JP2816505B2 - Production management system in the steel industry - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention uses a computer to manage a process of producing a material by knitting a material unit according to an order, performing various processes on the material, and collecting a final product. The present invention relates to a production management system for the steel industry.

[0002]

2. Description of the Related Art Conventionally, a steel material manufacturer has adopted an order-made production system for the production of steel materials. That is, when an order is received from a customer, the production line is instructed to produce steel according to the order, and the production line manufactures and processes the material (slab) based on the instruction.
In the final step, a predetermined quantity of a product of a kind and weight that can satisfy the customer's order is collected and delivered to the customer by a predetermined delivery date. In this case, production management includes efficiency of office work,
Computers are used from the viewpoint of reliability to ensure that products according to orders can be delivered to customers by a predetermined delivery date.

[0003]

However, the above-mentioned conventional production management method has the following problems. In other words, if there is an order from the customer first,
The order information is input to the computer, and the production line is instructed to produce steel according to the order, and the production line starts producing steel according to the instruction. In this case, the order from the customer usually has a total order quantity of, for example, 1
The weight (single weight) of each delivered product is, for example, 11 to 9 to 24 tons.
The specification is made such as t to 18t. However, conventionally, when such an order has been placed, the production unit is knitted in a material unit of 20 t corresponding to the total order amount of 19 t to 24 t, and the process is shifted to the production of the material. When collecting 11t products that can be used, only 11t products and 9t products can be collected from 20t materials, and 9t products cannot be delivered to customers due to the removal of single weight, so to satisfy the remaining orders 11
t had to be remanufactured. Such a situation is also caused by fluctuations in the actual weight such as fluctuations in the weight of the material occurring in each manufacturing process and occurrence of defective products. The occurrence of such unordered products reduces the manufacturing efficiency of ordered products. When remanufacturing the product (reclaiming), a surplus of, for example, 5 t (surplus in a material unit) is added in consideration of a loss in the manufacturing process, and the like.
Since the material unit knitting of 16t is performed, a large number of unordered products are generated in the final process due to the surplus, and the production efficiency of the ordered products is poor.

[0004] Furthermore, if the material unit knitting (re-billing) is performed again, the production of the remaining 11 tons of the order is greatly delayed, and the scheduled completion date (delivery date) of the ordered product is delayed. there were.

Accordingly, an object of the present invention is to provide a production management system in the steel industry, which can reliably collect all of ordered products without generating a single weight in the final step.

[0006]

SUMMARY OF THE INVENTION In order to achieve the above object, the present invention relates to a production management system for a steel industry in which production management from knitting of a material unit to collection of steel products in a final process is performed using a computer. Order information storage means for storing order information including information on an order quantity and an allowable unit weight range of an ordered product; material weight variation information on a material weight variation occurring in a product manufacturing process; and a material unit which can be manufactured in the product manufacturing process. Constraint information acquiring means for acquiring constraint information including at least one of the material information relating to unit weight, and the order quantity information, allowable unit weight range information of the ordered product, and the constraint condition information acquiring means. Product and material unit based on the
Of the difference between the target value and the maximum allowable unit weight at
Of the product and material unit that minimizes the evaluation value
An optimal unit weight determining means for determining the unit weight of the material unit and the unit weight of the product to be collected in the final step, which can satisfy the order without using the uniting pattern in the final step without causing the unit weight to deviate in the final step. And a unit weight information storage unit that stores the material unit weight and the product unit weight determined by the optimum unit weight determination unit in association with each order.

[0007]

According to the present invention, constraints such as material weight fluctuations in the product manufacturing process and the size (single weight) of material units that can be manufactured in each factory, and the allowable unit weight range of products to be delivered to customers. In consideration of the above, the unit weight of the material unit to be manufactured and the unit weight of the product to be collected in the final step are determined, and each unit weight is stored in the unit weight information storage unit in association with the order. Therefore,
If the material unit knitting is performed based on the stored material unit weight information and the final product is collected based on the stored product unit weight information, the unit weight in the final process will not be lost.

