JPH05298280A - Simulation method and device for stacking and removing load - Google Patents

Abstract

PURPOSE:To readily allocate loads in the process including a processing means processing an object and a processing means processing another type of object. CONSTITUTION:A group of load such as one order of lot is divided (41) into proper size of working lots. Each working lot is stacked (42) on each processing means capable of the processing assuming that all capacity of each processing means should be divided. Whether or not the amount of load stacked of each processing means exceeds the capacity of the processing means is checked (43), and if it does, the working lot related to a group of loads selected by the appointed date of delivery is kept in the processing means and ones related to the load of the other group is removed from the processing means to be allocated (44) to the other processing means capable of the other processing time of the processing means and its processing.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a load pile landslide simulation method and a load pile landslide simulation apparatus to which the method is applied. More specifically, the present invention relates to a processing means capable of processing a certain processing target and the certain type. To a processing step including a processing means having a capability of processing a different type of processing target, a simulation method of load hill collapse for optimal distribution of load, and a load hill collapse to which the method is applied. The present invention relates to a simulation device. The processing target referred to in the present invention includes not only various normal products produced and processed in a factory, but also clothes handled in each process of a cleaning factory, vehicles and aircrafts handled in each process of a maintenance factory, It includes everything handled in various industrial processes, such as ships. Similarly, the processing means includes not only an ordinary machine used for processing and inspection, but also a person, for example, an inspector who inspects a product by using his five senses in an inspection process. The machine includes not only a machine in a narrow sense but also any machine used in industrial activities, such as yeast in the brewing process. Similarly, in the treatment process, not only the process for producing normal products, but also various processes in industrial activities such as the process of ironing clothes and the like for which cleaning is requested, the process of inspecting each part of the vehicle, etc. included. Here, a person (worker) is also included as a processing means. Therefore, three types of processing steps are possible: a processing step consisting only of machines, a processing step consisting of both humans and machines, and a processing step consisting only of workers.

[0002]

2. Description of the Related Art A load pile landslide simulation method or apparatus is used in a production management system. As a conventional technique of this type, for example, Japanese Patent Laid-Open No. 2-71960.
There is one described in the official gazette. In this conventional technique, for each process for producing, inspecting, etc. a processing target, for example, the time required for the processing is short, the profitability is good or bad, and from other viewpoints, weighting is performed in advance, and the weight (important Every time)
The optimum load distribution is obtained by allocating the load from the process having the largest load.

[0003]

However, in the prior art including the one described in the above publication, it is assumed that the processing means of each step simply has the ability to process one kind of processing target, and the load is piled up. Was being done. Therefore, when the process includes a processing means capable of processing a certain processing target and a processing means capable of processing a processing target of a different type from the certain processing target, for example, only the product a. If it is assumed that the machine 1 capable of processing the product 1, the machine 2 capable of processing only the product b, and the machine 3 capable of processing the product a and the product b are included, it is difficult to optimally distribute the load in the conventional technology. It was The reason is as follows. 1) For example, when a load is piled up in each process to process the product a, according to the conventional technique, the processing capacity of a process is determined by the machines 1 and 3 capable of processing the product a in the process.
It is calculated based on the processing capacity of. Therefore, the ability of the machine 2 to process the product b is neglected. 2) Further, by devising a fitting method, the process concerned includes a plurality of processes, that is, "process x capable of processing product a which is composed of machines 1 and 3" and "product which is composed of machines 2 and 3." It is assumed that products a and b are piled up in these processes, assuming that they are processes y capable of processing b. However, according to this processing method, the machine 3 is piled up with the load as the step x and the load is piled up also with the step y. Therefore, the machine 3 must process the product a and the product b in the same time zone, and a process design that cannot be processed actually is performed. 3) Therefore, in the above (1) and (2), it was reiterated that each machine 1 to 3 existed in one process.
Think of a process that is originally one, such as “process x consisting of machine 1”, “process y consisting of machine 2”, and “process z consisting of machine 3” as three separate processes for each function. To Then, it is assumed that, for example, the products a are piled up in these steps by a conventional method. In this case, in the conventional technique, a product is handled as one processing unit, for example, a quantity corresponding to one order. That is, the entire processing unit is selectively piled up on either the machine 1 or the machine 3 that can perform the processing. Therefore, although the other machine can process the product a, the load is not piled up. The object of the present invention is to solve the above drawbacks of the prior art, and to mix the processing means having the ability to process a certain processing target and the processing means having the ability to process a different type of processing object from the certain type. In particular, it is an object of the present invention to provide a load pile up mountain collapse simulation method capable of allocating an optimum load and a load pile up mountain collapse simulation apparatus to which the method is applied.

[0004]

In order to achieve the above object, in the load pile-up landslide simulation method of the present invention, a division process for dividing a load of a group into work lots of a size convenient for processing, and In the case where it is assumed that only the work lots related to the load are processed, a pile process in which the above work lots are stacked in a processing means capable of processing the work lots, and a work lot having a load amount exceeding the processing capacity is piled up. , Each work lot related to the load of the selected group of the stacked work lots is left, and each work lot related to the load of the group other than the selected load of the group is left in another time zone of the processing means or A landslide process that assigns to other processing means capable of those processes is performed.

