JPH11151642A - Production control method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To shorten lead time by reorganizing a working/manufacturing condition and a working/manufacturing arranging quantity in each latter half process between the first and latter half processes, and supporting the working and manufacturing in each latter half process based on the reorganized condition and arranging quantity. SOLUTION: In one or two or more reorganizing timing points in the downstream in the first half process, reorganization is made of a working/ manufacturing condition and a working/manufacturing arranging quantity based on each quantity and actual delivery quantity concerning an article liable to the reorganization in each reorganization timing point. In each latter half process, working/manufacturing instructions are made to perform working/ manufacturing, based on the reorganized condition and arranging quantity. Consequently, the stock level of semi-finished products and finished product can be reduced to shorten lead time.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a production management method for a production line capable of processing and producing a wide variety of articles, comprising a plurality of types of processes and having a plurality of lower processes which can be separated from an upper process. About. In particular, the present invention relates to a production management method capable of efficiently responding to a customer's product delivery request in a production line having many production steps and a long production period.

[0002]

2. Description of the Related Art Conventionally, in a production line for producing a wide variety of products, an order production process for performing production based on an order from a customer and a planned production process based on a production plan based on demand forecast are usually independent of each other. Therefore, uniform production is performed according to the specified process.

[0003] The order-to-order production process and the planned production process are applied on the same production line or on separate production lines. Prevention of shortages and demand for short-term delivery have led to an increase in intermediate product inventory and product inventory. Also, some products have not been responded to requests for shorter delivery times.

[0004]

SUMMARY OF THE INVENTION An object of the present invention is to minimize the inventory of intermediate products and products without causing any shortage in view of the above-mentioned situation in a production line for producing a wide variety of products. It is an object of the present invention to provide a production management method for a production line for producing a wide variety of products, which can shorten the delivery time.

[0005]

SUMMARY OF THE INVENTION The present invention has been made to solve the above problems, and its gist is as set forth in the appended claims. That is, 1. Processing and processing of a wide variety of articles consisting of multiple types of processes and having multiple lower processes that can be separated from the upper process
In a production line that can be manufactured, between the above upper and lower processes, the processing / manufacturing conditions and the processing / manufacturing arrangement amount of each lower step are reorganized, and the reorganized processing / manufacturing conditions and the processing / manufacturing arrangement amount Production / manufacturing instructions in each lower process based on the method.

[0006] 2. Indicated delivery volume from each customer for a predetermined period based on the kanban delivery method contract, orders received from each customer based on futures contracts, work in process in each process, intermediate products and product inventory, and if necessary A production plan for the production line is formulated based on the predicted order quantity, processing and production of the upper process are started based on the production plan, and then at one or more reorganization timing points downstream of the upper process. , At each reorganization timing point, based on the above-mentioned respective quantities of articles that can be the subject of each reorganization, and the actual delivery amount, the processing / manufacturing conditions and processing /
2. The production management method according to the above item 1, wherein the production arrangement quantity is reorganized.

[0007]

[0008]

DESCRIPTION OF THE PREFERRED EMBODIMENTS After designing the manufacturing process of each product to be made to order or planned production, the manufacturing process is analyzed, and for each of the divided processes, the manufacturing specification condition and the manufacturing deadline condition of each product in the process are determined. It is possible to find processes that can be grouped together. Therefore, in such a process, the processing / manufacturing conditions and the processing / manufacturing arrangement amount of the process are determined based on the order quantity and / or the planned production quantity of each product grouped together from the manufacturing specification condition and the manufacturing deadline condition. To organize. The processing / manufacturing instruction for each process includes the processing / manufacturing conditions and the processing / manufacturing arrangement amount, as well as the processing / manufacturing start time in each process.

Downstream of the steps that can be grouped together, there are usually a plurality of lower steps that can be divided. Therefore, in the same manner as the knitting of the processing / manufacturing instruction in the above upper step, the processing / manufacturing conditions, the processing / manufacturing arrangement amount, and the processing / manufacturing start time in the lower step are reorganized. In this case, a plurality of intermediate products from the upper process may be combined for a certain lower process.

