JPH07178653A - Method and device for controlling production ratio - Google Patents

Abstract

PURPOSE:To provide a production ratio control method whereby a fluctuating width of a number of stocks can be decreased by immediately detecting a fluctuation of a number of the stocks properly corrected in a multikind lot production line. CONSTITUTION:A number of products, production-indicated by a production device M4 in a production-indicated product quantity detecting process M12, and a number of products, carried out from a product storage device M8 in a carry out product quantity detecting process M14, are detected in each kind. Based on these detection results, a number of products in a process, including from the production device M4 to the product storage device M8, is calculated in each kind in an in-process product quantity calculating process M16. Production ratio in each kind calculated from this number of products is compared with reference production ratio based on a production program in a production condition good or bad decision process M20, to decide a production condition for whether good or bad. Based on a decision result in this production condition good or bad decision process M20 and the production program M18, in a production correction indicating process M22, a kind and quantity of the product, produced in the production device M4, are determined to indicate correction.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a production ratio control technique for controlling a production ratio between various types in a multi-product type production line capable of producing and processing a plurality of types of products. Even if an article produced in this multi-product production line is a part in the next process, it is a product in this multi-product production line, and is therefore referred to as a product in this specification. Further, in this specification, when the term "production" or "production processing" is used, it means that some kind of manipulation is applied to the material, for example, not only processing operations such as cutting
It covers a wide range of operations related to production, such as assembly of parts.

[0002]

2. Description of the Related Art In a multi-product type production line capable of producing and processing a plurality of types of products, the production ratio is controlled in order to keep the production ratio between the products at a ratio defined in a production plan. As a specific example of such a production ratio control method, there is, for example, an invention of a method for determining a work input using a programmable controller described in Japanese Patent Laid-Open No. 61-265251. In the technique described in this publication, a production instruction is given in a multi-product production line on the basis of a leveling table that defines the production frequency and production sequence among various products based on a production plan. When there is a large amount of stock on the back process side of the type for which a production instruction is to be issued, the production instruction is stopped and the next order type is instructed.

The specific contents of this production ratio control method will be described with reference to FIGS. FIG. 22 shows
It is a schematic diagram which shows the whole structure of the multi-product production line to which the production ratio control method of the prior art is applied. In the multi-product production line 102 shown in FIG. 22, three networks 170A, 170B, 170C branched from the network 170 connected to the main computer device 180 are connected to the production instruction devices 110A, 110B, 110C, respectively. . In addition, four stock conveyors 130, 14
Between 0,150,160, three production processing devices 13
6,146,156 are provided. The second stock conveyor 140, the third stock conveyor 150, and the fourth stock conveyor 160 are provided with ratio change detection sensors 142, 152, 162 for each type.
The ratio change detection sensors 142, 152, 162 are connected to the production instruction devices 110A, 110B, 110C by detection signal lines 124A, 124B, 124C, respectively. In addition, the production instruction devices 110A, 110B, 11
From 0C, the instruction signal lines 128A, 128B, 128C
Are the first to third stock conveyors 130, 140, 15
0 carry-out devices 134, 144, 154, respectively.

The production in the multi-product production line 102 is performed as follows. First, the production instruction device 11
When a predetermined signal is output from the carry-out device 134 from 0A, the articles P ₁ in the first stock conveyor 130,
P ₂ and P ₃ are carried out and moved to the production processing device 136. Each product is carried into the second stock conveyor 140 after being subjected to a predetermined process in the production processing device 136. Similarly, in response to a signal from the production instruction device 110B, the unloading device 144 unloads the articles P ₁ , P ₂ , and P _{3 from} the second stock conveyor 140 and transfers them to the production processing device 146. Here, the article P ₁ is processed into two types of articles P ₁₁ and P ₁₂ , and then the other parts P ₂ and
It is carried into the third stock conveyor 150 together with P ₃ . The steps in the production instruction device 110C, the carry-out device 154, and the production processing device 156 are performed in the same manner. Here, the ratio change detection sensors 142, 152, 162 are provided one by one at a predetermined position in the storage space for each type of the second to fourth stock conveyors 140, 150, 160. In this storage space, parts are stored in order from the right end of each stock conveyor in FIG. 22, and when a predetermined number is reached, the ratio variation detection sensor 14
2, 152, 162.

Now, let us consider a case in which, in the production processing step, only the step of producing the parts P ₁₁ and P ₁₂ from the part P ₁ by the production processing device 146 is temporarily stopped. In this case, the number of parts P ₁ carried out from the second stock conveyor 140 is reduced, and the parts P ₁ carried in from the production processing device 136 are reduced.
, The number of parts P ₁ stored in the second stock conveyor 140 gradually increases. as a result,
The ratio change detection sensor 142 outputs a detection signal indicating that the number of stored parts P ₁ is excessive to the production instructing device 110A, and in response thereto, the production instructing device 110 causes the production amount of parts P ₁ to be carried out from the first stock conveyor 130. Is controlled to be smaller than usual.

FIG. 23 shows the specific contents of this control.
Will be described with reference to. FIG. 23 is a diagram showing an example of a leveling table used in the conventional production ratio control method.
Based on the production plan, the ratio of the production quantities of the parts P ₁ , P ₂ , P ₃ is set in advance to, for example, 3: 2: 1. No. of the leveling table 1-No. Based on this ratio, the numbers of instructions ₁ , ₂ , ₃ corresponding to the component types P ₁ , P ₂ , P ₃ are assigned to up to 200 frames. Here, the number of 100 series (101, 1
02, 103) are assigned. The number in the 100s is an instruction number which means that the instruction is omitted when the production ratio deviates from the schedule, whereby the production ratio is adjusted. That is, in the frame in which the number 101 in the 100s corresponding to the part P ₁ is designated, the part P ₁ is normally carried out or produced and processed. However, as described above, when the ratio fluctuation detection sensor 142 in FIG. 22 detects that the number of stored parts P ₁ is excessive, the number of indicated frames is 101 (for example, frame N).
o. 1, No. 21, ...) is ignored and the next frame is instructed.

In the production ratio control method described in the above publication, the number of instructions 1 in the leveling table shown in FIG. 23 is 1.
In response to to 3, product type P ₁ to P ₃ are produced one by one. However, in a casting process, for example, lots of products of the same type are collectively produced in some cases, because it takes a long time to replace the molds. Consider a case where the above production ratio control method is applied to such a multi-product lot production line. In this case, a plurality of types of products are produced in lot units based on the leveling table as shown in FIG. 23, and the produced products are stored in the stock conveyors by type as shown in FIG. Is stored in. Then, when the number of stored articles exceeds a certain number, the ratio change detection sensor provided for each type outputs a ratio change signal. FIG. 24 is a flowchart showing the control procedure in this case. The control program shown in this flowchart is executed in the main computer device of the multi-product lot production line corresponding to the main computer device 180 in FIG. Step S120
When the control is started in, the variable j is first set to the initial value 1 (step S122). The variable j is the frame No. of the leveling table shown in FIG. Is a number corresponding to. continue,
The variable i is set to the initial value 1 (step S124). This variable i corresponds to the type P _i of the part.

Next, the frame No. of the leveling table. It is determined whether the type P _i is designated by j (here, 1), that is, whether the ones digit of the designated number D _j is i (step S12).
6). Here, if the ones digit of the designated number D _j is not i, in step S128, i = i + 1 is set, and then step S is performed again.
A determination of 126 is made. The determination in step S126 is Y
If it is ES, it is determined whether or not the number of instructions D _j is in the 100s (step S130). If D _j is not in the 100s, the process proceeds to step S134, and the instructed number D _j is transferred to the lot production instructing device. In response to this, the lot production instructing device instructs the production of a unit lot of the product type P _i and returns an instruction end signal to the main computer device (step S136). On the other hand, if D _j is in the 100s, the process proceeds to step S132, and it is determined whether the ratio change signal for the type P _i is ON. Then, when the ratio change signal is OFF (the ratio fluctuation detection signal of the type P _i is not output), the instruction number D _j is transferred (step S1).
34) and the return of the instruction end signal (step S136) are executed. On the other hand, when D _j is in the 100s and the ratio change signal is ON, the instruction by the instruction number D _j is not executed, and the process proceeds to step S138 and j = j + 1. Then, it is judged whether or not the number of frames j exceeds 200 (step S140). If j does not exceed 200, the process returns to step S124, and if j exceeds 200, the process returns to step S122 and the same process is repeated. .

