity of the production site 4. The production capacity information 122 includes, for example, the maximum consumption (upper limit value) of resources that can be used in each process.

The product configuration information 123 indicates information indicating the configuration of a product produced in the past and the configuration of a product to be produced in the future. The product configuration information 123 is not required to be accurate enough to create a bill of materials.

The customer request information acquisition unit 13 is a function of acquiring customer request information. The customer request information is information requested for a product by a customer who is an orderer of the product, and includes, for example, information such as product specifications and the number of manufactured products. For example, a user of the production planning support system 1 can input customer request information into the production planning support system 1 by using the user interface unit 105 (see FIG. 2) described later. The customer request information can be changed as appropriate. When the customer request information is changed, the production plan can be modified based on the changed contents.

The production progress information acquisition unit 14 acquires information indicating the progress of each process of the production site 4 from the production management system 3 (see FIG. 2). The acquired production progress information is provided to the production planning unit 11 via the production planning storage unit 19.

The schedule planning information storage unit 15 stores the schedule planning information. The schedule planning information is information indicating a medium-term or long-term production planning schedule, and holds a schedule such as when the design starts and when it ends (ships). In addition, the scheduling information can include planning values to specifically indicate resource consumption. When the planned value is set in the schedule planning information, the planned value takes precedence over the resource consumption defined in the basic production information 121.

The selection unit 16 is an example of the “production basic information selection unit”. The selection unit 16 automatically stores at least one of the basic production information 121 stored in the storage unit 12 according to the customer request information by a manual operation of the user or as in the embodiment described later. select.

The information providing unit 17 is a function of presenting the production plan draft created by the production plan planning unit 11 to the user. The user gives a correction instruction or an approval instruction to the production plan planning support system 1 for the presented production plan plan.

The production plan reflection unit 18 is a function of storing the production plan as a production plan in the production plan storage unit 19 when the production plan is approved by the user.

The production plan storage unit 19 is a function of storing a production plan for each product. The production planning model is shown in FIG.

The load stacking unit 20 is a function of stacking the production load in each process in a predetermined time unit (for example, one day unit). In the following, the production load may be abbreviated as load. A maximum consumption amount (upper limit value) is set for each of the above-mentioned resources. In FIG. 3, this upper limit value is shown as a capacity line.

In this specification, accumulating the amount of resources (load) consumed in each process for each time zone is referred to as "stacking". Dispersing and rearranging the accumulated loads is called "mountain collapse".

The production planning unit 11 creates a production plan based on the processing result (result of the pile processing) of the load stacking unit 20 so as to be the optimum production plan for each process as a whole.

The correction unit 21 is a function of correcting the basic production information 121 stored in the storage unit 12 based on the actual value of the resource consumption.

The model-specific production basic information automatic generation unit 22 as the “production basic information generation unit” is a function that automatically generates model-specific production basic information 121 based on the actual value of resource consumption.

The automatic setting unit 22 as the "planned value setting unit" is a function of automatically calculating the planned value and setting it in the schedule planning information based on the actual value of the resource consumption and the product configuration information 123. In FIG. 1, the automatic setting unit 23 and the product configuration information 123 in the storage unit 12 are not connected, but the automatic setting unit 23 can refer to the product configuration information 123.

The lower part of FIG. 1 shows the production progress status managed by the production management system 3. The production control system 3 manufactures products according to the production plan received from the production plan planning support system 1. Before a product is designed and shipped, it goes through stages (processes) such as "design", "procurement", "manufacturing", "inspection", and "shipment". The production progress indicates in which process the product in process is currently located. The information indicating the production progress status is sent to the production planning support system 1 periodically or irregularly as the production progress information.

FIG. 2 is a hardware configuration diagram of the production planning support system. The production planning support system 1 is configured as, for example, a computer system, and is connected to the production management system 3 via the communication network CN1. The production management system 3 is connected to the production site 4 via another communication network CN2.

The production planning support system 1 includes, for example, a microprocessor (CPU) 101, a memory 102, a storage device 103, a communication interface 104, and a user interface unit 105.

A predetermined computer program 1031 is stored in the storage device 103. The microprocessor 101 realizes the function as the production planning support system 1 by reading the computer program 1031 into the memory 102 and executing it.

The communication interface 104 is a device for bidirectional communication between the production planning support system 1 and the production management system 3.

