JP5810040B2 - Production schedule creation device and production schedule creation method - Google Patents

Description

  The present invention relates to a production scheduling technique when manufacturing a variety of products, and more particularly to a technique for performing scheduling with better production efficiency.

  The creation of production schedules (production plans) at each facility when producing multiple types of products satisfied evaluation items such as adherence to delivery dates, maximization of productivity, and timely (timely) supply to downstream processes. You need to create a schedule.

  There is an equipment load plan as one of the production schedules. The equipment load plan is to calculate a processing amount (load) that must be produced in each process in accordance with an order, and assign it within the capacity of each process.

  If the production line is composed of multiple processes, if the load of one process is moved to another time zone, and the effect extends to another process, for example, the load must be destroyed even if there is a margin in processing capacity. There are cases where it is not possible. In addition, depending on the process, there is a process of performing batch processing for processing a plurality of products collectively. Depending on how the processes are performed, the processing capacity of the facility may not be utilized to the maximum extent.

  As described above, scheduling for producing a plurality of types of multi-process products often involves many points to be considered and is often complicated. Therefore, various techniques for generating a highly productive schedule have been proposed.

  For example, in Patent Document 1, even if a process using equipment that can be batch-processed is not the first process but an intermediate process, the load is grouped into batch processing units so that appropriate batch processing can be performed. Considering capacity, create a production plan that maximizes production.

JP 2011-123870 A

  Here, when there are a plurality of facilities used in the process, it is necessary not only to process the load allocated to the process but also to allocate each facility so as to increase the productivity. In addition, it is necessary not to consider only the productivity of each facility but to prevent delays in delivery in view of the overall schedule.

  Since there are many elements that must be considered even when planning a single facility, it is difficult to formulate an optimal schedule, and even if it can be planned, it will take time. Furthermore, in view of the schedule of the entire factory, it is difficult to create a schedule for each facility for each process so that timely supply to downstream processes is made and delays in delivery are not generated. It takes time.

  Therefore, the present invention is a schedule that takes into consideration the overall schedule when producing a product in a plurality of processes including a process that uses a plurality of facilities, and is capable of creating a schedule with high production efficiency for each facility in each process. The purpose is to do.

  In one aspect according to the present invention, the production schedule creation device is a production schedule creation device for creating a schedule for producing a plurality of products produced by a plurality of processes before each delivery date of each product. Or, a product is produced using a plurality of facilities, each process of each product is associated with one of the facilities used in each process of each product in a predetermined time unit, and the load of each product is associated with each process. In one step of using a plurality of facilities, a grouping unit that groups the products allocated by the allocation unit in one predetermined time according to production conditions for each facility, In the grouping by the group determining means, the number of products to be configured is compared to the number of all products that constitute the group grouped under the same production conditions. Moving group determination means for determining a group having the lowest ratio as a moving group to be moved from the facility to which the group is allocated to another facility to which another group grouped under the same production conditions is allocated It is characterized by providing.

  And the production schedule creation method which concerns on the other one aspect | mode of this invention is a several product produced by multiple processes, Comprising: The product produced using 1 or several equipment at each process, It is a production schedule creation method used in a production schedule creation device that creates a schedule for production by delivery date, and associates each process of each product with any equipment used in each process of each product in a predetermined time unit, In the allocation step of assigning the load of each product to the equipment associated with each process, and in one process using a plurality of equipment, the product assigned in the allocation step in one predetermined time is determined according to the production conditions for each equipment. Grouping step for grouping and grouping in the group determination step in the one process, grouping under the same production conditions. For the total number of products that make up the group, the group with the lowest ratio of the number of products that make up the group is changed from the equipment to which the group is assigned to other products grouped under the same production conditions. A moving group to be moved to another facility to which the group is assigned and a moving group determining step for determining are provided.

  The production schedule creation apparatus and production schedule creation method configured as described above, when assigning a product assigned to one process to equipment used in the process, groups the products according to the production conditions, and groups them under the same production conditions. The group having the lowest ratio of the number of products constituting the total number of products constituting the generalized group, that is, a group that can belong to another group can be moved to other equipment . Therefore, it is possible to improve production efficiency by combining products with the same production conditions into one facility without changing the process. Therefore, there is a high possibility that a production schedule with better production efficiency can be created without changing the overall schedule. In addition, since the group to be moved is determined in units of one predetermined time in one process, a production schedule can be created at high speed.

  In the production schedule creation device described above, the production schedule creation device further includes a destination determination unit that determines a destination facility that is a destination facility to which the movement group determined by the movement group determination unit is moved, and a facility Equipment schedule evaluation means for evaluating production efficiency when processing the product assigned to the equipment, and the destination determination means is equipment in the process to which the movement group is assigned, When the mobile group is assigned to equipment other than the equipment to which the mobile group is assigned, the equipment schedule evaluation means calculates the evaluation of the other equipment, and the other equipment with the best evaluation is It is preferable to determine the destination equipment.

  According to this configuration, when the movement group is moved to another facility, the movement group is moved to a facility whose production efficiency is high, so that it is highly possible that a schedule with higher production efficiency can be created.

  In the production schedule creation device described above, the assigning means associates each process of each product with each process of each product in a predetermined time unit so that each product can be produced by the delivery date of each product. Means for creating an overall schedule for assigning product loads to each process, and a process schedule for assigning products assigned to each process of the overall schedule in units of a predetermined time to equipment used in the process every predetermined time It is preferable to have a means for creating.

  According to this configuration, the schedule for each process is created from the entire schedule for observing the delivery date, so even if the product is moved to other equipment in the process, it is possible to create a schedule that can comply with the delivery date Becomes higher.

  Further, in the production schedule creation device described above, the group determination means performs a process other than a process of producing a product when the production conditions of the products have the same or common conditions and the products are processed continuously. It is preferable to group the products that are not required into one group.

  According to this configuration, it is possible to reduce processing that is not processing for producing a product in the facility, and therefore it is highly possible that a schedule with higher production efficiency can be created.

