JP6005535B2 - Production plan creation device, production plan creation method, and production plan creation program - Google Patents

Description

  The present invention relates to a production plan creation device, a production plan creation method, and a production plan creation program for creating a production plan for the production time of each lot when a plurality of lots are produced by a common production facility.

  In general, manufacturing companies formulate production plans (production schedules, schedules) to maximize productivity of production facilities, comply with delivery dates of orders, minimize inventory (in-process), or minimize costs. I am striving to. Also, once a production plan has been created, there may be some sudden events such as a sudden failure of a production facility or an unexpected order, which may require a review of the production plan. In the past, such production plans have been relied on by hand based on empirical intuition, but recently, production schedule planning methods and devices using computers have been researched and developed, and various technologies have been developed. Proposed. Such a production plan creation technique is disclosed in Patent Document 1, for example.

  The production facility planning apparatus disclosed in Patent Document 1 includes an input unit for inputting order information for a plurality of lots for which at least a delivery time, a delivery order, a quantity, and a mixed order are specified, and the input order information A production facility planning apparatus for a production facility having an operation unit for creating a production plan based on the output unit and an output unit for outputting the production plan generated by the operation unit, wherein the operation unit produces a lot for the order information. A time allocation unit that assigns the time to complete production at the facility, a lot size determination unit that sets a lot unit for each lot, adds an additional lot number of increments to the lot unit, and temporarily determines the lot size, Determine the order in which the lots are put into the production facility, and the time required for the production of the lot size, time allocation, lot unit and each step described above Referring to the setup time required from the production of the lot with the provisionally determined lot size to the production of the lot with the provisionally decided lot size in the next order, the setup time and provisional decision for each lot by the assigned time Work with the assigned lot size, the work / setup time for executing the setup and the assignment execution part, and the delivery delay determination part for judging whether the production is completed for each lot by the assigned time If the production is not completed by the assigned time, the lot size is changed and the lot size is provisionally determined again, and it is repeatedly processed whether the production is completed for each lot by the assigned time. . According to Patent Document 1, such a production facility production plan planning apparatus can generate an optimal lot size by a computer within a finite time, prevents an increase in product inventory, and delivers a delivery date for a strict order. It is said that it is possible to create a manufacturing process delivery schedule that can be produced with satisfaction.

JP 2005-148792 A

  By the way, when producing a plurality of different lots in a time-sharing manner with a common production facility, after producing a certain first lot with the production facility, before producing another second lot with the production facility, For example, it is necessary to prepare for so-called setup (including setup change) such as charging of the raw material of the second lot and maintenance of matching the production facility with the production of the second lot. Even when the same lot is produced continuously, for example, there is an upper limit on the amount of raw material that can be introduced at one time, and depending on the production equipment, maintenance is required every predetermined operating time. Therefore, the setup may be necessary. A lot (one mountain) is a group (group) of one or a plurality of products produced at a time using the same production facility within a predetermined time. Such a setup requires a predetermined time and requires an operator such as an operator. For this reason, the setup needs to be performed within the working hours of the worker. In particular, if the production equipment is automatically operating unattended even outside the worker's working hours, setting the setup process to perform this setup within the worker's working hours when creating a production plan is It becomes important.

  However, the production plan planning apparatus disclosed in Patent Document 1 does not formulate a production plan in consideration of the constraint that such a setup is performed within the working hours of the operator.

  The present invention is an invention made in view of the above-described circumstances, and its purpose is to produce a production plan creation device capable of creating a production plan that satisfies the constraint that the setup is performed within the working hours of the operator, and production It is to provide a plan creation method and a production plan creation program.

  As a result of various studies, the present inventor has found that the above object is achieved by the present invention described below. That is, in the production plan creation device according to one aspect of the present invention, when a plurality of lots are produced by a common production facility, each lot production period in which each of the plurality of lots is produced by the production facility is set to a predetermined period. A production plan creation device that creates a production plan by assigning it to any one of a plurality of divided periods divided into all planned periods in units of the maximum lot that indicates the upper limit value of the quantity of products collected in one lot The size restriction information and the required production time information indicating the required production time per unit quantity required for producing the products collected in the lot at the production facility are stored for each type of the product, and the products collected in the lot are stored. Required setup time information indicating the setup time required for setup when producing at the production facility, and work within the predetermined period A storage unit for storing working time information indicating the interval, and a production plan prepared in advance so as to comply with the delivery date of the lot, and the lot is equal to or less than the upper limit of the number of products collected in one lot. Based on the production plan including the product quantity information indicating the quantity of the products collected in the lot and the product type information indicating the type of the product, the required production time information, and the required setup time information. The total processing time required for the production of the assigned lot, and when performing setup during the sorting period, the total processing time including the setup time required for the setup, and when performing setup during the sorting period, A processing time calculation unit that performs a time calculation process for determining the start time and end time of the setup for each of the division periods, and the processing time calculation unit. When the total processing time exceeds the preset operation time of the production facility, and at least one of the start time and the end time of the setup determined by the processing time calculation unit is out of the working time If the total processing time in the classification period is within the operating hours of the production facility and the start time and end time of the setup in the classification period are within the working hours A lot adjustment processing unit for performing a reallocation process for reallocating a part or all of a lot allocated to a period to a classification period temporally prior to the classification period; and the time calculation process and the reallocation process. , The processing time calculation unit and the previous time period from the last division period in time to the first division period in the production plan. And a repetitive processing unit that repeatedly performs each of the lot adjustment processing units.

  Such a production plan creation device can create a production plan that satisfies the constraints related to the setup in which the setup is performed within the working hours of the worker. In addition, such a production plan creation device can determine a lot size that can reduce an inventory amount (in-process amount) while observing a delivery date.

  According to another aspect, in the above-described production plan creation device, the lot adjustment processing unit includes the lot assigned to the division period and the same type as the product type in the lot assigned to the division period. The reassignment process is performed by combining with other lots in which the products are combined.

  According to this configuration, it is possible to provide a production plan creation device that performs lot reassignment processing by combining the two lots.

  In another aspect, in the above-described production plan creation device, the lot adjustment processing unit reassigns a part or all of the lots assigned in the division period before and after the reallocation process. The reassignment process is performed so that the total number of lots in the reassignment destination division period does not increase.

  In such a production plan creation device, since the total number of lots does not increase, the total number of setups is maintained or decreased before and after the reallocation process, so that productivity does not decrease.

  Further, in another aspect, in the above-described production plan creation device, the lot adjustment processing unit is configured to perform a change between the division period and a reassignment destination division period in which a lot assigned to the division period is reassigned. The reallocation process is performed so that a multiplication result of the difference period and the quantity to be reassigned is minimized.

  The more the production is made before the delivery date, the longer the lead time and the higher the cost for the stock quantity (in-process quantity). Such a production plan creation apparatus performs the reassignment process so that the multiplication result is minimized, so that the reassignment process can be performed while minimizing the cost of the inventory amount (in-process amount). .

  In another aspect, in the above-described production plan creation device, information indicating that when the lot adjustment processing unit cannot perform the reallocation processing after the processing by the repetitive processing unit is completed. Is further provided with a notification unit for notifying the outside.

  Such a production plan creation apparatus can notify the outside that the lot adjustment processing unit cannot perform the reallocation process. By this notification, the operator can recognize that the delivery date cannot be observed when trying to perform the reallocation process.

  Further, in another aspect, in the above-described production plan creation device, the production created in advance so as to comply with the delivery date of the lot and to be equal to or less than the upper limit of the number of products collected in one lot. Instead of the plan, a production plan prepared in advance so as to comply with the delivery date of the lot is used, and for each lot included in the production plan, the lot exceeds the upper limit value of the maximum lot size constraint information A maximum lot size constraint satisfaction processing unit is further provided that divides a lot exceeding the upper limit value into a plurality of lots so as to be equal to or less than the upper limit value.

  Such a production plan creation device can make the size of each lot of the production plan below the upper limit value of the maximum lot size constraint information, and can make each lot of the production plan satisfy the maximum lot size constraint. .