[0009]

However, according to such a conventional production ratio control method, since the production quantity can be increased / decreased only in lot units, the inventory quantity greatly decreases due to a minute excess of the inventory quantity. I will end up. This phenomenon becomes more remarkable as the lot size (the number of products produced per unit lot) increases. Further, in the conventional production ratio control method, the stock quantity is detected in the product storage unit, and the detection result is used as a signal for the production ratio control. The larger the production lot, the longer the lead time in general, and it takes a long time for the effect of the ratio change control to appear as a change in the number of stocks, so the appropriate timing of the production ratio control is missed. For these reasons
The fluctuation range of the number of stocks or the stock ratio in the multi-product lot production line becomes very large, and in order to cover this, the storage space must be extremely large,
There was a problem that it was very inefficient. Therefore, in the present invention, in a multi-product production line including lot production, the fluctuation range of the number of products produced is detected by detecting the fluctuation of the stock quantity without time delay and making an appropriate correction according to the degree of the fluctuation. An object of the present invention is to provide a production ratio control method that can be reduced.

[0010]

In order to solve the above problems, the production ratio control method according to the invention of claim 1 is configured as follows. That is, this production ratio control method includes: a production device that produces a plurality of types of products, and lot-produces at least one type of the product; and a product storage device that stores the products produced by the production device for each type. A method for controlling the production ratio of the plurality of types of products according to the production ratio between the plurality of types of products determined based on a production plan in a multi-product production line having A production instruction product number detection step of detecting the number of production-instructed products for each type,
Based on the detection result in the carried-out product number detection step of detecting the number of products carried out from the product storage device for each type, the production instruction product number detection step and the carried-out product number detection step, from the production device The in-process product number calculating step for calculating the number of products in the process including the product storage device for each type, the production ratio for each type calculated from the number of products calculated in the in-process product number calculating step, and the above A production status pass / fail judgment step of determining whether the production status is good or bad by comparing with a standard production ratio, and a type and quantity of a product to be produced in the production apparatus based on the determination result in the production status pass / fail determination step and the production plan. And a production correction instructing step for determining and instructing.

Here, it is desirable to use a production ratio control method in which, in the in-process product number calculation step, the number of products extracted in the multi-product type production line is also taken into account for calculation (claim 2). Correspondence). Further, it may be a production ratio control method for correcting the number of production instructed products according to the production plan when the determination result in the production situation quality determination step is negative (corresponding to the invention of claim 3). Further, a production ratio control method may be adopted in which the production plan is changed when the determination result in the production situation quality determination step is not lower than the second determination level (corresponding to the invention of claim 4).

Further, in order to solve the above-mentioned problems, a production apparatus for producing a plurality of types of products, and at least one type of the product is lot-produced, and the products produced by the production apparatus are stored for each type. In a multi-product production line having a product storage device, a device for controlling the production ratio of the plurality of types of products in accordance with the reference production ratio between the plurality of types of products determined based on the production plan. A production instruction product number detection means for detecting the number of products instructed to be produced in the production apparatus for each type, and a delivery product number detection means for detecting the number of products delivered from the product storage device for each type, The number of products in the process including from the production device to the product storage device based on the detection results of the production instruction product number detection means and the carried-out product number detection means Comparing the in-process product number calculation means for each type, the production ratio for each type calculated from the number of products calculated by the in-process product number calculation means, and the reference production ratio And a production correction instructing means for determining and instructing the type and quantity of the product to be produced in the production device based on the determination result in the production status inferiority determination means and the production plan. A production ratio control device provided with is created (corresponding to the invention of claim 5).

Further, in the production ratio control method according to claim 1, between the production status good / bad determination step and the production correction instruction step, the determination result in the production status good / bad determination step, the production ratio, the production device, and Based on the operating rate of the product storage device, a production correction number determining step of determining the production correction number for correcting the number of products instructed to be produced in the production apparatus for each type, and in the production correction instruction step, It is more preferable that the production ratio control method according to claim 1 is characterized in that the production quantity produced in the production apparatus is corrected for each type based on the production correction number. Corresponding to).

Further, in the production ratio control device according to claim 5, a production instruction is issued in the production device based on the determination result by the production status good / bad determination means, the production ratio, and the operating rates of the production device and the product storage device. The production correction number determining means for determining the production correction number for each type for correcting the number of products to be produced, and the production quantity correcting means determines the production quantity produced in the production device based on the production correction number. It is more preferable to use the production ratio control device described in claim 5 which is corrected for each type (corresponding to the invention of claim 7).

[0015]

The operation of the production ratio control method according to claim 1 is
This will be described with reference to FIG. As shown in FIG. 1, in this production ratio control method, a plurality of types of products M6 to M6 are produced, and a production device M4 for producing at least one type of product in a lot, and a product produced by the production device M4. M6
In a multi-product production line M2 having a product storage device M8 for storing each type of products M6 to M6, a plurality of types of products M6 according to a standard production ratio among the plurality of types of products M6 to M6 determined based on the production plan. ~ M6 is a method for controlling the production ratio. As shown in FIG. 1, in this method, first, in the production instruction product number detection step M12, the number of products instructed to be produced by the production apparatus M4 is detected for each type. Next, in the carried-out product number detection step M14, the number of products carried out from the product storage device M8 is detected for each type. Then, in the in-process product number calculation step M16, based on the detection results in the production instruction product number detection step M12 and the carried-out product number detection step M14, the number of products in the process including the production apparatus M4 to the product storage apparatus M8 is different. It is calculated for each. Subsequently, in the production status good / bad determination step M20, the production ratio for each type calculated from the number of products calculated in the in-process product number calculation step M16 is compared with the reference production rate, and the quality of the production status is determined. It Then, in the production instructing step M22, the type and quantity of the product to be produced in the production apparatus M4 are determined and instructed based on the determination result in the production situation quality determining step M20 and the production plan M18.

As described above, in the production ratio control method according to the first aspect, the entire process including the production device M4 to the product storage device M8 is regarded as one pseudo storage space, and the production device M4 instructs production. It is counted as the number of stocks when it is given. Therefore, there is no influence of the time delay from the production in the production apparatus M4 until the production is stored in the product storage apparatus M8, and the fluctuation of the stock number is detected in real time, no matter how large the production quantity per unit lot is. can do. Further, in the production instructing step M22 for correcting the production ratio based on the determination result of the production situation and the production plan M18, not only the kind of the product but also the quantity to be produced is instructed, so that the degree of the fluctuation of the stock quantity can be reduced. It is possible to make an appropriate correction according to the above. In this way, in the production ratio control method according to the first aspect, it is possible to reduce the fluctuation range of the number of products produced in a multi-product production line including lot production.

Further, in the production ratio control method according to the second aspect, since the number of products withdrawn in the process is also taken into consideration in the process in-process product number calculation step,
The stock quantity in the process can be detected more accurately, and more appropriate production ratio control can be performed. Further, in the production ratio control method according to the third aspect, when the determination result in the production status quality determination step is negative, the number of products instructed to be produced by the production plan is corrected, so that an appropriate size is corrected. be able to. Further, in the production ratio control method according to claim 4, in the multi-product production line, the production plan is changed by changing the production plan when the decision result in the production situation pass / fail decision step is not less than the second decision level. When some abnormality or the like causes a large change in the stock quantity, the production plan is fundamentally changed and dealt with, whereby effective production ratio management can be performed.

