JPH05189446A - Self process plan sceheduling device - Google Patents

Abstract

PURPOSE:To rationalize the production control of self process by calculating the number of delivery of a self process plan, the number of times of delivery of the self process plan, and the delivery time of the self process plan from the number of production of a post process plan, and calculating another on-plan to deliver the plan at that time. CONSTITUTION:The plan value of the number of delivery is calculated by a self process plan delivery number calculation means 4, and the number of times of delivery planned by a plan delivery times calculation means 6. Thence, a time when delivery is performed is calculated by a self process plan delivery time calculation means 8, and the plan when production should be started is calculated by a self process in-process plan calculation means 10. A calculated in-process plan is corrected by a correction means 12, and the number of production when the production is continued is calculated by a production number calculation means 14 based on corrected in-process information. Finally, the number of stock planned in the self process is calculated from the planned number of production and planned delivery time.

Description

Detailed Description of the Invention

[0001]

[Industrial application] A child part is produced in a certain process and sent to a subsequent process, and in the subsequent process, a parent part is produced using the child part and sent to a further process, and then a further process. In many production systems, a chain of processes, such as producing a product using the parent part, is recognized. The present invention, when a production plan is given to a subsequent process, provides a plan for a process before supplying parts to the subsequent process (hereinafter, referred to as a post process) (hereinafter, also referred to as an own process). It relates to a device for planning.

[0002]

2. Description of the Related Art For example, a technique called a kanban system is often used when controlling production of a piston producing a piston for a post-process of producing an engine. In this technique, an identification card called kanban is attached to a part such as a piston, and the kanban is removed every time the part is used in a later process, and the kanban is sent back to its own process.
In this process, the parts are sent according to the Kanban that has been sent back, in this case the piston to the subsequent process. In this way, the parts used in the subsequent process are replenished, and the production of the own process is managed according to the production pace of the subsequent process.

[0003]

This kanban system is extremely effective and effective when the production pace does not fluctuate significantly. However, when a sudden load change occurs in the subsequent process, it directly affects the previous process (self process) and further propagates to the previous process.
Further, when the production time in the own process is long, or when the number of stocks in the own process is small, it is not possible to follow the sudden change in the order quantity, and there is a possibility that a stockout may occur. In order to avoid this, it is necessary to anticipate changes in the order quantity from the post-process and make a work-in-process plan for the own process. Become.

In view of this, the present invention has developed a device for formulating an own process plan which does not cause a stockout or an excessive inventory even when the production pace of the subsequent process suddenly changes, thereby making the production of the own process more rational. It can be managed manually.

[0005]

Therefore, in the present invention, the concept of the present invention is a device schematically shown in FIG. 1, that is, the number of productions planned to be produced in a post process within a predetermined period, that is, a post process plan. A means 2 for inputting the number of productions, a means 4 for calculating the number of shipments required to be shipped from the own process to satisfy the input number of planned post-process productions, that is, a number of planned shipments for the own process, a calculated number of planned shipments for the own process Is calculated by dividing the number of shipping units by the required number of shipments, that is, the own process planned shipment number, based on the operation schedule of the subsequent process, the number of delays of shipping flights, and the calculated own process planned shipment number. The time when the product is shipped from its own process, that is, the means 8 for calculating the own process planned shipping time, the calculated own process planned shipping time, and the time required from the start of production to the ready-to-ship state. Means 10 for calculating the extent of the progress plan,
Means 12 for correcting the in-process work-in-process plan calculated based on the correction information input by the production control staff, the corrected in-process work-in-process plan, and the time required from the start of production to the ready-to-ship state. From the calculated own process planned production number and the calculated own process planned shipping time, that is, the stock amount of the own process at the time specified, that is, the own process planned inventory number. Calculation means 1
6. An in-process planning apparatus is created which has means 18 for displaying the calculated in-process work plan, the corrected in-process work plan, and the calculated in-process plan inventory quantity. ..

[0006]

According to the above-mentioned process planning apparatus, a production plan for the process is prepared as follows. First, the planned value of the number of shipments is calculated by the own process planned shipment number calculation means 4.
For example, if 100 units are planned to be produced in the subsequent process and it is necessary to supply two parts from the own process for each unit, it is calculated that 200 units will be shipped.
Here, when the own process supplies parts to a plurality of post processes, the number of shipments that can meet the needs of all the post processes is calculated.

