Decentralized production planning and instruction device, decentralized production planning and instruction system

Abstract

The present invention provides a technique for appropriately setting conditions for determining whether replanning is necessary. A distributed production planning and instruction device comprises: a storage unit that stores production instructions that serve as operation instructions for production factors including a factory's production equipment, production resources, and operators; production status information that includes the occurrence of abnormalities in production factors; and equipment-process relationship information that identifies, for each process implemented by a production factor, other production factors that can be implemented in place of that process; a plan change determination unit that, when an abnormality in the execution of a production instruction occurs in a production factor, determines that a plan change is not necessary if the production instruction can be followed while taking into account the period of suspension of the production factor caused by the abnormality; a distributed plan range calculation unit that includes other production factors that can be implemented in place of the production factor in the scope of the replan; and a distributed plan generation unit that replans the production instructions within the generated scope of the replan.

Description

Technical Field

[0001] The present invention relates to a decentralized production planning and indicating device, and a decentralized production planning and indicating system. Background Art

[0002] Patent document 1 records "a production system comprising: an actual production department (1), which is composed of a plurality of production equipment that produces products based on a provided production plan; a production management department (3), which provides an optimized production plan to the actual production department and manages the pre-realization of the production plan of the actual production department in real time, and when it is determined that the conditions for implementing the replan are met, the production plan is replanned in an optimal manner and provided to the actual production department."

[0003] Prior art literature

[0004] Patent Document 1: Japanese Patent Application Laid-Open No. 2020-98541 Summary of the Invention

[0005] Problems to be solved by the invention

[0006] In the technology described in Patent Document 1, if a discrepancy occurs between the production plan and actual performance, the degree of the discrepancy determines whether replanning is necessary. If replanning is necessary, the production plan is replanned using a production simulator, and the replanned production plan is distributed to each production facility, thereby enabling transmission to the manufacturing site as a production instruction. However, there is no guidance on properly setting the conditions for determining whether replanning is necessary.

[0007] An object of the present invention is to appropriately set conditions for determining whether re-planning is necessary.

[0008] Means for solving problems

[0009] The present application solves the above-mentioned problems by, for example, adopting the means described in the claims. The present invention includes multiple means for solving the above-mentioned problems. One example is a decentralized production planning and instruction device, characterized by comprising: a storage unit that stores production instructions that serve as operation instructions for production factors including production equipment, production resources, and operators in a factory, production status information including the occurrence status of anomalies in the production factors, and equipment-process relationship information that identifies other production factors that can be substituted for each process implemented by the production factors; a plan change determination unit that, when an anomaly in the execution of the production instructions occurs in the production factors, determines that a plan change is not necessary, taking into account the downtime period of the production factors caused by the anomaly and if the production instructions can be complied with; a decentralized plan range calculation unit that includes the other production factors that can be substituted for in a replanning target range; and a decentralized plan generation unit that replans the production instructions within the generated replanning target range.

[0010] Effects of the Invention

[0011] According to the present invention, it is possible to provide a technique for appropriately setting conditions for determining whether re-planning is necessary.

[0012] Other problems, structures, and effects than those described above will become clear from the following description of the embodiments. BRIEF DESCRIPTION OF THE DRAWINGS

[0013] Figure 1 This is a diagram showing a configuration example of a distributed production planning and instruction system.

[0014] Figure 2 This is a diagram showing a configuration example of a distributed production planning and instruction device.

[0015] Figure 3 This is a diagram showing an example of the data structure of the production instruction storage unit.

[0016] Figure 4 This is a diagram showing an example of the data structure of the group production instruction storage unit.

[0017] Figure 5 This is a diagram showing an example of the data structure of the group production status storage unit.

[0018] Figure 6 This is a diagram showing an example of the data structure of the group abnormality storage unit.

[0019] Figure 7 This is a diagram showing an example of the data structure of the equipment-process relationship storage unit.

[0020] Figure 8 It is a diagram showing an example of the data structure of the production instruction change storage unit.

[0021] Figure 9 This is a diagram showing an example of the data structure of the distributed plan input information storage unit.

[0022] Figure 10 This is a diagram showing an example of the hardware configuration of a distributed production planning and instruction device.

[0023] Figure 11 This is a diagram showing an example of the flow of production instruction update processing.

