JPH11267951A - Production plan forming system of single continuous manufacturing process and production plan forming method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To prevent the bias of a manufacturing load and also properly keep the stock without being late for the appointed date of delivery by providing a second correcting means for transforming, to the production plan of the day discriminated by a second discriminating means, a part of the production plane of the day after this day to correct the production plan of the discriminated day. SOLUTION: A second discrimination part 24 retrieves the production plan corrected by a first correction part 23, and discriminates the day of the production plan not satisfying the operation time of one day. Since a prescribed operation time of one day is 24 hours, the first day is discriminated in the production period. The period to be retrieved is generally conformed to the target period of production plan formation. A second correction part 25 corrects the production plan corrected by the first correction part 23 by transferring at least a part of the production plan of the day after the day of the production plan discriminated by a second discrimination part 24 to this day. Since the first day is discriminated by the second discrimination part 24, the day after the first day, or two rots of the second day herein are moved to the first day.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a production planning system and a production planning method for a single-line manufacturing process in the manufacturing industry, in which products are continuously manufactured without stopping equipment for a certain period of time. About.

[0002]

2. Description of the Related Art A normal production plan creation method uses an arbitrary production plan creation rule prepared in advance for a shipment schedule having information on a product type, quantity, and a required date. It is done by the method of determining the expected production date for each. A production plan created in this way is suitable for a manufacturing process in which equipment can be stopped at any time.

[0003] However, in a manufacturing process in which a single line is required to continuously manufacture products without stopping the equipment for a certain period of time, the equipment is started up, operation is started, and then operation is continued for a certain period of time. There is a manufacturing constraint that products must be manufactured without interruption 24 hours a day until completed and the facilities are shut down. For example, in a process of manufacturing a copper wire, copper melted in a furnace is continuously flowed to equipment having a rolling mill to manufacture a copper wire. In this step,
For a certain period of time from when the furnace is turned on to when it is extinguished, multiple types and lots of copper wires must be continuously manufactured.

[0004] In such a case, if a production plan is created from a shipping schedule using only an arbitrary production plan creation rule prepared in advance, the following problem occurs. That is, since there is a variation in the normal shipping schedule, if the operation time per day of the equipment is set to the predetermined operation time, the production date may be less than the predetermined operation time as the time required for manufacturing. Since the process cannot be operated continuously, the facility must be stopped one day a day, and the facility cannot be used effectively. Conversely, in the production plan creation method based on only the production plan creation rules, there may be a scheduled production date in which the time required for manufacturing per day exceeds a predetermined operation time.

The above will be described with reference to FIG. Here, the vertical axis is the scale of the production time. Here, the predetermined operation time of one day is set to 24 hours, and the production time of each lot, which is a shipping unit, is displayed with a dividing line. The horizontal axis is the scale of the production date and the production period, and displays two production periods. Here, the “production period” indicates a unit of a period for performing a predetermined inventory adjustment. Therefore, it is necessary to continuously manufacture products until the production plan within the production period is completed.

[0006] It is assumed that a production plan is created based on a certain shipping schedule, and the result is as shown in FIG. In this case, in order to perform the continuous operation, if there is a production plan date that is shorter than the predetermined operation time of 24 hours, the production plan will be shifted by looking at the day immediately after that day one by one in order. In this example, two lots on the second day are moved to the first day because two lots are insufficient on the first day for 24 hours. The result is shown in FIG. By repeating this process until the twelfth day, which is the last day of production, a production plan as shown in FIG.
As in the production period 1, there is a production period in which the production plan fills the production capacity in the production process and the inventory amount has an appropriate amount or more, but as in the production period 2, the time during which the production process is stopped increases. A production period will also occur. This causes a bias in the manufacturing load of the process in one continuous manufacturing process, and causes a problem that it is not possible to maintain an appropriate stock.

[0007] As described above, in the conventional production planning method, the production schedule is maintained while maintaining an appropriate inventory for the production process in which a single line is continuously manufactured without stopping the equipment for a certain period of time. As a result, there were cases where products could not be manufactured efficiently, and cases where facilities could not be used effectively.

[0008]

SUMMARY OF THE INVENTION The present invention has been made to eliminate the above-mentioned disadvantages, and has as its object to reduce the production load in a single-line production process without delaying the delivery date. It is possible to continuously produce products without stopping the equipment until the production plan within the production period is completed without any bias and keeping the inventory properly and continuing production for a certain period of time. It is easy to create a production plan.

