JPH11236105A - Product physical distribution control method and device thereof - Google Patents

Abstract

PROBLEM TO BE SOLVED: To improve efficiency of a cargo collecting work by indicating interruption to a product shipping operation facility so as to forward products in a warehouse to the quay on the shipping position for preferentially executing a work for short delivery generation until the short delivery is generated when short delivery is judged to generate. SOLUTION: An obstacle prediction judging part 10 takes in respectively operation progress information 95 from an operation progress information memory part 25, and shipping plan information 94 from a shipping plan information memory part 24. When a forwarding work in a storehouse is continued to operate as it is in accordance with the plan, against a cargo handling work progressing at present on a shipping quay, delivery of shipping objective products from the warehouse by pallets and carriers to the shipping quay is delayed, shipping products disappear on the quay, and it is computed whether interruption of a shipping work by a quay crane is generated or not. When generation of interruption of the shipping is judged to generate, an emergent work interruption control part 11 is started, an objective work is most preferentially interrupted as an emergent work, and it is replaced with an appropriate operation order.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

[0001] 1. Field of the Invention [0002] The present invention relates to a control method and a control apparatus for automatically and accurately creating a schedule for loading and shipping products in a warehouse.

[0002]

2. Description of the Related Art For example, a shipping work plan for transporting a product in a warehouse to a quay, which is a loading dock, by using a crane and a transport vehicle is prepared by an operator. Because of having to rely on intuition and experience, the accuracy was low, corrections had to be made frequently, and the work load was high.

[0003] The operation of the crane and the transport vehicle is performed in accordance with the work instructions of the operator, and this is a form in which a work instruction based on human judgment is issued through an online terminal. And a manual cycle was repeated with the correction. For this reason, in recent years, a single scheduler has been proposed for automatically creating this plan using a computer, for example, for a berth plan for transporting products from a warehouse to a quay or for a product entry / exit plan for a warehouse. ing.

[0004]

Even if a plan is automatically created by the computer, when the difference between the plan and the actual shipping work becomes larger than a reference value, the plan must be rearranged. There is a time lag between the actual shipping work and the shipping work time is prolonged, and a large berthing fee must be paid.

[0005] In addition, when the port to be loaded is delayed due to the weather or the like, there may be a frequent deviation between the plan and the actual shipping operation. In this case, as described above, the plan must be rearranged each time, and the occupancy of the computer increases, so that other processes cannot be performed and there is a problem that the computer must be dedicated. Was. The present invention automatically prepares a shipping plan using a computer or the like, and when performing an actual shipping operation according to the created plan, predicts a gap between the created plan and the actual shipping work at an early stage, and prevents the occurrence of the gap. It is another object of the present invention to solve the above-mentioned problem by preventing an extension of a loading operation due to an out-of-load and reducing a frequency of occurrence of a rearrangement operation of a plan.

[0006]

Means for Solving the Problems The present invention has been made to solve the above-mentioned problems. Means 1 is to schedule a shipping plan for loading and shipping products in a warehouse by a planning unit, Based on the shipping plan information, the work order for loading and shipping the products in the warehouse to the product shipping work facilities such as cranes and transport vehicles is issued, and the product shipping work equipment performed based on the work instructions performs the progress of the actual shipping work. In a product logistics control method for comparing a situation with the scheduled shipping plan to obtain a deviation amount between the two and when the deviation amount exceeds a preset reference value, the planning unit is instructed to make a plan. The quay at the position to be loaded and shipped when the actual shipping work is performed according to the shipping plan and the progress of the actual shipping work Judgment is made as to whether or not unloading occurs and the time of unloading. If it is determined that unloading occurs, the warehouse will give priority to the unloading work by the time when the unloading occurs. The crane, which instructs to interrupt the product to be shipped to the quay in the position to be loaded and shipped,
This is a product distribution control method performed on a product shipping work facility such as a transport vehicle.

Further, the means 2 compares the shipping plan scheduled by the planning section with the operation result information of the actual shipping work to determine the amount of deviation between the two, and the work in which the amount of deviation exceeds a preset reference value. If there is a gap, the cause of the gap depending on the type of work in which the gap is occurring, the disturbance caused by stormy weather effects, delays in ship assignment, etc., and the plan standard value used for planning does not match the actual operation In order to analyze the resulting disturbance, the result of this analysis is classified according to the cause, and furthermore, a process of quantifying the difference between the shipment plan value and the actual operation value is performed for each analyzed cause of the difference, and the analysis is performed. This is a product distribution control method for correcting the plan reference value based on the deviation amount for each of the deviation occurrence categories.

