JPH08147366A - Production planning device - Google Patents

Abstract

PURPOSE: To provide a production planning device preparing a production schedule for performing a manufacturing operation, keeping the maximum of mechanical working rate even if the base material inventory amount before each manufacturing process is reduced. CONSTITUTION: Order information is arranged in order of high priority (S 201) and the following processings are performed in order of the orders with higher priority (S 202, 205, 206). At first, the day's schedule for performing a final process is assigned to the day when the work load on the day, when a work performed does not exceed a preliminarily set value and to the day's schedule which is shorten, it is assigned ahead of the schedule as mush as possible (S 203). Next, the day's schedule for starting the process one process before the final process is temporarily set back to origin based on the working time of the process. When the work load on the temporarily set day is the set value or more and the work can not be performed and the day when the work can be performed does not exists in also the previous day's schedule, the day's schedule of the process one process before the final process is shifted backward and the day's schedule for the final process is shifted by the shifted part. Going back to the first process in order in the same way, the day's schedule for each process is set (S 204).

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a production planning device, and more particularly to a production planning device in the steel industry.

[0002]

2. Description of the Related Art Conventionally, a production plan in the steel industry has been drafted by setting a work start date by back-calculating the order delivery date based on the number of days required for work after receiving an order.

[0003]

However, in the conventional production plan, since the manufacturing process work schedule was decided by neglecting the capacity load of the lower manufacturing process, the supply of the base material in each process became unstable. There was a problem that became.

Therefore, the present invention stabilizes the supply of the base material,
An object of the present invention is to provide a production planning device capable of creating a production plan that enables production operation while maintaining the maximum machine operating rate even if the amount of base material stock before each manufacturing process is reduced.

[0005]

A production planning device according to claim 1 is a production planning device for a product produced through a plurality of processes from a first process to a final process, and orders the products. Input means for inputting order management information including quantity and order delivery date, storage means for storing required time required by each process, and processing amount capable of maximum processing per unit time in each process And a deciding means for deciding the schedule of each process while going back from the final process to the first process based on the input order management information and the stored required time and processing amount.

A production planning system according to a second aspect of the present invention is the production planning system according to the first aspect, wherein the deciding means includes a discriminating means for deciding that each schedule of the process can be advanced in advance. In response to the discrimination output of the discriminating means, the pre-arranged schedule is determined as each schedule of the process.

The production planning apparatus according to a third aspect is the production planning apparatus according to the second aspect, further comprising setting means for setting a production date of the product based on the determined schedule as a delivery date. Be prepared.

The production planning apparatus according to claim 4 is the production planning apparatus according to any one of claims 1 to 3, wherein the input means inputs a plurality of order management information, and the production planning apparatus is input. The order management information is further provided with priority order setting means for setting a priority order for each of the plurality of order management information, and the determining means determines the schedule from each of the order management information in the order of the set priority order.

A production planning apparatus according to a fifth aspect is the production planning apparatus according to any one of the first to fourth aspects, wherein the order management information includes order work date information, and the determining means includes the order work date information. The schedule of each process is determined based on the input order management information and the stored required time and processing amount.

A production planning device according to a sixth aspect is a production planning device for various products produced through a plurality of processes from a first process to a final process, and an ordered quantity for each product. Input means for inputting order management information including the order delivery date, first storage means for storing the required via manufacturing process for each type of product, and each process constituting each of the via manufacturing processes are required. Second storage means for storing the required time and the maximum processing amount per unit time in each of the steps constituting each via manufacturing process, and the priority in the input order management information. Priority setting means for setting the input order management information in order according to the set priority, and the stored order management information and the stored route for the product corresponding to the extracted order management information Manufacturing process, when required And a determining means for determining the schedule of the production process of the product based on the processing amount, and repeating the determination of the schedule of the production process based on all the order management information inputted after being overlapped with the determined schedule. Be prepared.

[0011]

The production planning apparatus according to the first aspect inputs the order management information including the order quantity and the order delivery date of the product to be produced, and the time required for performing the work in each process, Based on the maximum processing amount that can be processed per unit time in each process, each schedule of the process is determined from the final process to the first process based on the order management information.

In addition to the operation of claim 1, the production planning apparatus according to claim 2 determines that each schedule of the process can be pre-arranged as a whole, and according to the discrimination result, the pre-arranged schedule is It is decided as each schedule of the process.

In addition to the function of the second aspect, the production planning apparatus according to the third aspect sets the production date of the product based on the determined schedule as the delivery date.

In addition to the operation according to any one of claims 1 to 3, the production planning apparatus according to claim 4 inputs a plurality of order management information, and gives priority to each of the input plurality of order management information. Set and process order management information in order of priority.

The production planning system according to a fifth aspect determines the schedule based on the order management information including the order work date information in addition to the operation according to any one of the first to fourth aspects.