The user interface unit 105 is a device for exchanging information between the production planning support system 1 and the user. The user interface unit 105 includes an information input device and an information output device. Examples of the information input device include a keyboard, a touch panel, a pointing device, a voice input device, and the like. Examples of the information output device include a display, a printer, a voice synthesizer, and the like. The user interface unit 105 may be configured as a computer terminal separate from the production planning support system 1, and the user interface unit 105 and the production planning support system 1 may be connected wirelessly or by wire.

The production management system 3 is also configured as a computer system and has a microprocessor, a memory, and the like. Details of the production control system 3 are omitted.

FIG. 3 is an explanatory diagram showing an outline of a production planning model used in the production planning unit (factory simulator) 11. Made-to-order products such as customized products and high-mix low-volume products are produced in a project type for each order from order to shipment. Therefore, in this embodiment, for example, based on PERT (Program Evaluation and Review Technique), which is a project-type schedule planning method, a sequential schedule planning method for each project / process is adopted.

In the method adopted in this embodiment, the resource consumption per unit period of each process is regarded as a resource constraint based on the basic unit code set in the production number or the production branch number, and the production load in each process / resource is reduced. Pile / collapse and make a leveled plan.

The factory simulator 11 can plan a schedule for each project / process by any of, for example, "forward", "backward", and "hybrid".

"Forward" is a planning mode in which a schedule is sequentially planned from a planning start date to a delivery date (planning end date) according to a process order for each production number or production branch number. For example, this planning mode is adopted when it is desired to predict the delivery date when receiving an order for a project or reviewing a process.

"Backward" is a mode in which a schedule is planned by going back in the reverse order of the process order from the delivery date to the planning start date. For example, this planning mode is adopted when it is desired to make a plan for production in a feasible and shortest schedule after the delivery date is confirmed.

"Hybrid (forward & backward)" is a mode in which the process sequence is planned from the beginning to the middle in the forward direction, and the subsequent steps are planned in the backward direction. For example, it can be adopted when the design process is planned in the forward direction, parts with a long delivery time are procured in advance, and the manufacturing process after processing and assembly is to be carried out by attracting the delivery time.

FIG. 3 shows an example in which "backward" is adopted as the planning mode. The calculation method of resource consumption will be described.

A case will be described in which the consumption amount of various resources is calculated for each project / process schedule planned in the backward planning mode shown in FIG. 3 (1). Here, it is assumed that the "delivery date (shipment)" and "comprehensive test process" have already been assigned, and the lead time (LT) of the previous process "unit test" is 10 days, and the test site Z (work area). ) Will be used 20 m ^ 2 per day. In this case, the work area AZ of the test site Z can be obtained as AZ = [u] / [bm] × (3 [m] +2).

Here, the resource consumption value [u] is "20 m ^ 2 / unit", the number of production [m] is "2 units", and if the reference number [bm] is one unit, it is 160 [m ^ 2]. It can be seen that it is necessary to secure a work area AZ.

The consumption of other resources can be calculated as follows. The resource "design unit X (production number collection)" consumed in the "design" process is required to be, for example, (production branch number) 1 [case]. The resource "manufacturing line Y (processing time)" consumed in the "processing" process is calculated as, for example, "20h / unit" x "2 units" = 40h. The resource "manufacturing line Y (working time)" consumed in the "assembly" process is obtained as, for example, [assembly plan ST]. In the example of FIG. 3, it is assumed that "50h" is set as the assembly plan ST of "manufacturing branch number C-1". ST means standard working time (Standard Time). Standard working time can also be called standard time.

Next, the method of stacking / breaking the production load will be described. The calculated resource consumption (production load) is piled up for each resource, it is checked whether the total value of the production load has reached the upper limit, and the production load is distributed as necessary (mountain collapse processing is performed). ).

With / without landslide can be set for each resource. When "with landslide" is set and the upper limit of each resource (capacity line in the lower graph of Fig. 3) is exceeded, the process allocation schedule is advanced (backward) or backward (forward). To do.

On the other hand, when "No landslide" is set, even if the upper limit of each resource is exceeded, the process allocation schedule is not changed and the resources are piled up as they are. “With landslide” can be adopted in processes and resources where there is little room for adjustment when resources are exceeded, such as equipment. "No mountain collapse" can be adopted, for example, in processes and resources that can be accommodated between departments or outsourced.