Further, in the load pile up mountain collapse simulation apparatus of the present invention to which the load pile up mountain collapse simulation method is applied, dividing means for dividing a group of loads to be processed into work lots of a size convenient for processing, Each processing means is provided at a rate of 1 per unit time zone,
A load cell having a stacked lot holding unit for holding the work lots to be stacked in the unit time zone, and a fixed lot holding unit for holding the work lots fixed as to be processed in the unit time zone When,
Assuming that only the work lots related to the group of loads are processed, the work lots for stacking the work lots in the stack lot holding section of the load cell of the processing means capable of processing the work lots, and For the load cell, an inspection means for inspecting whether the total load of the work lot of the fixed lot holding unit and the load of the work lot of the piled lot holding unit exceeds the processing capacity of the processing unit in the unit time zone. And, if the inspection shows that the total exceeds the processing capacity, the processing means processes the work lots associated with the selected group of loads among the work lots in the stacking lot list holding unit of the load cell. It is left as the load of the processing means within the range of the capacity, and each work lot relating to the load of the group other than the selected load of the group is set at another time zone of the processing means or Break Mountain assigned to these processes other processing unit capable and means.

[0006]

Function: For example, a machine 1 capable of processing the product a
And a process including a machine 2 capable of processing the product b and a machine 3 capable of processing both the products a and b, a group of loads, for example, an amount corresponding to one order from a certain customer. Suppose that the proposition of processing the product a (for example, 140,000 resistors) is given. Here, the group of loads refers to the amount of processing target treated as one processing unit at a production site or the like, for example, the amount of products corresponding to one order, the amount of products corresponding to a plurality of orders. , Or 1
It is an order, but because it is a large quantity, it means the amount of product for one division when it is divided and produced.

In the load pile-up landslide simulation method of the present invention, first, the group of loads is divided into work lots of an appropriate size convenient for the process, for example, a unit of 20000 pieces by a dividing process. The size of the work lot is
For example, it is determined corresponding to each processing step and the characteristics of the processing target, such as the number of pallets to be transported, the amount of inspection machines that can be received at one time, and the amount that an operator can handle. Then, the stacking process stacks each work lot onto a machine capable of processing them, assuming that all of the processing capacity of each machine is devoted to the processing of work lots associated with that group of loads. The pile-up is carried out for each “group of loads” corresponding to orders for a predetermined period, for example, three months in the future.
As mentioned above, heaping is performed assuming that each processing means (machine) only processes the current group of loads. Therefore, each machine may be overloaded with work load or more. This possibility is particularly high for a machine capable of processing a plurality of processing targets (products) (for example, when a lot of work lots for product a is piled up, work lots for product b are already in the same work time zone. It is a feature of the method and apparatus of the present invention that this is done intentionally). If the load exceeding the processing capacity is piled up, the work lot related to the load selected in consideration of the orderer, delivery date, and other factors among those piled up on the machine in the landslide processing Is left as a load on the machine. And other work lots related to a group of loads other than the selected group of loads are removed from the machine on which it was piled up,
It is assigned to another time zone of the machine or another machine capable of processing them.

In the load pile landslide simulation apparatus of the present invention, the dividing means divides a group of loads to be processed into work lots of a size convenient for the processing. The stacking means stacks each of the work lots in a stack lot holding unit of a load cell of a machine capable of processing the work lots, assuming that only the work lots related to the group of loads are processed.
The load cell is provided for each machine at a rate of one per unit time zone, for example, every 30 minutes, and includes a pile lot holding unit and a fixed lot holding unit. In the pile lot holding section,
The work lots piled up to be processed in the unit time zone are held. The fixed lot holding unit holds the work lot fixed as the one to be processed in the unit time zone. The inspection means, for the load cells of each machine, whether the total load of the work lot of the fixed lot holder and work load of the pile lot holder exceeds the processing capacity of the machine in the unit time zone. To inspect. If it is determined that the total exceeds the processing capacity by the inspection, the landslide means determines that one of the work lots in the pile lot list holding unit of the load cell related to the selected group of loads is loaded on the machine. It is left as the load of the machine within the range of the processing capacity, and work lots other than those related to the selected group of loads are allocated to other time zones of the machine or other machines capable of processing them.

These treatments are carried out, for example, for each group of load-bearing work lots which have to be treated in the next three months. The allocation state thus obtained is shown to the process design engineer or the like through a display device, a printer or the like, for example, in the form of a load table, a plan table or the like. As a result, it is possible to perform a load allocation simulation for each process and each machine for a predetermined period. The priority, lot size, and other parameters relating to the processing target are variously changed, the above-described processing is repeated, and the result of the processing is evaluated. By repeating this, the optimum load distribution can be found.

