JPH1043996A - Production schedule planing system - Google Patents

Abstract

PROBLEM TO BE SOLVED: To mutually switch different offline processes by providing a production schedule planning means for designating a production order to be changed, extracting a master process corresponding to this production order, and reforming a production order on the basis of the master process. SOLUTION: A process changing means 114 searches and changed another offline process having the same input item and production item as a certain offline process. Three means of order process decomposing means 110, collecting means 111, order number calculating means 112 have functions of breaking down each order into process unit to collect the same process and also calculating input quantity. A production schedule planning means 113 actually makes a production schedule on the basis of a production order file 105, and also corrects the plan in the state including the process changed by the process changing means 114.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a production planning system, and more particularly, to a production planning system capable of changing a process when there are a plurality of processes for producing a production item from an input item.

[0002]

2. Description of the Related Art When a plurality of items are produced using a plurality of production machines, at present, an efficient production plan is prepared in advance by a production planning system, and the production machines are operated based on the prepared plan. It is performed in the procedure as follows. Such a production planning system is disclosed by the present applicant in JP-A-3-32556, JP-A-3-256657, JP-A-5-305556, and the like. Has helped. Japanese Patent Application Laid-Open No. 5-305556 discloses a process in which an input item (a wide-width large-diameter product) and a production item (a narrow-width sheet product) are the same as shown in FIG. When there are two types of processes, an in-line process performed by one machine and an offline process performed by two machines as shown in Fig. 2 (b), a production plan that can freely switch between the in-line process and the offline process A planning system is described.

[0003]

However, the above-mentioned conventional production planning system can switch between an in-line process and an offline process, but cannot flexibly change processes such as switching between offline processes. Therefore, when a production delay, a failure of a production machine, or the like occurs, it is not possible to switch to another process combination, and there is a problem that a delivery date is delayed. An object of the present invention is to provide a production plan planning system in which the input item and the production item are the same and in which different off-line processes can be switched between in order to solve the above problems.

[0004]

The above objects are achieved by receiving an order file storing order data, a process master file in which a production process is registered, a manufacturing specification master file in which a combination of a production process and a production machine is registered, and A production order file storing a production order as a processing unit for planning, a designation unit for designating a production order to be changed, and a process change unit for extracting a master process corresponding to the designated production order And a production plan drafting means for re-creating the production order based on the extracted master process.

[0005]

DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described below.
FIG. 1 is a block diagram of an embodiment of a production planning system according to the present invention. In FIG. 1, reference numeral 100 denotes a production planning system according to the present invention. The production planning system 100 is connected to an order input terminal 20, a production terminal 30, and a warehouse terminal 40 via a network 50. A production machine 32 is connected to the terminal 30 via a production number counter 31. The order input terminal 20 is a terminal for inputting when an order is received, and the order data input here is registered in the production planning system 100. The production terminal 30 is a terminal that manages the operation of the production machine 32, transmits an instruction from the production planning system 100, and grasps the number produced by the production machine 32 via the production number counter 31. The entry / exit terminal 40 manages entry / exit of materials and products.

As shown in FIG. 1, a production planning system 100 includes an order file 101, a process master file 1
02, process disassembly order file 103, manufacturing specification master file 104, production order file 105, data read / write means 106, order data registration means 107, process master registration means 108, manufacturing specification master registration means 109, order receiving process disassembly means 110, summary Means 111, order quantity calculating means 112, production planning means 113, process changing means 114, input / output control means 115, keyboard 11
6, printer 117, mouse 118, display 11
9 is provided.

[0007] In FIG. 1, an order file 101, a process master file 102, a process disassembly order file 103, a manufacturing specification master file 104, and a production order file 105 are stored in a storage unit in the production planning system 100. . The data read / write means 106 is for reading / writing data from / to each file. The order data registration unit 107, the process master registration unit 108, and the manufacturing specification master registration unit 109
1. A process for registering data in the process master file 102 and the manufacturing specification master file 104 is performed. Order receiving process disassembling means 110, collecting means 111,
The three means of the order quantity calculation means 112 are characteristic parts of the present apparatus, and have a function of disassembling each order into process units to combine the same processes and calculate the input quantity.
The production planning unit 113 generates the production order file 105
This function is used to actually create a production plan on the basis of this function. In addition to the function similar to that of the conventional production planning system, this function is used to correct the plan while including the process changed by the process changing means 114. It also has the function of performing The process changing means 114 is a feature of the present invention, and has a function of searching for a certain offline process and another offline process in which the input item and the production item are the same, and changes the process. The input / output control unit 115 has a function of transmitting an input from the keyboard 116 and the mouse 118 to each unit, and giving an output from each unit to the printer 117 and the display 119.

