JPH0557577A - Production programming method and modifying method thereof - Google Patents

Abstract

PURPOSE:To achieve the most efficient production programming under allowable conditions. CONSTITUTION:In a parts manufacturing process, plural equipments S1-Sn for manufacturing parts, equipment control computers SC1-SCn for controlling and managing these equipments S1-Sn, and a master computer MA issuing each production indication to these equipment control computers SC1-SCn according to production programming, respectively are provided. First of all, setting of a prospective equipment level takes place, and these equipments S1-Sn, satisfying the setting level to each prospective equipment working table, are registered in the master computer MA. One equipment being highest in level is selected from the prospective equipment working tables. Then, allotment is carried out according to each number. When this allotment is not carried out, the equipment is removed from the prospective equipment working tables, and the next prospective one is allotted.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a production plan preparation method and a correction method therefor when producing various kinds of parts.

[0002]

2. Description of the Related Art Japanese Unexamined Patent Publication No. 1-277902 describes a method of producing a production plan of this kind. In this publication,
When a job that satisfies the constraint cannot be assigned, the constraint is uniformly relaxed and forcibly assigned, and the job is replaced for improvement later.

[0003]

In such a case, extra calculation time is required. Further, in Japanese Patent Laid-Open No. 1-310848, the type of input is determined depending on whether or not the preset continuous production amount has been reached in response to a next load input request from an equipment terminal that processes parts. I have only decided.

In such a case, there is a problem that the operating rate decreases when equipment trouble occurs. The present invention is provided in view of the above points, and enables the most efficient production plan creation under acceptable conditions.
Further, the present invention provides a production plan creation method and its correction method for the purpose of minimizing a decrease in the operating rate even when equipment trouble occurs.

[0005]

According to the present invention, when a production plan is produced in a production line for producing a plurality of types of parts by a plurality of facilities, a plurality of facilities are registered as levels according to a constraint condition in the production of parts for each product type. The level table is set to create a setting level in which the allowable level for the part is set in advance, and the level table and the setting level are satisfied for the part that is not assigned to which equipment to produce the part. The working table in which the equipment is registered is set, and it is determined whether or not the equipment can be allocated in order from the higher level equipment using the working table, and the production plan is created.

Further, in the second aspect, in a continuous production line in which a plurality of line computers connected to a master computer control the process and machine parts that are continuously input, the cause of trouble and the trouble recovery for each processing equipment are recovered. The recovery time up to is stored as a trouble information table, the trouble cause is sent from the processing equipment to the master computer when a trouble occurs, and the trouble recovery time is estimated by simulation using the above trouble information table in the master computer. The input parts are changed by.

[0007]

Thus, a level table in which a plurality of facilities are registered in levels according to the constraint conditions in the production of parts for each product type is set, and a setting level in which the level allowed for the parts is set in advance is created. Is it possible to set a working table in which the satisfied equipment is registered from the above level table and setting level for parts that are not assigned to which equipment is to be produced, and to allocate from the higher level equipment in order using the working table? By determining whether or not to create a production plan, the most efficient production plan can be created under acceptable conditions.

Further, in claim 2, the trouble factor for each processing equipment and the recovery time until the trouble recovery are accumulated as a trouble information table, and when the trouble occurs, the processing equipment sends the trouble cause to the master computer, and the master computer causes the trouble. Estimate the trouble recovery time by simulation using the information table, and change the parts to be put in according to this estimated recovery time,
Even when equipment trouble occurs, it is possible to minimize the decrease in operating rate.

[0009]

Embodiments of the present invention will be described below with reference to the drawings. FIG. 1 shows a schematic view of a production process according to the present invention,
It consists of two major production lines: the parts manufacturing process and the parts processing process. The component manufacturing process and the component processing process are independent production processes.

