TW201714122A - Production scheduling method and automatically scheduling system - Google Patents

Abstract

A production scheduling method includes: providing at least one production task to an automatically scheduling system; arranging, by the automatically scheduling system, a schedule for the production task, and generating a production plan; determining, by the automatically scheduling system, whether the production plan is reasonable; and enabling a machine, by the automatically scheduling system, to operate according to the production plan if the production plan is determined to be reasonable. A host having the automatically scheduling system is connected to the machine such as an injection machine via a network. Therefore, the automatically scheduling system transmits the production plan to the machine in real time, and the machine operates according to the production plan.

Description

Production scheduling method and automatic scheduling system

The invention relates to a production line, in particular to a method for producing a production schedule of an injection machine and an automatic scheduling system.

Figure 1 is a block diagram of a conventional method of producing a schedule. As shown in Figure 1, after receiving the order, the production task completion time and output are determined based on the inventory and delivery date. Next, the injection machine is selected according to the production task to arrange the time course, and in order to make the order continue to be discharged, usually the same product is produced by the fixed machine. In addition, in the actual scheduling, the mold will be transferred. If the mold is being used, use the backup mold or wait for the mold to be used before production.

However, in the conventional method of production scheduling, when the order belongs to a multi-variety small batch, the delivery, quality, and cost are difficult to control.

Moreover, when the order changes frequently, it is necessary to frequently change the mold and refuel, which makes the production plan difficult to implement.

Moreover, if the machine and the mold are used in different production plans, the quality and delivery time will be greatly affected.

In addition, most of the production lines of injection machines are manually scheduled. The way, but as the order volume increases, the traditional manual method is not enough. If there is a sudden situation such as damage to the machine during the production and maintenance, temporary and frequent insertion, it is easy to cause confusion at the production site, but cannot be guaranteed. Product delivery.

Therefore, how to overcome the various problems of the above-mentioned prior art has become a problem that is currently being solved.

In view of the above-mentioned various deficiencies of the prior art, in order to improve production efficiency and maximize the satisfaction of order requirements, and to minimize the number of times of mold changeover, the present invention provides a method for producing schedules, including: providing at least one production task Up to an automatic scheduling system; the automatic scheduling system schedules the production task to generate a production plan; the automatic scheduling system determines whether the production plan is reasonable; and when the production plan is reasonable, the The automatic scheduling system allows the machine to operate according to the production plan.

In the foregoing method, the automatic scheduling system includes a system management module, a material management module, a production scheduling module, and a report management module. The control system of the automatic scheduling system includes materials, production lines or process parameters.

In the foregoing method, in the operation of the automatic scheduling system, the planning of the time schedule includes: introducing an enterprise resource planning system; waiting for the production task; scheduling the production task, or canceling the production task; shut down.

In the foregoing method, in the operation of the automatic scheduling system, the execution of the production plan includes: waiting for confirmation; waiting for the instruction to be sent to the machine; the machine waiting for production; performing production or canceling production; and closing.

In the foregoing method, in the operation of the automatic scheduling system, when the production plan is unreasonable, another production plan is regenerated.

The present invention further provides an automatic scheduling system, comprising: an injection machine; and a host, comprising: an application server, the network is connected to the injection machine to exchange data with the application server group, and the application server The utility model comprises a data acquisition module, a data replication module, a data storage module, a production scheduling module, an information collection module and a data analysis module, and a data server, which comprises a record entity table, a temporary cache table and an interface entity table. And constructing a scheduling calculation module for the application server; and the interface server includes an enterprise resource planning (ERP) interface synchronization module and a manufacturing execution system (MES) interface synchronization module to receive the ERP production meter Draw orders and MES device connection data.

It should be noted that each module of the above application server is a technical step for implementing a specific function, and is more suitable for describing the execution process of the software in the computer than the program, so the description of the software is represented by a module (not including the foregoing). System management module, material management module, production scheduling module and report management module, etc. in the method).

In the foregoing automatic scheduling system, the data acquisition module is used to acquire basic data in the system to supplement the basic data of the production schedule.

