JPH0347340B2 - - Google Patents

Description

[Detailed Description of the Invention] [Industrial Application Field] The present invention is a device used to determine a production plan for a weaving process among textile production plans, and which automatically creates a loom arrangement plan. related to a device for

[Prior Art] Textiles are produced through a spinning process, a yarn processing process, a weaving process, and a finishing process in sequence. Among these, a large number of various types of looms are usually installed for the weaving process. The creation of a plan regarding which loom among these looms will be assigned to weave a certain textile, that is, the "composition", will directly affect the delivery date of the textile and the operating rate of the loom, so the production of the textile will be affected. This is particularly important in planning.

Conventionally, a machine arrangement plan is created manually by searching for a loom capable of weaving the textile while taking into consideration the delivery date of the textile and the planned production volume.
However, since it was not possible to fully consider the scheduled delivery date of yarn and the load on the loom, proceeding with the weaving process according to this plan would result in an increase in the amount of yarn in progress, and the loom would be overloaded. In addition, it is often necessary to change the arrangement of tables, making it difficult to carry out the weaving process in a planned manner.

Therefore, in Japanese Patent Application No. 61-273401, the applicant of the present application predicted the latest day when the raw yarn necessary for a certain textile could be input into the weaving process, that is, the latest date when the raw yarn could be input into the weaving process. , while calculating the number of looms selected for this fabric and calculating the number of days required for weaving on the looms,
Predict the date when the weaving machine currently in operation will be able to complete weaving and start weaving the next fabric, that is, the date when it is possible to start weaving, and calculate the latest date when yarn can be input, the number of days required for weaving, and when it is possible to start weaving. Determine the machine number of the bed loom from the date and the delivery date of the fabric, and set the latest date when yarn can be input or the date when weaving can be started as the scheduled start date of weaving on the loom with the machine number,
We have proposed an automatic loom arrangement plan creation device that outputs the machine number of the loom arranged on the fabric and the scheduled start date of weaving on this loom.

Now, when a loom runs out of weft or warp yarns to be supplied, it is necessary to replenish them. Among these, the replenishment of weft yarns can be executed in a short time, but when the warp wound around the beam runs out, that is, when warping occurs, replenishment of the weft yarns takes a long time. In particular, if the number of warp threads in the fabric to be woven later is different from that of the previous fabric, it is necessary to replace the healds and rethread the threads of a new beam through the healds, or ``pulling through'' the healds. In this case, it takes, for example, 6 hours to replenish or "switch" the warp threads. On the other hand, if the number of warp threads is the same, the warp threads can be replenished without performing the above-mentioned drawing and tying, by connecting the threads of a new beam to the warp threads remaining on the beam, or ``tying.'' It can be executed smoothly and in a shorter time than in the case of switching.

Therefore, when using the above-mentioned loom arrangement plan automatic creation device, the number of switching operations is reduced as much as possible, and warp yarns are replenished by tying whenever possible. In other words, for one order unit or contract, even if the patterns are different, the fabric structure is the same and the number of warp threads is the same. Therefore, within the same contract, fabrics with different patterns are sequentially placed on the same loom. Furthermore, even if the contracts were different, if the number of warp threads was the same, the woven fabrics of both contracts were placed on the same loom one after another. In this way, warp yarns can be replenished by tying instead of switching, and the number of switching can be reduced.

[Problems to be Solved by the Invention] The conventional automatic loom layout planning device as described above takes into account the scheduled arrival date of yarn and the load on the loom, so it reduces the amount of yarn in progress. Although this not only makes it possible to improve the operating rate of the loom, but also allows weaving to be carried out without changing the arrangement of the looms, the following problems occur.

In other words, because the timing of occurrence of turbulence was not taken into account, the created platform arrangement plan sometimes concentrated on the day when turbulence occurred. In this case,
Because it was necessary to carry out changeover or tying setups with a limited number of people, there were cases where we were unable to deal with the occurrence of weaving and had to stop the operation of the loom. . At this time, the operating rate of the loom decreases, and the production efficiency of the weaving process decreases.

SUMMARY OF THE INVENTION In view of the above points, it is an object of the present invention to provide a device that automatically creates a loom arrangement plan so that the weaving is not concentrated on a particular day.