There are multiple ways to pile up the production load. In this embodiment, for example, four types of stacking methods will be described as shown in the graph at the bottom of FIG. The areas with dotted line hatches in the graph are areas that have already been piled up due to the production load of the processes of other projects. On the other hand, the area where the lane hatching is included in the graph is the area of the production load piled up in each process of the "production branch number C-1" which is the target of the production plan.

In this embodiment, four types of resource consumption methods, "all-day occupancy type", "all-day apportionment type", "prepared type", and "first day consumption type", are used properly according to the nature of the resource. be able to. That is, in this embodiment, a plurality of patterns (resource consumption type) for consuming resources are prepared in advance according to the type (property) of the resource. As a result, the resource consumption can be distributed according to the type of resource, and a more appropriate production plan can be created.

In the "all-day occupancy type", the calculated resource consumption (production load) is piled up as it is for the lead time period of each process.

In the example of the resource "Design Department X (Work Summary)", one case is piled up over the lead time "10 days" of the design process. Since this resource is set to "No landslide", it will be piled up as it is even if the upper limit "10 cases / day" is exceeded. If this resource "Design Department X (Work Summary)" is set to "With landslide", the process is shifted forward in the "Backward" mode, and in the "Forward" mode. For example, the process is shifted backward in the schedule so that the schedule meets the resource upper limit for the entire lead time.

In the "all-day apportionment type", the calculated resource consumption (production load) is divided by the lead time period of each process to calculate the daily production load, which is piled up on each date. In the example of the resource "manufacturing line Y (machining time)", the production load "40h" is divided by the lead time "5 days" of the machining process, and the load of "8h" is piled up per day. Since this resource is set to "with landslide", processing is normally assigned from the day before the payout. In the example of FIG. 3, the date is advanced to the date when the resource upper limit is satisfied in the entire lead time.

In the "prepared type", the calculated resource consumption (production load) is sequentially piled up in advance for the lead time period of each process. In the example of the resource "manufacturing line Y (working time)", the resource consumption "50h" is piled up in advance. Here, assuming that "there is a landslide", if the pile cannot be piled up during the lead time period, the schedule will be advanced / advanced. If "No landslide" is set, all the items will be piled up on the first day of the lead time. On the other hand, when "with landslide" is set, resources are piled up in order from the date before the lead time period. Here, if the resource consumption cannot be piled up during the lead time period, the schedule is forwarded (backward) / forwarded (forward).

In the "first day consumption type", the calculated resource consumption (production load) is piled up on the first day of each process. The "first day consumption type" can be adopted, for example, when controlling the input amount of each process. In the "first day consumption type" method, all the items are piled up on the first day of the lead time period, and when "with mountain collapse" is set, the schedule is advanced (backward) / forward (forward).

Although the description is omitted in FIG. 3, a vacant schedule for a predetermined time (for example, a predetermined number of days) may be provided between the steps before and after. For example, there is a vacant schedule to absorb the risk of fluctuations in the parts delivery date between "procurement" and "payout", and a vacant schedule for transporting products between "assembly" and "unit test". May be provided. Here, "payout" means supplying the parts and units necessary for producing the target product.

FIG. 4 is a flowchart of the production planning support process. This process is realized by the microprocessor 101 of the production planning support system 1 executing the computer program 1031. Therefore, the main body of the operation of this process will be described as the production planning support system 1 (hereinafter, may be abbreviated as the planning support system 1). Here, the basic production information 121 for each product model is referred to as a basic unit 121.

First of all, the customer request information acquisition unit 13 of the planning support system 1 acquires the customer request information (S11). The selection unit 16 of the planning support system 1 sets the basic unit code according to the customer request information (S12).

For example, the user can select the basic unit 121 corresponding to the product model most similar to the target product based on the information such as the outline specifications and names of the products and the ordering party included in the customer request information. Then, the planning support system 1 sets a basic unit code that identifies the selected basic unit 121. The user may set it by inputting the basic unit code into the planning support system 1. It is also possible to automatically set the basic unit code of the product model most similar to the target product by comparing the configuration outline of the target product with the product configuration information 123 as in the embodiment described later.

The production planning unit 11 of the planning support system 1 formulates a production plan by executing a predetermined simulation process (S13). As described in FIG. 3, for example, the planning support system 1 accumulates the resource consumption according to the schedule of each process according to the resource consumption for each process defined in the basic unit 121 (stacking process). Then, the planning support system 1 creates a production plan by distributing and rearranging the resource consumption that can be destroyed by other schedules.

