JPS63306861A - Production plan creation and correction method - Google Patents

Abstract

(57) [Summary] This bulletin contains application data before electronic filing, so abstract data is not recorded.

Description

[Detailed Description of the Invention] [Industrial Application Field] The present invention relates to a production control system for a production line that performs high-mix, low-volume production, and is particularly applicable to a production line that has a large number of production plans and many planned changes. Production 3 [Relates to a production plan creation and correction method suitable for planning and modification of images.

[Conventional technology]

The conventional method of creating a production plan is disclosed in Japanese Patent Application Laid-Open No. 56-13260.
As described in Section 5, the system checked the process intervals, issued a warning, and set an interlock to prevent the train from starting. Further, as described in Japanese Patent Application Laid-Open No. 54-82583, changes in the production plan were handled by changing the item numbers of the production instructions.

[Problem that the invention seeks to solve]

The above-mentioned conventional technology creates a production plan for a combined production line in which parts are supplied from multiple parts supply lines, the supply speed from each part line is different, and the inventory amount of each part is also different.

No consideration is given to the point of flexibly responding to modifications, making it difficult to apply to the above-mentioned production line. Furthermore, since the production plan is determined by the will of the producer, changing the assembly order leads to a decrease in productivity. Another problem is that simply determining the time required for each process from the production plan and issuing a warning based on the comparison with the predetermined process time does not provide the operator with sufficient information to analyze problems in the production plan. there were.

It is an object of the present invention to provide a production plan creation and correction method that solves the above problems and makes it easy to create and modify a production plan for a production line that has a large number of parts and performs multi-product sunset production. Our goal is to provide the following.

[Means for solving problems]

The above purpose is to create a product configuration file that stores specification information of parts that make up a product, a parts inventory file that stores inventory information for each part, and a production tact and An equipment specification file is created to store setup change times for each shop, and parts plan development processing is performed to develop a parts production plan at the part level for each shop based on the production plan for the product input by the operator. The process time calculation process that calculates the process time for each shop from the product production plan, parts production plan, and equipment specification file is compared with the process time of each shop to identify shops where consumption and supply are unbalanced. There is a process time check process for checking out, a display process that outputs the characteristic curve of the consumption and supply amount for each part to a display device according to the operator's request, and a display process that outputs the characteristic curve of the consumption and supply amount for each part to the display device according to the operator's request. This is achieved by providing a production plan correction process that corrects the production plan.

[Effect]

The product configuration file is a product production plan for each part.

It is used to develop parts production plans for each shop.

This is executed by a parts production plan expansion process, and a parts production plan at the parts level for each shop on the production line can be obtained from the product production plan.

Inventory files and equipment specification files are used to analyze and check product production plans and parts production plans. That is, the process time calculation process and the process time check process are used to check the capacity of the parts supply shop and the production capacity of the assembly shop, and check whether the production plan is appropriate. This allows the operator to judge the quality of the production plan without relying on intuition or experience.

Furthermore, the processing results of the process time check processing can be displayed as a two-dimensional correlation curve by the operator activating the display processing, which is effective when manually correcting the production plan.

In addition, the production plan correction process automatically subtracts the quantity in the product production plan for unreasonable production plans and balances parts supply capacity and assembly capacity, making it possible to create a production plan that makes maximum use of equipment capacity. becomes.

〔Example〕

An embodiment of the present invention will be described below with reference to the drawings.

FIG. 1 shows an embodiment of a production line that performs production management to which the present invention is applied and a production management system that manages the same.

This system instructs each shop about a production plan and collects the production results for that plan. First, the production line consists of parts shops 1 to 1'' and assembly shop 2, and the parts produced in each parts job 1 to 1' join assembly shop 2, where products are assembled.Each shop has 3 counters. ～3″ and display 4～4# are installed,
The production results are reported to the production management system 6 via the process input devices 5 to 5', and the production plan and production results are displayed to manage the production progress.

A production plan, which serves as a reference for the production management system, is input by an operator through an operation console 8 and a display 7, and the data is taken into a production plan development process 10 via a man-machine control process 9. The production plan development process 10 creates a production plan file 13 for each shop by referring to a product configuration file 15 that stores information on parts that make up a product. Process time calculation processing 11 is provided to check whether the production plan created in this way is appropriate. This is based on the operator's request, production plan file 13 and number specification file 1.
Using the information in step 6, the process time and production quantity for the specified part are determined in chronological order and stored in the process time file 14. Further, if the production plan is not appropriate, a warning is output to the display 7 via the man-machine control device 9. If the production plan is not appropriate, enter the plan again or perform production plan correction process 1.
In step 2, the production plan can also be automatically corrected.

The production plan created in this way is processed in the work instruction output process 19.
The performance data produced according to the plan is outputted to the display of each shop, and is collected by the production performance collection process 18 and stored in the inventory file 17.

