JP6880343B1 - Scheduler system, scheduler management device and machine learning device - Google Patents

Abstract

The scheduler system includes a production scheduler, a manufacturing execution system, and a scheduler management device. The scheduler management device has a plan information acquisition unit and a replanning execution unit. The plan information acquisition unit connects other monitoring target data, which is data for monitoring the occurrence of an event that requires re-creation of the first production plan information after the creation of the first production plan information, to the scheduler management device. Obtain from the device. The replanning execution unit detects the presence or absence of an event using the monitored data, and when an event occurs, it is information other than the planning creation information, which is the information used for creating the first production planning information. Instruct the production scheduler to acquire additional information and planning information. After instructing the production scheduler to acquire the additional information and the plan creation information, the plan information acquisition unit recreates the second production plan information in which the order spans a plurality of processes by using the acquired additional information and the plan creation information. To the production scheduler.

Description

The present disclosure relates to a scheduler system, a scheduler management device, and a machine learning device for creating a product production plan.

Conventionally, a production scheduler creates a production plan that spans a plurality of orders, and sets the created production plan in a manufacturing execution system (hereinafter referred to as MES). Then, MES systematically performed the production based on the set production plan. However, depending on the production process, there may be a production delay that cannot be produced according to the production plan due to a delay in the progress of work at the production site or an unscheduled additional production. When production delays occurred, it was necessary to revise the production plan.

Therefore, Patent Document 1 discloses a production plan creating device capable of replanning a production plan straddling orders when a predetermined event occurs. Specifically, the production plan creation device described in Patent Document 1 creates a production plan for a plurality of types of products manufactured through a plurality of processes in a plurality of facilities, and includes a plurality of process scheduler devices and a plurality of process scheduler devices. It is equipped with a fully integrated device. A process scheduler device is provided for each process and creates a production plan for the process. The overall integrated device calculates each work-in-process amount for each product type for each process from the production plan and production results created by the process scheduler device, and calculates each excess / deficiency work-in-process amount from each work-in-process amount and each minimum required work-in-process amount. Ask. When there is a shortage of work in process, the overall integrated device requests the process scheduler device of the process prior to the process corresponding to the shortage of work in process to request the shortage of the shortage of work in process with the time when the shortage occurs as the delivery date. Further, in the case of a new order, the overall integrated device requests a production request for the new order from the process scheduler device of the final process of the type of product corresponding to the new order. Then, the process scheduler device recreates the production plan so as to satisfy the shortage request in the case of the shortage request and to satisfy the new order in the case of the production request.

Japanese Unexamined Patent Publication No. 2009-199143

However, in the technique described in Patent Document 1, when the production plan is replanned, the replanning is performed based on the information of the initially set items, that is, the information of the items corresponding to the shortage request or the production request. Therefore, if the cause of the delay in the production plan is caused by conditions other than the initially set items, for example, the shortage request and the conditions other than the production request, the technique described in Patent Document 1 causes the delay. There was a problem that it became difficult to re-plan an effective production plan because it was not possible to obtain the data of.

The present disclosure has been made in view of the above, and an object of the present disclosure is to obtain a scheduler system capable of replanning a production plan in consideration of conditions that cause replanning.

In order to solve the above-mentioned problems and achieve the object, the scheduler system of the present disclosure includes a production scheduler, a manufacturing execution system, and a scheduler management device. The production scheduler creates first production plan information indicating production plans of a plurality of orders. The manufacturing execution system receives the contents of the production plan corresponding to the order managed by itself from the first production plan information created by the production scheduler, and responds to a plurality of processes based on the contents of the received production plan. Perform production in manufacturing equipment. The scheduler management device instructs the production scheduler to recreate the first production plan information. The scheduler management device has a plan information acquisition unit and a replanning execution unit. The plan information acquisition unit connects other monitoring target data, which is data for monitoring the occurrence of an event that requires re-creation of the first production plan information after the creation of the first production plan information, to the scheduler management device. Obtain from the device. The replanning execution unit detects the presence or absence of an event using the monitored data, and when an event occurs, it is information other than the planning creation information, which is the information used for creating the first production planning information. Instruct the production scheduler to acquire additional information and planning information. An event is one or more of a failure of a manufacturing facility, which is a facility including a manufacturing device, a sign of a failure of the manufacturing facility, a delay in delivery of materials, and a deterioration in the quality of products manufactured by the manufacturing facility. The additional information is the monitored data used to monitor the occurrence of the event. After instructing the production scheduler to acquire the additional information and the plan creation information, the plan information acquisition unit recreates the second production plan information in which the order spans a plurality of processes by using the acquired additional information and the plan creation information. To the production scheduler.

The scheduler system according to the present disclosure has an effect that the production plan can be replanned in consideration of the conditions that cause the replanning.

A block diagram schematically showing an example of the configuration of the scheduler system according to the first embodiment. Diagram showing an example of production planning information A block diagram schematically showing an example of the functional configuration of the scheduler management device according to the first embodiment. A block diagram schematically showing an example of the functional configuration of the learning engine unit in the scheduler management device according to the first embodiment. A flowchart showing an example of a procedure of a method of recreating production planning information in the scheduler system according to the first embodiment. A block diagram schematically showing another example of the configuration of the scheduler system according to the first embodiment. A block diagram schematically showing an example of the hardware configuration of the scheduler management device according to the first embodiment.

Hereinafter, the scheduler system, the scheduler management device, and the machine learning device according to the embodiment of the present disclosure will be described in detail with reference to the drawings.

Embodiment 1.
FIG. 1 is a block diagram schematically showing an example of the configuration of the scheduler system according to the first embodiment. The scheduler system 1 creates MES2 that performs production based on production plan information indicating production plans of a plurality of orders, production scheduler 3 that creates production plan information in MES2, and production plan information for production scheduler 3. Alternatively, the scheduler management device 4 for instructing the re-creation is provided. The MES2 receives the contents of the production plan corresponding to the order managed by itself from the production plan information created by the production scheduler 3, and based on the contents of the received production plan, in the manufacturing apparatus corresponding to a plurality of processes. Perform production. Specifically, the MES2 controls the FA (Factory Automation) device 60 so as to produce a product based on production replanning information, a manufacturing order, an ordering order, and the like.