  The production schedule production device according to the present invention is a schedule that takes into consideration the overall schedule when producing a product in a plurality of processes including a process that uses a plurality of facilities, and is a schedule that has good production efficiency of each facility in each process. Creation can be performed at high speed.

It is a block diagram which shows the functional structure of the production schedule preparation apparatus in embodiment. It is a figure for demonstrating a production line. It is a figure for demonstrating the installation of the production line shown in FIG. It is a figure which shows the example of a structure and content of the equipment processing capacity table in the production schedule preparation apparatus shown in FIG. It is a figure which shows the example of a structure and content of an order information table in the production schedule preparation apparatus shown in FIG. It is a figure which shows the example of a structure and content of a setup condition table in the production schedule preparation apparatus shown in FIG. It is a figure which shows the example of a whole schedule. It is a figure which shows the example of a process schedule. It is a figure for demonstrating grouping. It is a figure for demonstrating the movement destination of a movement candidate group. It is a figure for demonstrating the schedule which moved the movement candidate group. It is a figure for demonstrating the movement destination of a movement candidate group. It is a figure for demonstrating the schedule which moved the movement candidate group. It is a figure for demonstrating the last schedule. It is a flowchart of a production schedule creation process.

<Embodiment>
<Overview>
It is desirable that the production schedule of the whole factory that manufactures multi-product and multi-process products on a plurality of production lines should not only comply with the delivery date but also maximize the productivity of the whole factory. As such a production line, for example, a production line of a material factory such as steel, copper plate, aluminum plate or the like can be cited.

  Some of these processes are performed using a single facility, while others are performed using a plurality of facilities. It is necessary to create a schedule for a process for processing using a plurality of facilities for each facility. That is, which load is allocated at each predetermined time of each facility is determined. However, it is difficult to determine the load distribution to each facility and the load processing order in each facility at the same time.

  In view of this, the production schedule creation device of the embodiment separately performs load distribution to each facility and determination of the load processing order in each facility, aiming to speed up schedule creation.

  In addition, the production schedule creation device of the embodiment assigns a load to each process as an overall schedule so as not to break the schedule of the factory as a whole, for example, compliance with the delivery date. The load assigned to is distributed to each facility. Therefore, it is possible to assign a load to each facility while observing the entire schedule, and a processing order that increases the productivity for each facility is determined.

  As described above, the production schedule creation device of the embodiment performs load distribution to each facility in view of the entire schedule, and then determines the processing order of loads in each facility, so that the productivity is high and the delivery date It is possible to make a high-quality plan that does not cause delays at high speed.

  Hereinafter, an embodiment according to the present invention will be described with reference to the drawings.

<Configuration>
FIG. 1 is a diagram showing a functional block configuration of the production schedule creation apparatus 1000.

  The production schedule creation apparatus 1000 includes a production schedule creation control unit 1001, an input unit 1002, and an output unit 1003.

  The input unit 1002 is a device that inputs various commands such as a command for starting a program for creating a production schedule and various data necessary for creating a schedule to the production schedule creating apparatus 1000. For example, a keyboard or a mouse.

  The output unit 1003 is a device that outputs (presents) the command and data input from the input unit 1002 and the schedule created by the production schedule creation device 1000. For example, a display device such as a CRT (Cathode Ray Tube) display, an LCD (Liquid Crystal Display), an organic EL (Electro Luminescence) display, a plasma display, or a printing device such as a printer.

  The production schedule creation control unit 1001 includes, for example, a microprocessor and its peripheral circuits. Functionally, the production schedule creation control unit 1001 is functionally configured as an initial plan creation unit 1100, a grouping unit 1200, a movement candidate determination unit 1300, a detachment degree calculation unit 1400, Destination determination unit 1500, destination evaluation value calculation unit 1600, process schedule creation unit 1700, per-equipment plan creation unit 1800, master storage unit 2000, grouping condition storage unit 2100, production schedule storage unit 2200, and final schedule storage Unit 2300, and controls input unit 1002 and output unit 1003 according to the function according to the control program. An arrow in the production schedule creation control unit 1001 represents a main data flow between functional blocks.

  The initial plan creation unit 1100 has a function of creating an overall schedule and a process schedule. The overall schedule is a schedule for several months, and is a schedule for the entire factory. The process schedule is a schedule for several days to several weeks, and is a schedule for each process. However, the process schedule created by the initial plan creation unit 1100 is the first process schedule, and a process schedule with good production efficiency is created by the process schedule creation unit 1700 described later.

  The overall schedule is a schedule created by virtually piled up the load for manufacturing the product according to the order quantity in the process for each unit time on the basis of the delivery date. A one-step schedule is extracted and rescheduled while changing the unit time.

  FIG. 7 shows an example of the entire schedule. In the present embodiment, the unit time of the entire schedule is 1 day, and the initial plan creation unit 1100 performs work steps for performing each process of the ordered product so as to trace the flow of time from the delivery date based on the delivery date of the order. To decide. Then, a load corresponding to the order quantity is virtually piled up for each process on the determined work day. Then, the load is crushed so that the load accumulated in the process does not exceed the processing capacity of the facility. The mountain climbing is performed by reassigning the load accumulated beyond the processing capacity of the facility to a work day before the work day to which the load is assigned. As a result of the mountain climbing, the load accumulated on the work day before the start date of the plan is further broken down so as to be assigned to the work day after the start date, and the entire schedule is created. The accumulated load is represented by a rectangle, and the name of the order is described in the rectangle (the same applies to FIGS. 8 to 14 and the like). In this embodiment, the load is loaded on each facility so as to go back from the delivery date. However, the load may be piled up by other methods, and the landslide may be carried out by other methods. Also good.