Means 3 are a planning section for scheduling a shipping plan for loading and shipping the products in the warehouse, and a product shipping operation such as cranes and transport vehicles based on the shipping plan information obtained by the planning section. An operation control unit that issues work instructions for transporting and shipping by equipment, and comparing the progress of the actual shipping work of the product shipping work equipment with the shipping plan created by the planning unit to determine the amount of deviation between the two, When the deviation exceeds a preset reference value, in a product distribution control device having a correction feedback unit B for instructing the planning unit to make a plan, a shipping plan scheduled by the planning unit and a progress status of the actual shipping work are used. If actual shipping work is performed in accordance with the shipping plan, it is determined whether or not the quay at the shipping / shipping position will be unloaded and the time of unloading, and the unloading will occur. If it is determined that the unloading will occur by the time the unloading occurs, the crane and the crane and the interrupt instruction to ship the products in the warehouse to the quay at the position where the products are loaded and shipped so as to give priority to the unloading work. Correction feedback section A that issues instructions to product shipping work equipment such as transport vehicles
Is a product distribution control device having:

Means 4 compares the shipping plan scheduled by the planning section with the operation result information of the actual shipping work to determine the amount of deviation between the two, and when the amount of deviation exceeds a preset reference value, an operation occurs. If there is a shift, the cause of the shift is determined by the type of work in which the shift occurs, because the disturbance caused by stormy weather, delays in ship assignment, etc., and the plan reference value used for planning does not match the actual operation. An analyzing unit that analyzes the generated disturbance and classifies the analyzed result according to cause, and further performs a process of quantifying a difference between a planned value and an actual value according to the analyzed difference occurrence cause class; and The analysis result information is compared with the plan reference value stored in the plan reference value storage unit to determine whether there is a difference. If it is determined that there is a difference, the plan stored in the plan reference value storage unit is determined. Correction to correct the reference value A product distribution control device having a fed back portion C.

According to the modified feedback section A of the present invention,
When carrying out actual shipping work according to the plan, the amount of misalignment between the created plan and the actual shipping work is predicted at an early stage in advance, and control is performed to change the work instructions so that the amount of deviation does not occur. To prevent the lengthening of shipping work and reduce berthing charges. Further, the correction feedback section C constantly analyzes and compares the reference value used for the plan with the actual value, and always keeps the reference value at a value commensurate with the actual operation, thereby stabilizing the accuracy of the plan itself at a high level, By minimizing the activation of the correction feedback unit, the load on the computer can be minimized.

By using the correction feedback section A and the correction feedback section C together with the product distribution control device having the correction feedback section B, automatic and highly efficient product distribution control can be realized.

[0012]

BEST MODE FOR CARRYING OUT THE INVENTION As an embodiment of the present invention, a case will be described in which, in a steel industry, a manufactured rolling coil (hereinafter simply referred to as a product) is transported by a carrier car from a temporary storage warehouse to a quay for loading. explain. First, an outline of the product shipping operation will be described.

As shown in FIG. 2, a product 55 manufactured on a manufacturing line 53 is temporarily stored in a warehouse 51 in which a plurality of warehouse cranes 57 are installed. And is loaded on an empty pallet 30 waiting at a predetermined unloading place. Then, the pallet 30 is transported to the shipping quay 50 by the carrier 31 as a transport vehicle, and the shipping quay 50 is
Is placed on the pallet 30. This stationary pallet 30
The product 40 is loaded onto a ship 54 by a quay crane 52 from above.