Further, in the production ratio control device according to the fifth aspect, the entire process including the production device M4 to the product storage device M8 is regarded as one pseudo storage space, and the production device M4 instructs production. It is counted as the number of stocks when it is given. In the production correction instruction means,
Indicate not only the type of product to be produced but also the quantity. Therefore, in a multi-product production line including lot production, it is possible to detect fluctuations in the number of stocks without time delay and make appropriate corrections according to the degree of fluctuations, and to reduce fluctuations in the number of products produced. You can

Further, in the production ratio control method according to the sixth aspect, in the production correction number determining step provided between the production status determining step and the production correction instructing step, the determination result in the production status determining step Based on the production ratio and the operating rates of the production device and the product storage device, the production correction number for correcting the number of products instructed for production in the production device is determined for each type. Then, based on the production correction number, the production quantity produced by the production device is corrected for each product type in the production correction instructing step. By this, in the production correction instruction process, the production quantity is not always mechanically corrected by a fixed correction number, but
The correction is performed by the appropriate number of corrections according to the actual stock status, production status, or future production schedule at that time.
Therefore, it is possible to surely prevent the situation where the number of stocks or the stock ratio of the type becomes too large or too small by correcting the production quantity with the fixed correction number. As described above, in the production ratio control method according to the sixth aspect, the deviation from the proper production ratio is always kept to a minimum by setting the correction range of the production quantity optimally according to the production situation at that time. be able to.

Further, in the production ratio control device according to the seventh aspect, the production correction number determining means produces the production rate based on the determination result of the production quality determining means, the production ratio, and the operating rate of the production device and the product storage device. A production correction number for correcting the number of products instructed to be produced by the apparatus is determined for each type. Then, based on the production correction number, the production correction instructing means corrects the production quantity produced by the production apparatus for each product type. As a result, in the production correction instructing means, the production quantity is not always mechanically corrected by a fixed number of corrections, but by a fixed number of corrections.
The most appropriate value is determined according to the actual stock situation at that time. Therefore, by correcting the production quantity with a fixed correction number, it is possible to surely prevent the situation where the number of stocks or the stock ratio of the type becomes excessive or insufficient,
The deviation from the proper production ratio can always be kept to a minimum.

[0021]

【Example】

First Embodiment Next, a first embodiment embodying the present invention will be described with reference to FIGS. FIG. 2 is a diagram showing an overall configuration of a multi-product type production line to which the first embodiment of the production ratio control method and the production ratio control device according to the present invention is applied. The multi-product production line 1 shown in FIG. 2 has three casting machines 2.
0, 22, 24, a heat treatment furnace 28, an intermediate storage 32, and a processing step 36 are mainly configured. The processing step 36 is connected to a subsequent subsequent step. Each of the three casting machines 20, 22, 24 has two shuttles 20A, 20B, 22A, 22B, 24A, 24B.
Is equipped with. Lot production is performed in both shuttles. Of these shuttles, shuttle 20
A and 22A are multi-casting shuttles for casting multiple types of products, and the remaining shuttles 20B, 22B, 24
A and 24B are dedicated shuttles that cast only one type. Each casting machine 20 to 24 can distribute hot water to only one shuttle at a time (supplying molten metal as a casting raw material), but during the waiting time for cooling and solidification of one shuttle, the hot water is distributed to the other shuttle alternately. By performing casting, efficient casting is possible. The casting cycle time for each product is about 3 minutes and the lot size is 180 pieces. Therefore, the lead time for lot production is about 9 hours.

A transfer device 26 is provided between the casting machines 20, 22, 24 and the heat treatment furnace 28. The transfer device 26 sequentially picks up the products cast by the shuttles 20A to 24B, moves them in the direction of the arrow, and carries them into the heat treatment furnace 28. The heat treatment furnace 28 is a line of one line, and each type of product cast by each shuttle is mixedly loaded on a pallet in units of 50 pieces and flowed. The lead time of this heat treatment process is 10 hours, and the number of products in the process is about 15
It will be 00. The product that has exited the heat treatment furnace 28 has an inspection process 3
After passing 0, it is stored in the intermediate storage 32. This intermediate storage 32 includes four storage spaces 32A, 32B,
32C and 32D are provided, and the products that have passed the inspection are stored for each type. Intermediate storage 32 and machining process 3
A carrier device 34 is provided between the carrier 6 and the carrier 6. This transfer device 34 is
Products are carried out from the intermediate storage 32 for each type.
The processing step 36 includes four processing devices 36A, 36B, 36.
It has C and 36D, and performs post-processing of the product.

In the multi-product production line 1 having such a configuration, the production ratio control device 2 of this embodiment is provided. The production ratio control device 2 includes a production management computer 4, a production result collecting device 6, a ratio production instructing device 8, a selecting device 10, two lot production instructing devices 12, 14, an inventory display device 16, and a take-back performance collecting device 18. It is configured as the center. The production control computer 4 has a central processing unit (CPU), a RAM, a memory device such as a ROM, and an input / output interface. These CPU, RAM,
The ROM and the input / output interface are connected to each other via a bus so that data can be transferred between them. Further, the input / output interface is connected to the above-mentioned production record collecting device 6, the ratio production instructing device 8, the selecting device 10, the two lot production instructing devices 12, 14, the inventory display device 16, and the collection record collecting device 18 by the data cable 40. It is connected.
The production performance collecting device 6 is used for each shuttle 2 of the casting machines 20 to 24.
0A to 24B are connected to the signal line 42, and a signal indicating the production record is input to the production record collector 6 every time casting is performed on each shuttle.

The ratio production instructing device 8 is connected to the selecting device 10 by a signal line 44, and the selecting device 10 is further connected by a signal line 46 to the lot production instructing devices 12, 14.
Connected with. The lot production instruction devices 12, 14 are
By the signal line 48, the multi-casting shuttles 20A, 22A
Connected with. That is, the lot production instruction device 1
The production instruction by 2, 14 is the multi-casting shuttle 20A,
22A only. An inventory display device 16 having a display screen for displaying inventory is provided near the inspection step 30. This inventory display device 16
Through the data cable 40, the data of the production record collecting device 6 and the ratio production instructing device 8 are fetched to display the inventory quantity on the display screen, and the inventory quantity data is transferred to the production management computer 4. Further, the intermediate storage 3
In the vicinity of the unloading side of No. 2, a collection record collecting device 18 is provided. The collection record collection device 18 outputs the data of the number of products (collection number) carried out from the intermediate storage 32 to the inventory display device 16 through the data cable 40.

The data flow in the production ratio control device 2 will be described in more detail with reference to FIG. FIG. 3 is a block diagram showing the connection of each part of the production ratio control device 2 and the flow of data. In the production control computer 4, a production instruction task and an inventory control task are constantly executed. The production instruction task is directed to the ratio production instructing device 8 according to the equalization table determined based on the intended production plan, and the instruction number data in the leveling table (D _{j in} FIG. 23).
To send. From the ratio production instructing device 8, the selecting device 10
In response, a gimmicking instruction is issued based on the leveled data table. In the selection device 10, the two lot production instruction devices 1 according to the operating status based on the device instruction.
Either 2, 14 is selected. Then, the in-process instruction data is transferred to the selected lot production instruction devices 12, 14. As described above, the lot production instruction device 1
When No. 2 is selected, No. No. 1 casting machine 20. 1
-1 when the shuttle production is performed in the shuttle 20A and the lot production instruction device 14 is selected. 2 casting machine 22
No. Casting is performed in the 2-1 shuttle 22A.

In parallel with this, the production control computer 4
From each dedicated shuttle 20B through a signal line not shown,
The production instruction signal is also output to the 22B, 24A, and 24B, and the dedicated shuttles 20B, 22B, 24A, and 24 are provided.
Casting in B is performed. Each casting machine 20, 22, 24
The casting in 1 is performed alternately with the two shuttles as described above. Then, every time casting is performed in each of the shuttles 20A to 24B, a signal indicating the production record is transferred to the production record collecting device 6. Production record collector 6
Collects the production record signals by type and sends them to the inventory display device 16. On the other hand, the products cast in the shuttles 20A to 24B are stored in the intermediate storage 3 as described above.
It is put in the warehouse 2 and is delivered in response to a request from a subsequent process (processing step 36 in FIG. 2). Every time a product is delivered from the intermediate storage 32, a signal indicating the take-back record is transferred to the take-back record collecting device 18. The collection record collection device 18 collects the collection record signals by type and transmits them to the inventory display device 16. The inventory display device 16 calculates the in-process inventory number and the in-process inventory ratio and displays the in-process inventory number based on the production result signal and the take-back result signal. And the data of the number of in-process inventory is the production management computer 4
The inventory management task of the production management computer 4 corrects and displays the inventory quantity. The control by the production instruction task is executed based on the data of the stock quantity.