[0009]

In order to solve the above-mentioned problems, a system according to the present invention comprises: a shipping schedule table for storing a product shipping schedule; a production planning rule file for storing a production planning rule; Means for creating a production plan based on the information on the shipment schedule read from the table and the production plan rules read from the production plan rule file;
The first to identify the date of the production plan that exceeds the predetermined operating time of the day
Identification means; first correction means for correcting a part of the production plan on the day identified by the first identification means, the part exceeding the predetermined operating time, by moving the part to a day earlier than that day; Second identifying means for retrieving the identified production plan and identifying a date of the production plan shorter than the predetermined operation time, and a production plan of a day later than the production plan on the day identified by the second identification means. And second correcting means for correcting at least a part of the production plan to correct the production plan on the identified day.

In order to solve the above-mentioned problems, the method of the present invention comprises the steps of: preparing a shipping schedule table for storing a product shipping schedule and a production planning rule file for storing a production planning rule; Creating a production plan based on the information on the shipment schedule read from the production planning rule file read from the production planning rule file, and searching the production plan for exceeding a predetermined operating time of one day. Identifying the date of the production plan; correcting the production plan by moving a portion of the production plan on the identified day that exceeds the predetermined operating time to a date earlier than the date; Retrieving a production plan and identifying a date of the production plan that is less than the predetermined operation time; and To production planning day production plan transferred at least a portion of the production plan day after the day including the step of modifying the production plan of the date of the identified.

[0011]

DESCRIPTION OF THE PREFERRED EMBODIMENTS The production planning system in the single-line continuous manufacturing process of the present invention can be constituted by designing a table, a file, and a program on a small computer, a workstation, a personal computer, or the like. Although the present invention can be implemented by designing a dedicated hardware circuit, it is more advantageous to use a program in terms of flexibility in changing the design.

An embodiment for carrying out the present invention will be described with reference to FIG. The control unit 1 is a control unit including a processor of a computer, and is connected to an input unit 2 such as a keyboard and a mouse, and a display unit 3 including a CRT display, a liquid crystal display, and the like. The shipping schedule table 5, the production plan rule file 6, and the program file 7 are files stored in the large-capacity storage device 10. The storage device 10 is typically a hard disk device, but a magneto-optical storage device or another rewritable storage device can be used. Memory 9 is usually R
The processor of the control unit 1 loads a program from the program file 7 or stores the program in the storage device 10.
Is used when reading and calculating the contents.

The production planning unit 20 stores the program file 7
The program stored in the memory 9 via the control unit 1
And a functional unit configured on a computer. The production plan creation unit 21, the first identification unit 22, the first correction unit 23, the second identification unit 24, the second correction unit 25, and preferably the production plan display unit 27.

The shipping schedule table 5 includes a shipping amount field, a delivery date field, and a delivery date destination for each product type to be shipped. Information is stored in each field in advance, and is used when executing a production plan creation unit described later.

The production plan rule file 6 defines rules for creating a unique production plan prepared in advance for each product type, for example. For example, a production amount per unit time, a predetermined operation time per day of equipment, and an upper limit of stock amount can be defined for each production type. Further, a calendar such as a production start date and a production final date, a range of a production period, a holiday, and the like can be defined. The rules may be determined for each product type, or may be determined depending on the timing.

Next, an embodiment of creating a production plan in a single-line continuous manufacturing process according to the present invention will be described with reference to FIGS.

The operator selects a product type for which a production plan is to be created on the display unit 3. The selection is performed using the input unit 2 such as a keyboard and a mouse. In addition, the operator can display a field for setting a production start date, a production end date, a production period, and a holiday on the display unit 3 so as to select a production plan creation target period. When the operator selects a product type for which a production plan is to be created and clicks a start button with the mouse of the input unit 2, the production plan creation program stored in the program file 7 is activated, and the production plan creation work is started. I do.

In step 103 of FIG. 2, the production planning unit 21 of the production planning unit 20 uses the shipping schedule table 5 based on information on the type of product selected by the operator, such as the shipping quantity and delivery date of the product. Read information. Further, the production plan rule file 6 is read, and the production plan is created by applying the production plan rule to the previously read shipment schedule information. (A) of FIG.
An example of this production plan is shown in FIG.

The production plan display section 27 preferably formats the production plan created at this point in a chart format, and the control section 1 can display the formatted production plan on the display section 3. Further, the production plan creating section 21 can proceed to the next process without passing control to the production plan display section 27. In this case, the production plan result is not displayed on the display section 3.

In the example of FIG. 3A, the vertical axis is the production time scale. In this case, the predetermined operation time of the equipment is set to 24 hours, and the production time in lot units is inserted with a dividing line for easy viewing. ing. The horizontal axis is the scale of the production date and the production period, and is displayed for each production period in the range of the production start date and the production final date for easy viewing. This is because inventory adjustment is performed in production period units, and it is more convenient to display each production period. The number of production periods is determined in advance, and in this example, two production periods are displayed with five days as one production period. further,
When a calendar is defined in the production plan creation rule file 6 or another table, it is also possible to display specific dates on the horizontal axis. The operator can select to display only a certain production period in a limited manner. In this case, a selection button is displayed on the display unit 3 and clicked with the mouse of the input unit 2. After finishing step 103, the process proceeds to step 105.