A production planning apparatus according to a sixth aspect inputs order management information including an order quantity and an order delivery date for each of various products, sets a priority in the input order management information, The input order management information is sequentially taken out in accordance with the set priority, and the production is performed based on the taken order management information and the transit manufacturing process, the required time and the processing amount for the product corresponding to the taken order management information. The schedule of the production process of the product is decided, and the decision of the schedule of the production process is repeated based on all the order management information input after the decided schedule.

[0017]

FIG. 2 is a block diagram of a production planning apparatus in the steel industry in one embodiment of the present invention.

Referring to the figure, the production planning apparatus 200 has the order entry information 211 transmitted from the head office sales system 201.
Processing unit 2 for processing the order and outputting order management information 213
03, a production schedule determination processing unit 205 that creates and outputs production plan information 215 from the order management information 213, and a production control processing unit 207 that transmits work instruction information 217 to the operation online system 209 based on the production plan information 215. Composed of.

FIG. 3 is a block diagram showing a specific configuration of the manufacturing schedule determination processing unit 205 of FIG. 2 which is a feature of the present invention.

Referring to the drawing, the manufacturing schedule determination processing unit 205
Is an order management database (D
B) 2051 and manufacturing process work day management database 20
53, a manufacturing process work required time management table 2055 for managing the work required time of each manufacturing process, a product type work amount management table 2057 for managing the product type work amount in each manufacturing process, and each manufacturing process. Manufacturing process work capability management table 20 for managing work capability in process
59 and a processing device 2061 for performing the processing described below.

FIG. 1 is a flow chart showing the processing of the processing device 2061 of FIG. The process includes a manufacturing process work day creation process of step S1, a manufacturing process work day replacement process of step S2, and an order management database update process of step S3. The processing performed in each step will be described in detail below.

FIG. 4 is a flow chart showing the specific contents of the manufacturing process work day creation processing routine performed in step S1 of FIG.

In step S101, the order management information for each order contained in the order management database 2051 is read. The order management information is the information shown in FIG. 5, and includes the order number, the order weight, the delivery date of the order, the designation of the order work day (whether the work day is specified), and the type of order. It is information including a process of passing raw materials through to make a product (transit manufacturing process) and an ordered product type.

In step S102, it is determined whether the read order management information has an order work date. If YES (for example, order numbers 1 and 2 in FIG. 5), step S1
Go to 03. In step S103, the work date of each via manufacturing process is determined from the order delivery date in the order management information, the via manufacturing process, and the manufacturing process work required time management table 2055. The manufacturing process work required time table is a table in which the standard required time required for the work in each manufacturing process is recorded as shown in FIG.

In step S104, the determined work days are recorded in the manufacturing process work day management database 2053 for each order number. The information recorded in the manufacturing process work day management database 2053 is specifically the information shown in FIG. 7. That is, the number of days to start the work in each manufacturing process is recorded for each order number.

For example, in FIG. 5, the order with the order number 1 has an order delivery date of February 15, and the manufacturing processes passing through are the manufacturing processes 1 → 3 → 4. Since the time required for the manufacturing process 4 is 5 days from FIG. 6, it is necessary to calculate backward from the delivery date February 15 and start the manufacturing process 4 on February 10. Similarly, since the time required for the manufacturing process 3 is 4 days, the manufacturing process 3 needs to be started on February 6 by calculating backward from the start date of the manufacturing process 4. Manufacturing process 1 needs to start on February 5 because the required time is one day. Information on these start dates is recorded as shown in FIG.

In step S105, it is determined whether or not all the order management information has been processed. If YES, then the processing in step S1 ends, and if NO, then step S1.
The processing from 01 is repeated.

On the other hand, if NO in step S102 (for example, order number 3 in FIG. 5), step S1
The work day set in 06 is unconditionally set as the via manufacturing process work day.

The order work date is artificially specified because the delivery date from the order destination is limited or the manufacturing facility operation is restricted. For example, the order with the order number 3 in FIG. 5 uses the via manufacturing process 4, and since the order work date is January 27, January 27 is recorded in the manufacturing process 4 as shown in FIG.

FIG. 8 is a flow chart showing the specific contents of the manufacturing process work day replacement process performed in step S2 of FIG.

In step S201, orders are arranged in descending order of priority from the order management information of all orders. Specifically, as shown in FIG. 9, in order from the item with the highest priority, the order work date designation category, the product type, the number of passing processes,
It will be a delivery date. The priority of each item is determined as follows.

Among the order work date designated categories, those with categories have a high priority, and those without categories have a low priority. Among the types, those having a small number of work cycles of each type (for example, once / month) have a higher priority than those having a large number (for example, every day). In terms of the number of transit steps, those with many steps have higher priority than those with few steps. Those with earlier delivery times have higher priority than those with later delivery times.

