JP3351220B2 - Production order confirmation device - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a sub-line for supplying a component to a main line for producing by circulating a plurality of jigs which are different for each component type in a fixed arrangement in an annular manner. The present invention relates to a production order determination device that determines a production order.

[0002]

2. Description of the Related Art A ring line (see FIG. 2) in which a main line and a sub-line for supplying parts to each other are produced by circularly circulating jigs different for each part type in a fixed arrangement order. Conventionally, as a method of producing sub-lines, the main line shipment plan is advanced by the production lead time (the time from input to shipment) in the order of jigs, and the jigs that are in short supply are trained by skilled personnel. It was going while exchanging with intuition and hang of. That is, the production order of the sub-line and the jig replacement timing are determined based on the know-how of the skilled person based on the shipment plan of the main line, and the sub-line is produced.

[0003]

As described above, according to the above-mentioned conventional sub-line production method, the line capacity and the arrangement order of the jigs are different between the main line and the sub-line. It is extremely difficult for a person to determine the arrangement order, the ratio, and the replacement timing of the jigs of the sub-line so that the production order can be performed, and there is a face that it is necessary to rely on the know-how of a skilled person. However, since the judgment of the expert is based on the main line shipment plan and the production order of the main line is not taken into account, in order to avoid a shortage of parts supply to the main line, it is necessary to have a large inventory of finished products of the sub line. Prone to production. For example,
In general, production is carried out with stocks for one or two shifts. In terms of production efficiency,
Due to the judgment of the skilled person, it could not always be said that efficient production was performed objectively.

SUMMARY OF THE INVENTION The present invention has been made in view of the above-mentioned problem in a method of producing a sub-line in a main line and a sub-line, both of which are ring lines, and minimizes the inventory of finished products and efficiently supplies parts. It is an object of the present invention to provide a production order determination device capable of creating a production order plan for a subline.

[0005]

In order to achieve the above object, an invention according to claim 1 is a main line for performing production by circulating a plurality of jigs different for each component type in a fixed arrangement order in a ring. to a device for determining the sub-line of the production sequence for supplying the parts by the line structure of this same type, main
Main line based on in-line production sequence planning
First calculating means for calculating the scheduled time of component insertion,
Sub-line based on the current jig arrangement of the line
A second calculating means for calculating a scheduled completion time of the part,
Based on the result of the first calculation means and the result of the second calculation means
To the sub line in time for the main line
Attach the jig of the line, and generate
The production efficiency evaluation parameters are evaluated, and the production
While replacing the actual jig to maximize the rate,
Computing means for creating a production sequence plan for the brine.
This is a production order determination device .

According to the present invention, the first calculating means calculates the scheduled input time of parts on the main line based on the production sequence plan of the main line, and the second calculating means calculates the current arrangement of jigs on the sub line. Based on the order, the scheduled completion time of the component in the sub line is calculated. The calculating means is configured to set the sub-line based on the main line insertion time calculated by the first calculating means and the sub-line completion time calculated by the second calculating means so as to meet the main line insertion order plan. Attach the jig, evaluate the result with predetermined production efficiency evaluation parameters, and replace the jig.
Evaluate production efficiency evaluation parameters based on man-hours
Replacement of actual jigs to maximize production efficiency based on results
And create a production sequence plan for the subline. That is, since the production order plan of the sub-line is created in consideration of the production order of the main line, the finished product inventory of the sub-line is minimized. Further, since the production sequence plan of the sub-line is created using the production efficiency evaluation parameters based on the number of man-hours for replacing the jig, the production sequence plan of the sub-line that can supply the parts most efficiently is drafted.

According to a second aspect of the present invention, the arithmetic means includes:
One jig from multiple allocation candidates requiring jig replacement
When selecting the jig, select the one that minimizes the
To choose.

[0008] The invention according to claim 3 is a method for evaluating production efficiency.
The parameters are also the energy of the empty fixture
Loss based.

[0009]

[0010] The invention according to claim 4 is the above-mentioned claims 1-3.
In the invention of the present invention, the production efficiency
In addition, it is based on inventory loss due to the allocation time difference.

[0011]

According to the present invention, the production efficiency of the sub-line production sequence plan is evaluated using the man-hour for replacing the jig, the energy loss of the empty jig, and the inventory loss due to the allocation time difference as parameters, and the production efficiency is determined to be maximum. A sub-line production sequence plan is created while exchanging jigs as needed.
That is, jig replacement man-hour, energy loss of empty jig,
Since the jig replacement timing is determined in consideration of the inventory loss due to the allocation time difference, a sub-line production sequence plan capable of supplying parts most efficiently is drafted.