In the foregoing automatic scheduling system, the data replication module is configured to copy the result of the production automatic scheduling to the data server.

In the foregoing automatic scheduling system, the data saving module is configured to copy the result of the production automatic scheduling to the data server.

In the foregoing automatic scheduling system, the production scheduling module is used for analysis Bill of materials (BOM) and inventory.

In the foregoing automatic scheduling system, the information collecting module is configured to receive the real-time data transmitted by the injection machine.

In the foregoing automatic scheduling system, the data analysis module is based on the data support of the information collection module to present the analysis result.

In the foregoing automatic scheduling system, the control room is further connected to the application server, the data server and the interface server, and the control room displays the production plan order and configures the production schedule plan.

In the foregoing automatic scheduling system, the utility model further comprises a console, which is used for regulating the operating parameters of the injection machine, and uses the network connection between the injection machine and the application server to display the automatic production schedule and upload it instantly. Equipment operation data.

As can be seen from the above, the method for scheduling production and the automatic scheduling system of the present invention mainly connect the host and the machine through a network, so that the production plan can be instantly transmitted to the machine by using an automatic scheduling system, so that The machine operates according to the production plan, so it can overcome the lack of conventional technology.

20‧‧‧Injector

200‧‧‧Control panel

21‧‧‧Application Server

22‧‧‧Data Server

23‧‧‧Interface server

(a), (b), (c), (d), (d1’), (d2’) ‧ ‧ steps

(b1), (b2), (b3), (b4), (b5), (b6), (b7) ‧ ‧ steps

(e1), (e2), (e3), (e4), (e5), (e6) ‧ ‧ steps

1 is a block diagram of a conventional method for producing a schedule; FIG. 2A is a schematic diagram of an automatic scheduling system of the present invention; and FIG. 2B is a block diagram of a method for producing a schedule of the present invention; Figure 4 is a block diagram of an automatic scheduling system for a method of production scheduling of the present invention; and Figure 4 is a block diagram of a production schedule of an automatic scheduling system for a method of production scheduling of the present invention; Figure 5 is a block diagram showing the execution of the production schedule of the automatic scheduling system of the method for producing the schedule of the present invention; and Figs. 6A to 6B' are diagrams showing the method of the production schedule of the present invention under normal conditions. The schematic diagrams shown; the 6C and 6C' diagrams are diagrams showing the display of the method of the present invention in a sudden situation; and the 7A and 7B' diagrams are the method of the production schedule of the present invention. A schematic representation of the display displayed in another emergency.

The other embodiments of the present invention will be readily understood by those skilled in the art from this disclosure.

It is to be understood that the structure, the proportions, the size, and the like of the present invention are intended to be used in conjunction with the disclosure of the specification, and are not intended to limit the invention. The conditions are limited, so it is not technically meaningful. Any modification of the structure, change of the proportional relationship or adjustment of the size should remain in this book without affecting the effects and the objectives that can be achieved by the present invention. The technical content disclosed in the invention can be covered.

2A is a schematic structural view of an automatic scheduling system of the present invention. As shown in FIG. 2A, the architecture of the automatic scheduling system includes a control room (such as a remote computer client), a network connection (such as a cloud network), a host of the control room, and a factory area (which includes the injection machine 20). And, for example, the console of the control panel 200).

The computer user terminal is loaded with a Windows operating system on a computer to display a production planning order in an upstream system such as Enterprise Resource Planning (ERP), and is in a computer interface (such as a production schedule Gantt). Figure) Configure the production schedule plan.

The host includes a set of servers, namely an application server 21, a data server 22, and an interface server 23.

The application server 21 is loaded with a Windows operating system and includes a data acquisition module, a data replication module, a data storage module, a production scheduling module, an information collection module, and a data analysis module.

In the embodiment, the data acquisition module is used to acquire basic data in the system to supplement the basic data of the production schedule.

In this embodiment, the data replication module is configured to copy the result of the production automatic scheduling to the temporary cache table of the data server 22.

In this embodiment, the data saving module is configured to copy the result of the automatic production scheduling to the record entity table of the data server 22. If an abnormal behavior occurs during the saving process, the data is servoed. The latest result in the temporary cache table of the device 22 is stored in the record entity table to prevent the production scheduling module from rescheduling.