[0024] Figure 12 This is a diagram showing an example of the flow of initialization processing of the information management unit.

[0025] Figure 13 This is a diagram showing an example of the flow of periodic update processing.

[0026] Figure 14 This is a diagram showing an example of the flow of plan change necessity determination processing.

[0027] Figure 15 This is a diagram showing an example of the flow of distributed planning range calculation processing.

[0028] Figure 16 This is a diagram showing an example of the flow of distributed plan generation processing.

[0029] Figure 17 This is a diagram showing an example of the flow of instruction change output processing.

[0030] Figure 18 This is a diagram showing an example of the flow of instruction generation processing.

[0031] Figure 19 This is a diagram showing an example of the flow of change instruction reception processing.

[0032] Figure 20 This is a diagram showing an example of the flow of alarm processing.

[0033] Figure 21 This is a diagram showing an example of a display screen of a distributed production planning and instruction device.

[0034] Description of Reference Numerals

[0035] 10: Distributed production planning and instruction system, 100: Distributed production planning and instruction device, 110: Storage unit, 111: Production instruction storage unit, 112: Group production instruction storage unit, 113: Group production status storage unit, 114: Group abnormality storage unit, 115: Equipment-process relationship storage unit, 116: Production instruction change storage unit, 117: Distributed plan input information storage unit, 120: Processing unit, 121: Information management unit, 122: Plan change and No judgment unit, 123: Distributed plan range calculation unit, 124: Distributed plan generation unit, 125: Production instruction change and management unit, 126: Alarm information management unit, 130: Communication unit, 140: Input unit, 150: Output unit, 200: Production management device, 210: Production planning device, 300: Manufacturing site (area), 310: Performance input terminal, 320: Production instruction terminal, 340, 350, 360: Production equipment, 370: Network. DETAILED DESCRIPTION

[0036] In the following embodiments, for convenience, when necessary, they are divided into multiple parts or embodiments for description, but except for cases where it is specifically stated, they are not unrelated to each other, but are in a relationship where one is a modification example, detail, supplementary description, etc. of part or all of the other.

[0037] In addition, in the following embodiments, when referring to the number of elements (including number, numerical value, amount, range, etc.), except for cases where it is specifically stated and cases where it is clearly limited to a specific number in principle, it is not limited to the specific number and can be more than or less than the specific number.

[0038] Furthermore, in the following embodiments, the structural elements (including element steps, etc.) are not necessarily essential unless otherwise specified or unless they are clearly considered to be essential in principle.

[0039] Similarly, in the following embodiments, when referring to the shapes, positional relationships, etc. of structural elements, etc., except for cases where it is specifically stated or where it is clearly considered that this is not the case in principle, shapes that are substantially similar or similar to the shapes, etc. are included. The same applies to the above-mentioned numerical values ​​and ranges.

[0040] In principle, identical components are denoted by the same reference numerals throughout all the drawings used to illustrate the embodiments, and duplicate descriptions thereof are omitted. However, even identical components may be denoted by different reference numerals or names if there is a high likelihood of confusion due to changes in the environment, for example, and the shared designations of the components prior to the change. The following describes various embodiments of the present invention using the drawings.

[0041] Generally, when a discrepancy between the production plan and actual production results occurs, the need for replanning is determined based on the extent of the discrepancy. If the criteria for determining whether replanning is necessary are loosely defined, replanning may not be performed at the required time, potentially negatively impacting future production. On the other hand, if the criteria are strictly defined, frequent replanning may cause disruption at the manufacturing site.

[0042] In an embodiment of the present invention, the impact of time-series changes in on-site conditions on future production, such as production equipment, production resources, and operators, is detected within a factory or production line. The conditions for determining whether replanning is necessary are then determined for each production equipment. If replanning is necessary, the production plan is replanned by localizing the scope of the replanned period, equipment, and processes, and then issuing production instructions based on this production plan. This allows for localization of the impact of changes in plans and instructions, even when the conditions for determining whether replanning is necessary are tightened.

[0043] In the following embodiments, "input unit," "output unit," and "interface device" may refer to one or more interface devices. The one or more interface devices may be at least one of the following.

[0044] One or more I / O (Input / Output) interface devices. An I / O interface device is an interface device between the I / O device and at least one of a remote display computer. The I / O interface device for the display computer may be a communication interface device. The at least one I / O device may be a user interface device, such as an input device such as a keyboard or pointing device, or an output device such as a display device.

