JPH1094948A - Production scheduling planning system - Google Patents

Abstract

PROBLEM TO BE SOLVED: To change the production corresponding to the production progressing state, by comprising production changing means for changing a production order when the value counted by production counting means, is not agreed with a schedule. SOLUTION: A production terminal 30 sends an instruction for the start of the production at the starting time, thereby the production is started. When the production is started, a production counter 31 counts the number input by a production equipment 32 and the number of production, and transmits the counted value to an actual result part of a production order file 105. Production changing means 114 checks whether the production order just finished, is agreed with the schedule or not, when the production order has been finished. When the just finished production order is not agreed with the schedule, the schedule is changed by the production 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 the number of products according to the progress of production.

[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.

[0003]

However, in the above-mentioned conventional production planning system, even if a production order once started does not go as planned, a later production order is executed according to the set plan. Products could be short or over due to production orders that did not go along. SUMMARY OF THE INVENTION An object of the present invention is to provide a production planning system capable of changing a production amount according to a production progress in order to solve the above-described problems.

[0004]

SUMMARY OF THE INVENTION The above-mentioned problems are caused by a production order file storing a production order as a processing unit for drafting a production plan, a production means for producing according to the production order, and an item inputted to the production means. Production number counting means for counting the number of items and the number of items produced by the production means,
The problem is solved by providing a production quantity changing means for changing the production order when the value counted by the production number counting means is not as planned.

[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 outputs the number of items input by the production machine 32 via the production number counter 31 and the number of items produced. Determine the number of items that have been lost.
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 It comprises means 111, order quantity calculating means 112, production planning means 113, production quantity changing means 114, input / output control means 115, keyboard 116, printer 117, mouse 118, and display 119. In FIG. 1, an order file 101, a process master file 102, a process disassembly order file 10
3. Each file of the manufacturing specification master file 104 and the production order file 105 is stored in the production planning system 100.
Is stored in the storage unit. Data read / write means 106
Is for reading and writing data in each file. Order data registration means 107, process master registration means 1
08, the manufacturing specification master registration means 109 performs processing for registering data in the order receiving file 101, the process master file 102, and the manufacturing specification master file 104, respectively. The order receiving process disassembling means 110, the consolidating means 111, and the order quantity calculating means 112 are characteristic parts of the present apparatus, and a function of disassembling each order into process units to combine the same process and calculate the input quantity. Having. The production plan drafting means 113 is for actually drafting a production plan based on the production order file 105. This function is the same as that of a conventional production plan drafting system. The production quantity changing means 114 has a function of changing the production order when the production by the production machine 32 is not as planned. The input / output control means 115 is the keyboard 1
16. It has a function of transmitting an input from the mouse 118 to each means and giving an output from each means to the printer 117 and the display 119.

Here, the items produced in this embodiment will be described. In this embodiment, as shown in FIG. 2, there are four items: a wide-width product 11, a narrow-width product 12, a sheet product 13, and a packaged product 14. A narrow-width product 12 is obtained by passing the wide-width product 11 through a slitting process, a sheet product 13 is obtained by passing the narrow-width product 12 through a sheet cutting process, and a bag is formed by passing the sheet product 13 through a bagging process. A filling 14 is obtained.

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 item name of the order, a delivery date, and a required number. For example, the order specified by the order number “1010” indicates that the item “bagged product B” is to be delivered “20000” on “February 17”.

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, Initial input loss, which is the number of defective items expected at the start of production in that process,
Running reserve ratio, which indicates the probability of defective products during production,
Even if there is any trouble, if there is a standard spare time to complete production earlier than the original delivery date so that it can be dealt with, Is composed of a collection period that indicates how many days the delivery date can be collected. For example, the process specified by the master process “a” is a process of inputting “sheet product C” to produce “bagged product A”, and in this process, the initial “100” regardless of the number of products to be produced. Since the operation of the machine is not stable, it cannot be used as a product, and a defective product is generated with a probability of “0.01” even after the operation of the machine is stabilized.

FIG. 5 is a diagram showing an example of a 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 the item, the required number of production, the required number of inputs, and the provisional delivery date of the process indicating the end schedule 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 collection of 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 unit, a planning unit, and an actual unit. The key part is composed of the order number, production item, and input item that are the actual processing units, the planning part is composed of production machines, the number of production required, and the number of input required, and the actual part is composed of status, number of production, and number of input. Is done. Actually, the planning section has data of a planned start time and a plan end time, and the actual section has data of a start time and an end time, but these are omitted here.