Here, the production process performed in the present embodiment will be described with reference to FIG. 2 (a) to 2 (c)
In each case, the process of producing the production item “narrow sheet product 12” from the input item “wide large winding diameter product 11” is shown. FIG. 2A shows a process of continuously performing slit and sheet cutting by a production machine capable of performing both slit and sheet cutting. FIG. 2 (b) shows that a production machine capable of performing only slitting produces a narrow-width large-diameter product 13 and then a production machine capable of performing only sheet cutting.
Is the process of producing FIG. 2C shows a process in which a wide-width sheet product 14 is produced by a production machine capable of performing only sheet cutting, and then a narrow-width sheet product 12 is produced by a production machine capable of performing only cutting.

Next, each file stored in the storage unit of the apparatus will be described. FIG. 3 is a diagram illustrating an example of the order file 101. As shown in FIG. 3, the order file 101 includes an order number for specifying an order, a final product name of the order, a required amount, and a delivery date. For example, the order specified by the order number “1010” is to deliver the product “80,000 pieces” of “bagged product A” on “February 17”,
Indicates that.

FIG. 4 is a diagram showing an example of the process master file 102. The process master file 102 is a file in which all the production processes that can be performed by the production machines managed by the production management system are registered, and a master process ID for specifying the process, a production item produced by the process, Production process priority, which indicates the priority when there are multiple processes with the same item, input items that are used as materials for producing the product, and initial input loss, which is the number of defective products expected at the start of production in that process , A running reserve rate that indicates the probability of defective products during production, a standard allowance period for completing production earlier than the original delivery date so that any trouble can be dealt with, and other order numbers When the production is carried out together with the same production item, it is composed of a collection period that indicates how many days the delivery date of the order can be collected up to . For example, the process specified in the process “a” is a process in which a “narrow sheet product C” is input to produce a “bagged product A”. In this process, the initial “1000” is set regardless of the production amount. "" Indicates that the operation of the machine is not stable, so that it cannot be a product, and that even after the operation of the machine is stabilized, a defective product is generated with a probability of "0.02".

FIG. 5 is a diagram showing an example of the process disassembly order file 103. The process disassembly order file 103 is obtained by disassembling each order for each process with reference to the process master file 102 until the final product of the order file 101 is created. The process ID, order number, production item, input It is composed of items, required production, required input, and a provisional delivery date indicating a scheduled end of the process.

FIG. 6 shows an example of the manufacturing specification master file 104. The manufacturing specification master file 104
This indicates that each production item is produced by inputting which item to which machine. When the production specification ID, production item, input item, and production item and input item are the same, which production machine has priority. And a standard time indicating how much can be produced in one minute.

FIG. 7 is a diagram showing an example of the production order file 105. The production order file 105 is a summary of the processes in which the production item and the input item are the same in the process disassembly order file 103 based on the collection period of the process master file 102, and includes a key portion and a planning portion. The planning section is composed of a production machine, a required production amount, a required input amount, a planned start time, and a planned end time.

Next, the processing operation of this system will be described with reference to the flowchart of FIG. First,
An order file 101, a process master file 102, and a manufacturing specification master file 104 are registered. This is done by inputting data using the keyboard 115 or the mouse 117, performing processing by the order data registration means 107, the process master registration means 108, and the manufacturing specification master registration means 109 via the input / output control means 114, This is done by creating the respective files via. The order file 101 can also be registered from the order input terminal 20 via the data read / write means 106. (S1)

Next, when an instruction to start the production order is issued, the order file 101, the process master file 10
2 is read by the data read / write unit 106 and passed to the order receiving process disassembling unit 110. Order process disassembly means 110
Decomposes each order data in the order file 101 into a plurality of processes with reference to the process master file 102. For example, in the order file 101 of FIG.
In the case of the order data of “010”, first, the order number “101”
0 based on the process data of the master process ID “a” of the process master file 102 in which the production item matches the final product “bagged product A” of the process ID “h” in the process disassembly order file 103. Create At this time, the required production amount of the process “h” is the required amount of the order file itself, but the required input amount is based on the required production amount, the initial input loss of the process master file 102, and the running reserve ratio.
It is calculated by the following formula (1).