Next, details of the control procedure in each device will be described with reference to FIGS. First, regarding the contents of the production instruction task of the production management computer 4,
This will be described with reference to FIG. The production instruction task is started in step S10, and initial data is first input (step S12). The input initial data is the type i (0 <i ≦ N) of the product to be cast, the lot size NR, the total production number S (i) by type, and the dedicated machine production number S1 by type.
(I), in-process reference inventory quantity Z, correction quantity H (i) corresponding to the correction range for controlling the production ratio, advance notice value DY for displaying the mold replacement time, delay reference value KL (i) , Advance reference value KF (i). Here, the "dedicated machine" means a dedicated shuttle 2 that casts only one type of product.
Refers to 0B, 22B, 24A and 24B. Of these initial data, the lot size NR, the correction number H (i), and the advance notice value DY for the two lot production instruction devices 12,
14 is transferred (step S14).

Next, using these initial data, the value required for the ratio control is calculated (step S16).
The calculated values are the total production ratio R (i) for each type, the general-purpose machine production number S2 (i), the general-purpose machine production ratio R2 (i), the in-process reference inventory ratio KZ (i), and the delay reference value DL.
(I), advance reference value DF (i). Here, the "general-purpose machine" refers to the multi-casting shuttles 20A and 22A that cast a plurality of types of products. Each of these values is calculated according to the following formulas. R (i) = S (i) / ΣS (i) (1) S2 (i) = S (i) -S1 (i) (2) R2 (i) = S2 (i) / ΣS2 (i) (3) KZ (i) = R (i) (4) DL (i) = R (i) * Z * (1-KL (i)) (5) DF (i) = R (i) * Z * (1 + KF (i)) (6) Of these values, the in-process reference inventory ratio KZ (i), the delay reference value DL (i), and the lead reference value DF (i) are the inventory display device 16 (Step S18). continue,
A leveled data table is created from the data of the general-purpose machine production number S2 (i) (step S20). The created leveled data table is transmitted to the ratio production instructing device 8 (step S2).
2) Then, the production instruction task ends (step S2).
4).

Next, the contents of the inventory management task in the production management computer 4 will be described with reference to FIG. The stock management task is started in step S28, and the actual production quantity DZ (i) (= SE (i) -HK (i)) in the process is displayed on the display of the production management computer 4.
The collection results and the stock quantity are displayed (step S3).
0). These values are input from the inventory display device 16 at. Next, when the correction instruction is input from the inventory display device 16 in, the correction display is performed on the display (step S32). Succeedingly, in a step S34, it is determined whether or not the in-process inventory quantity is corrected. The in-process inventory quantity is corrected when, for example, a stockout occurs due to a product defect in the inspection process 30 of FIG. In such a case, the operator manually inputs the number of missing items in the production management computer 4. As a result, the determination in step S34 becomes YES,
The in-process inventory quantity is corrected (step S36). After that, the process returns to step S30 again, and the in-process production number and the like are displayed. If the determination in step S34 is no, the inventory management task ends (step S3).
8).

Next, the control procedure in the ratio production instructing device 8 and the selecting device 10 will be described with reference to FIG. The control in the ratio production instructing device 8 is started by transferring the leveled data table from step S22 in the production instructing task of the production management computer 4 described above in FIG. As a result, the leveling data table is written in the ratio production instructing device 8 (step S40). Then, a device instruction is given based on the leveled data table (step S42). Then, this device instruction data is transferred to the selection device 10 (step S44).

Upon receipt of the device-instruction data, the selection device 10 displays the product type for which the device-instruction is instructed (step S46). By this display, the operator can know the type of the instructed device, and if necessary according to the production situation or the like, the operator can manually select the lot production instructing device without relying on the automatic processing after step S48. To do. Here, the selection device 10 selects a lot production instruction device. That is, in step S48, N
o. It is determined whether or not the in-process instruction in the one-lot production instructing device 12 has been completed. This judgment result is YES
If so, No. Device data is transmitted to the 1-lot production instructing device 12 (step S50), and No. The production instruction by the one-lot production instruction device 12 is executed. On the other hand, if the decision result in the step S48 is NO, a step S52
Proceed to No. It is determined whether or not the in-process instruction in the two-lot production instruction device 14 has been completed. If this determination result is YES, No. 2 lot production instruction device 14
Device data is transmitted to the device (step S54), and No.
The production instruction by the two-lot production instruction device 14 is executed.

On the other hand, if the decision result in the step S52 is also NO, the process returns to the step S48 and the No. It is determined whether or not the in-process instruction of the one-lot production instruction device 12 is completed. Normally, two lot production instruction devices 1
Since either 2 or 14 is in the device instruction completion state,
Either the process of step S50 or step S54 is executed, and the process shifts to the process in the lot production instruction device 12, 14. In addition, in the above step S46, it is also possible to adopt a method in which the device type is displayed for a plurality of candidates based on the leveling table and the operator selects one of the candidates. In this case, the worker selects the optimum product type in consideration of the production situation (necessity of change of stage, etc.) and the lot production instruction device corresponding to this regardless of the processing of steps S48 to S54. To send the instruction data.

Next, a control procedure in the lot production instruction device will be described with reference to FIG. In FIG. The control procedure in the 1-lot production instructing device 12 is shown. The control procedure in the two-lot production instruction device 14 is also the same. No. The process in the 1-lot production instructing device 12 is started by transmitting the device data from the selecting device 10 described above. First, in step S56, the presence or absence of a device request is determined. If the determination result is NO, step S56.
Return to and wait until YES. The judgment result is YES
If so, a device instruction is given (step S58), and the two shuttle Nos. 1-1 and No. Hot water is alternately distributed to 1-2 (step S60). Various shuttle No. If hot water is distributed to 1-1, step S
After the completion of pouring is confirmed at 64, a pouring completion signal is transmitted to the production record collecting device 6 as indicated by.
Then, in step S66, it is determined whether or not there is a correction request. The determination as to whether or not there is a correction request is executed only when there is a stage change request. If there is a change request,
This is indicated by turning on a stage change warning lamp (not shown). This stage change warning lamp automatically lights up at the end of each lot regardless of whether the type of product to be cast next is changed or not. In this case, it is determined whether a correction request has been made, that is, whether a correction instruction has been issued from the inventory display device 16 described later.

The determination result in step S66 is YES.
In the case of, the correction flag is turned on (step S6).
8). Then, in step S72, it is determined whether or not the lot is finished. On the other hand, if the decision result in the step S66 is NO, after the correction flag is turned off, the process advances to a step S72. If the decision result in the step S72 is YES, that is, if the production of one lot is completed, the process advances to a step S76 to decide whether or not the stage change is necessary. This determination is performed when the above-mentioned stage change warning lamp is lit. Then, the operator determines based on whether the type of the product to be cast changes, the state of the mold, and the like. That is, when the type of the product to be cast changes, the stage change is always performed, but even when the type of the product does not change, the stage is changed to a new mold depending on the state of the mold. In this embodiment, at the end of the lot, the operator manually turns off the stage change warning lamp to prepare for the next lot production. However, instead of such a manual operation, the light may be automatically turned off when it is determined that the lot is finished in step S72.

If it is determined in step S76 that a stage change is necessary, after the stage change work is performed in step S62, the process proceeds to step S60 to continue casting. On the other hand, if the decision result in the step S76 is NO, a step S78 decides whether or not the correction flag is ON. If the determination is NO, the device-instruction instruction is completed (step S82), and a device-instruction completion signal is transmitted to the ratio production instruction device 8 and the selection device 10, as shown in FIG. On the other hand, if the determination result in step S78 is YES, that is, if the correction flag is ON, it is determined in step S80 whether the correction counter is up. If this determination is YES, it proceeds to step S82, and if NO, it is step S5.
Returning to 6, the above-mentioned casting process is repeated.