[Means for solving the problems] The structure of the automatic loom arrangement plan creation device of the present invention is as follows.
This will be explained based on FIG.

102 calculates the average value of the number of pumpings per day based on the production volume 101 of a certain period, and determines the upper limit of the number of pumpings per day 103 by multiplying this average value by a certain value. This is a legal means of limiting the number of lifts.

Reference numeral 104 denotes a loom arrangement execution means for allocating looms to the textiles to be produced, that is, arranging the looms.

106 is a predicted value 1 of the number of lifts per day based on the table arrangement result 105 by the table arrangement execution means 104.
07.

108 compares the upper limit value 103 and the predicted value 107 obtained from the upper limit value determination means 102 and the predicted value determination means 106 for each day, and determines that the predicted value 107 is the upper limit value. When it is larger than 103, the table arrangement result 10 of the table arrangement execution means 104
5 is changed, and when the predicted value 107 is less than or equal to the upper limit value 103, the table arrangement result 10 of the table arrangement execution means 104 is
This is a comparison means to determine 5.

Then, the arrangement execution means 104 performs the comparison means 108.
In the case where the table arrangement result 105 is changed by the table arrangement result 105, if the table arrangement is not executable, the number-of-flyings upper limit value determining means 102 increases the upper limit value 103.

The loom arrangement plan automatic creation device of the present invention has the above-described configuration.

[Operation] The upper limit value determining means 102 for the number of pumpings per day calculates the average number of pumpings per day based on the production volume 101 in a certain period, for example, one month, and multiplies this average value by a constant value. Then, the upper limit 103 of the number of times of lifting per day is determined. On the other hand, the predicted number of lifts determined by the means 106 determines a predicted value 107 of the number of lifts per day based on the table arrangement result 105 by the table arrangement execution means 104.

The comparison means 108 compares the upper limit value 103 and the predicted value 107 on a daily basis. At this time, when the predicted value 107 is larger than the upper limit value 103, the comparison means 108 changes the table placement result 105 of the table placement execution means 104. Therefore, the platform arrangement execution means 104 outputs a new platform arrangement result 105 to the evacuation count predicted value determining means 106. The predicted value determining means 106 for the number of lifts uses this new platform arrangement result 10.
5, a new predicted value is output. The comparison means 108 compares the new predicted value 107 based on this new arrangement result 105 with the upper limit value 103 again. However, if the table arrangement execution means 104 is caused to change the table arrangement result 105 by the comparison means 108 and the table arrangement cannot be carried out, it turns out that the upper limit value 103 is too small. The upper limit value determining means 10 for the number of lifts is provided.
2 increases the upper limit value 103.

The above operations are continued until the predicted value 107 becomes equal to or less than the upper limit value 103. And the predicted value is 107
becomes below the upper limit value 103, the comparison means 108
finalizes the table arrangement result 105 of the table arrangement execution means 104.

Regarding the platform arrangement result 105 finally obtained from the platform arrangement execution means 105 through the above-described operations, the predicted number of landings 107 is equal to or less than the upper limit of the number of landings 103 on all days.

[Example] Hereinafter, an example of the present invention will be specifically described based on the drawings.

Figure 2 shows an outline of the device of this embodiment, where 1 is an input device such as a keyboard, 2 is an input device such as a keyboard, and 2 is an input device such as a keyboard.
Display devices such as CRT dayplays and printers, 3.
A microcomputer consisting of a CPU (central processing unit), ROM (read-only memory), RAM (random access memory), I/O ports, etc. 4 is an auxiliary storage device such as a magnetic disk or magnetic tape, 5 is an auxiliary storage device such as a magnetic disk or magnetic tape, etc. It is a loom, each device 1, 2, 4
The loom 5 is connected to the microcomputer 3 via an I/O port.

The input device 1 is used by a planner to input required information into the microcomputer 3.

The display device 2 is used to display intermediate results obtained by the microcomputer 3 and the final arrangement plan.

In the auxiliary storage device 4, a loom file 4a, a textile file 4b, and a stand file 4c are registered.