[0010]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The details of the load pile landslide simulation method of the present invention and the load pile landslide simulation apparatus to which this method is applied will be described below with reference to the drawings. FIG. 2 shows an outline of the apparatus of the embodiment. The apparatus of this embodiment is composed of an input device 1, an output device 2, a memory device 3 and a processing device 4. Details of each device are shown in FIG. The input device 1 includes a mouse / keyboard input unit 12. The mouse is used to point icons, menus, etc. on the screen with the cursor, and execute processing, confirm input, input numerical values, and the like.
The keyboard is used for inputting characters in the input field on the CRT screen. The output device 2 is a CRT
And a load table 21 as shown in FIG. 3, including a printer,
The plan table 22 as shown in FIG. 4 is displayed or printed out. The load table 21 represents the amount of load assigned to each process or each processing means over time. As a result, the process design engineer or the like can know which process or which processing means is overloaded to some extent in a certain simulation state. The plan table 22 shows the processing progress of each "group of loads" in each process. This allows the process design engineer or the like to know in what time zone each "group of loads" is processed in each process in a certain simulation state.

Next, details of the processing of the embodiment apparatus will be described.
The processing is roughly divided into three: (1) division processing, (2) pile-up processing, and (3) landslide processing. In the division processing of (1), a work lot is generated. That is, a group of production loads (group of loads) supplied from a preceding process, for example, a production process to the process, for example, an inspection process, is divided into work lots of a size determined for the process. In the pile processing of (2), the divided work lots are allocated to each machine (processing means) in the process. At this time, only the work lots related to the production load of the group are allocated to the process, that is, assuming that all the work capacity of the process is allocated to the processing of the production load of the group, the allocation is performed. Done. In a sense, overloading is performed, and a process of allocating the production load of the group to a processing means capable of processing that type of processing target is performed. In the landslide processing of (3), the above (1)
In this way, it is inspected whether a work lot with a processing capacity or more is assigned to the same processing means in the same work time zone, and if so, leave a work lot with a high priority there. , The rest is redistributed to another time zone of the processing means or to another processing means.

The working time zone is divided into, for example, 30 minutes, and this is made into a unit time zone. One unit time zone is represented by one scale on the time scale of each figure. If it corresponds to continuous production day and night, it will be 48 scales a day. And for example 9
If the simulation is performed for 0 days, the number of scales on the time scale is 4320. For each machine, work lots are piled up or collapsed every unit time zone. Therefore, 1 corresponding to 1 unit time zone
A load cell 331 (FIG. 5) is provided. For the next three months, each machine is provided with 4320 load cells 331. The load cell 331 (FIG. 5) is provided with a four-item data area including a piled lot list, a planned fixed lot list, a piled load amount, and a planned fixed load amount. In the area of the stacking lot list, the numbers of the work lots assigned to the machine by the stacking processing described above are stored.
The total load amount of the piled work lots is stored in the pile load amount area. For example, a work lot related to the production load of the product a is divided into 10 work capacities with the full work capacity of the machine, and a work lot related to the production load of the next product b is The work capacity of the machine is divided into 10 work capacities. In this case, the number of work lots related to the product a and the number of work lots related to product b are stored in the area of the stacked lot list, and the total load amount 20
Are stored in the heap loading area. In the area of the planned fixed lot list, the numbers of the so-called reserved work lots which are fixed as the load of the machine in the time zone are stored. The plan is fixed based on the result of the simulation or the judgment of the process design engineer. The total load amount for the planned fixed lot is stored in the planned fixed load amount area. The planned fixed load is the load for the work lot determined by simulation or by the judgment of the process design engineer, so unlike the pile load, the load that can be processed by the machine in the unit time zone is guaranteed. Is.

By using the load cell 331,
The following operations required for simulation can be executed at high speed. 1) Retrieval of load-allocatable time zone 2) Check of load amount in time zone in which arbitrary work lot is allocated 3) Extraction of all work lots allocated in arbitrary unit time zone 1) The search for the load allocatable time zone is executed to create a free cell table, which will be described later, that is, a table for the load cells to which the work lot to be moved can be allocated when performing the landslide processing. To be done. Specifically, it is executed in the form of "work capacity"-"planned fixed load amount" for each load cell 331. In the check of the load amount in the time zone in which the arbitrary work lot is assigned in 2), the work lots related to this load are piled up in the process of fixing a group of production loads to each machine, which will be described later. At the load cell, this is done to detect if the machine has overflowed with only the work lot in question. Specifically, in the load cell in which the relevant work lots are piled up, "work capacity"-"planned fixed load amount + fixed target work lot load amount" is calculated, and whether the value is negative? Is checked to determine whether or not the load cell can be fixed. The fixed target work lot load amount is obtained from the number of work lots related to the production load of the group stored in the piled lot list of the load cell. All work lots assigned to any unit time zone in 3) are extracted in the unit time zone in which there is a fixed work lot, and those that have overflowed are the fixed work lots. Other than the above, it is executed to detect other work lots. This can be easily executed by reading the data of the piled lot list of the load cell. In addition, the extraction of all work lots assigned to this arbitrary unit time zone is piled up in the load cell in a manner of competing with the work lots related to the production load of the fixed group when the mountain collapse occurs. It is also executed to detect the work lots of No., and specifically, the work lots competing here are detected by the process of “mounting lot list-fixed work lot list”. The fixed work lot list is a list of work lots related to the production load of a fixed set of work lots.

