JP7654158B2 - Production planning device, production planning method, and program - Google Patents

Description

The present disclosure relates to a production planning device, a production planning method, and a program.

In the manufacturing industry, a production planning system has been proposed that creates a manufacturing plan for ordered products. For example, Patent Document 1 discloses a production planning system that calculates the number of each part required based on order information, and sets the usage period of each piece of processing equipment based on the processing capacity of each piece of processing equipment.

JP 2019-175032 A

In this production planning system, manufacturing plans are drawn up assuming that processing for one order will occupy one piece of processing equipment, and no consideration is given to the parallel processing of parts for products of multiple orders at one processing equipment. As a result, even if processing is actually possible in parallel, orders may be assigned to other processing equipment or on a different day, reducing the operating efficiency of the processing equipment and lengthening manufacturing times, making it possible to obtain an appropriate production plan. This makes it difficult to draw up an appropriate production plan. Similar problems exist not only when manufacturing products, but also when drawing up production plans for various products, such as the production of raw materials.

This disclosure has been made in consideration of the above-mentioned situation, and aims to provide a production planning device, a production planning method, and a program capable of creating more appropriate production plans.

In order to achieve the above-mentioned object, the production planning device disclosed herein is a production planning device that creates a production plan for production using production equipment capable of processing multiple workpieces in parallel, and includes: a resource information acquisition unit that acquires resource information including a production capacity indicating the number of workpieces that each production equipment can process in parallel , equipment resources available to each production equipment, and a capacity occupancy indicating the capacity of the production equipment occupied by each equipment resource; an order information acquisition unit that acquires multiple order information each including a product, a required quantity, and a delivery date; and a production plan generation unit that allocates a processing period to the production equipment for each order information based on the order information acquired by the order information acquisition unit and the resource information acquired by the resource information acquisition unit, and creates a production plan that can produce the required quantity while complying with the delivery date. When creating a production plan for certain order information, the production plan generation unit identifies equipment resources required for producing the product included in the order information, calculates the capacity amount occupied by processing the order information based on the identified equipment resources and the capacity occupation amount of the equipment resources, and when the sum of the capacity amount of the production equipment occupied by processing for other order information and the calculated capacity amount of the order information for which the production plan is being created during a period when processing according to a production plan for other order information is already assigned to a certain production equipment is less than the production capacity of the production equipment , determines that products of multiple orders can be produced in parallel, and creates a production plan by overlappingly allocating processing according to the order information for which the production plan is being created to the period when processing for the other order information is assigned.

According to the present disclosure, when creating a production plan, if the number of workpieces already assigned for parallel processing is smaller than the production capacity of the production equipment, the production plan is generated by assigning the processing of workpieces according to the order information for which the production plan is to be created. Therefore, processing for multiple order information can be performed in parallel with one production equipment. This reduces waiting for free production equipment, increases the operating rate of the production equipment, and reduces production time, allowing for the creation of a more appropriate production plan.

FIG. 1 is a block diagram showing a functional configuration of a production planning device according to an embodiment. FIG. 2 is a diagram showing an example of order information stored in the order information storage unit shown in FIG. 1 ; FIG. 2 is a diagram showing an example of an item master table stored in an item master storage unit shown in FIG. 1 . FIG. 2 is a diagram showing an example of a process master table stored in a process master storage unit shown in FIG. 1 . FIG. 2 is a diagram showing an example of a resource master table stored in a resource master storage unit shown in FIG. 1 . FIG. 2 is a diagram showing an example of an operable table stored in the operable schedule storage unit shown in FIG. 1 . FIG. 2 is a diagram showing an example of a child resource status table stored in a child resource status storage unit shown in FIG. 1 . FIG. 2 is a diagram showing an example of a production plan table stored in a production plan storage unit shown in FIG. 1 . FIG. 1 is a block diagram showing an example of a physical configuration of a production planning device according to an embodiment. 1 is a flowchart showing a production planning process performed by a production planning device according to an embodiment. FIG. 2 is a block diagram showing a functional configuration of a modified example of the production planning device shown in FIG. FIG. 12 is a diagram showing an example of a resource master table stored in a resource master storage unit shown in FIG. 11 . FIG. 12 is a diagram showing an example of a resource shape master table stored in the resource shape master storage unit shown in FIG. 11 . FIG. 12 is a diagram showing an example of an arrangement result generated by the planar shape allocation calculation unit shown in FIG. 11 . FIG. 12 is a diagram showing an example of an arrangement result generated by the planar shape allocation calculation unit shown in FIG. 11 . A flowchart showing a production planning process by the production planning device shown in FIG.

Hereinafter, a production planning device, a production planning method, and a program according to an embodiment of the present disclosure will be described with reference to the drawings. Note that the same or corresponding parts in the drawings are denoted by the same reference numerals.

The production planning device according to this embodiment is a device that creates a production plan to meet the delivery deadlines of ordered products in a factory that manufactures multiple made-to-order products. The factory is equipped with processing equipment that processes multiple parts or intermediate products in parallel using multiple jigs in parallel that support, for example, hold, the workpieces that are the objects of the work. Here, processing includes any processing such as physical processing using tools such as drills and cutting tools, chemical processing using chemical substances such as chemical solutions and gases, and thermal processing involving heating, cooling, leaving at room temperature, etc. The workpieces may be amorphous objects such as tangible objects, materials, and substances.

The production planning device stores in advance a resource master including a production capacity indicating the number of workpieces that each processing equipment possesses can process in parallel. The production planning device identifies equipment resources including the necessary processing steps and processing equipment and jigs for each order. The production planning device identifies the number of workpieces that the identified processing equipment can process in parallel, and generates a production plan table in which the usage period of the processing steps for each order is assigned to each equipment resource. When planning a production plan for a certain order, if the number of workpieces to be processed in parallel that have already been assigned is smaller than the production capacity during a period in which processing has already been assigned by other orders, the production planning device assigns the processing of the workpieces according to the order for which the production plan is being planned. In this embodiment, an example is described in which each processing equipment is assigned a process for processing one workpiece in sequence using one jig for one order.