In the parts manufacturing process, a plurality of equipments S1 for manufacturing parts, equipment S2 ... Equipment Sn, and equipment control computer SC1, for controlling and managing each equipment S1 to equipment Sn.
SCn and a master computer MA that issues a production instruction to each equipment control computer SC1 to SCn according to the production plan. The equipment S1 ... Manufactures parts and stocks the parts. .. Then, in the subsequent part processing step, the parts are sequentially processed according to the production plan.

In the component processing step, in this embodiment, it is composed of three steps, that is, step 1, step 2 and step 3. In step 1, a machine M1 for processing parts is provided, and the machine M1 is controlled or managed. Line computer L
C1 is provided. In process 2, two machines M
2, M3 and line computer LC2 are arranged,
In step 3, three machines M4 to M6 and a line computer LC3 are arranged.

The machines M1 to M6 have parts in which the machining ranges of parts overlap, and a certain part can be machined by different machines M1 ... Each of the machines M1 ... Is connected by a plurality of conveyors C, and the line computers LC1 to LC3 respectively control or manage the conveyors and machines within the dotted lines. The master computer MB is located above the line computers LC1 to LC3 and communicates information with each other.

Here, in the parts production process, as shown in Tables 1 and 2, each equipment S1 ... Are divided into levels.

[0014]

[Table 1]

[0015]

[Table 2]

Table 1 shows examples of part numbers and candidate equipment levels, and Table 2 shows the contents of the candidate equipment levels. As shown in Tables 1 and 2, the level of equipment contents varies depending on each machine 1 ..., At which stage, the equipment S1 to Sn for manufacturing parts is determined at the production planning stage. For example,
It is assumed that a constraint condition is set such that the candidate equipment level is B. When allocating the part number, the machines 1 and 5 are selected from Table 1 as candidate equipment whose candidate equipment level is B or higher. If the machine 1 can be allocated, the allocation of the part is completed. However, only when the allocation cannot be performed, the machine 5 of the next candidate is allocated. Also, the equipment of the next rank is allocated in order from the equipment of the highest level.

The machine 1 corresponds to the equipment S1, the machine 2 corresponds to the equipment S2, the machine 3 corresponds to the equipment S3 ... FIG. 2 shows a flow in the case of allocating the above-mentioned equipment S1 ... First, the candidate equipment level is set, and the equipment S1 ... which satisfies the setting level in the candidate equipment working table is registered in the master computer MA. Then
The highest level equipment is selected from this candidate equipment working table. Then, allocation is performed according to each part number. If the allocation is not done, remove the equipment from the candidate equipment working table as described above,
Allocate the next candidate equipment.

As described above, by classifying each facility S1 ... In consideration of not only mechanical constraints but also operation in the candidate facility group, the constraint conditions are satisfied and efficiency is improved.
It is possible to make an appropriate production plan. Further, by constructing the candidate equipment group in the above format, it is possible to make a plurality of production plans. In addition, "in the form of considering operation" means the capacity (contents) of each facility S shown in Table 2,
In particular, in the case of D: finishing is required and E: quality testing is required, a new work is required by the operator, so it is desirable that the equipment is not allocated as much as possible.

(Embodiment 2) By the way, in a production line in which a plurality of machines are used for multi-product production, if the work (parts) is processed according to the production plan data, the line load balance is bad due to various circumstances. As a result, the operating rate of the entire production line may decrease.

As a solution, by sequentially grasping each processing line state (conveyor C ..., Processing machine M1 ...) And holding the past average value of the recovery time of the trouble factor of the machine M, Even if a trouble occurs, the cycle time can be converted for each processing line, and by controlling the input of members (parts), it is possible to maintain the operating rate of the entire production line.

In this embodiment, as shown in FIG. 1, the case where the processing machines M in which the processing areas of the parts overlap each other are arranged for each process will be considered as an example. The line computers LC1 to LC3 respectively control or manage the conveyor C and the machine M within the dotted line of each process. The line computers LC1 to LC3 are connected by a bus or the like so that information can be transmitted to each other. The line computer LC1 controls the input of components and the operation management of the machine M1.