[0013]

According to the first aspect of the present invention, the main
Efficiency based on production order of jigs and jig replacement man-hours
Production sequence planning of sub-line considering evaluation parameters
To minimize the finished product inventory of the subline
In addition, sublicensing using production efficiency
A production sequence plan for
Create a production sequence plan for sublines that can be paid
Is possible, and the cost is reduced.

According to the second aspect of the present invention, the above-mentioned claim is provided.
In addition to the effects of the invention described in 1, the replacement is performed in consideration of the replacement man-hour.
Since the jig to be selected is selected, efficient jig replacement is performed.
As a result, an even more efficient production sequence plan is drafted.

According to the third aspect of the present invention, the above-mentioned claim is provided.
In addition to the effects of the inventions described in 1 and 2, the energy
The jig replacement timing is determined in consideration of the
A more efficient production sequence plan is drafted.

According to the fourth aspect of the present invention, the above-mentioned claim is provided.
In addition to the effects of the invention described in 1-3,
Determine the jig replacement timing considering the storage loss
Thus, a more efficient production sequence plan is drafted.

[0017]

[0018]

Embodiments of the present invention will be described below with reference to the drawings. FIG. 2 is a conceptual diagram showing a line model of a main line and a sub line to which the present invention is applied. As shown in FIG. 2, both the main line and the sub-line for supplying parts to the main line are ring lines configured to perform production by circulating jigs different for each part type in a fixed arrangement in a circular manner. Therefore, a dedicated jig is determined for each component type, and the arrangement order of the jigs is determined by an annular line. For example, the main line is a chrome plating process of a plating production line, and the sub line is a pretreatment process. The main line and the sub line are different in the production capacity and the arrangement order of the jigs. Here, the main line is 10
Equipped with jigs, parts A, B, C, D are A → A → B → C
→ D → B → B → B → A → C.
On the other hand, the sub-line has six jigs, and the parts A, B, C, and D to be supplied to the main line are B → B → A → C → D → A
To produce repeatedly. Parts completed in the sub-line are put into the main line. At that time, the completed parts of the sub-line before being put into the main line are temporarily stored in the stock yard.

The present invention is to automatically create an optimal production sequence plan for a sub-line in a main line and a sub-line as shown in FIG.

FIG. 1 is a block diagram showing the configuration of a production order determination device according to one embodiment of the present invention. This device is
It has a main line jig configuration file 1, a main line component-specific cycle time file 2, a sub line jig configuration file 3, and a sub line component-specific cycle time file 4. The main line jig configuration file 1 and the sub line jig configuration file 3 store the jig configuration of the main line and the sub line in a predetermined format, respectively, and have a file configuration as shown in FIG. 3, for example. I have. That is, each jig configuration file 1, 3
Is composed of a jig No., a jig type, and a component type. In the example of FIG. 2, the jig No. of the main line jig configuration file 1 is 1 to 10 (n = 10), and the jig No. of the sub line jig configuration file 3 is 1 to 6 (n = 6). The main line component-specific cycle time file 2 and the sub-line component-specific cycle time file 4 store the main line and sub-line component-specific cycle times in a predetermined format. FIG. 4 is a diagram showing an example of a file configuration of the cycle time file 2 for each main line component. Here, a basic cycle time is set (5 minutes), and a cycle time for each component is represented by a time difference (difference cycle time) from the basic cycle time. The configuration of the subline component-specific cycle time file 4 is the same as that of FIG. 4, but here, for simplification, the basic cycle time of the subline is set to 3 minutes for all components.