Next, the configuration of the production planning device according to the present embodiment will be described. As shown in FIG. 1, the production planning device 100 includes a storage unit 110 that stores various data, and an execution unit 120 that executes a process for creating a production plan.

The memory unit 110 includes an order information memory unit 111 that stores order information indicating the contents of an order, an item master memory unit 112 that stores an item master table that indicates the items of products being manufactured in the factory, a process master memory unit 113 that stores a process master table that indicates the processing processes for processing parts or intermediate products of each product, a resource master memory unit 114 that stores a resource master table that indicates information about the processing equipment and jigs owned by the factory, an operable schedule memory unit 115 that stores the operable schedule of each processing equipment, a child resource status memory unit 116 that stores a child resource status table that indicates the dates and times when each jig cannot be used, and a production plan memory unit 117 that stores a production plan.

The order information storage unit 111 stores order information indicating the contents of an order. As illustrated in FIG. 2, the order information includes an "order ID" indicating information that uniquely identifies the order, an "order date" indicating the date on which the order was received, a "product name" which is an example of identification information for the ordered product, an "order quantity" indicating the required quantity of the product, and a "delivery date" indicating the delivery date of the product. In the illustrated example, the contents of an order with an order ID of "M100001" indicate that the order date is "April 1, 2022", the product name of the ordered product is "Product A", the number of orders is 10, and the delivery date of the product is "October 30, 2022".

Returning to Figure 1, the item master storage unit 112 stores an item master table that indicates the items of products produced in the factory. As shown in Figure 3, the item master table includes information such as a "product ID" that indicates information that uniquely identifies each product, and a "product name" that indicates the name of each product.

Returning to FIG. 1, the process master storage unit 113 stores a process master table indicating the processing steps for processing the parts or intermediate products of each product. As illustrated in FIG. 4, the process master table includes information such as "product ID" indicating information that uniquely identifies the product, and "process 1", "process 2", "process 3", "process 4", etc., indicating the process order of each processing step. In addition, the process master table includes information such as "process ID" indicating information that uniquely identifies each processing step, "LT" indicating the time required to process one product part or intermediate product in each processing step in hours, and "equipment" indicating information that uniquely identifies the processing equipment and jigs used when performing each processing step. In the illustrated example, a product with a product ID of "A-1" is a product manufactured by three processing steps, and the first processing step performed is "PA1", the second processing step performed is "PA2", and the last processing step performed is "PA3". Furthermore, the time required per product in the processing step "PA1" is 0.5 hours, the identification ID of the processing equipment used is "F0001", and the identification ID of the jig used is "J01". The process master table is an example of process information.

Returning to FIG. 1, the resource master storage unit 114 stores a resource master table showing information on the processing equipment and jigs owned by the factory. As shown in FIG. 5, the resource master table includes the following information: "equipment ID" showing information that uniquely identifies each processing equipment; "capacity" showing the number of workpieces that each processing equipment can process in parallel; "child resource ID" showing information that uniquely identifies jigs that can be used in each processing equipment; and "capacity occupancy" showing the capacity of the processing equipment occupied by one jig. In the example shown in the figure, the processing equipment with equipment ID "F0001" has the capacity to work on two workpieces using two jigs in parallel, and the available jigs are "J01" and "J02". Also, it is shown that the jigs "J01" and "J02" each occupy one capacity of "F0001". In other words, "F0001" can process multiple parts or intermediate products in parallel by using the jigs "J01" and "J02" in parallel. Also, this means that the processing equipment with equipment ID "F0004" with a capacity of 0 is not currently operating. Note that the resource master table is an example of resource information, and the capacity stored in the resource master table is an example of production capacity.

Returning to Figure 1, the operable schedule memory unit 115 stores an operable table indicating the available operation time for each piece of processing equipment each day. As illustrated in Figure 6, the operable table has information on an "equipment ID" that indicates information that uniquely identifies the processing equipment, and a "date" that indicates the available operation time for each piece of processing equipment each day. The available operation time for each day is stored in the "date". The available operation time is set by the user, taking into account the target operation rate of each piece of equipment, the number of personnel, etc.

Returning to FIG. 1, the child resource status storage unit 116 stores a child resource status table indicating the date and time when each jig cannot be used. As illustrated in FIG. 7, the child resource status table has a "child resource ID" indicating information that uniquely identifies each jig, a "status" indicating whether the jig is in a usable state or not, and a "start time" and "end time" indicating the period during which the jig cannot be used. In the illustrated example, a jig with a child resource ID of "J01" indicates that it is in an unusable state from midnight on September 1, 2022 to midnight on September 30, 2022. Additionally, jigs with child resource IDs of "J02", "J04", and "J05" indicate that there is no period during which they are in an unusable state.

Returning to FIG. 1, the production plan storage unit 117 stores a production plan table, which is information indicating which equipment resources, including processing equipment and jigs, are used for which order and for which period of time. As illustrated in FIG. 8, the production plan table has an "equipment ID" indicating information that uniquely identifies each equipment resource, an "order ID" indicating information that uniquely identifies each order, a "product ID" indicating information that uniquely identifies a product, a "process ID" indicating information that uniquely identifies a processing process, a "start date and time" indicating the start date and time when each equipment resource is used, and an "end date and time" indicating the end date and time when each equipment resource is used. In the illustrated example, the processing equipment with the equipment ID "F0001" is used by the processing process "PB1" of the product "B-1" of the order with the order ID "M090001" from 8:00 on October 27, 2022 to 18:00 on October 27, 2022.

Returning to Figure 1, the execution unit 120 includes an order information receiving unit 121 that receives input of order information, a priority calculation unit 122 that determines the priority of each order, an operable schedule receiving unit 123 that receives input of the operable schedule of each processing equipment, a child resource status receiving unit 124 that receives input of unavailable periods for each jig, a production plan generation unit 125 that generates a production plan, and a production plan output unit 126 that outputs the generated production plan.

