JPH05101073A - Production schedule planning device - Google Patents

Abstract

PURPOSE:To prepare a plan so as to completely produce all the items by the date of delivery by correcting a process programming the production schedule while overlapping plural items in the same time zone. CONSTITUTION:Based on order reception information, the date of delivery and the quantity of products to be produced are inputted to an order reception information inputting means (a) and on the other hand, processes required for producing these products, the order of the processes and further production efficiency for each process are inputted to a process information input means (b). Then, production system information expressing the time zone working machines in each process is inputted to a production system information input means (c). A first calculation means (d) calculates the required time for each process according to the quantity of the products and the production efficiency of the process. Next, a second calculating means (e) calculates the production schedule of these products. For this calculation, the required time of each process is piled-up successively from the final process with the end of delivery as a reference. Further, a first correcting means (f) corrects the production schedule of each item concerning the process competing the plural items in the same time zone.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a production planning device for efficiently producing a product having a plurality of specifications in accordance with a delivery date.

[0002]

2. Description of the Related Art Conventionally, a computer is used to create a production plan. For example, Japanese Patent Laid-Open No. 63-298665 discloses a production planning apparatus that automatically obtains a start date from a delivery date, a machine efficiency, and an input upper limit value in a specific process of producing a product of a certain item.

[0003]

However, since the above-mentioned production planning apparatus makes a production plan for a specific process for producing a product of one item, when a plurality of items are produced simultaneously, I can't handle it. That is,
If you try to make products of multiple items in parallel to meet the deadline, you may have to process two or more items at the same time (in duplicate) in a certain process. I couldn't. Therefore, especially when multiple items with different production processes are produced in parallel, it is necessary to check which process overlaps and eliminate the duplication in time to meet the deadline. It was a load.

Further, due to various reasons such as machine failure,
In many cases, there is a gap between the production plan set in advance and the actual production. In this case, it was not possible to correct the production plan so as to actually produce the product by reflecting the work record (progress).

[0005]

SUMMARY OF THE INVENTION The present invention has been made to solve the above-mentioned problems, and receives order information input means a for inputting the delivery date and quantity of a product to be produced, and producing the product. Process information input means b for inputting the necessary steps, order of steps and production efficiency of each step, and production system information input means c for inputting the production system information of each step.
And a first calculation means d for calculating a required time for each process from the quantity and the production efficiency, and a required time for each process is piled up in order from the final process based on the delivery date to produce a production plan of the product. A production plan creating apparatus comprising: a second computing means (e) to be created; and a first modifying means (f) to modify a production plan of each item in a process in which a plurality of items compete in the same time zone. is there.

[0006] Further, the order information input means for inputting the delivery date and quantity of the product to be produced and a, the process information for inputting the process required for producing the product, the sequence of the process and the production efficiency of each process. The input means b, the production system information input means c to which the production system information of each process is input, the first calculation means d for calculating the required time for each process from the quantity and the production efficiency, and the delivery date. Based on the standard, the second computing means e for creating the production plan of the product by stacking the required time of each process in order from the final process, and the production plan of each item for the process in which a plurality of items compete in the same time zone A first correction means f for correcting, a progress information input means g for inputting progress information of each process, and a second correction means h for correcting the produced production plan from the progress information. With the characteristic production planning device That. It is preferable that any of the above-mentioned production planning apparatuses is provided with condition data input means i for inputting condition data for creating a production plan.

[0007]

According to the production plan creating apparatus of the present invention, the delivery date and quantity of the product to be produced are input to the order receiving information input means a on the basis of the order receiving information and, on the other hand, necessary for producing this product. Processes, the order of the processes, and the production efficiency indicating how many products can be processed per time in each process are input to the process information input means b. Further, the production system information indicating the time zone in which the machine is operating in each process is input to the production system information input means c. The first calculation means d calculates the required time for each process, which indicates how much time is required for each process, from the quantity of products and the production efficiency of the process. If the required time for each process is determined by the first calculation means d, the second
The production plan of the product is obtained by the calculation means e. This is done by taking the input production system information into account and accumulating the required time for each process while sequentially tracing back from the final process to the first process based on the delivery date.

The production schedule thus obtained does not take into consideration duplication with products of other items, and in reality it may not be possible to produce according to this schedule. In this case, the first correction means f performs a correction operation for a process in which a plurality of items are duplicated and a production plan is set up in the same time zone. This prioritizes late (later) delivery items and advances production plans for early (previous) delivery items to create a plan in which all items are completed by the delivery date. Here, when making a production plan, in order to create the number of orders in the final process in consideration of the occurrence of defective products, it is necessary to produce with enough margin (number) in each process. The condition data input means i is used to determine the safety factor data for deciding whether or not to change the plan later, or to give a certain time margin to each process in time to meet the deadline even if it is necessary to correct the plan later. By inputting in, it becomes possible to make a production plan that matches the actual production.