The production scheduler 3 holds the latest master data and transaction data, and creates production planning information across a plurality of orders in response to an instruction from the scheduler management device 4. Master data includes an item master that indicates the items of products manufactured at the manufacturing site, a parts master that indicates the parts that make up each product registered in the item master, and each product registered in the item master. Includes a process master that indicates the manufacturing process for. The transaction data includes actual information such as inventory status and manufacturing results for products registered in the master data, material delivery schedule data, and the like. In the first embodiment, the production scheduler 3 is started by the scheduler management device 4 to create or recreate the production plan information. The production plan information first created by the production scheduler 3 corresponds to the first production plan information, and the production plan information recreated after the first production plan information corresponds to the second production plan information.

The production scheduler 3 has a data acquisition unit 31, a data table 32, and a production plan creation unit 33. The data acquisition unit 31 acquires the data necessary for creating or recreating the production plan information from the MES2, the information management system 50, or the FA device 60 according to the instruction from the scheduler management device 4. The data table 32 is data storage information including data necessary for creating or recreating the production planning information acquired by the data acquisition unit 31. The data table 32 is stored in the storage unit. The production plan creation unit 33 creates production plan information in which a production order including a delivery date and a quantity is allocated to a production resource including a production facility, personnel, tools, etc. along a time axis. The production plan creation unit 33 creates the production plan information according to the allocation method designated from the plurality of allocation methods. The allocation method includes "a method of defining priorities for each order and allocating in that order", "a method of allocating to minimize inventory on time to meet delivery dates", and "minimizing setup time on time to meet delivery dates". There are "methods of allocating to maximize the operating rate" and "methods of allocating to maximize the operating rate on time for delivery".

FIG. 2 is a diagram showing an example of production planning information. In the production plan information 100, the vertical axis is the production line name 101 and the horizontal axis is the time 102. On the vertical axis, the production line names 101 are arranged in the order of the production processes. When a product is manufactured, the production line is a facility provided corresponding to the manufacturing process for manufacturing the product and includes one or more manufacturing devices. The production line name 101 is a name given to the production line used in each process. When there are a plurality of production lines in one process, a plurality of production line names 101 are arranged. The horizontal axis is the time axis. Then, the occupied production line name 101 and the usage time zone are set for each production order 103 of the product. In the production plan information 100, a plurality of production orders 103 are configured across the production lines along the time axis, and the production orders 103 do not overlap, so that production can be performed without overbooking on the production lines. It will be possible.

Returning to FIG. 1, the scheduler management device 4 instructs the production scheduler 3 to create the production plan information of the product in the manufacturing facility, and as a result, the production plan information which is the created first production plan information is transmitted from the production scheduler 3. It is a device to acquire. Further, the scheduler management device 4 monitors the occurrence of an event for which the production plan information currently being executed must be changed, and when the occurrence of the event is detected, the production scheduler 3 is started and the production plan information is generated. Is instructed to the production scheduler 3 to be recreated, and as a result, the recreated second production plan information, which is the production plan information, is acquired. The case where the production planning information is recreated will be described below.

The scheduler management device 4 is connected to an information system interface (InterFace: hereinafter referred to as I / F) unit 45 connected to the information management system 50, a manufacturing site I / F unit 46 connected to the FA device 60, and a production scheduler 3. The production scheduler I / F unit 47 to be connected and the MES I / F unit 48 connected to the MES2 are provided. The specifications of each I / F section of the information system I / F section 45, the manufacturing site I / F section 46, the production scheduler I / F section 47, and the MES I / F section 48 match the specifications of the connected external devices such as MES2. This makes it possible to freely connect to other external devices.

The information system I / F unit 45 is connected to the information management system 50 via a network. An example of the information management system 50 is a core information system (Enterprise Resources Planning: hereinafter referred to as ERP) 51, a product lifecycle management system (hereinafter referred to as PLM) 52, and a sales force automation system (hereinafter referred to as PLM). , SFA) 53. The ERP 51 outputs actual information such as product orders, orders, and inventory information to the scheduler management device 4 and the MES 2. The PLM 52 outputs the product design information to the scheduler management device 4. The SFA 53 outputs the demand forecast information of the product to the scheduler management device 4.

The manufacturing site I / F unit 46 is connected to the FA device 60 via a network. An example of the FA device 60 is a programmable logic controller (PLC) installed at the manufacturing site. The programmable logic controller is connected to the equipment, sensors, robots, etc. that make up the production line. The sensor detects the operating status of the device or robot. The staff works according to the production plan information at the manufacturing site where the FA device 60 is arranged. The FA device 60 outputs information including the actual result information of the manufactured product and the operating status of the manufacturing device to the scheduler management device 4 and the MES2.

The production scheduler I / F unit 47 is connected to the production scheduler 3. The scheduler management device 4 outputs a replanning instruction, which is an instruction for recreating the production plan information, to the production scheduler 3, and acquires the production plan information from the production scheduler 3.

The MES I / F unit 48 is connected to the MES2. The scheduler management device 4 outputs the production plan information acquired from the production scheduler 3 and the manufacturing order and the ordering order corresponding to the production plan information to MES2, and also outputs the actual information executed by MES2 based on the production plan information. Obtained from MES2.

The scheduler management device 4 includes a scheduler database 41, a plan information acquisition unit 42, a replanning execution unit 43, and a learning engine unit 44.

The scheduler database 41 is a schedule information storage unit that stores schedule information, which is data necessary for recreating production planning information. Specifically, the scheduler database 41 is a condition for determining monitoring target data, which is data for monitoring the occurrence of an event that requires re-creation of production plan information, and re-creation of production plan information. Stores schedule information including replanning conditions and replanning rules, which are rules that should be followed with priority when recreating production planning information.

