JP7215087B2 - Input plan creation support device, input plan creation support method, and input plan creation support program - Google Patents

Description

TECHNICAL FIELD The present invention relates to an input plan creation support device and an input plan creation support method.

Industrial products are generally produced by putting raw materials and parts into a production line and sequentially passing through a plurality of processes. A production line is generally composed of a plurality of sub-lines, and each sub-line performs a plurality of processes. In recent years, with the diversification of needs, it has become common to produce a wide variety of products on one production line. In such multi-variety production, it is important to set the order and timing of introducing the varieties so as to improve the overall production efficiency.

A technique for improving the above efficiency is disclosed in Patent Document 1, for example. In this technique, first, the takt time of the post-process is calculated backward based on the work delivery time of the post-process to calculate the work delivery time of the previous process. Furthermore, the takt time in the previous process is calculated backward to calculate the work input time to the previous process, and the work input order and work input time to the previous process are indicated. As a result, the payout time for the post-process of a certain sub-line can be matched with the payout time for another post-process, thereby preventing the occurrence of waiting time at the junction.

Further, Patent Document 2 discloses an invention for improving work efficiency when producing a wide variety of products on a production line that mounts components on a printed circuit board. In this invention, a plurality of types of products are put into one mounter, and at this time, the parts with the largest number of commonly used types are placed at positions where the mounter can mount them fastest. Next, the parts with the most common types are arranged at positions where they can be mounted next quickly, and this is sequentially repeated to determine the supply positions of the parts. By doing so, the same number of products can be produced in less time.

JP-A-09-141542 JP-A-11-054991

However, the technique of Patent Document 1 has a problem that it cannot be applied to production in which many processes with short processing times are continuously performed. In this type of production, semi-finished products of the same type are delivered before the products that have been input to the previous process are delivered, so when focusing on one product, the timing of the completion of the previous process and the start of the subsequent process do not match. be.

Further, the technique of Patent Document 2 can shorten the processing time for component mounting in one mounter, but has the problem that it does not necessarily lead to an improvement in overall production efficiency. This is because when a plurality of facilities are used, the production efficiency may change greatly depending on the order in which the product types are put into each facility.

SUMMARY OF THE INVENTION The present invention has been made in view of the above problems, and it is an object of the present invention to provide an input plan creation support device that supports creation of an input plan with good overall production efficiency.

In order to solve the above-mentioned problems, the input plan creation support device includes production quantity acquisition means, product-specific process acquisition means, common sub-process extraction means, product group set creation means, sub-process processing time acquisition means, It has setup change time acquisition means, product group set production time calculation means, and product group input order setting means. The product group set creating means creates a product group by combining product types having many common sub-processes, and creates a product group set made up of combinations of product groups. Then, the product group set production time required to produce each product group set is calculated based on the obtained production quantity of each product type, sub-process processing time, and setup change time. Next, based on the calculated product group production time, the input order of the product group is set.

An effect of the present invention is to provide an input plan creation support device that supports input plan creation with good overall production efficiency.

1 is a block diagram showing an input plan creation support device according to a first embodiment; FIG. It is a block diagram which shows the injection|throwing-in plan preparation support apparatus of 2nd Embodiment. 9 is a flow chart showing the operation of the second embodiment; 9 is a flow chart showing details of the operation of the second embodiment; It is a schematic diagram which shows the image of the injection|throwing-in order of 2nd Embodiment. It is a block diagram which shows the injection|throwing-in plan creation assistance apparatus of 3rd Embodiment. It is a schematic diagram which shows the image of the injection|throwing-in order of 3rd Embodiment. It is a block diagram which shows the injection|throwing-in plan creation assistance apparatus of 4th Embodiment. It is a schematic diagram which shows the image of the injection|throwing-in order of 2nd Embodiment.

Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings. However, the embodiments described below are technically preferable for carrying out the present invention, but the scope of the invention is not limited to the following. In addition, the same number may be attached|subjected to the same component of each drawing, and description may be abbreviate|omitted.