In the embodiment, the production scheduling module is used to analyze Bill of Material (BOM) and inventory, and in combination with the use of the mold and the equipment, the production planning order meets less and less downtime. Standard scheduling technology such as mold change, feed supply, and priority production, and analyze the real-time data of the host (including equipment maintenance, sudden abnormality) and emergency customer inserts, and then automatically re-schedule.

In this embodiment, the information collection module is configured to receive the real-time data uploaded by the injection machine 20.

In the embodiment, the data analysis module is based on the data support of the information collection module to present the analysis results of the obtained graph, histogram, and Gantt chart.

The data server 22 is loaded with a Windows operating system, and installs a database software (SQL Server 2008), and includes a record entity table, a temporary cache table, and an interface entity table, and a schedule calculation module is constructed for the application server. The production scheduling module of the device 21 is used to implement the core algorithm of the automatic scheduling.

The interface server 23 is loaded with a Windows operating system and includes an ERP interface synchronization module and a Manufacturing Execution System (MES) interface synchronization module to receive ERP production planning orders and MES device connections. data.

The injection machine 20 is one of the production line devices, and is connected to the application server 21 through a User Datagram Protocol (UDP) to communicate with the application server 21. The group exchanges data.

The control panel 200 is used to regulate the operating parameters of the injector 20, and utilizes the network connection between the injector 20 and the application server 21 to display the automatic scheduling Gantt chart and upload the device instantly. Operation data.

Figure 2B is a block diagram of the method of production scheduling of the present invention. As shown in FIG. 2B, the production scheduling configuration of the production schedule includes a plurality of machines (such as an injection machine) and a host connected to the machine through a network. And the host has an application server 21, a data server 22 and an interface server 23 of the automatic scheduling system.

The production scheduling method of the present invention combines the production technology of the injection machine with the production management to realize an automatic production scheduling method of the injection molding process.

The automatic scheduling system is as shown in FIG. 3, and includes a system management module, a material management module, a production scheduling module, and a report management module (the specific items of each module are as shown in FIG. 3). The operation sequence of the automatic scheduling system is as follows according to FIG. 2B. It should be noted that the system management module, the material management module, the production scheduling module, and the report management module are the machines, which are not used to represent the software, and are hereby stated.

(a) A plurality of production tasks awaiting arrangement, wherein the production tasks are task lists of coordinated work of each machine according to the material demand plan.

(b) Production scheduling, that is, scheduling the time of each production task to produce a production plan.

(c) The operator confirms whether the production plan is reasonable.

(d) when the production plan is reasonable, the production plan is transmitted to the machines, so that the machines operate according to the production plan; or, when the production plan is unreasonable, (d1' Manually adjust the production plan or (d2') manually adjust the capacity rearrangement to reproduce another production plan.

In this embodiment, according to the above modules, the control system of the automatic scheduling system includes materials, production lines or process parameters for reference to the production schedule, and the process of the rear end of the production line is the machine The finished product is put into storage.

Furthermore, the definition of the module of the automatic scheduling system of Fig. 3 is as follows: Bottom: The bill of materials (BOM) refers to the technical file composed of the product of the enterprise, which is the structural relationship between the total assembly, the parts, components, components, parts, and materials of the product.

The bill of routings (BOR) refers to a processing route (processing order) of an enterprise product in an enterprise and a standard working hour quota in each process.

The list of machines mentioned refers to the list of machines that can be used for production in the factory.

The list of molds refers to a list of molds or jigs that can be used for production in the factory.

The working shift refers to: the working time of the operator in the factory.

The product refers to: the final sale item, the product in the factory.

The raw material refers to an article obtained by mixing materials, toners, and additives.

Moreover, in the step (b) or (d1'), the automatic scheduling system can confirm at least one item (such as machine maintenance to machine maintenance, equipment calendar maintenance, work calendar maintenance, or ongoing). Production tasks, etc.) for production scheduling. Here, the ongoing production task refers to an order being produced in the factory.