The main line jig configuration file 1 and the cycle time file 2 for each main line component are connected to a main line introduction scheduled time calculation unit 5, and the sub line jig configuration file 3 and the cycle time file 4 for each sub line component are scheduled to be completed in a sub line. It is connected to the time calculation unit 6. The scheduled main line insertion time calculation unit 5 functions as a first calculating unit, and calculates a scheduled insertion time of a component on the main line from the jig configuration of the main line and a cycle time for each component, and calculates the determined insertion schedule. Create a main line input order plan with time. More specifically,
The cycle time file 2 for each main line component is searched for each component type of the main line jig configuration file 1, and the basic cycle time and the difference cycle time (the sum of both becomes the cycle time of each component) is started. The expected completion time is calculated by adding the time to the time. Then, this process is repeated until the production end time in the order in which the jigs are arranged, thereby creating a main line loading sequence plan with a scheduled loading time. An example of the main line insertion sequence plan created by the scheduled main line insertion time calculation unit 5 is as shown in FIG. 5, for example, when the production start time is set to 8:35. The result is the order planning file 7
Is stored. In addition, a subline scheduled completion time calculation unit 6
Functions as a second calculating means, calculates the scheduled completion time of the component in the subline from the jig configuration of the subline and the cycle time for each part, and creates a subline completion order plan with the calculated expected completion time. . The more specific processing procedure is the same as in the case of the main line insertion scheduled time calculation unit 5 described above. An example of the subline completion order plan created by the estimated subline completion time calculation unit 6 is as shown in FIG. 6 when the production start time is 8:30, for example. This result is stored in the order planning file 8 with the scheduled subline completion time.

The sequence planning file with scheduled main line input time 7 and the sequence planning file with scheduled subline completion time 8 are connected to a sub-line production sequence planning section 10 as an arithmetic means. Further, the sub-line production sequence plan creation unit 10 includes a condition parameter file 9 for each part.
Is connected. The part-specific condition parameter file 9 stores condition parameters for each part. Here, the number of replacement steps and energy loss are set as the condition parameters. The replacement man-hour is the man-hour required for exchanging the jig, and the energy loss is an energy loss caused by flowing an unallocated empty jig through the line, and both are factors that reduce the production efficiency of the sub-line. These are used as parameters for evaluating the production efficiency when evaluating the production efficiency of the production sequence plan of the subline. Also,
The replacement man-hour is also used when selecting a replacement jig. An example of the component-specific condition parameters is as shown in FIG. As shown in the figure, the parameter of the replacement man-hour is determined by the combination of the jig type before replacement and the jig type after replacement. When calculating the replacement man-hour, the replacement man-hour of the component type before replacement and the replacement man-hour of the component type after replacement are added, and the added value is used as the replacement man-hour. In the present invention, inventory loss is further considered as a production efficiency evaluation parameter, which is automatically calculated by the sub-line production order plan creation unit 10 at the time of evaluation, as described later.

The sub-line production sequence plan creating section 10 is a central part of the present apparatus and is based on the sequence plan with the scheduled main line input time in the file 7 and the sequence plan with the scheduled sub-line completion time in the file 8. Then, the jigs of the sub-line are allocated in time for the main line input sequence plan, and the results are evaluated using predetermined production efficiency evaluation parameters (replacement man-hours, energy loss, inventory loss) so that the production efficiency is maximized. Has a function of automatically creating a sub-line production sequence plan while exchanging jigs. As a result, a production order plan for sub-lines that can produce parts at the optimal timing to minimize parts inventory and maximize production efficiency without causing a shortage of supply to the main line is created. become. The processing procedure in the sub-line production order plan creation unit 10 will be described in detail with reference to a flowchart described later. The final subline production sequence plan created by the subline production sequence plan creation unit 10 is output and stored in the production sequence plan file 11.

Next, the operation of the present apparatus configured as described above will be described with reference to flowcharts. FIG. 8 is a main flowchart showing the operation of the present apparatus. Here, in order to make it easy to understand the contents of the processing, FIGS.
Referring to FIG.

First, the scheduled main line input time calculating section 5
Calculates the scheduled introduction time of parts in the main line from the jig configuration of the main line and the cycle time for each part, creates a main line insertion sequence plan P with the estimated introduction time, and puts the result with the estimated main line insertion time. It is stored in the order plan file 7 (step S1). That is, the main line component cycle time file 2 (see FIG. 4) is searched for each component type of the main line jig configuration file 1 (see FIG. 3), and the searched time (cycle time) is added to the production start time. To calculate the expected completion time. And
This processing is repeated until the production end time in the order in which the jigs are arranged, and the main line loading sequence plan P (see FIG.
See). The subline scheduled completion time calculation unit 6 calculates the scheduled completion time of the component in the subline from the jig configuration of the subline and the cycle time for each part, and calculates the subline completion order plan Q with the determined expected completion time.
Is created, and the result is stored in the sequence planning file 8 with the scheduled subline completion time (step S2). That is, similar to the processing in the scheduled main line insertion time calculation unit 5, the subline component-specific cycle time file 4 is searched for each component type of the subline jig configuration file 3 (see FIG. 3), and the searched time (cycle time) is calculated. The expected completion time is calculated by adding the estimated time to the production start time. This process is repeated until the production end time in the order in which the jigs are arranged, thereby creating a subline completion order plan Q (see FIG. 6) with a scheduled completion time.