The information providing unit 17 of the planning support system 1 provides the processing result in step S13 to the user via the user interface unit 105 (S14). When the user modifies the presented production plan, the modified content is input to the planning support system 1 via the user interface unit 105 (S15).

The production plan reflection unit 18 of the planning support system 1 monitors whether the user approves the production plan (S16), and if the user approves the production plan (S16: YES), the production plan approved by the user is used for the production plan. It is registered in the storage unit 19 (S17).

When the user modifies the production plan (S16: NO), the planning support system 1 returns to step S13 and executes the simulation process again.

Customer request information may change after the production plan is created. When the customer request information acquisition unit 13 of the planning support system 1 confirms that the customer request information has been changed (S18: YES), the changed parameters of the customer request information (for example, delivery date, number of production, specifications) (S19), the simulation process is executed again (S13).

If there is no change in the customer request information (S18: NO), this process ends. Although steps S18 and S19 can be displayed as separate flowcharts, they are shown here as processes following steps S1 to S17 for convenience of explanation.

FIG. 5 is an explanatory diagram showing an example of a production planning method. The schedule planning information storage unit 15 stores the schedule planning information 151 for each production number model ordered from the customer. The factory simulator 11, which is a production planning unit, formulates a production plan by inputting predetermined information into the factory simulator engine 111.

The schedule planning information 151 stored in the schedule planning information storage unit 15 includes, for example, a serial number code 1511, a basic unit code 1512, a number of productions 1513, and process information 1514 for each process. The process information 1514 includes a scheduled end date 15141 of the process, an actual date 15142 when the process is actually completed, and a planned work standard time (plan ST) 15143.

Here, the serial number code 1511 is identification information given to the ordered product. The basic unit code 1512 is information indicating the basic unit 121 corresponding to a product model similar to the product (ordered product) specified by the serial number code 1511. The production number 1512 is the quantity of ordered products, that is, the number of products ordered by the customer. The process information 1514 is process management information related to the production of the ordered product. For example, for each process such as "design", "procurement", "manufacturing", "inspection", and "shipment", the scheduled end date 15141 and the actual end date 15142 of the process are recorded.

In the plan ST15143, for example, when the ordered product has individual circumstances that are difficult to deal with in the basic unit 121, the value is set if the working time can be estimated in consideration of the individual circumstances. For example, when there are individual circumstances that affect the working time of the production process, such as the addition of special parts or the addition of special processing compared to the configuration of the product model corresponding to the basic unit 121. The user sets the work time in consideration of the individual circumstances in the plan ST15143. Therefore, the value set in the plan ST15143 is different from the standard working time (ST) included in the consumption resource 12141 of the basic unit 121 described later.

The basic unit 121 (basic unit information 121) stored in the storage unit 12 includes, for example, a basic unit code 1211, a standard production number 1212, a process sequence 1213, and process information 1214 for each process. The process information 1214 includes the consumption amount of each resource 12141 used (consumed) in the process, the standard lead time 12142, and the lead time coefficient condition 12143.

As described above, the basic unit 121 is information created in advance for each product model, and one or more products are associated with one product model (one basic unit). If you receive an order for a product that does not resemble any of the existing product models, you can define a new product model (basic unit).

The basic unit code 1211 is identification information that identifies the basic unit 121. The standard production number 1212 is the standard production number. The standard number of manufactured products is usually one, but in the case of products manufactured as a set of a plurality of products, a value other than "1" is set. The process sequence 1213 indicates the sequence of a plurality of steps for producing the product specified by the basic unit 121. Process information 1214 is prepared for each process. The consumption resource 12141 is the consumption amount of the resource used in the process. Here, the working time (ST) is illustrated. The standard lead time 12142 is the standard lead time for the process. The lead coefficient condition 12143 is a coefficient used when the standard lead time is corrected by the value of the plan ST15143.

The storage unit 12 also stores the production capacity information 122 for each resource. The production capacity information 122 includes, for example, a capacity value (upper limit value) 1221 which is the maximum consumption amount and a resource consumption type 1222. The resource consumption type 1222 is, for example, the above-mentioned "all-day occupancy type", "all-day apportionment type", "prepared type", and "first day consumption type". That is, in this embodiment, it is possible to define the consumption type according to the property of each resource used in each process.