The plan information acquisition unit 42 collects or creates monitored data from the MES2, the information management system 50, and the FA device 60. The plan information acquisition unit 42 acquires plan information including product performance information, design information, and demand forecast information from the information management system 50 as monitoring target data via the information system I / F unit 45. Further, the plan information acquisition unit 42 acquires the plan information including the actual information and the operation status of the equipment from the FA device 60 as the monitoring target data via the manufacturing site I / F unit 46. The plan information acquisition unit 42 acquires the plan information including the actual data from the MES2 as the monitoring target data via the MES I / F unit 48. The actual data may be acquired from the information management system 50, the FA device 60, or the MES2. The plan information acquisition unit 42 stores the acquired monitored data in the scheduler database 41. The scheduler management device 4 is connected to the data collection platform 70, which is a device into which software for acquiring data from the FA device 60 is installed, without depending on the specifications of the FA device 60 installed at the manufacturing site. May be good. The plan information acquisition unit 42 can also collect the actual information from the FA device 60 or the operation status of the equipment via the data collection platform 70. Further, when the production plan information needs to be recreated, the plan information acquisition unit 42 instructs the production scheduler 3 to recreate the production plan information including the replanning rule according to the instruction from the replanning execution unit 43. To send.

The replanning execution unit 43 acquires the monitored data and the replanning condition from the scheduler database 41, compares the acquired monitored data with the replanning condition, and recreates the production planning information at that time. Check if has occurred. When an event requiring re-creation occurs, the re-planning execution unit 43 holds the contents of the monitored data acquired from another device connected to the scheduler system 1 such as the information management system 50 in the production scheduler 3. It is reflected in various data tables 32. In one example, the replanning execution unit 43 reads the master data and the transaction data from the scheduler database 41, performs processing such as format conversion, and reflects them in various data tables 32 held by the production scheduler 3.

Further, the replanning execution unit 43 instructs the production scheduler 3 to acquire the information necessary for executing the replanning of the production planning information as needed. This is when the cause of the replanning of the production planning information is based on the additional information which is the additional information which is not included in the planning creation information used for creating the production planning information set by default. On the other hand, additional information is collected in addition to the planning information. In one example, the planning information is monitored data. The replanning execution unit 43 acquires the production planning information created by the production scheduler 3.

The learning engine unit 44 learns the execution logic of recreating the production plan information. The learning engine unit 44 learns the delay amount of the production plan information that has occurred in the past, and reflects the learning result in the re-creation of the new production plan information. Specifically, the learning engine unit 44 learns the replanning conditions and the monitoring target data necessary for improving the accuracy of recreating the production plan information, and the newly learned monitoring target data is used as the planning information acquisition unit 42. The replanning conditions and replanning rules are reflected in the replanning execution unit 43.

Here, the function of performing the process of replanning the production plan information in the scheduler management device 4 will be described in more detail. FIG. 3 is a block diagram schematically showing an example of the functional configuration of the scheduler management device according to the first embodiment. In FIG. 3, the scheduler database 41, the plan information acquisition unit 42, and the replanning execution unit 43 of the scheduler management device 4 are shown, and the other functional processing units are not shown.

The scheduler database 41 stores the monitoring target data 411, the replanning condition 412, the replanning determination result 413, the replanning rule 414, and the actual data 415. The monitored data 411 is data necessary for monitoring the occurrence of an event that requires re-creation of the production plan information, and is also data necessary for re-creating the production plan information. The monitored data 411 is acquired by the plan information acquisition unit 42. That is, the monitored data 411 has contents that can determine the re-creation of the production plan information by using the re-planning condition 412, and has the contents for re-creating the production plan information. An example of monitored data 411 is order information indicating the order status of a product, information indicating the operation status of equipment, equipment failure information indicating an equipment failure, inventory information indicating the inventory status of a product, and a record indicating a manufacturing record of a product. Information.

Replanning condition 412 is a condition that requires re-creation of production planning information. The replanning condition 412 is set for each event according to a plurality of events. Examples of the replanning condition 412 include the following (1) to (5).
(1) Replanning conditions when an urgent order occurs (2) Replanning conditions when an equipment failure occurs (3) Replanning conditions when a sign of equipment failure occurs (4) Material delivery delay occurs Replanning conditions in case (5) Replanning conditions when product quality deteriorates

As a method for confirming the sign of equipment failure in (3), time-based maintenance (TBM) or condition-based maintenance (CBM) may be used, or machine learning or deep learning may be used. A maintenance method using the above technology may be used.

The replanning determination result 413 is data indicating a result in which the monitored data 411 is compared with the replanning condition 412 by the replanning execution unit 43 and the necessity of replanning is determined.

The replanning rule 414 is information that defines the contents to be observed when the production planning information is recreated. The replanning rule 414 is defined in response to the replanning condition 412. Examples of the replanning rule 414 include the following (A) to (E). Each of the following (A) to (E) corresponds to the example of (1) to (5) of the above-mentioned replanning condition 412.
(A) Rule to raise the priority of the order detected as an urgent order when an urgent order occurs (B) When an equipment failure occurs, the equipment in which the equipment failure has occurred is set on the failure date. Rule to make the equipment non-operating until the next day (C) Rule to make the equipment non-operating during the time when the equipment is predicted to fail based on the equipment failure prediction information when the equipment failure prediction response occurs (C) D) Rule to update the order information of the production scheduler 3 in response to the material delivery delay information when the material delivery delay occurs (E) When the product quality deteriorates, the product inspection pass rate Rule to postpone the production start time of items whose product inspection pass rate is decreasing in response to the decrease

The actual data 415 is actual data of the product produced according to the production plan information created or recreated by the production scheduler 3. The scheduler database 41 stores data acquired from the MES2, the information management system 50, or the FA device 60 for each data item. When only the latest data is required among the data items, the scheduler database 41 updates and stores the corresponding data.

The plan information acquisition unit 42 has a monitoring target table 421, a data input / output unit 422, and a reschedule unit 423. The monitoring target table 421 is a monitoring target information storage unit that stores the monitoring target information in which the data items of the monitoring target data to be acquired and the acquisition destination information of the monitoring target data are described.