When the main line ordering plan P and the subline ordering plan Q are created, the subline production ordering plan creator 10 generates a plan q constituting the subline ordering plan Q for each plan p constituting the main line ordering plan P. Is performed (first allocation processing) (step S3).
Here, a subline plan q of the same component type in time for the scheduled introduction time of the main line is allocated. At this time, a plan q to be completed earlier than a predetermined time (for example, 25 minutes) is not allocated. This is because if the capacity of the sub-line is high, parts may be produced too much and the stock amount may increase. The allocated main line plan p is marked with an allocated mark (see the symbol “*” in FIG. 14A or the like), and the jig N of the sub line plan q of the allocation destination is assigned.
o is written (see FIG. 14 (A) and the like), and an allocated mark is also added to the subline plan q of the allocation destination (see the symbol “*” in FIG. 14 (B) and the like). . The result of this processing is as shown in FIG.

FIG. 9 is a flowchart showing the contents of the first allocation processing in FIG. In the first allocation process, first, an unallocated one plan p is selected from the main line order plan P.
(Step S)
21), One unassigned plan q is read from the subline order plan Q in order from the earliest scheduled completion time (step S22).

Whether the sub-line plan q precedes the main line plan p (ie, whether or not the main line introduction scheduled time is in time) (step S23)
In the case of YES, it is determined whether or not the vehicle is ahead of the predetermined time (25 minutes) (step S24).
It is determined whether or not and the subline plan q are the same part type (step S26). When the result of this determination is YES, that is, when the subline plan q read in step S22 is within the predetermined time difference (25 minutes) in time for the scheduled main line insertion time and has the same component type as the main line plan p In step S27, the sub-line plan q is assigned to the main line plan p to associate the two with each other (step S27), and the process proceeds to step S28. Specifically, in step S27, the main line plan p and the sub line plan q are marked with an assigned mark (*), and the jig No of the sub line plan q is written in the main line plan p.

On the other hand, steps S23 to S
As a result of the determination in step 25, the subline plan q does not precede the main line plan p, or precedes the main line plan p but for a predetermined time (2
5 minutes) or more, or the main line plan p
If the sub-line plan q is different from the sub-line plan q, the process immediately proceeds to step S26, where it is determined whether the unallocated plan q remains in the sub-line order plan Q. If YES, the next unallocated The process returns to step S22 in order to consider the plan q, and if NO, the process proceeds to step S28 in order to perform the allocation process for the next unallocated plan p.

In step S28, it is determined whether or not all records of the main line order plan P (all plans p) have been examined. If YES, the process returns to the main flowchart. If NO, step S21 is performed.
And the same processing is repeated for the next unallocated plan p.

When the first allocation process is completed, it is determined whether or not all plans p in the main line order plan P have been allocated from the presence or absence of the allocated mark (step S4), and YE is performed.
If S, the process immediately proceeds to step S6. If NO, the second allocation process involving jig replacement is performed (step S6).
5). The allocation of all plans p in the main line order plan P is determined by the second allocation processing.

FIG. 10 is a flowchart showing the contents of the second allocation processing in FIG. First, one unallocated plan p is read from the main line order plan P in the order of earlier input scheduled time (step S31), and the plan p from the subline order plan Q is preceded within a predetermined time (25 minutes). The unassigned candidate q to be searched is searched (step S32), and the candidate q having the least assigned mark is selected from the searched candidates q. That is, since the same jig makes several rounds during the production within one shift, the one with the least allocation in one shift is selected (step S33).

When the number of candidates q is reduced to one in step S33 (step S34), the jig of the selected plan q is replaced with the jig of the main line plan p read in step S31, and its subline is replaced. The plan q is assigned to the main line plan p (step S35). At this time, if there is a main line plan p 'that has been assigned to the same jig No. as the main line plan p and has been deleted, the subline plan q of the same jig No. is also assigned to this main line plan p'. And the main line order plan P
If there is a main line plan p assigned to the jig of the subline plan q (step S36), the correspondence with the main line plan p is deleted. That is, the allocated mark on the main line and the sub line jig No are deleted, and the allocated mark on the sub line is also deleted (step S37), and then the process proceeds to step S38. On the other hand, as a result of the determination in step S36, N
If O, the process immediately proceeds to step S38.