The order information receiving unit 121 receives input of order information and generates order information indicating the contents of the order based on the received information. Specifically, when information such as the product name, order date, order quantity, and delivery date of the ordered product is input by the user's input operation, the order information receiving unit 121 assigns unique identification information to each order and generates the order information shown in FIG. 2. The order information receiving unit 121 stores the generated order information in the order information storage unit 111.

Returning to FIG. 1, the priority calculation unit 122 executes a process of calculating the priority of each order. Specifically, the priority calculation unit 122 calculates the start date for starting the manufacture of each order product from the product name, order quantity, and delivery date included in the order information shown in FIG. 2, and the time required for each processing step for each product included in the process master table shown in FIG. 4. For example, when calculating the start date for an order with order ID "M100001" shown in FIG. 2, the priority calculation unit 122 multiplies "10", which is the order quantity of product A, by "0.5h", "1h", and "1h", which are the time required per product for each process ID "PA1", "PA2", and "PA3" included in the process master table shown in FIG. 4. The priority calculation unit 122 then calculates that the time required for each process is "5h", "10h", and "10h", respectively. Next, the priority calculation unit 122 adds up the time required for each calculated process and calculates that the time required for all processes is 25 hours. Next, since the normal operating hours of the factory are 10 hours from 8:00 to 18:00, the priority calculation unit 122 divides the calculated 25 hours by 10 hours, and calculates the production lead time required to complete the product of this order by rounding up the decimal point of the result of the division, "2.5", to "3 days". Next, the priority calculation unit 122 calculates backwards from the delivery date of the order ID "M100001" on October 30, 2022, and calculates that the start date of this order is October 27, 2022, three days before. The priority calculation unit 122 sets the priority order in order of the calculated start date. Note that the priority calculation unit 122 is an example of a priority calculation unit and a start date calculation unit.

Returning to FIG. 1, the operable schedule reception unit 123 receives the input of the daily operable schedule of each processing equipment, and generates an operable table based on the received information. Specifically, when the user operates the interface screen for generating the operable table and selects tabs such as "Full-day operation", "Half-day operation in the morning", "Half-day operation in the afternoon", and "Full-day + 2-hour operation" displayed on the screen for each processing equipment for each day, which is a unit period, the operable schedule reception unit 123 automatically inputs the operable time corresponding to the selected tab to generate the operable table shown in FIG. 6. For example, when the "Full-day operation" tab is selected by the user, the period "8:00-18:00" is automatically input, when the "Half-day operation in the morning" tab is selected, the period "8:00-13:00" is automatically input, and when the "Half-day operation in the afternoon" tab is selected, the period "13:00-18:00" is automatically input. The operable schedule reception unit 123 stores the generated operable table in the operable schedule storage unit 115.

Returning to Figure 1, the child resource status receiving unit 124 receives input of the period during which each jig held cannot be used, and generates a child resource status table indicating the period during which each jig cannot be used based on the received information. Specifically, when the period during which each jig cannot be used is input by the user's input operation, the child resource status receiving unit 124 generates the child resource status table shown in Figure 7. The child resource status receiving unit 124 stores the generated child resource status table in the child resource status storage unit 116.

Returning to FIG. 1, the production plan generating unit 125 generates a production plan table, which is information indicating which order uses which equipment resource for which period. Specifically, the production plan generating unit 125 assigns to each equipment resource a period to be used for a processing step for processing the parts or intermediate products of each order, according to the priority according to the start date of each order determined by the priority calculation unit 122. First, the production plan generating unit 125 identifies the processing steps required to process the parts or intermediate products of each order, the time required for each processing step, and the necessary equipment resources from the process master table shown in FIG. 4. Next, the production plan generating unit 125 refers to the processing equipment operation table shown in FIG. 6 and the child resource status table showing the usable status of the jig shown in FIG. 7, and assigns the usage period according to the number of orders to the identified equipment resource in a backward manner. When allocating, the production plan generating unit 125 refers to the resource master table shown in Fig. 5 to determine whether the identified processing equipment can use multiple jigs in parallel to produce multiple ordered products in parallel, and if it is determined that the equipment can produce the products, the production plan generating unit 125 allocates the multiple orders to the same period. The details of the processing by the production plan generating unit 125 will be described later.

Returning to Figure 1, the production plan output unit 126 outputs the production plan table generated by the production plan generation unit 125.

The production planning device 100 having the functional configuration described above physically comprises, as shown in FIG. 9, a CPU (Central Processing Unit) 11 that executes processing according to a program, a RAM (Random Access Memory) 12 which is a volatile memory, a ROM (Read Only Memory) 13 which is a non-volatile memory, a memory unit 14 that stores data, an input unit 15 that accepts input of information, and a display unit 16 that visualizes and displays information, all of which are connected via an internal bus 99.

The CPU 11 executes various processes by reading the programs stored in the memory unit 14 into the RAM 12 and executing them. As the main functions provided by the programs, the CPU 11 executes each process by the order information receiving unit 121, the priority calculation unit 122, the operable schedule receiving unit 123, the child resource status receiving unit 124, the production plan generation unit 125, and the production plan output unit 126 that outputs the production plan.

The RAM 12 is used as a work area for the CPU 11. The ROM 13 stores the control program executed by the CPU 11 for the basic operation of the production planning device 100, the BIOS (Basic Input Output System), etc.

The storage unit 14 includes a hard disk drive, stores the programs executed by the CPU 11, and stores various data used when the programs are executed. The storage unit 14 functions as an order information storage unit 111, an item master storage unit 112, a process master storage unit 113, a resource master storage unit 114, an operable schedule storage unit 115, a child resource status storage unit 116, and a production plan storage unit 117.