  Further, in another aspect, in the above-described production plan creation apparatus, the storage unit further stores minimum lot size constraint information indicating a lower limit value of the quantity of products collected in one lot, and the production plan For each included lot, when the lot falls below the lower limit value of the minimum lot size constraint information, from the other lots allocated in the division period later in time than the division period of the lot, The lot is a quantity that is not more than the upper limit value of the maximum lot size constraint information in the lot and is not less than the lower limit value of the minimum lot size constraint information, and the other lot is the maximum lot size in the other lot. A minimum lot size constraint satisfaction processing unit that extracts a quantity that is less than or equal to the upper limit value of the constraint information and puts the extracted quantity into the lot. Characterized in that it comprises a.

  Such a production plan creation device can prevent the delay of delivery date and can make the size of each lot of the production plan more than the upper limit value of the minimum lot size constraint information. Can be met.

  In another aspect, in the above-described production plan creation device, the minimum lot size constraint satisfaction processing unit sequentially extracts the other lots from which the quantity is extracted from a segmentation period adjacent to the segmentation period of the lot. It is determined whether or not the quantity can be extracted, and the quantity is extracted from a lot in a division period that is determined for the first time that the quantity can be extracted.

  Such a production plan creation device determines whether or not the quantity can be extracted in order from the division period adjacent to the lot division period to the division period later in time than the lot division period. In addition, since the quantity is extracted from the lots in the classification period that is determined for the first time that the quantity can be extracted, each lot in the production plan can be reduced to the minimum lot size by reducing the cost of the inventory quantity (in-process quantity). The constraints can be met.

  In another aspect, in the above-described production plan creation device, the minimum lot size constraint satisfaction processing unit extracts the minimum quantity.

  Since such a production plan creation apparatus extracts the minimum quantity, it is possible to minimize the cost of the inventory quantity (in-process quantity) so that each lot of the production plan satisfies the minimum lot size constraint. it can.

  In another aspect, in the above-described production plan creation device, if the minimum lot size constraint satisfaction processing unit cannot extract the quantity, the lot is the minimum lot size constraint information in the minimum lot size constraint information. A quantity that is equal to or greater than the lower limit is added to the lot.

  Even if the production plan creation device cannot extract the quantity, it adds the quantity that the lot is equal to or more than the lower limit value of the minimum lot size constraint information to the lot even if there is no order. Each lot in the production plan can meet the minimum lot size constraint.

  In the production plan creation method according to another aspect of the present invention, when a plurality of lots are produced by a common production facility, each lot production period for producing each of the plurality of lots by the production facility is determined in advance. This is a production plan creation method for creating a production plan by assigning it to any of a plurality of divided periods obtained by dividing the entire planning period in units of the period, and indicates the upper limit value of the quantity of products collected in one lot The maximum lot size constraint information and the required production time information indicating the required production time per unit quantity required for producing the products collected in the lot at the production facility are stored for each type of the product and can be collected in the lot. Required setup time information indicating the setup time required for setup when the product is produced at the production facility, and work within the predetermined period A storage process for storing working time information indicating time, and a production plan prepared in advance so as to comply with the delivery date of the lot and the lot is less than or equal to the upper limit of the quantity of products combined into one lot. Based on the production plan including the product quantity information indicating the quantity of the products collected in the lot and the product type information indicating the type of the product, the required production time information, and the required setup time information. The total processing time required for the production of the assigned lot, and when performing setup during the sorting period, the total processing time including the setup time required for the setup, and when performing setup during the sorting period, A process time calculation step for performing a time calculation process for obtaining a setup start time and an end time for each of the division periods, and the process time calculation step. When the determined total processing time exceeds the preset operation time of the production facility, and at least one of the setup start time and end time determined by the processing time calculation step is the work time. In the case of at least one of the cases where there is a deviation, the total processing time in the division period is within the operation time of the production facility, and the start time and end time of the setup in the division period are within the working hours, Lot adjustment processing step for performing reallocation processing for reassigning part or all of the lots assigned to the division period to the division period temporally prior to the division period, and the time of the processing time calculation step The reassignment process of the calculation process and the lot adjustment process step is divided into the final division in time in the production plan. And a repetitive processing step that is repeatedly performed from the start period to the first division period.

  Such a production plan creation method can create a production plan that satisfies the constraints on the setup in which the setup is performed within the working hours of the worker. In addition, such a production plan creation method can determine a lot size that can reduce an inventory amount (in-process amount) while observing a delivery date.

  The production plan creation program according to another aspect of the present invention provides a predetermined lot production period for producing each of the plurality of lots at the production facility when a plurality of lots are produced at a common production facility. A production plan creation program for creating a production plan by assigning it to any one of a plurality of divided periods obtained by dividing the entire planned period in units of the above-mentioned period, and the upper limit of the quantity of products collected in one lot on a computer Maximum lot size constraint information indicating a value and required production time information indicating a required production time per unit quantity required for producing the products collected in the lot by the production facility are stored for each type of the product, and the lot Required setup time information indicating the setup time required for setup when the products collected in the above-mentioned production facility are produced, and A storage unit that stores working time information indicating working hours within the predetermined period, and created in advance so as to comply with the delivery date of the lot and the lot is equal to or less than the upper limit of the number of products that can be collected in one lot. A production plan including the product quantity information indicating the quantity of the products assembled in the lot and the product type information indicating the product type, the required production time information, and the required setup time information. On the basis of the total processing time required for production of the lot allocated in the division period, and when the setup is performed in the division period, the total processing time including the necessary setup time required for the setup, and the division period In the case of performing the setup, a processing time calculation unit that performs a time calculation process for obtaining the start time and the end time of the setup for each of the division periods; When the total processing time obtained by the processing time calculation unit exceeds the preset operation time of the production facility, and at least one of the setup start time and end time obtained by the processing time calculation unit Is at least one of the above hours, the total processing time in the division period is within the operating hours of the production facility, and the start time and end time of the setup in the division period are within the working hours. A lot adjustment processing unit for performing a reallocation process for reallocating a part or all of the lots allocated in the classification period to a classification period temporally prior to the classification period, and the time calculation The process and the reallocation process are performed from the last time period in the production plan to the first time period. Thus, the processing time calculation unit and the lot adjustment processing unit repeatedly execute the program for realizing the repetition processing unit.

  Such a production plan creation program can create a production plan that satisfies the constraints related to the setup in which the setup is performed within the working hours of the worker. In addition, such a production plan creation program can determine a lot size that can reduce the inventory amount (in-process amount) while observing the delivery date.

  The production plan creation device, the production plan creation method, and the production plan creation program according to the present invention can create a production plan that satisfies a constraint condition that setup (including setup change) is performed within an operator's working hours.

It is a block diagram which shows the structure of the production plan preparation apparatus in embodiment. It is a figure which shows the structure of the order information table memorize | stored in the order information storage part in the production plan preparation apparatus of embodiment. It is a figure which shows the structure of the lot size constraint information table memorize | stored in the lot size constraint information storage part in the production plan preparation apparatus of embodiment. It is a figure which shows the structure of the production time information table memorize | stored in the production time information storage part in the production plan preparation apparatus of embodiment. It is a figure which shows each structure of the setup time information, working time information, and working time information which are each stored in the setup time information storage part, the working time information storage part, and the working time information storage part in the production plan preparation apparatus of embodiment. It is a flowchart which shows operation | movement of the production plan preparation apparatus in embodiment. In a production plan creation device of an embodiment, it is a figure showing a given production plan as an example. In a production plan creation device of an embodiment, it is a figure showing a production plan after maximum lot size restriction satisfaction processing as an example. In a production plan creation device of an embodiment, it is a figure showing a production plan after minimum lot size restriction fulfillment processing as an example. In a production plan creation device of an embodiment, it is a figure showing a production plan in the middle of lot size determination processing as an example. In a production plan creation device of an embodiment, it is a figure showing a production plan after lot size determination processing as an example.

  Hereinafter, an embodiment according to the present invention will be described with reference to the drawings. In addition, the structure which attached | subjected the same code | symbol in each figure shows that it is the same structure, The description is abbreviate | omitted suitably. Further, in this specification, when referring generically, it is indicated by a reference symbol without a suffix, and when referring to an individual configuration, it is indicated by a reference symbol with a suffix.

  FIG. 1 is a block diagram illustrating a configuration of a production plan creation apparatus according to the embodiment. FIG. 2 is a diagram illustrating a configuration of an order information table stored in an order information storage unit in the production plan creation apparatus according to the embodiment. FIG. 3 is a diagram illustrating a configuration of a lot size constraint information table stored in the lot size constraint information storage unit in the production plan creation apparatus according to the embodiment. FIG. 4 is a diagram illustrating a configuration of a production time information table stored in the production time information storage unit in the production plan creation apparatus according to the embodiment. FIG. 5 shows configurations of setup time information, work time information, and operation time information stored in the setup time information storage unit, the work time information storage unit, and the operation time information storage unit, respectively, in the production plan creation apparatus of the embodiment. FIG. FIG. 5A shows setup time information, FIG. 5B shows work time information, and FIG. 5C shows operation time information.