At the production planning stage, even if the component loading sequence data that maximizes the operating rate of the entire production line is created, various factors (machine M trouble, maintenance, manual Etc.), the production is often not performed according to the production plan. Therefore, each time a component is input to the production line, it is determined whether or not to input the component registered in the component supply order data, while considering the influence of the line computer LC1 on the operation rate of the entire production line of the component input. If the supply is abandoned, another part that seems to be appropriate is supplied, and the part supply control is performed in consideration of the production situation.

[0023]

[Table 3]

The above-mentioned Table 3 shows a trouble factor table of the machine M. For example, if the trouble content is the abnormality of the hydraulic line filter, the alarm code is 1 and the average recovery time is 120 seconds. The number of occurrences in the past is 5. An alarm code is given in response to each of these various troubles, and the past average recovery time is tabulated to store data in each of the line computers LC1 to LC3.
Registered in.

For example, when a trouble occurs in the machine M5 in the component processing step shown in FIG. 1, the line computer LC3 immediately notifies the alarm code from the machine M5 and immediately reports the past averages from the trouble factor table shown in Table 3. Knowing the recovery time, the line computer LC
Notify 1 and update the trouble factor table. In addition, the line computers LC2 and LC3 move the work (parts) (between the conveyors C, from the conveyor C to the machine M).
Etc.), the line computer LC1 grasps the situation of the entire production line in real time, and the machine M5 puts in the parts that require machining, and the production line Machine M4 or Machine M at the time when it is determined that the overall operation rate is affected
At 6, the parts that need to be processed are put in.

After the machine M5 is restored and it is determined that there is no effect even if the machine M5 puts in a part that requires machining, the part is put in. An example of the closing control based on specific data will be described later,
Even if a trouble occurs in the processing machine M, if it is determined that the operation rate of the entire production line is not affected (by calculating the cycle time), it goes without saying that the input is performed according to the input order data. In short, any other method may be used as long as the various information collected in real time at the time of the above-described component loading can be reflected in the component loading control so as to increase the operation rate of the entire production line.

With this configuration, the operating status of the production line can be grasped in real time, and it can be utilized for the component loading control, so that the efficient operation control of the multi-product production line can be performed at all times. Further, by providing each line computer LC1 to LC3 with the past average recovery time for each trouble factor of the processing machine M when a trouble occurs, the recovery time when a trouble actually occurs can be estimated. Parts can be loaded without significantly reducing the operating rate of the entire line.

Next, the component loading control will be described based on concrete data. Description will be made by replacing the component processing step shown in FIG. 1 with a simplified processing step as shown in FIG.

[0029]

[Table 4]

Table 4 shows the time required for each machine M1, M2, M3 when processing different kinds of parts (part 1 to part 6). Each component can be machined by at least two of the three machines M. Which machine M is machined is performed based on preset component placement order data, or the machine M is abnormal. When it occurs, it is determined based on the recovery time according to the content of the trouble factor.

As shown in FIG. 3, the machining process comprises steps 1 and 2, and three machines M1, M2, M3, and 15 are used.
It is assumed that each of the conveyors C1 to C15 is composed of two line computers LC1 and LC2 and one master computer MB. As shown in Table 4, the machining time of the parts is determined respectively, and those having a horizontal line indicate that the machine M cannot process them.
For example, the component 5 can be machined by both the machine M1 and the machine M3, but which machine M is machined is determined at the production planning stage.

As shown in Table 3, the average recovery time is stored in the table for each trouble of each machine M, and the line computers LC1 and LC2 can estimate the recovery time. The loading control checks whether or not the evaluation standard is satisfied according to the process outline flow shown in FIG. 4 before the component is loaded, and selects the component that satisfies the criteria and instructs the loading.