The input unit 15 is a user interface equipped with a keyboard, a mouse, a communication device, etc. The display unit 16 is a display device such as a liquid crystal display or an organic EL (Electro Luminescence) display that visualizes and displays information.

Next, the operation of the production planning device 100 will be described with reference to FIG. 10. The production planning device 100 executes a production planning process that creates a production plan table by allocating the usage period of the processing process that processes the product parts or intermediate products of each order on a daily basis to facility resources including processing equipment and jigs owned by the factory. The production planning device 100 calculates the start date for production for each order, and calculates a priority according to the calculated start date. The production planning device 100 allocates the usage period of the processing process that processes the product parts or intermediate products in descending order of priority.

The order information receiving unit 121 of the production planning device 100 receives order information from the user, and based on the received information, inputs the "order date" indicating the date the order was received, the "product name" indicating the name of the ordered product, the "order quantity" indicating the ordered quantity of the product, and the "delivery date" indicating the delivery date of the product, to create the order information shown in Figure 2 in which an identification ID is assigned to each order, and stores the order information in the order information storage unit 111.

In addition, the memory unit 110 of the production planning device 100 pre-stores, by being set in advance by the user, an item master table indicating the items of products being manufactured in the factory shown in Figure 3, a process master table indicating the processing processes for processing parts or intermediate products of each product shown in Figure 4, a resource master table indicating information on the processing equipment and jigs held in the factory shown in Figure 5, an operation availability table indicating the operation schedule of each processing equipment shown in Figure 6, and a child resource status table indicating the period during which each jig is unavailable shown in Figure 7.

When a user operates the input unit 15 of the production planning device 100, specifies the period for which a production plan is to be created, and requests the start of the production planning process, the production planning device 100 starts the process.

The priority calculation unit 122 reads out from the order information storage unit 111 each piece of order information received during a period designated by the user (step S101). Specifically, the priority calculation unit 122 reads out the order information shown in FIG. 2 from the order information storage unit 111, and acquires the "order ID", "order date", "product name", "order quantity", and "delivery date" of orders for which the "order date" falls within the designated period. The priority calculation unit 122 is an example of an order information acquisition unit, and step S101 is an example of an order information acquisition step.

Returning to FIG. 10, next, the priority calculation unit 122 identifies the processing steps required to process the parts or intermediate products of the product of the acquired order, and the time and equipment resources required for each processing step (step S102). The priority calculation unit 122 estimates the time required to perform the process by calculating the time required to perform each processing step on the premise that the number of workpieces in each processing facility is one. Specifically, the priority calculation unit 122 refers to the item master table shown in FIG. 3 and acquires the product IDs corresponding to the product names acquired in step S101. Next, the priority calculation unit 122 acquires information on the processing steps required to manufacture the parts or intermediate products of each product, and the time and equipment resources required for each process from the process master table shown in FIG. 4 using the acquired product IDs as a key. In the case of product A in FIG. 2, the priority calculation unit 122 uses the product ID "A-1" acquired from the item master table shown in FIG. 3 as a key to determine from the process master table in FIG. 4 that the processing steps required to process the parts or intermediate products of product A are three steps, "PA1", "PA2", and "PA3", that the lead times per product in each step are "0.5 hours", "1 hour", and "1 hour", and that the equipment to be used is "F0001", "J01", "F0002", "J02", and "F0003" and "J04", respectively. The priority calculation unit 122 performs similar processing to determine the processing steps and the time and equipment resources required for each processing step for other ordered products included in the order information, such as product B, . ...

Returning to FIG. 10, next, the priority calculation unit 122 calculates the priority of each order acquired in step S101 (step S103). Specifically, first, the priority calculation unit 122 calculates a production lead time indicating the shortest number of days from start to finish of production of each order based on the delivery date and order quantity of each order included in the order information read in step S101, and the processing steps of the product identified in step S102 and the time required for each processing step. The priority calculation unit 122 calculates backwards from the delivery date to the calculated lead time, assuming that production will be completed by the day before the delivery date, and calculates the start date for the first processing step for each order.

For example, when calculating the start date of an order with order ID "M100001" shown in FIG. 2, the priority calculation unit 122 multiplies "10", which is the number of ordered items of product A, by "0.5h", "1h", and "1h", which are stored in "LT", which is the time required per product for each of the process IDs "PA1", "PA2", and "PA3" included in the process master table shown in FIG. 4, respectively, to obtain the product, and calculates that the time required for each process is "5h", "10h", and "10h", respectively. Next, the priority calculation unit 122 adds up the calculated time required for each process and calculates that the time required for all processes is 25 hours. Next, since the normal operating hours of the factory are 10 hours from 8:00 to 18:00, the priority calculation unit 122 divides the calculated 25 hours by 10 hours, and calculates the division result "2.5" as "3 days" by rounding up the decimal points, as the production lead time required to complete the product of this order.

Next, the priority calculation unit 122 calculates backwards from the delivery date of order ID "M100001" of October 30, 2022, and calculates that the start date of this order is October 27, 2022, three days before that. The priority calculation unit 122 calculates the start dates for each of the other orders "M100002", ... using a similar method. The priority calculation unit 122 links the time required for each processing step, the calculated production lead time, and the start date to each order ID and stores them in the memory unit 110. The calculated start dates are used as priorities for determining which orders to prioritize when the production plan generation unit 125 generates a production plan table.

Returning to FIG. 10, the production plan generation unit 125 then reads out the available operation schedule for each piece of processing equipment (step S104). Specifically, the production plan generation unit 125 reads out the available operation table for the processing equipment shown in FIG. 6, and obtains the date and time when each piece of processing equipment is scheduled to operate.