  FIG. 8 shows an example of a process schedule. The process schedule is a schedule for one process. That is, a schedule in which a load accumulated in one process in the entire schedule is assigned to equipment used in the process, for example, equipment A, B, C, for each unit time of the process schedule, and the processing order of the assigned loads is determined. Say. That is, one process schedule is a schedule for a plurality of facilities used in one process. In the embodiment, the unit time of the process schedule is 2 days. Accordingly, in FIG. 8, for each of the equipments A to C, “May 30 to 31”, “June 1 to 2”, “June 3 to 4”, and “June 5 to 6” A load is assigned every four unit times. Hereinafter, the schedule of the equipments A to C per unit time is referred to as “unit time schedule”. Note that the unit time of the process schedule is determined in consideration of the process contents of each process, the start time of the process in the next process, and the like. Incidentally, the unit time of the process schedule may be set to one day as with the entire schedule. The specific contents of the overall schedule and process schedule will be described in the section <Overall schedule / process schedule>.

  The grouping unit 1200 groups the loads accumulated in a certain unit time in the process schedule created by the initial plan creation unit 1100, that is, the unit time schedule according to the production conditions of each load (product). It has a function. In the grouping, loads that do not reduce the production efficiency as much as possible even if they are continuously processed are regarded as one group. That is, loads that share all or part of the production conditions are often made into one group.

  The grouping unit 1200 performs grouping based on the grouping conditions stored in the grouping condition storage unit 2100. This grouping condition varies depending on the process. For example, in the case of a rolling process, the rolling roll to be used may differ depending on the load (product). When the rolls used for two loads (products) to be processed successively are different, it is necessary to replace the rolls for rolling. Become. Further, for example, in the annealing process, if the annealing temperatures of the two loads (products) are not within an allowable range, a time for adjusting the temperature is required, so that “the annealing temperature is within the allowable range”. "" Is the grouping condition.

  In other words, grouping means finding friends, and a group can be called a friend. In the embodiment, grouping is performed without changing the processing order of the loads assigned to the facilities. This is because the processing order is set in consideration of the delivery date and the like at the initial scheduling stage.

  The movement candidate determination unit 1300 has a function of determining a group (hereinafter referred to as “movement candidate group”) to be moved to other equipment of the same unit time schedule from the group of unit time schedules created by the grouping unit 1200. Have The movement candidate determination unit 1300 determines a group having the largest degree of detachment as a movement candidate group. The movement candidate determination unit 1300 determines that a group that is configured with a small number of friends has a high degree of detachment despite having many friends who can form the same group. That is, it is determined that the group with the smallest ratio of the number of loads constituting the same group has the highest degree of disjointness. The detachment degree calculation unit 1400 calculates the detachment degree.

  The detachment degree calculation unit 1400 calculates the detachment degree in the unit time schedule for each group created by the grouping unit 1200 in a unit time with a process schedule. A specific calculation method will be described in the section <Movement candidate group determination method>.

  The movement destination determination unit 1500 determines the movement destination group of the movement candidate group determined by the movement candidate determination unit 1300, the group that belongs to the movement, and the processing order within the group. The movement is performed within a unit time schedule. That is, the movement destination equipment is another equipment in the same process as the process to which the movement candidate group belongs, and the unit time of the movement destination is the same unit time as the unit time to which the movement candidate group belongs. The destination determination unit 1500 determines the candidate destination that has the highest schedule evaluation when moving among the plurality of destination candidates (hereinafter referred to as “candidate destination”) as the destination. This schedule evaluation is calculated by the destination evaluation value calculation unit 1600. Specific candidate destinations will be described in the section <Destination Determination Method>.

  The movement destination evaluation value calculation unit 1600 has a function of evaluating a schedule when a movement candidate group is moved to a candidate movement destination. A specific evaluation calculation method will be described in the section <Destination Determination Method>.

  The process schedule creation unit 1700 has a function of creating a unit time schedule for moving the movement candidate group determined by the movement candidate determination unit 1300 to the movement destination determined by the movement candidate determination unit 1300 and storing the unit time schedule in the production schedule storage unit 2200. Have.

  The facility-specific plan creation unit 1800 has a function of rescheduling the unit time schedule created by the process schedule creation unit 1700 for each facility to create a final schedule. For example, the processing order is determined such that the number of times that the setup change occurs is small. In the embodiment, the process is performed for each unit time schedule, but a plurality of unit time schedules may be collected and a load may be crushed to create a schedule with high production efficiency.

  The master storage unit 2000 has a function of storing various kinds of information necessary for generating a schedule. For example, information on the processing capacity of equipment, information on production conditions in each process of products, information on orders, and the like. Among the information stored in the master storage unit 2000, main information (data) used in the present embodiment will be described in the section <Production schedule target>.

  The grouping condition storage unit 2100 has a function of storing grouping conditions when the grouping unit 1200 performs grouping.

  The production schedule storage unit 2200 has a function of storing the entire schedule and process schedule created by the initial plan creation unit 1100 and the unit time schedule created by the process schedule creation unit 1700.

  The final schedule storage unit 2300 has a function of storing the final schedule created by the facility-specific plan creation unit 1800. By combining the final schedule, an optimal overall schedule is created.

  The master storage unit 2000, the grouping condition storage unit 2100, the production schedule storage unit 2200, and the final schedule storage unit 2300 described above may be, for example, a RAM (Random Access) serving as a so-called working memory of the production schedule creation device 1000, depending on the application. A volatile storage element such as a memory (ROM), a nonvolatile storage element such as a ROM (Read Only Memory) and a rewritable EEPROM (Electrically Erasable Programmable Read Only Memory), a hard disk, and the like.

  Further, the production schedule creation apparatus 1000 displays the contents of order information and the like stored in the master storage unit 2000 on the output unit 1003 according to a command input from the user via the input unit 1002, It also has a function of creating, modifying, etc. the contents of order information and the like via 1002.

  The production schedule creation apparatus 1000 having such a configuration can be configured by using a computer such as a personal computer, for example, and is described above by executing software programmed with a schedule creation method stored in a storage unit such as a hard disk. The grouping unit 1200 and the like are functionally configured in the computer. Note that one or more of the other functional units shown in FIG. 1 may be configured in the computer.

  When a program for programming a schedule creation method or the like is not stored in a storage unit such as a hard disk of the production schedule creation device 1000, the storage in the production schedule creation device 1000 is recorded from the recording medium on which these are recorded via an external storage unit. It may be configured such that each program is downloaded from a server (not shown) that manages these programs via a network and a communication interface unit. Further, the data stored in the master storage unit 1100 may be configured to be input to the production schedule creation apparatus 1000 via the external storage unit by a recording medium storing this data, or from the user to the network In addition, it may be configured to be input to the production schedule creation apparatus 1000 via the communication interface unit.