  The production plan creation apparatus according to the present embodiment, when a plurality of lots are produced by a common production facility, each lot production period in which each of the plurality of lots is produced by the production facility is all planned in units of a predetermined period. It is an apparatus that creates a production plan by assigning it to one of a plurality of divided periods divided into periods. The production plan creation device works on the production plan prepared in advance (including setup change) so that the lot will meet the delivery date of the lot and the lot will be less than the upper limit of the quantity of products collected in one lot. However, in this embodiment, the production plan creation device uses a production plan (given a given plan) created in advance so as to comply with the lot delivery date. The production plan is reorganized so as to satisfy the constraint that the setup (setup change) is performed within the working hours of the worker. The production plan creation apparatus according to the present embodiment is configured so that a given production plan is equal to or less than the upper limit value of the quantity of products in which each lot in a given production plan is combined into one lot. And adjusted so that each lot in the production plan is less than or equal to the upper limit value and greater than or equal to the lower limit value even during the reorganization. To do. In the present embodiment, the predetermined period for dividing is a unit of one day, but may be an appropriate unit such as a unit of a plurality of days (for example, a unit of three days) or a unit of one or a plurality of weeks. The production plan creation method and the production plan creation program are implemented in the production plan creation apparatus in the present embodiment.

  For example, as shown in FIG. 1, the production plan creation apparatus SC in this embodiment includes a storage unit 1, a control calculation unit 2, an input unit 3, an output unit 4, and an interface unit (hereinafter, “ Abbreviated as “IF section”).

  The storage unit 1 is a device that stores various programs such as a production plan creation program for creating a production plan, and various data such as data necessary for execution of the various programs and data generated during the execution. The storage unit 4 includes, for example, a volatile storage element such as a RAM (Random Access Memory), which is a so-called working memory of the control arithmetic unit 2, a ROM (Read Only Memory), and a rewritable EEPROM (Electrically Readable Programmable Read Only Memory). ) And the like, and a peripheral circuit thereof. Further, for example, the storage unit 1 may be configured to include a so-called mass storage device such as a hard disk device.

  Then, the storage unit 1 indicates the maximum lot size constraint information indicating the upper limit value of the quantity of products collected in one lot and the required production time per unit quantity required for producing the products collected in the lot by the production facility. The required production time information is stored for each type of product, and the necessary setup time information indicating the setup time required for setup when the products collected in the lot are produced at the production facility, and the working time within the predetermined period The working time information indicating is stored. More specifically, in the present embodiment, the storage unit 1 functionally includes a production plan information storage unit 11 that stores production plan information, an order information storage unit 12 that stores order information, and lot size constraint information. (Hereinafter abbreviated as “LS constraint information”) 13 for storing lot size constraint information (hereinafter abbreviated as “LS constraint information storage unit”) 13 and production time information storage for storing production time information Unit 14, a setup time information storage unit 15 that stores setup time information, a work time information storage unit 16 that stores work time information, and an operation time information storage unit 17 that stores operation time information.

  The production plan information includes a plurality of lot production periods in which each of the plurality of lots is produced by the production facility when a plurality of lots are produced by a common production facility. In this embodiment, the production plan information includes order information indicating an order, and a product quantity indicating a quantity of products collected in a lot corresponding to the order. Information and product type information indicating the type of the product. In the present embodiment, as described above, the predetermined period is in units of one day, and for convenience of explanation, the start of the day is 9 o'clock in time with the start time of work hours. That is, in the present embodiment, one day is from time 9:00 to time 9:00 on the next day. The production plan information storage unit 11 stores, as production plan information, not only a given production plan at an initial stage, but also information indicating a production plan being reorganized and a production plan after the end of reorganization (final).

  The order information is information indicating the content of the order, that is, the content of the request relating to the production of the product, and in this embodiment, includes the type of the ordered product, the quantity (order quantity, that is, the quantity to be produced), and the delivery date. Information. In the present embodiment, the order information is stored in the order information storage unit 12 in a table format, for example. The order information table 60 for storing the order information in a table format includes, for example, an order field 61 for storing an order and a product for storing the type of product in the order stored in the order field 61 as shown in FIG. A field 62; a quantity field 63 for storing the quantity of the product in the order stored in the order field 61; and a delivery date field 64 for storing the delivery date of the order stored in the order field 61. With a record. An order identifier that identifies and identifies an order is stored in the order field 61, and thus the order is stored in the order field 61. The product field 62 stores a product type identifier that identifies and identifies the type of product, whereby the product type is stored in the product field 62. The unit quantity of the product is the number of products in the present embodiment, but may be an appropriate unit according to the form of the product. In the example shown in FIG. 2, the order information table 60 stores order information for 17 orders from order A to order Q. For example, the order A is a request to produce 10 products of type a with the delivery date of the first day. The order field 61, the product field 62, the number field 63, and the delivery date field 64 of the order information table 60 are respectively , A, a, 10, 1 are stored. Further, for example, the order I is a request to produce 10 products of type a with the delivery date of the sixth day. The order field 61, the product field 62, the number field 63, and the delivery date field 64 of the order information table 60 include I, a, 10, and 6 are stored, respectively. Further, for example, the order Q is a request to produce 10 products of type i with a delivery date of the 10th day. The order field 61, the product field 62, the quantity field 63, and the delivery date field 64 of the order information table 60 include Q, i, 10 and 10 are stored, respectively.

  The LS restriction information is information indicating a range (lot size) of product quantities that can be collected in one lot. In the present embodiment, the LS constraint information is information indicating the upper and lower limit values of the quantity of products that can be collected in one lot, and is set in advance for each type of product. In the present embodiment, the LS constraint information is stored in the LS constraint information storage unit 13 in a table format, for example. The LS constraint information table 70 that stores LS constraint information in a table format includes, for example, a product field 71 that stores a product type and a product type stored in the product field 71 as shown in FIG. When grouping into one lot, a lot size lower limit field (hereinafter abbreviated as “LS lower limit field”) 72 for storing the lower limit value of the quantity of products that can be combined into one lot, and the product field 71 When the types of stored products are collected into one lot, a lot size upper limit value field (hereinafter referred to as “LS upper limit value field”) that stores an upper limit value of the quantity of products that can be combined into one lot. 73) and a record for each type of product. Similar to the product field 62, the product type identifier is stored in the product field 71, whereby the product type is stored in the product field 71. The unit quantity of the upper and lower limit values is a unit according to the unit quantity of the product, and is the number in this embodiment. In the example shown in FIG. 3, the lower limit values corresponding to each type of product are all five, and the upper limit values are all 20, and the LS constraint information table 70 includes products a to i. The product type identifiers a to i of the nine types of products are stored in the product fields 71, and 5 is stored in the LS lower limit value fields 72 corresponding to the products a to i, respectively. In each LS upper limit field 73 corresponding to i, 20 is stored. In the present embodiment, the upper and lower limit values of each type of product are set in common for the sake of simplification of description, but of course, may be different for each type of product.

  The production time information (required production time information) is information indicating the required production time per unit quantity required for producing the products to be collected in the lot with the production facility. Is set. In the present embodiment, the production time information is stored in the production time information storage unit 14 in a table format, for example. A production time information table 80 that stores production time information in a table format corresponds to, for example, a product field 81 that stores a product type and a product type stored in the product field 81 as shown in FIG. A production time field 82 for storing a required production time per unit quantity required for producing the product to be produced by the production facility, and a record for each type of product. Similar to the product field 62, the product type identifier is stored in the product field 81, whereby the product type is stored in the product field 81. In the example shown in FIG. 4, the required production time for each type of product is one hour, and the product time identifier table ai for nine types of products from product a to product i is shown in the production time information table 80. Is stored in each product field 81, and 1 hour (1 Hr) is stored in each production time field 82 corresponding to each product a to i. In the present embodiment, the required production time for each type of product is set in common for one hour in order to simplify the explanation, but of course, it may be different for each type of product.