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 a keyboard 116 or a mouse 118, performing processing by an order data registering unit 107, a process master registering unit 108, and a manufacturing specification master registering unit 109 via an input / output control unit 115. 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”
Based on the process data of the master process ID “b” of the process master file 102 in which the final item “bagged product B” of “0” matches the production item, the process data of the process ID “e” is stored in the process disassembly order file 103. Create At this time, the required production quantity of the process “e” is the required quantity of the order file itself, but the required input quantity is based on the required production quantity, the initial input loss of the process master file 102, and the running reserve rate.
It is calculated by the following formula (1).

[Equation 1] (Required input number) = (Required production number) × (1 + Running reserve ratio) + (Initial input loss)

When the required number of inputs for the process “f” is calculated according to the formula of Equation 1, (the required number of inputs) = 20,000 ×
(1 + 0.01) + 100 = 20300. Also,
Since the standard slack period of the process master file is “1 day”, “February 16”, which is one day earlier than the delivery date “February 17” of the order number “1010”, is provisional delivery date of the process “e”. And Here, a process in which the input item “sheet product C” of the process “e” is a production item is further searched from the process master file 102, and this is searched for in the process master file 10.
Since it is known that this is the master process “c” of the second process, the process disassembly order file 1 based on the data of the master process “c”
In step 03, a process “f” is created. Since the required number of “sheet products C” to be produced in the process “f” is the required number of “sheet products C” to be input in the process “e” is “20300”, the “narrow winding product” The required input number of "D" is "22830". In addition, the provisional delivery date of the process “f” is “February 15” in which the provisional delivery date “February 16” of the process “e” is given a margin of the standard allowance period “1 day” of the master process “c”. Day ”. Subsequently, when a process in which the input item “narrow width product D” of the process “f” is a production item is searched from the process master file 102, the process is the master process “d”. First, a process “g” is created in the process disassembly order file 103. Further, the step "g"
Is searched for in the process master file 102, but the process disassembly of the order number "1010" ends. In this way, the process is disassembled for all the order numbers in the order file 101, and the process disassembly order file 103 is completed. (S2)

After the process disassembly order file 103 is created by the order accepting process disassembling means 110, a production order file 105 is created by the consolidating means 111, the order quantity calculating means 112, and the production plan drafting means 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 “bagged product B” and the input item “sheet product C” of the process “e” in 3, it is searched whether or not the process having the same production item and input item exists in the process disassembly order file 103. . In this case, since there is no product having the same combination of the production item and the input item as the process “f”, the integration with other processes is not performed. The order number “2010” is assigned to this process, and the production order “2” is added to the production order file 105.
010 "is created. When there are a plurality of processes having the same combination of production item and input item in the process disassembly order file 103, the provisional delivery dates of the processes are included in the process consolidation period in the process master file corresponding to the process. In this case, the processes are arranged in order from the one with the earliest provisional delivery date, and one production order is created. For example, in the example of FIG. 5, the process “f”, the process “i”, and the process “l” have the same combination of the production item and the input item, and the corresponding master process “c” in the process master file 102.
Is "2 days". The provisional delivery dates of the process “f”, the process “i”, and the process “l” are “February 1”, respectively.
5 ”,“ February 16 ”, and“ February 18 ”, and the provisional delivery date of the process“ f ”and the process“ i ”is within 2 days. Is created, and the production order of the order number “2060” is created for the process “l” as it is. (S
3)

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 required production quantity of the production order “2020” is calculated by the order quantity calculation means 112 as the sum of the required production quantities of the process “f” and the process “i”, and the calculated required production quantity and the process master file 102 are calculated. The required number of inputs for the production order “2020” 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, since the production item is “sheet product C” and the input item is “narrow width product D”, the production specification of the same combination of production item and input item is searched from the production specification master file 104. In this case, since this corresponds to the manufacturing specification “r”, the production machine “Sheet cut machine 1” with the manufacturing specification “r” is assigned to the production order “2020”. In this case, the number of corresponding manufacturing specifications is one, but if there are two or more, the one with a higher priority is assigned. Next, the order quantity calculation means 112 calculates the required time of the production order based on the required number of inputs of the production order file 105, the switching time of the manufacturing specification master file 104, and the standard speed. The calculation of the required time of the production order is performed by the following equation (2).

