JPH11245142A - Method and device for making production plan - Google Patents

Abstract

PROBLEM TO BE SOLVED: To prevent the delay of a production plan by improving a balance of loads applied, on a plurality of production steps provided in production facfilities so as to increase the availability factor of the production facilities. SOLUTION: A priority deciding section 7 calculates a scheduled work date in each manufacturing step set in the route manufacturing process of each order by using a standard lead time predetermined for the delivery date of each order and each manufacturing step, sets a point for a load rate in each calculated scheduled date, calculates the total points of the route manufacturing process by integrating these points, and these points are set for the load rates of respective orders. The priority deciding section 7 adds a total point obtained by integrating a plurality of points for the respective orders to each order, and decides the priority of each order included in an order group. An allocation deciding section 8 selects orders in the highest priority order.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for creating a production plan by allocating a plurality of requests received from customers to the material of a product, and an apparatus used for implementing the method.

[0002]

2. Description of the Related Art A cut plate product, which is one of the steel plate products, is manufactured by rolling a slab into a plate material having a predetermined thickness and cutting it into a predetermined width and length. The plate material remaining after cutting is managed as surplus material. When manufacturing such a cut plate product, it is important to quickly allocate a plurality of orders for materials such as newly manufactured plate materials or surplus materials so as to obtain a high yield.

For this reason, Japanese Patent Application Laid-Open No. 6-149850 discloses the following method. Reads data of unassigned materials from a material database in which the characteristics, weight, and presence / absence of order assignment related to a plurality of materials are registered, and classifies each read material into a plurality of groups having the same characteristics. Then, the classified material groups are stored. In addition, an order that is not assigned to a material is read from an order database in which characteristics related to a plurality of orders, the total weight of ordered products, the product weight of one product, and the presence / absence of assignment are registered and read. The orders are classified into a plurality of groups having the same characteristics, and the classified order groups are stored.

[0004] For a plurality of combinations of each stored material group and each order group, the characteristics of the order and the material, the total weight of the products related to all the orders included in the order group, and the total of all the materials included in the material group. weight,
The combination of the material group and the order group to be allocated is determined based on the product weight of each order included in the order group and the weight of each material included in the material group.

[0005] Then, by using each material in the material group of the determined combination and each order in the order group,
The board removal that maximizes the yield is obtained by calculation, and the order is allocated to each material according to the calculation result. Also,
As before, each order in the order group that has not been allocated is allocated to a newly manufactured material so as to maximize the yield. As a result, orders can be quickly allocated to the materials, and the occurrence of surplus materials is suppressed, and the yield is improved.

[0006]

A manufacturing facility for manufacturing a product from a material is provided with a plurality of manufacturing equipments corresponding to a plurality of manufacturing processes for manufacturing a plurality of types of products. In response to this, a required manufacturing process is performed. However, in the conventional method, since the load balance of a plurality of manufacturing processes provided in the manufacturing equipment is not considered, when the load is small, the operation rate of the equipment installed in the manufacturing equipment decreases. In the case of an overload, there is a problem that a manufacturing plan for a product passing through the manufacturing process is delayed.

The present invention has been made in view of such circumstances, and an object of the present invention is to, in each production process, gradually change the amount of requests allocated to a plurality of production materials passing through the production process. On the other hand, while calculating, the scheduled times at which the product materials pertaining to each request should pass through the corresponding production process are determined, and the amount of the request allocated to the corresponding production process at each determined scheduled time, and the unit in the production process. By comparing the amount of product material that can be processed during the period, and allocating each request to product material using the priority of each request determined based on the comparison result,
A method of creating a production plan capable of improving the load balance of a plurality of production processes provided in a production facility, improving the operation rate of the production facility, and preventing a delay in the production plan, and a method for implementing the method. It is to provide a device to be used.

[0008]

According to a first aspect of the present invention, there is provided a production plan creating method in which a predetermined amount of a plurality of product materials is passed through a required production process among a plurality of production processes in a predetermined order and time. If multiple products are produced by
An operation of allocating a request including one or more product materials, including a time at which a product is supplied and a production process through which the product material is produced to produce the product, and an order of the production process, for each request based on a result of the plurality of requests. In the method of creating a production plan for a corresponding product, in each production process, the amount of demand allocated to a plurality of production materials passing through the production process is calculated with time, while the time at which the product is supplied and the product material are calculated. Based on the production processes to be passed through and the order thereof, the scheduled times at which the product materials relating to the respective requests should be passed through the corresponding production processes are respectively obtained, and a plurality of production processes via the corresponding production processes at each of the determined scheduled times are obtained. Compare the amount of demand allocated to the material with the amount of product material that can be processed in a unit period in the production process. It determines the priority of each request Zui, characterized by allocating each request based on the determined priority to the product material.