In addition, in step (b), as shown in FIG. 4, the planning steps of the time course (ie, the production schedule) are sequentially included: first, (b1) importing enterprise resource planning (EPR). The system or operator enters a production task to import or enter a production task (can be new) The production task, if not participating in the original scheduling calculation), wherein the ERP import data can only modify the number of schedules, and the modification of the operator input data is not limited. Next, (b2) the production task is waiting for the schedule. Thereafter, (b3) schedules the production task, (b4) cancels the production task, or (b5) manually closes, wherein (b5) is, for example, only partial scheduling (ie, "scheduled quantity" is not achieved "Task demand" situation). Next, (b6) confirms that all the schedules are completed. Finally, (b7) the production plan is automatically closed after completion of the production, or (b8) the production plan is returned. Here, there are two ways to perform a closed job:

1. When all the schedules are completed, the "scheduled quantity" reaches the "task demand amount", and the system is automatically turned off, as in (b7).

2. When part of the schedule, the "scheduled quantity" does not reach the "task demand", and there is no scheduling demand, manually set the system to the off state, such as (b5).

On the other hand, in steps (c) to (d), as shown in Fig. 5, the execution of the production plan is sequentially included: first, (e1) waiting for confirmation, the production machine can be manually modified, and the production mold can be manually modified. Or start time, and the subsequent production plan will be postponed. Next, after confirming the production plan (e2), it waits for the instruction to be issued to the machines or denies the production plan. After that, after (e3) issues an order to the machines, the machine waits for production, or denies the instruction. Next, (e4) is produced (can be suspended during production), or (e5) the production plan is canceled and the canceled state is entered. Finally, after (e6) ends production, it enters the closed state.

In this embodiment, the cancel status means: when canceling a production plan, the number of scheduled items of the source task list needs to be deducted from the plan list. Quantity, and set the status of the source ticket to the (b2) state.

Furthermore, the closed state means that when a production plan is completed, the plan is set to be closed, and the production plan of the same source task list is retrieved, and when the "total production quantity" is greater than or equal to " When the total demand quantity is set, the source task list is set to off.

Therefore, according to the method of production scheduling described in Figures 2 to 5, the present invention is applicable to the case of "insertion", and the steps of automatic scheduling are as follows:

1. Receive the production task to be scheduled: insert the “temporary table to be scheduled task” in the task that is scheduled to be scheduled.

2, the start of the pre-scheduling cycle: first sort according to the task type (emergency, regular), product, delivery date order, and then start the cycle.

3. Calculate the number of molds: Calculate the number of molds that can be used to produce the product. If the task cannot be completed, split the plan.

4. Check whether the area is supplied: according to the raw materials used in the product, distribute it to the machine that can be produced, and then insert the “temporary table of available machine”.

5. Update the mold change replenishment priority order: According to the change order of the mold change and refueling set by the system, compare with the last mold and material of the available machine plan to set the mold change requisition priority.

6. Equalizing the actual load of the machine: The optimal replacement algorithm (OPTimal replacement, OPT for short) is implemented by the built-in paging algorithm of the computer. Specifically, according to the last production plan of the available machine, the mold and the raw materials used in the production plan are determined to be the same as the molds and materials required for the task to be inserted in the schedule, and then according to the mold change re-prioritization order. Updates can further ensure less mold change and less refueling. For example, if the same, excellent The order is low first; if it is different, the order of precedence is high. The OPT refers to: selecting a machine in the subsequent plan that does not use the current mold and the current raw material for replacement (further ensuring less mold change and less refueling).

7. Confirm the mold and machine: According to the change order, OPT, Least-Recently Used (LRU), etc., the order is prioritized to cycle. Specifically, it can be calculated: the latest available time of the device, the time required for the production of the task, the auxiliary time (changing the mold refueling time), and the like. Furthermore, it is judged whether "this task end time can satisfy the delivery date". The satisfied delivery period means: updating the machine number (ID), the mold number (ID), the project start time, the project end time, and the "setting the finished flag" is True; otherwise, the payment is not satisfied. The delivery period means: "Set the completed identification" to False. The LRU refers to: selecting a machine that has not been used for a long time to replace it (equalizing the actual production load of the machine).