Next, the control procedure of the production record collecting device 6, the inventory display device 16, and the take-back record collecting device 18 will be described with reference to FIG. In the production record collecting device 6, the production record SE (i) for each type is counted in response to the input of the pouring completion signal described above (step S84). On the other hand, in the intermediate storage 32, storage of products from the casting machine (step S110),
Stock (step S112), shipping (step S11)
4) is performed. The collection record collection device 18 counts the collection record HK (i) for each type according to the delivery (step S116). The data of the production record SE (i) and the collection record HK (i) are stored in the inventory display device 16
The inventory display device 16 calculates the in-process inventory quantity for each type based on these (step S86).
Then, the calculated in-process inventory quantity is displayed on the display screen of the inventory display device 16 (step S88). This in-process inventory quantity is also transferred to the production instruction task of the production management computer 4, as shown in FIG.

Next, in step S90, it is determined whether or not the inventory record (in-process inventory quantity) DZ (i) is to be modified. When the in-process inventory quantity is corrected in the inventory management task of FIG. 5, the data is transmitted from the production management computer 4 to the inventory display device 16, and this determination result is YE.
It becomes S. In this case, the inventory quantity is corrected (step S92).
After that, the process returns to step S88, and the corrected in-process inventory quantity is displayed. If the determination result in step S90 is NO, the in-process current inventory ratio RZ for each type
(I) is calculated (step S94). Subsequently, in step S96 and subsequent steps, a correction instruction process is performed. First,
The function i indicating the type is set to the initial value 1 (step S9).
6). Succeedingly, in a step S98, it is determined whether or not a type i (here, a type corresponding to i = 1) is currently under work.

If the determination result is YES, the in-process current stock ratio RZ (i) calculated in step S94 is
It is determined whether it is smaller than the in-process standard inventory ratio KZ (i) (step S100). And RZ (i) <K
In the case of Z (i), since the number of types i in stock is insufficient, additional production is performed to compensate for this shortage, and the inventory management task of FIG. 5 and the production instruction device of FIG. And a correction instruction signal is transmitted (step S10).
6). On the other hand, if RZ (i) ≧ KZ (i), the process proceeds to step S102 to initialize the function i, and then it is determined in step S104 whether the variable i exceeds the number N of types. If i ≦ N, step S9
Returning to 8, the above-mentioned processing is repeated. If i> N, all types have been examined, so the process returns to step S86 and the above-described processing is repeated. On the other hand, if the determination result in step S98 is NO, the process directly proceeds to step S102 without performing the determination in step S100.

Specific contents of the production ratio control described above will be described with reference to FIGS. 9 and 10. Figure 9
FIG. 6 is a diagram showing a part of a leveling table in the production ratio control method of this embodiment. As shown in FIG. 9, in the production ratio control method of the present embodiment, in the multi-product type production line 1 shown in FIG. 2, three types of products Pa, Pb, Pc are cast and produced. The ratio of the production quantities of the products Pa, Pb, and Pc is 1: 1: 2 in advance based on the production plan.
Has been defined. Based on this ratio, the leveling table shown in FIG. 9 is created in step S20 of FIG. No. of the leveling table 1-No. Up to 200 frames, the number of instructions 1, 2, etc. corresponding to the products Pa, Pb, Pc
3, is assigned. The data of this leveling table is written in the ratio production instructing device 8 in step S40 of FIG. 6, and the ratio production commanding device 8 gives a production instruction based on the leveling table.

FIG. 10 shows the results obtained by the production ratio control method of this embodiment under the specific conditions shown in FIG. FIG. 10 is a graph showing changes in the number of stocks obtained by the production ratio control method of this embodiment. As shown in FIG. 10, the fluctuation range of the stock numbers of the products Pa and Pb is within about 100 over a long period of process days. In addition, the fluctuation range of the stock quantity of the product Pc whose production ratio is double is 2
It is around 00. These fluctuation widths are sufficiently smaller than the lot size (180 pieces) and much smaller than the fluctuation width obtained by the conventional production ratio control method described above. As described above, in the production ratio control method of the present embodiment, the casting machines 20, 22, which perform casting in lot units,
The entire process from 24 to the intermediate storage 32 is regarded as one pseudo storage device, and is counted as the inventory quantity at the time when the production instructing device 12, 14 instructs the casting machine 20, 22, 24 to perform production. Therefore, in the multi-product production line 1 including lot production, it is possible to detect a change in the number of stocks without a time delay and make an appropriate correction according to the degree of the change. By this, the intermediate storage 32
It is possible to reduce the fluctuation range of the number of stocks.

In this embodiment, a part of the production ratio control process is judged or instructed by the workers, but it is of course possible to automate the process by these workers. In addition, the operator may manually process a part of the automatically performed processing. Furthermore, each ratio in the leveling table and the production ratio between product types in this embodiment are merely examples, and various ratios can be taken according to the applied process. The other steps of the production ratio control method, the configuration of the production ratio control device and the other parts of the multi-product type production line, etc. are not limited to those in this embodiment.

Second Embodiment Next, a second embodiment embodying the present invention will be described with reference to FIGS.
This will be described with reference to FIG. In the first embodiment described above, the additional production number, that is, the correction number H (i) for the type i for which RZ (i) <KZ (i) is set to a predetermined value. This correction number H (i) is input in the production instruction task of FIG. 4 (step S12) and transmitted to the two lot production instruction devices (step S14). On the other hand, in this embodiment, the time point at which it is determined whether or not the correction production is performed (hereinafter, referred to as the “correction production determination time point”).
Inventories and inventory ratios, and the planned changes in inventory numbers and inventory ratios in the period during which correction production is performed (that is, the period from the correction production determination time to the correction production end time; hereinafter referred to as the "correction production period") A feature is that a method is adopted in which the correction number H (i) is determined every time according to the number and the like. In the first embodiment in which the correction number H (i) is constant, the same type of product is produced in two or more of the plurality of production devices (the shuttles 20A to 24B of the casting machines 20 to 24 in FIGS. 2 and 3). In such a case, a problem may occur depending on the timing of switching the production type. Hereinafter, this problem will be specifically described with reference to FIGS. 11 to 13.

FIG. 11 and FIG. 12 are graphs showing an example of changes over time in the inventory ratio before and after the corrected production period for the product type for which the corrected production instruction is given in the production ratio control device 2 of the first embodiment. Is. FIG. 11 shows that the products having the same inventory ratio R10 at the corrected production determination time t1 change in the inventory ratio at the corrected production end time t2 due to the difference in the increase rate in the corrected production period. Such a difference in the rate of increase occurs when the product of the type is produced in two or more production devices, and the production or take-back is started or ended in the production device other than the production device for which the correction production instruction is given. Is due to. That is, in the case shown by the solid line L1 in FIG. 11, the increase rate in the correction production period becomes larger than expected because the production of the type has started or the end of the take-back has been completed in the other production apparatus, and the correction production ends. At time t2, the inventory ratio R12 exceeds the standard inventory ratio. On the other hand, in the case indicated by the broken line L2, the increase rate in the correction production period becomes smaller than expected because the production of the type concerned has ended or the take-back has started in another production apparatus, and at the correction production end time t2. The inventory ratio R14 is smaller than the standard inventory ratio.

Further, in FIG. 12, the corrected production determination time t3
It is shown that the stock ratios in are different. Broken line L
3, the inventory ratio R16 that is lower than the standard inventory ratio at the corrected production determination time t3 is
Since the increase rate in the corrected production period has become larger than expected, the standard inventory ratio is exceeded at the corrected production end time t4. On the other hand, in the case of the solid line L4, the inventory ratio R18 at the corrected production determination time t3 is the solid line L3.
However, since the increase rate in the corrected production period was smaller than expected, the standard inventory ratio has not been reached even at the corrected production end time t4. In this way, when the product of the type is produced in two or more production devices, the start or end of production or take-back in the production device other than the production device for which the correction production instruction is performed causes the correction production period to be There is a case where the increase rate in the above-mentioned change and the inventory ratio at the end of the correction production deviates from the standard inventory ratio.