[0033]

[Table 5]

[0034]

[Table 6]

First, the case where the evaluation criterion is the line operating rate will be described. Table 5 above shows the types of parts and arrival times in each of the machines M1 to M3. In the machine M3, the part 1 arrives at 9:15:00, and in the machine M1, the part 2 arrives at 9:14:30. Then, as shown in Table 6, the component 3 arrives at 9:14:35 on the conveyor C1 which is the component input port.

[0036]

[Table 7]

[0037]

[Table 8]

Table 7 shows the case where the components are sequentially loaded from the component 1, and shows the arrival time and departure time of each component in each of the machines 1 to 3 and the arrival time of the conveyor C15. Further, as will be described later, Table 9 shows the time when the component 5 is inserted before the component 4 in the component insertion order when a trouble occurs. Here, the production plan is determined so as to sequentially insert the parts from the part 1 in Table 4,
In the production process, it is assumed that the parts exist in the states of the tracking information tables in Tables 5 and 6 as described above.

When the conveyor C1 becomes empty, the parts are loaded into the conveyor C1 as soon as the parts are loaded into the machine M.
The processing of the parts is finished at 1 and the parts are sent to the conveyor C2. Then, when the machine M1 becomes empty, the next component is already loaded on the conveyor C1 and is therefore sent to the machine M1. Also, when the conveyor C also becomes empty, the parts move immediately. Furthermore, the time required to move parts between conveyors C is 5
Seconds.

In Table 7, after the component 1 is loaded at 9:13:40, the components are sequentially loaded if the conveyor C1 becomes empty. Focusing on the component 1, it takes 5 seconds to move on the conveyor C1 and arrives at the machine M1, and the machine M1 processes for 40 seconds (from Table 3). Then, it takes 35 seconds to move on the conveyors C2 to C8 and arrives at the machine M3.
Process for 50 seconds (from Table 3). Then, it takes 30 seconds on the conveyor C10 to the conveyor C15 to convey the conveyor C.
Arriving at 15. In this way, the parts 2 ...

If there is no trouble as it is, 9:16:
Master computer MB so that the component 4 is put into the 15
From the line computer LC1. However, at 9:15:10, the alarm code 7 (air abnormality (recovery time: 200 seconds)) in the machine M2 is transmitted from the line computer LC2 to the master computer MB.
Consider when you are notified.

When the simulation is executed as shown in FIG. 4 by using Tables 3 to 8, the following is obtained. That is, as shown in Table 7, even if a trouble occurs,
When the components 1 are sequentially loaded into the component 6 and then the component 4 is loaded as scheduled next to the component 3, the time at which all the components pass through the conveyor C15 is 9:21:15. On the other hand, as shown in Table 8, when the component 5 is inserted and then the component 4 is inserted, the time is 9:20:15.

In other words, in Table 7, for the parts 2 and after, the machine M2 is in trouble during the period from 9:15:10 to 9:18:30 as described above. There is a component 2 on C7, a component 4 on the conveyor C3, a component 5 on the conveyor C2, and a component 6 on the machine M1 (the component 6 cannot be departed from the machine M1 because processing is finished but the front is blocked). There is.

Incidentally, since the conveyor C3 was empty for the component 3, it was processed by the machine M3 through the conveyor C3,
It has already passed the conveyor C15. Focusing on the part 5, when the trouble of the machine M2 is released at 9:18:30, the parts 2 and 4 previously clogged are the machine M2,
In order to move to the conveyor C7, it took 30 seconds from the conveyor C2 to arrive at the machine M3, processed for 100 seconds,
It takes 30 seconds to reach the conveyor C15. However, since it is the same as the part 6, it arrives at the conveyor C15 at 9:21:15 with a delay of 5 seconds.

The parts 2, 4 and 6 are sequentially processed by the machine M2 and passed through the conveyor C15. In Table 8 showing the time relationship when the component 5 is inserted before the component 4, as shown in the simulation result, the component 6 finally passes the conveyor C15, but since it is 9:20:15,
Compared with the case of Table 7 in which the parts are put in order, the parts can be finished at a faster time.