[0008]

Embodiments of the present invention will be described below with reference to the drawings. FIG. 1 is a block diagram showing one configuration example of a production management system in the steel industry to which the present invention is applied. Production line 1
Is a facility for performing the process from tapping to shipping of a steel material, and includes each manufacturing process such as slab production, rolling, and winding.

The order input unit 2 is for inputting an order from a customer. For example, customer information, a type of a product to be ordered, an order quantity, an allowable unit weight range of the ordered product via a keyboard or the like. , Delivery date information, and the like. The permissible unit weight range of the ordered product is the weight range per product specified by the orderer at the time of ordering. At the time of customer delivery, the total weight of the delivered product must satisfy the order quantity and The weight must be within this specified weight range.

[0010] The performance taking-in section 3 relates to various constraint conditions in manufacturing a product such as a range of slab weight (single slab weight) per one manufacturable in the production line 1, a weight variation in each process, a manufacturing error, and the like. The information and the information such as the production status of the product in each production process of the production line 1 are fetched, and the fetched information is sent to the data processing unit 5.

The work instructing section 4 sends information for instructing a predetermined work to the production line 1 based on the information obtained from the data processing section 5.

The data processing unit 5 comprises, for example, a CPU,
Various data processing is executed according to the program stored in the program memory 6.

The display unit 7 comprises, for example, a CRT and is controlled by the data processing unit 5 to display various information.

The order data storage memory 8 includes an order input unit 2
The order information input via the server is sequentially accumulated, and an order management database is constructed.

The various table storage memories 9 include an order information table described later, a product unit weight range table for each pattern,
Various tables such as a product single weight evaluation table are stored.

The product progress management memory 10 stores a material unit weight and a product weight determined by a product unit weight determination process, which will be described later, in a correspondence relationship with each order. The production of the steel material in the production line 1 is controlled based on the information on the unit weight thus received, and the order is processed reliably.

FIG. 5 is a diagram for explaining an outline of the material unit weight and product weight determination processing executed by the data processing unit 5.

In FIG. 1, if there is an order T1 having an order quantity of 19 to 24 t and a product unit weight of 11 to 18 t, the order information and the constraint condition information taken from the production line 1 through the performance taking section 3 are shown. Based on this, the unit weight of the material unit manufactured to process the order T1 and the unit weight of the product to be collected in the final step are determined. The constraint information used here is information such as the slab single weight range that can be manufactured on the production line 1 and the weight variation in the intermediate process. When determining the unit weight, the optimum unit weight that can satisfy the order T1 is obtained by data processing such as calculation under the imported constraint conditions. Here, the optimum unit weight that can satisfy the order is, in the case of the product unit weight, the unit weight is the unit weight range according to the order, that is, 11 to 18 t.
The order quantity 19 to 24 t can be satisfied by delivering as few products as possible, and the total weight of the delivered product is as close as possible to the order quantity 19 to 24 t . In the case of single unit weight of the material unit (slab), it is possible to extract the product of the optimum single unit weight as described above so that the capacity of the equipment is maximized and the most reasonable and single unit weight is not deviated. It is such a simple weight.

In this example, it is assumed here that the unit weight of the product collected in the final step is determined to be 11 t, and the unit weight of the material unit (slab) manufactured for collecting the product is determined to be 22 t. This determination result is stored in the product progress management database (memory 10) in a correspondence relationship with the order T1, and production is managed based on the information in this database. That is, when knitting the material unit for processing the order T1, the knitting is performed by knitting the material unit having the unit weight of 22t, and two products having the unit weight of 11t are collected from the material in the final process. Delivered to customer.