The loom file 4a contains the loom machine number M (=
1 to Y), model S (M), rotation speed R (S (M))
and the planned amount of yarn to be loaded onto one warp beam V
(S(M)) is stored. Furthermore, depending on the operating status of the loom 5, a date when weaving can be started, that is, a weaving start date DX(M) is also stored.

The textile file 4b contains textile contract A (=1 to
For each X), the delivery date T(A) of this woven fabric, the weft density U(A), the model C(A) of the loom that can be installed on this woven fabric, and the pattern of the fabric included in this woven fabric. P
(A) (=1 to X') is stored. Also, for each pattern P(A) of the woven fabric, the production amount Q(P(A)) of this woven fabric
is memorized. In addition, the latest date D1 (P(A)), which is the latest date on which it is expected that the raw yarn necessary for manufacturing the woven fabric of each pattern P(A) can be input into the weaving process, that is, the latest date when raw yarn can be input is remembered. In woven fabrics with the same contract, the woven structure is the same even though the patterns may differ, so the weft density U(A) and the type of loom C(A) that can be installed on this woven fabric are )
is stored for each contract A.

The mounting film 4c is the microcomputer 3
This is used to store the final platform arrangement plan obtained by

A program described below is stored in the ROM of the microcomputer 3, and the above-mentioned lifting number upper limit value determining means 102 and platform arrangement executing means 10
4. It is used as the predicted value determination means 106 and the comparison means 108 for the number of evacuations. However, these programs do not need to be stored in the ROM, and may be stored in the auxiliary storage device 4, loaded into the RAM, and then executed.

Next, the processing performed by the microcomputer 3 will be explained in detail using the flowcharts shown in FIGS. 3 to 5.

In step 1, the average required number of warp beams per day, that is, the average number of warp lifts W, is calculated from the monthly fabric production amount (length) L using the following equation (1).

W=L/(y*a*d)...(1) Here, y is the length of the fabric per unit weight, for example, one roll, or the contracted length, and a and d are:
These are the average number of turns per beam and the number of operating days per month, respectively. Note that the symbols * and / are symbols representing multiplication and division, respectively. (The same applies hereinafter.) In step 2, the weekday parameter α and the holiday parameter β are initialized to, for example, 1.2 and 0.5, respectively.

In step 3, upper limit values W1 and W2 of the number of lifts per day are calculated using the following equations (2) and (3). W1
is for weekdays, and W2 is for holidays.

W1=W*α...(2) W2=W*β...(3) However, W1 and W2 are rounded up or down to integers.

In step 4, the lift counter L(I) and the lift machine stand are
Clear LM(I). The weight counter L(I) is 1
It is set corresponding to each day I of the month and is cleared to 0 in this step. The lifting machine LM(I) is
It is provided to memorize the machine number in which a lift occurs on a daily basis.

In step 5, the fabric contract A is initialized to 1.

In step 6, for the fabric of contract A, a loom type S(A) to be blended is selected from among the loom types C(A) that can be arranged from the fabric file 4b. Even if the patterns are different in the fabrics of one contract, the fabric structure is the same, so for the fabrics of the same contract A, the same model S(A) is selected. During this selection, the items are selected in descending order of enumeration. Therefore, if we give a high ranking to high-speed looms,
High-speed looms can be selected preferentially.

In step 7, the machine number M1 of the selected loom S(A) is extracted by referring to the model S(M) of the loom having the machine number M in the loom file 4a.

In step 8, for the selected loom type S(A), using the loom file 4a, the rotation speed R(S(A)) of the loom and the loading of the yarn to one of the warp beams of the loom are determined. Input the planned amount V(S(A)).

In step 9, pattern P(A) of deal A is initialized to 1.

In step 10, for the fabric of pattern P(A), the arrangement of the loom of the model S(A) selected for the fabric of pattern P(A) is determined in step 6. Calculate the number NA (P(A)) using the following formula (4).