When production is actually started, production progress information is input to the progress information input means g. This is for inputting information that a schedule established in advance in a certain process is delayed due to, for example, failure of a machine or processing of a priority item. The second correction means h makes the production plan based on the progress information before the production start time of each process is earlier).
Modify the production plan by prioritizing the items and moving back the schedule for each item. It should be noted that, in the above-mentioned "means for solving the problem" and "action", the reference numerals shown in FIG. 1 are used for explanation, but it goes without saying that the present invention is not limited to the constitution shown in FIG. is there.

[0010]

An embodiment of the present invention will be described in detail with reference to the drawings. FIG. 2 is a block diagram showing a configuration example of the production plan creation device according to the present invention. 1 is an input device such as a keyboard and mouse, 2 is a CRT display, printer, XY
An output device such as a plotter, 3 is a workstation including a CPU (central processing unit), a user interface, a communication control device with a host computer, 4 is a host computer, and 5 is an auxiliary storage device such as a magnetic disk or a magnetic tape. is there.

The following information is input from the input device 1. First, when an order is decided, order information such as delivery date and quantity of the product to be produced by the order is input. Next, based on the manufacturing specifications of the product, the process required for production, that is, the instruction of the machine at the production site or, if there is no facility for processing at the production site, instructs to use the machine of another department. Here, the process does not necessarily mean a work by a machine, and a process such as product movement between processes or a process such as drying when each process is not in the same production site is regarded as one process. In this way, the order of the steps to be performed for the instructed steps, the production efficiency of each step (the amount of processing per hour), and the like are also input. In addition, regarding the instructed process, the production system information of each process that indicates how long the machine etc. is operating, and when the production plan is corrected after the actual production is started, the current production Plan progress information is also input from the input device 1. Furthermore, if necessary, condition data such as the safety factor for making a production plan is also input.

The output device 2 converts the created production plan into a required form such as a graph or a table and displays or draws it. The workstation 3 generates data for producing a production plan based on the information input from the input means 1 and transmits it to the host computer 4, and receives and displays the production plan produced by the host computer 4. Generates graphs for use (or drawing). The host computer 4 performs various calculations for creating a production plan based on the data from the workstation 3,
The auxiliary storage device 5 stores order information, process information, production system information,
It stores and manages production planning data, etc. as a database. The data input to the input means 1 may be data input to another device via a communication line or a magnetic recording medium, or may be created as a database by calling necessary data. Good.

The operation of this embodiment will be described in detail with reference to the flowchart of FIG. (1) Input of various data When the order is determined, the delivery date and quantity (order information) of the ordered product are first input from the input device 1 of the workstation 3 (step SP11). This is the data input by another system for managing order information to the host computer 4
Display device 2 of workstation 3
Alternatively, the information necessary for the production plan may be selected and loaded into the apparatus. Of these items of ordering information, it may be better to collectively manufacture products of items having similar manufacturing specifications. In such a case, processing such as combining and handling a plurality of items as one item is performed. Next, the process information is input by the input device 1 based on the manufacturing specifications indicating what kind of product the ordered product is.
(Step SP12). As process information,
The processes required to produce a product, the sequence of processes, and the production efficiency of each process are input. The steps required to produce a product and their order specify what steps should be taken in what order to produce a certain product. For example, make a paper container product. If you do, printing, surface treatment (finishing),
It is necessary to go through each process such as cutting, assembling, and packing in order. By specifying these, the production equipment (machine) to be used is determined. At the same time, the processing sequence of each of these processes and the production efficiency of each designated process, that is, the processable amount per time are input. These process information are registered in advance in the host computer 4 by giving an identification code for each manufacturing specification, and the process information matching the manufacturing specification corresponding to the item ordered this time is called by the identification code from the process information stored in the database. You should do so. Also, each process (machine)
The production system information such as the operation start time, the operation time, and the down time is also stored in the host computer 4 in advance as a database.

With the above data, a production plan can be created, but when there are a plurality of the same process equipment, which is prioritized from the viewpoint of quality and the like, and the past defect occurrence rate for each process. From the above, safety factor data for deciding at what safety factor should be decided for the delivered amount, and assuming that the plan will be revised later, there will be some time margin for each process. By inputting the condition data such as the safety factor data for giving the above, it becomes possible to create a production plan that actually matches. It is preferable that these condition data are not input each time, but are stored in the host computer 4 as knowledge data in a database so that the optimum condition data for the manufacturing specifications of the ordered items are automatically called.