Next, data related to these processes will be described. a. Product master data (reference numeral 34 in FIG. 7 and the like) Indicates the product type and the like corresponding to the product name. The product name is something like a proper noun, by which the specification of the product is specified. For example, the part number (RA30 ...) Of the resistor based on the JIS standard corresponds to this. The product type is a parameter for selecting the machine to be applied to the product, such as product size, type, etc.In the case of resistors, size, fixed / variable, coating, etc.
This is the case for solids. Therefore, as in the example of FIG. 7, even if the product names are a and x, the product type may be the same a. b. Work process characteristic master data (reference numeral 35 in FIG. 8 and the like) Shows a processable product type, a work capacity per unit time zone, and the like for each machine in each process. The process name may be defined by a superordinate concept or may be determined by a subordinate concept. If it is a superordinate concept, it will be a concept such as a production process, an inspection process, a packing process, and a shipping process, and if it is a subordinate concept, it will be a resistance value inspection process, a dimension inspection process, etc. in the inspection process. Will be. For the work machine, one physical machine may be assigned with a single number, or machines capable of performing the same processing may be grouped together and defined as, for example, "machine 1". The work capacity is expressed per one unit work time zone.
Specifically, it may be represented by a direct number such as 1000, or may be further represented by “1 work capacity”. Regarding processing steps involving people, it is preferable to use a group as a unit of one processing means in order to prevent variations due to differences in individual processing capacities. Note that FIG.
In the above example, since the machine 13 has the ability to process a plurality of products, and the work capacity varies depending on the product type,
The work capacity for each product type of the same machine 13 is described in two places on the third and sixth lines.

FIG. 9 shows the concrete procedure of the load stacking process, and FIG. 10 shows the allocation of work lots to each machine.
It shows in (A). (1) Generation of Work Lot (Step S1) (Hereinafter, the word "step" is omitted.) In this S1, data of a group of production loads 31 is first input. With reference to the product master data 34, a work lot relating to this group of production loads is generated. As shown in FIG. 9, the data of the group of production loads 31 includes product name, customer name, delivery date, quantity,
It is composed of a production line payout start time, a production line payout end time, and the like. Here, in order to facilitate understanding, as shown in FIG. 11, it is assumed that a certain amount of product A, which is a group of production loads, is put into a certain process from scale 0 to scale 3 of the time scale. The term "scale" will be omitted hereinafter. By referring to the work lot quantity of the product characteristic master data 34, the product quantity of the group of production loads is divided into work lots of this size. The processing device 4 during generation of the work lot corresponds to the dividing means 41. As a result, it is assumed that the work lots 1 to 9 are generated as shown in FIG. In this case, for example, the payout time from the production process of the work lot 1 is the time t1 in FIG. (2) Selection of Inspection Machine (S2) In S2 of FIG. 9, a machine capable of processing the product type is selected in the process. First, the product master data 34 (FIG. 7) is searched by the product name of the input group of production loads, and the product type is obtained. Then, the work process characteristic master data 35 is searched for by the process number and this product type, and the machine capable of processing the product of that type in the process is read out. For example, when the process is performed on the product a in the process 1, the “process” column of the work process characteristic master data 35 (FIG. 8) is searched and the process 1
Machines belonging to are extracted. The “product type” column of the extracted data is searched, and machines capable of inspecting the product type a in step 1, for example, machines 11 to 15 are extracted (FIG. 1).
2).

(3) Pile of work lots The work lots "1" to "9" thus generated are piled up on each machine capable of processing them according to the payout time (FIG. 12). The processing device 4 in the state of performing this processing corresponds to the pile-up means 42. At this time, it is assumed that the work capacity of the machine in the process is allotted to the processing of the work lot related to the group of production loads at this time.
That is, it is not taken into consideration whether or not work lots related to another group of production loads are already piled up on each machine. This process is performed by referring to the work capacity of each machine in the work process characteristic master data 35 when stacking work lots related to the production load of each group on each machine, and stacking work lots to the full capacity. Will be realized. For example, in FIG. 12, the work lot “1” is delivered at time t2. Here, it is assumed that 20 work capacities are required to process one work lot in this process 1. When stacking such work lots on the previously selected machines 11 to 15, first, referring to the work process characteristic master data 35 (FIG. 8), the work capacity of the machine 11 and 10 work capacities per unit work time zone are determined. Desired. Since a work lot 1 having a work capacity of 20 is processed, 2 unit time zones are required for the processing. Load cell 33 in the time zone of time scale 1 and 2 of machine 11
1 (FIG. 5) is accessed, and this work lot 1 is registered (stacked) in the area of the stacking lot list. The next work lot 1 is delivered at time t3.
At this time, regarding the production load of this group, the previous work lot 1 is already piled up in the machine 11 to its capacity.
Thus, at this point, it is the machine 12 that is unloaded with respect to this group of production loads. Therefore, this work lot 2 is registered in each load cell 331 of the time scales 1-2. In the same manner, as shown in FIG. 12, the work lots 3 to 9 of the group of production loads are piled up on the machines 11 to 15 in the process 1. (4) Packing processing (S4 in FIG. 9, FIG. 13) When all the work lots related to a group of production loads are piled up, the work lots are processed in parallel at the same time in each machine as much as possible. As described above, the packing process (time reduction process) is performed. In this way, the work ability of the process can be used more effectively. This process is
This can be realized by searching the payout time of the work lot processed last in the process and delaying the payout time of other work lots to the nearest time. For example, in the case of the process 1 of FIG. 12, the payout time t9 of the work lot 9 is the latest, and therefore the payout times of the other work lots 1 to 8 are moved back to the time t9 as close as possible.