NA(P(A)) = [((U(A) *Q(P(A))*60*24) /R(S(A)) /(T(A)−D1(P(A)) )+1] ...(4) Here, U(A) and T(A) are the weft density and delivery date of the fabric of contract A, respectively, and Q(P(A))
and D1 (P(A))) are the production amount of the fabric of pattern P(A) and the latest date when yarn can be input, respectively. these are,
Both are input from the textile film 4b. The delivery date T(A) is expressed in days, and the unit of rotation speed R(S(A)) is rpm. In addition, the symbol [z]
is a Gaussian symbol representing the largest integer not exceeding z. (The same applies hereinafter.) In step 11, the number of warp beams NC (P(A)) to be assigned to the loom of model S(A) is calculated using the following equation (5).

NC(P(A))=[Q(P(A))/V(S(A)+1]...(5) Note that V(S(A)) is input from the loom file 4a in step 8. It is something that

In step 12, the number of these devices NA (P(A))
and the number of beams NC(P(A)), it is checked whether the former is larger than the latter. NA(P(A))＞NC
(P(A)), a problem arises in that some looms cannot be equipped with beams. Therefore, in this case, in step 13, these are displayed on the display device 2 to prompt the planner's instructions, and in step 14, one of them is changed and inputted using the input device 1 to obtain NA(P(A) )≦NC(P(A)). NA (P(A)) at step 12
If ≦NC(P(A)), the process jumps to step 15 without executing steps 13 and 14.

In step 15, for each beam B(P(A)) for warp yarns whose required number is given by NC(P(A)), the planned amount of yarn to be loaded VB(B(P(A))) is determined by these. The sum of the numbers is determined to be equal to the production quantity Q (P(A)) of fabrics with pattern P(A)), and the number of required machines NA(P(A)) for which machine numbers have not yet been determined is determined. Assign these beams to the loom. For example, the number of
NA(P(A)) is 1 and the number of beams NC(P(A))
is 2 or more, each beam is allocated sequentially. When the number of looms NA (P(A)) is 2 or more and NA (P(A)) = NC (P(A)), beams are allocated in parallel, ie, one beam to each loom. If the number NA(P(A)) is 2 or more and NA(P(A))<NC(P(A)), beams are allocated in series and parallel.

In step 16, for each beam B (P(A)),
Calculate the number of days DB (B(P(A))) in which the beam is used for the selected loom of model S(A) using the following formula (6), and allocate it to each loom for the number of installed looms NA(P(A)). The sum of the number of days the beams are used is the number of days required for weaving for each loom D2 (P(A)).

DB(B(P(A))) =VB(B(P(A)))*U(A) /R(S(A))...(6) In step 17, variables for loop control of the program are set. Initialize J to 1.

In step 18, the machine number M2 of the loom that satisfies the following two equations (7) and (8) at the same time is extracted from the looms with the machine number M1 extracted in step 7.

T(A)−DX(M1)≧D2(P(A)) ……(7) T(A)−D1(P(A))≧D2(P(A)) ……(8) Equation (7) ), the initial period from the possible weaving start date DX (M1) obtained from the loom file 4a for the loom with machine number M1 to the delivery date T (A) of the fabric of contract A is the pattern P
This means confirming that the number of days required for weaving the fabric in (A) is longer than or equal to D2 (P(A)). On the other hand, equation (8)
is the delivery date T(A) from the latest yarn input date D1 (P(A)) obtained from the fabric file 4b for the fabric with pattern P(A).
This means confirming that the period until the weaving process is longer than or equal to the number of days required for weaving D2 (P(A)).

If there is no loom that satisfies these two equations at the same time, the process proceeds from step 19 to step 20, registers the result that it is impossible to arrange the fabric of pattern P(A) among the fabrics of contract A, and then jumps to step 30. If there is a loom that satisfies the requirements at the same time, in step 21, the priorities of the machine numbers M2 are determined according to the following rules (a) and (b), and these machine numbers are assigned in descending order of priority. Sorting.

(a) Priority is given to looms whose latest yarn input date D1 (P(A)) is earlier than weaving start date DX (M2). This is to reduce the in-process inventory of raw yarn.

(b) Referring to the placement results for which provisional registration has already been performed, which will be explained later, priority is given to the loom on which the same contract A was placed last. This is to reduce the number of switching operations by replenishing warp threads through tying.

In step 22, select the highest machine number in M2.
Temporarily place M3 on the fabric of pattern P(A), and use this machine number M3.
is removed from M1.