Returning to FIG. 10, the production plan generating unit 125 then assigns each processing step to processing equipment in the order of the order with the earliest start date calculated in step S103. In the case of an order with multiple processing steps, the production plan generating unit 125 refers to the operable table shown in FIG. 6 and assigns the processing steps to processing equipment in the order of the latest processing step using a backward method. For example, in the case of an order with order ID "M100001" shown in FIG. 2, the period required to perform each step is assigned to the target processing equipment in the order of "PA3" → "PA2" → "PA1". Specifically, on October 29, the day before the delivery date, the equipment can operate from 8:00 to 18:00, and 10 hours are required to perform "PA3", so the production plan generating unit 125 assigns the processing step "PA3" of order ID "M100001" to the period from 8:00 to 18:00 on October 29 of equipment ID "F0003". Similarly, since the equipment is operable from 8:00 to 20:00 on October 28th and 10 hours are required to execute "PA2", the production plan generating unit 125 allocates the processing step "PA2" of the order ID "M100001" to the equipment ID "F0002" from 10:00 to 20:00 on October 28th. Also, since the equipment is operable from 8:00 to 18:00 on October 27th and 5 hours are required to execute "PA1", the production plan generating unit 125 allocates the processing step "PA1" of the order ID "M100001" to the equipment ID "F0001" from 8:00 to 10:00 on October 28th and from 15:00 to 18:00 on October 27th.

Returning to FIG. 10, the production plan generation unit 125 next determines whether the capacity of the processing equipment used in each processing step is sufficient, in other words, whether there is available capacity (step S105). Specifically, the production plan generation unit 125 refers to the resource master table shown in FIG. 5 to obtain a "capacity" value indicating the number of workpieces that each processing equipment can process in parallel.

Next, the production plan generation unit 125 determines that the capacity of the processing equipment is sufficient if the number of orders already assigned to the processing equipment + 1 = number of tools to which orders are assigned + 1 is less than or equal to the acquired capacity value.

For example, when allocating processing process PA1 with order ID "M100001" shown in Fig. 2 to processing equipment with equipment ID F0003 for the period from 8:00 to 18:00 on October 29, 2022, the production plan generation unit 125 obtains the capacity value of F0003, which is 2, from the resource master table shown in Fig. 5. Next, the production plan generation unit 125 checks the production plan table and finds the number of orders already allocated for the same period = the number of jigs to which orders are assigned. For example, as described above, when the process with process ID "PA1" of order ID "M100001" is assigned to October 27th, if the production plan table shown in Fig. 8 is an already created table, one order with order ID "M090001" that uses processing equipment F0001 during the same period has already been assigned to use jig J01, so the production plan generation unit 125 determines that the capacity of F00001 is sufficient, that is, there is free space, since the numerical value after allocating order ID "M100001" is 2, which is less than the acquired capacity (step S105; Yes). Note that the production plan generation unit 125 is an example of a resource information acquisition unit, and step S105 is an example of a resource information acquisition step and a production plan generation step.

Returning to FIG. 10, the production plan generating unit 125 next determines whether the jigs used in each processing facility are available (step S106). Specifically, the production plan generating unit 125 refers to the child resource status table showing the unavailable period of each jig shown in FIG. 7 and the created production plan table shown in FIG. 8, and determines that the jig is available if the period to which the processing process is to be assigned is not a period during which the jig is unavailable and if no other orders have already been assigned. When the production plan generating unit 125 determines that the jig is available (step S106; Yes), it assigns the processing process of the target order to the processing facility by setting the start date and time and the end date and time of each processing process of the target order to the target facility resource and updating the production plan table (step S107).

Returning to FIG. 10, the production plan generation unit 125 next determines whether there are any unprocessed orders (step S108). If the production plan generation unit 125 determines that there are no unprocessed orders (step S108; No), it generates and outputs the latest updated production plan table as a production plan (step S109), and ends the process. On the other hand, if the production plan generation unit 125 determines that there are unprocessed orders (step S108; Yes), it returns to step S105 and determines whether the capacity of the processing equipment used for each processing step of the unprocessed orders is sufficient (step S105).

In step S105, if the production plan generating unit 125 determines that the capacity of the processing equipment is insufficient (step S105; No), or if the production plan generating unit 125 determines in step S106 that the target jig cannot be used (step S106; No), the production plan generating unit 125 determines whether the start date of the order to be processed can be changed (step S110). Specifically, the production plan generating unit 125 changes the start date of the target order calculated in step S103 to a date one day earlier, and if the change date is a date after the order date of the target order, it determines that the change is possible (step S110; Yes). Next, the production plan generating unit 125 returns to step S105 and determines whether the capacity of the processing equipment used in each processing step of the target order is sufficient on the changed start date (step S105).

Returning to step S110, if the production plan generation unit 125 determines that the start date of the order to be processed cannot be changed (step S110; No), it outputs an error message to the effect that the target order cannot be allocated (step S111) and terminates the process. The user then resets the resource master table shown in FIG. 6 or the child resource status table shown in FIG. 7, and repeats the production plan creation process until the error message is no longer displayed.

As described above, the production planning device 100 calculates the number of workpieces that can be processed in parallel depending on the number of jigs that the owned processing equipment can use in parallel, and allocates each processing step to the processing equipment. When planning a production plan for an order, if the number of workpieces already assigned to be processed is smaller than the production capacity during a period when processing has already been allocated for other orders, the processing of the workpieces for the order for which the production plan is being planned is allocated. This makes it possible to create an appropriate production plan.

(Modification)
In the above embodiment, the resource master table shown in Fig. 5 is set with "capacity" indicating the number of workpieces that each piece of processing equipment can process in parallel and "capacity occupancy" indicating the capacity of the processing equipment occupied by one jig, and the production plan generating unit 125 determines whether or not the capacity of the processing equipment occupied by the jig to which the order is assigned is equal to or less than the capacity of the processing equipment to determine whether or not the order can be assigned. In contrast, the production plan planning device 100a according to the modified example determines whether or not the jig can be placed on the processing table based on the shape and size of the mounting surface of the processing table on which the jig provided in the processing equipment is placed, and the shape and size of the surface of the jig that contacts the mounting surface of the processing table.