The selection of the working time (ST) by the factory simulator 11 will be described. The factory simulator 11 uses the plan ST when the plan ST15143 is set in the schedule plan information 151. Since the planning ST is a value that reflects the difference between the product that is the target of the production planning and the product model that is similar to the product, it is more accurate to formulate the production plan using the planning ST. Is.

On the other hand, the factory simulator 11 uses the working time (ST) defined in the basic unit 121 when the plan ST15143 is not set in the schedule planning information 151. That is, even when it is not possible to estimate the working time for special specifications or processing, the factory simulator 11 can generate a production plan with a certain degree of accuracy by using the basic unit 121.

The selection of the lead time (LT) will be described. When the plan ST15143 is set, the lead time used for the production plan is calculated based on the value of the plan ST15143, the value of the standard lead time 12142, and the lead coefficient condition 12143. In the lead time coefficient condition 12143, a coefficient is set according to the value of the working time (ST).

For example, the standard lead time is one day, the planned ST is 30 hours, the coefficient is "1" for working hours from 1 hour to 10 hours, and "2" for working hours exceeding 10 hours to 30 hours. ".

The factory simulator 11 adopts the plan ST when the plan ST exists. Since the value of the plan ST is 30 hours, the coefficient is "2". The factory simulator 11 obtains a lead time of "2 days" by multiplying the standard lead time of "1 day" by a coefficient of "2". If the plan ST15143 is not set, the factory simulator 11 adopts the value of the standard lead time 12142.

FIG. 6 is an example of the screen G1 for setting the basic unit 121 of the product model considered to be the most similar among the existing basic units 121 for the product for which the production plan is to be formulated.

The basic unit code setting screen G1 includes, for example, a matter search condition unit GP11, a search result display unit GP12, a search button B11, and a registration button B12.

The user can search for the product for which the basic unit code is to be set (the product for which the production plan is planned) by specifying the search conditions such as the order number, the serial number, and the serial number status (completed, incomplete, etc.). it can.

In the search result display unit GP12, for example, a serial number, a check column (selection column), an order number, a serial number, a product name, a number of productions, a serial number status, a basic unit code, etc. are listed in a list format for products corresponding to the search conditions. Is displayed. When the user selects the basic unit code field, the screen GP13 for selecting the basic unit code appears as shown in the lower part of FIG.

The basic unit code selection screen GP13 displays, for example, the basic unit code and the product name in association with each other. It is convenient if the product name is registered so as to include information such as the product type, general specifications, and destination. Based on the product name, the user selects the basic unit code that seems to be the closest to the product for which production planning is to be made.

FIG. 7 is an example of the screen G2 for selecting a product to be created as a production plan. The simulation target selection screen G2 includes, for example, a matter search condition GP21, a search result display unit GP22, a search button B21, and a simulation start button B22.

The user specifies search conditions such as an order number and a serial number to search, and selects at least one product to be a production plan from the search results. It is also possible to select all of a plurality of products having overlapping production periods at once. When the user operates the start button B22 after selecting the target product or product group, the screen transitions to the simulation start screen G3.

FIG. 8 is an example of the simulation start screen G3. The simulation start screen G3 includes, for example, a simulation mode selection unit GP31, a simulation target product display unit GP32, and a simulation start button B31.

The simulation mode selection unit GP31 includes, for example, a scheduling mode selection unit GP311, a landslide processing setting unit GP312, and a simulation order designation unit GP313.

In the scheduling mode selection unit GP311, for example, any one of "as planned", "all task forward", "all task backward", and "forward & backward (hybrid)" can be selected. "As planned" means to simulate according to the already set schedule. A task means a process. The other modes are as described in FIG.

The mountain collapse processing setting unit GP312 sets whether or not to carry out the mountain collapse processing (load distribution processing). When set to have landslide processing (with landslide in the figure), the factory simulator 11 has the capacity value (upper limit value) of the consumption amount (production load or resource load) of each resource in each unit period of each process. ) Make a process plan so that it is within the range. On the other hand, when it is set without the landslide process, the factory simulator 11 makes a process plan without considering the capacity of each resource. That is, since the factory simulator 11 performs the simulation on the assumption that the capacity of each resource is unlimited, it is possible to formulate a process plan that minimizes the lead time. The user can confirm the presence or absence of a bottleneck from the simulation result without the crushing process. The user can eliminate the bottleneck in the portion where the ability value is exceeded, for example, by adjusting the number of worker groups or adding equipment.