[0045] One or more communication interface devices. The one or more communication interface devices may be one or more communication interface devices of the same type (e.g., one or more NICs (Network Interface Cards)) or two or more communication interface devices of different types (e.g., a NIC and an HBA (Host Bus Adapter)).

[0046] In the following description, "memory" is one or more memory devices as an example of one or more memory devices, typically a main memory device. At least one memory device in the memory may be either a volatile memory device or a nonvolatile memory device.

[0047] In the following description, a "persistent storage device" may be one or more persistent storage devices as an example of one or more storage devices. Persistent storage devices are typically non-volatile storage devices (e.g., auxiliary storage devices), and specifically, may be, for example, hard disk drives (HDDs), solid state drives (SSDs), non-volatile memory express (NVME) drives, or storage class memory (SCM).

[0048] In the following description, a "storage unit" or a "storage device" may be a memory or a nonvolatile memory device, or both of them.

[0049] In addition, in the following description, a "processing unit" or "processor" may be one or more processor devices. The at least one processor device may typically be a microprocessor device such as a CPU (Central Processing Unit), but may also be another type of processor device such as a GPU (Graphics Processing Unit). The at least one processor device may be a single-core device or a multi-core device. The at least one processor device may be a processor core. The at least one processor device may be a broad processor device such as a circuit that is a collection of gate arrays (e.g., an FPGA (Field-Programmable Gate Array), a CPLD (Complex Programmable Logic Device), or an ASIC (Application Specific Integrated Circuit)) that performs part or all of the processing in a hardware description language.

[0050] In addition, in the following description, the function is sometimes described in terms of "yyy unit", but the function can be implemented by executing one or more computer programs by a processor, or by one or more hardware circuits (such as FPGA or ASIC), or by a combination thereof. In the case where the function is implemented by executing a program by a processor, a storage device and / or an interface device is appropriately used to perform the determined processing, so the function can also be set as at least a part of the processor. The processing described with the function as the subject can also be the processing performed by the processor or a device having the processor. The program can also be installed from a program source. The program source can also be, for example, a program distribution computer or a computer-readable recording medium (such as a non-temporary recording medium). The description of each function is an example, and multiple functions can also be summarized into one function, or one function can be divided into multiple functions.

[0051] In the following description, "program" or "processing unit" may be used as the subject to describe a process. However, a process described using a program as the subject may also be a process performed by a processor or a device having the processor. Furthermore, two or more programs may be implemented as a single program, or a single program may be implemented as two or more programs.

[0052] In the following description, sometimes "xxx table" is used to describe information that generates output for input. However, this information can be a table of any structure, or a neural network that generates output for input, or a learning model represented by a genetic algorithm or random forest. Therefore, "xxx table" can be referred to as "xxx information." In the following description, the structure of each table is an example. A table can be divided into two or more tables, and all or part of two or more tables can also be a single table.

[0053] In the following description, a "distributed production planning and instruction system" may be a system comprised of one or more physical computers, or a system implemented on a group of physical computing resources (e.g., a cloud infrastructure) (e.g., a cloud computing system). The term "display" of display information in the distributed production planning and instruction system may be performed by displaying the display information on a display device included in the computer, or by transmitting the display information to a display computer (in the latter case, the display computer displays the display information).

[0054] Figure 1 This diagram shows an example configuration of a distributed production planning and instruction system. The distributed production planning and instruction system 10 includes a production site device group installed at a manufacturing site (area) 300, a production management device 200 installed outside the manufacturing site and communicably connected via a network, and a production planning device 210.

[0055] The production site device group includes a plurality of production facilities, such as production equipment 340, production equipment 350, production equipment 360, etc.; performance input terminals 310 installed in predetermined units; production instruction terminals 320 installed in units of production facilities and displaying work instructions, etc.; a distributed production planning and instruction device 100; and other devices. These are interconnected via a network 370 for communication.

[0056] Network 370 may be, for example, a LAN (Local Area Network), a WAN (Wide Area Network), a VPN (Virtual Private Network), a communication network partially or entirely utilizing a general public line such as the Internet, a mobile phone communication network, or a combination thereof. Alternatively, network 370 may be a wireless communication network such as Wi-Fi (registered trademark) or 5G (Generation).