As shown in FIG. 11, the production planning device 100a includes an order information storage unit 111, an item master storage unit 112, a process master storage unit 113, an operable schedule storage unit 115, a child resource status storage unit 116, and a production plan storage unit 117 that are included in the production planning device 100, as well as a resource shape master storage unit 201 that indicates the shape and size of the mounting surface of the processing table of the processing equipment and the surface of the jig that contacts the mounting surface of the processing table. 4, the production planning device 100 is provided with a storage unit 110a including a resource master storage unit 114a that stores a resource master indicating the processing equipment owned by the factory and the jigs that can be used for each processing equipment, and an execution unit 120a including an order information receiving unit 121, a priority order calculation unit 122, an operable schedule receiving unit 123, a child resource status receiving unit 124, a production plan generation unit 125, and a production plan output unit 126 that are provided in the production plan planning device 100, as well as a planar shape allocation calculation unit 202 that determines whether or not a jig can be installed on the processing table.

The resource master storage unit 114a stores a resource master table that indicates the processing equipment owned by the factory and the jigs that can be used with each processing equipment. As shown in FIG. 12, the resource master table includes information such as an "equipment ID" that indicates information that uniquely identifies each processing equipment, and a "child resource ID" that indicates information that uniquely identifies the jigs that can be used with each processing equipment. In the example shown, the processing equipment with an equipment ID of "F0005" indicates that the jigs "J06" and "J07" can be used.

Returning to FIG. 11, the resource shape master storage unit 201 stores a resource shape master table indicating the shape and size of the placement surface of the processing table of the processing equipment and the surface of the jig that contacts the placement surface of the processing table. As illustrated in FIG. 13, the resource shape master table includes information such as "equipment ID/child resource ID" indicating information that uniquely identifies the processing equipment or jig, and "vertex coordinate 1", "vertex coordinate 2", "vertex coordinate 3", and "vertex coordinate 4" indicating the shape and size of each processing equipment and jig. In the illustrated example, the placement surfaces of the processing tables of the processing equipment "F0005" and "F0006", and the surface of the jig that contacts the placement surface of the processing table are each rectangular, but may be polygonal by setting 3 or 4 or more vertex coordinates. The resource shape master table is an example of resource shape information.

Returning to FIG. 11, the planar shape allocation calculation unit 202 determines whether or not a jig can be placed on the machining table based on the shape and size of the placement surface of the machining table set in the resource shape master table shown in FIG. 13 and the shape and size of the surface of the jig that contacts the placement surface of the machining table. Specifically, the planar shape allocation calculation unit 202 obtains the placement result of placing the jig on the machining table using a mathematical optimization algorithm set in advance by pulp, python-mip, etc. When determining whether or not the jigs "J06" and "J07" can be placed on the placement surface of the machining table of the machining equipment "F0005" illustrated in FIG. 13, the planar shape allocation calculation unit 202 determines that the jigs "J06" and "J07" can be placed, respectively, based on the placement result of placing the jigs "J06" and "J07" on the placement surface 20 of the machining table of the machining equipment "F0005" illustrated in FIG. 14. On the other hand, when determining whether the jigs "J06" and "J07" can be installed on the placement surface of the processing table of the processing equipment "F0006" illustrated in FIG. 13, the planar shape allocation calculation unit 202 determines that only the jig "J06" can be installed based on the placement result of the jig "J06" being placed on the placement surface 21 of the processing table of the processing equipment "F0006" illustrated in FIG. 15. It should be noted that which of "J06" and "J07" is placed first may be arbitrarily set, for example, by prioritizing placement of a jig with a smaller difference in area with the placement surface of the processing table, or by prioritizing a jig assigned to an order with a close delivery date. It should be noted that the planar shape allocation calculation unit 202 is an example of a production plan generation unit and a resource shape information acquisition unit.

Next, the operation of the production planning device 100a will be described with reference to Figure 16. Note that Figure 16 includes steps common to the flowchart shown in Figure 10, so the differences will be mainly described.

The memory unit 110a of the production planning device 100a pre-stores a resource shape master table shown in FIG. 13 and, instead of the resource master table shown in FIG. 5, a resource master table shown in FIG. 12.

In step S205, the production planning device 100a determines whether the capacity of the processing equipment used in each processing step is sufficient (step S205). Specifically, for example, when allocating an order for a processing step in which the jig "J07" is used during a certain period of the processing equipment "F0005", the planar shape allocation calculation unit 202 reads out the already created production plan table shown in FIG. 8 and determines whether there is an order using the processing equipment "F0005" during the same period. If another order using the jig "J06" has already been allocated, the planar shape allocation calculation unit 202 refers to the resource shape master table shown in FIG. 13 to obtain the shape and size of the placement surface of the processing table of the processing equipment "F0005" and the shape and size of the surface in contact with the placement surface of the processing table of the jigs "J06" and "J07". The planar shape allocation calculation unit 202 uses a preset mathematical optimization algorithm to obtain the placement result of the jig placed on the processing table. When the planar shape allocation calculation unit 202 obtains an arrangement result in which the jigs "J06" and "J07" illustrated in Fig. 14 are arranged, the planar shape allocation calculation unit 202 determines that the capacity of the processing equipment "F0005" is sufficient (step S205; Yes). After that, the process proceeds to step S106, and a production plan is generated by the same process as steps S106 to S111 by the production planning device 100. On the other hand, when there is a jig that has not been arranged by the calculation, the planar shape allocation calculation unit 202 determines that the capacity of the processing equipment "F0005" is insufficient (step S205; No), and proceeds to step S110 in which the planar shape allocation calculation unit 202 determines whether or not the start date of the order to be processed can be changed for the order of the processing process that uses the jig that has not been arranged, as in the production planning device 100.

As described above, the production planning device 100a can determine whether the capacity of the processing equipment is sufficient by determining whether a jig can be installed on the processing table based on the shape and size of the mounting surface of the processing table of the processing equipment and the shape and size of the surface of the jig that contacts the mounting surface of the processing table.