[0010] Such reorganization timing points are usually
This is the timing at which intermediate products can be bundled and allocated.

Next, the relationship between the production line, the processing / manufacturing conditions, and the reorganization of the processing / manufacturing arrangement amount will be described.

[0012] First, the delivery volume of each customer for a predetermined period based on the kanban delivery system contract, the order quantity from each customer based on the futures contract, the work in process in each process, the intermediate product, and the product Formulate a production plan for the production line based on the inventory amount and, if necessary, the forecasted order volume,
Processing / manufacturing of the upper process is started based on the production plan.

Next, at one or more reorganization timing points downstream of the above-mentioned upper process, based on the respective quantities and the actual delivery quantities of the articles to be reorganized at the respective reorganization timing points. And reorganize the processing / manufacturing conditions and the processing / manufacturing arrangement amount of each lower process.

In each lower step, processing / manufacturing is instructed based on the reconfigured processing / manufacturing conditions and the amount of processing / manufacturing arrangement, and processing / manufacturing is performed.

According to the production management method for reorganizing processing / manufacturing instructions as described above, for example, in production based on a kanban delivery system contract, processing / manufacturing instructions in each process at each reorganization timing point, particularly processing / manufacturing instructions. It is possible to optimize the production arrangement amount. Further, in the production based on the order forecast, there is an advantage that the planned production can be performed up to the reorganization timing point that satisfies the minimum risk and the shortest construction period. As described above, according to the production management method of the present invention, it is possible to flexibly cope with a change in the required amount for each product type. In addition, this makes it possible to reduce the levels of intermediate product inventory and product inventory, and to realize a production line capable of shortening the delivery time.

[0016]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS An embodiment of the present invention will be described below with reference to the drawings.

FIG. 1 is a diagram showing an outline of a special steel manufacturing process having a plurality of types of processes to which the production management method according to the embodiment of the present invention is applied, and a reorganization timing point. The reorganization timing point is set after the completion of the intermediate inspection of each production line shown in the drawing, and the intermediate material can be supplied to a plurality of subsequent production lines.

In this embodiment, first, on a predetermined regular basis, for example, twice a day on the 1st and 15th every month, each production line (a steel making line, a large bar, a billet, a pipe material production line, It is determined that processing / manufacturing conditions and the amount of processing / manufacturing arrangement are specified for the manufacturing chances of a section steel bar manufacturing line, a hot steel pipe manufacturing line, a cold steel pipe manufacturing line, and a ring processing line) for a predetermined period.

FIG. 2 shows processing / manufacturing conditions and processing / manufacturing conditions.
4 shows an example of a flow for determining a production arrangement quantity. The order form from the customer is a future order form where the delivery date / delivery amount is contracted at the time of ordering, and a so-called “individual delivery amount for a predetermined period based on a continuous transaction contract without contracting the delivery time / delivery amount at the time of ordering. It is categorized as "Kanban delivery" order form. From the viewpoint of economy, the production line of the special steel of the present embodiment needs to arrange arranged lots with the same production content in a single production line, and the standard of this identity is determined for each production line. They are different (for example, the same steel type in a steelmaking line and the same size in a rolling line). The processing / manufacturing conditions and the processing / manufacturing arrangement amount need to prioritize the identity (= manufacturing chance) of the arranged lot in each manufacturing process, and satisfy the demand (delivery request) of the above-mentioned different order forms.

First, FIG. 3 shows an example of a procedure for calculating the processing / manufacturing conditions and the processing / manufacturing arrangement amount of the intermediate material for the ordered future product based on the forecasted order. The customers who are contracts for futures orders are classified in advance, and the expected order quantity for the next month is regularly registered in the order entry registration unit for all the applicable customers. Next, based on the past order history of the customer stored in the order history storage unit, the previously registered amount is distributed to individual products by statistical analysis processing (measurement of pitch variation between orders, Distribute the previous registration amount to the items in the order of likelihood). Next, the intermediate material description for the future ordered product stored in the intermediate material performance grasping unit and the individual product are linked (assigning the intermediate material to the individual product), and the individual product details that could not be linked are obtained. Intermediate material required for processing is defined as processing / manufacturing conditions and processing / manufacturing arrangement data of the material for futures ordering. At this time, a production stop point (reorganization timing point) of the intermediate material arrangement is added.