(2) Calculation of production time for each process When the input of various information is completed as described above, the host computer 4 calculates the theoretical production time for each process (step SP13). When it is necessary to consider the production efficiency of the process, the quantity of orders received, and the machine switching time, which is determined based on the input manufacturing specification code, the following calculation is additionally performed. (Theoretical time) = (Process unit quantity) / (Production efficiency) + (Switching time) where (Process unit quantity) = (Delivery quantity) × (Yield rate up to previous process) + (Product loss number) (Efficiency) = (number of processed products per unit) x (mechanical efficiency) Here, the yield rate in the previous process is how many products should be made in that process in consideration of the defect occurrence rate. To represent. For example, in a production process consisting of three processes, if the delivery quantity to the customer is 100, the yield rate of the process immediately before the final process is 1.1, and the yield of the process before that (that is, the first process) is When the accumulation rate is 1.1, the quantity required in the first step is 100 × 1.1 × 1.1 = 100 × 1.21 = 121. Furthermore, if it is desired to supplement the loss number for each process, the product loss number may be added. The machine efficiency represents the speed of the machine per unit time, and the switching time represents the machine stop time when switching from one item to another. As an example, if the process unit quantity is 1000 (m), the production efficiency is 100 (m / h), and the switching time is 1.5 (h), the theoretical time is (theoretical time) = 1000/100 + 1.5 = 11.5.
(H) Obtain such theoretical time for the required number of processes, refer to the production system information in which the required time for each process is input in advance, and accumulate the required time for each process in order from the final process based on the delivery date. By doing so (step SP14), the time required from the start to the end of the production of a certain item can be obtained.

(3) Preparation of long-term production plan The production plan obtained in this way is effective when producing only the item at the production site, but when producing a plurality of items in parallel, it is duplicated. There may be a process to do. As a general rule, only one item can be processed in the same time frame in one process, so it is necessary to reconfigure the production plan to avoid these duplications. In this embodiment,
By the backward scheduling method, the host computer 4 corrects the production plan for each item (step SP15). Backward scheduling is a plan that gives priority to the end time (delivery date in this case),
This will be described with reference to FIG. The goal here is to determine the process end time (ET) of this process. in this case,
The process start time (ST.F) of the subsequent process has already been determined, and the machine of this process can be used only until the machine available time (WT) (end this process by WT). Not). Process start time (S
T. F) is the available time of the machine used in this process (W
The following two patterns are separated depending on whether (T) is before (ST.F) or after (ST.F). (WT) becomes (ST.
In the case of (WT1) which is before F) and when (WT) is (S
T. The case of (WT2) after F) will be considered separately. In the case of WT2 (ST.F <WT) In this case, the time (E
T) depends on the post-process. That is, the machine of this process is (W
It can be used up to T2), but the start time (ST.
Since this step must be completed by F), ET = ST. F ST = ST. It becomes F-PT. Here, (PT) is the operating time of this process. In the case of WT1 (ST.F> WT) In this case, the time (E
T) depends on the available time of the machine. That is, since this step must be completed by (WT1), ET = WT1 ST = WT1-PT. Here, (PT) is the operating time of this process.
In this way, the production start date (time) and production completion date (hour) of each process are traced back from the delivery date.
Is obtained.

An example of modifying the production plan by such backward scheduling will be described with reference to FIG. For simplification, consider as an example the item A produced by the three steps of the first step to the third step and the item B produced by the two steps of the first step and the third step, which are represented by solid lines. Comparing the two production plans, it can be seen that the production plans of the items A and B overlap in the third process. Therefore, when the items A and B are compared, the delivery time of the item A is later (later), so the item A is used as a reference first, and the plan of the item A in the third step is left unchanged. Next, if you look at the third process of item B, you can see that it overlaps with item A, so
In order to eliminate duplicates in time for delivery, the plan for item B is moved as shown by the dotted line. That is, the process end time of item B is matched with the process start time of item A.

As a result of this modification, the schedule of the item B has changed in the third step, so it is necessary to change the schedule of the first step as indicated by the dotted line.
That is, it is necessary to change the plan so that the first step is finished by the start time of the third step. With this fix,
Since the plan for item B has been changed, items A and B will overlap in the first step. Therefore, the item B for which the end time of the first process is later (late) is used as a reference, and the plan for the first process of the item B is not changed and is left as it is. Next, in order to eliminate duplication of Item A with Item B, the first of Item A
Change the process end time as shown by the dotted line. That is, the process end time of the item A is matched with the first process end time of the item B. If the correction of the item A according to this example is applied to the description in FIG. 4, this process is the first process, the subsequent process is the second process, and the machine available time (WT) of this process is the first time of the item B.
It can be considered as a process start time. There is no need to revise the plan for non-overlapping processes. As described above, the production plans of all the items are modified so that the delivery time can be met and the duplication in each process is eliminated. Although preparation time and production system information are not taken into consideration, it is needless to say that these factors must be taken into consideration when making an actual plan.

In this way, the produced production plan can be displayed on the output device 2 of the workstation 3 or the like. In addition, for items that have been determined to be unmanufacturable until the delivery date by making a correction (for example, when the production start date must be set before the current due to the correction), the output device It is possible to notify the worker by issuing a warning on the above.