Without departing from the spirit of this disclosure, it is possible to select and/or change the configurations set forth in the above embodiments to other configurations as appropriate.

In the above embodiment, a workpiece, meaning a part or intermediate product that constitutes a product, is given as an example of the object to be processed. However, the product does not have to be something that can be counted, and the type of object can be any type, such as substances, materials, raw materials, energy, etc., with quantities such as mass, length, or area as units. The memory unit 110 only needs to store order information including information that can identify each object and a quantity indicating the number or amount of the objects according to the type of object.

For one order, the processing steps are assigned to the processing equipment so that one part is processed in sequence. However, it is also possible to assign one order to the processing equipment so that two or more n parts are processed in parallel. In this case, when determining whether there is sufficient capacity in step S105, it is determined whether the number of assigned orders + n is less than or equal to the capacity, and in step S106 it is determined whether n or more jigs are available.

In addition, in the above embodiment, the usage period of a processing process is assigned to processing equipment, but the usage period of a production process that produces each product may be assigned to production equipment that produces any of the above-mentioned objects. The memory unit 110 may store a process master table that includes information that can identify the production equipment, the number of objects produced, and the production process that produces each product according to the type of object.

In step S103 of the above embodiment, the priority calculation unit 122 calculates the production lead time assuming that the product will be completed the day before the delivery date, but this is not limited to this. For example, a transportation lead time, which is the number of days required for transportation for each order, may be preset in the order information shown in FIG. 2, and the production lead time may be calculated assuming that the product will be completed on the date obtained by subtracting the transportation lead time from the delivery date. In addition, any date and time may be specified as the product completion date.

In the above embodiment, the production plan generation unit 125 assigns the orders to processing equipment in the order of the highest priority by setting the priority from the order with the earliest start date calculated in step S103, but this is not limited to the above. For example, the priority may be set based on an arbitrarily set rule such as the order with the earliest delivery date or the order date, and the orders may be assigned to processing equipment in the order of priority. In this case, the orders may be assigned to processing equipment in the order of the highest priority. Alternatively, the orders may be assigned to processing equipment in the order of the smallest order ID, and if it is determined in step S105 that the capacity of the processing equipment is insufficient (step S105; No), the processing of the work by the high priority order and the processing of the low priority order may be interchanged, and the start date for the processing of the low priority order may be changed (step S110).

In addition, in the above embodiment, the production plan generation unit 125 uses a backward method in which processing processes are allocated by calculating backwards from each delivery date, but this is not limited to this, and a forward method in which processing processes are allocated forward from the order date may also be used.

The "LT" for each process included in the process master table shown in Figure 4 is the time required to produce one product, but is not limited to this and may be the time required to produce any unit quantity of products, such as 1 dozen, 10 units, 100 units, "1 kg," "1 m3," "10 L (liters)," etc., depending on the form of the processing target. When calculating the start date for each order in step S103, the time required to perform each process can be calculated by dividing the order quantity by the unit quantity.

In the above embodiment, the production plan output unit 126 outputs the production plan table shown in FIG. 8 generated by the production plan generation unit as the production plan, but this is not limited to this. The production plan table may be processed as desired and converted into output data in a different output format for output. For example, the production plan table may be converted into a Gantt chart in which the horizontal axis represents time and the vertical axis represents equipment resources, and the implementation period for each assigned order is represented by a bar graph, and then output.

In addition, the information stored in the memory unit 110 may be managed collectively by a cloud server on the network, and the execution unit 120 may access the cloud server as necessary to read and write information. In this case, the production plan planning device 100 may not be provided with the memory unit 110.

In addition, the production planning device 100 can be realized using a normal computer system, not a dedicated device. For example, a program for realizing each function of the production planning device 100 may be stored and distributed on a computer-readable recording medium such as a CD-ROM (Compact Disc Read Only Memory) or a DVD-ROM (Digital Versatile Disc Read Only Memory), and a computer that can realize each of the above-mentioned functions may be configured by installing the program on a computer.

In addition, when each function is realized by sharing the functions between an OS (Operating System) and an application, or by cooperation between an OS and an application, only the application may be stored on the recording medium.

Various embodiments and modifications of the present disclosure are possible without departing from the broad spirit and scope of the present disclosure. Furthermore, the above-described embodiments are intended to explain the present disclosure and do not limit the scope of the present disclosure. In other words, the scope of the present disclosure is indicated by the claims, not the embodiments. Various modifications made within the scope of the claims and within the scope of the disclosure equivalent thereto are deemed to be within the scope of the present disclosure.

This application is based on Japanese Patent Application No. 2022-041916, filed on March 16, 2022. The entire specification, claims, and drawings of Japanese Patent Application No. 2022-041916 are incorporated herein by reference.

100, 100a Production planning device, 110, 110a Memory unit, 111 Order information memory unit, 112 Item master memory unit, 113 Process master memory unit, 114, 114a Resource master memory unit, 115 Available schedule memory unit, 116 Child resource status memory unit, 117 Production plan memory unit, 120, 120a Execution unit, 121 Order information reception unit, 122 Priority calculation unit, 123 Available schedule reception unit, 124 Child resource status reception unit, 125 Production plan generation unit, 126 Production plan output unit, 201 Resource shape master memory unit, 202 Planar shape allocation calculation unit, 99 Internal bus, 11 CPU, 12 RAM, 13 ROM, 14 Memory unit, 15 Input unit, 16 Display unit, 20, 21 Placement surface.