The simulation order designation unit GP313 selects the simulation order. For example, the simulation order can be specified from the viewpoint of order number, serial number, number of production, and the like. The priority order of the simulation target is determined by the simulation order specified by the simulation order designation unit GP313 and the scheduling mode selected by the scheduling mode selection unit GP311.

In the simulation target product display unit GP32, the user can select a product to be excluded from the simulation process from the extracted products.

FIG. 9 is an example of the simulation result screen G4. The simulation result screen G4 includes, for example, a simulation mode display unit GP41, a display method display unit GP42, a Gantt chart GP43, a production load heap graph GP44, and a schedule plan reflection button B41.

The simulation mode display unit GP41 displays parameters (scheduling mode, etc.) used for the simulation process. Display method The display unit GP42 displays the order of items to be displayed on the Gantt chart GP43. For example, the order number, serial number, and date of the starting task can be displayed in either ascending or descending order. Further, the display method display unit GP42 may include a button for selecting which of the Gantt chart GP43, the pile graph GP44, and the deadline information (not shown) is to be displayed. In FIG. 9, both the Gantt chart GP43 and the pile graph GP44 are displayed as if they are displayed on one screen G4, but whichever is selected may be displayed.

Pile graph GP44 can display a graph in which resource consumption (production load) is piled up for each resource in each process. In the pile graph GP44, the symbols Th1 to Th3 are threshold values indicating the ability values.

According to this embodiment configured in this way, the basic unit 121, which is the basic production information for each product model, is prepared, and the production plan is formulated based on the basic unit 121 of the product model close to the target product. Therefore, it is possible to efficiently create a production plan without the trouble of creating a parts composition table.

Further, according to this embodiment, the resource consumption that can be estimated in advance can be set as a planned value, so that a production plan can be created even for a product having a large deviation from the product model. It is possible and easy to use.

The second embodiment will be described with reference to FIGS. 10 and 11. Since each of the following examples including this embodiment corresponds to a modified example of the first embodiment, the differences from the first embodiment will be mainly described. In this embodiment, the working time (ST) is automatically learned.

FIG. 10 is an explanatory diagram showing an example of a production planning method. Comparing FIGS. 10 and 5, in this embodiment, the work time automatic correction unit 21 and the work time automatic setting unit 23 are provided. The working time automatic correction unit 21 is an example of the correction unit 21 in FIG. The working time automatic setting unit 23 is an example of the automatic setting unit 23 in FIG.

FIG. 11 shows an example of the actual value database 124. The actual value database 124 can manage, for example, the basic unit code, the product name, the process name, and the actual working time in association with each other.

The work time automatic correction unit 21 corrects the work time in the consumption resource 12141 of the basic unit 121 based on the actual value database 124 that manages the actual value of the work time. The work time automatic correction unit 21 can automatically correct the work time in the basic unit 121 by, for example, taking out a predetermined actual value of the actual value stored in the actual value database 124 and performing statistical processing. .. That is, in this embodiment, a function of automatically learning a predetermined part of the information possessed by the basic unit 121 is added.

The working time automatic setting unit 23 calculates and sets the value of the plan ST15143 in the schedule planning information 151 based on the product configuration information 123 and the actual value database 124. The value of the plan ST15143 can be automatically set by correcting the actual value read from the actual value database 124 according to the comparison result between the product configuration manufactured in the past and the configuration of the target product. The user can also manually change the automatically set value of the plan ST15143.

This embodiment configured in this way also has the same effect as that of the first embodiment. Further, according to this embodiment, the resource consumption (working time ST) in the basic unit 121 can be automatically corrected (learned), and the value of the plan ST15143 can also be automatically set. , The usability of the user is improved.

A third embodiment will be described with reference to FIG. In this embodiment, a new basic unit 121 can be automatically set, and a basic unit code suitable for the target product can be automatically set.

FIG. 12 is an explanatory diagram showing an example of a production planning method. Comparing FIG. 12 and FIG. 10, in this embodiment, the basic unit automatic generation unit 22 that automatically generates the basic unit 121 and the basic unit code automatic that automatically sets the basic unit 121 in the schedule planning information 151 It is provided with a setting unit 16a.