  The setup time information (required setup time information) is information indicating a setup time required for setup when the products collected in the lot are produced by the production facility. The setup time information is stored in the setup time information storage unit 15. In the present embodiment, the setup time information storage unit 15 stores, for example, a setup time of 1.5 hours (1 hour and 30 minutes, 1.5 hours) as shown in FIG. Note that the setup time information may be stored in the setup time information storage unit 15 in a table format, and the setup time information table for storing the setup time information in the table format includes a setup time field for storing the setup time. In this embodiment, the setup time for each type of product is set to 1.5 hours in common for the sake of simplicity. Of course, the setup time information may be different for each product type. In this case, the setup time information is preset for each product type, and the setup time information table 90 includes a product field that stores the product type by using the product type identifier, and a product stored in the product field. A setup time field for storing a setup time of a product corresponding to the type of product is provided, and a record is provided for each product type.

  The working time information is information indicating working hours within a predetermined period, which is a unit for dividing the entire planning period. The working time information is stored in the working time information storage unit 16. In the present embodiment, the working hours are in the range from 9:00 to 17:00, and the working hours information storage unit 16 includes, for example, working hours 9: 00-17 as shown in FIG. : 00 is stored. The working time information may be stored in the working time information storage unit 16 in a table format, and the working time information table storing the working time information in a table format includes a working time field for storing the working time. In the present embodiment, the working hours are set in common for the sake of simplicity of explanation. The working hours may be different for each season, may be different for each day of the week, and may be set for morning and afternoon. In such a case, for example, when working hours differ for each season, the working time information table includes a seasonal field that stores the season with a seasonal identifier that identifies and identifies the season, and a seasonal identifier that is stored in the seasonal field. A working time field for storing the working time of the season corresponding to is provided, and a record is provided for each season.

  The operating time information is information indicating the operating time of the production facility. The operating time information is stored in the operating time information storage unit 17. In the present embodiment, the operating time is in the range from time 9:00 to time 9:00 on the next day, and the operating time information storage unit 17 stores, for example, operating time 9: 00- as shown in FIG. 9:00 of the next day is stored. That is, in this embodiment, the production facility is in full operation for 24 hours. The operating time information may be stored in the operating time information storage unit 17 in a table format, and the operating time information table for storing the operating time information in the table format includes an operating time field for storing the operating time. In the present embodiment, the operating time is set in common for the sake of simplicity of explanation. The operating time may be different for each season, may be different between the busy season and the quiet season, and may be set in the morning and afternoon. In such a case, for example, when the operation time differs for each season, the operation time information table stores the season field storing the season with the season identifier, and the season operation corresponding to the season identifier stored in the season field. It has an operation time field for storing time, and a record for each season.

  The control calculation unit 2 controls each part of the production plan creation device SC according to the function of each part in order to create a production plan. The control calculation unit 2 includes, for example, a CPU (Central Processing Unit) and its peripheral circuits.

  The control calculation unit 2 functionally includes a control unit 21, a lot size constraint satisfaction processing unit (hereinafter abbreviated as “LS constraint satisfaction processing unit”) 22, and a lot processing unit 23.

  The control part 21 controls each part of the memory | storage part 1, the input part 3, the output part 4, and the IF part 5 according to the function of the said each part, respectively.

  The LS constraint satisfaction processing unit 22 makes the lot within the range (lot size) of the products that can be combined into one lot for each lot included in the production plan (constraint conditions regarding the lot size). The lot size of the lot (the number of products included in the lot) is adjusted. In the present embodiment, the LS constraint satisfaction processing unit 22 is functionally a maximum lot size constraint satisfaction processing unit (hereinafter abbreviated as “maximum LS constraint satisfaction processing unit”) 221 and a minimum lot size constraint satisfaction processing unit. (Hereinafter abbreviated as “minimum LS constraint satisfaction processing unit”) 222.

  The maximum LS constraint satisfaction processing unit 221 sets a constraint for each lot included in the production plan so that the lot is less than or equal to the upper limit of the number of products that can be combined in one lot (the constraint on the maximum lot size is set). The lot size of the lot (the number of products included in the lot (number in this embodiment)) is adjusted. More specifically, in the present embodiment, the maximum LS constraint satisfaction processing unit 221 determines, for each lot included in the production plan, that the lot is the upper limit of the LS constraint information according to the type of product included in the lot. When exceeding the value, the lot exceeding the upper limit value is divided into a plurality so as to be equal to or less than the upper limit value. In this division process, the maximum LS constraint satisfaction processing unit 221 preferably divides each lot after division so that it is equal to or greater than the lower limit value of the LS constraint information.

  For each lot included in the production plan, the minimum LS constraint satisfaction processing unit 222 sets the constraint for the minimum lot size so that the lot is equal to or greater than the lower limit of the number of products that can be combined in one lot. The lot size of the lot (the number of products included in the lot (number in this embodiment)) is adjusted. More specifically, in this embodiment, the minimum LS constraint satisfaction processing unit 222 determines, for each lot included in the production plan, that the lot is the lower limit of the LS constraint information according to the type of product included in the lot. If the value is below the value, the lot is less than or equal to the upper limit value of the LS constraint information in the lot from other lots assigned in the division period that is later in time than the division period of the lot, and the LS constraint A quantity that is greater than or equal to the lower limit value of the information and that the other lot is less than or equal to the upper limit value of the LS constraint information in the other lot is extracted, and the extracted quantity is put into the lot. When searching for a lot from which the quantity is extracted, preferably, the minimum LS constraint satisfaction processing unit 222 selects other lots from which the quantity is extracted in order from the division period adjacent to the lot division period. It is determined whether or not the quantity can be extracted, and the quantity is extracted from the lot in the classification period that is determined for the first time that the quantity can be extracted. In addition, when extracting the quantity, preferably, the minimum LS constraint satisfaction processing unit 222 extracts the quantity that becomes the minimum. In addition, when the lot cannot be extracted as a result of searching for the lot from which the quantity is extracted, preferably, the minimum LS constraint satisfaction processing unit 222 determines that the lot is equal to or more than the lower limit value of the LS constraint information. To the lot.

  For each lot included in the production plan, the lot processing unit 23 adjusts the lot so that the predetermined constraint condition is satisfied when the lot does not satisfy the predetermined constraint condition. In the present embodiment, the lot processing unit 23 performs the setup when the lot cannot be produced by the production facility within the division period to which the lot is assigned, or when the setup is performed outside the working hours in the division period to which the lot is assigned. So that the lot can be produced in the production facility within the division period, and the setup is included in the working time in the division period, such as when the lot cannot be produced in the production facility. Is to adjust. More specifically, in the present embodiment, the lot processing unit 23 functionally includes a processing time calculation unit 231, a lot adjustment processing unit 232, and a repetition processing unit 233.

  Based on the production plan, the required production time information, and the required setup time information, the processing time calculation unit 231 is a total processing time required for the production of the lot assigned to the division period, and performs the setup in the division period. In this case, a time calculation process is performed for obtaining the total processing time including the required setup time required for the setup, and the setup start time and end time for each setup period when the setup is performed during the setup period. Is.

  The lot adjustment processing unit 232 starts the setup determined by the processing time calculation unit 231 when the total processing time calculated by the processing time calculation unit 231 exceeds the preset operation time of the production facility. If at least one of the time and the end time is out of working hours, the total processing time in the segmentation period is within the operating time of the production facility, and the setup start time and end in the segmentation period Reassignment process (lot adjustment process) that reassigns part or all of the lots assigned to the division period to the division period earlier in time than the division period so that the time falls within the working hours ). When this reallocation process is performed, preferably, the lot adjustment processing unit 232 collects lots allocated in the classification period and products of the same type as the types of products in the lot allocated in the classification period. The reassignment process is performed by combining the lots. Further, when performing this reassignment process, preferably, the lot adjustment processing unit 232 reassigns a part or all of the lots assigned in the classification period before and after the reassignment process. The reallocation process is performed so that the total number of lots in the divided period does not increase. In addition, when performing this reassignment process, preferably, the lot adjustment processing unit 232 sets the reassignment destination reassignment period in which the lottery assigned to the division period and the lot assigned to the division period is reassigned. The reassignment process is performed so that the multiplication result of the difference period between them and the reassigned quantity is minimized.

  The iterative processing unit 233 repeatedly performs the time calculation process and the reallocation process for each of the processing time calculation unit 231 and the lot adjustment processing unit 232 from the last division period in time to the first division period in the production plan. It is something to make.