(First embodiment)
FIG. 1 is a block diagram showing the input plan creation support device of this embodiment. The input plan creation support device of the present embodiment is a device that assists creation of an input plan that determines the order of inputting each product type in a production line that produces a plurality of product types. The input plan creation support device has production quantity acquisition means 1 , product-specific process information acquisition means 2 , common sub-process extraction means 3 , and product group set creation means 4 . It also has sub-process processing speed acquisition means 5 , setup change time acquisition means 6 , product group set production time calculation means 7 , and product group input order setting means 8 .

A production quantity acquisition unit 1 acquires a target production quantity for a predetermined period on a production line based on a production plan.

The product-specific process information acquisition means 2 acquires the process set for each product. This product type process includes at least one sub-process. That is, the process is assumed to consist of a series of sub-processes. The product-specific process information also includes setup information necessary for carrying out sub-processes.

The common sub-process extracting means 3 extracts sub-processes that are common among different product types. This is to extract the same sub-process as a common sub-process even if the product type is different, and to associate the product types having the common sub-process with each other.

The product group set creating means 4 creates product groups by combining products that have common setups and many common sub-processes. This product type group is used to collectively supply the product types belonging to the same product group to the production line. Then, a product group set is created as a cluster of a plurality of product groups.

The sub-process processing speed acquisition means 5 acquires the processing speed of each sub-process. The sub-process processing speed can be, for example, a standard value determined from past performance.

A setup change time acquisition means 6 acquires a setup change time required for switching the product group produced on the production line. Here, the setup change is the work of exchanging materials or parts to be supplied or adjusting the equipment in order to perform different sub-processes with the same equipment. The setup change time can be, for example, a standard value determined based on past performance.

The product group set production time calculation means 7 calculates the time required to produce the product group set based on the set product group set, the acquired production number of each product type, the sub-process processing speed, and the setup change time. Calculate the product group set production time. This calculation can be performed by calculating the production time for each product group using the sub-process processing speed and production volume, obtaining the setup changeover time required for switching product groups, and taking the sum of these. can.

The product group input order setting means 8 sets the product group input order in the product group set based on the calculated product group production time. As one method, it is possible to introduce product groups in descending order of production time.

As described above, according to the present embodiment, by creating product group sets with common sub-processes, the number of setup changes can be reduced, and by determining the order of input based on the production time, input with good production efficiency. Can make a plan.

(Second embodiment)
FIG. 2 is a block diagram showing the input plan creation support device 100 of the second embodiment. The input plan creation support device 100 has a planned production quantity acquisition unit 110 , a product-specific process information acquisition unit 120 , a common sub-process extraction unit 130 , and a product group set creation unit 140 . It also has a sub-process processing speed acquisition unit 150 , a setup change time acquisition unit 160 , a product group set production time calculation unit 170 , a recommended product group set setting unit 180 , and a product group input order setting unit 190 . As the hardware of the investment plan creation support device 100, for example, a general computer having a processor and a memory can be used.

The input plan creation support device 100 acquires information necessary for creation of an input plan from the storage device 200 . The storage device 200 stores planned production quantity 210 , product-specific process information 220 , sub-process processing speed information 230 , and setup change time information 240 . As the hardware of the storage device 200, for example, a general storage device such as a hard disk or a semiconductor memory can be used.

The planned production quantity information 210 holds the quantity of products to be produced in a predetermined period for each product type. The predetermined period is, for example, one day or one week.

The product-specific process information 220 includes sub-process information 221 representing sub-processes constituting the process of each product type, and setup information 222 representing the setup required to carry out each sub-process. Here, a sub-process represents a processing element such as mixing a certain material, performing a certain process, or mounting a certain part. In addition, it is assumed that setup is preparation at equipment and work points, and is work necessary for carrying out sub-processes such as supply of materials and parts, preparation of jigs and tools, and adjustment of equipment. One piece of equipment or work point often carries out a plurality of sub-processes, and generally one set-up can carry out a plurality of sub-processes. That is, there is a group of sub-processes that can be performed in one setup, and when switching between sub-processes, there are cases where a setup change is necessary and cases where a setup change is not necessary. As will be described later, product groups are created so that setup changes do not occur during sub-process processing for one product group.