[Equation 1] (required input) = (required production) × (1 + running reserve ratio) + (initial input loss)

When the required input amount of the process “h” is calculated according to the calculation formula of Expression 1, (required input amount) = 80000 ×
(1 + 0.02) + 1000 = 82600. Also, since the standard allowance period of the process master file is “3 days”, “February 14”, which is “3 days” earlier than the delivery date “February 17” of the order number “1010”, is changed to the process “h”. Provisional delivery date. Here, the process in which the input item “narrow sheet product B” of the process “h” is a production item is further searched from the process master file 102. Although there are three processes in which the “narrow sheet product B” is a production item, the process “c”, the process “d”, and the process “e” in the process master file 102, the process “ The process “i” is created in the process disassembly order file 103 based on the data “c”. The required production amount of the “narrow sheet product C” in the process “i” is the required input amount “8” of the “narrow sheet product C” in the process “h”.
2600 pieces ", the necessary amount of the" wide and large wound product D "is" 92208 pieces "according to the calculation formula of Expression 1. The provisional delivery date of the process “i” is “February 12” obtained by adding a margin of the standard allowance period “2 days” of the master process “c” to the provisional delivery date “February 14” of the process “h”. Day ”.
Subsequently, a process in which the input item “wide and large diameter product D” of the process “i” is a production item is searched from the process master file 102, but is not found, so the process disassembly of the order number “1010” ends. . Thus, the order file 1
The process is disassembled for all the order numbers 01, and the process disassembly order file 103 is completed. (S2)

After the order disassembly process file 110 is created by the order disassembly process unit 110, the production order file 105 is created by the consolidation unit 111, the order quantity calculation unit 112, and the production planning unit 113. (S3-S5)

The collecting means 111 collects the process data for performing the same processing in the process disassembly order file 103 to create one production order. A specific example will be described with reference to FIGS. First, the process disassembly order file 10
Focusing on the production item “bag-packed product A” and the input item “narrow-width sheet product C” of process “h” in 3, whether or not the process with the same production item and input item exists in the process disassembly order file 103 Search for In this case, since there is no one having the same combination of the production item and the input item as the process “h”, the integration with other processes is not performed. In this process, the order number “201”
"0" is added, and a key portion of the production order "2010" is created in the production order file 105. When there are a plurality of processes having the same combination of the production item and the input item in the process disassembly order file 103, the provisional delivery dates of the plurality of processes are as follows.
If the process is included in the process integration period in the process master file corresponding to the process, the processes are integrated and one production order is created. For example, in the example of FIG.
The combination of the production item and the input item is the same in the process “i” and the process “k”, and the collection period of the master process “e” in the corresponding process master file 102 is “5 days”.
The provisional delivery dates of the process “i” and the process “k” are respectively “2”.
Since the date is "Month 12" and "February 13", which are within 5 days, the production is ordered and the production order with the order number "2030" is created. (S3)

After the processing of the collecting means 111 is completed, the order quantity calculating means 112 calculates the required production quantity and the required input quantity. For example, the production order file 1 shown in FIG.
In step 05, the production requirement of the production order “2030” is calculated by the order quantity calculation means 112 as the total production requirement of the process “i” and the process “k”, and the calculated production requirement and the process master file 102 are calculated. The required input amount of the production order “2030” is calculated based on the initial input loss and the running reserve rate of the master process “c”. Further, the order quantity calculation means 112 performs a task of allocating a production machine to a production order. For example, in the production order file 105 of FIG.
In the case of, the production item is “narrow-width sheet product C” and the input item is “wide-width and large-diameter product D”.
The production specification of the combination of the input items is searched from the production specification master file 104. In this case, there are two specifications corresponding to the manufacturing specification “n” and the manufacturing specification “o”, but the production machine “slit + sheet cutting machine 1” of the manufacturing specification “n” having the priority order “1” is produced. Assign to order “2030”. Next, the order quantity calculation means 112 outputs the necessary input amount of the production order file 105, the production specification master file 1
Based on the switching time 04 and the standard speed, the required time of the production order is calculated. The calculation of the required time of the production order is performed by the following equation (2).

[Equation 2] (Time required) = (Required input amount) ÷ (Standard speed)
+ (Switching time)

For example, in the case of production order "2030",
The required input amount is “148368” and the standard speed is “20
0 ", and the switching time is" 150 ".
= 148368/200 + 150 = 891.84 (min)
Becomes (S4) When the required time is calculated, the production planning unit 113
Each production order is assigned to an open time zone of each production machine. Thereby, as shown in FIG. 7, data of the planned start time and the planned end time of the production order file 105 are created. (S5) The production order for which there is no instruction to change the process until the start time is passed to the production terminal 30 as it is, and when the planned start time comes, the production is started. If there is a process change instruction before the start time, the process is changed. (S6)