<Target of production schedule>
Here, an example in which the production schedule planning apparatus 1000 generates a schedule will be described. Hereinafter, a case where a schedule is generated for this target example will be described.

<Process and equipment>
There are a plurality of processes targeted when the production schedule creating apparatus 1000 creates a schedule. In the embodiment, description will be given using one of these processes.

  As shown in FIG. 2, processing is performed in steps 1 to 4. There are products that are produced by processing in the order of step 1, step 2, and step 3, and products that are produced by processing in the order of step 1, step 4, and step 3.

  FIG. 3 is a diagram for explaining the equipment used in each step. In each step, processing is performed using one or a plurality of facilities. In FIG. 3, for convenience of explanation, only the process 2 is described with the equipment used in the process 2. In step 2, processing is performed using three facilities, facility A, facility B, and facility C.

  FIG. 4 is a diagram illustrating an example of the configuration and contents of the facility information table 2010.

  The facility information table 2010 indicates the production capacity of each facility, and is stored in the master storage unit 2000 in advance.

  The equipment information table 2010 includes equipment names 2011 and processing capabilities 2012.

  The facility name 2011 indicates a name for identifying and distinguishing a certain facility among the plurality of facilities. In the embodiment, the name of the equipment is used, but any equipment that can identify each equipment may be used.

  The processing capacity 2012 indicates the maximum amount of products that can be produced in one day in the facility indicated by the facility name 2011. The unit is tons. For example, since “20 (ton / day)” is set as the processing capability 2012 in the record in which “facility A” is set as the facility name 2011, the facility A can produce 20 tons of products per day. .

<Order>
FIG. 5 is a diagram illustrating an example of the configuration and contents of the order information table 2020. The order information table 2020 is a table in which received orders are registered, and is stored in advance in the master storage unit 2000. The initial plan creation unit 1100 creates an overall schedule with reference to the order information table 2020.

  The order information table 2020 includes an order name 2021, an order quantity 2022, a delivery date 2023, and a process 2024.

  The order name 2021 indicates a name for identifying and distinguishing a certain order. Here, orders such as “order a” to “order x” and “order 10” to “order 20” are registered. A product to be produced in accordance with the order indicated by the order name 2011 is set as “load” and is loaded on each facility in order units.

  The order quantity 2022 indicates a necessary quantity in the order indicated by the order name 2021. The unit is t (tons).

  The delivery date 2023 indicates the delivery date of the order indicated by the order name 2021.

  Step 2024 shows a step for producing the ordered product indicated by the order name 2021. Here, only steps 1 to 4 are described, and the steps before and after that are omitted. In step 2024, equipments are described by being connected by arrows, and products are manufactured by performing processing in each equipment in the order indicated by the arrows. For example, “→ step 1 → step 2 → step 3 →” is set as the step 2024 in the record in which “order a” is set as the order name 2021. This indicates that the product ordered as “order a” is processed in order by a plurality of facilities, but is processed in step 1 in the middle, and then processed in order of step 2 and step 3.

  FIG. 6 is a diagram illustrating an example of the configuration and contents of the setup information table 2030.

  The setup information table 2030 is stored in advance in the master storage unit 2000 and is referred to by the initial plan creation unit 1100 and the like.

  The setup information table 2030 includes an order name 2031 and setup conditions 2032.

  The order name 2031 indicates a name for identifying and distinguishing a certain order. The order name set as the order name 2031 is the same as the order name set as the order name 2021 in the order information table 2020.

  The setup condition 2032 indicates a setup condition necessary for processing the order indicated by the order name 2031. In the embodiment, there are nine types “a” to “i”. Further, when orders with the same setup conditions are continuously processed, setup change is not necessary. For example, when processing of “order b” is to be started, it is assumed that the order processed before that is “order a”. In this case, the setup condition set as the setup condition 2032 for the record whose order name 2031 is “order b” is “a”, and the setup condition for the record whose order name 2031 is “order a”. Since the setup condition set as 2032 is “a”, the setup change is not performed.

<Overall schedule, process schedule>
Hereinafter, based on the order information table 2020, the overall schedule and process schedule created by the initial plan creation unit 1100 will be described.

  FIG. 7 shows the entire schedule. The processes of “order a” to “order l” are “→ process 1 → process 2 → process 3 →”, and the processes of “order 10” to “order 15” are “→ process 1 → process 4 → process 3”. → "(see step 2024 in FIG. 5). Accordingly, when “Order a” to “Order 1” and “Order 10” to “Order 15” are loaded on “June 2” of “Process 1” (see arrow 10), In “June 3” of “Process 2”, only the load of “Order a” to “Order l” is loaded (see arrow 11), and “Order 3” in “Process 4” 10 ”to“ order 15 ”are loaded (see arrow 12). Then, “June 4” of “Process 3” is loaded with “Order a” to “Order l” and “Order 10” to “Order 15” (see arrow 13). Thus, according to the process of each order, a load is loaded every unit time “1 day” so as to go back from the delivery date of the order, and the entire schedule is created.

  Next, FIG. 8 shows a process schedule. This process schedule is the schedule of process 2. The equipment A, equipment B, and equipment C used in the process 2 (see FIG. 3) are loaded every unit time “2 days”. For example, “Order a” to “Order l” are loaded on “June 3” of “Process 2” of the overall schedule, and “Order m” to “Order” are loaded on “June 4”. x "is stacked. Therefore, “Order a” to “Order x” are allocated to “Equipment A”, “Equipment B”, and “Equipment C” on “June 3 to 4” in the process schedule of FIG. ing. In the embodiment, it is assumed that 24 loads of “order a” to “order x” are evenly allocated in the order of the order and stacked 8 by 8. In addition, you may allocate by another method. For example, one load is assigned in order of "equipment A", "equipment B", and "equipment C" in consideration of the processing capacity of the equipment. In FIG. 8, it is assumed that the loaded loads are processed in order from the top. For example, in “June 3 to 4” of “Equipment A”, “Order a” is processed first.