In this product shipping operation, an optimum one is selected from the plurality of carriers 31 and the carrier 3 is selected.
This is performed by controlling the order and timing of issuing the work instruction to the first. Next, the overall basic configuration will be described. As shown in FIG. 1, a device for scheduling a product shipping operation is roughly divided into a planning unit 1 for scheduling a shipping plan, a pallet 30, a carrier 31, and a warehouse crane based on the shipping plan created by the planning unit 1. An operation control unit 2 that controls the conveyance of the product 55 by issuing a work instruction to the operation unit 57, an analysis unit 3 that analyzes a deviation between the shipping plan and the operation result from the operation result storage unit 26, and an operation progress information storage unit 25. Feedback section A for correcting the work instruction (replacement of the work order) in accordance with the operation progress status, correction feedback section B for performing a plan correction (plan restart) for the deviation between the shipping plan and the operation progress status, analysis It is composed of six processing units of a correction feedback unit C for correcting an internal reference value at the time of creating a plan based on the analysis result from the unit 3. Information transmission between the respective processing units is performed by exchanging data via a plurality of information storage units according to the purpose of use, and has a cyclical mechanism that always maintains an appropriate automatic schedule system.

Further details will be described. The planning unit 1 is a distributed processing system that includes a berth planning scheduler 4 and an entry / exit planning scheduler 5, and is separated from the host computer. At the time of the plan creation processing, the planning unit 1 stores the warehouse 51 stored in the basic information storage unit 21 in advance.
Shipment product information (size, weight, number of breeds, variety, target ship name, wetness etc.), equipment (warehouse and quay cranes, carriers, etc.) and shutdown plan information (repair
(Inspection time, etc.), vessel assignment information (ship name, port entry time, etc.), weather information (precipitation probability, typhoon information, etc.) (Each time a change occurs, information is automatically or manually updated and registered and always kept up to date. Information group 91 and the operation progress information storage unit 2
The operation progress information 95 such as quay cargo handling work updated to the latest information in real time stored in the storage unit 5 is periodically taken in, and further set based on past statistical values stored in the reference value setting unit 29. Quay crane cycle time,
A plan reference value 20, which is a value serving as an internal reference such as a standard time for ancillary work, is fetched. When this fetch is completed, the berth planning scheduler 4 is started.

The berth planning scheduler 4 performs a chronological analysis of a plurality of quay cranes 52 existing on the shipping quay 50 and ancillary facilities within a planning time range on the basis of various information such as the acquired capacity of various facilities and operation suspension plan information. The effective cargo handling capacity. The loading target ship 54 and the quay crane 52 are associated with each other such as the determined cargo handling capacity and the input shipping product information, ship allocation information, and the like.

The cargo handling time (start time and end time) for each loading target ship 54 is calculated based on the linking result and the input information such as the plan reference value, the number of shipped products, and the weather information. Based on the calculation result, the cargo handling time is allocated in time series for each quay crane 52.

This allocation result is visually displayed for 32 hours on a separately provided display screen, and is used as common information for shipping work controllers. The entry / exit scheduler 5,
The loading / unloading work time (start time and end time) calculated by the berth planning scheduler 4 for each loading target ship 54 and each loading target ship 54 created in advance by the host computer and stored in the outgoing lot information storage unit 23. Product delivery lot organization information 93 such as lot (one lot for one pallet), product quantity in each lot, warehouse storage position, pallet loading position, etc., and manufacturing stored in the storage lot information storage unit 22 Product 5 delivered to warehouse 51 from line 53
The lot number 5 and the received lot organization information 92 such as the product amount in each rod, the pallet stacking position, the storage position in the warehouse 51, and the like, and are stored in the operation progress information storage unit 25 and updated to the latest information in real time. Progress information 95 such as loading / unloading and loading / unloading work of the warehouse 51, beaching work, etc., and furthermore, a warehouse crane cycle time, ancillary work standard time, etc. stored in the reference value setting unit 29 and set by past statistical values. A plan reference value 20, which is a value serving as an internal reference, is taken.

Then, the product 40 to be shipped is appropriately determined based on each of the loaded cargo handling work time, outgoing lot information 93, incoming lot information 92, equipment operation suspension plan information 91, plan reference value 20, and the like. In order to realize beaching from the warehouse 51 to the shipping quay 50 at the time, a plurality of warehouse cranes 57 existing in the warehouse 51 are unloaded from each warehouse crane 57 so as not to be congested (products in the warehouse 51). Are loaded on the pallet 30).