In step 105 of FIG. 2, the first identification unit 22 searches the production plan created by the production plan creation unit 21 and identifies the date of the production plan exceeding a predetermined operating time of one day. In this example, the predetermined operating time of one day is 24 hours, but it can be set shorter. According to FIG. 3A, in this step 105, the eleventh day and the third day are identified. The search target period matches the production plan creation target period. The search is preferably performed in order from the last day of production to the previous day, one day at a time, up to the production start date, but is not limited to this search method. The identified production plan date is stored in the memory 9 or the storage device 10. The process then proceeds to step 106.

In step 106 of FIG. 2, the first correction unit 23 has exceeded the predetermined operation time in the production plan on the day of the production plan that exceeds the predetermined operation time of the day identified by the first identification unit 22. The part is moved to a day before that day, and the production plan created by the production plan creation unit 21 is corrected. In the example of FIG. 3, the dates of the production plan exceeding 24 hours in (A) are identified as the 11th day and the 3rd day, and therefore, are the respective 24 hour excesses on the 11th day and the 3rd day. Each production plan of one lot is transferred to a date earlier than that. (B) shows processing for moving one lot on the eleventh day to the tenth day. The production plan corrected by continuing this movement processing until the production start date is shown in FIG.
It is. Here, this is called a second production plan for convenience.

The target period of the transfer destination usually coincides with the target period of the production plan creation, and it is preferable to set the production start date from the last production date, but it is also possible to limit to a certain period. In such a case, the target period can be set in the production plan rule file 6, or a selection button can be displayed on the display unit 3 so that the operator can select it. Although not shown in the figure, the destination of the production plan may be any day before the date of the production plan to be moved, and is not limited to the day before. Further, it is possible to move over the production period such as from the production period 2 to the production period 1. In this example, movement is performed in lot units, which are shipping units,
It is possible to arbitrarily set the unit in which the movement is performed. At the stage when the second production plan is created, a production plan that exceeds the capacity of the equipment can be eliminated.

After step 106, control can be passed to the production plan display section 27. In this case, the second production plan can be displayed on the display section 3. At this time, it is preferable that the moved lot portion is marked so that the operator can clearly understand.

Next, the process proceeds to step 108. Here, the second identification unit 24 searches the production plan corrected by the first correction unit 23, and identifies a date of the production plan that is shorter than a predetermined operating time of one day. In this example, the predetermined operating time of one day is 2
Since it is 4 hours, as is apparent from FIG.
In production period 1, the first day is first identified. The search target period usually coincides with the production plan creation target period.
In addition, it is preferable to search a day after the production start date one day at a time until the last production day, but the search method is not limited to this search method as in step 105. The identified production plan date is stored in the memory 9 or the storage device 10. After step 108 is completed, the process proceeds to step 10
Go to 9.

In step 109, the second correction unit:
By moving at least a part of the production plan on a day after the production plan identified by the second identification unit, the production plan (second production plan) modified by the first modification unit in step 106 Correct). In the example of FIG. 4B, since the first day is first identified by the second identification unit, it is possible to move two lots on the day after the first day, that is, here, the two lots on the second day. It is shown.

When the first transfer is completed, two lots on the second day are moved to the first day. As a result, the second day is short of two lots with respect to the predetermined operation time. It is necessary to shift the production plan from the day to the second day.
One of the methods for this is to execute the processing of step 108 again, identify the date of the production plan that is less than the predetermined operation time, that is, the second day here, and then execute step 10 again.
9 is executed. Thus, the repetition processing of steps 108 and 109 is continued for the production period 1 until the last day of the production period 1, in this example, the fifth day.

Alternatively, it can be carried out by the following method. For example, in step 108, the second identification unit identifies the date of the production plan that is less than the predetermined operation time, and stores in advance the number of lot shortages for the predetermined operation time on each day of the search target period in a memory. . Next, when the second correction unit moves the lot in Step 109, the number of moved lots is added to the shortage of lots held in the memory above the date on which the lot was moved. In this example, in step 108, the second identification unit determines the first,
4 and 5 days are identified as production planning days that are less than the specified operating time, 1 lot is specified on the first day, 0 lot is specified on the 2nd and 3rd days, and 1 lot is specified on the 4th and 5th days. The lack of operation time is stored in memory. In step 109, the second correction unit first moves two lots on the second day to the first day. Thereafter, since two lots have been moved, these two lots are added to the zero lot on the second day identified in step 108. The two lots resulting from the addition are the number of shortage lots for the predetermined operation time on the second day at this point. Therefore, the second correction unit moves two lots of the number of missing lots on the second day from the third day. Such processing is continued until the fifth day.