[0057] The performance input terminal 310 receives input from the operator of performance information such as the identifier of an individual manufacturing object, the start and end times of a process, and transmits it to the production management device 200. The production instruction terminal 320 is an operator-operated terminal that displays production instruction information generated by the decentralized production planning and instruction device 100, receives on-screen operational input, and performs changes to the displayed content.

[0058] The production management device 200 collects and manages production performance information, equipment information, and operator information, and transfers this information to the distributed production planning and instruction device 100 in response to a request from the distributed production planning and instruction device 100. Furthermore, the distributed production planning and instruction device 100 may, in lieu of the production management device 200, request and receive data from an MES (Manufacturing Executing System) connected to the network (not shown).

[0059] The production planning device 210 creates future production plan data using information such as the manufacturing process for each product, the factory's production equipment list, maintenance plans, operator-assigned equipment lists, operator transfer plans, master information including the factory's operating calendar, information on semi-finished products with planned dates and times, and factory input plans. The production planning device 210 then transfers the generated production plan data to the distributed production planning and instruction system. Alternatively, the distributed production planning and instruction system 100 can receive production plan data from a network-connected MES (not shown), instead of the production planning device 210.

[0060] The distributed production planning and instruction device 100 is deployed at the production site, either per production facility or, in work areas where no production facilities are being used, per production resource. The distributed production planning and instruction device 100 requests and obtains production plan data from the production planning device 210. Using production instructions related to the production facility 340 where the device is installed, production instructions for associated equipment used, production progress information obtained from the production management device 200, and abnormality information obtained from the production facility 340, the distributed production planning and instruction device 100 determines whether to change the production instructions for that facility, determines the replanning scope, generates a replan, and applies instructions.

[0061] In particular, when production delays occur due to anomalies or the like caused by the production equipment 340 under its jurisdiction, the distributed production planning and instruction device 100 uses the master data of the relationship between the production equipment and the process of the production equipment 340, the change information of the production instructions based on the replan, and various information used for replanning to determine whether the production instructions of the production equipment have been changed, determine the scope of the replan, generate the replan, and process the instruction reflection.

[0062] The distributed production planning and instruction device 100 includes information such as a distributed planning input information storage unit 117, a production instruction storage unit 111, a group production instruction storage unit 112, a group production status storage unit 113, a group anomaly storage unit 114, a device-process relationship storage unit 115, and a production instruction change storage unit 116. The distributed planning input information storage unit 117, the production instruction storage unit 111, the group production instruction storage unit 112, the group production status storage unit 113, the group anomaly storage unit 114, the device-process relationship storage unit 115, and the production instruction change storage unit 116 are managed by an information management unit 121.

[0063] Furthermore, the distributed production planning and instruction device 100 includes, as processing units, an information management unit 121, a plan change determination unit 122, a distributed plan range calculation unit 123, a distributed plan generation unit 124, a production instruction change and management unit 125, and an alarm information management unit 126. In particular, the production instruction change and management unit 125 transmits modified production instructions via the network 370 to other distributed production planning and instruction devices 100 to which the changes have been made, thereby locally modifying the production plan.

[0064] Figure 2 1 is a diagram showing a configuration example of a distributed production planning and instruction device. The distributed production planning and instruction device 100 includes a storage unit 110 , a processing unit 120 , a communication unit 130 , an input unit 140 , and an output unit 150 .

[0065] The storage unit 110 includes: a production instruction storage unit 111, a group production instruction storage unit 112, a group production status storage unit 113, a group abnormality storage unit 114, an equipment-process relationship storage unit 115, a production instruction change storage unit 116, and a distributed plan input information storage unit 117.

[0066] The production instruction storage unit 111 stores production instructions for the production equipment 340 or production resources in the production area where the distributed production planning and instruction device 100 is installed and targeted.

[0067] Figure 3 111 is a diagram showing an example of a data structure of the production instruction storage unit. The production instruction storage unit 111 stores information acquired from the production planning device 210 by the information management unit 121 described later.

[0068] The production instruction storage unit 111 has: an equipment ID column 111a, a product ID column 111b, a variety ID column 111c, a quantity column 111d, a process ID column 111e, a process No. column 111f, a scheduled start time column 111g, a scheduled end time column 111h, a next process scheduled start time column 111j, a next process equipment ID column 111k, and a completion column 111m.