FIG. 13 shows this state over a longer period. FIG. 13 is a graph showing the change over time in the inventory ratio when a plurality of production devices produce the same type of product in the case of the first embodiment. FIG.
The vertical axis represents the inventory ratio for a certain product type, and the horizontal axis represents the passage of time. Also, points R10 to R15
Indicates the point where the inventory ratio reaches the maximum / minimum. As a result of the above-mentioned cause, the stock quantity of the product type being corrected and manufactured fluctuates more than expected, and as a result, the stock ratio at the end of the corrected production may remain above or below the standard stock ratio. For example, in FIG. 13, the reference inventory ratio has not been reached even at the point R14, even though the correction production is performed by determining that RZ (i) <KZ (i) at the point R13. That is, for the type i, the shortage of stocks continues for the period from time t10 to time t12. Therefore, in this embodiment, in order to solve such a problem, not only the production status of the target line of the correction production at the time of determining the correction number but also the status of other lines are considered and The method of determining the correction number H (i) is also taken into consideration in consideration of the planned change number. Hereinafter, the specific content will be described with reference to FIGS. 14 to 21.

First, regarding the overall construction of this embodiment,
This will be described with reference to FIG. The same components as those of the first embodiment are designated by the same reference numerals and the description thereof will be omitted. FIG. 14 is a diagram showing the overall configuration of a multi-product type production line to which the second embodiment of the production ratio control device of the present invention is applied. The production ratio controller 20 of this embodiment shown in FIG.
2 has substantially the same configuration as the production ratio control device 2 of the first embodiment shown in FIG. That is, the production ratio control device 202 also includes the production management computer 4, the production result collection device 6, the ratio production instruction device 8, the selection device 10, the two lot production instruction devices 12, 14, the inventory display device 16, and the take-back result collection device 18. It is composed mainly of. What is different from the first embodiment is the content of data transmitted from the production record collecting device 6 and the take-back record collecting device 18 to the production management computer 4. That is, in addition to the production performance SE (i) similar to that of the first embodiment, the production performance collection device 6 transmits the remaining planned production quantity for each product type. In addition, not only the collection result HK (i) but also the remaining collection amount for each product type is transmitted from the collection result collection device 18. If there is a start / end of production / collection on another line within the corrected production period,
Using these remaining planned production quantity and remaining planned production quantity, the planned change quantity of the inventory quantity within the corrected production period is calculated,
The correction number H (i) is calculated based on this.

A specific example of the calculation of the correction number H (i) will be described with reference to FIGS. 15 and 16. Figure 1
5 and 16 are charts showing the changes over time of the production type and the take-back type in each line when the production is performed in a plurality of production lines and the products are sequentially picked up from each line. Note that FIG. 15 and FIG. 16 briefly show an example of changes in production types with time. ~
Does not necessarily correspond to the casting machines 20A to 24B in FIG. In FIG. 15 and FIG. 16, six line Nos. In Fig. 4, four kinds of products A to D are produced, and the products are picked up from four lines. The solid line indicates the type of product being produced on that line, and the broken line indicates the type of product being picked up from that line. Further, the type (i) that is the target of the determination as to whether the correction production is performed is the product A, and the types B, C, and D are not the targets of the correction determination.

First, a method of calculating the correction number H (i) in the case where the production number and the take-back number of the type A do not change within the corrected production period will be described with reference to FIG. In FIG. 15, the line targeted for correction determination is No.
The type A is No. And No. Are produced on the line. Therefore, when calculating the correction number H (i) for the type A, N in the correction production period is calculated.
o. Production and pick-up of type A on the line must also be considered. Here, as shown in FIG. In the line, the production and receipt of the type A are continuously performed throughout the corrected production period. That is, No. In the line, a certain number of types A (= i) are produced and collected per hour throughout the corrected production period. Therefore, the inventory quantity ΔRZ (i) that changes during the corrected production period Δt is calculated by the following equation (7). ΔRZ (i) = (Δt · n _S / C _S ) − (Δt · n _H / C _H ) ... (7) where n _S is the number of lines producing the type i, and n _H is the type i represents the number of lines that have been taken. C _S is the cycle time of production, and C
_H is the collection cycle time.

Here, assuming that the total inventory quantity ΣRZ (i) is constant, it is only necessary that the inventory ratio of the type i after the time Δt becomes the standard inventory ratio as a result of the corrected production. Therefore, the following equation (8) is obtained. It holds. KZ (i) = (RZ (i) + ΔRZ (i)) / ΣRZ (i) (8) Further, when there are a plurality of lines producing the type i, the total corrected production in the above formula (8) The number will be assigned by the number of lines n _S. From the above, the correction number H (i)
Is calculated by the following equation (9). H (i) = {KZ (i) × ΣRZ (i) −RZ (i)} / n _S (9)

Next, a method of calculating the correction number H (i) in the case where the production number of the type A or the take-back number changes within the correction production period will be described with reference to FIG. Also in FIG. 16, the line that is the target of the correction determination is No. The type A is No. It is produced on the line of. Furthermore, No. In the line, the type A is produced at the correction start time point (= correction production determination time point), but is switched to the type B production within the correction production period. Further, although the type B take-over is carried out at the start of the correction, the type A take-over is switched within the corrected production period. As a result, the number of stocks of type A that had increased at the start of correction decreased at the end of correction. On the other hand, No. In the line, the type C is produced at the start of correction, but the production is switched to the type A within the corrected production period. Further, although the type A is collected at the start of the correction, the type C is collected within the corrected production period.
It has been switched to the collection of. As a result, the number of types A inventories, which had decreased at the start of correction, increased at the end of correction. From the above, in the case of FIG. 16, the correction number H (i) cannot be simply calculated by the equation (9),
No. It is necessary to consider the change in the number of stocks on the line of. For this purpose, the above-mentioned remaining production planned quantity and remaining planned receipt quantity are introduced.

Here, if the production or take-back of the type A (= i) is started within the corrected production period, it is not taken into consideration because it is undecided at the start of the correction. That is, the type A production or take-back is being performed at the start of the correction, and only when the production is finished within the correction production period, the calculation is performed. Therefore, in the case of FIG. Number of remaining production lines and No. Only the number of remaining lines to be collected will be included. In this case, the remaining production quantity DZL
(I) is the following equation (10), and the remaining planned number of collections DZM (i)
Is expressed by the following equation (11). DZL (i) = DZL1 (i) + DZL2 (i) + DZL3 (i) + DZL4 (i) + DZL5 (i) + DZL6 (i) (10) DZM (i) = DZM1 (i) + DZM2 (i) + DZM3 (i) ) ＋ DZM4 (i)… (11) However, DZL1 (i) to DZL6 (i) are the remaining planned production quantity of type i in each casting line (total 6 lines).
(i) to DZM4 (i) are the remaining planned number of types i to be collected in each processing line (four lines in total).

The remaining planned production quantity and the remaining planned production quantity are the production (casting) lot size NR (i) for each type.
Alternatively, from the lot size NM (i) of the take-back (processing), the actual production SE (i) or the take-back HK (i) at that time
It is calculated by subtracting. In order to enable this calculation, as will be described later, in the production instruction task of the management computer 4 shown in FIG. 17, the lot size NR
(I) and lot size NM (i) are transmitted. The correction number H (i) is calculated by the following equation (12) using the remaining planned production number DZL (i) and the remaining planned delivery number DZM (i). H (i) = {KZ (i) × ΣRZ (i) − (RZ (i) + DZL (i) −DZM (i))} / n _S (12) In this way, the types within the corrected production period The correction number H (i) is calculated according to equation (9) when neither the number of productions nor the number of collections of i changes, and according to equation (12) when the number of productions or the number of collections changes.

Next, details of the control procedure in each device will be described with reference to FIGS. In addition,
In the following description, a number such as “○ 11” in which an arithmetic number is written immediately after “○” means that in the drawings,
Similar to "~", it corresponds to the symbol with a number in the circle. First, the contents of the production instruction task of the production management computer 4 will be described with reference to FIG. The production instruction task is started in step S200, and initial data is input (step S202), but the input data contents are partially different from those in the first embodiment. That is, as the lot size, the casting lot size NR
Not only (i) but also the lot size NM (i) of processing is input. This is the number of remaining planned collection DZM (i) mentioned above.
Is for calculating. On the other hand, the correction number H (i), which was used in the first embodiment (FIG. 4), is not input. In the present embodiment, instead of using a predetermined correction number,
This is because the method of calculating the appropriate correction number H (i) according to the stock situation and the like is adopted.