A production plan creating apparatus according to a second aspect of the present invention produces a plurality of products by passing a predetermined amount of a plurality of product materials through a required production process among a plurality of production processes according to a predetermined order and time. In such a case, an operation of allocating a request including one or more product materials, including a quantity of a product, a time at which the product is supplied, a production process for passing the product material to produce the product, and an order thereof, is performed for a plurality of product materials. In an apparatus for creating a production plan of a product corresponding to each request based on the result, in each production process, a means for calculating, over time, an amount of a request allocated to a plurality of production materials passing through the production process, Based on the time at which the product is supplied and the production process and the order in which the product material is passed, the estimated time at which the product material according to each requirement should be passed through the corresponding production process is determined. The means to be determined respectively, the amount of the request allocated to a plurality of production materials passing through the corresponding production process at each estimated scheduled time, and the amount of the product material that can be processed in a unit period in the production process, respectively. It is characterized by comprising means for comparing, means for determining the priority of each request based on the comparison result, and means for allocating each request to the product material based on the determined priority.

According to the present invention, based on the time at which the product is supplied and the production process and the order in which the product material is passed, the scheduled time at which the product material according to each request is to be passed through the corresponding production process is determined. By obtaining each, a time at which the product is supplied, that is, a scheduled time at which the delivery date of the product is satisfied is obtained. At each calculated scheduled time, the total amount of requests allocated to multiple production materials passing through the corresponding production process is compared with the total amount of product materials that can be processed in a unit period in the production process. If the number is smaller, that is, if the load is small, the priority of the request is set higher. Then, of the plurality of requests, the request is allocated to the product material in order from the one with the highest priority. by this,
For a production process with a small load, the load is increased to make the load balance uniform, the operation rate of the production process is improved, and a delay in the production plan is prevented.

[0011]

Embodiments of the present invention will be specifically described below with reference to the drawings. FIG. 1 is a block diagram showing the configuration of an apparatus according to the present invention. In the figure, reference numeral 21 denotes order information in which order information, such as a plurality of order numbers, delivery dates, and ordered weights, received from customers is registered. Database (D.
B. ), 22 is a material information database in which material information such as a plurality of material numbers being manufactured and not manufactured and weights to be manufactured are registered, and 23 is an operation plan in which operation plans of a plurality of manufacturing processes are respectively registered. It is a database.

FIG. 6 is a chart showing an example of order information registered in the order information database 21 shown in FIG.
As shown in FIG. 6, the order information includes order numbers C1, C
2, ..., the total weight of the ordered product, the order weight, the delivery date,
Among the ordered weights, the material allocation weight, which is the weight already allocated to the material, the number of a plurality of manufacturing processes for manufacturing the ordered product, and the order manufacturing characteristics indicating the order of the order, the order characteristics such as steel type and dimensions, The information includes a plurality of pieces of information such as a material allocation remaining weight obtained by subtracting the material allocation weight from the order weight, and a product single weight which is the weight of one product.

FIG. 8 is a chart showing an example of material information registered in the material information database 22 shown in FIG. As shown in FIG. 8, the material information includes the material number S
1, S2,..., The material weight which is the total weight of the material, the order allocation weight which is the weight to which the order has already been allocated among the material weights, the number of the manufacturing process which has already passed, and A plurality of pieces of information such as a manufacturing process, a steel type, material characteristics such as dimensions of the material after passing through the final manufacturing process, and an order allocation remaining weight obtained by subtracting the order allocation weight from the material weight are included.

FIG. 10 is a chart showing an example of an operation plan registered in the operation plan database 23 shown in FIG. As shown in FIG. 10, as the operation plan, the numbers of a plurality of manufacturing processes for processing the material of the material number and the date of performing the processing in each manufacturing process are registered separately for the plurality of material numbers S1, S2,. is there.

The CPU 2 of the computer 1 activates the order information reading unit 3, the material information reading unit 4, and the operation plan reading unit 5 to allocate an order to a material.

FIGS. 2, 3 and 4 are flowcharts showing the procedure by which the computer 1 shown in FIG. 1 assigns orders to materials. The order information reading unit 3 searches the order information database 21 (step S1) and determines whether the order weight and the material allocation weight are not equal, that is, whether there is order information having the material allocation remaining weight. If it exists, the order information corresponding to the order number is read out (step S2), and the read out order information is categorized into a plurality of order characteristic allowable ranges to generate a plurality of order groups (step S2). S3) Each order information is provided to the first memory 11 for each generated order group and stored therein (step S4).