The sub-process processing speed information 230 is information representing the processing speed of each sub-process, and can be expressed as the number of sub-processes that can be executed per unit time. The sub-process processing speed can be a standard value determined from, for example, equipment specifications or a value obtained by averaging past results.

The setup change time information 240 represents the time required to change the setup of equipment or the like. As described above, when switching sub-processes, there are cases where setup changes are necessary and cases where they are unnecessary.

Next, the configuration and function of each part of the input plan creation support device 100 will be described. The planned production quantity acquisition unit 110 acquires planned production quantity information 210 from the storage device 200 .

The product-specific process information acquisition unit 120 acquires product-specific process information 220 from the storage device 200 . At this time, sub-process information 221 representing sub-processes constituting the product-specific process and setup information 222 representing necessary setup, which are included in the product-specific process information 220, are also acquired.

The common setup extraction unit 130 compares the setup information 222 of each product type for which production is planned, extracts a setup common among the product types, and creates a provisional group having a common setup. Next, the common sub-process extraction unit 131 extracts sub-processes that are common among product types in the provisional group. The product group set creating unit 140 creates a product group set by combining those who have many common sub-processes in the provisional group. At this time, various groupings are possible depending on the number of common sub-processes used for grouping. If a threshold value is set for the number of common sub-processes, the method of grouping can be determined. Also, a plurality of threshold values may be provided to create a plurality of product group sets. In this way, by creating a plurality of product group sets and comparing the superiority and inferiority, it is possible to set a product group set with high production efficiency.

The sub-process processing speed acquisition unit 150 acquires the sub-process processing speed of the sub-process used in the created product group.

The setup change time acquisition unit 160 acquires the setup time required when switching the product group from the setup change time information 240 .

The product group set production time calculation unit 170 calculates the production time for each product group set. The production time of the product group set can be calculated as follows. First, for one product type in the product group, the production time for one product type is calculated based on the sub-processes constituting the process and the processing speed of the sub-processes. By multiplying this by the number of production of the variety, the production time of the variety can be obtained. Similarly, the production time of other product types is calculated, and the production time of each product type in the product group is added up. The product group set production time can be calculated by adding the setup time that occurs when switching the product group to this result.

The recommended product group set setting unit 180 sets a recommended product group set by comparing a plurality of product group set production times calculated as described above. For the recommended product group set, for example, a product group with the shortest overall production time can be recommended. However, in an actual production line, there are cases where there are restrictions on parts supply, setup changes, and the like. For this reason, a plurality of recommended product group sets may be set in descending order of production time so that the operator can judge the superiority or inferiority.

The product group introduction order setting unit 190 sets the order in which product groups are introduced in the recommended product group set determined above. The order can be, for example, in descending order of product group production time. Although not shown, the recommended product group set and the set loading order can be displayed on the display unit of the loading plan creation support device, printed on a printer, or otherwise output to the outside.

Next, the operation of the input plan creation support device 100 will be described. FIG. 3 is a flowchart showing the operation of the input plan creation support device 100. As shown in FIG. First, the planned production quantity is acquired (S1). Next, a provisional group is created for the product types having common setups (S2). Next, in the provisional group, a product group is created by combining product types having common sub-processes (S3). At this time, different product groups may be created according to the number of common sub-processes. Next, a product group set is created as a combination of the created product groups. At this time, if the method of dividing the product group is different, it is treated as a different product group set. In this way, since there is more than one way to create a product group set as a combination of product groups, all possible product group sets are created (S4). Next, the production time for each product group set is calculated (S5). The details of this calculation will be described later. Next, the obtained production time for each product group and the changeover time required for production of each product group are added together to calculate the production time for each candidate product group set (S5). Next, a recommended product group set is determined by comparing the calculated total production times (S6). In principle, a product group set with a short production time is recommended, but a plurality of product group sets may be recommended. Next, the production times of the product groups in the product group set are compared to set the input order of the product groups (S7). For example, the input order can be set so that product groups with long production times are input first. Then, the recommended product group set, the product group input order in the product group set, the required changeover, the estimated production time, etc. are output to the outside (S8). At this time, information on not only the product group set with the highest production efficiency but also the second and third product group sets may be displayed.