In step 23, the latest date D1 (P
(A)) and possible weaving start date DX (M3)), whichever is later, is the scheduled weaving start date DZ (P(A)) of the fabric with pattern P(A).
tentatively determined.

In step 24, for each beam B(P(A)) assigned to machine number M3, the day when delifting occurs, that is, the evacuation date DT(B(P(A))), is predicted.
That is, the lifting date DT(B(P(A))) of the first beam among these beams is the expected start date DZ(P(A)) of the weaving of the woven fabric with pattern P(A). Number of days of use
Calculated by adding DB(B(P(A))).
Regarding the second beam, the number of days of use of the second beam is added to the evacuation date of the first beam, and the calculation is performed in the same manner.

In step 25, the evacuation date DT(B(P
Increment the lift counter L(I) corresponding to (A))), and
Store the temporarily allocated machine number M3 in LM(I).

In step 26, the machine number M3 is determined by the following formula (9).
The weaving start date DX ( M3).

DX (M3) = DZ (P (A)) + D2 (P (A)) ... (9) In step 27, the value of variable J is incremented to execute the required number of machines, and in step 28, this J It is checked whether the value of is larger than the number NA (P(A)), and if it is not larger, the process returns to step 18. Pattern P
When the required number of fabrics (A) have been arranged, the process proceeds from step 28 to step 29.

In step 29, the above arrangement results regarding the fabric of pattern P(A) among the fabrics of contract A are temporarily registered. The provisional registration items are the pattern P(A), the number of looms NA (P(A)), the machine number M3 of the looms corresponding to the number of looms arranged, and the scheduled weaving start date DZ (P(A)) of the looms with each machine number. , Number of days required for weaving
D2 (P(A)), scheduled amount of yarn to be loaded on each assigned beam VB (B(P(A))), and number of days each beam will be used
DB(B(P(A))).

In step 30, P(A) is incremented to check for the next pattern of fabric, and in step 31 it is checked whether it is greater than X', and if it is not, the process returns to step 10.

In step 32, it is checked whether the values of all the lift counters L(I) are less than or equal to the upper limit of the number of lifts. At this time, if I falls on a weekday, the upper limit W1
, and when it falls on a holiday, the upper limit value W2 is used. If the upper limit value W2 is set smaller than the upper limit value W1 as described above, the number of warp lifts on holidays can be reduced compared to weekdays, and warp yarns can be replenished by a small number of workers.

The upper limit value W1 is a lift counter L larger than W2.
If (I) exists, proceed to step 33. step
33, the same machine number M3 for each pattern P(A) in the machine arrangement result provisionally registered in step 29.
For beam B (P(A)) assigned to , the landing order is exchanged. Even if this exchange is performed, tying is still possible.

In step 34, based on the changes made in step 33, the evacuation date DT (B(P(A))), evacuation counter L(I), and evacuation machine platform for each beam are calculated in the same way as in steps 24 and 25. LM(I) is changed, and in step 35, it is checked again whether the values of all the lift counters L(I) are below the upper limit W1 or W2 of the number of lifts. At this time, if there is a lift counter L(I) larger than these upper limits, the process proceeds to step 36. In step 36, the machine registration order is exchanged for the pattern P(A) arranged on the same machine number M3 in the temporarily registered machine arrangement result, and in step 37, in the same manner as step 23, each pattern P is changed. Scheduled start date for weaving (A)
Change DZ(P(A)). Since the contracts are the same A, tying is still possible even if this exchange is executed.

In step 38, the evacuation date of each beam is determined again based on the changes made in steps 36 and 37.
DT (B(P(A))), lift counter L(I) and lift machine stand
LM(I) is changed, and in step 39, it is further checked whether the values of all the lift counters L(I) are below the upper limit for the number of lifts. At this time, if there is a lift counter L(I) larger than these upper limits, the process proceeds to steps 40, 41, and 42. In these steps, other replacements are performed, and the evacuation date DT(B(P(A))) and evacuation counter L(I) of each beam are
and the lift-off machine LM(I), and then check the value of the lift-off counter L(I).