<Movement group determination method>
Here, the movement candidate determining unit 1300 will explain the method of determining the movement candidate group using the load accumulated on “June 3 to 4” in FIG. 8, that is, the unit time schedule (see arrow 20). . Specifically, two methods of <group creation method> and <exclusion degree calculation method> will be described below.

  FIG. 9 is a diagram for explaining the grouping of loads loaded on the unit time schedule of “June 3 to 4” in FIG. The unit time schedule of “June 3-4” in FIG. 8 is described on the left side of the figure, and the group identifier assigned by the grouping unit 1200 is described in the “Group ID” column. Further, the “exclusion degree” column on the right side describes the degree of inequality calculated for each group.

<How to create a group>
The load grouping is performed by the grouping unit 1200, and loads that do not decrease the production efficiency as much as possible even if they are continuously processed are regarded as one group. In the embodiment, when loads having the same setup condition continue, these loads are set to the same group. Therefore, it is assumed that “when these loads with the same setup condition continue, make these loads the same group” is stored in the grouping condition storage unit 2100 as a grouping condition.

  As shown in FIG. 9, the grouping unit 1200 groups loads loaded on the facilities A to C in order of load processing, that is, from the top of the drawing for each facility. The load setup conditions are acquired with reference to the setup information table 2030 (see FIG. 6). For example, the setup condition of “order a” to be processed first in the facility A is set as the setup condition 2032 in the record in which “order a” is set as the order name 2031 in the setup information table 2030. “A”. Next, the setup condition of “order b” processed after “order a” of facility A is set as setup condition 2032 in the record in which “order b” is set as the order name 2031. “A”. Therefore, it is determined that “order a” and “order b” are friends, ie, the same group. Next, the setup condition of “order c” processed after “order b” is “b”. Therefore, it is determined that “order c” is a different group from “order b”, and a group indicated by group ID “companies a-1” is created for “order a” and “order b”. The setup condition of “order d” processed after “” is acquired, and it is determined whether or not it is a friend.

  In this way, the setup conditions of the order are acquired in accordance with the execution order, and when the setup conditions are the same, the same group is set. The group ID includes a setup condition and a serial number. The serial number is assigned to each facility. For example, the group ID “companion a-1” of the equipment A is a group whose setup condition is “a” and indicates a group of the serial number “1” in the equipment A. In “facility C” in FIG. 9, “order q” to “order t” constitute a group with group ID “companion h−1”, and “order w” to “order x” have group ID “companion h-2”. ”Group. In this way, when the same setup condition group is created in the same equipment, different serial numbers are assigned.

<Method for calculating degree of detachment>
Next, a method for calculating the degree of detachment of each group by the degree of detachment calculating unit 1400 will be described. In the unit time schedule, the degree of detachment is calculated so that the group with a smaller number of loads constituting the group has a higher degree of detachment with respect to the total load that can be a mate. This is because when the load of one's group is small even though there is a lot of load to be a friend, the group is out of the group.

The degree of detachment is calculated using the following formula.
Departure degree = 1- (Number of friends in group) / (Number of friends in all facilities) (Formula)
The degree of detachment of “friend a-1” is 1-2 / 2 = 0. In addition, the degree of losing the friend of “friend e-1” is 1-1 / 5 = 0.8. In this manner, the degree of detachment from the “companion a-1” of the facility A to the “companion h-2” of the facility C is calculated.

  The movement candidate determination unit 1300 is the group with the highest degree of detachment calculated by the detachment degree calculation unit 1400. In FIG. 9, the detachment degree of the “companion c-1” of the facility A is the largest as “0.8” (arrow 30), “companion c-1” is determined as the movement candidate group. In addition, even if it is the highest degree of detachment, if it falls below a predetermined threshold or antagonizes the degree of detachment of another group, that is, if the difference in degree of detachment is within a predetermined range, the movement candidate It may be determined that there is no group.

<Determination method of destination>
Next, a method in which the movement destination determination unit 1500 determines the movement destination of the movement candidate group determined by the movement candidate determination unit 1300 will be described. The movement destination determination unit 1500 determines at least the movement destination equipment as the movement destination of the movement candidate group. In the embodiment, a group that belongs after the movement is further determined.

  FIG. 10 is a diagram for explaining a moving destination determination method of “companion c-1” having the highest degree of detachment in FIG.

  The destination facility is a facility other than the facility A other than the facility on which the “companion c-1” is loaded, that is, the facility B or the facility C. And in embodiment, the front and back of each group piled up in the equipment B and the equipment C are made into the candidate of a movement location. In FIG. 10, “movement location 01” to “movement location 09”.

  The destination determination unit 1500 uses the destination evaluation value for the schedule when the candidate group “mate c-1” is moved to each of the nine locations “movement location 01” to “movement location 09”. The value calculation unit 1600 is made to calculate, and the movement destination of the highest evaluation value is determined as the movement destination of “friend c-1”. Even if the evaluation value is the highest, it may be determined that there is no destination when it falls below a predetermined threshold value or when it antagonizes with another evaluation value.

  In the embodiment, it is assumed that the movement destination evaluation value calculation unit 1600 calculates a higher evaluation value as the number of times the setup condition changes, that is, the number of times the setup change occurs. Therefore, the evaluation value increases when moving to a location before or after a group having the same setup condition as the setup condition of the movement candidate group. Since it is possible to reduce the number of times of setup changes at the source equipment without increasing the number of setup changes at the destination equipment, it is possible to improve the productivity of processing in the process.

  In FIG. 10, since the setup condition of the movement candidate group “mate c-1” is “c”, the evaluation value increases when the setup condition moves to a place before and after the friend whose setup condition is “c”. . Therefore, the evaluation value when moving to “movement location 01” or “movement location 02” of “facility B” becomes high. In the embodiment, since the evaluation is performed only by the number of times of setup change, the evaluation values of “moving location 01” and “moving location 02” are equal, so that the evaluation moves to the end of the group, that is, “moving location 02”. Shall.