Next, the planned shipping number calculation means 6 calculates the planned shipping number. For example, in the case of shipping 40 parts of 200 parts at one time, it is calculated that a shipping frequency of 5 times is planned.

Next, the scheduled shipping time is calculated by the own process planned shipping time calculating means 8. Here, the operating timetable of the subsequent process is referred to, and the operating time is divided by the number of shipments to be delivered to the subsequent process. For this reason, the number of delays of shipping flights is also referred to, and the shipping time is shifted in the past by that amount.

Next, the own process in-process plan calculation means 10 calculates a plan for when to start production. For this reason, the time required from the start of production to the ready-to-ship state is referred to. If production is started according to this work-in-process plan, a work-in-process plan in which the required number of products should have been produced by the planned shipping time is calculated.

The in-process plan thus calculated is corrected by the correction means 12. For example, if it is known that the production pace will temporarily increase in the subsequent process, it is possible to make it in advance by the own process and make modifications to reduce the load fluctuations in the own process. .. If the correction is not necessary, the correction information that makes the correction amount zero may be input.

The production quantity calculation means 14 calculates the production quantity when the production is carried out based on the work-in-process information corrected as necessary. Then, the inventory quantity planned in the own process is calculated from the finally planned production quantity and the planned shipping time. The in-process plan and the inventory quantity calculated or corrected in this way are displayed on the display unit 1.
8, the production manager can grasp the whole plan.

According to this apparatus, the person in charge of production management can easily obtain necessary information. Further, it becomes possible to accurately grasp the influence of the decision to modify the plan based on one's own experience, etc., and it becomes easy to make a final decision on a rational plan.

The plan made by this apparatus is not necessarily an actual plan, and, for example, actual production control may be based on the Kanban system. Even in such a case, the production management person can easily compare the production results with the plan, grasp the problems that may occur in the future, and take necessary measures.

[0014]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS FIG. 2 shows the system configuration of an own process planning apparatus according to an embodiment of the present invention. This device 24 is connected to the related devices A and B online, and data can be input / output to / from the related devices. The device 24 is composed of a computer system having an arithmetic processing device 36 as a main component, and the input device 3 is provided inside.
4, an output device 38, and various storage tables 40 to 48. Peripheral devices such as a keyboard 26, a floppy disk device 28, a printer 30 and a display 32 are connected to this computer system.

In this embodiment, the production schedule of the post-process is sent from the related apparatus A to the apparatus 24, and the own-process plan prepared by the apparatus 24 is sent to the related apparatus B that manages the preceding step. It is configured. The data can also be sent and received by a floppy disk.

The work form table 44 stores data relating to operating time schedules as exemplified in the column a of FIG. In the case of this example, on June 30, the operating time from 8:00 am to 18:00 (but a break from 12:00 to 13:00),
Operating hours from 21:00 pm to 7:00 the following morning (but from 1:00 pm
It shows that a break is planned until 2 o'clock, and that similar operating hours are planned for July 1st.

From the related apparatus A, data on the number of products planned to be produced in the subsequent process is input. Figure 3b,
In the column c, the back-end process A is planned to produce 50 pieces on June 30, 45th on July 1st, and the back-end step B is planned to produce 37 pieces on June 30th and 28 pieces on July 1st. This is illustrated.
Here, the post-processes A and B are the destinations of the products shipped from the own process, and if there are other post-processes to which the products are sent, the production numbers thereof are also given. In addition, the planned production quantity for the back-end process is the planned production quantity for normal working days (corresponding to June 30th), as well as the amount of production for temporary work on a day that should be a holiday (July 1st). Minutes correspond to it).

When the planned production number of the subsequent process is input to the arithmetic processing unit 36, the arithmetic processing unit 36 next refers to the process / configuration table 40 to calculate the planned shipment number of the own process. Here, the process / configuration table 40 stores the number of parts used in each product for each type of product produced in the subsequent process. In the case of FIG. 3, the products produced in the post-processes A and B exemplify a case in which two parts produced in the own process are used for each product. Therefore, in order to meet the planned production quantity given to the subsequent processes A and B, 6
It is calculated that it is necessary to ship 174 pieces on the 30th day of the month and 146 pieces on the 1st of July. The arithmetic processing unit 36 at this stage embodies the own process planned shipment number calculation means of the present invention.