Therefore, in this case, the master computer MB is controlled to instruct the line computer LC1 to insert the component 5 before the component 4. Then, after the trouble is recovered (the master computer MB is notified through the line computer LC2), the data shown in Table 3 in the master computer MB is updated with the actual trouble recovery time.

[0047]

[Table 9]

[0048]

[Table 10]

Next, the case where the evaluation criterion is the delivery date will be described. With the same setting as the case where the above-mentioned evaluation standard is the line operation rate, in this case, when the alarm code 1 (hydraulic line filter abnormality (recovery time 120 seconds)) is notified from the machine M1 at 9:15:10. think of. The trouble factor table of Table 3 should be held for each machine M, but the same one is used here.

Assuming that the component 6 is 9: 2 on the conveyor C15.
If you had to pass by 1:00,
As shown in Table 9, the simulation result when the components 4 and subsequent components are sequentially inserted according to Table 4 is that the component 6 passes through the conveyor C15 at 9:21:40, as shown in Table 9. on the other hand,
As shown in Table 10, the simulation result when the component 6 is loaded instead of the component 4 is that the component 6 passes through the conveyor C15 at 9:20:50, and an instruction to load the component 6 is issued by the master computer. Output from MB to line computer LC1. Further, similar to the above, after the trouble recovery, the recovery time in Table 3 is updated with the actual recovery time.

The machine M1 for each part shown in Table 9 and Table 10
The method of calculating the arrival times and departure times of M3 to M3 and the arrival time of the conveyor C15 is the same as in Tables 7 and 8, and thus the description thereof is omitted.

[0052]

As described above, the present invention sets a level table in which a plurality of facilities are registered as levels according to the constraint conditions in the production of parts for each product type, and the level allowed for the parts is set in advance. Create a level, set a working table in which the equipment that satisfies the requirements is registered from the level table and setting level for the parts that are not assigned to which equipment the high-level equipment is to be used. It is possible to make the most efficient production plan under acceptable conditions by determining whether or not allocation is possible in order and creating the production plan.

Further, in claim 2, the trouble factor of each processing equipment and the recovery time until the trouble recovery is accumulated as a trouble information table, and when the trouble occurs, the processing equipment sends the trouble cause to the master computer, and the master computer causes the trouble. Estimate the trouble recovery time by simulation using the information table, and change the parts to be put in according to this estimated recovery time,
Even when equipment trouble occurs, it is possible to minimize the decrease in operating rate.

[Brief description of drawings]

FIG. 1 is a schematic configuration diagram showing manufacturing and processing steps of a component according to an embodiment of the present invention.

FIG. 2 is a flow diagram when selecting the above equipment.

FIG. 3 is a schematic configuration diagram of a main part of the above-described processing step.

FIG. 4 is a flow chart in the case of selecting a component to be inserted next when the same trouble occurs.

[Explanation of symbols]

 S1 to Sn equipment SC1 to SCn equipment control computer MA master computer M machine LC1 to LC3 line computer C conveyor MB master computer

Claims (2)

[Claims] 1. When creating a production plan in a production line for producing a plurality of types of parts with a plurality of facilities, a level table is set in which a plurality of facilities are registered as levels according to a constraint condition in the production of parts for each product type, and the level table is set in advance. Create a setting level that sets the allowable level for parts, and set a working table that registers the satisfied equipment from the above level table and setting level for parts that are not assigned to which equipment to produce the part. A production plan creating method characterized in that the working table is used to determine whether or not allocation is possible in order from a higher level of equipment to create a production plan. 2. In a continuous production line in which a plurality of line computers connected to a master computer perform process control to process parts that are continuously input, the trouble factors of each processing equipment and the recovery time until trouble recovery are set. Accumulates as a trouble information table, sends the cause of trouble from the processing equipment to the master computer when a trouble occurs, estimates the trouble recovery time by simulation using the above trouble information table in the master computer, and changes the parts to be inserted by this estimated recovery time A method of correcting a production plan, characterized in that