Further, on the basis of this allocation result and the information of the imported cargo handling work place, the product storage position in the warehouse 51, the plan reference value 20, etc., the shipping products 40 are moved from the warehouse 51 to the shipping quay 50. The dispatch location and the time of the pallet 30 on which the product 40 is placed, and furthermore, the pallet 3
The shipping plan information 94 including the location and time of the carrier 31 carrying the 0, the transport destination of the pallet 30 and the arrival time of the transport destination is calculated and stored in the shipping plan information storage unit 24.

The result of assignment to each warehouse crane 57 is visually displayed for 32 hours, and is used as common information for shipping work controllers. The shipping plan information 94, which is the result of the automatic scheduling obtained by the planning unit 1, can be easily manually corrected by a mouse or a keyboard on the visual display of the distributed terminal according to the judgment of the shipping work controller. It is.

The operation control section 2 comprises a carrier / pallet selecting section 6 and a dispatch instruction control section 7, and is processed online in real time. At the time of processing, the carrier / pallet selector 6 stores the shipping plan information storage 2
4, the dispatch time of each carrier 31 based on the information on the dispatch time and the location of the pallet 30 and the carrier 31 of the shipping plan information 94 and the information such as the usage status of the plurality of pallets 30 and the carrier 31. Is selected, a combination of the carrier 31 and the pallet 30 having the minimum moving time is selected from the plurality of empty carriers 31 and the plurality of empty pallets 30.

The dispatch instruction control unit 7 controls the carrier 3 selected by the carrier / pallet selecting unit 6.
1 is dispatched. Then, the carrier 31 that has received the dispatch instruction moves to the designated place at the designated time. Further, when it is confirmed that the pallet 30 and the carrier 31 have arrived at the designated place, the warehouse crane 57
Is instructed to load the product 40 on the pallet 30.

Next, when it is confirmed that the loading of the product 40 on the pallet 30 is completed, the carrier 31 is instructed to transport the product 40 to the product storage area of the ship to be loaded. After confirming that the carrier 31 has traveled and placed the pallet 30 on the product storage area of the target ship according to this instruction, the quay crane 52 issues an instruction to load the product 40 into the target ship 54.

The operation progress information storage unit 25 stores warehouse cranes 57, quay cranes 52, pallets 30, and carriers 3 related to shipping operations existing in the warehouse 51 and the shipping quay 50.
1. Information 95 on the progress of operation (operation) of each facility (for example, the number of times each crane is hung, the arrival signal of the destination of the carrier, etc.) information 95 is sequentially taken from sensors and the like (not shown) provided in each facility and stored. The stored information is updated in real time in accordance with the work progress.

Further, each time the work related to each loading target ship 54 is completed, the operation result information storage unit 26 stores the operation result (eg, cargo handling work start time, end time, etc.) information 96.
Is stored for a certain period of time. The analysis unit 3 includes an occurrence cause analysis unit 8 and a difference quantitative analysis unit 9, and is a form in which processing is periodically and collectively performed.

In the analysis process, first, the shipping plan information 94 from the shipping plan information storage unit 24 and the operation result storage unit 2
6 is fetched as analysis information 97 at a preset timing via the analysis information storage unit 27 via the analysis information storage unit 27, the occurrence cause analysis unit 8 is activated, and the following analysis is performed. Based on the analysis information 97, the location where the deviation between the shipping plan and the actual operation (work start time and work end time) is equal to or greater than a preset reference value, that is, the type of work (warehouse loading work, beaching work, quay) Sorting).

The causes of the displacement for each type of work in which the displacement is occurring include disturbances caused by stormy weather effects, delays in ship assignment, and disturbances caused by a reference value 20 used for planning not matching actual operation. Perform stratified processing. That is, the equipment operation stoppage information, ship allocation information, weather information, etc. stored in the basic information storage unit 21 are sequentially input, and the time when the plan is created and the subsequent change state of the above information are checked. If the deviation is larger than the preset reference value, it is determined that the disturbance is caused by stormy weather effects, delays in ship arrangement, sudden failure of the carrier or crane, etc. Is determined to be not applicable, and it is determined that the internal disturbance occurs because the reference value used for planning does not match the actual operation.

When it is determined that a disturbance has occurred in this manner, the result is classified according to the type of the work and the equipment used for the work (each unit such as a warehouse crane, a quay crane, and a carrier).
Sorting. The deviation quantitative analysis unit 9 performs a process of quantifying the deviation between the planned value and the actual value for each occurrence cause (for each type of work and equipment used) analyzed by the occurrence cause analysis unit 8.