This pile processing is carried out for each process through which the production load of the group should pass. The process to be passed is drawn from the inspection process list of the product master data 34. For example, it is assumed that the product related to the production load of this group passes through the process 1 and the process 2. Also for step 2, the series of processes in FIG. 9 is executed. The stacking in the process 2 is performed as follows. First, for each work lot 1 to 9, each machine 11 in the previous step 1
The time to be paid out from ~ 15 is required. Based on this time point, after that time point, the work lots are piled up on the machines that can accept the work lots. In this step 2 as well, at the time of stacking, the entire working capacity of the machine in step 2 is applied to the processing of the work lot related to the production load of this group, and the stacking is performed.
The result is shown in FIG. Note that, for example, S1 is step 1
And step 2 are executed, and then S2 is step 1 and step 2.
The steps of FIG. 9 may be sequentially performed for a series of processes through which the product should pass. However, in this case, for example, when the packing process of the process 1 is performed in S4, the product loading time to the process 2 is changed, and the processes of S1 to S3 must be redone for the process 2 and subsequent processes. There is, so be careful.

The above-described series of pile-up processing is executed for each group of production loads to be subjected to the simulation, for example, all of each group of production loads to be processed in the next 90 days. As described above, a load is piled up for each machine in each process on the assumption that the entire processing capacity of the machine is allotted to the processing of the work lot related to the production load of each group. Therefore, it is assumed that, for example, there is a production load of two different product types for two customers, for example, two production loads of the product type a and the product type b, which are to be processed in 90 days, and a simulation is performed for this. In this case, due to the pile-up processing here, for each machine capable of processing two types of products in each process, there is a work lot of a quantity that is twice the work capacity of that machine in a certain time zone. It will be piled up. Figure 1
0 (A) shows such an example. In this example, since the machine 13 can process both the product type a and the product type b, the work lots 2a and 5a related to the product type a and the work lots 2b related to the product type b are processed in the same time zone.
Both 5b are piled up. This phenomenon is
It also occurs when a pile of multiple "groups of production loads" of products of the same type. This is, so to speak, consciously done. That is, in the present invention, so to speak, the processing capacity of each machine is ignored, and the work lot is piled up on a machine capable of processing them, and after that,
Each machine is checked for overloads and if there is, leave a work lot for the selected batch of production loads and leave work lots for other products on the other machines. Reallocate to time zone or other machine (land collapse). Thus, in a process including a machine capable of processing a certain product and a machine capable of processing another type of product different from the certain type, the processing capacity of each machine is maximized. It is the aim of the present invention to try to draw the limit.

Next, the mountain collapse processing (conflict resolution processing) will be described. FIG. 14 shows the entire processing. (1) Creation of priority table (S11) The details of this S11 are shown in FIG. That is, in S111, the priority key items set and input by the process design engineer are fetched. What is used as a key item is determined according to the characteristics of the process in which the simulation is performed and the characteristics of the processing target. Various items related to a group of production loads, such as delivery date,
Customers, profit margins, length of parts procurement period, amount of production at that company or its factory, ratio to production amount, length of setup time, various other items can be key items of priority. In step S112, the setting area of the priority table is secured. FIG. 16 shows an example of the configuration. In this example, an area for storing data of two priority key items (key item 1 and key item 2) and a group of production load storage address pointers are stored for each group of production loads simulated at that time. It is provided. In step S113, the data and the like for each key item of the production load of each group is stored in each of these data storage areas. S
Proceeding to 114, these data are sorted by the key item 1 and the key item 2 of each group of production loads. For example, when the key item 1 is the delivery date and the key item 2 is the customer name, if the delivery dates are different, the delivery date is closer to the higher priority, and if the delivery dates are the same, the priority is high. A group of production loads for one customer is placed at a high priority.

