JPH10116364A - Lubricant production plan supporting device - Google Patents

Abstract

PROBLEM TO BE SOLVED: To easily and efficiently generate the production plan of lubricant while the burden of a person in charge of a plan is reduced by providing a simulation means for simulating a provisional plan generated by means of a provisional plan generation means and outputting the result. SOLUTION: A mix tank is selected at first in a mix tank selection means B1. A provisional plan generation means B2 generates the provisional plan based on the mix tank selected in the mix tank selection means B1 and a procurement request file. A simulation means B3 simulates the generated provisional plan and outputs the result to a Gantt chart. The contention state of equipments is grasped from the Gantt chart, a correction means B4 corrects the provisional plan and generates the plane approximated to the optimum one. The execution equipments, an execution date, a rotation order in the respective procurement requests and the start/end time of respective processes, which are calculated by simulation, are added to the procurement request file as the plan results and they are returned to a product stock management device.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a lubricating oil production planning support device. More specifically, the present invention relates to a lubricating oil production plan support device used for making a lubricating oil production plan in a lubricating oil production facility provided with a plurality of types of mixing tanks having different capacities allocated to oil types.

[0002]

2. Description of the Related Art FIG. 1 is a schematic diagram showing a lubricating oil production facility. The lubricating oil products produced by this lubricating oil production facility can be broadly divided into product tank (P / T) products and indoor batch (I / B) products. Product tank (P / T) products are products manufactured in bulk in multiple product tanks P / T. The product in the product tank P / T is
Filling headers DM-H, CS-H, LR-H are used to fill lorries, drums, pail cans, 4L cans, 1L cans and other packages. Here, DM-H is a drum filling header, CS-H is a pail, 4
L can, 1 L can filling header, and LR-H are lorry filling headers. If the stock in the product tank P / T is less than the appropriate stock, a “mixing request” is issued, and according to this, it is manufactured in a mixing tank called Outdoor Batch 0 / B and filled in the product tank P / T. Since indoor batch (I / B) products do not have a loose product inventory, a `` formulation request '' and a `` filling request '' are issued at the same time, and accordingly, they are manufactured in multiple preparation tanks called indoor batch I / B. , Filling header DM-H, CS-
H, LR-H is used to fill the package.

[0003] Manufacturing is broadly divided into formulation (O / B formulation, I / B formulation) and filling. Mixing is a step of blending a base oil and an additive, and heating and stirring. Mixing equipment is independent for indoor batch and outdoor batch. The blending process is slightly different between indoor batch and outdoor batch. Formulation in outdoor batch O / B (O
/ B formulation) is as follows. The outdoor batch O / B is connected to an outlet batch C / B and a filling header BO-H (flow meter) from a raw material tank BO / T for base oil and additives. Add the additive and a part of base oil in outlet batch C / B to make a high concentration outlet. This is divided into several batches, and the outdoor batch O / B
Transfer to At the same time, base oil is poured directly from the raw material tank BO / T into the outdoor batch O / B. After filling in the specified quantity, the mixture is heated and stirred, transferred to the product tank P / T, tested, and the lot is established.

[0004] Formulation in the indoor batch I / B (I / B formulation) is as follows. The indoor batch I / B has a suction weighing device called a vacuum tank B / B and an outdoor batch
As with O / B, the filling header BO-H from the raw material tank BO / T is connected. The additive is sucked and weighed in the vacuum tank B / B,
Alternatively, manual weighing by hand and indoor batch I / B
Stick to At the same time, the base oil is applied directly to the indoor batch I / B as well as the outdoor batch O / B. After mixing at a predetermined compounding ratio, the mixture is heated and stirred, then tested to establish a lot, and filled into each package according to a filling request. Boiling header BO-H for mounting vacuum tank B / B and base oil
Is shared by multiple indoor batch I / Bs per unit, causing competition. Filling headers DM-H, CS-H,
The LR-H is also shared between the indoor batch I / B and the product tank P / T, so it is important to plan to avoid equipment conflict.