In step S38, similarly to step S4, it is determined whether all the plans p in the main line order plan P have been allocated. If YES, the process returns to the main flowchart. It returns to step S31. In addition, even when there is no unallocated plan between the head and the tail of the subline order plan Q, a series of processing is completed and the process proceeds to step S6.

If the result of the determination in step S34 is NO, the part-specific condition parameter file 9 (see FIG. 7)
The replacement man-hours of a plurality of candidates q are read from the
9), only one replacement man-hour is selected (step S40), and the process proceeds to step S35. As described above, when one of the plurality of candidates for jig replacement q is selected, the jig replacement man-hour is taken into consideration, so that the jig can be replaced while minimizing the decrease in production efficiency.

For example, in the case shown in FIG. 14, since the plan p of the jig No. 1 on the main line has not been allocated, an unallocated sub-line plan q is searched before the scheduled input time (8:35). The part type of the plan is changed (jig replacement) and assigned to the main line plan p of the jig No. 1. Accordingly, the part type of the same jig No. is also changed. If there is a main line plan p assigned to this jig No., the allocated marks of the main line and the sub line are deleted, and the main line is deleted. In the case of, the sub-line jig No is also deleted (corresponding relation is deleted). The result of this processing is as shown in FIG. Here, the candidate for the unassigned subline plan q before the scheduled insertion time (8:35) is only the jig No. 2 and is selected. Along with this, the part type of the subsequent jig No. 2 also becomes B
A is changed to A, and the assignment of the jigs No. 7 and No. 3 on the main line is deleted by the change of the component type (jig replacement).

As described above, since the component type of the jig No. 2 of the sub line is changed from B to A, the jig No. of the main line is changed.
Since 7 is unallocated, further allocation is searched from the current subline order plan Q, and candidates are picked up. Here, as shown in FIG. 16, three candidates (1 to
3) is picked up. Then, the replacement man-hours of the three candidate jigs are compared, and the jig having the smallest replacement man-hour is selected. The jigs of candidates 1 and 2 are A, the replacement man-hour of A is 5 from the part-specific condition parameters, and the jig of candidate 3 is D.
Since the replacement man-hour is 2, the candidate 3 (jig No. 5) having the smallest replacement man-hour is selected, and the jig No. 7 of the main line is selected.
Is assigned to the plan p. At this time, the plan of the unallocated jig No. 3 on the main line is the one whose allocation has been deleted at the same time as the plan p of the jig No. 7 (p ′). Attraction. In this way, all the plans p in the main line order plan P are allocated (see FIG. 17). Note that FIG.
The allocated mark <*> in (B) means that the allocation has been made by replacement of the jig (change of component type), and is added for convenience of explanation.

When the allocation of all plans p in the main line order plan P is determined, the main line order plan P1 and the sub line order plan Q1 at this time are temporarily stored in the built-in memory (step S6), and the current sub line order plan is stored. Q
1 is calculated (step S).
7). Here, the production efficiency reduction index V1 is obtained by the sum of the total replacement man-hours of the planned replacement of the jig and the total energy loss of the unassigned empty jig. Here, the sub-line has a higher capacity than the main line, so at this stage the sub-line allocation plan is in a so-called toothless state, and the jig flows to the line with the empty jig, so energy loss occurs. It happens. The greater the energy loss, the lower the production efficiency. It is natural that the greater the number of jig replacement steps, the lower the production efficiency. The production efficiency decrease index V1 obtained in step S7 is also stored in the built-in memory.

For example, the production efficiency decrease index V1 in the case shown in FIG. 17 is obtained as follows. The symbol “記号” in FIG. 17 (B) indicates a plan with jig replacement, and the symbol “●” indicates an unallocated plan from the beginning to the end of the subline order plan Q. Each is attached for convenience of explanation.

In this case, one jig is exchanged for B → A (Jig No. 2) and one jig for D → B (Jig No. 5). Therefore, from the part-specific condition parameter file 9, the total number of replacement steps is B → A: 1 case × (1 + 5) = 6 D → B: 1 case × (1 + 1) = 2 and is 8 (= 6 + 2). Become. Since there are three unallocated empty jigs for jig A and one jig C, the total energy loss from the component-specific condition parameter file 9 is: A: 3 × 3 = 9 C: 1 The sum of the cases × 3 = 3 is 12 (= 9 + 3). Therefore,
The production efficiency decrease index V1 of the subline order plan Q1 shown in FIG. 17 is 20 (= 8 + 12) by adding the total number of replacement steps and the total energy loss.