FIG. 4 is a flow chart showing the details of the process of S4 in the flow chart of FIG. To calculate the production time for each product group, loop processing L1 is executed to calculate the production time for each product in the product group. In L1, first, sub-processes necessary for producing the product type are acquired (S41). Next, the processing speed of this sub-process is acquired (S42). Using the sub-process and the sub-process processing speed, the production time for one item of the product type is calculated (S43). This is multiplied by the production number to calculate the production time for the product (S44). The processing of S41-S44 is performed until all product types in the product group set are completed. Next, the sum of the production times of the product groups that make up the product group set is obtained, and the sum of the required changeover time is obtained to calculate the production time of the product group set (S45). The above calculation of the production time for the product group is performed until completion for all the set product group sets (L2).

As described above, it is possible to set a product group set with good production efficiency and to set the input order of product groups within the set. FIG. 5 is a schematic diagram showing an image of charging when the above charging order is set. τ in the figure represents the production time of the product group, and its length is proportional to the production time. As shown in FIG. 5, the production line starts with product type Gr (group) 1 having the longest production time τ1, and then product type Gr2 (production time τ2) and product type Gr3 (production time τ3). I try to put them in order.

(Third embodiment)
In the second embodiment, the case where there is one production line has been described, but an actual production line is generally provided with a plurality of sublines capable of producing the same product type. In this embodiment, an input plan creation support device suitable for a case where there are a plurality of sublines will be described.

FIG. 6 is a block diagram showing the input plan creation support device 101 of the third embodiment. The input plan creation support device 101 has a subline information acquisition unit 141 in addition to the configuration of the input plan creation support device 100 of the second embodiment. The product group set creating unit 142 also operates to create a product group set by reflecting the subline information 232 . Further, since the processing speed of the same sub-process may differ between sub-lines, the storage device 201 holds sub-line information 231 and sub-process processing speed information 232 classified for each sub-line. The production time for each product group set can be the same as in the second embodiment, but the production time and required setup change may differ depending on the subline to be introduced. For this reason, when inputting to different sublines, even if the combined product types are the same, they are treated as different product group sets. With this kind of treatment, it is possible to calculate the production time of each product group set and compare superiority and inferiority without being conscious of the existence of sublines.

FIG. 7 is a schematic diagram showing an image of loading when the loading order of product groups is determined by the loading plan creation support device 101 of the present embodiment. In the present embodiment, the loading order is set including designation of the sub-line to be loaded. In FIG. 7, the long product type Gr1 with the longest production time τ1 is put first into the subline 1 with the highest processing capacity P (processing capacity P1). Then, the product type Gr2 having the next longest production time τ2 is first put into the subline 2 (processing capacity P2) having the next highest processing capacity. Subsequently, the product type Gr3 is supplied to the sub-line 3, and the product type Gr4 is supplied to the sub-line 1 in sequence.

When considering the production time for the product group set, it is necessary to consider the changeover time in addition to the processing capacity of the sub-line. The number of setup changes and the setup change time per time change depending on the product group and the sub-line to be input. In this embodiment, it is assumed that the necessary setup change and the setup change time are reflected in the setting of the subline information 231 and the product group set.

As described above, the product group with the longer production time is first supplied to the sub-line with the higher processing capacity, so that the production efficiency can be improved.