8. Before the split, judge that the mark has been completed: "True" means: submit the transaction, and enter the loop until the end of the loop; "False" means: split the task.

9. Task splitting: Sorting according to the priority order of the mold change, OPT, LRU, etc., to cycle. Specifically, it can be calculated: the latest available time of the equipment, the auxiliary time (changeover time), the number of products that can be completed before the delivery date, and the number of unscheduled items. When splitting the task, confirm the number of machines, molds, and plans until the end of the cycle.

On the other hand, the core algorithm of the automatic scheduling system according to Figures 2 to 5 mainly refers to the conditions such as order delivery, downtime, production cycle, etc. Combined with other factors such as equipment, personnel, materials, inventory, etc., and adjusted according to the site conditions to ensure the best production capacity.

The expectation of the order delivery is based on the equipment capacity, and the order is completed on time to complete the order as the first target, and the delivery delay is eliminated as much as possible.

The expected downtime is to combine the production tasks of the same product in the case of ample order delivery, reducing the downtime loss caused by the mold change.

The expectation of the production cycle is that for a large order, the method of shortening the production cycle can be adopted to avoid problems such as overload of the equipment and long-term occupation of the mold.

Other factors mentioned include equipment maintenance, personnel scheduling, material supply, and finished product inventory, all of which affect automatic scheduling.

If the scene situation is a special case, especially the unexpected situation in the non-plan, mainly due to equipment or mold failure, emergency insertion and other reasons.

6A to 6B' are schematic views showing the display of the method of the present invention in a normal state.

As shown in Figure 6A, it is a regular order, which includes orders A, B, C, and D for four products, and order A is marked as "A1", "A2" and "" due to the quantity and delivery date conditions. A3", while other orders B, C, D and so on.

As shown in Figure 6B, according to the order quantity and delivery date, the automatic scheduling system automatically schedules the regular orders, and the order A1 is marked as "A1-1" and "A1-2" due to the assignment to the two machines. And other orders B, C, D and so on. Next, as shown in Figure 6B', according to the "order delivery" The principle of priority, combined with "downtime" and "production cycle", forms a production schedule Gantt chart.

In the present embodiment, the order A1-2: because the early shift is insufficient, the order task of the "machine 02" is delayed by 3 hours, starting from noon and extending for three hours at night.

In addition, order B1 will be delivered on the second day, so four equipments will be arranged at the same time to ensure that they are completed on time.

Also, according to the order C, after the order C1 is completed, in order to ensure the stability of the mold use, sufficient maintenance time is reserved for the required mold, and then the orders C2 and C3 are successively executed.

In addition, due to the close life cycle of the equipment, arrange a small production order D and reserve sufficient maintenance and downtime.

The 6C and 6C' diagrams are schematic diagrams of the display of the method of production scheduling of the present invention in the event of an emergency.

As shown in Figures 6C and 6C', when the production plan of Figure 6B occurs in the event of a sudden failure of the equipment, that is, the "machine 10" suddenly fails due to aging of the equipment, causing the shutdown. At this time, the automatic discharge The schedule system will reschedule the time of each order.

In this embodiment, the "machine 10" needs to be repaired. It is expected that the production will resume after 48 hours. Therefore, the order D1-2 is reassigned to the "machine 09", that is, it is combined with the order D1-1 to ensure the order. D1 is delivered on schedule.

Furthermore, order D2-2 is reassigned to "Machine 09", but depending on the condition of the equipment and personnel, a six-hour downtime is reserved.

Also, when the "machine 10" is repaired, the order D3 is reassigned to the "machine" Table 10" and "Machine 10" are continuously produced for 24 hours to ensure delivery on time.

Therefore, as can be seen from the 6C and 6C' diagrams, when the automatic scheduling system determines that the production plan is reasonable, that is, the operating schedules of the "machine 10" and the "machine 09" conform to the on-site condition, and each of the machines is based on The production plan operates. On the other hand, if the operating schedules of "machine 10" and "machine 09" do not meet the on-site conditions (such as "machine 10" still needs to operate during maintenance), the automatic scheduling system determines that the production plan is not Reasonable, at this time, each machine will not work.