Thereafter, it is determined from the allocated mark whether or not there is an unallocated plan q between the head and the tail of the sub-line order plan Q1 (step S8), and if YES, steps S9 to S15 are performed. Then, it is simulated whether it is more efficient to replace the jig and produce in advance.

That is, first, in step S9, the jig is replaced. The contents of the jig replacement process are as shown in the flowchart of FIG. First, the jig of the unallocated top plan q is changed to the allocated jig of the last plan, and the component type of the same jig No is changed accordingly (step S41). Then, the correspondence between the jig No. and the main line plan p assigned to the jig of the subline plan q is deleted. That is, the allocated mark on the main line and the sub line jig No are deleted, and the allocated mark on the sub line is also deleted (step S).
42). For example, in the case shown in FIG. 17, the first jig (A) of the unassigned subline plan q (jig No. 6) is the last jig (Jig No. 5) of the allocated plan jig (B). Change to Thus, the arrangement order of the jigs on the sub-line is as shown in FIG. In this way, by changing the jig of the unallocated top plan q to the allocated jig of the last plan, the omission state of the subline is gradually eliminated.

When the jig replacement process in step S9 is completed, a third allocation process is performed in the next step S10 to rebuild the plan. The third allocation process is basically performed in step S
3 has the same contents as the first allocation process, but in the third allocation process, unlike the first allocation process, the priorities of allocation are changed. Specifically, the restriction in the first allocation process (see step S24 in FIG. 9) for disabling the advance for a predetermined time (25 minutes) or more is eliminated, and the advance for 25 minutes or more is also possible. Along with this, if a loss condition due to an increase in inventory (inventory loss) is further provided as a parameter for evaluating production efficiency and the allocation is made for 25 minutes or more, +1 is added in units of a fixed time (for example, 15 minutes). To

FIG. 12 is a flowchart showing the contents of the third allocation processing in FIG. Note that the third allocation processing is basically the same as the first allocation processing as described above, and thus will be described only briefly.

First, one unallocated plan p is read from the current main line order plan P (P1 or P2), which is the base of the simulation, in order from the earliest scheduled input time (step S51). After reading the unallocated one plan q from the current subline order plan Q (Q1 or Q2) starting from the earliest scheduled completion time (step S52), the subline plan q precedes the main line plan p. (Step S53), and whether the main line plan p and the subline plan q are of the same part type (step S54)
If both are YES, that is, if the read subline plan q is in time for the scheduled introduction time of the main line and has the same component type as the main line plan p, the subline plan q is The corresponding relationship is assigned between the two by assigning them to p (the assigned marks are assigned to plans p and q, and the jig No of plan q is written to plan p) (step S56), and the process proceeds to step S57. On the other hand, step S53 or step S54
If the result of this determination is NO, the process immediately proceeds to step S55, and it is determined whether or not the unallocated plan q remains in the subline order plan Q. If YES, the process returns to step S52, and if NO, Step S5
Go to 7. In step S57, it is determined whether or not all records of the main line order plan P (all plans p) have been completely examined. If YES, the process returns to the main flowchart. If NO, the process returns to step S51 to return to the next step S51. The same processing is repeated for the unallocated plan p.

The result of the third allocation processing is, for example, as shown in FIG. Here, the symbol “○” in FIG. 9A indicates that the allocation is made earlier than a predetermined time (25 minutes), and is added for convenience of explanation.

When the allocation of all the plans p in the main line order plan P is determined in this way, the main line order plan P2 and the subline order plan Q2 at the time of this simulation are temporarily stored in the built-in memory (however, the second and subsequent times). Those are temporarily stored in other areas of the built-in memory as plans P2 'and Q2' (step S11), and a production efficiency reduction index V2 of the current subline order plan Q2 is calculated (step S12). Production efficiency decrease index V2 here
Is determined by the sum of the total replacement man-hours of the plan in which the jig was replaced, the total energy loss of the empty jig without allocation, and the total of the inventory loss when the allocation was performed for a predetermined time (25 minutes) or more. The production efficiency decrease index V2 obtained in step S12 is also stored in the built-in memory.

For example, the production efficiency decrease index V2 in the case shown in FIG. 18 is obtained as follows. In this case, the jig needs to be exchanged for one B → A (Jig No. 2) and A →
B: 1 case (Jig No. 6), D → B: 1 case (Jig No. 5)
From the part-specific condition parameter file 9, the total number of replacement steps is: B → A: 1 item × (1 + 5) = 6 A → B: 1 item × (1 + 1) = 2 D → B: 1 item × (1 + 1) = 2 gives 10 (= 6 + 2 + 2). In addition, since there is one unallocated empty jig for jig B, the total energy loss from component-specific condition parameter file 9 is B: 1 × 5 = 5. In addition, there is a 2
Case (Jig No. 1 was 29 minutes, Jig No. 3 was 30
Therefore, the total inventory loss is 3 (= 1 + 2) by adding the jig No. 1: 1 × 1 = 1. The jig No. 3: 1 × 2 = 2. Therefore, the production efficiency reduction index V2 of the subline order plan Q2 shown in FIG. 18 is 18 (= 10 + 5 + 3) by adding the total number of replacement steps, the total energy loss, and the total inventory loss.

Thereafter, the production efficiency reduction index V2 in the previous and current simulation results is compared (step S13). For example, if the previous index is larger than the current index, the current simulation result has a larger total loss. Since the value is small and the production efficiency is high, the stored order plans P2 and Q2 are rewritten with the current one (step S14), and the process proceeds to step S15. On the other hand, if the previous index is equal to or smaller than the current index, the process immediately proceeds to step S15. In step S15, it is determined whether there is an unallocated one between the head and the tail of the latest subline order plan Q2 (or Q2 '). If YES, the process returns to step S9; if NO, step S16. Proceed to. In the case of the first simulation,
Since there is no previous simulation, step S
By the judgment of 13, the process is immediately led to step S15. Here, in the determination of step S13, if the production efficiency decrease index is the same, the previous simulation result is selected. However, the present invention is not limited to this, and the current simulation result is selected. Of course, it is good. Further, it is also possible to set a selection criterion such as which parameter is to be emphasized.

For example, the order plans P2 and Q shown in FIG.
2 is obtained in the first simulation. Since there is an unallocated plan q (jig No. 1) in the subline order plan Q2, the process returns to step S9 to perform another simulation. Here, the last jig A to which jig B of jig No. 1 (scheduled completion time is 9:06) has been allocated.
Replace with As a result, there is no unallocated jig from the beginning to the end of the subline. Therefore, a plan is made in which the third allocation process is performed to reduce the energy loss to zero. The results (plan P2 ', Q2') are as shown in FIG.

The production efficiency reduction index V2 in the case shown in FIG. 19 is obtained as follows. In this case, two jigs are exchanged for B → A (Jig No. 2 and No. 1), one for A → B (Jig No. 6), and one for D → B (Jig No. 5). From the part-specific condition parameter file 9,
The total number of replacement steps is: B → A: 2 cases × (1 + 5) = 12 A → B: 1 case × (1 + 1) = 2 D → B: 1 case × (1 + 1) = 2 16 (= 12 + 2 + 2) ). Also,
Since there is no unallocated air jig, the total energy loss is zero. In addition, two cases were allocated in advance of 25 minutes or more (the leading time was 29 minutes for jig No. 1 and 3 for jig No. 3).
0 minutes), the total inventory loss is 3 (= 1 + 2) by adding jig No. 1: 1 × 1 = 1 jig No. 3: 1 × 2 = 2. Therefore, the production efficiency reduction index V2 of the sub-line order plan Q2 'shown in FIG. 19 becomes 19 (= 16 + 0 + 3) by adding the total replacement man-hours, the total energy loss, and the total inventory loss. This is worse than the previous simulation result shown in FIG. 18, and the production efficiency is better in the previous simulation. Therefore, the first simulation shown in FIG. 18 is selected as the optimal simulation result by the determination in step S13.

If the result of the determination in step S8 is NO and if the result of the determination in step S15 is NO, the subline order plan is finally determined (step S16). Here, a process with the smallest loss total value (production efficiency reduction index) is selected from the sequence plans obtained so far, and the process is used as a final subline sequence plan.

FIG. 13 is a flowchart showing the contents of the sub-line order plan determination process in FIG. Here, first, whether the simulation was performed,
It is determined whether or not the processing of steps S9 to S15 has been performed (step S61). If NO, the order plan Q1 stored in step S6 is used as the final subline order plan (step S63). Compares the production efficiency decrease index V1 of the sequence plan Q1 stored in step S6 with the production efficiency decrease index V2 of the sequence plan Q2 obtained by simulation (step S62). For example, if V1 <V2, the loss The order plan Q1 with the smaller total value is the final subline order plan (step S63), and if V1 ≥ V2, the order plan Q2 with the smaller total loss value is the final subline order plan (step S64). Then, the process returns to the main flowchart. Here, in the determination of step S62, when the production efficiency decrease index is the same, the plan Q1 is selected. However, the present invention is not limited to this, and the plan Q2, which is the simulation result, is selected. Of course, you may select. Further, it is also possible to set a selection criterion such as which parameter is to be emphasized.

For example, in the example of the present invention, a simulation is performed. The production efficiency decrease index V1 of the plan Q1 shown in FIG. 17 is 20, and the production efficiency decrease index V2 of the plan Q2 shown in FIG. Is 18
Therefore, the plan Q2 shown in FIG. 18 having the smaller total loss value is the final subline plan.

When the final subline order plan is determined, the result is output to the production order plan file 11 and stored (step S17).

Therefore, according to the present embodiment, the sub-line order plan is created in consideration of the scheduled introduction time of the main line, so that the finished product inventory of the sub-line can be minimized. In addition, since the sub-line ordering plan is created while evaluating the production efficiency based on the number of replacement steps, energy loss, and inventory loss, the most efficient sub-line ordering plan can always be planned objectively, reducing costs. Is achieved.

[Brief description of the drawings]

FIG. 1 is a block diagram illustrating a configuration of a production order determination device according to an embodiment of the present invention.

FIG. 2 is a conceptual diagram showing a line model of a main line and a sub line to which the present invention is applied;

FIG. 3 is a diagram showing an example of a file configuration of a jig configuration file of a main line and a sub line.

FIG. 4 is a diagram showing an example of a file configuration of a cycle time file for each main line part.

FIG. 5 is a diagram showing an example of a sequence plan with scheduled main line introduction times.

FIG. 6 is a diagram showing an example of a sequence plan with a scheduled subline completion time.

FIG. 7 is a diagram showing an example of part-specific condition parameters;

8 is a main flowchart showing the operation of the apparatus shown in FIG.

FIG. 9 is a flowchart showing the content of a first allocation process in FIG. 8;

FIG. 10 is a flowchart showing the contents of a second allocation process in FIG. 8;

FIG. 11 is a flowchart showing the contents of a jig replacement process in FIG. 8;

FIG. 12 is a flowchart showing the contents of a third allocation process in FIG. 8;

FIG. 13 is a flowchart showing the contents of a subline order plan determination process in FIG. 8;

FIG. 14 is a diagram showing one stage of a specific example.

FIG. 15 shows the next stage of the same example.

FIG. 16 shows the next stage of the same example.

FIG. 17 shows the next stage of the same example.

FIG. 18 shows the next stage of the same example.

FIG. 19 shows the next stage of the same example.

[Explanation of symbols]

 1, 2, 3, 4, 7, 8, 9, 11 file 5 scheduled main line input time calculation unit (first calculation means) 6 scheduled sub line completion time calculation unit (second calculation means) 10 sub line production Sequence plan creation unit (calculation means)

──────────────────────────────────────────────────続 き Continued on the front page (58) Field surveyed (Int.Cl. ⁷ , DB name) G05B 19/418 G06F 17/60

Claims (4)

(57) [Claims] 1. A main line for performing production by circulating a plurality of jigs different for each component type in a fixed arrangement order in a ring.
This is a device that determines the production order of sub-lines that supply parts with the same type of line configuration .
A first calculating means for calculating a scheduled insertion time of a component to be inserted into a sub-line based on a current jig arrangement order of the sub-line.
A second calculating means for calculating a scheduled completion time of the part in the first calculating means, and a result of the first calculating means and a result of the second calculating means.
So that it can be timely planned for the main line
Allocate the jig of the sub line, and
Production efficiency evaluation parameters, and
While replacing the actual jig to maximize the production efficiency,
Production sequence confirmation device having an arithmetic means for creating a production sequence plan Luo subline. 2. The computing device according to claim 1, wherein the plurality of jigs need to be replaced.
When selecting one jig from among the allocation candidates of
2. The method according to claim 1, wherein the one that minimizes the number of replacement steps is selected.
Production order confirmation device. 3. The production efficiency evaluation parameter further includes:
It is based on the energy loss of unassigned air jigs.
3. The production order determination device according to claim 1, wherein: 4. The production efficiency evaluation parameter further includes:
Claim based on inventory loss due to allocation time difference
The production order determination device according to any one of claims 1 to 3.