FIG. 7 is a chart showing an example of the order information stored in the first memory 11 shown in FIG. As shown in FIG. 7, the first memory 11 stores a plurality of order groups A, B,
.. Are stored.

The material information reading unit 4 searches the material information database 22 (step S5) and determines whether the material weight is not equal to the order allocation weight, that is, whether there is material information having the remaining order allocation weight. And if it exists, read out the material information associated with the material number (step S6), classify the read-out material information into a plurality of predetermined material characteristic allowable ranges, and group a plurality of material groups. Generated (step S7), and as shown in FIG.
Generated material groups a, b,.
Is given to the memory 12 and stored there (step S
8).

Further, the operation plan reading section 5 reads the operation plan registered therein from the operation plan database 23 (step S9), and refers to the material information stored in the second memory 12 to operate the operation plan. As shown in FIG. 11, the order allocation weights for the respective material numbers included in the operation plan read out from the plan database 23 are fetched, and using the operation plan, the order allocation weight, and the following equation (1), as shown in FIG. The load ratio R (%) at which the material is loaded is calculated for each date (step S10), and the result is given to the third memory 13 and stored there (step S11). R _X = {total order allocation weight applied to the X-th manufacturing process on the relevant date {total weight of material that can be processed in one day in the X-th manufacturing process} × 100 (1) where X = 1, 2, ..., n (n is the number of the final manufacturing process)

As described above, when the load factor for each date is obtained for each of the manufacturing processes, the determination unit 6 determines the order characteristics of the plurality of order groups stored in the first memory 11,
Based on the material characteristics of the plurality of material groups stored in the second memory 12, for each of the plurality of combinations of the material group and the order group, each order included in the order group is assigned to each material included in the material group. It is determined whether or not the assignment can be made (step S21), and the result of combination of the material group and the order group determined to be possible is given to the priority determination unit 7 and the allocation determination unit 8 described later.

In the priority determination section 7, points are set in advance in accordance with the load factor, the order delivery date, the adaptability between the characteristics of the material and the characteristics of the order, and the like. Assigns a score to each order included in the order group for each combination of the material group and the order group given by the determination unit 6 (step S22).

FIG. 5 is a flowchart showing a procedure for assigning a score relating to the load factor to each order. Priority determination unit 7
0 points for 100% or more, 95%
One point is set for the range from less than 100% to less than 100%, two points are set for the range from 90% to less than 95%, and the priority determination unit 7 determines the delivery time of each order and the standard lead time predetermined for each manufacturing process. Are used to determine the planned dates for processing in the respective manufacturing processes defined in the via-line manufacturing process for each order (step S221), and the load factor score on each of the determined planned dates is determined (step S222). The total score of the intermediate manufacturing process is calculated by integrating the values, and the score is set as the score related to the load factor of each order (step S223).

Further, the priority determining unit 7 calculates the points related to the delivery date as 10 points when the number of days until the delivery date is less than 1 day, 6 points when 1 day or more and less than 2 days, 3 points when 2 days or more and less than 3 days, Are set, and the priority determination unit 7 calculates the number of days until the delivery date of each order, and sets a score corresponding to the calculated number of days as a score related to the delivery date of each order.

The priority determining unit 7 integrates the plurality of points thus given for each order to obtain the total points, assigns the total points to each order as a point relating to the priority, and then assigns the points to the order group. , The priority is determined by sorting the orders included in the order in descending order of the points assigned thereto (step S23), and the result is given to the allocation determining unit 8.

The allocation determining unit 8 selects an appropriate combination from the respective combinations of the material group and the order group (step S24), and selects one of the plurality of materials included in the material group of the selected combination. A material having a younger date for processing in the final manufacturing process is selected (step S25). The allocation determining unit 8 selects the first order, that is, the order with the highest priority, out of the plurality of orders included in the order group of the selected combination (step S26), and the material allocation remaining weight exists in the selected order. It is determined whether or not to perform the process (step S27).
Returning to 26, an order with a lower priority is selected.

If the allocation deciding unit 8 determines that there is a material allocation remaining weight in the order selected in step S26, it determines whether or not the selected material has an order allocation remaining weight. It is determined whether or not an order can be allocated to the material based on whether or not the allocated remaining weight is equal to or more than the unit weight of the selected order (step S28). If the allocation determining unit 8 determines that the order can be allocated to the material, the allocation determining unit 8 allocates the weight within the range of the remaining weight of the order allocation and the remaining weight of the material allocation and an integral multiple of the unit weight of the order (step S31). Then, the order allocation remaining weight and the material allocation remaining weight are updated by the allocated weight (step S32).