  Here, when the lot adjustment processing unit 232 cannot perform the reallocation processing after the end of the processing by the repetition processing unit 233, the lot processing unit 23 notifies the output unit 4 of information indicating that fact to the outside. To do.

  The input unit 3 is a device that inputs various commands such as a creation start command for instructing creation of a production plan and various data necessary for creating the production plan to the production plan creation device SC. Such as a mouse. The output unit 4 is a device that outputs commands and data input from the input unit 3 and a production plan created by the production plan creation device SC. For example, a CRT display, LCD, organic EL display, plasma display, etc. Display devices and printing devices such as printers. The output unit 4 is also an example of a notification unit for notifying the outside of information indicating that the lot adjustment processing unit 232 of the lot processing unit 23 cannot perform the reallocation processing.

  The IF unit 5 is a circuit that inputs and outputs data with an external device. For example, an RS-232C interface circuit that is a serial communication method, an interface circuit that uses the Bluetooth (registered trademark) standard, and an IrDA (Infrared) An interface circuit that performs infrared communication such as a Data Association (Standard Association) standard, and an interface circuit that uses a USB (Universal Serial Bus) standard. Various data necessary for creating the production plan may be input to the production plan creating apparatus SC by using the IF unit 5.

  Note that the production plan creation device SC may further include an external storage unit as necessary. The external storage unit is, for example, a flexible disk, a CD-ROM (Compact Disc Read Only Memory), a CD-R (Compact Disc Recordable), a DVD-R (Digital Versatile Disc Recordable), and a Blu-ray Disc (registered trademark). For example, a flexible disk drive, a CD-ROM drive, a CD-R drive, a DVD-R drive, a Blu-ray disk drive, and the like.

  Here, when the production plan creation program or the like is not stored, the production plan creation program is installed in the storage unit 1 via the external storage unit from the recording medium that records the production plan creation program or the like. A production plan creation device SC may be configured.

  Next, the operation of this embodiment will be described. FIG. 6 is a flowchart illustrating the operation of the production plan creation apparatus according to the embodiment. FIG. 7 is a diagram illustrating a given production plan as an example in the production plan creation apparatus of the embodiment. FIG. 8 is a diagram illustrating the production plan after the maximum lot size constraint satisfaction process as an example in the production plan creation apparatus of the embodiment. FIG. 9 is a diagram illustrating a production plan after the minimum lot size constraint satisfaction process as an example in the production plan creation apparatus of the embodiment. FIG. 10 is a diagram illustrating a production plan in the middle of lot size determination processing as an example in the production plan creation apparatus of the embodiment. FIG. 11 is a diagram illustrating a production plan after lot size determination processing as an example in the production plan creation apparatus of the embodiment.

  In the present embodiment, it is assumed that a production plan created in advance so as to comply with the lot delivery date is stored in advance in the production plan information storage unit 11 of the storage unit 1. Such a production plan can be created by a known technique. The simplest creation method is a method of allocating (stacking) the lot (the load) in the sorting period corresponding to the delivery date of the lot based on the order information. For example, in the case of the order information shown in FIG. 2, the production plan is created as shown in FIG. 7 by such a simple creation method.

  That is, a lot (order A lot) corresponding to the order A having 10 products a as the order contents is assigned to one day. On the 2nd, a lot corresponding to order B having 10 products b as the order contents (lot of order B) and a lot corresponding to order C having 3 products c as the order contents (lot of order C) Is assigned. On the 3rd, a lot corresponding to order D having the order contents of three products d (lot of order D) and a lot corresponding to order E having the order contents of five products e (lot of order E) Is assigned. On the 4th, a lot (order F) corresponding to order F having 10 products f as the order contents is assigned. On the 5th, a lot (order G lot) corresponding to the order G having the order of 15 products h is allocated. On the 6th, a lot corresponding to the order H including 10 products i (order H lot) and a lot corresponding to the order I including 10 products a (order I lot) Is assigned. On the 7th, a lot corresponding to the order J having the order of 10 products b (lot of order J) and a lot corresponding to the order K having the order of 2 products c (lot of order K) Is assigned. On the 8th, a lot corresponding to the order L including 8 products d (order L) and a lot corresponding to the order M including 5 products e (lot of order M) Is assigned. On the 9th, a lot corresponding to order N (order N) having 10 products f as order contents and a lot (order O lot) corresponding to order O including 10 products g as order contents Is assigned. On the 10th, a lot corresponding to the order P including 25 products h (order P lot) and a lot corresponding to the order Q including 10 products i (order Q lot) Is assigned.

  In addition, as shown by the broken line in FIG. 1, the production plan creation device SC is functionally provided with a load pile processing unit 24 that creates a production plan so as to comply with the lot delivery date based on the order information. It may be configured to further comprise. More specifically, for example, as described above, the load stacking processing unit 24 allocates (stacks) the lot (the load) in the sorting period corresponding to the delivery date of the lot based on the order information. is there.

  When such a production plan is given, the production plan creation device SC executes the production plan creation program when receiving a production plan creation start command from the input unit 3 by the operation of the user (operator), for example. By executing this production plan creation program, an LS constraint satisfaction processing unit 22 and a lot processing unit 23 are functionally configured in the control calculation unit 2, and the LS constraint satisfaction processing unit 22 includes a maximum LS constraint satisfaction processing unit 221 and a minimum The LS constraint satisfaction processing unit 222 is functionally configured, and the lot processing unit 23 is functionally configured with a processing time calculation unit 231, a lot adjustment processing unit 232, and a repetition processing unit 233. The production plan creation device SC reorganizes the given production plan and creates a new production plan that satisfies a predetermined constraint condition by the following operation.

  More specifically, in FIG. 6, first, the maximum LS constraint satisfaction processing unit 221 in the LS constraint satisfaction processing unit 22 of the control calculation unit 2 has one lot for each lot included in the production plan. The maximum lot size constraint satisfaction process (maximum LS constraint satisfaction process) is performed (S1), in which the lot size of the lot is adjusted so as to be equal to or less than the upper limit value of the quantity of products that can be grouped together. As a result, the production plan creation device SC can make the size of each lot of the production plan less than or equal to the upper limit of the maximum lot size constraint information so that each lot of the production plan satisfies the maximum lot size constraint. it can.

  More specifically, the maximum LS constraint satisfaction processing unit 221 performs the following processes for each lot included in the production plan. First, the maximum LS constraint satisfaction processing unit 221 searches for the upper limit value of the LS constraint information stored in the LS constraint information storage unit 13 based on the product type of the lot, and corresponds to the product type of the lot. The upper limit value of the LS constraint information is extracted. Next, the maximum LS constraint satisfaction processing unit 221 compares the extracted upper limit value of the LS constraint information with the number of the lot (in this embodiment, the number), and as a result of the comparison, the lot is determined to be the LS constraint information. When the upper limit value is exceeded, the lot is divided into a plurality so as to be equal to or less than the upper limit value of the LS constraint information. In this division process, from the viewpoint of reducing the stock amount (in-process amount), it is preferable that the division is performed so that at least one lot after division matches the upper limit value of the LS constraint information. Further, at the time of the division process, it is preferable that the lots after division are divided so as to be equal to or more than the lower limit value of the LS constraint information.

  In the above-described production plan shown in FIG. 7, the lot of the order P on the 10th day exceeds the upper limit of the LS constraint information, and the lot of the order P includes the lot of 5 products h and the lot of 20 products h. It is divided into. The result is shown in FIG.

  Returning to FIG. 6, next, the minimum LS constraint satisfaction processing unit 222 in the LS constraint satisfaction processing unit 22 of the control calculation unit 2 collects the lots into one lot for each lot included in the production plan. The minimum lot size constraint satisfaction process (minimum LS) that adjusts the lot size of the lot (the number of products included in the lot (number in this embodiment)) so as to be equal to or greater than the lower limit of the number of products that can be processed Constraint satisfaction processing) is performed (S2). As a result, the production plan creation device SC can make the size of each lot of the production plan equal to or greater than the upper limit value of the minimum lot size constraint information so that each lot of the production plan satisfies the minimum lot size constraint. it can.