Replacement can be done, for example, as follows. In other words, regarding contract A placed on the same machine number M3 in the provisionally registered machine placement results,
The order of boarding can be exchanged. Referring to the lifting machine LM(I) corresponding to the day I when the lifting counter L(I) is larger than the upper limit value, the fabric of contract A placed on another stored machine number is checked. You can also exchange machine numbers between them. Furthermore, the planned amount of yarn to be loaded on each beam determined in step 15
By changing VB(B(P(A))), the distribution of the production amount Q(P(A)) of the fabric with pattern P(A)) may be changed.

In step 42, if there is still a lift counter L(I) larger than the upper limit of the number of lifts,
In step 43, the parameters α and β are increased, and the process returns to step 3 to redo the arrangement of the tables from the beginning. The increase in the values of parameters α and β is, for example, 0.2
It can be done in increments.

In steps 32, 35, 39 or 42, the values of all the lift counters L(I) reach the upper limit of the number of lifts W1 or W2.
If so, proceed to step 44 and execute contract A
Regarding the fabric of , the placement result temporarily registered in step 29 and changed according to the above replacement is registered. At this time, in addition to the above items, the date of creation of the arrangement plan is registered. In addition,
This information may be registered for each loom number. These registrations are made in the above-mentioned distribution file 4c.
However, these information may be further displayed on the display device 2.

Next, in step 45, A is incremented to check the fabric of the next contract, and the step
At step 46, it is checked whether this is greater than X, and if it is not, the process returns to step 6. When A is greater than X, the process ends.

[Effects of the Invention] As explained above, in the present invention, the average number of pumpings per day is calculated based on the production volume for a certain period, and this average value is multiplied by a constant value. Then, the upper limit of the number of lifts per day is determined, and when the predicted number of lifts per day is larger than the upper limit, not only the previously created platform arrangement result is changed, but also this change may affect the upper limit. Since the above-mentioned upper limit value is sequentially increased and the above-mentioned change is repeated only when it is impossible to arrange the aircraft, the predicted number of flights can be set to be less than or equal to the above-mentioned upper limit value for all days during the period. Furthermore, this can be executed in a shorter time than the case where the predicted value of the number of passes is minimized while executing all combinations of table arrangement changes. Furthermore, if the upper limit is fixed, there may be cases where it is impossible to arrange the machines, but even non-experts can easily and reliably obtain an optimal machine arrangement plan.

Therefore, according to the present invention, it is possible to provide an apparatus that automatically creates a planar arrangement plan that evens out the evacuation so that the evacuation is not concentrated on a specific day.

[Brief explanation of drawings]

FIG. 1 is a block diagram for explaining the configuration of the present invention, FIG. 2 is a block diagram showing an embodiment of the present invention, and FIG. 3 is a flowchart showing the processing performed by the microcomputer in the previous figure. FIG. 4 is a flowchart showing the process following the previous figure, and FIG. 5 is a flowchart showing the process further continuing from the previous figure. Explanation of symbols, 1... Input device, 2... Display device, 3... Microcomputer, 4... Auxiliary storage device, 4a... Loom file, 4b... Textile file, 4c... Stand file, 5... ...loom, 1
01...Manufacturing amount, 102...Upper lift count upper limit value determining means, 103...Upload count upper limit value, 104...Table arrangement execution means, 105...Table placement result, 106...Letter count predicted value determination Means, 107... Predicted value of the number of lifts, 108... Comparison means.

Claims (1)

[Scope of Claims] 1 (a) Calculate the average number of pumpings per day based on the production amount for a certain period, and multiplying this average value by a certain value to calculate the number of pumpings per day. (b) a loom arrangement execution means for allocating a loom to a fabric to be produced, that is, arranging the looms; (c) arranging the looms by the loom arrangement execution means; (d) a means for determining a predicted value of the number of flights per day based on the results; The obtained upper limit value and the predicted value are compared every day, and when the predicted value is larger than the upper limit value, the machine arrangement result of the machine arrangement execution means is changed, and the predicted value is the upper limit value. a comparison means for determining the table arrangement result of the table arrangement execution means when The automatic loom arrangement plan creation device is characterized in that when it is impossible to carry out the weaving, the upper limit value determining means increases the upper limit value.