The basic unit automatic generation unit 22 is an example of the model-specific production basic information automatic generation unit 22 in FIG. The basic unit code automatic setting unit 16a is an example of the selection unit 16 in FIG.

The basic unit automatic generation unit 22 determines whether or not to generate a new basic unit 121, for example, based on the processing result of the working time automatic correction unit 21. When the basic unit automatic generation unit 22 determines that a new basic unit 121 should be generated, it generates a new basic unit 121 by rewriting at least a part of the original basic unit 121. The newly generated basic unit 121 is stored in the storage unit 12.

For example, it is conceivable that the work time automatic correction unit 21 may discover a different work time pattern as a result of statistically processing the actual value of the work time of a certain basic unit. In this case, in the basic unit generated according to one working time pattern, the other working time patterns are different, which may affect the accuracy of the production plan. Therefore, in this embodiment, for example, a new basic unit 121 is automatically generated based on the difference in the pattern of resource consumption (working time).

The basic unit code automatic setting unit 16a extracts the basic unit 121 of the product model determined to be the closest to the target product by comparing the outline configuration of the target product with the product configuration information 123, and plans the schedule of the target product. Set to information 151.

This embodiment configured in this way also has the same effects as those of the first and second embodiments. Further, according to this embodiment, usability can be further improved.

The present invention is not limited to the above-described embodiment. A person skilled in the art can make various additions and changes within the scope of the present invention. In the above-described embodiment, the configuration is not limited to the configuration example shown in the accompanying drawings. The configuration and processing method of the embodiment can be appropriately changed within the range of achieving the object of the present invention.

In addition, each component of the present invention can be arbitrarily selected, and the present invention also includes an invention having the selected configuration. Further, the configurations described in the claims can be combined in addition to the combinations specified in the claims.

Further, the present embodiment discloses a method of supporting the formulation of a production plan using a computer. This production plan planning support method is, for example, "a production plan planning support method that supports the drafting of a production plan using a computer, and the computer provides predetermined basic production information and production capacity used for production management of a product. The production capacity information to be managed is stored in the storage unit, and at least one basic production information is selected from the basic production information stored in the storage unit based on the input customer request information, and the selected one is selected. A production plan is generated based on the basic production information, the production capacity information, and the production progress information acquired from the production site, and the production plan generated by the production plan planning department is stored in the production plan storage unit. It can be expressed as a production plan planning support method that reflects the production plan. "

1: Production planning support system, 3: Production management system, 4: Production site, 11: Production planning department, 12: Storage department, 13: Customer request information acquisition department, 14: Production progress information acquisition department, 15: Schedule Planning information storage unit, 16: Selection unit, 17: Information provision unit, 18: Production plan reflection unit, 19: Production plan storage unit, 20: Load stacking unit, 21: Correction unit, 22: Automatic generation of basic production information by model Department, 23: Automatic setting unit

Claims (8)

It is a production planning support system that supports the planning of production plans.
A storage unit that stores predetermined basic production information used for product production management and production capacity information for managing production capacity,
A production basic information selection unit that selects at least one production basic information from the production basic information stored in the storage unit based on the input customer request information.
A production planning department that generates a production plan based on the selected basic production information, the production capacity information, and the production progress information acquired from the production site.
A production plan reflection unit that reflects the production plan draft generated by the production plan planning department as a production plan stored in the production plan storage unit,
Production planning support system equipped with. It further includes an information providing unit that provides the user with the production planning plan generated by the production planning unit.
The production planning support system according to claim 1. The basic production information is generated for each model of the product, and includes information on each process required for production of the product and resource consumption for each resource used in each process.
The production planning support system according to claim 2. When a planned value is input for a predetermined resource consumption among the resource consumption, the production planning unit uses the planned value instead of the resource consumption included in the selected basic production information. ,
The production planning support system according to claim 3. A correction unit for correcting the predetermined resource consumption based on the actual value of the predetermined resource consumption is further provided.
The production planning support system according to claim 4. A planned value setting unit for setting the planned value based on the actual value of the predetermined resource consumption and the configuration information of the product to be processed is further provided.
The production planning support system according to claim 4. A production basic information generation unit that generates new production basic information based on the processing result of the correction unit and stores it in the storage unit is further provided.
The production planning support system according to claim 5. The production basic information selection unit selects at least one production basic information based on the customer request information and the configuration information of the product to be processed.
The production planning support system according to claim 6.

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