  More specifically, the minimum LS constraint satisfaction processing unit 222 performs the following processes for each lot included in the production plan. First, the minimum LS constraint satisfaction processing unit 222 searches the lower limit value of the LS constraint information stored in the LS constraint information storage unit 13 based on the product type of the lot, and corresponds to the product type of the lot. The lower limit value of the LS constraint information is extracted. Next, the minimum LS constraint satisfaction processing unit 222 compares the lower limit value of the extracted LS constraint information with the quantity of the lot (in this embodiment, the number), and as a result of this comparison, the lot is the LS constraint information. When the value falls below the lower limit value, a predetermined quantity is extracted from another lot in which products of the same type as the product type in the lot are collected, and the extracted quantity is put into the lot.

  The other lots are selected from the lots assigned in the division period later in time than the division period of the lot. By selecting the other lot in this way, the predetermined quantity of the product put in the lot is produced ahead of schedule, so that the production plan creation device SC can delay the delivery date in the other lot. Can be prevented. In general, the longer the production is made before the delivery date, the longer the lead time, and the higher the cost for the stock quantity (in-process quantity). For this reason, it is preferable that the minimum LS constraint satisfaction processing unit 222 determines whether or not the predetermined quantity can be extracted from the other lots in order from the division period adjacent to the lot division period. , The lot of the division period determined for the first time that the predetermined quantity can be extracted. By selecting the other lots in this way, the production plan creation device SC can reduce the cost of the inventory quantity (in-process quantity) and make each lot of the production plan satisfy the minimum lot size constraint. Can do.

  The extracted predetermined quantity is a quantity that is less than or equal to the upper limit value of the LS constraint information in the lot and greater than or equal to the lower limit value, and the upper limit value of the LS constraint information in the other lot is the other lot. The quantity is as follows. By determining the predetermined quantity in this way, each lot in the production plan is finally within the upper and lower limit values of the LS constraint information and satisfies the lot size constraint condition. Preferably, the extracted predetermined quantity is a quantity in which the lot is equal to or less than the upper limit value of the LS constraint information in the lot and equal to or greater than the lower limit value, and the other lot is an LS in the other lot. It is a quantity that is not more than the upper limit value of the constraint information, and is the minimum quantity. By determining the extracted predetermined quantity in this way, the production plan creation device SC minimizes the cost of the inventory quantity (in-process quantity) so that each lot of the production plan satisfies the minimum lot size constraint. Can be. When the predetermined quantity cannot be extracted as a result of searching for the other lots, preferably, the minimum LS constraint satisfaction processing unit 222 determines that the lot is equal to or more than the lower limit value of the LS constraint information. To the lot. Even if the production plan creation device SC cannot extract the quantity, the production plan creation apparatus SC adds the quantity that the lot is equal to or more than the lower limit value of the minimum lot size constraint information to the lot even if there is no order. Thus, each lot of the production plan can satisfy the minimum lot size constraint.

  In the above-described production plan shown in FIG. 8, the lot of order C on the 2nd, the lot of order D on the 3rd, and the lot of order K on the 7th are below the lower limit of the LS constraint information. For this reason, processing is performed in order from the first division period in time to the first division period in the production plan. First, a lot in which the products c of the same type as the type of the product c in the lot of the order C for two days are collected And the lot of order K on the 7th is searched. From the 7-day order K lot, the 2-day order C lot is a quantity that is less than or equal to the upper limit value 20 of the LS constraint information and the lower limit value is 5 or more, and the 7-day order K lot. Is the quantity that is equal to or less than the upper limit value 20 of the LS constraint information in this lot, and further, the two minimum quantities are extracted, and these two are placed in the lot of order C on the 2nd. As a result, the number of products in the lot of the order K allocated on the 7th becomes zero, and the lot of the order K allocated on the 7th is substantially moved and deleted on the 2nd. Next, a lot of products d of the same type as the product d in the lot of the order D on the 3rd is searched, and a lot of the order L on the 8th is searched. From the 8th order L lot, the 3rd order D lot is a quantity that is less than or equal to the upper limit value 20 of the LS constraint information in this lot and the lower limit value is 5 or more. Is a quantity that is equal to or less than the upper limit value 20 of the LS constraint information in this lot, and two further minimum quantities are extracted, and these two are put into the lot of order D on the 3rd. As a result, the number of products in the lot of the order L allocated on the 8th is six. The result is shown in FIG.

  Returning to FIG. 6, the processing time calculation unit 231 in the lot processing unit 23 of the control calculation unit 2 is assigned to the division period based on the production plan, the required production time information, and the required setup time information. The total processing time required for the production of the lot, and when the setup is performed during the sorting period, the total processing time including the setup time required for the setup, and when the setup is performed during the sorting period, A time calculation process for obtaining a start time and an end time for each segment period is performed (S3). In the case where a plurality of lots are included in the classification period, in this embodiment, for example, the production order of each lot in the classification period is given priority so that production of a lot with a short processing time required for production of the lot is given priority. The start time and end time of the setup are determined.

  In the example shown in FIG. 9, for example, the processing time calculation unit 231 performs processing as follows for one day to which a lot corresponding to the order A having 10 products a as the order contents is assigned. First, the processing time calculation unit 231 extracts the order contents of an order assigned to one day from the production plan information, that is, the type and number of products a in the order A. The processing time calculation unit 231 searches the production plan information for an order assigned to one day, extracts the order A as a search result, and stores it in the order information storage unit 12 based on the extracted order A. Order information may be searched, and the order contents of order A may be extracted as a search result. Next, the processing time calculation unit 231 searches the production time information stored in the production time information storage unit 14 based on the type of the product a in the order A, and a unit corresponding to the type of the product a as a search result. The production time per quantity (1 hour) is taken out. Then, the processing time calculation unit 231 multiplies the quantity (10 pieces) of the product a in the order A by the production time (1 hour) per unit quantity, thereby processing time required for producing the lot of the order A. (10 × 1 = 10 hours) is obtained. Since there is no setup in one day, the processing time calculation unit 231 sets the processing time (10 × 1 = 10 hours) required for production of the lot of the order A thus obtained as the total processing time.

  Also, for example, a lot corresponding to an order B having 10 products b as an order content, an order C having 3 products c as an order content and an order K having 2 products c as an order content and one. The processing time calculation unit 231 performs processing as follows for the two days to which the lots summarized in are assigned. First, the processing time calculation unit 231 determines the order contents of the order allocated on the 2nd from the production plan information, that is, the type and number of the product b in the order B, and the type and number of the product c in the orders C and K. Take out. The processing time calculation unit 231 searches the production plan information for an order assigned to one day, extracts orders B, C, and K as search results, and orders information based on the extracted orders B, C, and K. The order information stored in the storage unit 12 may be searched, and the order contents of orders B, C, and K may be extracted as a search result. Next, the processing time calculation unit 231 searches the production time information stored in the production time information storage unit 14 based on the type of the product b in the order B, and a unit corresponding to the type of the product b as a search result. The production time per quantity (1 hour) is taken out. Then, the processing time calculation unit 231 multiplies the quantity (10 pieces) of the product b in the order B by the production time per unit quantity (1 hour), thereby processing time required for producing the lot of the order B. (10 × 1 = 10 hours) is obtained. Next, the processing time calculation unit 231 searches the production time information stored in the production time information storage unit 14 based on the type of the product c in the orders C and K, and corresponds to the type of the product c as a search result. The production time per unit quantity (1 hour) is taken out. Then, the processing time calculation unit 231 multiplies the quantity of the product c in the orders C and K (5 pieces) by the production time per unit quantity (1 hour) to collect the lots of the orders C and K. The processing time (5 × 1 = 5 hours) required for production is determined. Then, the processing time calculation unit 231 processes the processing time (10 × 1 = 10 hours) required for the production of the lot of the order B and the processing time (5 × 1 = 5 hours) required for the production of the lot including the orders C and K. And (10 + 5 = 15 hours). On the second day, the type of product to be produced is different from that on the first day, and there are two lots of different products on the second day, so there are two setups. For this reason, the processing time calculation unit 231 takes out the setup time (1.5 hours) from the setup time information storage unit 15 and multiplies the extracted setup time (1.5 hours) by the number of setups (two times). The total setup time (1.5 × 2 = 3 hours) is obtained. The processing time calculation unit 231 adds up the processing time (15 hours) required for the production of the lots of the orders A, C, and K thus obtained, and the total setup time (3 hours). 15 + 3 = 18 hours). Next, the processing time calculation unit 231 compares the processing times required for the production of the lots of the obtained orders B, C, and K. As a result of the comparison, each processing time calculation unit 231 gives priority to the production of a lot with a short processing time. The lot production order is determined, and the start time (9:30, 15:30) and the end time (10:30, 17:00) of the setup are obtained. Thus, on the 2nd, the preparation from product a to product c is performed from 9 o'clock to 10:30, and then the production of 5 products c is performed from 10:30 to 15:30, Next, the preparation from the product c to the product b is performed from 15:30 to 17:00, and then the production of ten products b is performed from 17:00 to 3 on the next three days.