By performing such production control, knitting of material units is performed in consideration of the order quantity, the unit weight of the product collected in the final process, the production capacity of the manufacturing equipment, and the like. Can reliably and rationally collect the required number of single weight products within the single weight range required by the customer. Therefore, it is possible to prevent the occurrence of a product that is out of unit weight in the final process and to prevent re-billing (re-manufacturing of ordered products) based on that. Since it is possible to prevent the production of unordered products in the final process caused by the surplus part given, the production efficiency of ordered products is increased, and the re-invoicing is eliminated, and the in-season production achievement rate is reduced. Improvement can be achieved.

Next, a data processing procedure in the data processing unit 5 for executing the above-described material unit single weight and product single weight determination processing will be described with reference to FIGS. This data processing is executed when an additional order is input from the order input unit 2.
It may be executed at an appropriate time according to the instruction of the operator.

First, as shown in FIG.
Fetches order information from the order data storage memory 8 and creates an order information table 20 shown in FIG. In this table 20, each order (order management No.
In each case, the information on the unit weight of the ordered product and the order quantity are written, and the information on the unit weight of the slab that can be manufactured on the production line 1 is written as a constraint. The order amount information includes information on the order amount (20t) from the customer, the maximum value MAX (24t) indicating the allowable range, and the minimum value MIN (19t). The product unit weight information includes information of a maximum value MAX (18t) and a minimum value MIN (11t) indicating the unit weight range (permissible unit weight range) of each product that the customer wants to deliver. Further, the slab unit weight information is a maximum value M indicating the unit weight range of the slab that can be manufactured in the production line 1.
AX (25t) and minimum value MIN (11t).

After completing the creation of this table,
The processing shifts to the creation processing of the pattern-specific product single weight range table 30 shown in FIG. In this process, the number of products to be delivered (see the order column of the combination pattern item) and the number of products to be incorporated in one slab (see the slab column of the combination pattern item)
The maximum value MAX and the minimum value MIN of the unit weight of the product determined from the unit weight of the product in the slab and the order quantity in each combination are calculated based on the above order information for each combination of In the individual product unit weight item slab and order column, the maximum value MAX and the minimum value MIN of the product unit weight for each pattern are determined based on the calculation result,
The data is written in the product single weight column for each pattern in the table 30.

The maximum and minimum values written in the slab column of the individual product single weight item are values obtained by dividing the maximum and minimum values of the slab single weight in the order information by the number of products to be incorporated into one slab of the combination pattern. At this time, if the value obtained as a result of this calculation does not fall within the allowable unit weight range, the maximum value and the minimum value indicating the allowable unit weight range are written as the maximum value and the minimum value.

The maximum and minimum values written in the order column of the individual product single weight item are values obtained by dividing the maximum and minimum values of the order quantity information by the number of products to be delivered in the combination pattern.
Also in this case, if the value obtained as a result of this operation does not fall within the allowable unit weight range, the maximum value and the minimum value indicating the allowable unit weight range are written as the maximum value and the minimum value.

Regarding the maximum and minimum values of the product weight per pattern, the smallest value among the maximum values of the individual product weights determined as described above is taken as the maximum value. The largest value among the minimum values is the minimum value. Then, if the maximum value MAX and the minimum value MIN of the product weight by pattern are MAX, product weight by pattern MAX ≧ product weight by pattern MIN, it is determined that the pattern is selectable. The data processing unit 5 performs such a process for all the combination patterns, extracts all the patterns that can be combined, and shifts to the next optimal product single weight determination process. In this process,
A product weight evaluation table 40 as shown in FIG. 4 is created,
The optimum product single weight is determined based on the evaluation table 40.