Next, FIG. 4 and FIG. 5 show an example of the processing / manufacturing conditions and the calculation procedure of the processing / manufacturing arrangement amount for the product of the kanban delivery system. As described above, this product is based on a continuous transaction agreement. The production process information of the product and the intermediate stock specification (hereinafter referred to as material type) of the upper process of each production line are given information and are stored in the production specification storage unit for each individual product.
FIG. 4.2. As shown in (1), production schedule information for each material or product type for each production line at the time of the previous production plan is stored in the production schedule storage unit for a predetermined future period. This classification mesh to be produced indicates the necessity of grouping the production lot orders in each production line. As a pre-process for calculating the processing / manufacturing conditions and the processing / manufacturing arrangement amount, a manufacturing specification is added to each product, and a production chance in a predetermined future period is determined for each manufacturing line.

Further, as shown in FIG. 5, via the inter-company online device or the unofficial information registration device, the unofficial information history stored in the unofficial information storage unit and the delivery history stored in the delivery result grasping unit are used. Calculate the amount of safety stock for each individual product. The safety stock amount is obtained by calculating the standard deviation of the absolute difference between the unofficial amount and the delivered amount in the past predetermined period, and multiplying the standard deviation by a safety factor defined separately. For KANBAN-manufactured products, the in-process information on all production lines is linked to the manufacturing information storage unit, and the information on the intermediate stock held at the reorganization timing point is linked to the individual product details in the intermediate material results grasping unit. It is memorized in the state where it was set. Product inventory information is also grasped in real time. The processing / manufacturing conditions and processing / manufacturing arrangement amount / production / manufacturing condition of each production line are obtained based on the above-described various data and the unofficial information for a predetermined period stored in the unofficial information storage unit.
After the manufacturing chance is manufactured and consumed after the stock period, the processing / manufacturing conditions and the processing / manufacturing arrangement amount of each manufacturing line are determined so that the product stock amount matches the safety stock amount as much as possible.

FIG. 6 shows a manufacturing example based on the processing / manufacturing instruction performed by the production management method of the embodiment of the present invention for the product of the "kanban delivery system" described above. Looking at the connection of the production opportunities in chronological order, the production arrangement 1-A for the steelmaking line, 2-A 'for the large pipe production line, 3-A''for the hot steel pipe production line, and the 3-A''for the cold steel pipe production line 4-
Although it is linked to A ″ ′, the production arrangement amounts are changed as follows: steel making line = 107 t, large-sized line = 107 t, hot steel pipe manufacturing line = 68 t, cold steel pipe manufacturing line = 112 t. Looking at the quantity of each production line in May, 4
Following the decrease in the delivery volume from mid-March to the end of April, each production line has been almost synchronized and decreasing. As an overall effect,
The intermediate material inventory and product inventory at each reorganization timing point are optimized and stable, and the production arrangement for each production line satisfies the proposition "what you need, when you need it".

Based on the above, orders for futures orders are given to the processing / manufacturing conditions and the processing / manufacturing arrangement amount of the materials of the forecasted order and the processing / manufacturing conditions and the processing / manufacturing arrangement amounts of each material for kanban delivery. The processing / manufacturing conditions and the processing / manufacturing arrangement amount of the finished material are added, and as shown in FIG. 7, lot processing / manufacturing instructions are organized for each manufacturing line / material type / manufacturing deadline. At this time, since each order quantity refers to the same production schedule, there is almost no variation in the production deadline. If the determined order quantity does not satisfy the reference order quantity x n times of each production line, the shortage quantity is set as the preceding order quantity, and the material type is appropriately determined and added.