After this processing is completed, S11 to S1 in FIG.
Go to 2. Here, as a result of the load over test, that is, the above-mentioned pile processing, during the time when each work lot is piled, whether the machine can process those work lots, that is, the work lots are linked. It is checked whether the total load of the loaded load cells during the time period exceeds the processing capacity of the machine. The processing device 4 when performing this inspection corresponds to the inspection means 43. Details are shown in FIG. First, in step S121, the priority table is searched, the contents of the pointer for the "first group of production loads" that are given the highest priority are read, and the first data is read from the first group of production load data 31 indicated by the pointer. Get work lot number. The group of production loads given the highest priority here corresponds to the “selected group of production loads”. Proceeding to S122, the load cell 331 in which the work lots are linked (stacked) in the target process is obtained. When the work lot size is one unit time zone or more (for example, in the case of the process of step 1 in FIG. 12), the work lots are stacked in a plurality of load cells. In this case, read it all. In S123, the piled load amount and the planned fixed load amount of the load cells or those load cells are obtained. Also, the work capability of the machine is obtained from the process characteristic master data. In step S124, "working capacity"-"planned fixed load amount"-"mounting load amount" is calculated. If the answer is 0 or positive, the load cell, ie the load on the machine in the unit time zone, is within the working capacity of the machine, and the machine has Fixed lots already fixed there can be processed. In this case, proceed to S125,
It is inspected whether or not there is a remaining work lot related to the production load of the group, and if there is, the same process (the processes of S122 to S124) is repeated. When all the work lots are completed without any abnormality, the answer in S125 is "no", and this process is ended. In the repetition of steps S121 to 125, if the value of "work capacity-planned fixed load amount-mounting load amount" becomes negative, the answer of S124 in FIG. 17 is "overflow".
become. That is, in the unit time zone related to the load cell 331, the load amount of the machine exceeds the processing capacity. In this case, the process of FIG. 17 is ended there, and the process proceeds from S13 to S14 of FIG.

In step S14, with respect to the overflowed load cells, a work lot relating to a group of production loads having a high priority is left, and the remaining work lots are reallocated to other load cells. In this case, the work lots for the “group of production loads” located in the higher order of the priority table (FIG. 16) are reallocated so that they are processed first. The processing device 4 in this allocation state corresponds to the landslide means 44. Details are shown in FIG. First, in S140, the work lot overflowed in the process is moved. Specifically, S1 in FIG.
The processing of 401 to S1404 is performed. That is, first S1
At 401, a work lot to be removed is extracted from the overflowed load cell, and the data is logged (recorded) in an appropriate memory area. For example, as shown in FIG.
At the same time, for example, on time scales 3 to 5, work lots 2a related to product a and work lots 2b related to product b are piled up, and the load table related to this time scale of machine 13 has overflowed. .. At this time, it is assumed that the priority P of the product a is higher than the priority P of the product b. In this case, all work lots 2b to 6b after this time scale for the product b are extracted and their data are logged. If a work lot related to another group of production loads is piled up in the load cell, only the work lot related to the highest priority is left within the range of the work capacity of the machine, and the others are Everything is logged this way. Next, proceeding to S1402, a free cell table is created for the load cells of each machine in the process after this time scale. The free cell table is the number of unit time zones necessary for processing the work lot to be moved, and is an array of load cells of a machine having a space, and is divided into, for example, the machine 13 and the like in FIG. 10 (A). If the work lots 2b to 6b removed from the processing lots are to be processed by the machines 13 and 14, these machines require three unit time zones to process one of the work lots 2b to 6b. A load cell table corresponding to the work lot at this time is obtained by dividing the arrangement of the load cells of the machines 14, 15 and the like into units of the three time scales. Proceeding to S1403 in FIG. 19, the overflowing work lot, in the example of FIG. 10, work lots 2b to 6b are removed from the load cells of the machines 13 to 15. Proceeding to S1404, referring to the free cell table, the removed work lots, here, 2b to 6b, as shown in FIG.
Allocate to 4, 15 again.

Now, the process of FIG. 19, that is, S14 of FIG.
The process of 0 is ended, and the process proceeds to S141 in FIG. Check whether the work lot moved here is late for delivery. The term "delivery date" here means the "latest payout time in the process (process payout limit)" set for each work lot, and the payout time of the moved work lot is compared with this. .. The latest payment time is
For example, the process of stacking from the last process to the previous process in sequence based on the delivery date to the customer (called the latest stacking) is executed in advance, and the payout in each process of each work lot obtained by this is executed. Set the time as this time. If the load allocation of a process after a certain process is fixed for some reason during the simulation, a work lot must be input to that process before that time. In this case, the latest payout time of the preceding process of the process is updated to match the acceptance time of the fixed process in accordance with the fixed process.

If there is no delay, the flow advances to S144 to check whether it is the final process for the production load of the group. If it is the final step, the moving work has been normally completed, and therefore, the procedure proceeds to S148, in which S140 in FIG.
The journal table generated in (401 logging) is released. When the process is not the final process for the work lot related to the production load of the group, for example, work lots 2b to 6b, the process proceeds from S144 to S145, and from the data 31 related to the production load of the group, the next process for the work lot is performed. A process, for example, the process 2 in FIG. 12 is read out, and the process proceeds from S145 to S146 in FIG. Here, whether the load of the process is fixed, that is, the landslide treatment has already been completed,
Check if the pile load of the load cells of each machine in the process is "0". When the answer is “Yes”, the moving process of FIG. 18 is finished, and the process of S148 described above is performed. Process where the load is not fixed,
That is, in the case of a process in which the landslide treatment has not been completed, the process proceeds to S147 in FIG. 18, and if the next process, for example, the process previously performed is process 1 in FIG. 12, this time, process 2 in FIG.
In S147, the movement process is performed for each work lot related to the same group of production loads. S1
Details of the process of 47 are shown in FIG. The processing of FIG. 20 is basically the same as the processing of FIG.
The process of 1474 corresponds to each process of S1401 to S1404. The description will be omitted because it is redundant. However, since the process of FIG. 20 is a process of a post process, for example, a process of process 2 following process 1 of FIG. 12, regarding the work lot, each work lot is paid out in the previous process. It is necessary to allocate these work lots to each machine in the subsequent process according to the time. Therefore, S14
In this respect, 74 has more processing contents than S1404.