The allocation determining unit 8 determines whether or not an unselected order exists in the order group (step S3).
3), Steps S26 to S26 until it is determined that it does not exist
After the operation up to step S33 is repeated, it is determined whether or not there is any unselected material in the material group (step S34). Until it is determined that there is no material, the operations from step S25 to step S34 are performed. repeat. As a result, the load factor of the manufacturing process having a small load factor is increased, the load balance of each manufacturing process is made uniform, and the operation rate of the manufacturing process is improved, while the yield is also improved.

In this way, when the allocation to the plurality of materials included in the material group of the plurality of orders included in the order group of the selected combination is completed, the allocation determining unit 8 determines that there is a combination not selected. It is determined whether or not it is included (Step S35), and the operations from Step S24 to Step S35 are repeated until it is determined that the material group does not exist. Are assigned to a plurality of materials, and the result is assigned to the fourth as shown in FIG.
Giving it to the memory 14 and storing it there (step S36)
At the same time, the result is given to the display unit 9 and displayed there.

When the results of the allocation to the ordered materials are stored in the fourth memory 14, the output unit 10 outputs the information stored in the fourth memory 14 to an operation plan creation device (not shown) (step S10). S37).

[0030]

As described in detail above, in the present invention,
For a production process with a small load, the load is increased to make the load balance uniform, and the operation rate of the production process is improved. Further, the present invention has excellent effects such as improvement in yield and prevention of delay in production planning.

[Brief description of the drawings]

FIG. 1 is a block diagram showing a configuration of an apparatus according to the present invention.

FIG. 2 is a flowchart showing a procedure in which the computer shown in FIG. 1 assigns orders to materials.

FIG. 3 is a flowchart showing a procedure in which the computer shown in FIG. 1 assigns orders to materials.

FIG. 4 is a flowchart showing a procedure in which the computer shown in FIG. 1 assigns orders to materials.

FIG. 5 is a flowchart showing a procedure for giving a score relating to a load factor to each order.

FIG. 6 is a table showing an example of order information registered in the order information database shown in FIG. 1;

FIG. 7 is a chart showing an example of order information stored in a first memory shown in FIG. 1;

FIG. 8 is a chart showing an example of material information registered in the material information database shown in FIG. 1;

FIG. 9 is a chart showing an example of material information stored in a second memory shown in FIG. 1;

FIG. 10 is a chart showing an example of an operation plan registered in the operation plan database shown in FIG. 1;

FIG. 11 is a chart showing an example of a load factor stored in a third memory shown in FIG. 1;

FIG. 12 is a chart showing an example of an allocation result stored in a fourth memory shown in FIG. 1;

[Explanation of symbols]

 3 Order information readout unit 4 Material information readout unit 5 Operation plan readout unit 6 Judgment unit 7 Priority determination unit 8 Allocation determination unit 21 Order information database 22 Material information database 23 Operation plan database

Claims (2)

[Claims] When a plurality of products are produced by passing a predetermined amount of a plurality of product materials through a required production process among a plurality of production processes in accordance with a predetermined order and time, the amount of the product and the product are determined. An operation of allocating, to one or a plurality of product materials, a request including a supply time, a production process for passing the product material to produce the product, and an order of the production process, corresponds to each request based on a result of the plurality of requests. In the method of creating a product production plan, in each production process, the amount of demand allocated to a plurality of production materials passing through the production process is calculated over time, while the product supply time and product Based on the production processes to be performed and their order, the scheduled times at which the product materials relating to each request should pass through the corresponding production processes are determined, and at each determined scheduled time, Compare the amount of requirements allocated to multiple production materials that go through the corresponding production process with the amount of product materials that can be processed in a unit period in the production process, and based on the comparison result, A method for creating a production plan, wherein priorities are determined, and requests are allocated to product materials based on the determined priorities. 2. When a plurality of products are produced by passing a predetermined amount of a plurality of product materials through a required production process among a plurality of production processes according to a predetermined order and time, the amount of the product and the product An operation of allocating, to one or a plurality of product materials, a request including a supply time, a production process for passing the product material to produce the product, and an order of the production process, corresponds to each request based on a result of the plurality of requests. In an apparatus for creating a product production plan, in each production process, a means for calculating, over time, the amount of a request allocated to a plurality of production materials passing through the production process, and a time for supplying the product and a product material. Means for determining the scheduled times at which the product materials relating to each request are to be passed through the corresponding production processes, based on the production processes to be passed and the order thereof, Means for comparing the amount of demand allocated to a plurality of production materials passing through the corresponding production process at each time with the amount of product material that can be processed in a unit period in the production process, and based on the comparison result. A means for determining the priority of each request and a means for allocating each request to a product material based on the determined priority.