[0069] The equipment ID column 111a, the product ID column 111b, the variety ID column 111c, the quantity column 111d, the process ID column 111e, the process No. column 111f, the scheduled start time column 111g, the scheduled end time column 111h, the next process scheduled start time column 111j, the next process equipment ID column 111k, and the completion column 111m are respectively associated.

[0070] The equipment ID column 111 a stores equipment IDs that are identification information uniquely identifying production equipment or production resources in a production area.

[0071] The product ID column 111 b stores a product ID that is identification information capable of uniquely identifying each product, component, or other product instructed to be processed by the production equipment specified in the equipment ID column 111 a .

[0072] The item ID column 111 c stores information identifying the item of the product identified in the product ID column 111 b .

[0073] The number column 111d stores information specifying the number of products specified in the product ID column 111b.

[0074] The process ID column 111 e stores information specifying a process in which the product specified in the product ID column 111 b is processed by the production equipment specified in the equipment ID column 111 a .

[0075] The process No. column 111 f stores information identifying the number of the process from the initial process of the process in the process ID column 111 e of the product identified in the product ID column 111 b .

[0076] The scheduled start time column 111g stores information as a production instruction specifying the scheduled time for starting processing of the process specified in the process ID column 111e with the product specified in the product ID column 111b in the production equipment specified in the equipment ID column 111a.

[0077] The scheduled end time column 111h stores information specifying the scheduled time at which the process specified in the process ID column 111e will be completed with the product specified in the product ID column 111b in the production equipment specified in the equipment ID column 111a as the target.

[0078] The next process start scheduled time column 111j stores information specifying a scheduled time for starting processing of the next process after the process specified in the process ID column 111e for the product specified in the product ID column 111b as a production instruction.

[0079] The next process equipment ID column 111 k stores, as a production instruction, information identifying a production equipment scheduled to process the next process after the process identified in the process ID column 111 e for the product identified in the product ID column 111 b .

[0080] The completion column 111m stores information indicating whether the process specified in the process ID column 111e has been completed for the product specified in the product ID column 111b in the production equipment specified in the equipment ID column 111a. If not completed, the column is blank.

[0081] Return to Figure 2 The group production instruction storage unit 112 stores production instructions for production facilities or production resources in production areas targeted by the distributed production planning and instruction device 100, as well as production instructions for replanning delayed recovery of production plans. The group production instruction storage unit 112 may contain multiple production facilities or production resources in production areas storing production instructions, and the information management unit 121, described later, extracts the targeted production facilities or production areas.

[0082] Figure 4112 is a diagram showing an example of a data structure of the group production instruction storage unit. The group production instruction storage unit 112 stores information acquired from the production planning device 210 by the information management unit 121 described later.

[0083] The group production instruction storage unit 112 has: an equipment ID column 112a, a product ID column 112b, a variety ID column 112c, a quantity column 112d, a process ID column 112e, a process No. column 112f, a scheduled start time column 112g, a scheduled end time column 112h, a next process scheduled start time column 112j, a next process equipment ID column 112k and a completion column 112m.

[0084] The equipment ID column 112a, the product ID column 112b, the variety ID column 112c, the quantity column 112d, the process ID column 112e, the process No. column 112f, the scheduled start time column 112g, the scheduled end time column 112h, the next process scheduled start time column 112j, the next process equipment ID column 112k and the completion column 112m are respectively associated.

[0085] The device ID column 112 a stores a device ID that is identification information uniquely identifying a production resource such as a production device or a production area.

[0086] The product ID column 112 b stores a product ID that is identification information capable of uniquely identifying each product, component, or other product instructed to be processed by the production equipment specified in the equipment ID column 112 a .

[0087] The item ID column 112 c stores information identifying the item of the product identified in the product ID column 112 b .

[0088] The number column 112d stores information specifying the number of products specified in the product ID column 112b.

[0089] The process ID column 112 e stores information specifying a process in which the product specified in the product ID column 112 b is processed by the production equipment specified in the equipment ID column 112 a .

[0090] The process No. column 112f stores information identifying the number of the process from the initial process of the process in the process ID column 112e of the product specified in the product ID column 112b.

[0091] The scheduled start time column 112g stores information as a production instruction specifying the scheduled time for starting processing of the process specified in the process ID column 112e with the product specified in the product ID column 112b in the production equipment specified in the equipment ID column 112a.