The movement may be performed from the production plan on the day after the day identified by the second identification unit, and it is not always necessary to move from the day immediately after the identified day as in this example. . Further, when it is necessary to adjust the stock amount in the unit of the production period in the manufacturing process as in this example, it is preferable to limit the movement target within the same production period and perform the processing in the unit of the production period. However, it is also possible to allow the operator to select another period instead of the same production period as the object of the movement, or to move over a certain production period. Further, the movement can be performed not in the lot unit but in another unit as in the case of step 106.

In FIG. 4, the production plan in which the movement process in the production period 1 has been completed is (C), and thereafter steps 108 and 109 are performed for the production period 2. (D) shows a process of moving two lots on the ninth day in the step 109 with respect to the eighth day identified in the step 108 in the production period 2. Processed through steps 108 and 109 until the twelfth day of the production period 2 to complete the production plan 11
0 is (E), which is the production plan aimed at by the present invention.

By the processing of the second correction unit 25, it is possible to eliminate manufacturing processing days that are shorter than the predetermined operating time of one day in the middle of the production period, thereby enabling continuous manufacturing. In addition, there is no deviation in production for each production period, and it is possible to keep inventory properly. Further, it is possible to easily know the manufacturing process stop information 111 such as the time and date when the equipment can be stopped.

When the production plan as a result of the process of the second correction unit is completed, the control is transferred to the production plan display unit 27, so that the completed production plan can be displayed on the display unit 3. It is preferable that the display mark the lot portion subjected to the transfer processing. Further, the production plan can be stored in the storage device 10 and can be read later at any time.

[0033]

According to the present invention, it is possible to create a production plan that continues production for a certain period of time in one production process without delaying the delivery date, without bias in the production load, and maintaining proper inventory. Can be obtained.

Further, it is possible to continuously produce without exceeding the facility capacity and without stopping the facility until the production plan is completed in the production period in which the production is continuously performed for a certain period of time. The effect is obtained.

Further, it is easy to clarify that the production process may be stopped by the created production plan, so that the effect that the equipment can be used effectively can be obtained.

[Brief description of the drawings]

FIG. 1 is a block diagram showing the overall configuration of a production plan creation system in a single continuous manufacturing process.

FIG. 2 is a flowchart of creating a production plan in a single continuous manufacturing process.

FIG. 3 is a first identification process and a first identification process in creating a production plan;
The figure which showed the correction process.

FIG. 4 is a diagram illustrating a second identification process and a second identification process in production plan creation.
The figure which showed the correction process.

FIG. 5 is a diagram showing a production plan created when the identification processing and the correction processing of the present invention are not performed.

[Explanation of symbols]

 5 Shipping Schedule Table 6 Production Plan Rule File 21 Production Plan Creation Unit 22 First Identification Unit 23 First Correction Unit 24 Second Identification Unit 25 Second Correction Unit

Claims (2)

[Claims] 1. A shipping schedule table storing a product shipping schedule, a production planning rule file storing a production planning rule, information on the shipping schedule read from the shipping schedule table, and the production planning rule file. Means for creating a production plan based on the read production plan rules; first identification means for retrieving the production plan and identifying a date of the production plan exceeding a predetermined operating time of one day; and first identification. Means for correcting the production plan by moving a portion of the production plan on the day identified by the means that exceeds the predetermined operating time to a date earlier than that day; and searching for the corrected production plan, A second identification unit for identifying a date of the production plan that is less than the predetermined operation time; and a production plan of a day later than the production plan on the day identified by the second identification unit. Without even the production planning system in a single continuous production process comprising a second correction means for correcting the production plan of the date of the identified transferred portions, the. 2. A step of preparing a shipping schedule table for storing a product shipping schedule and a production planning rule file for storing a production planning rule, information on the shipping schedule and the production plan read from the shipping schedule table. Creating a production plan based on the production plan rules read from the rule file; retrieving the production plan to identify a date of the production plan exceeding a predetermined operating time of one day; Correcting the production plan by moving a portion of the production plan on the day of the production plan that exceeds the predetermined operation time to a day earlier than the predetermined operation time, and searching for the modified production plan; Identifying a date of the production plan that is shorter than the predetermined operation time; and Step a method producing planning in a single continuous production process including modifying the production plan at least a portion of the transferred date of the identified production plan days after that date to the production plan.