Upon completion of this process, that is, the process of S147 in FIG. 18, the process returns to S141 in the same figure, and as in the first process, for example, the process 1 in FIG. Check if the production load is delayed. If there is no delay in delivery, the processes of S144 to S147 described above are carried out for all the processes related to the production load of the group, and finally, in S144, the answer is "Yes", that is, the production load of the group. The process of FIG. 18, that is, FIG. 14 is performed when the respective work lots have been moved for all the processes for which the work lot of FIG.
The processing of S14 is finished. If there is a delivery delay,
From S141 to S142. Check here whether forced movement is possible. This check is determined by whether or not the forced transfer flag of the data 31 of the group of production loads related to the work lot is turned on. The forced movement flag itself is set by the process design engineer or the like as a parameter for performing the simulation in consideration of the delivery destination of the group of production loads and other circumstances. If forced transfer is possible, this work lot is assigned to the load cell of the machine selected as the transfer destination at that time as a planned fixed lot within the range of its work capacity. Then, the processing from S144 onward is continued again. If the forced movement is not possible in S142, the state that motivates this processing, that is, the state of the load overload (overflow) of the machine having the process of interest at that time cannot be eliminated. , S149, the state before movement stored in the journal table is read, and the state of each load cell is changed to S1.
At 42, the process returns to the state before the state in which the "forced movement is impossible", and the process ends.

The processing of FIG. 18 is completed, that is, S of FIG.
When the processing of 14 is completed, or after the processing of S13 in FIG.
When the process of 14 is not performed, the process proceeds to S15 in the same figure, and the fixing process of each work lot is performed, that is, the work lot is transferred from the pile lot list of the load cell in which it is piled to the column of the planned fixed lot list. Carry out. This completes the landslide process. Note that FIG. 1 showing the detailed processing of S14.
In the process of 8, when S149 is executed and ended, the priority order set in the simulation at this time,
With a group of production loads, the process cannot be performed in the target process. The processing device 4 (FIG. 1) displays a message to that effect on the CRT or the like of the output device 2 (FIG. 1). If necessary, for each group of production loads to be simulated here, the priority order is changed, the number of groups of production loads is reduced, and the like, and the simulation is performed again. In this embodiment, the work lot can be moved manually (Figs. 1 and 4).
5). You could try doing this as a form of simulation.

In this embodiment, a single-function processing means, for example, a machine capable of processing the product a or the product b, and a multi-function processing means, for example, a machine capable of processing both the product a and the product b. Although the case where each type of product is put into the included processing steps is taken up, only a single-function processing means, for example, a machine capable of processing the product a and a machine capable of processing the product b are configured. Various types of loads and processing steps not mentioned in the embodiment, such as inputting each type of product to the processing step, or inputting these loads to a processing step including a person or including only a person. On the other hand, the simulation can be performed by applying the method of the present invention or the apparatus of the present invention.

[0027]

As described above, according to the method of the present invention,
By the division processing, the load of a group given to the process is
Divide into work lots of appropriate size that are convenient for processing,
Without considering whether or not the processing capacity of each processing means is exceeded by the pile-up processing, the work lots are stacked on the processing means capable of processing them, and the work that exceeds the processing capacity by the mountain collapse processing is performed. When lots are piled up, a work lot related to a group of loads selected in consideration of delivery time and other circumstances is left as the load of the processing means, the rest is destroyed from the processing means, and the Allotted to other time zones or processing means capable of processing them. Further, in the device of the present invention, it is assumed that the group of loads to be processed is divided into work lots of a size convenient for processing by the dividing means, and that only the work lots having the group of loads are processed. The work lots are piled up in the pile holding unit of the load cells of the processing means capable of processing them by the pile means, and the load cells of the load cells of the respective processing means and the piles related to the fixed lots held in the fixed lot holding unit The inspection means inspects whether the total load related to the piled lots stacked in the lot holding unit exceeds the processing capacity of the processing means in the unit time zone, and the total exceeds the processing capacity by the inspection. If it is determined that the work load related to the load of the selected group of the work lots held in the piled lot list holding unit of the load cell is Leaving the lot as a load of the processing means within the processing capacity of the processing unit, and to allocate the remaining other other processing means capable hours or their processing of the processing means. As described above, in the method and apparatus of the present invention, knowing that overloading occurs, the work lot is assigned to the processing means capable of processing the processing target, and the overloading occurs. If there is a processing means, the work lot related to the selected group of loads is left as the load of the processing means, and the overflowed portion can be processed by another time zone of the processing means or the type of the processing target. It is arranged to be assigned to other processing means in order. Therefore, even for a process including a processing means having the ability to process a certain processing target and a processing means having the ability to process a processing target of a type different from the certain type, each type of processing target Can be appropriately allocated to a processing means capable of processing, and a simulation of load allocation to such a process, which has been difficult with the conventional apparatus, can be appropriately and quickly performed. In addition, by stacking and displaying this state, the process design engineer, etc. can determine which time zone, day, day of the week, period, etc. the load is concentrated on.
On the contrary, it is possible to intuitively understand which time zone, day, etc. are in a state of low load. As a result, in the case of programming, that is, a case where a good allocation state cannot be easily obtained by a predetermined routine procedure, an engineer directly designs the process based on this intuitively grasped situation. Such processing is also possible.
On the contrary, it is possible to adjust the parameters of the simulation such as the operating time of machines and people, the arrangement, the number of machines and the number of people so that the load state is optimized. With this, it is possible to obtain data for strategic planning such as installation of machines, securing of personnel, and relocation of these.
Further, although the load cell is used in the device of the present invention, by this, the search for the time zone in which the load can be allocated, the check of the load amount in the time zone in which an arbitrary work lot is allocated, and the allocation in the arbitrary time zone are carried out. The operations required for simulation, such as extraction of all the work lots that have been performed, can be executed at high speed. Therefore, the processing time can be shortened, the necessary and sufficient number of simulations can be executed, and the process design and the like can be speeded up and further optimized.