Conventionally, each of these products is managed for each product name and package in an inventory management device constituted by a general-purpose computer or the like. Forecasts for weeks after the order and withdrawal inventory are forecasted, and products that have lost proper inventory are requested to be mixed or filled. For example, when the stock of a certain product falls below the proper stock, a "fill request" is issued for the product and its packaging. If the product does not have a product tank P / T, a “mixing request” is issued as an indoor batch (I / B) product. At this time, the “filling request” and the “formulation request” are linked.
In addition, the inventory of product tanks P / T is also managed as a loose inventory, and when this inventory is cut off, the product is requested to prepare an outdoor batch O / B. A production plan is created according to the mixing request and the filling request.

[0006] A production plan is created by a skilled planner with the following items in mind. With or without product tank Products with product tanks are planned as product tank (P / T) products, and products without product tanks are planned as indoor batch (I / B) products. Oil Group and Mixing Tank Group Lubricants are classified into various applications based on their properties. Formulations are divided into several oil classes depending on the application. Indoor batch I / B is also allocated to each oil type group. For example, products of oil type group A must be prepared in a mixing tank of the oil type group A (indoor batch I / B). Presence or absence of stuffing header B0-H connected to the raw material tank BO / T Components with a large mixing ratio will be extremely inefficient unless stuffed with piping. Therefore, the components to be blended are indoor batches that are blended as raw material tanks BO / T.
Must be connected to I / B.

[0007] Connection to the filling header As described above, the filling form is lorry, drum, pail,
There are 4L cans and 1L cans. Filling headers DM-H, CS-H, LR-H for these packing types are all mixed tanks (indoor batch I / B)
Not connected to. Therefore, the product tank P / T of the product requested to be filled or the indoor batch I / B that mixes it is filled with the filling headers DM-H, CS-H, and LR-H that can fill the required packing style of the product. Must be connected. Competition of equipment Vacuum tank B / B and stuffing header BO-H are shared by multiple compounding tanks. Without proper planning, equipment competition will occur and productivity will drop due to product waiting for equipment or equipment waiting for product. Therefore, it is necessary to change the priority of the procurement request, the date of implementation, and the turning point so as to avoid competition. Equalization of operation rate in each facility It is desirable to equalize the operation rate by minimizing the bias in the equipment to be implemented as much as possible.

[0008]

Until now, skilled planners have accumulated these items as information, such as PID, equipment capacity, product recipes, and many years of experience as know-how, and have performed their duties. Was. The information in ~ is physical information, and although this information is stored in a database, most of it is provided by paper, and unskilled planners You have to spend a lot of time retrieving from the library. The information of and is information serving as an index indicating the validity of the created plan. However, since there was no simulator up to now, it was difficult to evaluate the validity of the plan by calculating the competitive condition and the operation rate of the facilities, and it was possible to evaluate it only with the experience of the planner.

The production planning work has been performed according to the procedure shown in FIG. An inventory management device A such as a general-purpose computer that manages each product for each product name and package type prints out the predicted inventory from an arbitrary date to a specified date. The planner looks at the projected inventory that was printed out,
Products that require inventory procurement are picked up as procurement requests, and the picked-up procurement requests are written on a planning sheet for pot splitting with a pencil and assigned to make a production plan. The plan of an arbitrary date is copied to another form and manually transferred from the keyboard to a computer (control computer for the lubricating oil production facility in FIG. 2).

However, almost all of these operations are performed manually, which requires a great deal of time, such as creation of forms and data entry. In addition, when a sudden change in a procurement request occurs, rescheduling becomes necessary. It was a heavy burden for planners.

SUMMARY OF THE INVENTION An object of the present invention is to solve such a conventional problem and reduce the burden on planners, and to easily and efficiently prepare a lubricating oil production plan. It is to provide a support device.

[0012]

A lubricating oil production plan supporting apparatus according to the present invention makes a lubricating oil production plan in a lubricating oil production facility provided with a plurality of types of mixing tanks having different capacities which are allocated to different oil types. A lubricating oil production plan support device used in the process, based on a procurement request file including an oil type code, a quantity, and a planned procurement date, based on the oil type code and the quantity, selecting a dispensable mixing tank. Selection means, provisional plan preparation means for preparing a provisional plan based on the preparation tank selected by the preparation tank selection means and the planned procurement date of the procurement request file, and a provisional plan prepared by the provisional plan preparation means. Simulation means for simulating the plan and outputting the result.