The analysis result storage unit 28 stores the result information 98 analyzed by the analysis unit 3. The correction feedback unit A includes a failure prediction determination unit 10 and an emergency work interrupt control unit 11. The failure prediction determination unit 10 captures the operation progress information 95 from the operation progress information storage unit 25 and the shipment plan information 94 from the shipment plan information storage unit 24, respectively. Warehouse 51
If the unloading operation is continued as planned, the delivery of the products 40 to be shipped from the warehouse 51 to the shipping quay 50 by the pallet 30 and the carrier 31 is delayed by the pallet 30 and the carrier 31. Is calculated, and whether the loading (loading) work by the quay crane 52 is interrupted or not is calculated. Then, when it is determined that the loading operation is interrupted (the loading product 40 disappears on the quay 50), the emergency operation interrupt control unit 11 is activated, and the target operation is interrupted as the highest priority operation as the emergency operation. The control is activated, and the proper work order is changed as follows.

Normally, the beaching work is performed by giving a work instruction to the carrier 31 and the warehouse crane 57.
The work instruction issued by the dispatch instruction control unit 7 is transmitted to the operation control unit 2.
Is temporarily registered in the work instruction registration file, and remains registered until the carrier 31 or the warehouse crane 57 performing the work becomes empty. Since the work instructions are registered according to the plan, a plurality of work instructions are generated in the normal operation, and a queue is formed. The work is linked (executed) basically in the order of the registration time. However, only when the emergency work interrupt control unit 11 operates, the emergency work target is placed at the head of the queue. Perform the replacement process. If there are no work instructions for urgent work,
A work instruction is issued on the spot and registered at the head of the queue. As a result, the emergency target work is registered in the work instruction registration file and is executed with higher priority than the next work.

The correction feedback section A is automatically processed in real time in order to directly cope with a change in the ongoing operation. In addition, it is preferable that the work order can be changed by manual intervention as necessary. The correction feedback unit B includes a plan difference determining unit 12 and a plan restart control unit 13. The plan difference determining unit 12 stores the shipping plan information 94 from the shipping plan information storage unit 24,
The operation progress information 95 is fetched from the operation progress information storage unit 25, the shipping plan information 94 and the operation progress information 95 are compared to determine the difference, and it is determined whether the difference exceeds a preset reference value. I do. If the difference amount exceeds the reference value, the plan restart control unit 13 starts, and restarts the plan unit 1. The correction feedback unit B is automatically processed in real time in order to appropriately start the operation control unit 2, and updates the shipping plan information 94 as appropriate while maintaining consistency with the operation progress. Further, if necessary, a restart by manual intervention is also possible. In the entire processing system, the correction feedback unit B also has a role of suppressing the activation frequency of the correction feedback unit A. Further, the plan restart control unit 13 of the correction feedback unit B periodically starts based on the elapse of a preset time irrespective of whether there is a difference between the plan and the operation progress, in addition to the start based on the determination result of the plan difference determination unit 12. It also has a periodic automatic rescheduling function for periodically restarting the planning unit 1.

The correction feedback section C comprises a comparative evaluation judging section 14 and a reference value correction control section 15. The comparative evaluation judging section 14 sets analysis result information 98 from the analysis result storage section 28 in advance. The analysis result information 98 is periodically taken in every period, and the analysis result information 98 is compared with the plan reference value 20 to determine whether there is any difference by performing a statistical test.
If the comparative evaluation determination unit 14 determines that there is a difference,
The reference value correction control unit 15 is activated, and corrects the plan reference value 20 to a reference value based on the analysis result information 98. The value of the plan reference value 20 corrected in this way becomes effective from the next time the planning unit 1 starts. In the processing of the correction feedback unit C, since a statistical test is performed, it is necessary to secure a certain number of data. Therefore, a mode is adopted in which processing is performed collectively in a preset period unit. In addition, the reference value correction control unit 15 of the correction feedback unit C
As a method of correcting to an appropriate value, once output and display,
It is composed of two methods, a method of changing the plan reference value 20 by an artificial judgment based on that and a method of automatic correction, and functions by selecting either one.