In other words, first, all orders are divided into a group with an order work date designation category (a group with a high priority) and a group without an order work date designation category (a group with a low priority). They are divided into groups according to the priority depending on the type of product, and the groups are further divided into groups in the order of the number of transit processes and the delivery date. As described above, the rearrangement in the order of priority is performed.

Orders having completely the same priority in all items are arranged in ascending order of order numbers, for example.

In step S202, the variable N is initialized to N = 1. In step S203, the final process of the Nth priority order is allocated. The assigned processes are specifically recorded on the manufacturing process work capability management table shown in FIG. The maximum work amount (maximum work weight) of each manufacturing process for each day is set in advance by the manufacturing performance evaluation, and the allocation is performed so that the weight of the assigned order does not exceed the maximum work weight of each manufacturing process.

The maximum work weight is artificially set according to the production plan, machine maintenance, manufacturing performance evaluation, and the like.

For example, it is assumed that the monthly production plan in the manufacturing process 2 is planned to be 30000t in April and 35000t in May. If the amount actually produced in April is 40,000 tons, the production in April is over 10,000 tons from the plan, so the overage is reduced from the production plan in May. Specifically, 10,000 tons are subtracted from the initial plan of 35,000 tons in May, and the production plan for May will be 25,000 tons.

Here, the daily maximum work amount is obtained by dividing the monthly production plan by the days when the machine is operated. For example, if the machine is operated in May for 29 days in consideration of a repair plan and the like, the maximum work weight of one day is about 860 t obtained by dividing the production plan of 25,000 t in May by 29.

The maximum work weight for each product type produced in each process is set by the product type operation table shown in FIG. 11, and the weight of each product type is the weight set in the product type operation amount management table. Allocated so that it does not exceed.

When the final process is assigned, step S2
In 04, the date of performing the process one process before the final process is obtained by back calculation from the manufacturing process work required time management table of FIG. At this time, if it is impossible to carry out the process on the date calculated backward, the schedule is set backward until the date when the process can be carried out. The schedule on the day when the final process is assigned is also shifted backward by the shifted schedule.

FIG. 12 shows a method of allocating dates, taking as an example the case of allocating the order of order number 1 in FIG.
Will be described with reference to.

The order number 1 is for the product type P manufacturing process 1 → 3 → 4
It means that it is necessary to make 50t by February 15th.

Therefore, as shown in FIG. 12, in this order, the process of manufacturing process 4 must be completed on February 15 (point X). Since the standard required time of the manufacturing process 4 is 5 days according to the manufacturing process work required time management table of FIG. 6, the work of the manufacturing process 4 starts on February 10 (Z point), which is 5 days back from February 15. It's the day we have to do.

In FIG. 12, the days when the weight P of 50 t exceeds the weight defined in the work management table for each product type in FIG. 11 and the work weight for each day are indicated by diagonal lines in FIG. .

As described above, the work schedule is assigned to the front of the workable days, so the work start date of the manufacturing process 4 is provisionally set as February 8 (point A).

Next, the schedule of the manufacturing process 3 which is one process before the final process is set. Since the standard required time for the manufacturing process 3 is 4 days as shown in FIG. 6, the work start date for the manufacturing process 4 needs to be set to February 4 (point B), which is 4 days back from point A. However, since February 4th is a day (the shaded area) where the manufacturing process 3 has the maximum work load and cannot work,
The work start date of manufacturing process 3 is a workable day (C
Point). At the same time, the work start date (point A) of the manufacturing process 4 is also lowered by the same amount and moved to point D.

Next, the schedule of the manufacturing process 1 is set. Figure 6
Since the standard required time for manufacturing process 1 is 1 day, the work start date for manufacturing process 1 is February 4 (E
Points). Since point E is a workable day, this order is to be worked on by the schedule of executing each process on the schedule of point E → point C → point D. The weight to be processed in this process is recorded in the manufacturing process work capacity management table of FIG. 10, and the next priority order is assigned.

In step S205, it is determined whether all orders have been processed. If NO, step S20.
In step 6, N is incremented by 1, and step S203
Repeat the process from. If YES in step S205, the manufacturing process work day replacement process in step S2 ends.

Although work cannot be performed at point B, if there is a workable day before the point B, work is assigned to that point.

Further, for an order having an order work day designation category, a preset work day is set as each via manufacturing process work day.

By deciding the manufacturing work date from the subordinate manufacturing process in this way, it is possible to make a manufacturing schedule while keeping the working capacity of the intermediate process.

In step S3, the all via manufacturing process work dates assigned to each order unit in step S2 are registered in the order management database. By this processing, the delivery date planned in step S2 is registered in the order management database.