According to such a configuration, first, in the blending tank selecting means, a blending tank which can be blended is selected from the oil type code and the quantity of the procurement request file, and then the blending tank selected in the provisional plan creating means. A provisional plan will be prepared based on the planned procurement date of the tank and procurement request file. Therefore, the burden on the planner can be reduced, and a lubricating oil production plan can be created easily and efficiently. Then, the provisional plan created by the provisional plan creation means is simulated by the simulation means, and the result is output, so that the operation status and the competitive state of the equipment can be grasped from the result. Therefore, the validity of the plan can be evaluated. In the above configuration, if a configuration including a correction unit for correcting the provisional plan created by the provisional plan creation unit is used, the provisional plan can be corrected by looking at the simulation results, so that a near-optimal plan can be made. it can.

[0014] Another lubricating oil production plan support device of the present invention is:
Multiple types of mixing tanks with different capacities allocated to different oil types,
A filling header that is selectively connected to the plurality of mixing tanks and feeds the raw material oil and the additive into these mixing tanks, and a lubricating oil that is selectively connected to the plurality of mixing tanks and mixed in these mixing tanks. Is a lubricating oil production plan support device used to make a lubricating oil production plan in a lubricating oil production facility equipped with a plurality of types of filling headers for filling oil into different packages. Date and time, based on the procurement request file including the packing code, based on the oil type code and quantity, select a mixable mixing tank and connect the selected mixing tank to the filling header corresponding to the packing code. A mixing tank selecting means for selecting the mixing tank on condition that the preparation tank is selected, and a provisional plan for creating a provisional plan based on the mixing tank selected by the mixing tank selecting means and the planned procurement date of the procurement request file plan And forming means, to simulate the interim plan created by the provisional planning unit, characterized in that a simulation means for outputting the result.

According to such a configuration, in addition to the above-described functions and effects, the blending tank selecting means selects a blending tank which can be blended from the oil type code and the quantity of the procurement request file, and selects the blended tank. Since the mixing tank is selected including whether or not the tank is connected to the filling header corresponding to the packing code, an efficient production plan can be made.

In the above-mentioned configuration, if the configuration including the correction means for correcting the provisional plan created by the provisional plan creation means is provided, the provisional plan can be corrected on the basis of the simulation result. Can stand. In this case, the correcting means, when correcting the mixing tank in the provisional plan, checks the capacity of the corrected mixing tank and the suitability of the filling header and the filling header connected to the mixing tank. It is desirable to have. In this way, a case study can be easily performed, and sudden changes in the plan can be easily dealt with.
In the above configuration, it is preferable that the simulation means outputs a result of the simulation as a Gantt chart. In this way, the operating status and the competitive status of the equipment can be grasped at a glance, so that the validity of the plan can be easily evaluated, and the plan can be easily corrected by the correcting means.

[0017]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS One embodiment of the present invention will be described below in detail with reference to the drawings. FIG. 3 is a diagram showing the entire system of the present embodiment. The system includes an inventory management device A that manages product inventory for each product name and package, and a production plan support device B. The inventory management device A is configured to issue only a product whose proper stock has been cut out of the products as a procurement request. Here, the information of the issued procurement request file includes the procurement request N
o, product name code, packing code, quantity, scheduled procurement date, product attribute code (oil type code), priority, etc.

As shown in FIG. 4, the production planning support device B includes a mixing tank selecting means B1 for selecting a mixing tank that can be mixed based on the procurement request file output from the inventory management apparatus A.
Simulates a provisional plan creation means B2 for creating a provisional plan based on the preparation tank selected by the preparation tank selection means B1 and the procurement request file, and simulates a provisional plan created by the provisional plan creation means B2; It comprises a simulation means B3 for outputting the result and a correction means B4 for correcting the provisional plan created by the provisional plan creation means B2.