(3) Preparation of short-term production plan As mentioned above, the production plan is prepared within a range of, for example, about one month. However, at the production site, actual production is often performed based on a production plan of, for example, about 3 days, depending on the type of product. Therefore, a long-term production plan is unnecessary, and there are many cases where an accident or an item that must be urgently processed occurs in reality, and it is rare that production can be carried out according to a preset long-term plan. is there. Therefore, it is necessary to extract the long-term production plan created earlier in a short range of about several days and modify the production plan in consideration of the progress situation at the production site.

Specifically, from a long-term production plan,
The contents for several days from the specified date are taken out, and the current progress information of each process in the taken out production plan is input to the workstation 3 (step SP16). For example, the input device 1 inputs which process is delayed by how many hours. When such progress information is input, the host computer 4 corrects the schedule by the forward scheduling method (step SP17). The forward scheduling is a process that is the reverse of the backward scheduling, and is a plan that gives priority to the start time.

Explaining a concrete example with reference to FIG. 6, it is assumed that two items represented by solid lines were planned to be handled in a certain process. However, if the progress information indicates that the production of the process is not good, the item a for which production must be started first by the forward scheduling is used as a reference, and the process start time of the item a is based on the progress information. Make corrections such as the dotted line. That is, the work start time of the item a is corrected by the delay of the process. Next, the process start time of item b is corrected as indicated by the dotted line, as in the case of item a. That is, the process start time of item b is matched with the process end time of item a. By making such a correction, there will be a delay from the production plan originally set up, but anticipate the delay of the process in advance,
It is possible to modify these by making a plan with a margin of safety. However, in some cases, it may be necessary to correct the plan beyond the range of possible corrections, in which case it is possible to notify the operator by displaying a warning or the like. If there is no delay in each process, the production plan remains unchanged and is not modified.

The short-term production plan thus created is
The production plan is displayed by the output device 2 and the operator inspects the contents (step SP18). If it is confirmed and there is no problem, the person in charge of each work outputs necessary information from the screen of the display device 2 or the plotter (step SP22). When there is a problem in the result, the process and production system are changed (step SP19) and corrected again (step SP).
20). An inspection is carried out again (step SP21). If there is no problem, the process goes back to step SP22. If there is a problem, the process returns to step SP19 to change the conditions again, and a loop for creating a final production plan is provided. ..

The production plan information thus created is managed by the host computer 4, so that the content can be confirmed on the workstation 3 at each workplace through a communication line or the like.

[0025]

As described above, according to the production plan generating apparatus of the present invention, it is possible to make a production plan for a plurality of items in consideration of duplication in each process. Moreover, since the plan can be modified in consideration of the progress status of the actual production site, it is possible to make a highly accurate production plan that matches the actual production.

[Brief description of drawings]

FIG. 1 is a block diagram showing a schematic configuration of a production planning apparatus of the present invention.

FIG. 2 is a block diagram showing a schematic configuration of a production planning apparatus according to an embodiment of the present invention.

FIG. 3 is a flowchart showing the operation of the present invention.

FIG. 4 is an explanatory diagram of backward scheduling.

FIG. 5 is an explanatory diagram of correction of the long-term production plan according to this embodiment.

FIG. 6 is an explanatory diagram of correction of the short-term production plan according to this embodiment.

[Explanation of symbols]

 1 input device 2 output device 3 workstation 4 host computer 5 auxiliary storage device

Claims (3)

[Claims] 1. Order information input means for inputting a delivery date and quantity of a product to be produced, and process information input for inputting a process necessary for producing the product, a sequence of processes and a production efficiency of each process. Means, production system information input means for inputting production system information of each process, first computing means for calculating a required time for each process from the quantity and the production efficiency, and a final process based on the delivery date. From the second calculation means for creating the production plan of the product by stacking the required time of each process in order from the first and the first calculation means for correcting the production plan of each item for the process in which a plurality of items overlap in the same time zone. A production plan creation apparatus comprising: a correction unit. 2. An order information input means for inputting a delivery date and quantity of a product to be produced, and a process information input for inputting a process necessary for producing the product, a sequence of processes and a production efficiency of each process. Means, production system information input means for inputting production system information of each process, first computing means for calculating a required time for each process from the quantity and the production efficiency, and a final process based on the delivery date. From the second calculation means for creating the production plan of the product by stacking the required time of each process in order from the first and the first calculation means for correcting the production plan of each item for the process in which a plurality of items overlap in the same time zone. A production plan planning apparatus comprising: a correction unit, a progress information input unit for inputting progress information of each process, and a second correction unit for correcting the produced production plan from the progress information. .. 3. The production plan planning apparatus according to claim 1, further comprising condition data input means for inputting condition data for creating a production plan.