When the process is changed, the operator uses the keyboard 116 or the mouse 118 to specify the production order to be changed in the production order file 105. For example, the production order “2030” is specified in the example of FIG.
Then, the process changing unit 114 sets the production order “203
A process for producing a production item “narrow sheet product C” of “0” is retrieved from the process master file 102, and master processes “c”, “d”, and “e” are extracted. Since the master process “c” is the same as the current production order “2030”, for the other master processes “d” and “e”, the input items “narrow wide large diameter product E” and “wide sheet product” A process in which “F” is a production item is searched from the process master file 102. Then, the corresponding master processes “f” and “g” are extracted. Combination of master process “d” and “f”, master process “e”,
The combination of the production item and the input item by the combination of “g” is the production item of the production order “2030”,
Since it matches the combination of the input items, the combination of the master processes “d” and “f”, the master process “e”,
The combination of “g” is displayed on the display 119, and the operator is requested to select one of the combinations of steps. For example, if the operator selects a combination of the master processes “d” and “f” here, FIG.
As shown in (a), the production orders "2031" and "2032" are created in the production order file 105. Next, FIG.
By performing the same processing as in S4, data on the production machine, the required production amount, and the required input amount are created, and the required time is calculated. Further, by performing the same processing as S5 in FIG. 8, data of the planned start time and the planned end time is created. (S7)

The production order whose process has been changed in this way is transferred to the production terminal 30, and when the planned start time is reached, production is started. In the above example, the case where the in-line process is changed to the offline process has been described. Next, in S7, the case where the offline process is changed to another offline process will be described. Fig. 9 (a)
In the case where the production orders “2031” and “2032” are created in the production order file 105 as shown in FIG. 19, when the operator issues a process change instruction to the production orders “2031” and “2032”, the process change means 113a Is a production item “narrow sheet product C” of the production order “2031” which is a post-process of the production orders “2031” and “2032”.
Are retrieved from the process master file 102, and master processes “c”, “d”, and “e” are extracted.
The input item “wide and large diameter product D” of the master process “c” matches the input item of the production order “2032”, and is therefore a change process candidate. The master process “d” corresponds to the production order “20”.
31 "is not the same as the change process candidate. When the process for producing the input item “wide sheet product F” of the master process “e” is searched from the process master file 102, the master process “g” is extracted, and the input item “wide wide large diameter product” of the master process “g” is extracted. Since “D” matches the input item of the production order “2032”, a combination of the master processes “e” and “g” is set as a change process candidate. Here, a combination of the master process “c”, the master process “e”, and “g”, which are the change process candidates, is displayed on the display 119, and the operator is requested to select one of the process combinations. If the operator selects a combination of the master processes “e” and “g” here, the production orders “2033” and “203” are stored in the production order file 105 as shown in FIG.
4 "is created. Thereafter, data of the production machine, the required production amount, the required input amount, the planned start time, and the planned end time are created.

[0023]

According to the present invention, the production order to be changed is specified from among the production orders which are the processing units for drafting the production plan, and the process change means specifies the master process corresponding to the specified production order. Since the production order is re-created based on the extracted master process, the production order can be changed according to the progress of the production and the condition of the machine.

[Brief description of the drawings]

FIG. 1 is a block diagram of an embodiment of a production planning system according to the present invention.

FIG. 2 is an explanatory diagram of a production process according to the embodiment of the present invention.

FIG. 3 shows an example of an order file 101.

FIG. 4 is a diagram showing an example of a process master file 102.

FIG. 5 is a view showing an example of a process disassembly order file 103;

FIG. 6 is a diagram showing an example of a manufacturing specification master file 104;

FIG. 7 shows an example of a production order file 105.

FIG. 8 is a flowchart showing a processing operation of the production planning system of the present invention.

FIG. 9 is a diagram showing an example of a production order file 105 whose process has been changed.

[Explanation of symbols]

 Reference Signs List 101 Order file 102 Process master file 103 Process disassembly order file 104 Manufacturing specification master file 105 Production order file 106 Data reading / writing means 107 Order data registration means 108 Process master registration means 109 Manufacturing specification master registration means 110 Order processing disassembly means 111 Collecting means 112 Order quantity calculation means 113 Production planning means 114 Process change means 115 Input / output control means

Claims (1)

[Claims] An order file storing order data;
It has a process master file in which production processes are registered, a production specification master file in which combinations of production processes and production machines are registered, and a production order file in which production orders are stored as processing units for production planning. Designation means for designating a production order to be provided, process change means for extracting a master process corresponding to the designated production order, and production plan drafting means for re-creating a production order based on the extracted master process Production planning system characterized by