The data input / output unit 422 acquires the monitored data from the outside of the scheduler management device 4 based on the monitored table 421 at predetermined time intervals, and saves the acquired monitored data in the scheduler database 41. The method of acquiring the monitored data in the data input / output unit 422 is not only to go to the outside by itself at a predetermined time interval, but also to acquire the monitored data sent from the outside at a predetermined time interval. May be obtained. Further, the data input / output unit 422 may acquire the monitored data in real time. Further, the data input / output unit 422 acquires the production plan information recreated by the production scheduler 3 and outputs it to the replanning execution unit 43.

The reschedule unit 423 is activated by an instruction from the replanning execution unit 43, which will be described later, and transmits an instruction to cause the production scheduler 3 to recreate the production planning information.

The replanning execution unit 43 includes an event monitoring unit 431, a replanning unit 432, and a replanning result confirmation unit 433.

The event monitoring unit 431 monitors an event related to the execution of re-creation of production planning information from the monitored data acquired from the MES2, the information management system 50, and the FA device 60. The event monitoring unit 431 includes a replanning event monitoring unit 4311 and a replanning activation unit 4312.

The replanning event monitoring unit 4311 acquires the monitored data 411 and the latest replanning condition 412 from the scheduler database 41 at predetermined intervals, for example, every 30 minutes. The replanning event monitoring unit 4311 sequentially determines whether or not the monitored data 411 meets the plurality of replanning conditions 412, and detects the occurrence of an event for recreating the production plan information. The replanning event monitoring unit 4311 outputs the determination result as the replanning determination result information to the replanning activation unit 4312 and the scheduler database 41. The scheduler database 41 stores the acquired replanning determination result information in the item of the replanning determination result 413.

Here, a case of determining whether or not the replanning condition 412 of the urgent order is satisfied will be given as an example. In this case, it is assumed that the replanning condition 412 is set to "accumulate the manufacturing lead time and the distribution lead time at the current time, and the integrated time is within the delivery date". The replanning event monitoring unit 4311 determines whether or not the replanning condition 412 of the urgent order is satisfied by using the acquired current time, manufacturing lead time, distribution lead time, and delivery date monitoring data. That is, the replanning event monitoring unit 4311 indicates that it is not necessary to recreate the production planning information when the "time obtained by integrating the manufacturing lead time and the distribution lead time at the current time" is "within the delivery date". The replanning judgment result information is notified to the replanning start-up unit 4312, and if "not within the delivery date", the replanning judgment result information indicating that the production plan information needs to be recreated is notified to the replanning start-up unit 4312. To do. Further, the replanning event monitoring unit 4311 stores the replanning determination result information in the item of the replanning determination result 413 of the scheduler database 41.

When the replanning activation unit 4312 receives a notification from the replanning event monitoring unit 4311 that the production planning information needs to be recreated, the replanning activation unit 4312 activates the replanning unit 432.

When the production plan information needs to be recreated, the replanning unit 432 prepares for the production scheduler 3 to replan the production plan information according to the content of the event detected by the event monitoring unit 431. .. The replanning unit 432 has a replanning rule execution unit 4321, a scheduler environment update unit 4322, and a reschedule activation unit 4323.

The replanning rule execution unit 4321 executes the replanning rule 414 according to the type of event detected by the event monitoring unit 431. Specifically, the replanning rule execution unit 4321 acquires the replanning rule 414 from the scheduler database 41 and sequentially executes the replanning rule 414. Taking the case of executing the urgent order replanning rule 414 of (A) as an example, the replanning rule execution unit 4321 attaches a code for urgent order to the urgent order order. As a result, the production scheduler 3 can create the production plan information that preferentially executes the order with the code for urgent order when the production plan information is recreated. After executing all the set replanning rules 414, the replanning rule execution unit 4321 notifies the scheduler environment update unit 4322 that the execution of the replanning rule 414 is completed.

The scheduler environment update unit 4322 updates the data corresponding to the transaction information among the items of the data table 32 held by the production scheduler 3. Further, the data table 32 held by the production scheduler 3 and the monitored table 421 held by the plan information acquisition unit 42 are linked so that the items match. Therefore, when the items in the data table 32 of the production scheduler 3 and the items in the monitored table 421 do not match, the scheduler environment update unit 4322 refers to the plan information acquisition unit 42 with respect to the data table of the production scheduler 3. Instruct the 32 items to match the items in the monitored table 421. As a result, the data input / output unit 422 of the plan information acquisition unit 42 updates the data table 32 of the production scheduler 3. When the update process of the data table 32 of the production scheduler 3 is completed, the scheduler environment update unit 4322 notifies the reschedule start unit 4323 that the update of the data table 32 is completed.

The reschedule activation unit 4323 activates the reschedule unit 423 of the plan information acquisition unit 42. As a result, the reschedule unit 423 of the plan information acquisition unit 42 causes the production scheduler 3 to recreate the production plan information. That is, after the update of the data table 32 of the production scheduler 3 is completed, the production scheduler 3 is instructed to recreate the production plan information. When the re-creation of production planning information is instructed by a cause other than the monitored data set by default, the item in the data table 32 of the production scheduler 3 becomes the item of the monitored data including the data that causes the re-creation. It will be updated accordingly. Then, the production scheduler 3 can recreate the production plan information by using the monitored data including the data that causes the re-creation.

The replanning result confirmation unit 433 confirms whether or not the recreated new production plan information acquired from the production scheduler 3 is an acceptable plan in actual production. The replanning result confirmation unit 433 changes the recreated production plan information acquired from the production scheduler 3 to the production plan information at that time when the recreated production plan information is acceptable in the actual production. The changed part, which is the changed point, is extracted, and the changed part of the recreated production plan information with respect to the production plan information at that time is displayed on a display unit (not shown) to notify the user. In addition, the replanning result confirmation unit 433 calculates the delay amount of the recreated production plan information with respect to the production plan information at that time.

In the scheduler management device 4 of the first embodiment, the items corresponding to the replanning condition 412 are registered as the monitoring target data 411. In one example, the above (1) to (5) are the default replanning conditions 412, and at the manufacturing site, the replanning conditions 412 that do not correspond to the default replanning conditions 412 (1) to (5) are newly added. May be generated in. In this case, the user adds a new replanning condition 412 to the scheduler database 41, and updates the new monitoring item to be monitored by the monitored data 411 accordingly. However, at this point, this update is not reflected in the production scheduler 3.