The product single weight evaluation table 40 is created for a pattern determined to be selectable by the above processing. When creating this table 40, first,
The maximum and minimum values of the slab unit weight for each pattern are obtained based on the maximum and minimum values of the product unit weight for each pattern obtained in the above processing, and are written in the slab single unit weight for each pattern of this table 40. That is, the maximum and minimum values of the product weight of each pattern are multiplied by the number of products to be incorporated in one slab of the combination pattern to obtain the maximum and minimum values of the slab single weight of each combination. Next, using the maximum value MAX and the minimum value MIN of the slab unit weight for each pattern obtained in this manner, the calculation of 3- (MAX-MIN) is performed to obtain the slab unit weight evaluation value. Where
"3" in the equation is the variation of the material weight obtained statistically in advance.
Shows the median (median) of (material weight fluctuation)
You. Also, "MAX-MIN" in the above equation is
Indicates the allowable range. That is, "MAX-MIN"
The small value of
Means a high probability of being out of the heavy tolerance range,
Conversely, being large means that even if there is a certain material weight fluctuation
Meaning that the probability of falling within the allowable range of product weight is high
I have. The overall evaluation value described later is obtained by the above equation.
Is obtained by adding the unfavorable value of the slab unit weight evaluation value.
Therefore, it is preferable that the total evaluation value is large.
In the above expression, "-(MAX-
MIN) ”is the difference from the above“ 3 ”.
Thus, the slab unit weight evaluation value obtained by the above equation is
By including it in the overall evaluation value,
The optimal unit weight is determined.

Next, the maximum and minimum values of the product weight per pattern are multiplied by the number of products to be delivered in the combination pattern to obtain the maximum and minimum values of the total weight of the ordered products of each combination. Write to. Then, of the maximum value and the minimum value obtained in this way, the value closer to the target of the order quantity (20t in this example) is set as the representative order quantity in Table 4.
Write to 0. Then, the representative order quantity is divided by the number of products to be delivered in the combination pattern to obtain a representative product unit weight, and then the representative product unit weight is multiplied by the number of products to be incorporated in one slab of the combination pattern to obtain a representative slab unit weight. Next, a deviation value is obtained for each of the product and the slab. In the case of a product, this deviation value is a value obtained by subtracting the representative product unit weight from the maximum value of the product unit weight pertaining to the order. In the case of a slab, it is a value obtained by subtracting the representative slab unit weight from the maximum value of the slab unit weight that can be manufactured in the production line 1. The number of representative products indicates the number of products and the number of slabs required to process an order in each combination pattern, where the number of representative products is the number of products delivered for the combination pattern, and the number of representative slabs is the number of products. Divided by the number of products incorporated in the slab.

Next, an overall evaluation value is obtained by the following equation using the values thus obtained. Comprehensive evaluation value = (product divergence value x number of representative products) + (slab divergence value x representative number of slabs) + single weight evaluation value of slab This comprehensive evaluation value is a value obtained by adding an undesirable value. The smaller the overall evaluation value, the better. Therefore, in the example of FIG. 4, the combination pattern (order 2-slab 2) in the lower column is preferable, and the adoption of this pattern is determined. That is, the pattern adopted here is such that two products having a slab single weight of 22t and a product single weight of 11t are taken from one slab and delivered to the customer (combination pattern, representative product single weight). , Representative slab single weight section).

When the pattern to be adopted is determined as described above, the process proceeds to the next data editing / updating process, in which the data of the adopted pattern is edited and the edited data is stored in the product progress management memory 10. Writing is performed. At the time of writing data to the product progress management memory 10, each data of the adopted pattern including information on the determined slab unit weight and product unit weight is stored in the order management NO. Is stored in association with Therefore, based on the data stored in the product progress management memory 10, if the knitting of the material unit and the sampling of the product in the final process are performed, the product which can satisfy the customer's order without generating the unit weight is surely produced. Delivery can be made.

Although an embodiment of the present invention has been described above, the present invention is not limited to the above-described embodiment, and various effective modifications can be made based on the technical idea of the present invention. For example, as the constraint condition information, not only the information on the slab single-weight range that can be manufactured in the production line 1 but also information such as manufacturing errors and material weight fluctuations in each manufacturing process may be used. Further, by the data processing in the data processing unit 5, not only the collected product single weight and the slab single weight in the final step, but also various types of material single weights such as coils may be simultaneously obtained. Further, the unit weight of the slab and the unit weight of the product determined as described above may be stored in dedicated memories for process management.