Figure 2 shows the correlation between the parts that make up the product and the shops where they are manufactured. Product A21 is part a20. The product configuration file 15 is composed of the component b20' and the component c20#, and stores the configuration information and component specifications. Each component has its own inventory file 17. Parts also have an index with the shop where they are produced, and parts a20 and c20' are in shop X22.
is associated with. Each shop has an equipment specification file 16 that stores data such as line takt, setup time, charge time, etc., which are unique information of the equipment.

FIG. 3 shows the processing flow of the production plan development process 10. While looping for each plan in the product production plan, the product configuration file 15 is indexed in block C, and expanded into a parts production plan in blocks E and F while looping for the number of parts that make up the product.

FIG. 4 shows the processing flow of the process time calculation process 11. In blocks A to F, the consumption quantity and the process time in the assembly shop 2 are calculated. Next, in block G = M, the supply quantity and process time at parts shops 1 to 1 are calculated.Finally, using the consumption and supply quantities and process time calculated in this way, the cumulative supply quantity of parts at the time of the final assembly plan is calculated. The value is compared with the cumulative total consumption value, and when the consumption amount exceeds the supply amount, an alarm is output in blocks N and O.

FIG. 5 shows the processing flow of the production plan correction processing 12. Each parts production plan developed from the product production plan is checked in a loop. Each time the product production plan is switched, the consumption quantity and supply quantity obtained in the process flow of process time calculation process 11 in Fig. 4 are calculated in block C.
If the supply amount is less than the consumption amount, the assembly production plan is corrected in block D so that the village cost amount and the supply amount are equal.

6 and 7 show examples of display on the display 7 using the production planning guidance function,
The figure shows a normal production plan, and FIG. 7 shows an abnormal production plan and its correction results.

In FIG. 6, as for the consumption amount 24, the number of consumed parts, plotted on the vertical axis, increases as the process time, plotted on the horizontal axis, increases. On the other hand, the supply amount 23 increases from the initial inventory amount 26 in the same way as at the start. Products A, B, C, and D are assembly plans.

The relationship of supply > consumption is maintained between these two curves in E's final plan, and the difference between the two exists as inventory amount 25. On the other hand, in the example shown in Fig. 7, the abnormal plan 28 intersects the supply amount 23 at the part shortage point 27 in the section of the final assembled product E, making it impossible to continue production and therefore excluding it as an abnormal plan. There is a need to. According to the present invention, the process time calculation process 11 outputs an alarm, and the production plan correction process 12 corrects the production plan. The correction plan 29 of the production plan corrected by the production plan correction process 12 is corrected to match the cumulative supply quantity value.

According to this embodiment, a product production plan can be easily developed into a parts production plan for each shop, and the guidance display function, abnormality plan alarm function, and production plan correction function prevent the production line from stopping (a highly reliable Able to formulate production plans.

〔Effect of the invention〕

According to the present invention, production planning is performed using a product configuration file,
Equipment specification files and inventory file information can be automatically developed into parts work plans for each shop, resulting in labor savings. In addition, in contrast to the conventional planning by experts, it becomes possible to create a plan for each shop at the same time.

guidance and warning functions for planners;
Since it also has a production plan correction function, even non-experts can easily create a production plan. Furthermore, the reliability of production planning by the above functions is improved, and production line stoppages due to parts shortages can be prevented, leading to improved productivity.

[Brief explanation of drawings]

Fig. 1 is an explanatory diagram of an embodiment of a production line and its management system to which the present invention is applied; Fig. 2 is a correlation diagram of file information used for production plan development, checking, and correction; and Fig. 3 is a production plan development processing flow diagram. , Figure 4 is a process time calculation processing flow diagram, Figure 5 is a production plan correction processing flow diagram, and Figures 6 and 7 are
The figure is an explanatory diagram of an example of guidance display based on production prediction and an example of production plan correction processing. 1...Parts shop, 2...Assembly shop, 3...
Counter, 4, 7...Display, S...Process input device, 8...Operation console, 9...Man-machine control processing, 10...Production plan development processing, 11...Process time Arithmetic processing, 12... Production plan correction processing, 13... Production plan file, 14... Process time file, 15...
・Product configuration file, 16...Equipment specification file, 1
7...Inventory file, 23...Supply amount, 24...
Consumption amount, 25... RFL amount in stock, 27... Parts shortage, 28... Abnormality plan, 29... Correction plan. Agent Patent Attorney Katsuo Ogawa Nouma 3 Zukka 4

Claims (1)

[Claims] 1. A production management system that uses electronic computers to manage production line information for production plants that process purchased and in-house parts, assemble and manufacture products, and define product production plan files and product component configurations. It has a product configuration file, a parts inventory file, and an equipment specification file with information such as production tact and setup time for each shop, and uses the product production plan file information to create a parts supply plan for each shop. In the planning process, based on the product production plan, from the parts supply plan developed using the product configuration file information, the supply quantity of each part and assembly are calculated by taking into account equipment specification file information and parts inventory file information. The system calculates the consumed quantity in chronological order, displays guidance on the display device so that they can be compared, and outputs a warning if the consumed quantity exceeds the supplied quantity, and automatically corrects the product production plan. A production plan creation and correction method characterized by: