Production sequence planning system

Abstract

To provide a production sequence planning system that merges products in correct order even if a planned product merging sequence changes during an upstream process.SOLUTION: A production sequence planning system for planning an order to merge inspected products, which have been manufactured with a plurality of specifications in a production line having a plurality of manufacturing processes and sampled at an inspection process, back into a production line, is configured to: compare a target serial number nx of a product that has reached a point before an inspection product merges with a confirmed serial number na for which a production instruction to merge has been fixed; and determine whether the product with the target serial number is within a planned production sequence, based on the serial number of the product following the target serial number. If the product with the target serial number is within the planned production sequence, the system compares the target serial number with a serial number n of the inspection product to determine whether the inspected product can be merged, and updates the serial number of the merged inspection product to the fixed serial number. If the product with the target serial number is outside the planned production sequence, the system does not merge the inspection product, but merges the product with the target serial number and does not update the confirmed serial number.SELECTED DRAWING: Figure 2

Description

[Technical Field]

[0001] This invention relates to a production sequence planning system, and more particularly to a production sequence planning system for producing products of multiple specifications on a production line having multiple manufacturing processes, and for planning the sequence in which products sampled in an inspection process are to be merged into the production line. [Background technology]

[0002] Generally, in a production line where products with multiple specifications are produced through multiple manufacturing processes, products manufactured in one manufacturing process are sampled in an inspection process and inspected to check for any problems before proceeding to the next manufacturing process. Furthermore, if there are no problems with the inspection products sampled in the inspection process proceeding to the next manufacturing process, they must be merged into the production line in the planned order. Conventionally, inspection products sampled in the inspection process are merged when they reach the merge point for products with a serial number higher than the inspection product's serial number.

[0003] Patent Document 1 discloses a technology for switching inspection products sampled from a production line with multiple specifications by merging them at an order switching point. However, Patent Document 1 does not mention how to merge the inspection products in the correct order. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Japanese Patent Application Publication No. 2022-133944 Summary of the Invention [Problem to be solved by the invention]

[0005] However, in a production line that produces products with multiple specifications in multiple manufacturing processes, the planned merging order may be changed upstream of the inspection process, and conventional techniques that merge products when a product with a serial number higher than the serial number of the product being inspected reaches the merging point may result in the product being inspected merging at a time that does not match the planned order.If the product being inspected merges at a time that does not match the planned order, there is a concern that production efficiency will decrease in the process after the merging.

[0006] The present invention has been made in view of the above circumstances, and an object of the present invention is to provide a production sequence planning system that allows products to merge in the correct order even if the planned merge order of products has been changed in an upstream process. [Means for solving the problem]

[0007] In order to solve the above-mentioned problems, the present invention provides a production sequence planning system for producing products with multiple specifications on a production line having multiple manufacturing processes, and for planning the sequence for merging inspection products sampled in an inspection process into the production line, the system defining the sequence serial number of a product whose production instruction to merge has been confirmed as a confirmed sequence number based on the acquired information on the production sequence and the merge plan sequence serial number, and defining the sequence serial number of a product that has reached a point before the inspection product merges as a target sequence number, comparing the target sequence number with the confirmed sequence number, and determining whether the product with the target sequence number is within the planned production sequence based on the sequence number of the product after the target sequence number, if the product with the target sequence number is within the planned production sequence, comparing the target sequence number with the sequence number of the inspection product to determine whether the inspection product can be merged, and updating the sequence number of the merged inspection product to a confirmed sequence number, if the product with the target sequence number is not within the planned production sequence, not merging the inspection product but merging the product with the target sequence number, and not updating the confirmed sequence number.

[0008] In this invention, when the target serial number is larger than the serial number immediately above the confirmed serial number, it is preferable to determine whether the product with the target serial number is within the scheduled production order by checking whether there is a serial number that has been overtaken by the target serial number within the range of the difference between the confirmed serial number and the target serial number.If there is, the target serial number is determined to be unscheduled, and if there is no serial number, the target serial number is determined to be within the scheduled order.

[0009] Furthermore, in this invention, when it is determined that the product with the target serial number is within the scheduled production sequence, if the scheduled serial number is greater than the serial number of the inspected product, it is preferable to add the serial number of the inspected product to the merged production instruction and update the merged serial number to a confirmed serial number, and if the scheduled serial number is smaller than the serial number of the inspected product, to add the scheduled serial number to the merged production instruction and update the merged serial number to a confirmed serial number.

[0010] By configuring as described above, the confirmed serial number of the merging production instruction is compared with the target serial number that has reached the point before the merging, and whether or not the product of the target serial number is within the scheduled production order is determined based on the serial number of the product after the target serial number. When the target serial number is larger than the serial number immediately above the confirmed serial number, the determination of whether or not the product of the target serial number is within the scheduled production order is made based on whether or not there is a serial number that has been overtaken by the target serial number within the range of the difference between the confirmed serial number and the target serial number. If there is, the target serial number can be determined to be outside the schedule, and if there is not, the target serial number can be determined to be within the schedule.

[0011] If the result of the determination is that the product with the target serial number is within the scheduled production sequence, the target serial number is compared with the serial number of the inspected product to determine whether the inspected product can be merged, and the serial number of the merged inspected product is updated to a confirmed serial number. In other words, if the product with the target serial number is determined to be within the scheduled production sequence and the scheduled serial number is larger than the inspected product's serial number, the inspected product's serial number is added to the merged production instruction, and the merged serial number is updated to a confirmed serial number. On the other hand, if the scheduled serial number is smaller than the inspected product's serial number, the scheduled serial number is added to the merged production instruction, and the merged serial number is updated to a confirmed serial number.

[0012] Furthermore, if the product with the target serial number is not in the planned production sequence, the inspected product is not merged, but the product with the target serial number is merged, and the confirmed serial number is not updated. [Effects of the Invention]

[0013] According to this invention, by configuring as described above, not only the products before the merger but also the products before and after that are evaluated, so that even if the planned merger order of products is changed in an upstream process, the products can be merged in the correct order. [Brief explanation of the drawings]

[0014] [Figure 1] 1 is a schematic configuration diagram of a confluence production instruction creation device that embodies a production sequence planning system according to the present invention. [Figure 2] 1 is a flowchart showing a procedure for creating a confluence production instruction using the production sequence planning system according to the present invention. [Figure 3] 10 is a schematic diagram showing an example of creating a planned confluence sequence for inspected products in the present invention; FIG. [Figure 4] FIG. 10 is an explanatory diagram showing a processing procedure for determining the planned junction order of inspected products in the present invention. [Figure 5] FIG. 2 is a diagram illustrating the production sequence of branch production instructions and the confluence plan sequence serial number in the first embodiment of the present invention. [Figure 6] FIG. 3 is a schematic diagram showing an example of creating a planned junction sequence for inspected products in the first embodiment of the present invention. [Figure 7] FIG. 2 is a diagram illustrating the production sequence of branch production instructions and the confluence plan sequence serial number in the first embodiment of the present invention. [Figure 8] FIG. 10 is a diagram illustrating the production sequence and the confluence planned sequence number of the confluence production instruction created in the first embodiment of the present invention. [Figure 9] FIG. 10 is a diagram illustrating the production sequence of branch production instructions and the confluence plan sequence serial number in the second embodiment of the present invention. [Figure 10] FIG. 10 is a schematic diagram showing an example of creating a planned junction sequence for inspected products in the second embodiment of the present invention. [Figure 11] FIG. 10 is a diagram illustrating the production sequence of branch production instructions and the confluence plan sequence serial number in the second embodiment of the present invention. [Figure 12] FIG. 10 is a diagram illustrating the production sequence and the confluence planned sequence number of the confluence production instruction created in the second embodiment of the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0015] DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, embodiments of the present invention will be described in detail with reference to the accompanying drawings. Here, we will explain a production sequence system that plans the order in which inspected products sampled in an inspection process are to be merged into a production line that produces products with multiple specifications through multiple manufacturing processes. The production sequence planning system according to the present invention is embodied, that is, executed, by a production sequence planning device 20.

[0016] As shown in FIG. 1, the production sequence planning device 20 is equipped with an acquisition unit 21 that acquires information data on the production sequence and merging plan sequence serial numbers, which will be described later; a determination unit 22 that compares the sequence serial numbers of products whose merging production instructions have been confirmed (hereinafter referred to as confirmed serial numbers) with the serial numbers of products that have reached the point before the inspection product is merging (hereinafter referred to as target serial numbers) to determine whether the product with the target serial number is within the planned production sequence; a rewriting unit 23 that updates the serial numbers of the inspection products determined by the determination unit 22 to the confirmed serial numbers; and an output unit 24 that has a display or the like and displays the production sequence updated by the rewriting unit 23 on the display or the like.

[0017] The procedure for creating a merging production instruction using the production sequence planning system according to the present invention will be described with reference to Figures 2 to 4. First, as shown in Figure 2, information data (branching production instruction) on the production sequence and merging planning sequence serial number, which will be described later, is acquired by the acquisition unit 21 (step S1).

[0018] Based on the information data (branch production instructions) of the production sequence and the merging plan sequence sequence number acquired by the acquisition unit 21, the sequence sequence number of the product for which the merging production instruction has been confirmed is defined as the confirmed sequence number, and the sequence sequence number of the product that has arrived at the point before the merging of the inspected product is defined as the target sequence number. Specifically, as shown in Figure 3, the sequence sequence number of the product at the merging point P0 for which the merging production instruction has been confirmed is defined as the confirmed sequence number na, and the sequence sequence number of the product that has arrived at the point Pa before the merging of the inspected product is defined as the target sequence number nx. In Figure 3, the symbol n is the sequence number of the inspected product.

[0019] Next, the determination unit 22 compares the target serial number nx with the confirmed serial number na, and determines whether the product with the target serial number nx is within the planned production sequence based on the serial numbers of products after the target serial number nx (step S2). Specifically, as shown in Figure 4, when the target serial number nx is larger than the serial number immediately above the confirmed serial number na (hereinafter referred to as the expected value na+1), the system checks whether or not there is a serial number that has been overtaken by the target serial number nx within the range of the difference between the confirmed serial number na and the target serial number nx. If there is, the target serial number nx is determined to be outside the schedule, and if not, it is determined to be within the schedule. Here, the reason why the expected value is set to the serial number na+1 immediately above the confirmed serial number na is that the confirmed serial number na is smaller than the serial number n of the inspection product that will be merging, and therefore will arrive at the merging point P0 before the inspection product according to the production order.

[0020] If the determining unit 22 determines that the target serial number nx is not scheduled, the target serial number nx is added to the merged production instruction, and the confirmed serial number is not updated (step S3).

[0021] If the determining unit 22 determines that the target serial number nx is within the schedule, it compares the target serial number nx with the serial number n of the product to determine whether the scheduled serial number is greater than the serial number n of the product to be inspected (step S4).

[0022] If the scheduled serial number is larger than the serial number n of the inspected product, the serial number n of the inspected product is added to the merged production instruction, and the rewriting unit 23 rewrites and updates the merged serial number to a confirmed serial number (step S5).

[0023] If the scheduled serial number is smaller than the serial number n of the inspected product, the scheduled serial number is added to the merged production instruction, and the rewriting unit 23 rewrites and updates the merged serial number to a confirmed serial number (step S6).

[0024] A specific embodiment of the production sequence planning system according to the present invention will be described below. First Embodiment In the first embodiment, as shown in Fig. 5, a branch production instruction is created by combining information on the production sequence of the preceding process and the merge planned sequence serial number. This branch production instruction is acquired by the acquisition unit 21 (step S1). In this case, as shown in Fig. 5, the branch production instruction is created for the production sequence 1, 2, 3, 4, 5, 6, 7 ... 13, and the merge planned sequence is the inspection sequence numbers (005), (001), (002), (003), (004), (008), (004), (006) ... (013).

[0025] In the first embodiment, as shown in Fig. 6, an example is shown in which an inspected product with an inspection serial number (005) is merged, and the confirmed serial number (003) of the product at the merge point P0 where the merge production instruction is confirmed, and the target serial number (008) of the product that has arrived at point Pa before the inspected product merges, is used. Note that, for ease of understanding the following explanation, the confirmed serial number (003), inspection serial number (005), target serial number (008), etc. will be explained as confirmed serial number (3), inspection serial number (5), target serial number (8), etc. in Figs. 7 and 8.

[0026] The determination unit 22 compares the confirmed serial number (3) with the target serial number (8) and determines whether the product with the target serial number (8) is within the planned production order based on the serial numbers of products after the target serial number (8) (step S2). In this determination, the confirmed serial number (3) is compared with the target serial number (8), and if the target serial number (8) is greater than the serial number immediately above the confirmed serial number (3) (expected value 3 + 1), the range of the difference between the confirmed serial number (3) and the target serial number (8) is checked. In this case, the expected value for the target serial number (8) is (3 + 1 = 4), so the range of the difference is 8 - 4 = 4.

[0027] Within the range of the difference, if there is even one serial number (4, 6, 7) that has been overtaken by the target serial number (8), the target serial number (8) is determined to be outside the schedule, and if there is no such serial number, the target serial number (8) is determined to be within the schedule. In this case, since there are overtaken serial numbers (4, 6, 7), the target serial number (8) is determined to be outside the schedule, and the confirmed serial number (3) is not updated, and the process moves to the next step. Note that the target serial number (8) is added to the merge production instruction, and the confirmed serial number is not updated (step S3).

[0028] Based on the above process, the merge production instruction shown in Figure 8 is created, and the inspection serial number (5) merges after the merge plan order serial number (4). The rewriting unit 23 rewrites and updates the merged inspection serial number (5) to a confirmed serial number.

[0029] As described above, the production sequence planning system of the first embodiment deals with the case where the target sequence number (8) is larger than the sequence number immediately above the confirmed sequence number (3) (expected value: 3 + 1), and the sequence numbers (4, 6, 7) that have been overtaken by the target sequence number (8) are within the range of the difference between the test sequence number (3) and the target sequence number (8). In this case, the target sequence number (8) is determined to be out of schedule, the confirmed sequence number is not updated, the inspection sequence number (5) is merged after the merge plan sequence number (4), the inspection sequence number (5) is updated to the confirmed sequence number, and a merge production instruction is created. The created merge production instruction is displayed, for example, on a display by the output unit 24. Therefore, based on the created merge production instruction, products can be merged in the correct order even if the merge plan sequence of products has been changed in an upstream process.

[0030] Second Embodiment In the second embodiment, as shown in Fig. 9, a branch production instruction is created by combining information on the production sequence of the preceding process and the merge planned sequence serial number, and this branch production instruction is acquired by the acquisition unit 21 (step S1). In this case, as shown in Fig. 9, the branch production instruction is created for the production sequence 1, 2, 3, 4, 5, 6, 7 ... 13, and the merge planned sequence is the inspection sequence numbers (005), (001), (002), (003), (006), (007), (008), (004), (009) ... (013).

[0031] In the second embodiment, as shown in Fig. 10, an example is shown in which an inspected product with an inspection serial number (005) is merged, where the confirmed serial number (003) of the product at the merge point P0 where the merge production instruction is confirmed, and the target serial number (006) of the product that has arrived at point Pa before the inspected product merges, is used. Note that, for ease of understanding the following explanation, the confirmed serial number (003), inspection serial number (005), target serial number (006), etc. will be explained as confirmed serial number (3), inspection serial number (5), target serial number (6), etc. in Figs. 11 and 12.

[0032] The determination unit 22 compares the confirmed serial number (3) with the target serial number (6) and determines whether the product with the target serial number (6) is within the planned production order based on the serial numbers of products after the target serial number (6) (step S2). In this determination, the confirmed serial number (3) is compared with the target serial number (6), and if the target serial number (6) is larger than the serial number immediately above the confirmed serial number (3) (expected value 3 + 1), the range of the difference between the confirmed serial number (3) and the target serial number (6) is checked. In this case, the expected value for the target serial number (6) is (3 + 1 = 4), so the range of the difference is 6 - 4 = 2.

[0033] If there is even one serial number (4, 5) that has been overtaken by the target serial number (6) within the range of the difference, the target serial number (6) is determined to be out of schedule, and if there is no overtaken serial number, the target serial number (6) is determined to be within schedule. In this case, since there is no overtaken serial number, the target serial number (6) is determined to be within schedule, the confirmed serial number is updated to (6), and the process moves to the next step (step S6).

[0034] Based on the above process, the merge production instruction shown in Figure 12 is created, and the inspection serial number (5) merges after the merge plan order serial number (4). The rewriting unit 23 rewrites and updates the merged inspection serial number (5) to a confirmed serial number.

[0035] As described above, the production sequence planning system of the second embodiment applies to the case where the target sequence number (6) is larger than the sequence number immediately above the confirmed sequence number (3) (expected value: 3 + 1), and there are no sequence numbers (4, 5) that have been overtaken by the target sequence number (6) within the range of the difference between the test sequence number (3) and the target sequence number (6). In this case, the target sequence number (6) is determined to be within the schedule, the target sequence number (6) is updated to a confirmed sequence number, the inspection sequence number (5) merges after the merge planned sequence number (4), and the inspection sequence number (5) is updated to a confirmed sequence number and a merge production instruction is created. The created merge production instruction is displayed, for example, on a display by the output unit 24. Therefore, based on the created merge production instruction, products can be merged in the correct order even if the merge planned sequence of products has been changed in an upstream process.

[0036] In the above embodiment, an inspection product sampled during the inspection process of a production line is merged with the production line from which the inspection product was sampled. However, a product sampled during the inspection process of one of two parallel production lines may also be merged with the other production line.

[0037] The production sequence planning system according to the present invention is not limited to the above-described embodiment, and can be applied to cases where products that have been sampled during the manufacturing process on a production line other than for inspection are to be merged back into the production line, thereby achieving the same effects as those described above. [Explanation of symbols]

[0038] 20 Production sequence planning device 21 Acquisition Department 22 Judgment section 23 Rewriting section 24 Output section P0 Meeting point Pa Pre-merging point n Inspection serial number na Fixed serial number nx Target serial number na+1 expectation

Claims

1. A production sequence planning system for producing products of multiple specifications on a production line having multiple manufacturing processes, and for planning an order in which inspection products sampled in an inspection process are to be merged with the production line, comprising: Based on the acquired information on the production sequence and the merge plan sequence sequence number, the sequence sequence number of the product whose merge production instruction has been confirmed is defined as the confirmed sequence number, and the sequence sequence number of the product that has reached the point before the merge of the inspection product is defined as the target sequence number; comparing the target serial number with the confirmed serial number, and determining whether the product with the target serial number is within the scheduled production sequence based on the serial number of the product after the target serial number; If the product with the target serial number is within the planned production sequence, the target serial number is compared with the serial number of the inspection product to determine whether the inspection product can be merged, and the serial number of the merged inspection product is updated to a confirmed serial number; If the product with the target serial number is not in the planned production sequence, the inspected product is not merged, but the product with the target serial number is merged, and the confirmed serial number is not updated. A production sequence planning system characterized by:

2. 2. The production sequence planning system according to claim 1, A production sequence planning system characterized in that, when the target serial number is larger than the serial number immediately above the confirmed serial number, the determination of whether the product of the target serial number is within the scheduled production sequence is made by checking whether there is a serial number that has been overtaken by the target serial number within the range of the difference between the confirmed serial number and the target serial number; if there is, the target serial number is determined to be unscheduled, and if there is not, the target serial number is determined to be within the scheduled sequence.

3. 2. The production sequence planning system according to claim 1, When the product with the target serial number is determined to be within the scheduled production sequence, if the scheduled serial number is greater than the serial number of the product being inspected, the serial number of the product being inspected is added to the merged production instruction, and the merged serial number is updated to a confirmed serial number.

4. 2. The production sequence planning system according to claim 1, When the product with the target serial number is determined to be within the scheduled production sequence, if the scheduled serial number is smaller than the serial number of the inspected product, the scheduled serial number is added to the merged production instruction, and the merged serial number is updated to a confirmed serial number.

Images