In the schedule of the planned work process, when the delivery date of the order is not in time, the fact may be displayed to inform the operator.

[0054]

In the production planning apparatus according to the first aspect of the present invention, it is possible to set the manufacturing schedule in which the work load of the intermediate process and the delivery date are balanced.

In addition to the effect of the first aspect, the production planning apparatus according to the second aspect makes it possible to formulate a production plan without waste because the schedules of the respective processes are entirely put forward.

In addition to the effect of the second aspect, the production planning apparatus according to the third aspect resets the date when the product is generated as the delivery date based on the determined schedule. It is possible to answer with high accuracy.

In addition to the effect according to any one of claims 1 to 3, the production planning apparatus according to claim 4 sets priority to a plurality of order management information and processes the order management information in order of priority. The information according to the order can be efficiently processed.

The production planning system according to claim 5 can specify the order work day in addition to the effect according to any one of claims 1 to 4.

According to the sixth aspect of the production planning apparatus, it is possible to set the manufacturing process in which the work load of the intermediate process and the delivery date are balanced from a plurality of order management information of various products according to the actual order. it can.

[Brief description of drawings]

FIG. 1 is a flowchart showing a process of a processing device of a production planning apparatus of the present invention.

FIG. 2 is a block diagram of a production planning apparatus in the steel industry in one embodiment of the present invention.

3 is a block diagram showing a specific configuration of a manufacturing schedule determination processing unit 205 of FIG. 2, which is a feature of the present invention.

4 is a flowchart showing the specific contents of a manufacturing process work day creation processing routine performed in step S1 of FIG. 1. FIG.

FIG. 5 is a diagram showing order management information.

FIG. 6 is a diagram showing a manufacturing process work required time table.

FIG. 7 is a diagram showing information recorded in a manufacturing process work day management database 2053.

FIG. 8 is a flowchart showing the specific contents of manufacturing process work day replacement processing performed in step S2 of FIG.

FIG. 9 is a diagram for explaining a method of setting priorities set in order management information.

FIG. 10 is a diagram showing a manufacturing process work capability management table.

FIG. 11 is a diagram showing a work amount management table for each product type.

12 is a diagram for explaining allocation of an order with order number 1 in FIG.

[Explanation of symbols]

 201 Head Office Sales System 203 Order Processing Department 205 Manufacturing Schedule Decision Processing Department 207 Production Control Processing Department 209 Operation Online System 211 Order Placement Information 213 Order Management Information 215 Production Planning Information 217 Work Instruction Information 2051 Order Management Database 2053 Manufacturing Process Work Day Management Database 2055 Manufacturing process work required time management table 2057 Product type work amount management table 2059 Manufacturing process work capacity management table 2061 Processing device

Claims (6)

[Claims] 1. A production planning apparatus for a product produced through a plurality of processes from a first process to a final process, wherein an input for inputting order management information including an order quantity and an order delivery date of the product. Means, a storage means for storing a required time required by each of the steps, and a maximum processing amount per unit time in each of the steps; the input order management information; A production planning apparatus, comprising: a determination unit that determines a schedule of each of the steps while tracing back from the final step to the first step based on the stored required time and processing amount. 2. The deciding means includes a deciding means for deciding that each of the schedules of the steps can be advanced as a whole.
The production planning apparatus according to claim 1, wherein the pre-arranged schedule is determined as each schedule of the process in response to the determination output of the determination unit. 3. The production planning apparatus according to claim 2, further comprising setting means for setting a production date of the product based on the determined schedule as a delivery date. 4. The input means inputs a plurality of order management information, and the production planning apparatus further comprises priority order setting means for setting a priority order for each of the plurality of input order management information, wherein the determination is made. 4. The production planning apparatus according to claim 1, wherein the means determines the schedule from each of the order management information in order of the set priority order. 5. The order management information includes order work date information, and the determining means is based on the order work date information, the input order management information, and the stored required time and processing amount. The production planning apparatus according to claim 1, wherein a schedule for each of the steps is determined. 6. A production planning apparatus for various products produced through a plurality of processes from a first process to a final process, the order management including an order quantity and an order delivery date for each of the products. Input means for inputting information, a first storage means for storing a via manufacturing process required for each type of the product, and a required time required for each of the processes constituting each of the via manufacturing processes, Second storage means for storing the maximum processing amount per unit time in each of the steps constituting each of the via manufacturing steps, and priority for setting a priority in the input order management information. Degree setting means, the input order management information is sequentially fetched in accordance with the set priority, and the stored order management information and the product corresponding to the fetched order management information are stored. Manufacturing via The schedule of the production process of the product based on the process schedule, the required time, and the processing amount, and thereafter, the schedule of the production process is determined based on all of the input order management information superimposed on the determined schedule. And a production planning device having a determining means for repeating.