[0092] The scheduled end time column 112h stores information as a production instruction specifying the scheduled time at which the process specified in the process ID column 112e will be completed, with the product specified in the product ID column 112b as the target, in the production equipment specified in the equipment ID column 112a.

[0093] The next process start scheduled time column 112j stores information specifying a scheduled time for starting processing of the next process after the process specified in the process ID column 112e for the product specified in the product ID column 112b as a production instruction.

[0094] The next process equipment ID column 112k stores, as a production instruction, information identifying a production equipment scheduled to process the next process after the process identified in the process ID column 112e for the product identified in the product ID column 112b.

[0095] The completion column 112m stores information indicating whether the process specified in the process ID column 112e has been completed for the product specified in the product ID column 112b in the production equipment specified in the equipment ID column 112a. If not completed, the column is blank.

[0096] Return to Figure 2 In the group production status storage unit 113, information related to the production status is stored, with the production equipment or production resources in the production area being the target and the production equipment or production resources in the production area being the target and the production equipment or production resources in the production area being the target for replanning the delayed recovery of the production plan being the target.

[0097] Figure 5 The group production status storage unit 113 stores information acquired by the information management unit 121 (described later) from production facilities targeted by the production management device 200 and the distributed production planning and instruction device 100, as well as information generated using the acquired information.

[0098] The group production status storage unit 113 includes a device ID column 113a, a status column 113b, a product ID column 113c, a product ID column 113d, a quantity column 113e, a process ID column 113f, a process No. column 113g, a start time column 113h, and an expected end time column 113j.

[0099] The equipment ID column 113a, the status column 113b, the product ID column 113c, the product ID column 113d, the quantity column 113e, the process ID column 113f, the process No. column 113g, the start time column 113h, and the expected end time column 113j are respectively associated with each other.

[0100] The device ID column 113 a stores a device ID that is identification information uniquely identifying a production resource of a production device or a production area.

[0101] The status column 113 b stores information on the status (mainly the operating status) of the production equipment specified in the equipment ID column 113 a .

[0102] The product ID column 113c stores the product ID, which is identification information that uniquely identifies each product, component, or other product being processed by the production equipment specified in the equipment ID column 113a. Depending on the value stored in the status column 113b, the product ID column 113c may be blank.

[0103] The product ID column 113d stores information identifying the product type specified in the product ID column 113c. Depending on the value stored in the status column 113b, the product ID column 113d may be blank.

[0104] The number column 113e stores information specifying the number of products specified in the product ID column 113c. Depending on the value stored in the status column 113b, the number column 113e may be blank.

[0105] The process ID column 113f stores information identifying a process in which the product identified in the product ID column 113c is processed by the production equipment identified in the equipment ID column 113a. Depending on the value stored in the status column 113b, the process ID column 113f may be blank.

[0106] The process No. column 113g stores information identifying the number of the process in the process ID column 113f, counting from the initial process, associated with the product identified in the product ID column 113c. Depending on the value stored in the status column 113b, the process No. column 113g may be blank.

[0107] The start time column 113h stores, as a production instruction, information specifying the time at which the production equipment specified in the equipment ID column 113a starts processing the process specified in the process ID column 113f for the product specified in the product ID column 113c. Depending on the value stored in the status column 113b, the start time column 113h may be blank.

[0108] The scheduled end time column 113j stores, as a production instruction, information specifying the scheduled time at which processing of the process specified in the process ID column 113f will be completed, using the product specified in the product ID column 113c, at the production equipment specified in the equipment ID column 113a. Depending on the value stored in the status column 113b, the scheduled end time column 113j may be blank.

[0109] Return to Figure 2 In the group abnormality storage unit 114, information related to abnormalities is stored, with the production equipment or production resources in the production area for which the distributed production planning and instruction device 100 is installed and set as the target, and the production equipment or production resources in the production area for replanning delayed recovery of the production plan as the target.

[0110] Figure 6 The group abnormality storage unit 114 stores information acquired by the information management unit 121 described later from production facilities equipped with the production management device 200 and the distributed production planning and instruction device 100, and information generated using the acquired information.

[0111] The group abnormality storage unit 114 includes a device ID column 114 a , an abnormality status column 114 b , a generation time column 114 c , a scheduled recovery time column 114 d , and a countermeasure status column 114 e .

[0112] The device ID column 114a, the abnormal status column 114b, the occurrence time column 114c, the expected recovery time column 114d, and the countermeasure status column 114e are respectively associated with each other.

[0113] The device ID column 114 a stores a device ID that is identification information uniquely identifying a production resource such as a production device or a production area.

[0114] The abnormal status column 114b stores information on the abnormal status of the device specified in the device ID column 114a. The abnormal status includes, for example, "failure" or "inspection" and the reason for the abnormality.

[0115] The occurrence time column 114 c stores information identifying the time when the abnormality identified in the abnormal state column 114 b occurred in the device identified in the device ID column 114 a .

[0116] In the scheduled recovery time column 114d, information is stored on the scheduled time when the abnormality specified in the abnormal status column 114b generated at the time specified in the generation time column 114c in the device specified in the device ID column 114a is eliminated and the device specified in the device ID column 114a is restored to a normal state.

[0117] The countermeasure status column 114e stores information related to the response status corresponding to the abnormality specified in the abnormality status column 114b that occurred at the time specified in the occurrence time column 114c in the production equipment specified in the equipment ID column 114a. The response status includes, for example, "Not (not responded)" and "Not Required (no countermeasure required)" indicating the implementation status of the countermeasures for recovering from the abnormality.

[0118] Return to Figure 2 In the equipment-process relationship storage unit 115, production equipment capable of implementing the process or production resources including a production area are stored in correspondence with each combination of a product and its process.

[0119] Figure 7 This diagram shows an example of the data structure of the equipment-process relationship storage unit. The equipment-process relationship storage unit 115 stores information related to production equipment targeted by the distributed production planning and instruction device 100, obtained from the production management device 200 or the production planning device 210 by the information management unit 121 (described later). This information is also updated when changes are made to the production equipment.

[0120] The equipment-process relationship storage unit 115 includes a product ID column 115 a , a process ID column 115 b , and an equipment column 115 c including a plurality of equipment IDs.

[0121] The item ID column 115a, the process ID column 115b, and the equipment column 115c are associated with each other.

[0122] The product ID column 115a stores information identifying the product type. The process ID column 115b stores information identifying the process. The equipment column 115c stores information identifying the production equipment capable of processing the process specified in the process ID column 115b for the product specified in the product ID column 115a. Furthermore, the equipment column 115c is further subdivided by production equipment. For example, in this embodiment, the equipment column 115c lists and includes the equipment IDs of all production equipment capable of processing the process, such as the equipment ID1 column 115d, the equipment ID2 column 115e, the equipment ID3 column 115f, and so on.

[0123] Return to Figure 2The production instruction change storage unit 116 stores information related to changes in production instructions for production facilities or production resources in production areas where the distributed production planning and instruction device 100 is installed.

[0124] Figure 8 This figure shows an example of the data structure of the production instruction change storage unit. The production instruction change storage unit 116 stores information related to production instruction changes generated by the production instruction change and management unit 125 based on a schedule generated by the distributed plan generation unit 124 (described later). The production instruction change storage unit 116 also stores information related to production instruction changes received by the production instruction change and management unit 125 from other distributed production planning and instruction devices 100.

[0125] The production instruction change storage unit 116 has: a device ID column before change 116a, a device ID column after change 116b, a product ID column 116c, a variety ID column 116d, a quantity column 116e, a process ID column 116f, a process No. column 116g, a scheduled start time column 116h, a scheduled end time column 116j, a next process scheduled start time column 116k, a next process device ID column 116m and a change status column 116p.

[0126] The equipment ID column before change 116a, the equipment ID column after change 116b, the product ID column 116c, the variety ID column 116d, the number column 116e, the process ID column 116f, the process No. column 116g, the scheduled start time column 116h, the scheduled end time column 116j, the next process scheduled start time column 116k, the next process equipment ID column 116m and the change status column 116p are respectively associated with each other.

[0127] The pre-change device ID column 116a stores the device ID, which is identification information uniquely identifying a production device or production resource in a production area. Furthermore, the pre-change device ID column 116a stores the device ID that received the production instruction before the production instruction change and management unit 125 generated the production instruction change.

[0128] The changed device ID column 116b stores the device ID, which is identification information uniquely identifying a production device or production resource in a production area. The changed device ID column 116b also stores the device ID that received the production instruction in the production instruction change generated by the production instruction change management unit 125.