  In the embodiment, the destination evaluation value calculation unit 1600 performs evaluation for each facility within the unit time schedule, but may perform evaluation in consideration of the entire schedule. For example, evaluating the amount of delay in delivery. Further, not only one item but also a plurality of items, for example, the number of times of setup change and the amount of delivery delay are evaluated. Furthermore, the evaluation value may be calculated by another evaluation method. For example, the load level used in the same way for all facilities. In this case, for example, with reference to the equipment information table 2010 (FIG. 4), the evaluation value of the movement destination where the amount exceeding the processing capacity of the equipment exceeds the predetermined threshold value is lowered.

  Moreover, it may be the same as the evaluation method used when the initial plan creation unit 1100 creates a schedule. For example, the evaluation method is such that the higher the delay in delivery date, the lower the evaluation because the load is accumulated retroactively from the delivery date. Moreover, the same evaluation method may be used when the facility-specific plan creation unit 1800 performs final scheduling. This is because, since the evaluation policy does not change, it becomes possible to create a desired item, for example, a schedule for observing the delivery date.

<Operation>
Hereinafter, the operation of the production schedule creation apparatus 1000 will be described with reference to FIGS. 15 and 8 to 14.

  FIG. 15 is a flowchart of the production schedule creation process of the production schedule creation apparatus 1000.

  First, the general flow of the production schedule creation process will be described. In steps S10 and S11, an overall schedule (FIG. 7) and a process schedule (FIG. 8) are created. In steps S12 to S18, a unit time schedule is recreated. At this time, the processes from S12 to S17 are repeated until a predetermined end condition is satisfied. In the embodiment, when the movement candidate determination unit 1300 cannot determine the movement candidate group (step S14: NO) or when the movement destination determination unit 1500 cannot determine the movement destination (step S16: NO). , The repetition shall be terminated. The repetition may be terminated when a predetermined number of repetitions are performed.

  And the process of step S12-S18 is performed until it determines with YES in step S19. That is, a schedule for all unit times is created for one process schedule. And the process of step S12-S19 is performed until it determines with YES in step S20. That is, a schedule for all unit times is created for all processes of the entire schedule. Thereby, the schedule for every equipment of all the processes in consideration of the whole schedule was created.

  Details of the processing will be described below according to the flowchart.

  First, the user creates information necessary for creating a schedule in the master storage unit 2000 via the input unit 1002. Specifically, an equipment information table 2010 (see FIG. 4), an order information table 2020 (see FIG. 5), and a setup information table 2030 (see FIG. 6) are created and stored in the master storage unit 1100. Further, other information necessary for scheduling is created as necessary and stored in the master storage unit 2000.

  Next, the user inputs a command for instructing creation of a schedule via the input unit 1002.

  When the production schedule creation control unit 1001 receives a notification that a command for creating a schedule has been input, the production schedule creation control unit 1001 instructs the initial plan creation unit 1100 to create a production schedule.

  Upon receiving the instruction, the initial plan creation unit 1100 reads various information necessary for creating the entire schedule such as the order information table 2020 from the master storage unit 2000 (step S10).

  The initial plan creation unit 1100 that has read the order information table 2020 and the like creates an overall schedule (see FIG. 7) based on the order information table 2020 (step S11). Specifically, the record is read from the order information table 2020, and the work date in the process set as the process 2024 is determined so as to trace the flow of time from the due date set as the delivery date 2023. . Then, a load corresponding to the amount set as the order amount 2022 is accumulated for the determined work day process. An order name set as the order name 2021 is associated with the load. The initial plan creation unit 1100 performs the above process for all records registered in the order information table 2020.

  The initial plan creation unit 1100 that created the overall schedule further creates a process schedule (see FIG. 8) for each process from the created overall schedule. Specifically, a load is assigned to equipment used in a process every unit time, and a process schedule for the process is created. For example, when creating a process schedule (FIG. 8) for “Process 2”, the facilities A to C on “May 30-31” may have “May of“ Process 2 ”in the entire schedule (FIG. 7). “30 days” and “May 31” assigned to “orders” (not shown) are equally allocated, and similarly, “June 1-2”, “June 3-4” On “June 5th to 6th”, the “order” assigned to the entire schedule is assigned. The facilities A to C of “June 3 to 4” have “Order a” to “Order x” assigned to “June 3” and “June 4” of “Process 2” of the entire schedule. Load is evenly allocated.

  The initial plan creation unit 1100 stores the created overall schedule and the process schedule created for each process in the production schedule storage unit 2200.

  When the initial plan creation unit 1100 stores the entire schedule and the process schedule in the production schedule storage unit 2200, the production schedule creation control unit 1001 designates one unit time of one process, and the grouping unit 1200 performs grouping. Ask.

  Upon receiving the request, the grouping unit 1200 reads from the production schedule storage unit 2200 a unit time schedule in which a load is assigned to the unit time of the process specified by the production schedule creation control unit 1001. Here, a case where “June 3-4” of “Step 2” is designated will be described (see FIG. 8). The grouping unit 1200 that has read the unit time schedule of “June 3 to 4” of “Process 2” designated from the production schedule creation control unit 1001 stores the grouping conditions stored in the grouping condition storage unit 2100. Are grouped as described in the section <Group creation method> above, and a group ID is added and stored in the production schedule storage unit 2200 (see the group ID column in step S12, FIG. 9). ).

  The grouping unit 1200 that has performed the grouping notifies the movement candidate determination unit 1300 of the unit time schedule of “June 3 to 4” of the “process 2” that has been grouped, and requests the determination of the movement candidate group. .

  The movement candidate determination unit 1300 that has received the request requests the fellowship degree calculation unit 1400 to calculate the degree of detachment of each group in the unit time schedule of “June 3 to 4th” of the notified “process 2”. . Upon receipt of the request, the detachment degree calculation unit 1400 refers to the unit time schedule stored in the production schedule storage unit 2200, and determines the detachment degree of each group as described in the section <Method of calculating detachment degree>. calculate. The detachment degree calculation unit 1400 returns the calculated detachment degree to the movement candidate determination unit 1300 (see step S13, column of detachment degree in FIG. 9).