Of the input initial data, the lot size NR (i) of the casting line and the preliminary change value DY are
It is transferred to the two lot production instruction devices 12 and 14 (step S204). The lot size NR (i) is also transferred to the production record collecting device 6 (step S20).
6). Furthermore, the lot size NM (i) of the processing line
Is transferred to the take-back performance collection device 18 (step S
208). Next, using these initial data, a value required for ratio control is calculated (step S210).
The calculated values are the total production ratio R (i) for each type, the general-purpose machine production number S2 (i), the general-purpose machine production ratio R2 (i), the in-process reference inventory ratio KZ (i), and the delay reference value DL.
(I), advance reference value DF (i). These values are
Similar to the first embodiment, it is calculated according to the above equations (1) to (6). The following processing of steps S212 to S218 is the same as that of the first embodiment. The contents of the inventory management task executed subsequent to this production instruction task are the same as in the first embodiment (FIG. 5), as shown in FIG. That is,
In order to display the in-process production number and the like in step S222, data is input from the inventory display device 16 in FIG. Further, in order to perform the correction display in step S224, the correction instruction signal is input from the inventory display device 16 at ◯ 22.

Next, a control procedure in the ratio production instructing device 8 and the selecting device 10 will be described with reference to FIG. The control in the ratio production instructing device 8 is started by transferring the leveling data table to ○ 15 in FIG. 19 from step S216 of the above-described production instructing task in FIG. Is written (step S232). The following process is performed in the same manner as in the first embodiment (FIG. 6), and the device-instruction data transferred from the ratio production instructing device 8 to the selecting device 10 (step S236) is determined in the selecting device 10 (step S240). ~ S24
6) depending on the lot production instructing device 12, 1
4 is transmitted. Note that, also in the present embodiment, in step S238 in FIG. 19, it is possible to display a device type for a plurality of candidates based on the leveling table and allow the operator to select one of the candidates. In this case, regardless of the processing of steps S240 to S246, the operator selects the optimum product type in consideration of the production status (necessity of stage change, etc.) and sets the lot production instruction device corresponding thereto. Select to send instruction data.

Next, the control procedure in the lot production instruction device will be described with reference to FIG. In FIG. 20, N
o. The control procedure in the 1-lot production instructing device 12 is shown. The control procedure in the two-lot production instruction device 14 is also the same. No. 1-lot production instruction device 12
The processing in is performed by the selection device 10 described above indicated by ○ 19.
Example 1 started by transmission of device data from
Unlike the above, first, the data of the device type (i) is transmitted to the inventory display device 16 (step S250). Subsequently, it is determined whether or not there is a device request (step S252), and if the result of the determination is YES, a device instruction is given (step S254). Thus, the two shuttle No. 1-
1, No. Hot water is alternately delivered to 1-2 (step S2
56), multi-type shuttle No. When the hot water is distributed to 1-1, it is determined whether or not there is a correction request after completion of casting (step S260) (step S262). This determination is executed when the advance notice of the stage change is given as in the first embodiment. The change request is indicated by turning on a change notice lamp (not shown), and is turned on at the end of each lot regardless of whether the product type changes. The advance notice lamp for the stage change is turned on and off manually. Any of the automatic devices may be used.

The following processing procedure is different from that of the first embodiment because the correction number is calculated for each corrected production in this embodiment. First, it is determined whether or not the correction number is ready for input (step S264). This judgment is YE
If S, the correction flag is turned ON and the correction number H (i) is input (step S266). This correction number H (i) is calculated in the inventory display device (FIG. 21) described later and is input from ◯ 22. Then, after the correction number cannot be input (step S268), it is determined whether or not the production lot is completed (step S27).
0). If this determination is NO, it is not yet the stage to start the correction production, and therefore the process returns to step S252 and the lot production is continued. If the decision result in the step S270 is YES, it is decided whether or not the stage change is necessary (step S272), and if it is determined that the stage change is necessary, the step change work of the casting mold is executed in the step S258. If the correction flag is set to ON in step S264, it is not necessary to determine YES in step S272 because it is necessary to perform correction production.

If NO at step S272,
It is determined whether the correction flag is ON (step S27).
2) If the correction flag is OFF, the device instruction is completed as it is (step S280). On the other hand, when the correction flag is ON, it is determined whether or not the correction counter has counted up to the planned correction number (step S272). If this determination is NO, that is, if the corrected production number has not yet been produced, the process returns to step S252 and lot production is continued. On the other hand, when the determination is YES and the production of the corrected number is completed, the input of the corrected number is enabled and the correction flag is turned off (step S278). After the correction production is finished in this way, the work instruction is completed (step S280), and
As shown by 18, the device-instruction completion is transmitted to the ratio production instructing device 8 and the selecting device 10.

Next, the control procedure of the production record collecting device 6, the inventory display device 16, and the take-back record collecting device 18 will be described with reference to FIG. In the production result collecting device 6, the production results SE (i) for each type are counted in response to the input of the above-mentioned device-instruction end signal indicated by ∘21 (step S282). Also, in ○ 12,
The lot size NR (i) of the casting line is input from the production instruction task of FIG. This lot size NR
The planned production quantity DZL (i) for each type is calculated by subtracting the production performance SE (i) from the value of (i) (step S284). On the other hand, product storage (step S310), stock (step S312), and product output (step S314) are performed in the intermediate storage 32, and the collection record collecting device 18 collects products HK (i by type according to the distribution. ) Is counted (step S
316). Further, in ◯ 13, the lot size NM (i) of the processing line is input from the production instruction task of FIG. By subtracting the actual take-back performance HK (i) from the value of the lot size NM (i), the remaining planned take-back number DZM (i) for each type is calculated (step S31).
8).

The data of the production record SE (i), the remaining production plan number DZL (i), the take-back record HK (i), and the remaining planned delivery number DZM (i) are transmitted to the inventory display device 16 to display the inventory. The device 16 calculates the in-process inventory quantity for each type based on these (step S286). The following processing procedure (steps S288 to S306) is as shown in FIG.
This is almost the same as the first embodiment. However, in this embodiment,
The difference from the first embodiment is that a step of calculating the correction number H (i) is incorporated in step S304. This correction number H (i)
The calculation of is performed based on the equation (9) or the equation (12) according to the procedure described above. Calculated correction number H
The data of (i) is transmitted to the lot production instruction device 12 or 14 together with the correction instruction signal (step S30).
6).

As described above, also in the production ratio control device 202 of the present embodiment, the entire process from the casting machines 20, 22, 24 to the intermediate storage 32 is regarded as one pseudo storage device, and the production instruction device 12 is used. , 14 to casting machine 20,2
It is counted as the number of stocks when production is instructed in 2, 24. Further, in the correction production for correcting the fluctuation of the stock quantity, the production instruction is given by the correction quantity calculated according to the fluctuation of the stock quantity at that time. Therefore, in the multi-product production line 1 including lot production,
It is possible to detect fluctuations in the number of stocks without time delay and make appropriate corrections according to the degree of fluctuations. As a result, the fluctuation range of the number of stocks in the intermediate storage 32 can be further reduced.

[0062]

According to the first aspect of the present invention, the process of detecting the stock quantity of the entire process including the production device to the product storage device and the type and quantity of the product to be produced in order to correct the production ratio are indicated. Since the production ratio control method including the step of performing the production process has been created, it is possible to detect a change in the number of stocks in real time in a multi-product production line including lot production and make an appropriate correction according to the degree of the change. As a result, the fluctuation range of the number of stocks in a multi-product production line including lot production can be reduced, so that the storage space of the product storage device can be minimized and the production ratio control method is extremely efficient.

Further, in the invention according to claim 2, since the number of products withdrawn in the process is taken into consideration in the in-process product number calculation process, more appropriate production ratio control can be performed.