When the added new monitoring item causes a delay, even if the production scheduler 3 is instructed to recreate the production planning information without updating the added new monitoring item to the production scheduler 3. The production scheduler 3 cannot acquire the monitored data corresponding to the newly added monitoring item. That is, since the production scheduler 3 replans the production plan information without using the monitored data that causes the delay, the recreated production plan information is appropriate for eliminating the delay. It cannot be said that there is.

However, in the first embodiment, the scheduler environment update unit 4322 of the replanning unit 432 has the items of the data table 32 held by the production scheduler 3 and the items of the monitored table 421 held by the plan information acquisition unit 42. Check if they match, and if they do not match, instruct them to match. After the plan information acquisition unit 42 updates the items in the data table 32 of the production scheduler 3 based on this instruction, the reschedule start unit 4323 activates the reschedule unit 423 to re-execute the production plan information in the production scheduler 3. Send instructions to execute the plan. Then, the production scheduler 3 acquires data from the outside based on the items of the data table 32 whose items match those of the monitored table 421, and recreates the production plan information using the acquired data. That is, in the first embodiment, by linking the monitoring target table 421 of the plan information acquisition unit 42 and the data table 32 of the production scheduler 3, the production scheduler 3 is monitored including data that causes a delay. Production planning information can be recreated using the data. As a result, the recreated production planning information becomes appropriate to eliminate the delay.

The plan information acquisition unit 42 can set the items of the data table 32 by setting the parameters of the items of the data table 32 of the production scheduler 3 based on the instruction from the scheduler environment update unit 4322. .. In one example, when the parameter setting of the item in the data table 32 can be set by setting the data item on or off, the plan information acquisition unit 42 sets the parameter setting of the data item to on to set the data. Add items in table 32. When the above-mentioned new replanning condition 412 is added, the data item corresponding to the new monitoring item based on the addition of the new replanning condition 412 is set to be turned on, so that the data table 32 of the production scheduler 3 is set. Items can be added. Further, by setting the unnecessary data items to off, the production scheduler 3 can recreate the production planning information without using unnecessary information. In this case, in one example, the scheduler environment update unit 4322 displays a parameter setting screen on which the display of data items can be switched on or off on a display unit (not shown), and receives an input result by the user from an input unit (not shown). .. Then, the plan information acquisition unit 42 reflects the input result in the data table 32 of the production scheduler 3.

By updating the monitoring target table 421 of the plan information acquisition unit 42 in this way, the production scheduler 3 can additionally acquire information for improving the accuracy of the production plan information, and the acquired data is used to obtain high accuracy. Production planning information can be recreated.

Next, the learning of the new replanning condition and the new monitored data in the learning engine unit 44 will be described. If the replanning conditions can be learned, the monitored data can be derived using the items of the replanning conditions. Therefore, the learning of the replanning conditions will be described below.

FIG. 4 is a block diagram schematically showing an example of the functional configuration of the learning engine unit in the scheduler management device according to the first embodiment. The learning engine unit 44 includes a state observation unit 441 and a learning unit 442.

The state observation unit 441 observes the recreated production plan information 201, the delay cause 202 of the production plan information, and the delay amount 203 as state variables. The recreated production plan information 201 is obtained from the production scheduler 3. The delay cause 202 of the production plan information is obtained from the replanning determination result determined by the replanning event monitoring unit 4311 of the replanning execution unit 43 or the replanning determination result 413 stored in the scheduler database 41. The delay amount 203 is obtained from the replanning result confirmation unit 433 of the replanning execution unit 43.

The learning unit 442 machine-learns the production plan information having the smallest delay amount according to the data set created based on the state variables of the recreated production plan information 201, the delay cause 202 of the production plan information, and the delay amount 203. .. The production plan information machine-learned by the learning unit 442 corresponds to the third production plan information.

Any learning algorithm may be used as the learning algorithm used by the learning unit 442. As an example, the case where reinforcement learning is applied will be described. Reinforcement learning is that an action subject who is an agent in a certain environment observes the current state and decides an action to be taken. Agents get rewarded from the environment by choosing an action and learn how to get the most reward through a series of actions. Q-learning or TD-learning is known as a typical method of reinforcement learning. For example, in the case of Q-learning, the general update equation (behavior value table) of the action value function Q (s, a) is expressed by the following equation (1).

(1) In the formula, s _t represents the environment at time t, a _t represents the behavior in time t. By the action a _t, the environment is changed to s _{t + 1.} rt _{+ 1} represents the reward received by the change of the environment, γ represents the discount rate, and α represents the learning coefficient. Note that γ is in the range of 0 <γ ≦ 1 and α is in the range of 0 <α ≦ 1. If you apply the Q-learning, production planning information 201 to re-create is the action a _t.

In the update formula represented by the equation (1), if the action value of the best action a at time t + 1 is larger than the action value Q of the action a executed at time t, the action value Q is increased, and vice versa. In that case, the action value Q is reduced. In other words, the action value function Q (s, a) is updated so that the action value Q of the action a at time t approaches the best action value at time t + 1. As a result, the best behavioral value in a certain environment is sequentially propagated to the behavioral value in the previous environment.

The learning unit 442 further includes a reward calculation unit 4421 and a function update unit 4422.

The reward calculation unit 4421 calculates the reward based on the state variable. The remuneration calculation unit 4421 calculates the remuneration r based on the allowable range of the planned delay, which is the delay amount of the recreated production plan information with respect to the production plan information before the recreated. For example, when the planning delay is reduced, the reward r is increased (for example, a reward of "1" is given). On the other hand, when the planning delay increases, the reward r is reduced (for example, a reward of "-1" is given). Tolerances for planned delays are extracted according to known methods.

The function update unit 4422 updates the production planning information so that the reward is the largest, that is, the delay amount is the smallest, according to the reward calculated by the reward calculation unit 4421. For example, in the case of Q-learning, it is used as a function for calculating the (1) Action value function formula Q (s _t, a _t).

In the present embodiment, the case where reinforcement learning is applied to the learning algorithm used by the learning unit 442 has been described, but the present invention is not limited to this. As for the learning algorithm, in addition to reinforcement learning, supervised learning, unsupervised learning, semi-supervised learning, and the like can also be applied.

Further, as the learning algorithm described above, deep learning, which learns the extraction of the feature amount itself, can also be used, and other known methods such as neural networks, genetic programming, functional logic programming, and support vectors can be used. Machine learning may be executed according to the machine or the like.

The learning engine unit 44 is used to learn the production planning information that minimizes the delay amount of the scheduler system 1. For example, the learning engine unit 44 is connected to the scheduler system 1 via a network, and is referred to as the scheduler system 1. It may be a separate device. Further, the learning engine unit 44 may be built in the scheduler system 1. Further, the learning engine unit 44 may exist on the cloud server.

Further, the learning unit 442 may learn the production planning information having the smallest delay amount according to the data sets created for the plurality of scheduler systems 1. The learning unit 442 may acquire data sets from a plurality of scheduler systems 1 used at the same site, or data sets collected from a plurality of machine tools operating independently at different sites. You may use to learn the production planning information that minimizes the delay amount. Further, the scheduler system 1 that collects the data set can be added to the target on the way, or conversely, can be removed from the target. Further, the learning engine unit 44 that has learned the production planning information that has the smallest delay amount for a certain scheduler system 1 is attached to another scheduler system 1, and the production that has the smallest delay amount for the other scheduler system 1 is attached. The plan information may be relearned and updated.

The scheduler management device 4 may have a detachable configuration between the MES 2 and the production scheduler 3. As a result, the scheduler management device 4 can select the MES2 or the production scheduler 3 according to the user's request, and can add a function to improve the planning accuracy of the production plan information to the selected production scheduler 3.

Next, a method of recreating the production plan information in the scheduler system 1 will be described. FIG. 5 is a flowchart showing an example of a procedure of a method of recreating production planning information in the scheduler system according to the first embodiment.

First, the data input / output unit 422 of the scheduler management device 4 acquires the monitored data 411 from the outside based on the monitored table 421 at a predetermined cycle (step S11). Next, the data input / output unit 422 saves the acquired monitored data 411 in the scheduler database 41 (step S12).

Next, the replanning event monitoring unit 4311 of the event monitoring unit 431 acquires the monitored data 411 and the latest replanning condition 412 from the scheduler database 41 at predetermined intervals (step S13). After that, the replanning event monitoring unit 4311 determines whether or not the monitored data 411 meets the replanning condition 412 (step S14). The determination result is output to the replanning activation unit 4312 and the scheduler database 41 as the determination result information. The scheduler database 41 stores the acquired determination result information in the item of the replanning determination result 413.

If the monitored data 411 does not meet the replanning condition 412 (No in step S14), the replanning event monitoring unit 4311 notifies the replanning activation unit that it is not necessary to recreate the production plan information. Notifying 4312 (step S15), the process returns to step S11.

If the monitored data 411 meets the replanning condition 412 (Yes in step S14), the replanning event monitoring unit 4311 indicates that the production plan information needs to be recreated. (Step S16).

Upon receiving the notification that the re-creation is necessary, the re-planning activation unit 4312 activates the re-planning unit 432 (step S17), and the re-planning rule execution unit 4321 of the re-planning unit 432 executes the re-planning rule 414. (Step S18). After executing all the replanning rules 414, the replanning rule execution unit 4321 notifies the scheduler environment update unit 4322 that all the replanning rules 414 have been executed (step S19).

Subsequently, the scheduler environment update unit 4322 instructs the plan information acquisition unit 42 to update the data corresponding to the transaction information among the items in the data table 32 of the production scheduler 3 (step S20). Further, when the item of the data table 32 of the production scheduler 3 does not match the item of the monitoring target table 421, the scheduler environment update unit 4322 monitors the item of the data table 32 with respect to the plan information acquisition unit 42. Instruct to match the items in Table 421 (step S21). Then, the plan information acquisition unit 42 updates the data table 32 of the production scheduler 3 (step S22). After the update process of the data table 32 is completed, the scheduler environment update unit 4322 notifies the reschedule start unit 4323 that the update process of the data table 32 is completed (step S23).

The reschedule activation unit 4323 activates the reschedule unit 423 of the plan information acquisition unit 42 (step S24). The reschedule unit 423 transmits an instruction to cause the production scheduler 3 to recreate the production plan information (step S25). As a result, the production scheduler 3 recreates the production plan information and transmits the result to the scheduler management device 4.

The plan information acquisition unit 42 acquires the production plan information recreated from the production scheduler 3 and transmits it to the replanning result confirmation unit 433 (step S26). The replanning result confirmation unit 433 extracts the points changed by the re-creation from the received production planning information and displays them on the display unit to the user (step S27). This completes the process.

In the above description, the case where the scheduler management device 4 and the production scheduler 3 are provided separately has been described, but the production scheduler 3 may include the functions of the scheduler management device 4 described above. FIG. 6 is a block diagram schematically showing another example of the configuration of the scheduler system according to the first embodiment. Those having the same functions as those in FIG. 1 are designated by the same reference numerals, and the description thereof will be omitted.

As described above, the production scheduler 3 has the function of the scheduler management device 4. The production scheduler 3 includes a data acquisition unit 31, a data table 32, a production plan creation unit 33, a scheduler database 341, a plan information acquisition unit 342, a replanning execution unit 343, a learning engine unit 344, an information system I / F unit 345, and manufacturing. The site I / F unit 346 and the MES I / F unit 348 are provided.

The scheduler database 341, the plan information acquisition unit 342, the replanning execution unit 343, the learning engine unit 344, the information system I / F unit 345, the manufacturing site I / F unit 346, and the MES I / F unit 348 are the scheduler management in FIG. Corresponds to the scheduler database 41 of the device 4, the plan information acquisition unit 42, the replanning execution unit 43, the learning engine unit 44, the information system I / F unit 45, the manufacturing site I / F unit 46, and the MES I / F unit 48, respectively. ing. Therefore, the description of these processing units will be omitted.

FIG. 7 is a block diagram schematically showing an example of the hardware configuration of the scheduler management device according to the first embodiment. The scheduler management device 4 is a connection interface between a processor 210 that executes various processes, a memory 220 that stores information, an input unit 230 that inputs information according to an operation by a user, and an external device of the scheduler management device 4. It is composed of a computer including a communication unit 240 and a display unit 250 for displaying information. The processor 210, the memory 220, the input unit 230, the communication unit 240, and the display unit 250 are connected by a bus line 260.

An example of the processor 210 is a CPU (Central Processing Unit, a central processing unit, a processing unit, an arithmetic unit, a microprocessor, a microcomputer, a processor, a DSP (Digital Signal Processor)) or a system LSI (Large Scale Integration). The memory 220 includes a RAM (Random Access Memory), a ROM (Read Only Memory), or an external storage device. The RAM is loaded with a replanning program that describes the procedure for recreating production planning information executed by the processor 210, and data used by the processor 210 is temporarily held. The ROM stores a BIOS (Basic Input / Output System) or UEFI (Unified Extensible Firmware Interface), which is a program for basic control of a computer which is a scheduler management device 4. The external storage device is an HDD (Hard Disk Drive) or an SSD (Solid State Drive). The replanning program and various data are stored in the external storage device. The replanning program may be stored in the ROM.

The programs stored in the ROM and the external storage device are loaded into the RAM. The processor 210 loads the replanning program into the RAM and executes various processes. In the first embodiment, the processor 210 realizes the functions of the processing units of the planning information acquisition unit 42, the replanning execution unit 43, and the learning engine unit 44 by executing the replanning program.

The replanning program may be stored on a computer-readable storage medium. The scheduler management device 4 may store the replanning program stored in the storage medium in the external storage device. The storage medium may be a portable storage medium that is a flexible disk, or a flash memory that is a semiconductor memory. The replanning program may be installed from another computer or server device to the computer to be the scheduler management device 4 via the network.

In the first embodiment, the monitoring target table 421 that defines the data to be monitored by the scheduler management device 4 and the data table 32 that shows the data used when the production planning information is recreated by the production scheduler 3 are linked. I did. When the production plan information is recreated, if the items in the data table 32 of the production scheduler 3 do not match the items in the monitored table 421 of the scheduler management device 4, the scheduler management device 4 sets the data of the production scheduler 3. After matching the items in the table 32 with the items in the monitored table 421, an instruction to recreate the production planning information is issued. As a result, even if the data that causes the production plan information to be recreated is the data that is not set to be acquired by the production scheduler 3, the production scheduler 3 can generate the data that causes the production plan information to be recreated. Can be obtained. As a result, it has the effect of being able to recreate effective production planning information that reflects the cause of replanning, that is, the cause of delay.

In addition, the production plan information is obtained by monitoring the monitored data 411 in real time, immediately recognizing the occurrence of the replanning condition 412, and executing the replanning rule 414 defined in association with the replanning condition 412. Can be automated to recreate. Furthermore, when recreating the production plan information, the production plan information is recreated after acquiring the plan creation information from other equipment, etc., so that the production plan information is highly accurate based on the latest plan creation information. Can be created.

The configuration shown in the above embodiment is an example, and can be combined with another known technique, or a part of the configuration may be omitted or changed without departing from the gist. It is possible.

1 scheduler system, 2 MES, 3 production scheduler, 4 scheduler management device, 31 data acquisition unit, 32 data table, 33 production plan creation unit, 41,341 scheduler database, 42,342 plan information acquisition unit, 43,343 replanning Execution section, 44,344 Learning engine section, 45,345 Information system I / F section, 46,346 Manufacturing site I / F section, 47 Production scheduler I / F section, 48,348 MES I / F section, 50 Information management System, 60 FA equipment, 70 Data collection platform, 411 Monitoring target data, 412 Replanning conditions, 413 Replanning judgment result, 414 Replanning rule, 415 Actual data, 421 Monitoring target table, 422 Data input / output unit, 423 Rescheduling Department, 431 Event Monitoring Department, 432 Replanning Department, 433 Replanning Result Confirmation Department, 441 Status Observation Department, 442 Learning Department, 4311 Replanning Event Monitoring Department, 4312 Replanning Starter Department, 4321 Replanning Rule Execution Department, 4322 Scheduler Environment update part, 4323 reschedule start part, 4421 reward calculation part, 4422 function update part.

Claims (13)