Claims (8)

A production planning device that creates a production plan for production using production equipment capable of performing processes for a plurality of workpieces in parallel,
a resource information acquisition unit that acquires resource information including a production capacity indicating the number of works that each piece of production equipment can process in parallel, equipment resources that each piece of production equipment can use, and a capacity occupancy amount indicating the capacity of the production equipment that each equipment resource occupies;
an order information acquisition unit that acquires a plurality of pieces of order information each including a product, a required quantity, and a delivery date;
a production plan generating unit which, based on the order information acquired by the order information acquiring unit and the resource information acquired by the resource information acquiring unit, allocates a processing period to a production facility for each piece of order information, and creates a production plan which is capable of producing a required quantity while complying with a delivery date;
the production plan generation unit, when creating a production plan for certain order information, identifies equipment resources required for producing a product included in the order information, calculates a capacity amount to be occupied by processing the order information based on the identified equipment resources and the capacity occupancy amount of the equipment resources, and, when a sum of the capacity amount of the production equipment occupied by the processing for the other order information and the calculated capacity amount of the order information for which the production plan is to be created is equal to or less than the production capacity of the production equipment during a period in which processing according to a production plan for other order information is already assigned to a certain production equipment, determines that products of a plurality of orders can be produced in parallel, and creates a production plan by overlappingly allocating the processing according to the order information for which the production plan is to be created to the period in which processing for the other order information is assigned.
Production planning device. a priority calculation unit for calculating priorities of a plurality of pieces of order information;
When there are a plurality of pieces of order information for which a production plan is to be created, the production plan creation unit creates a production plan in the order information with the highest priority calculated by the priority calculation unit.
The production planning device according to claim 1 . a process information acquiring unit that acquires process information including a plurality of production processes for producing products and a reference time required for producing a unit quantity of the products for each of the production processes;
a start date calculation unit that calculates a production lead time, which is the number of days required to produce the product of each order information item, based on the product of the required quantity of the product and the total value of the reference time of a plurality of production processes for producing the product, and calculates a production start date by subtracting the production lead time from a date set based on the delivery date of the product,
the priority calculation unit sets a high priority according to the calculated earlyness of the start date;
The production planning device according to claim 2 . The resource information includes information on jigs for supporting workpieces to be processed by each piece of production equipment,
When allocating processing to the production equipment, the production plan generation unit creates a production plan by identifying a jig that supports a workpiece to be processed, and when creating a production plan for certain order information, the production plan generation unit determines whether or not there is a jig to which processing has not been assigned during a period in which processing according to a production plan based on other order information has already been assigned to the production equipment, and if there is a jig to which processing has not been assigned, identifies at least one of the unassigned jigs and creates a production plan.
The production planning device according to claim 1 . The production plan generation unit
When making a production plan for certain order information, if it is determined that there is no jig to which processing is not assigned during a period in which processing according to a production plan based on other order information has already been assigned to the production equipment, the period for processing according to the order information for which the production plan is to be made is changed to a period in which there is a jig to which processing is not assigned.
The production planning device according to claim 4. The resource information includes information on jigs for supporting workpieces to be processed by each piece of production equipment,
a resource shape information acquiring unit that acquires resource shape information indicating a shape and a size of a mounting surface of a processing table on which the jig is placed and a shape and a size of a surface of the jig that contacts the mounting surface,
When allocating processing to the production equipment, the production plan generation unit creates a production plan by identifying a jig that supports the workpieces to be processed, and when creating a production plan for certain order information, the production plan generation unit determines whether or not there is a jig to which processing has not been assigned during a period in which processing according to a production plan based on other order information has already been assigned to the production equipment, and if it is determined that there is a jig to which processing has not been assigned, the production plan generation unit uses the resource shape information acquired by the resource shape information acquisition unit to determine whether or not the jig can be placed on the placement surface based on preset rules, and if it is determined that the jig can be placed, determines that the number of workpieces to be processed in parallel that have already been assigned is less than the production capacity of the production equipment, and allocates the jig to the period to create the production plan.
The production planning device according to claim 1 . A production planning method executed by a production planning device that creates a production plan for production using production equipment capable of performing processes for a plurality of workpieces in parallel, comprising:
a resource information acquisition step of acquiring resource information including a production capacity indicating the number of works that each production facility can process in parallel, equipment resources that each production facility can use, and a capacity occupancy amount indicating the capacity of the production facility occupied by each equipment resource;
an order information acquisition step of acquiring a plurality of pieces of order information each including a product, a required quantity, and a delivery date;
a production plan generating step of, when creating a production plan for certain order information, identifying equipment resources required for producing a product included in the order information, calculating a capacity amount occupied by processing the order information based on the identified equipment resources and the capacity occupancy amount of the equipment resources, and determining that products of a plurality of orders can be produced in parallel when a sum of a capacity amount of the production equipment occupied by the processing for the other order information and the calculated capacity amount of the order information for which the production plan is to be created is equal to or less than a production capacity of the production equipment during a period in which a processing according to a production plan for other order information is already assigned to the production equipment, and generating a production plan by overlappingly allocating the processing according to the order information for which the production plan is to be created to the period in which the processing for the other order information is assigned;
A production planning method comprising: A computer that is a production planning device that creates a production plan for production using production equipment that has the ability to execute processing for a plurality of workpieces in parallel,
A process of acquiring resource information including a production capacity indicating the number of works that each production facility can process in parallel, equipment resources that each production facility can use, and a capacity occupancy amount indicating the capacity of the production facility occupied by each equipment resource ;
A process of acquiring a plurality of pieces of order information each including a product, a required quantity, and a delivery date;
a process of, when creating a production plan for certain order information, identifying equipment resources required for producing a product included in the order information, calculating a capacity amount occupied by processing the order information based on the identified equipment resources and the capacity occupancy amount of the equipment resources, and determining that products of a plurality of orders can be produced in parallel when a sum of a capacity amount of the production equipment occupied by the processing for the other order information and the calculated capacity amount of the order information for which the production plan is being created is equal to or less than a production capacity of the production equipment during a period during which a processing according to a production plan for other order information is already assigned to the production equipment, and generating a production plan by overlappingly allocating the processing according to the order information for which the production plan is being created to the period during which the processing for the other order information is assigned;
A program that executes the following.