[0032]

As described above, according to the present invention, based on order quantity information, allowable unit weight range information of ordered products, material weight fluctuation information, and constraint information including material information, product and product information are obtained.
And the deviation for each material unit is converted into an evaluation value.
Combined putter of product and material unit to minimize
By adopting the emissions, and the material unit unit weight and products unit weight as can be satisfied orders without causing the unit weight out in the final step Ru it is determined by the optimum unit weight determining means
Therefore, if the knitting of the material unit and the sampling of the final steel product are performed based on the decision, the sampling of the ordered product can be reliably performed without generating a single weight deviation in the final process of the steel product manufacturing. . Therefore, it is possible to prevent the occurrence of unordered products and the occurrence of re-billing due to deviation from the unit weight, thereby increasing the production efficiency of ordered products,
Delivery time can be ensured.

[Brief description of the drawings]

FIG. 1 is a block diagram showing a configuration example of a production management system in the steel industry to which the present invention is applied.

FIG. 2 is a diagram for explaining an order information table.

FIG. 3 is a diagram for explaining a product single weight range table by pattern.

FIG. 4 is a diagram for explaining a product single weight evaluation table.

FIG. 5 is a diagram for explaining an outline of a unit weight determination process.

FIG. 6 is a flowchart illustrating a processing procedure of a unit weight determination process executed in the data processing unit.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Production line 2 Order input part 3 Result taking part 4 Work instruction part 5 Data processing part 6 Program memory 8 Order data storage memory 9 Various table storage memory 10 Product progress management memory 20 Order information table 30 Product single weight range by pattern Table 40 Product single weight evaluation table

──────────────────────────────────────────────────の Continued on the front page (72) Inventor Kentaro Ikeda 1 Kimitsu, Kimitsu City Nippon Steel Information and Communication System Co., Ltd. Kimitsu Branch Office (72) Inventor Mutsumi Yamada 1 Kimitsu, Kimitsu City Nippon Steel Corporation Kimitsu Steel Corporation In-house (72) Inventor Kazuki Kakimi 1 Kimitsu, Kimitsu-shi Nippon Steel Corporation Kimitsu Works (56) References JP-A-3-117542 (JP, A) JP-A 3-161250 (JP, A) JP-A-61-17347 (JP, A) JP-A-59-116510 (JP, A) (58) Fields investigated (Int. Cl. ⁶ , DB name) G05B 15/02 C21B 5/00 310 G06F 17/60

Claims (2)

(57) [Claims] 1. A production management system in the iron and steel industry that uses a computer to control production from knitting of a material unit to collection of a steel product in a final step, wherein an order including information on an order quantity and an allowable unit weight range of the ordered product. Order information storage means for storing information; constraint conditions including at least one of material weight variation information relating to material weight variation occurring in the product manufacturing process and material information relating to unit weight of a material unit that can be manufactured in the product manufacturing process. A constraint value information acquiring means for acquiring information ; a target value in a product and a material unit based on the order amount information, the allowable unit weight range information of the ordered product, and the constraint information acquired by the constraint information acquiring means. And allowable unit weight
The deviation from the maximum value of the
Adopt a combination pattern of products and material units
In this way, the optimum unit weight determining means for determining the unit weight of the material unit and the unit weight of the product to be collected in the final step, which can satisfy the order without generating the unit weight in the final step, A production management system in the steel industry, comprising: a unit weight information storage unit that stores the material unit weight and the product weight determined by the weight determination unit in association with each order. 2. The method according to claim 1, wherein the optimal unit weight determining means simultaneously determines the number of steel products to be collected from one material unit and the total number of steel products to be delivered to a customer.
The production management system of the stated steel industry.