A production scheduler that creates first production plan information that shows production plans for multiple orders,
Among the first production plan information created by the production scheduler, the contents of the production plan corresponding to the order managed by oneself are received, and the production corresponding to a plurality of processes is performed based on the received contents of the production plan. A manufacturing execution system that executes production in the equipment,
A scheduler management device that instructs the production scheduler to recreate the first production plan information,
With
The scheduler management device
Acquiring monitored data, which is data for monitoring the occurrence of an event that requires re-creation of the first production plan information after the creation of the first production plan information, from another device connected to the scheduler management device. Planning information acquisition department and
The presence or absence of the event is detected using the monitored data, and when the event occurs, additional information other than the plan creation information, which is the information used for creating the first production plan information. And the replanning execution unit that instructs the production scheduler to acquire the planning creation information.
Have,
The event is one or more of a failure of a manufacturing facility, which is a facility including the manufacturing device, a sign of a failure of the manufacturing facility, a delay in delivery of materials, and a deterioration in the quality of products manufactured by the manufacturing facility.
The additional information is the monitored data used to monitor the occurrence of the event.
After instructing the production scheduler to acquire the additional information and the plan creation information, the plan information acquisition unit uses the acquired additional information and the plan creation information to cause the order to span the plurality of steps. A scheduler system characterized in that the production scheduler is instructed to recreate the second production plan information. The production scheduler has data storage information for storing information to be acquired used for creating the first production plan information.
The plan information acquisition unit of the scheduler management device acquires the monitoring target data from the other device based on the monitoring target table that defines the monitoring target data which is the data to be monitored.
The replanning execution unit of the scheduler management device determines whether the monitored data satisfies the replanning condition, which is a predetermined condition that requires replanning, and if replanning is required, the data. The data storage information item is updated so that the storage information item matches the monitoring target table item.
The scheduler according to claim 1, wherein the plan information acquisition unit of the scheduler management device instructs the production scheduler to recreate the second production plan information when replanning is required. system. The replanning execution unit extracts the changed part of the second production plan information acquired from the production scheduler with respect to the first production plan information before re-creation, and the second production plan information with respect to the first production plan information. The scheduler system according to claim 2, wherein the changed portion of the above is displayed on the display unit. The scheduler management device is characterized by including a learning engine unit that learns a delay amount of the first production plan information that has occurred in the past and reflects the learning result in recreating the second production plan information. The scheduler system according to any one of items 1 to 3. The learning engine unit
A state observation unit that observes the second production plan information, the delay cause of the first production plan information, and the delay amount of the second production plan information with respect to the first production plan information as state variables.
A learning unit that machine-learns the third production plan information that minimizes the delay amount according to the data set created based on the state variables.
The scheduler system according to claim 4, wherein the scheduler system comprises. The scheduler system according to any one of claims 1 to 5, wherein the scheduler management device is detachably configured between the manufacturing execution system and the production scheduler. A production scheduler that creates first production plan information that shows production plans for multiple orders,
Among the first production plan information created by the production scheduler, the contents of the production plan corresponding to the order managed by oneself are received, and the production corresponding to a plurality of processes is performed based on the received contents of the production plan. A manufacturing execution system that executes production in the equipment,
With
The production scheduler
A data acquisition unit that acquires planning creation information, which is information used for creating the first production planning information, and a data acquisition unit.
Using the acquired plan creation information, the production plan creation unit in which the order creates the first production plan information straddling the plurality of processes, and
Acquiring monitored data, which is data for monitoring the occurrence of an event that requires re-creation of the first production plan information after the creation of the first production plan information, from another device connected to the production scheduler. Planning information acquisition department and
The presence or absence of the event is detected using the monitored data, and when the event occurs, the plan creation information and the plan creation information used by the order to create the second production plan information straddling the plurality of processes. A replanning execution unit that gives an instruction to acquire additional information other than planning information to the data acquisition unit, and
Have,
The event is one or more of a failure of a manufacturing facility, which is a facility including the manufacturing device, a sign of a failure of the manufacturing facility, a delay in delivery of materials, and a deterioration in the quality of products manufactured by the manufacturing facility.
The additional information is the monitored data used to monitor the occurrence of the event.
Upon receiving the instruction from the replanning execution unit, the data acquisition unit acquires the plan creation information and the additional information.
The production plan creation unit is a scheduler system characterized in that the second production plan information is recreated by using the acquired plan creation information and the additional information. The production scheduler further includes a learning engine unit that learns the delay amount of the first production plan information that has occurred in the past and reflects the learning result in the re-creation of the second production plan information. Item 7. The scheduler system according to Item 7. The learning engine unit
A state observation unit that observes the second production plan information, the delay cause of the first production plan information, and the delay amount of the second production plan information with respect to the first production plan information as state variables.
A learning unit that machine-learns the third production plan information that minimizes the delay amount according to the data set created based on the state variables.
8. The scheduler system according to claim 8. A scheduler management device that instructs a production scheduler that creates production plan information indicating production plans of a plurality of orders to recreate the production plan information.
Acquire monitoring target data, which is data for monitoring the occurrence of an event that requires re-creation of the first production plan information after the creation of the first production plan information, from another device connected to the scheduler management device. Planning information acquisition department and
The presence or absence of the event is detected using the monitored data, and when the event occurs, additional information other than the plan creation information, which is the information used for creating the first production plan information. And the replanning execution unit that instructs the production scheduler to acquire the planning creation information.
Have,
The event is one or more of a failure of the manufacturing equipment, a sign of the failure of the manufacturing equipment, a delay in delivery of materials, and a deterioration in the quality of products manufactured by the manufacturing equipment.
The additional information is the monitored data used to monitor the occurrence of the event.
After instructing the production scheduler, the plan information acquisition unit uses the acquired additional information and the plan creation information to regenerate the second production plan information for the production scheduler in which the order spans a plurality of processes. A scheduler management device characterized by instructing creation. The plan information acquisition unit acquires the monitoring target data from the other device based on the monitoring target table that defines the monitoring target data which is the data to be monitored.
The replanning execution unit determines whether the monitored data satisfies the replanning condition, which is a predetermined condition that requires replanning, and if replanning is necessary, the production scheduler has. The item of the data storage information is updated so that the item of the data storage information for storing the information to be acquired used for creating the second production plan information matches the item of the monitoring target table.
When replanning is required, the plan information acquisition unit instructs the production scheduler to recreate the first production plan information after updating the item of the data storage information. Item 10. The scheduler management device according to Item 10. The tenth or eleventh aspect of claim 10 or 11, further comprising a learning engine unit that learns the delay amount of the first production plan information that has occurred in the past and reflects the learning result in the re-creation of the second production plan information. Described scheduler management device. When a predetermined event occurs after creating the first production plan information indicating the production plans of a plurality of orders, the information other than the plan creation information which is the information used for creating the first production plan information is used. A certain additional information is acquired from another device connected to the scheduler system together with the plan creation information, and the second production plan information in which the order spans a plurality of processes is re-used by using the acquired additional information and the plan creation information. A machine learning device for machine learning the third production plan information in which the delay amount of the second production plan information with respect to the first production plan information is the smallest in the scheduler system to be created.
A state observing unit that observes the second production plan information, the delay cause of the first production plan information, and the delay amount as state variables.
A learning unit that machine-learns the third production plan information that minimizes the delay amount according to the data set created based on the state variables.
Equipped with a,
The event is one or more of a failure of the manufacturing equipment, a sign of the failure of the manufacturing equipment, a delay in delivery of materials, and a deterioration in the quality of products manufactured by the manufacturing equipment.
The additional information, machine learning device according to claim Oh Rukoto with data used to monitor the occurrence of the event.

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