[0034]

According to the present invention, it is possible to automatically and accurately perform a work instruction for loading and shipping products in a warehouse, and to improve the efficiency of shipping work. The extension of the loading operation can be suppressed to reduce the demurrage fee of the ship, and the number of times of preparing the shipping plan can be reduced, and the effect in this field is great.

[Brief description of the drawings]

FIG. 1 is a diagram showing a functional configuration of a product distribution control device.

FIG. 2 is a diagram showing an equipment configuration related to a product shipping operation.

 ──────────────────────────────────────────────────続 き Continuing from the front page (72) Inventor Colonel Kodama 1 Oshinozu, Oita-shi, Oita Prefecture Inside Nippon Steel Corporation Oita Works

Claims (4)

[Claims] 1. A planning section schedules a shipping plan for loading and shipping products in a warehouse, and loads and ships products in a warehouse to product shipping work facilities such as cranes and transport vehicles based on the scheduled shipping plan information. The product shipping work equipment that performs the work instruction based on the work instruction compares the progress of the actual shipping work with the scheduled shipping plan to determine the amount of deviation between the two, and the amount of deviation is set in advance. In a product distribution control method for instructing the planning unit to create a plan when the standard value is exceeded,
From the shipping plan scheduled by the planning unit and the progress of the actual shipping work, whether or not unloading occurs at the quay at the position to be loaded and shipped when the actual shipping work is performed according to the shipping plan, and the unloading occurrence time If it is determined that unloading will occur, ship the products in the warehouse to the quay at the position where the products will be loaded and shipped so that the unloading work will be given priority by the time when the unloading occurs. A product distribution control method, wherein an interruption instruction is issued to a product shipping work facility such as the crane or the transport vehicle. 2. A shipping plan scheduled by the planning unit and operation result information of the actual shipping work are compared to determine an amount of deviation between the two, and when a work in which the amount of deviation exceeds a preset reference value occurs. In the case where there is a shift, the cause of the shift for each type of work in which the shift occurs is caused by disturbance caused by stormy weather effects, delays in ship assignment, etc., and because the plan reference value used for planning does not match the actual operation Analyzing the internal disturbance and classifying the result of this analysis according to the cause, further quantifying the difference between the shipment plan value and the actual operation value for each analyzed cause of the difference A method of controlling product distribution, wherein the plan reference value is corrected based on a shift amount for each category. 3. A planning unit that schedules a shipping plan for loading and shipping products in a warehouse, and based on the shipping plan information obtained by the planning unit, the products in the warehouse are transferred to product shipping work facilities such as cranes and transport vehicles. An operation control unit that issues a work instruction for carrying and carrying and shipping, and comparing the progress of the actual shipping work of the product shipping work equipment with the shipping plan created by the planning unit to determine the amount of deviation between the two, When the value exceeds a preset reference value, in the product distribution control device having a correction feedback unit B for instructing the planning unit to make a plan, the shipping plan is determined based on the shipping plan scheduled by the planning unit and the progress of the actual shipping work. Determines whether or not unloading will occur on the quay at the shipping / shipping position and the time of unloading when the actual shipping work is performed according to, and determines that unloading occurs. In such a case, the crane, the transport vehicle, etc. are instructed to ship the products in the warehouse to the quay at the position where the products are to be loaded and shipped so that the unloading work will be given priority by the time when the unloading occurs. A product distribution control device comprising a correction feedback section A for issuing an instruction to a product shipping work facility of the present invention. 4. A shipping plan scheduled by the planning unit and operation result information of the actual shipping work are compared to obtain a shift amount between the two, and when a work in which the shift amount exceeds a preset reference value occurs. In the case where there is a shift, the cause of the shift for each type of work in which the shift occurs is caused by disturbance caused by stormy weather effects, delays in ship assignment, etc., and because the plan reference value used for planning does not match the actual operation An analysis unit that analyzes the internal disturbance and classifies the result of the analysis by cause, and further performs a process of quantifying a difference between a planned value and an actual value according to the analyzed cause of the difference; and an analysis result of the analysis unit. The information and the plan reference value stored in the plan reference value storage unit are compared to determine whether there is a difference. If it is determined that there is a difference, the plan reference value stored in the plan reference value storage unit is determined. Correction feedback to correct A product logistics control device having a lock section C.