(Fourth embodiment)
In the second and third embodiments, the setup change time is assumed to be uniquely determined by determining the subline and the product group to be switched, but the setup change time also changes depending on available resources. The input plan creation support device of the present embodiment creates a product group set that distinguishes between cases in which usable resources are different, and examines the possibility of improving production efficiency.

FIG. 8 is a block diagram showing the input plan creation support device 102 of this embodiment. In addition to the configuration of the input plan creation support device 101 of the third embodiment, the input plan creation support device 102 includes a setup changeover time acquisition unit 161 that acquires the resource-specific setup change time information 241 held in the storage device 202. I have. The resource-specific setup change time information is information on the setup change time distinguished by the amount of resources that can be used. The product group set creation unit 143 of the input plan creation support device 102 creates product group sets so that, even if the combination of product types and input sublines is the same, if the resources are different, the product group sets are treated as different product group sets. do. By making these distinctions, as in the second and third embodiments, it is possible to calculate the total production time for each product group set and select a product group set with good production efficiency.

FIG. 9 is a schematic diagram showing the relationship between available resources and setup change time T. In FIG. In the case of FIG. 9A, there is one worker M who is a human resource and one hardware resource H. In FIG. At this time, the required time for setup change 1 is T1a. However, if there are two workers M as shown in FIG. 9(b), the time required for the changeover 1 is shortened to T1b. Furthermore, the time required for setup change 1 is shortened to T1c by using two hardware resources as shown in FIG. 9(c). The product group set creation unit 143 creates product group sets so that even when only the resources are different, the product group sets are different. Therefore, subsequent calculations can be performed in the same manner as in the second and third embodiments. It is also possible to create product group sets, set the order of input to sub-lines, and allocate resources, all of which improve production efficiency. In addition, since usable resources are generally limited, it is desirable to display a plurality of candidates for each usable resource when outputting the results of the product group set and the input order.

As described above, according to this embodiment, it is possible to improve production efficiency including effective distribution of resources.

The scope of the present invention also includes a program for causing a computer to execute the processes of the above-described first to fourth embodiments and a recording medium storing the program. Examples of recording media that can be used include magnetic disks, magnetic tapes, optical disks, magneto-optical disks, and semiconductor memories.

The present invention has been described above using the above-described embodiments as exemplary examples. However, the invention is not limited to the above embodiments. That is, within the scope of the present invention, various aspects that can be understood by those skilled in the art can be applied to the present invention.

1 production quantity acquisition means 2 product-specific process information acquisition means 3 common sub-process extraction means 4 product group set creation means 5 sub-process processing speed acquisition means 6 setup change time acquisition means 7 product group set production time calculation means 8 product group input order Setting means 100 Input plan creation support device 110 Planned production quantity acquisition unit 120 Product-specific process information acquisition unit 130 Common setup extraction unit 131 Common sub-process extraction unit 140 Product group set creation unit 150 Sub-process processing speed acquisition unit 160 Setup changeover time acquisition Unit 170 Product group set production time calculation unit 180 Recommended product group set setting unit 190 Product group input order setting unit 200 Storage device 210 Planned production quantity information 220 Product-specific process information 230 Sub-process processing speed information 240 Setup change time information

Claims (8)