The processing / manufacturing conditions and the processing / manufacturing arrangement amounts thus determined are disclosed to each manufacturing line.
During the production of each production line, processing and manufacturing conditions and processing and
No changes to the production arrangements will be made. At the reorganization point immediately after each production line, based on the breakdown of manufacturing arrangements linked to the manufacturing instructions, in the case of ordered products, the production process of the next process will be waiting, and the predicted order product will be waiting for the order at the reorganization timing point. State. For kanban products, the next process manufacturing instruction has been issued, and there is a case where the next process material waits for the manufacturing timing of the next process and a case where the intermediate material stock waits for the next manufacturing arrangement quantity calculation timing. The above-described calculation of the production arrangement amount and the production instruction amount is first performed as preprocessing of a production plan, and after the production plan, recalculation is performed again in the same procedure. According to the production plan, adjust the capacity and load, and after the production schedule,
By performing the same procedure, the reliability of the production plan and the optimality of each production instruction amount are secured. FIG. 8 shows the relationship between the calculation of the production arrangement quantity and the production plan.

Further, as is apparent from the above-described embodiment, by adopting the present system management apparatus, the input amount of lots of the production line by the planned production can be controlled in real time and statistically controlled by the latest processing status. Can be determined based on the notification information of the production line, not only minimizing the unnecessary inventory quantity, but also making it possible to receive interrupt requests, and managing the production line that efficiently produces small numbers of products of various types Can be realized.

Although the present invention has been described in detail with reference to the embodiments, it goes without saying that the present invention can be variously modified without departing from the scope of the invention.

[0028]

As described above, according to the production management method of the present invention, it is possible to flexibly cope with fluctuations in the required amount for each product type. In addition, this makes it possible to reduce the levels of intermediate product inventory and product inventory, and to realize a production line capable of shortening the delivery time.

As described above, the present invention is a very useful invention that meets the needs of the industry.

[Brief description of the drawings]

FIG. 1 is a diagram showing an outline of a special steel manufacturing process having a plurality of types of processes to which a production management method according to an embodiment of the present invention is applied, and a reorganization timing point.

FIG. 2 is a diagram showing an example of a flow for determining processing / manufacturing conditions and processing / manufacturing arrangement amounts;

FIG. 3 is a diagram showing an example of a procedure for calculating the processing / manufacturing conditions and the processing / manufacturing arrangement amount of an intermediate material for a future ordered product based on a forecasted order;

FIG. 4 is a diagram showing an example of manufacturing specification information and production schedule information regarding a kanban delivery method product.

FIG. 5 is a diagram showing an example of processing / manufacturing conditions and a calculation procedure of the processing / manufacturing arrangement amount for a kanban delivery method product.

FIG. 6 is a diagram showing a production example based on a processing / production instruction performed by the production management method according to the embodiment of the present invention;

FIG. 7 is a diagram showing an example of knitting of lots and processing / manufacturing instructions for each manufacturing line / material type / manufacturing deadline.

FIG. 8 is a diagram showing an example of a relationship between a production arrangement amount calculation and a production plan.

Claims (2)

[Claims] 1. In a production line which can process and manufacture a wide variety of articles, comprising a plurality of types of processes and having a plurality of lower processes which can be separated from the upper process, a process between the upper process and the lower process is performed. In addition, reorganize the processing / manufacturing conditions and processing / manufacturing arrangement amount of each lower process, and issue processing / manufacturing instructions in each lower process based on the reorganized processing / manufacturing conditions and processing / manufacturing arrangement amount. A production management method. 2. The delivery volume from each customer for a predetermined period based on a kanban delivery system contract, the order volume from each customer based on a futures contract, the work in process in each process, the intermediate product and product inventory, Further, if necessary, a production plan for the production line is formulated based on the predicted order quantity, processing and production of the upper process are started based on the production plan, and then one or more downstream processes of the upper process are performed. At the reorganization timing point, at each reorganization timing point, based on the respective quantities relating to the articles that can be the subject of each reorganization, and the actual delivery amount, the processing / manufacturing conditions and the processing / manufacturing arrangement amount of each lower process are determined. 2. The production management method according to claim 1, wherein reorganization is performed.