The mixing tank selecting means B1 selects a mixing tank according to the procedure shown in FIG. First, it identifies the product tank (P / T) product or indoor batch (I / B) product from the product name code in the procurement request file. For product tank (P / T) products, select the product tank P / T corresponding to the product name code. For indoor batch (I / B) products, identify whether the quantity (VOL) of the procurement request file is greater than or less than the first reference quantity. If the quantity is greater than or equal to the first reference quantity,
Select an indoor batch I / B (for example, V _m ) with a capacity that allows the quantity to be dispensed as a large quantity. At this time, the indoor batch I / B corresponding to the oil type code is selected from among the indoor batch I / Bs assigned for the preparation of a large number of products according to the oil type code of the product.

When the quantity is less than the first reference quantity (in the case of small and medium quantities), it is subsequently determined whether the quantity is equal to or greater than the second reference quantity. If the quantity is less than the second reference quantity, an indoor batch I / B (for example, V _s ) having a capacity that allows the quantity to be mixed is selected as a small quantity. In this case, as in the case of large-volume products, the indoor batch I / B corresponding to the oil type code is selected from the indoor batch I / B assigned for the preparation of small-volume products according to the oil type code of the product. You.

If the quantity is equal to or greater than the second reference quantity, that is, if the quantity is a medium quantity product that is equal to or greater than the second reference quantity and less than the first reference quantity, then the oil type code in the procurement request file is changed. After the identification, it is identified whether the quantity is equal to or more than the third reference quantity in each of these oil type codes.
If the quantity is greater than or equal to the third reference quantity, that is, if the quantity is greater than or equal to the third reference quantity and less than the first reference quantity, then the packaging code is checked. That is, the indoor batch I / B of the indoor batch of the oil type group selected by the oil type code and having a capacity capable of blending a product whose quantity is equal to or more than the third reference quantity to less than the first reference quantity is designated by the packing code. Check whether the filling headers DM-H, CS-H, LR-H are connected. Filling header DM-H, C specified by packing code
If SH, LR-H is connected, its indoor batch I / B
(For example, V ₄₀ , V ₄₂ , V ₆₀ , V ₆₂ ) are selected. Indoor batch I / B is not selected unless the filling header DM-H, CS-H, LR-H specified by the packing code is connected.
(NG). In this case, the planner may select one of the indoor batch I / Bs based on experience, or may select another indoor batch I / B determined in advance. If the quantity is greater than or equal to the second reference quantity and less than the third reference quantity, the second
Indoor batch I / B of the oil type group selected with the oil type code with a capacity that allows the product that is greater than or equal to the reference quantity to less than the third reference quantity (for example, _V41 , _V43 , _V61 , _V63 ) Is selected. Thereby, it is possible to automatically select which mixing tank should be mixed. The criteria for determining the reference quantity of each of the large, medium, and small capacities can be arbitrarily changed by moving the icon.

The provisional plan creation means B2 creates a provisional plan based on the preparation tank selected by the preparation tank selection means B1 and the procurement request file. For example, as shown in the entry screen of FIG. 6, on the scheduled procurement date, the blending process (formulation) and the filling process are performed in accordance with the blending tank (here, V ₄₆ ) selected by the blending tank selecting means B1. (DM: Fill drum).

Here, in the correcting means B4, the mixing tank to be allocated can be changed by dragging with a mouse. Also, every time you make a change,
Check whether physical constraints such as the presence or absence of the filling header BO-H, the presence or absence of the filling header DM-H, CS-H, LR-H, and the capacity of the mixing tank are satisfied. Can be changed to inform the planner of that fact. As a result, a case study can be easily performed, and sudden changes in the plan can be easily dealt with. The parameters that can be changed include a mixing tank, a mixing rotation number, a mixing quantity, and a priority. In addition, the change of the parameter is not limited to the change by the planner's manual, and the GA (Genetic Algorithm) or SA (simu
Optimization techniques such as lated annealing are also possible.