  When the total processing time and the setup are included in this way, the results of obtaining the start time and the end time of the setup for each day are shown in Table 1.

  Returning to FIG. 6, next, the lot adjustment processing unit 232 in the lot processing unit 23 of the control calculation unit 2 calculates the operation time of the production facility set in advance by the total processing time obtained by the processing time calculation unit 231. If the time exceeds the total time, and at least one of the start time and the end time of the setup determined by the processing time calculation unit 231 is out of working hours, the total processing time in the division period is Part or all of the lots assigned to the division period from the division period so that the start time and end time of the setup in the division period are within the working hours within the operating hours of the production facility Also, reassignment processing (lot adjustment processing) for reassigning to the previous classification period is performed (S4).

  More specifically, first, the lot adjustment processing unit 232 takes out the working hours (time 9 o'clock to 17 o'clock) stored in the working time information storage unit 16, and then extracts the working hours from the operation time information storage unit 17. The operating time of the production facility (time 9:00 to time 9:00 of the next day) is taken out. Then, the lot adjustment processing unit 232 determines whether or not the total processing time obtained by the processing time calculation unit 231 in the process S3 is within the operation time of the extracted production facility for the predetermined segmentation period. Then, it is determined whether or not the start time and end time of the setup determined by the processing time calculation unit 231 in the process S3 are within the extracted working hours. As a result of this determination, if the total processing time exceeds the operating time, and at least one of the setup start time and end time is out of the working time, the lot The adjustment processing unit 232 performs the reassignment process (lot adjustment process).

  When performing this reassignment process, in this embodiment, the lot adjustment processing unit 232 determines the lot assigned in the predetermined division period and the product type in the lot assigned in the predetermined division period. The reassignment process is performed by combining lots in which products of the same type are combined.

  In this embodiment, when this reallocation process is performed, the lot adjustment processing unit 232 reallocates a part or all of the lot allocated in the classification period before and after the reallocation process. The reallocation process is performed so that the total number of lots in the reallocation destination division period does not increase. By performing the reassignment process in this way, the total number of lots does not increase. Therefore, the total number of setups is maintained or decreased before and after the reassignment process, so that productivity does not decrease.

  In this embodiment, when this reassignment process is performed, the lot adjustment processing unit 232 assigns the reassignment destination reassignment destination to which a part or all of the lots assigned in the pertinent period and the pertinent period are reassigned. The reallocation process is performed so that the multiplication result of the difference period between the periods and the quantity to be reassigned is minimized. As described above, the longer the production is made before the delivery date, the longer the lead time and the higher the cost for the stock quantity (in-process quantity). Such a production plan creation device SC performs the reassignment process so that the multiplication result is minimized. Therefore, the reassignment process can be performed while minimizing the cost of the inventory amount (in-process amount). it can.

  Further, when this reassignment process is performed, if there is no reassignment destination (when lots cannot be merged), the lot adjustment processing unit 232 determines that the total processing time in the classification period is the operation of the production facility. In order that the start time and the end time of the setup in the division period are within the working hours within the time, a part or all of the lots assigned to the division period may be put forward production. It is reassigned to a division period which is a division period before the division period and whose total processing time is less than the operation time of the production facility.

  Then, the repetitive processing unit 233 causes the processing time calculation unit 231 and the lot adjustment processing unit 232 to perform the time calculation process and the reallocation process from the last division period to the first division period in time in the production plan. Repeatedly (S5). That is, in the first process S4, the lot adjustment processing unit 232 determines whether or not the total processing time and the start time and the end time of the setup satisfy the above-described constraint conditions with respect to the final time period in the production plan. If the above-mentioned constraints are not satisfied, the reassignment process is performed on the lot assigned in the final segmentation period (S4), and then the repetitive processing unit 233 performs the production plan. It is determined whether or not each of the above processes has been completed until the first division period in time (S5). If the result of this determination is that the processing has not ended, the iterative processing unit 233 returns the processing to step S3. On the other hand, if it has ended, the iterative processing unit 233 ends the processing.

  Here, when the lot adjustment processing unit 232 cannot perform the reassignment processing, the lot processing unit 23 notifies the output unit 4 of information indicating the fact to the outside. As a result, the production plan creation device SC can notify the outside that the lot adjustment processing unit cannot perform the reassignment process. By this notification, the operator observes the delivery date when trying to perform the reassignment process. You can recognize that you can't.

  In the example shown in FIG. 9 and Table 1, the lot adjustment processing unit 232 first determines the total processing time and the start time and the end time of the setup for the 10 days that are the final division period in the production plan. It is determined whether or not the constraint condition is satisfied. On this 10th day, the total processing time is 25 hours, the first setup is from 9:00 to 10:30, the second setup is from 15:30 to 17:00, and the third setup is Since it is from 3 o'clock to 4:30 the next time, the lot adjustment processing unit 232 determines that the total processing time does not satisfy the above-described constraint condition and that the third process does not satisfy the above-described constraint condition. To do. For this reason, the lot adjustment processing unit 232 first performs the reassignment process. First, the lot adjustment processing unit 232 executes the product i of the same type as the type of the product i in the lot of the order Q assigned on the 10th. In order to reallocate the lots that are grouped in the division period temporally prior to the 10th day, the lots of the order H on the 6th are searched for in the division period temporally prior to the 10th day. Search for. Then, the lot adjustment processing unit 232 reassigns the lot of the order Q assigned on the 10th to the 6th, and combines the lot of the order H and the lot of the order Q together. The combined lot is within the upper and lower limit values of the LS constraint condition, and the total number of lots in the reassignment destination classification period does not increase before and after the reassignment process. Then, the lot adjustment processing unit 232 searches for a lot in which the products h of the same type as the product h in the lot of the order P assigned to the 10th day are collected in the division period temporally before the 10th day. Then, the lot of the order H for 5 days is searched. Since the order Q is divided into 5 products h and 20 products h, the lot adjustment processing unit 232 determines what to reallocate on the 5th. If the 20 divided products h are reassigned on the 5th, the number of lots on the 5th will be 35 and the above-mentioned constraint condition will not be satisfied. Therefore, the lot adjustment processing unit 232 Are reassigned on the 5th, and the order G lot and the order P lot are combined into one. The combined lot is within the upper and lower limit values of the LS constraint condition, and the total number of lots in the reassignment destination classification period does not increase before and after the reassignment process. Furthermore, as compared with the case where 20 products h are reassigned on the 5th, the multiplication result of the difference period of 5 days between the 10th and 5th days and the quantity of 5 lots to be reassigned is 10 It is smaller than the result of multiplying the difference period of 5 days between days 5 and 5 and the quantity of lots to be reassigned by 20 pieces, and is the smallest of both. The result of reassigning such 10-day lots is shown in FIG.

  FIG. 11 shows a final result in which the processes S3 to S5 are executed on the production plan shown in FIG. In FIG. 11, the order N on the 4th is the result of the reassignment of the order N assigned on the 9th, and the order I on the 1st is the result of the order Q on the 10th being reassigned on the 6th. The order I that was originally assigned on the 6th is reassigned.

  By operating in this way, the production plan creation apparatus and the production plan creation method and the production plan creation program implemented in this embodiment perform setup (including setup change) within the working hours of the operator. A production plan that satisfies the constraint conditions can be created. Further, such a production plan creation device, the method, and the program can determine a lot size that can reduce the inventory amount (in-process amount) while complying with the delivery date.

  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 or improve the above embodiments. Should be recognized. 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.