Further, when the planned shipment number of the own process is calculated,
Next, the arithmetic processing unit 36 calculates the required number of shipments by dividing this by the number of shipping units (rounding up after the decimal point). In the case of FIG. 3, the number of shipping units is 30, and [17
4 ÷ 30] = 6, [146 ÷ 30] = 5 (where []
Indicates the smallest number of integers above the division value) is calculated. The arithmetic processing unit 36 at this stage constitutes the own process planned shipment number calculation means.

When the number of shipments has been calculated, the number of deliveries to the subsequent process is calculated, as illustrated in FIG. 3f. Here, the operating hours per day (in this example, 18 hours on both June 30th and July 1st) are divided by the number of deliveries. For example, on June 30, every 3 hours (that is, 8:00 , 11
30 pieces are delivered at each hour, 15:00, 21:00, 24:00, 4:00), and in the case of July 1, every 3 hours and 36 minutes (ie 8 hours).
If 30 pieces are delivered at each hour, 11:36, 16:12, 22:48 ...), the delivery plan should be calculated because no shortage should occur.

Next, the arithmetic processing unit 36 calculates the shipping time. In the case of FIG. 3, the case where the product shipped in the own process is delivered one flight later in the subsequent process is illustrated, and the shipping time is shifted by one flight in the past direction as shown by the dotted arrow. Since the above processing is executed by the arithmetic processing unit 36, the planned shipping time of the own process is calculated based on the operating timetable of the subsequent process, the number of delays of shipping flights, and the number of shipments. At the stage where the arithmetic processing unit 36 executes this processing, the own process planned shipping time calculation means is configured.

When the planned shipping time is calculated, the in-process plan is calculated by the arithmetic processing unit 36 (FIG. 3h).
reference). Here, the time required from the start of production to the ready for shipment is referred to. The case of FIG. 3 exemplifies a case where this time is one hour, and for example, a plan is calculated in which, if production is started from 10:00 on June 30, shipment can be performed by a flight at 11:00. The arithmetic processing unit 36 that executes this process embodies a work-in-process plan calculating means for the own process. The work-in-process plan thus calculated is displayed on the display 32 and is used as a reference for the person in charge of production management.

The person in charge of production management can refer to the calculated in-process plan and input data for correcting the plan from the keyboard 26. For example, in the case where the number of work-in-progress is rapidly increasing after July 2, which is not shown in FIG.
As illustrated in, for example, 30 June and 15 July each
Data is input to produce extra pieces to prepare for future increase in demand. If no correction is required, data that makes the correction amount zero is input.

When the daily production allowance is input as required, it is then reflected in the in-process plan. This process is executed according to FIG.

As shown in the column p of FIG. 4, if the extra production of 2.5 pieces per flight interval on June 30 and the extra 3 pieces on July 1 will result in the input daily production per day. Should be satisfied. However, since the number must be an integer, it is converted into an integer as follows. First, the cumulative error is assumed to be zero. In the first flight, it is necessary to produce 2.5 pieces, but if it is not produced, the new error will be 2.5 pieces. Therefore, on the first flight, the minimum number that exceeds this, that is, three is set. The cumulative error is set to -0.5 because there are 0.5 extra when 3 are set. A new error should be 2.0 from where 2.5 should be produced next. Therefore, on the next flight, set the smallest integer that exceeds this, in this case two. The result thus obtained is shown in the column of s, and this is shown in the column of j in FIG. From the columns of h and j of FIG. 3, the first stage correction result of the in-process plan can be obtained (see the column of FIG. 3k).

This processing is carried out by the arithmetic processing unit 36 on the basis of the correction information inputted by the person in charge of production management as necessary, and the arithmetic processing unit 36 for executing this processing constructs an in-process information correcting means. ing.