The simulation means B3 simulates the provisional plan created by the provisional plan creation means B2 and outputs the result. The procurement request process used in the simulation is, for example, as shown in FIG. FIG. 7 shows a process of producing a lubricating oil of industrial gear oil. In the figure, the first stage from the top shows that the washing step, the blending step, and the filling step (the filling step of filling the drum DM) are performed in order. The second row shows a breakdown of the blending process, showing a first outlet C1, a second outlet C2, a third outlet C3, a temperature rise, a stirring process, and a test process. The third row is the first outlet C
After the base oil is applied and stirred in 1, the additive is applied, a process in which the base oil is applied in the second outlet C2 and the additive is applied in the vacuum tank are performed in parallel, and the additive is manually applied in the third outlet C3. Respectively, to perform the process of sticking and stirring. The fourth row shows the types of base oil and additives used in each step.

Starting from the beginning of the process, when each process is completed, the Current-pointer moves and processes according to the connection. In the process of each process, as shown in FIG. 8, each process in a processable state is inserted at the end of the equipment list. As soon as the equipment becomes idle (idling), it is checked from the top of the list whether or not the equipment can be manufactured, and if manufacturing is possible, the process is assigned to the equipment. When a plurality of processes are allocated at the same time, the process with the higher priority is allocated to the equipment first.
In this case, it is also possible to perform a simulation of allocating equipment while arbitrarily changing the order in the list according to the priority order or quantity of the procurement request.

The result of the simulation is output to a Gantt chart as shown in FIG. In FIG. 9, V
_{42, V 43, V 44,} V 45, V 46, V 47 represents an indoor batch I / B. Although not shown here, in addition to the indoor batch I / B, the vacuum tank B / B, the outdoor batch O / B, the outlet batch C / B, the filling header BO-H, the filling The processing of the headers DM-H, CS-H, and LR-H is also displayed. Since the competitive state of the equipment can be grasped from the output Gantt chart, the provisional plan is corrected by the correcting means B4. That is, the planning parameters are changed. Thereby, a plan that is close to optimal can be created. Finally, the equipment to be executed, the date of implementation, the number of rotations, the start and end times of each process, which are calculated by simulation, are added to the procurement request file as planning results, and returned to the product inventory management device A.

According to the present embodiment, first, the preparation tank selecting means B1 identifies the product tank (P / T) product or the indoor batch (I / B) product by the product name code of the procurement request file, and For (P / T) products, select the product tank P / T corresponding to the product name code. Also, indoor batch
(I / B) products are classified into large, medium, and small products according to the quantity in the procurement request file, and then the type of lubricating oil is identified by the oil type code. , A mixing tank (indoor batch)
Since I / B) is selected, the optimum mixing tank can be selected without putting a burden on the planner. In addition, when selecting the mixing tank, the mixing tank selected from the quantity and each type is filled with the filling header DM-H, CS-H,
Since the mixing tank is selected including whether or not it is connected to the LR-H, an efficient production plan can be made.

Then, in the provisional plan creation means B2,
Since the provisional plan is created based on the selected compounding tank and the planned procurement date of the procurement request file, the burden on the planner can be reduced and the lubricating oil production plan can be efficiently created. . In addition, the simulation means B3 simulates the provisional plan created by the provisional plan creation means B2, and outputs the result, so that the operation state and the competitive state of the equipment can be grasped from the result. Therefore, the validity of the plan can be evaluated. that time,
The simulation means B3 outputs the result of the simulation as a Gantt chart, so that the operation status of the equipment and the competitive condition can be grasped at a glance.

Further, since the provisional plan can be corrected by the correction means B4 based on the simulation result, a plan that is close to optimal can be made. Moreover, when the blending tank in the provisional plan is modified, the capacity of the modified blending tank and the extension header BO-H connected to the blending tank are modified.
And the filling headers DM-H, CS-H, and LR-H are checked for suitability, making case studies easier.
Sudden plan changes can be easily handled.

In the above-described embodiment, in the mixing tank selecting means B1, the number of mixing tanks selected from each system and the filling headers DM-H, CS-H, LR connected thereto are selected.
Although the suitability of -H is checked, the embedding header BO-H may be checked at this time. Further, the simulation means B3 outputs the simulation result in a Gantt chart, but the output method is not limited. In addition, in the correction means B4, every time a change is made, the presence / absence of the insertion header BO-H, the filling header DM-H, CS-H, LR
-Check if physical constraints such as the presence of -H and the capacity of the mixing tank are satisfied, and if not, change the color to notify the planner of that, but not limited to these, blinking, message, The notification may be made by a sound or the like.