  The movement candidate determining unit 1300 that has received the degree of detachment of each group from the degree of detachment calculating unit 1400 determines a group having the highest degree of detachment as a movement candidate group. As illustrated in FIG. 9, since the degree of disjoint “0.8” of “companion c-1” of facility A is the highest (see arrow 30), destination determination unit 1500 selects “companion c-1” as a movement candidate. A group is determined (step S14: YES).

  The movement candidate determination unit 1300 that has determined the movement candidate group passes the group ID of the determined movement candidate group to the movement destination determination unit 1500 and requests determination of the movement destination. The destination determination unit 1500 that has received the request refers to the unit time schedule stored in the production schedule storage unit 2200, and evaluates each movement point as described in the section <Destination Determination Method> above. Requests the destination evaluation value calculation unit 1600 to calculate the value. Receiving the request, the destination evaluation value calculation unit 1600 calculates the evaluation value of each movement location and passes it to the destination determination unit 1500 (step S15). The destination determination unit 1500 that has received the evaluation value of each movement location determines the movement location with the highest evaluation as the movement destination (step S16: YES, see “movement location 02” in FIG. 10).

  The movement destination determination unit 1500 that has determined the movement destination uses the group ID “companion c-1” of the movement candidate group passed from the movement candidate determination unit 1300 and the determined movement destination “movement point 02” as the process schedule creation unit 1700. And request for re-creation of the unit time schedule of “June 3 to 4” of “Process 2”. Upon receiving the request, the process schedule creation unit 1700 creates a unit time schedule in which the movement candidate group is moved to the movement destination, and stores the unit time schedule in the production schedule storage unit 2200 (step S17). The created schedule for “June 3-4” of “Step 2” is shown on the left side of FIG.

  When the process schedule creation unit 1700 creates a schedule and stores it in the production schedule storage unit 2200, the production schedule creation control unit 1001 performs the second iteration of steps S12 to S17. Specifically, “June 3-4” of “Process 2” is designated and the grouping unit 1200 is requested to group the latest schedule.

  Upon receiving the request, the grouping unit 1200 receives the unit time schedule of “June 3 to 4” of the latest “Process 2”, that is, the schedule stored by the process schedule creating unit 1700 from the production schedule storage unit 2200. Read (see schedule on the left side of FIG. 11). Then, the grouping unit 1200 performs grouping, attaches a group ID, and stores the group ID in the production schedule storage unit 2200 (see step S12, group ID column in FIG. 11).

  The grouping unit 1200 that has performed the grouping specifies “June 3 to 4” of “Step 2” and requests the movement candidate determination unit 1300 to determine a movement candidate group.

  The movement candidate determination unit 1300 that has received the request requests the fellowship degree calculation unit 1400 to calculate the degree of fellowship removal of each group of “June 3 to 4” of “Process 2”. Upon receiving the request, the detachment degree calculation unit 1400 calculates the detachment degree of each group and returns it to the movement candidate determination unit 1300 (see step S13, column of detachment degree in FIG. 11).

  The movement candidate determining unit 1300 that has received the degree of detachment of each group from the degree of detachment calculating unit 1400 determines a group having the highest degree of detachment as a movement candidate group. As shown in FIG. 11, the “companion d-1” of the facility A and the “companion h-2” of the facility C have the highest degree of disjoint “0.66” (see arrows 40 and 41). In the embodiment, the movement destination determination unit 1500 determines “companion d−1”, which is earlier in the order of calculating the degree of detachment, as a movement candidate group (step S14: YES).

  The movement candidate determination unit 1300 that has determined the movement candidate group passes the group ID “companion d-1” to the movement destination determination unit 1500 and requests determination of the movement destination. Receiving the request, the destination determination unit 1500 requests the destination evaluation value calculation unit 1600 to calculate the evaluation value of each movement point, and the evaluation value of each movement point calculated by the destination evaluation value calculation unit 1600 (step S15). ) Is determined as the movement destination (step S16: YES, see “movement point 03” in FIG. 12).

  The movement destination determination unit 1500 that has determined the movement destination passes the group ID “companion d-1” of the movement candidate group and the movement destination “movement point 03” to the process schedule creation unit 1700 to create a process schedule. Ask. Upon receiving the request, the process schedule creation unit 1700 creates a process schedule in which the movement candidate group is moved to the movement destination, and stores it in the production schedule storage unit 2200 (step S17). The created schedule for “June 3-4” of “Step 2” is shown on the left side of FIG.

  When the process schedule creation unit 1700 creates a process schedule and stores it in the production schedule storage unit 2200, the production schedule creation control unit 1001 performs the third iteration of steps S12 to S17. Specifically, “June 3 to 4” of “Process 2” is designated and the grouping unit 1200 is requested to group the latest unit time schedule.

  Upon receiving the request, the grouping unit 1200 reads the latest unit time schedule of “June 3 to 4” of “Process 2” from the production schedule storage unit 2200 (see the schedule on the left side of FIG. 13), and performs grouping. Then, a group ID is added and stored in the production schedule storage unit 2200 (see step S12, column of group ID in FIG. 13).

  The grouping unit 1200 that has performed the grouping specifies “June 3 to 4” of “Step 2” and requests the movement candidate determination unit 1300 to determine a movement candidate group.

  The movement candidate determination unit 1300 that has received the request requests the fellowship degree calculation unit 1400 to calculate the degree of fellowship removal of each group of “June 3 to 4” of “Process 2”. Upon receiving the request, the detachment degree calculation unit 1400 calculates the detachment degree of each group and returns it to the movement candidate determination unit 1300 (see step S13, column of detachment degree in FIG. 13).

  The movement candidate determination unit 1300 that has received the degree of detachment of each group from the degree of detachment calculating unit 1400 is the group with the highest degree of detachment, that is, the facility C that is the degree of detachment “0.66” (see arrow 50) in FIG. The group “companion d-1” of “companion h-2” is determined as a movement candidate group (step S14: YES).