In the case of the present apparatus, the work-in-progress plan is modified in consideration of the yield. This is done according to FIG. In the case of this example, according to the modified work-in-progress plan 1 shown in the column of FIG. 3k, 195 units will be produced on June 1 and 165 units will be produced on July 1. 98 when you set 100 here
Assuming that one good product is produced, it is necessary to install four more products in order to produce 195 good products and three more products in order to produce 165 good products. is there. In the column of FIG. 5u, the number of extra devices that need to be set when the yield is taken into account is evenly allocated to each flight, 4/6 on June 30 and 3/5 on July 1. It shows that you can set extra one by one. v, w, x
The column of indicates the processing for converting this into an integer, and the cumulative error is initially set to zero. If the first flight is not set extra, the error will be 4/6. Therefore, round this up to 4 and assign one to the first flight. Then, the next accumulated error becomes −2/6, and here again, if no allocation is made, the new error becomes 2/6. Do not assign it to the second flight because it will be zero if it is rounded to four. By making the integers in this way, the allocation shown in the column of x can be obtained.
In the column 1 of FIG. 3, the value in the column k is corrected by the value in the column x. When the setting is made in accordance with this, a correct in-process plan considering the yield is corrected.

After the above processing is completed, the arithmetic processing unit 36 calculates the number of good products produced according to the in-process plan in the column l. Here, as a matter of course, the number shown in the column k is calculated. Further, here, the time required from the start of production to the ready-to-ship state is referred to. In this way, it is calculated that 32 pieces will be completed at 11:00, corresponding to the start of production of 32 pieces at 10 o'clock on June 30, for example.

Next, the arithmetic processing unit 36 accumulates the value obtained by subtracting the planned shipment number from the planned production number to calculate the planned inventory quantity. In the case of FIG. 3, 3 o'clock on June 30th at 8 o'clock
The number of stocks such as 5 pieces at 11:00 and 8 pieces at 15:00 will be calculated. Here, the planned shipping time is referred to. The planned inventory quantity and the modified work-in-progress plan are output to the display 32 for use by the person in charge of production management.

The person in charge of production management can know the work in process plan, the result of the revision, and the number of stocks when the revision is carried out through the display 32. You can decide while making decisions. Although the above example shows an example in which the planned number of post-processes is given every day, this is not limited to this period, and may be any period when the pace of use is substantially uniform.

[0033]

According to the present invention, the self-process plan for satisfying the needs of the post-process is calculated, and the production management person can know this and make necessary corrections. You can predict the outcome. Therefore, the person in charge of production control can know the necessary information accurately and easily, and more rational production control becomes possible.

[Brief description of drawings]

FIG. 1 is a diagram schematically showing the concept of the present invention.

FIG. 2 is a system diagram of an embodiment.

FIG. 3 is a diagram showing the processing contents of the embodiment.

FIG. 4 is a diagram showing allocation processing of advance correction.

FIG. 5 is a diagram showing yield correction allocation processing.

[Explanation of symbols]

 2 Post-process plan production quantity input means 4 Own-process plan shipment number calculation means 6 Own-process plan shipment number calculation means 8 Own-process plan shipping time calculation means 10 Own-process work plan calculation means 12 Own-process work plan correction means 14 Own-process plan Production quantity calculation means 16 Own process plan inventory quantity calculation means 18 Display means

Claims (1)

[Claims] 1. A means for inputting the number of productions planned to be produced in a post-process within a predetermined period, that is, the number of post-process planned productions, and shipping from its own process to satisfy the input post-process planned productions A means for calculating the required number of shipments, that is, the own process planned shipment number, a means for calculating the required number of shipments, that is, the own process planned shipment number by dividing the calculated own process planned shipment number by the number of shipping units, The time to ship from the own process, that is, the means for calculating the own process planned shipping time, based on the operating timetable, the number of delays of shipping flights, and the calculated own process planned shipping number, the calculated own process planned shipping time And the time it takes from the start of production to the ready state for shipment, the means to calculate the in-process plan of the own process, and the own process calculated based on the correction information input by the person in charge of production management. Means to modify the schedule plan, means to calculate the planned production quantity of the own process from the revised in-process work plan and the time required from the start of production to the ready state for shipment, the calculated own process plan A means for calculating the inventory quantity of the own process at the specified time, that is, the own process planned inventory quantity, from the number of productions and the calculated own process planned shipping time, the calculated own process work plan, and the modified own process work A means for displaying the plan and the calculated inventory quantity of the own process plan,
A self-process planning apparatus characterized by having.