[0031]

The lubricating oil production plan support device of the present invention can easily and efficiently prepare a lubricating oil production plan while reducing the burden on planners.

[Brief description of the drawings]

FIG. 1 is a diagram showing a schematic configuration of a lubricating oil production facility.

FIG. 2 is a diagram showing a flow of creating a conventional lubricating oil production plan.

FIG. 3 is a diagram showing an entire embodiment to which a lubricating oil production plan support device of the present invention is applied.

FIG. 4 is a diagram for explaining internal functions of the lubricating oil production plan support device in the embodiment.

FIG. 5 is a diagram showing a flow in a selection direction of a preparation tank selection unit in the embodiment.

FIG. 6 is a diagram showing an entry screen in a provisional plan creation unit in the embodiment.

FIG. 7 is a view showing steps of a simulation means in the embodiment.

FIG. 8 is a diagram showing a procedure of processing by a simulation means in the embodiment.

FIG. 9 is a diagram showing a Gantt chart output from the simulation means in the embodiment.

[Explanation of symbols]

P / T Product tank O / B Outdoor batch (mixing tank) I / B Indoor batch (mixing tank) C / B Outlet batch B / B Vacuum tank BO-H Filling header DM-H Filling header (Drum filling header) CS-H Filling header (Pail can, 4L can, 1L can filling header) LR-H Filling header (Rolling filling header) A Inventory control device B Production planning support device B1 Mixing tank selection means B2 Temporary plan creation means B3 Simulation Means B4 Correction means

Claims (6)

[Claims] 1. A lubricating oil production plan support device for use in making a lubricating oil production plan in a lubricating oil production facility provided with a plurality of types of mixing tanks having different capacities allocated to oil types. A mixing tank selecting means for selecting a mixing tank that can be mixed based on the oil type code and the quantity based on a procurement request file including a code, a quantity, and a planned procurement date; and a mixing tank selected by the mixing tank selecting means. And provisional plan creation means for creating a provisional plan based on the planned procurement date of the procurement request file, and simulation means for simulating the provisional plan created by the provisional plan creation means and outputting the result. A lubricating oil production plan support device. 2. The lubricating oil production plan support device according to claim 1, further comprising a correction unit that corrects the provisional plan created by said provisional plan creation unit. 3. A plurality of compounding tanks having different capacities allocated to oil types and having different capacities, a plug header which is selectively connected to the plurality of compounding tanks and in which a raw material oil and an additive are inserted into these compounding tanks, When preparing a lubricating oil production plan at a lubricating oil production facility equipped with multiple types of filling headers that are selectively connected to different types of mixing tanks and that fill the lubricating oil mixed in these mixing tanks into different packages. A lubricating oil production plan support device to be used, based on a procurement request file including an oil type code, a quantity, a scheduled procurement date, and a packing code, select a blending tank that can be prepared from the oil type code and the quantity. A mixing tank selecting means for selecting the mixing tank on condition that the selected mixing tank is connected to a filling header corresponding to the packing code; and a mixing tank selected by the mixing tank selecting means. And said Provisional plan creation means for creating a provisional plan based on the expected date of procurement of the delivery request file, and simulation means for simulating the provisional plan created by the provisional plan creation means and outputting the result A lubricating oil production planning support device characterized by the following. 4. The lubricating oil production plan support device according to claim 3, further comprising a correction unit that corrects the provisional plan created by the provisional plan creation unit. 5. The lubricating oil production planning support device according to claim 4, wherein the correction means, when correcting the mixing tank in the tentative plan, adjusts the capacity of the corrected mixing tank and the capacity of the mixing tank. A lubricating oil production planning support device having a function of checking the suitability of a connected header and a filling header. 6. The lubricating oil production plan support device according to claim 1, wherein said simulation means outputs a result of the simulation as a Gantt chart. apparatus.