7A and 7B' are diagrams showing the display of the method of production scheduling of the present invention in another unexpected situation.

As shown in Figure 7A, when the production plan of Figure 6C occurs, such as an emergency situation of an emergency order insertion, that is, when the order is near saturation, an order E1 that needs to be expedited is received, that is, the delivery time is very high. urgent.

As shown in Figures 7B and 7B', at this time, according to the current order scheduling, the automatic scheduling system will re-arrange the time schedule of each order with the existing equipment, personnel and other resources.

In this embodiment, the order A1-1 and the order A1-2 are reassigned to the "machine 01" and combined to ensure that the order A1 is delivered on schedule.

Furthermore, the order E1 is assigned to the "machine 02" for production, and since the night shift is sufficient, the order A1 can be simultaneously considered.

In addition, since the "machine 01" equipment is relatively new and has the capability of continuous production, the plan for order A2-1 remains unchanged.

Therefore, as can be seen from the figures 7B and 7B', when the automatic scheduling system determines that the production plan is reasonable, that is, the operating schedules of "machine 01" and "machine 02" conform to the on-site condition, and each of the machines is based on The production plan operates. on the contrary, If the operating schedules of "machine 01" and "machine 02" do not meet the on-site conditions (such as "machine 02" is not assigned to order E1 or order A2-1 is required), the automatic scheduling system determines the production. The plan is unreasonable. At this time, each machine will not operate.

The above embodiments are intended to illustrate the principles of the invention and its effects, and are not intended to limit the invention. Any of the above-described embodiments may be modified by those skilled in the art without departing from the spirit and scope of the invention. Therefore, the scope of protection of the present invention should be as set forth in the appended claims.

(a), (b), (c), (d), (d1’), (d2’) ‧ ‧ steps

Claims (10)

An automatic scheduling system includes: an injection machine; and a host, comprising: an application server, the network is connected to the injection machine to exchange data with the application server group, and the application server includes a data acquisition module Group, data replication module, data storage module, production scheduling module, information collection module and data analysis module; data server, including record entity table, temporary cache table and interface entity table, and construct schedule The computing module is used by the application server; and the interface server includes an enterprise resource planning (ERP) interface synchronization module and a manufacturing execution system (MES) interface synchronization module to receive the ERP production planning order and the MES Device connection information. The automatic scheduling system of claim 1, wherein the data acquisition module is configured to acquire basic data in the system to supplement the basic data of the production schedule. The automatic scheduling system of claim 1, wherein the data replication module is configured to copy the result of the production automatic scheduling to the data server. For example, the automatic scheduling system described in claim 1 includes a control room, and the network connects the application server, the data server, and the interface server. The server, and the control room displays the production plan order and configures the production schedule. The automatic scheduling system as described in claim 1, further comprising a console for regulating operating parameters of the injector, and using the network connection between the injector and the application server to display production Automatic scheduling and upload device running data instantly. A method for producing a schedule includes: providing at least one production task to an automatic scheduling system; the automatic scheduling system scheduling a time course of the production task to generate a production plan; the automatic scheduling system determining the production Whether the plan is reasonable; and when the production plan is reasonable, the automatic scheduling system allows the machine to operate according to the production plan. The method for producing a scheduling as described in claim 6 wherein the automatic scheduling system comprises a system management module, a material management module, a production scheduling module, and a report management module. The method of the production schedule described in claim 6 wherein, in the operation of the automatic scheduling system, the planning of the time schedule comprises: importing an enterprise resource planning system; the production task is awaiting arrangement; The time course of the production task, or cancel the production task; and close. A method for producing a production schedule as described in claim 6 of the patent scope, wherein In the operation of the automatic scheduling system, the execution of the production plan includes: waiting for confirmation; waiting for the order to be sent to the machine; the machine waiting for production; performing production or canceling production; and closing. A method of producing a schedule as described in claim 6 wherein, in the operation of the automatic scheduling system, when the production plan is unreasonable, another production plan is regenerated.