SC production plan creation device 1 storage unit 2 control operation unit 3 input unit 4 output unit 11 production plan information storage unit 12 order information storage unit 13 lot size information storage unit 14 production time information storage unit 15 setup time information storage unit 16 working hours Information storage unit 17 Operating time information storage unit 22 Lot size constraint satisfaction processing unit 23 Lot processing unit 24 Load pile processing unit 221 Maximum lot size constraint satisfaction processing unit 222 Minimum lot size constraint satisfaction processing unit 231 Processing time calculation unit 232 Lot adjustment processing Part 233 Repeat processing part

Claims (12)

When a plurality of lots are produced by a common production facility, each lot production period in which each of the plurality of lots is produced by the production facility is selected from any of a plurality of division periods obtained by dividing the entire planning period by a predetermined period. A production plan creation device for creating a production plan by assigning to
Maximum lot size constraint information indicating the upper limit value of the quantity of products collected in one lot and required production time information indicating the required production time per unit quantity required for producing the products collected in the lot at the production facility Is stored for each type of the product, and the necessary setup time information indicating the setup time required for setup when the products collected in the lot are produced at the production facility, and the working time within the predetermined period is indicated. A storage unit for storing working time information;
Product quantity indicating the quantity of products collected in the lot, which is a production plan prepared in advance so as to comply with the delivery date of the lot and be less than or equal to the upper limit of the quantity of products collected in one lot. Information and the total processing time required for production of the lot assigned to the division period based on the production plan including the product type information indicating the product type, the required production time information, and the required setup time information. When the setup is performed during the sorting period, the total processing time including the necessary setup time required for the setup, and when the setup is performed during the sorting period, the start time and the end time of the setup are displayed in the sorting period. A processing time calculation unit that performs a time calculation process to be obtained every time,
When the total processing time obtained by the processing time calculation unit exceeds the preset operation time of the production facility, and at least the start time and end time of the setup obtained by the processing time calculation unit If at least one of the cases is out of the working hours, the total processing time in the division period is within the operation time of the production facility, and the start time and end time of the setup in the division period are the working hours. A lot adjustment processing unit that performs a reassignment process for reassigning a part or all of the lots assigned to the division period to a division period that is temporally prior to the division period,
A repetition processing unit that causes the processing time calculation unit and the lot adjustment processing unit to repeatedly perform the time calculation process and the reallocation process from the last division period in time to the first division period in the production plan; A production plan creation device characterized by comprising: The lot adjustment processing unit combines the lot assigned in the division period with another lot in which products of the same type as the product type in the lot assigned in the division period are combined. The production plan creation apparatus according to claim 1, wherein reassignment processing is performed. The lot adjustment processing unit, before and after the reassignment process, so that the total number of lots in the reassignment destination divided period in which a part or all of the lots assigned in the classification period is reassigned does not increase. The production plan creation device according to claim 1 or 2, wherein a reallocation process is performed. The lot adjustment processing unit multiplies the difference period between the division period and the reassignment destination division period to which a part or all of the lots assigned to the division period are reassigned, and the quantity to be reassigned. The production plan creation device according to any one of claims 1 to 3, wherein the reassignment process is performed so that the value is minimized. When the lot adjustment processing unit cannot perform the reallocation processing after the end of the processing by the repetitive processing unit, the information processing device further comprises a notification unit for notifying the outside of information indicating the fact. The production plan creation device according to any one of claims 1 to 4. It was created in advance to comply with the lot delivery date instead of the production plan prepared in advance so that the lot delivery date was observed and the lot was less than the upper limit of the quantity of products collected in one lot. Production plan is used,
For each lot included in the production plan, when the lot exceeds the upper limit value of the maximum lot size constraint information, the lot that exceeds the upper limit value is divided into a plurality so as to be less than or equal to the upper limit value. The production plan creation device according to any one of claims 1 to 5, further comprising a lot size constraint satisfaction processing unit. The storage unit further stores minimum lot size constraint information indicating a lower limit value of the quantity of products collected in one lot,
For each lot included in the production plan, when the lot falls below the lower limit value of the minimum lot size constraint information, other lots assigned to a division period that is later in time than the division period of the lot From the above, the lot is a quantity that is not more than the upper limit value of the maximum lot size constraint information in the lot and is not less than the lower limit value of the minimum lot size constraint information, and the other lot is the quantity in the other lot. 7. The system according to claim 1, further comprising a minimum lot size constraint satisfaction processing unit that extracts a quantity that is equal to or less than the upper limit value of the maximum lot size constraint information and puts the extracted quantity into the lot. The production plan creation device according to claim 1. The minimum lot size constraint satisfaction processing unit determines whether the other lots from which the quantity is extracted can be extracted in order from the division period adjacent to the lot division period, The production plan creation device according to claim 7, wherein the quantity is extracted from a lot in a classification period in which it is determined for the first time that the quantity can be extracted. The production plan creation device according to claim 7 or 8, wherein the minimum lot size constraint satisfaction processing unit extracts the quantity that is minimized. The minimum lot size constraint satisfaction processing unit, when the quantity cannot be extracted, adds a quantity that the lot is equal to or more than the lower limit value of the minimum lot size constraint information to the lot. The production plan creation device according to any one of claims 7 to 9. When a plurality of lots are produced by a common production facility, each lot production period in which each of the plurality of lots is produced by the production facility is selected from any of a plurality of division periods obtained by dividing the entire planning period by a predetermined period. A production plan creation method for creating a production plan by assigning to
Maximum lot size constraint information indicating the upper limit value of the quantity of products collected in one lot and required production time information indicating the required production time per unit quantity required for producing the products collected in the lot at the production facility Is stored for each type of the product, and the necessary setup time information indicating the setup time required for setup when the products collected in the lot are produced at the production facility, and the working time within the predetermined period is indicated. A storage process for storing working time information;
Product quantity indicating the quantity of products collected in the lot, which is a production plan prepared in advance so as to comply with the delivery date of the lot and be less than or equal to the upper limit of the quantity of products collected in one lot. Information and the total processing time required for production of the lot assigned to the division period based on the production plan including the product type information indicating the product type, the required production time information, and the required setup time information. When the setup is performed during the sorting period, the total processing time including the necessary setup time required for the setup, and when the setup is performed during the sorting period, the start time and the end time of the setup are displayed in the sorting period. A processing time calculation step for performing a time calculation process to be obtained for each,
When the total processing time obtained by the processing time calculation step exceeds the preset operation time of the production facility, and at least the start time and end time of the setup determined by the processing time calculation step If at least one of the cases is out of the working hours, the total processing time in the division period is within the operation time of the production facility, and the start time and end time of the setup in the division period are the working hours. A lot adjustment processing step for performing a reassignment process for reassigning a part or all of the lot assigned to the division period to a division period temporally prior to the division period,
A repetition processing step of repeatedly performing the time calculation processing of the processing time calculation step and the reallocation processing of the lot adjustment processing step from the last division period in time to the first division period in the production plan. A production plan creation method characterized by When a plurality of lots are produced by a common production facility, each lot production period in which each of the plurality of lots is produced by the production facility is selected from any of a plurality of division periods obtained by dividing the entire planning period by a predetermined period. A production plan creation program for creating a production plan by assigning to
On the computer,
Maximum lot size constraint information indicating the upper limit value of the quantity of products collected in one lot and required production time information indicating the required production time per unit quantity required for producing the products collected in the lot at the production facility Is stored for each type of the product, and the necessary setup time information indicating the setup time required for setup when the products collected in the lot are produced at the production facility, and the working time within the predetermined period is indicated. A storage unit for storing working time information;
Product quantity indicating the quantity of products collected in the lot, which is a production plan prepared in advance so as to comply with the delivery date of the lot and be less than or equal to the upper limit of the quantity of products collected in one lot. Information and the total processing time required for production of the lot assigned to the division period based on the production plan including the product type information indicating the product type, the required production time information, and the required setup time information. When the setup is performed during the sorting period, the total processing time including the necessary setup time required for the setup, and when the setup is performed during the sorting period, the start time and the end time of the setup are displayed in the sorting period. A processing time calculation unit that performs a time calculation process to be obtained every time,
When the total processing time obtained by the processing time calculation unit exceeds the preset operation time of the production facility, and at least the start time and end time of the setup obtained by the processing time calculation unit If at least one of the cases is out of the working hours, the total processing time in the division period is within the operation time of the production facility, and the start time and end time of the setup in the division period are the working hours. A lot adjustment processing unit that performs a reassignment process for reassigning a part or all of the lots assigned to the division period to a division period that is temporally prior to the division period,
A repetition processing unit that causes the processing time calculation unit and the lot adjustment processing unit to repeatedly perform the time calculation process and the reassignment process from a temporally final division period to an initial division period in the production plan;
Production plan creation program to realize

Images