[Equation 2] (Time required) = (Required number of inputs) / (Standard speed)
+ (Switching time)

For example, in the case of a production order "2010",
Since the required number of inputs is “20300”, the standard speed is “60”, and the switching time is “130”, (required time) = 203
00 ÷ 60 + 130 = 468 (minutes). (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. When the production order in the production order file 105 in FIG. 7 is assigned according to the operation status of each production machine, a plan progress screen 119 a shown in FIG. 9 is displayed, which is displayed on the display 119. By allocating the production order, data of the planned start time and the planned end time of the production order file 105 are created. In the plan progress screen 119a shown in FIG. 9, the horizontal axis indicates the production machine, the vertical axis indicates the date and time, and a rectangle indicating the production order is assigned. Within the rectangle indicating the production order, the order number, the production item and its actual and planned number, and the input item and its actual and planned number are displayed. The length of this rectangle in the vertical direction is proportional to the required time doing. For example, “2” of “Slit machine 1”
Production order “2030” assigned to “Month 15”
Means that the production item is “narrow width product D” and the actual number is “0”, the planned number is “28446”, the input item is “wide width product E” and the actual number is “0” and the planned number is “35136” It is shown that. The planned number is the required number of productions and the required number of inputs in the production order file 105. (S5)

In the production order file 105, a performance section for storing performance data is assigned to each production order. However, at this point, no data has been entered because production has not started. Production order file 105
Is created, the data of the key part and the planning part of the production order file 105 are passed to the production terminal 30. When the start time comes, the production terminal 30 sends a production start instruction to the production machine 32, and production starts. When the production is started, the production number counter 31 counts the number input by the production machine and the number produced, and passes the counted value to the performance section of the production order file 105. (S6)

At the end of the production order, the production quantity changing means 114 checks whether or not the production order just completed is as planned. If the actual number of production items and the actual number of input items of the production order that has just finished reach the planned number at the same time, it is as planned.When the actual number of production items or input items reaches the planned number, the other actual If the number does not reach the planned number, it is not as planned. (S
7)

If the production order just completed is as planned, it is checked whether all production orders have been completed. If all production orders have been completed, the production is terminated. If production continues. (S
8)

If the production order just finished is not as planned, the plan is changed by the production quantity changing means 114. (S9)

Hereinafter, the processing of S7 to S9 will be specifically described. For example, as shown in FIG. 10A and FIG. 11, when the input number of the production order “2030” reaches the required input number and the production number reaches the required production number at the same time, the next production order “2020” is left as it is. Is processed. Production order "20
When the input number of “20” reaches the required input number, the production number of “sheet products C” is insufficient by “4000” in the required production number. If the "sheet product C" is short of "4000", the production order "2010" can be performed, but the production order "2040" cannot be executed. Therefore, in order to supplement the shortage of “Sheet product C”, the required production number of another production order “2060” for producing “Sheet product C” is “40”.
00 "is increased, the required number of inputs is recalculated, and the required time is recalculated. Also, the end time of the production order “2060” is set to be earlier than the start time of the production order “2040” so that the production order “2040” can be executed. Next, according to the increase in the input item “narrow width product D” of the production order “2060”, the production order “2060” is increased.
70, the required number of input items “wide-width products E” and production items “narrow-width products D” is increased. In addition, the production order “207
After recalculating the required time of “0”, the planned end time is set before the planned start time of the production order “2060”.

Conversely, as shown in FIGS. 10 (b) and 12, when the production number of the production order "2020" has reached the required production number, and the input number has not reached the required production number, the "narrow width" Since the "winding product D" has a surplus of "2000", this surplus is used for the production order "2060". In this way, the required production quantity of the production order “2070” is reduced to “20”.
00 ", and the required number of inputs can be reduced accordingly. Since the required number of inputs has decreased, the required time of the production order “2070” is recalculated, and the production order “2.
070 ”is moved forward. At the same time as the planned time is changed, the planned start time and the planned end time of the production order file 105 are also rewritten. (S7-S9)

[0026]

As described above, according to the present invention, when a production machine performs production according to a production order, the number of input items and the number of produced items are counted by the production number counting means. When the count value is different from the plan value, the production order is changed, so that it is possible to prevent excess stock and shortage of items.

[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 product produced in an 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 a plan progress screen 119a at the time of planning.

FIG. 10 is a diagram illustrating an example of a production order file 105 after a plan change based on actual values.

FIG. 11 is a plan progress screen 1 after a plan change based on actual values
Diagram showing 19b

FIG. 12 is a plan progress screen 1 after a plan change based on actual values
Figure showing 19c

[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 calculating means 113 Production planning means 114 Production quantity changing means

Claims (1)

[Claims] 1. A production order file storing a production order as a processing unit for drafting a production plan, a production means for producing according to the production order, the number of items input to the production means, and production by the production means. A production planning system comprising: a production number counting means for counting the number of items; and a production quantity changing means for changing a production order when a value counted by the production number counting means is not as planned.