In a production line producing multiple varieties using at least one piece of equipment,
production number acquiring means for acquiring the production number of each of the varieties;
product-specific process information acquisition means for acquiring product-specific process information including at least one sub-process set for each of the product types and a setup required to implement the sub-process;
common sub-process extracting means for extracting a common sub-process that is the sub-process common among the different product-specific process information;
a product group set creating means for creating a product group by combining the products having the common setup and many common sub-processes, and creating a product group set by combining the product groups;
sub-process processing speed acquisition means for acquiring the sub-process processing speed of each of the sub-processes;
A setup change time acquiring means for acquiring a setup change time required for a setup change for switching from one sub-process to another sub-process in the equipment;
Based on the sub-processes constituting the process of the product type and the processing speed of the sub-processes, the production time of the one product type included in the product type group is calculated, and the production time of the product type is the production time of the product type. The production number is multiplied to calculate the production time of the product type, and the product group production time required to produce the product group is obtained by adding the production time of each product type included in the product group. is calculated from the product group production time of each product group included in the product group set and the setup change time required for setup change when producing the product group included in the product group set. a product group set production time calculation means for calculating a product group set production time required to produce the product group set;
and a product group introduction order setting means for setting the order of introduction of the product groups so that the product groups with longer production times are preferentially introduced . The breed group set creation means is
creating a plurality of product group sets in which at least one of the product group, the sub-process processing speed, or the setup change time is different;
The product group set production time calculation means,
calculating each of the breed group set production times;
product group set recommendation means for setting the product group set for recommending the product group set for which the calculated product group set production time is short ;
2. The input plan creation support device according to claim 1, characterized by: When the production line includes multiple sublines,
The breed group set creation means is
3. The introduction plan creation support device according to claim 1, wherein the product group set is created by distinguishing the sub-lines to which the product group is introduced. When there is a difference in the processing capacity of the sub-lines,
The product group input order setting means,
4. The introduction plan creation support device according to claim 3 , wherein the introduction order is set so that the product group with a longer product group production time is preferentially introduced into the sub-line with a high throughput. the setup change time acquisition means acquires the setup change time when the resource for the setup change is changed;
The breed group set creation means is
5. The loading plan creation support device according to any one of claims 1 to 4 , wherein when the setup change time is different, another product group set is created. A production line that produces multiple varieties using at least one piece of equipment,
Acquire the number of production of each said variety,
Acquiring product-specific process information including at least one sub-process set for each of the product types and a setup required to implement the sub-process;
extracting a common sub-process that is the sub-process common among the different product-specific process information;
creating a product group by combining the products having the common setup and many common sub-processes;
creating a breed group set by combining the breed groups;
obtaining a sub-process processing rate for each of said sub-processes;
Acquiring a setup change time required for a setup change for switching from one sub-process to another sub-process in the equipment;
calculating the production time for one of the product types included in the product group based on the sub-processes and the processing speed of the sub-processes that constitute the process of the product type;
calculating the production time of the variety by multiplying the production time of one of the varieties by the number of production of the variety;
calculating the product group production time required to produce the product group by adding up the production time of each of the product types included in the product group;
Each of the product group sets is determined from the product group production time of each product group included in the product group set and the setup change time required for the setup change when producing the product group included in the product group set. Calculate the breed group set production time required for production,
A method for assisting creation of an introduction plan, characterized in that the order of introduction of the product group is set so that the product group having a longer product group production time is preferentially introduced . creating a plurality of product group sets in which at least one of the product group, the sub-process processing speed, or the setup change time is different;
calculating each of the breed group set production times;
7. The method for supporting production planning according to claim 6 , wherein the product group set is set to recommend a product group set having a short calculated product group set production time. A production line that produces multiple varieties using at least one piece of equipment,
obtaining a production number of each of said varieties;
a step of acquiring product-specific process information including at least one sub-process set for each of the product types and a setup required to implement the sub-process;
a step of extracting a common sub-process that is the sub-process common among the different product-specific process information;
a step of creating a product group by combining the products that have the common setup and many common sub-processes;
creating a product group set by combining the product groups;
obtaining a sub-process processing rate for each of said sub-processes;
obtaining a setup change time required for a setup change for switching from one sub-process to another sub-process in the equipment;
Based on the sub-processes constituting the process of the product type and the processing speed of the sub-processes, the production time of the one product type included in the product type group is calculated, and the production time of the product type is the production time of the product type. The production number is multiplied to calculate the production time of the product type, and the product group production time required to produce the product group is obtained by adding the production time of each product type included in the product group. a step of calculating
Each of the product group sets is determined from the product group production time of each product group included in the product group set and the setup change time required for the setup change when producing the product group included in the product group set. calculating the breed group set production time required for production;
and setting the order of introduction of the product group so that the product group having the longest production time is preferentially introduced .

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