Further, in the invention according to claim 3, when the determination result in the production status quality determination step is negative, the number of products instructed by the production plan is corrected, so that a more appropriate size is corrected. You can

Further, in the invention according to claim 4,
By changing the production plan in the case where the determination result in the production status quality determination step is the second determination level or higher, the production quantity is changed when a large variation in the inventory quantity occurs due to some abnormality of the multi-product production line. The plan can be fundamentally changed and dealt with, and effective production ratio management can be performed.

Further, in the invention according to claim 5, a means for detecting the inventory quantity of the whole process including the production device to the product storage device, and the kind and quantity of the products to be produced in order to correct the production ratio are indicated. Since the production ratio control device having the means for performing the production has been created, it is possible to detect a change in the stock quantity in real time in a multi-product production line including lot production and make an appropriate correction according to the degree of the change. As a result, the fluctuation range of the number of stocks in a multi-product production line including lot production can be reduced, so that the storage space of the product storage device can be minimized.
It becomes a very practical production ratio control device.

In the invention according to claim 6, the production ratio control for determining the production correction number for each type based on the determination result in the production status determination process, the production ratio, and the operating rates of the production device and the product storage device. Since the method was created, appropriate modifications can be made according to the degree of fluctuation. This makes it possible to further reduce the fluctuation range of the number of stocks in a multi-product production line including lot production, which is an extremely practical production ratio control method.

Further, in the invention according to claim 7, the production ratio control for deciding the production correction number for each type based on the judgment result in the production quality judging means, the production ratio, and the operating rates of the production device and the product storage device. Since the device was created, appropriate correction can be made according to the degree of fluctuation. As a result, it is possible to further reduce the fluctuation range of the number of stocks in a multi-product production line including lot production, and it becomes a very practical production ratio control device.

[Brief description of drawings]

FIG. 1 is a schematic diagram showing a configuration of a production ratio control method according to the present invention.

FIG. 2 is a schematic diagram showing an overall configuration of a multi-product lot production line to which the first embodiment of the production ratio control method and the production ratio control device according to the present invention is applied.

FIG. 3 is a block diagram showing a connection of respective parts and a data flow in the first embodiment of the production ratio control method and the production ratio control device.

FIG. 4 is a block diagram showing the content of a production instruction task in the first embodiment of the production ratio control method and the production ratio control device.

FIG. 5 is a block diagram showing the contents of an inventory management task in the first embodiment of the production ratio control method and the production ratio control device.

FIG. 6 is a block diagram showing a processing procedure in the ratio production instruction device and the selection device of the embodiment 1 of the production ratio control method and the production ratio control device.

FIG. 7 is a block diagram showing a processing procedure in the lot production instruction apparatus of the first embodiment of the production ratio control method and the production ratio control apparatus.

FIG. 8 is a block diagram showing a processing procedure in the inventory display device and the like according to the first embodiment of the production ratio control method and the production ratio control device.

FIG. 9 is a diagram showing a part of a leveling table in the first embodiment of the production ratio control method and the production ratio control device.

FIG. 10 is a diagram showing a change in the number of stocks obtained according to the first embodiment of the production ratio control method and the production ratio control device.

FIG. 11 is an explanatory diagram showing the difference between the first and second embodiments of the production ratio control method and the production ratio control device.

FIG. 12 is an explanatory diagram showing the difference between the first and second embodiments of the production ratio control method and the production ratio control device.

FIG. 13 is an explanatory diagram showing differences between the production ratio control method and the production ratio control device according to the first and second embodiments.

FIG. 14 is a schematic diagram showing an overall configuration of a multi-product lot production line to which the second embodiment of the production ratio control method and the production ratio control device according to the present invention is applied.

FIG. 15 is a diagram showing an example of production in a plurality of lines in the second embodiment of the production ratio control method and the production ratio control device.

FIG. 16 is a diagram showing another example of production on a plurality of lines in the second embodiment of the production ratio control method and the production ratio control device.

FIG. 17 is a block diagram showing the contents of a production instruction task in the second embodiment of the production ratio control method and the production ratio control device.

FIG. 18 is a block diagram showing the contents of an inventory management task in the second embodiment of the production ratio control method and the production ratio control device.

FIG. 19 is a block diagram showing a processing procedure in a ratio production instruction device and a selection device according to a second embodiment of the production ratio control method and the production ratio control device.

FIG. 20 is a block diagram showing a processing procedure in a lot production instruction device according to a second embodiment of the production ratio control method and the production ratio control device.

FIG. 21 is a block diagram showing a processing procedure in the inventory display device according to the second embodiment of the production ratio control method and the production ratio control device.

FIG. 22 is a schematic diagram showing an overall configuration of a multi-product production line to which the production ratio control method of the conventional example is applied.

FIG. 23 is a diagram showing an example of a leveling table used in a conventional production ratio control method.

FIG. 24 is a flowchart showing a control procedure in a production ratio control method of a conventional example.

[Explanation of symbols]

 2,202 Production ratio control device M2, M4, M8,1 Multi-product production line M4, 20, 22, 24 Production device M6, Pa, Pb, Pc Multiple types of product M8, 32 Product storage device M10 Production ratio control method M12 Production instruction product number detection step M14 Exported product number detection step M16 In-process product number calculation step M18 Production plan M20 Production status pass / fail judgment step M22 Production correction instruction step

Claims (7)

[Claims] 1. A multi-product having a production device for producing a plurality of types of products, at least one of which is manufactured in lots, and a product storage device for storing the products produced by the production device for each type. In a production line, a method for controlling a production ratio of the plurality of types of products according to a standard production ratio between the plurality of types of products determined based on a production plan, wherein production is instructed in the production device. Production instruction product number detection step of detecting the number of products for each type, a delivery product number detection step of detecting the number of products delivered from the product storage device for each type, the production instruction product number detection step, and In-process manufacturing for calculating the number of products in each process including the production device to the product storage device based on the detection result in the output product number detection process for each type A product number calculation step, and a production status quality determination step of comparing the production ratio for each type calculated from the number of products calculated in the in-process product number calculation step with the reference production ratio to determine the quality of the production status A production ratio instructing step of deciding and instructing the type and quantity of the product to be produced in the production apparatus based on the determination result in the production situation quality determining step and the production plan. 2. The production ratio control method according to claim 1, wherein in the in-process product number calculation step, the number of products extracted in the step is also taken into consideration for the calculation. 3. The production ratio control method according to claim 1, wherein the number of products instructed to be produced according to the production plan is corrected when the determination result in the production status quality determination step is negative. 4. The production ratio control method according to claim 1, wherein the production plan is changed when the determination result in the production status pass / fail determination step is not lower than the second determination level. 5. A multi-product having a production device for producing a plurality of types of products and lot-producing at least one type of the product, and a product storage device for storing the products produced by the production device for each type. In the production line, a device for controlling the production ratio of the plurality of types of products according to the standard production ratio between the plurality of types of products determined based on the production plan, the production instruction in the production device A production instruction product number detection means for detecting the number of products for each type, a delivery product number detection means for detecting the number of products delivered from the product storage device for each type, the production instruction product number detection means, and In-process manufacturing for calculating, for each type, the number of products in the process including the production device to the product storage device based on the detection result of the carried-out product number detection means Product number calculating means and production status quality determining means for comparing the production ratio for each type calculated from the number of products calculated by the in-process product number calculating means with the reference production ratio to determine the quality of the production status A production ratio control device comprising: a production correction instructing device for determining and instructing the type and quantity of a product to be produced in the production device based on the determination result of the production situation quality determining device and the production plan. 6. Between the production status quality determination step and the production correction instruction step, based on the determination result in the production status quality determination step, the production ratio, and the operating rate of the production device and the product storage device, A production correction number determining step for determining, for each type, a production correction number for correcting the number of products instructed to be produced in the production apparatus, and the production apparatus based on the production correction number in the production correction instruction step. The production ratio control method according to claim 1, characterized in that the production quantity produced in (3) is corrected for each type. 7. A type for correcting the number of products instructed to be produced in the production apparatus, based on the determination result by the production status quality determination unit, the production ratio, and the operating rates of the production apparatus and the product storage apparatus. Production correction number determining means for determining a production correction number for each type, and the production quantity correcting means corrects the production quantity produced in the production apparatus for each type based on the production correction number. The production ratio control device according to claim 5.