  The movement candidate determination unit 1300 that has determined the movement candidate group passes the group ID of the determined movement candidate group to the movement destination determination unit 1500 and requests determination of the movement destination. The destination determination unit 1500 that has received the request requests the destination evaluation value calculation unit 1600 to calculate the evaluation value of each movement location, and calculates the evaluation value of each movement location (step S15). Since there is no companion whose setup condition is “h”, all moving parts have the same evaluation value. Therefore, the destination determination unit 1500 determines that there is no destination (step S16: NO) and notifies the production schedule creation control unit 1001.

  Upon receiving the notification, the production schedule creation control unit 1001 designates “June 3 to 4th” of “Process 2” and requests the facility-specific plan creation unit 1800 to create a final schedule. Upon receiving the request, the facility-specific plan creation unit 1800 processes the load loaded on each of the facilities A, B, and C in the unit time schedule (FIG. 13) of “June 3 to 4” of “Process 2”. Is determined (step S18). In the embodiment, the “companion h-1” and the “companion h-2” of the equipment C are processed in succession, and a schedule with a reduced number of setup changes is created and stored in the final schedule storage unit 2300. (See FIG. 14).

  The production schedule creation control unit 1001 repeats the processing of steps S12 to S19 until it is determined that the final schedule of all unit times has been created for one process of the process schedule (step S19: NO). If it is determined that the final schedule for time has been created (step S19: YES), the processing for one unit time of the next process is started (step S12). The production schedule creation control unit 1001 repeats the processes of steps S12 to S19 until it determines that the final schedule of all unit times has been created for all processes of the entire schedule (step S20: NO). If it is determined that the final schedule for all unit times has been created (step S20: YES), the process ends.

  In this way, by scheduling optimally for each unit time of each process, it is possible to create a production schedule that improves the productivity of each facility at high speed without breaking the overall schedule. It is possible to create a schedule for improving productivity.

  In the embodiment, in FIG. 12, the movement destination determination unit 1500 determines the movement destination of the movement candidate group “companion d-1” as “movement point 03”, but the load loaded on “facility B” becomes excessive. It may be determined that there is no destination. For example, if the movement candidate group is moved, if the load accumulated on the equipment is greater than + 20% of the processable amount (see the equipment information table 2010 in FIG. 4), the equipment cannot be set as the destination, etc. It is. This is because if one facility is overloaded, there is a possibility that the entire schedule will collapse and orders that are delayed in delivery will occur.

  In order to express the present invention, the present invention has been properly and fully described through the embodiments with reference to the drawings. However, those skilled in the art can easily change and / or improve the above-described embodiments. It should be recognized that this is possible. Therefore, unless the modifications or improvements implemented by those skilled in the art are at a level that departs from the scope of the claims recited in the claims, the modifications or improvements are not covered by the claims. To be construed as inclusive.

1000 Production Schedule Creation Device 1001 Production Schedule Creation Control Unit 1002 Input Unit 1003 Output Unit 1100 Initial Plan Creation Unit 1200 Grouping Unit 1300 Movement Candidate Determination Unit 1400 Displacement Degree Calculation Unit 1500 Destination Determination Unit 1600 Destination Evaluation Value Calculation Unit 1700 Schedule creation unit 1800 Equipment-specific plan creation unit 2000 Master storage unit 2010 Equipment information table 2020 Order information table 2030 Setup information table 2100 Grouping condition storage unit 2200 Production schedule storage unit 2300 Final schedule storage unit

Claims (5)

A production schedule creation device for creating a schedule for producing a plurality of products produced by a plurality of processes before each delivery date of each product,
Each process produces products using one or more equipment,
Allocating means for associating each process of each product with any facility used in each process of each product in a predetermined time unit, and allocating the load of each product to the facility associated with each process;
In one process using a plurality of facilities, grouping means for grouping the products allocated by the allocation means in one predetermined time according to production conditions for each facility;
In the one step, among the groups grouped by the group determination means, the group having the lowest ratio of the number of products to be configured with respect to the total number of products that constitute the group grouped under the same production conditions. A moving group to be moved from the facility to which the group is allocated to another facility to which another group grouped under the same production conditions is allocated, and a moving group determining means for determining. Production schedule creation device. The production schedule creation device further includes:
A destination determination means for determining a destination equipment which is a destination equipment for moving the movement group determined by the movement group determination means;
Equipment schedule evaluation means for evaluating the production efficiency when processing products assigned to equipment in the equipment,
The movement destination determination means is a facility in the process to which the movement group is allocated, and the other group when the movement group is allocated to other facilities other than the facility to which the movement group is allocated. The production schedule creation device according to claim 1, wherein the equipment schedule evaluation unit calculates the evaluation of the equipment, and determines the other equipment having the best evaluation as the destination equipment. The assigning means associates each process of each product with each process of each product in a predetermined time unit so that each product can be produced by the delivery date of each product, and assigns the load of each product to each process. A means for creating an overall schedule; and means for creating a process schedule for assigning products assigned to each process of the overall schedule in predetermined time units to the equipment used in the process at predetermined time intervals. The production schedule creation device according to claim 1. The group determination means has a condition in which the production conditions of the products are the same or in common, and when products are processed continuously, products that do not require processing excluding processing for producing the products are grouped together. The production schedule creation device according to claim 1. Production used in a production schedule creation device that creates a schedule for producing a plurality of products produced by a plurality of processes by using one or more facilities in each process before each delivery date of each product. A schedule creation method,
An allocation step of associating each process of each product with any equipment used in each process of each product in a predetermined time unit, and assigning the load of each product to the equipment associated with each process;
In one process using a plurality of facilities, a grouping step of grouping the products allocated in the allocation step in one predetermined time according to production conditions for each facility;
In the one process, among the groups grouped in the group determination step, the group having the lowest ratio of the number of products to be configured with respect to the total number of products that constitute the group grouped under the same production conditions. A moving group to be moved from the equipment to which the group is assigned to another equipment to which another group grouped under the same production conditions is assigned, and a moving group determination step for determining. Production schedule creation method.

Images