[Brief description of drawings]

FIG. 1 is a block diagram showing a detailed configuration of an embodiment apparatus.

FIG. 2 is a block diagram showing a schematic configuration of an apparatus according to an embodiment.

FIG. 3 is a diagram showing an example of a load table.

FIG. 4 is a diagram showing an example of a plan table.

FIG. 5 is a diagram showing an example of a load cell.

FIG. 6 is a diagram showing an example of a load cell table.

FIG. 7 is a diagram showing an example of product master data.

FIG. 8 is a diagram showing an example of work process master data.

FIG. 9 is a flowchart showing an example of a procedure of pile processing.

FIG. 10 is a diagram showing an example of a result of pile-up and landslide.

FIG. 11 is a diagram showing an example of a group of production loads and their work lots.

FIG. 12 is a diagram showing an example of stacking each work lot on each machine.

FIG. 13 is a diagram showing an example of a state where processing time is shortened.

FIG. 14 is a flowchart showing an example of a procedure of a mountain collapse process.

FIG. 15 is a diagram showing an example of a procedure for creating a priority table (step S11 in FIG. 14).

FIG. 16 is a diagram showing an example of a priority table.

FIG. 17 is a diagram showing a detailed example of the procedure of step S12 of FIG.

FIG. 18 is a diagram showing a detailed example of the procedure of step S14 in FIG.

FIG. 19 is a diagram showing a detailed example of the procedure of step S140 in FIG.

FIG. 20 is a diagram showing a detailed example of the procedure of step S147 of FIG.

[Explanation of symbols]

 31 load of a group 41 dividing means 42 pile means 43 inspection means 44 landslide means 331 load cell

 ─────────────────────────────────────────────────── ─── Continuation of the front page (72) Inventor Satoshi Saito 32-1 Sakado, Takatsu-ku, Kawasaki City, Kanagawa Prefecture KSP R & D Business Park Building Fuji Xerox Co., Ltd. (72) Toru Ogai Sakado, Takatsu-ku, Kawasaki City, Kanagawa Prefecture 3-2-1 KSP R & D Business Park Building Fuji Xerox Co., Ltd.

Claims (2)

[Claims] 1. A load pileup collapse simulation for a processing step including a processing means capable of processing a certain processing target and a processing means capable of processing a processing target of a different type from the certain type. A method of dividing a load of a group into work lots of a size convenient for processing, and assuming that only work lots related to the load of a group are processed, When a pile of processing lots is piled up on a processing means capable of processing and a work lot with a load amount exceeding the processing capacity is piled up, each work lot related to the load of the selected group among the piled work lots is loaded. Remaining, each work lot relating to a group of loads other than the selected group of loads is assigned to another processing time zone of the processing means or another processing means capable of processing them. Load pile mountain break simulation method characterized by performing a process. 2. A load pile up collapse simulation for a processing step including a processing means capable of processing a certain processing target and a processing means capable of processing a processing target of a different type from the certain type. An apparatus, which is provided with a dividing means for dividing a group of loads to be processed into work lots of a size convenient for processing, and one for each processing means per unit time zone. A load cell having a piled lot holding unit for holding the work lots to be piled up to be processed, and a fixed lot holding unit for holding the work lots fixed to be processed in the unit time zone; Assuming that only the work lots related to the load are processed, the respective work lots are piled up on the lot holding unit of the load cell of the processing means capable of processing them. For the stacking means and the load cells of each processing means, the total of the load on the work lot of the fixed lot holding unit and the load on the work lot of the stacking lot holding unit is the processing capacity of the processing unit in the unit time zone. Inspecting means for inspecting whether or not the load exceeds the processing capacity, and when the total exceeds the processing capacity by the inspection, the load of the selected group among the work lots in the pile lot list holding unit of the load cell is The work lot concerned is left as the load of the treatment means within the range of the processing capacity of the treatment means, and each work lot related to the load of the group other than the selected load of the group is treated at another time zone of the treatment means or those Load landslide simulation device, which is provided with another landslide means that can be assigned to other processing means capable of processing.