[0129] The product ID column 116 c stores the product ID of each product, component, or the like that has been changed so as to be processed by the production equipment specified in the after-change equipment ID column 116 b .

[0130] The item ID column 116d stores information identifying the item of the product identified in the product ID column 116c.

[0131] The number column 116e stores information specifying the number of products specified in the product ID column 116c.

[0132] The process ID column 116f stores information specifying a process instructing the production equipment specified in the after-change equipment ID column 116b to process the product specified in the product ID column 116c.

[0133] The process No. column 116g stores information identifying the number of the process from the initial process of the process in the process ID column 116f of the product identified in the product ID column 116c.

[0134] In the scheduled start time column 116h, as a production instruction, information is stored that specifies the scheduled time for starting processing of the process specified in the process ID column 116f with the product specified in the product ID column 116c in the production equipment specified in the changed equipment ID column 116b.

[0135] In the scheduled end time column 116j, as a production indication, information is stored that specifies the scheduled time at which the processing of the process specified in the process ID column 116f is completed, with the product specified in the product ID column 116c as the object, in the production equipment specified in the changed equipment ID column 116b.

[0136] The next process start scheduled time column 116k stores information specifying a scheduled time for starting processing of the next process after the process specified in the process ID column 116f for the product specified in the product ID column 116c as a production instruction.

[0137] The next process equipment ID column 116m stores, as a production instruction, information identifying a production equipment scheduled to process the next process after the process identified in the process ID column 116f for the product identified in the product ID column 116c.

[0138] The change status column 116p stores information identifying whether the change instruction from the production equipment identified in the pre-change equipment ID column 116a, used in the process identified in the process ID column 116f, which processes the product identified in the product ID column 116c, to the production equipment identified in the post-change equipment ID column 116b, has been reflected in the production instructions of the distributed production planning and instructing device 100 installed at the production equipment identified in the post-change equipment ID 116b. If the change instruction has not been reflected, the change status column 116p remains blank or stores the value "Not yet." If the change instruction has been completed, the value "Complete" is stored in the change status column 116p.

[0139] Return to Figure 2 The distributed plan input information storage unit 117 stores information necessary for processing by the information management unit 121, the plan change determination unit 122, the distributed plan range calculation unit 123, the distributed plan generation unit 124, and the production instruction change and management unit 125, targeting production resources in production facilities or production areas. The distributed plan input information storage unit 117 stores the following production resources in production facilities or production areas.

[0140] The distributed production planning and instructing device 100 is installed and used as the production resources of the production facilities or production areas targeted.

[0141] Production resources of production equipment or production areas that are involved in replanning for delayed recovery of production orders.

[0142] The production resources in the production equipment or production area responsible for the next process of the production instruction of the decentralized production planning and instruction device 100.

[0143] Figure 9 117 is a diagram showing an example of a data structure of a distributed plan input information storage unit. The distributed plan input information storage unit 117 stores information acquired from the production management device 200 and the production planning device 210 by the information management unit 121 described later.

[0144] The distribution plan input information storage unit 117 includes a device ID column 117 a , a device capability column 117 b , a connection information column 117 c , a transfer time column 117 d , a transfer request destination information column 117 e , and a type column 117 f .

[0145] The device ID column 117a, the device capability column 117b, the connection information column 117c, the transfer time column 117d, the transfer request destination information column 117e, and the type column 117f are associated with each other.

[0146] The device ID column 117 a stores a device ID that is identification information uniquely identifying a production resource such as a production device or a production area.

[0147] The equipment capacity column 117 b stores numerical information (for example, production volume per unit time) obtained by quantifying the production capacity of the production equipment specified in the equipment ID column 117 a .

[0148] The connection information column 117 c stores information (for example, an IP (Internet Protocol) address) for connecting to the distributed production planning and instructing apparatus 100 installed in the production facility specified in the facility ID column 117 a via the network 370 .

[0149] The transport time column 117d stores information identifying the time required to transport a product from the production facility 340, in which the distributed production planning and instructing device 100 including the distributed plan input information storage unit 117 is installed, to the production facility identified in the facility ID column 117a. For example, if the transport time is 10 minutes, the value "10" is stored in the transport time column 117d.

[0150] The transport request destination information column 117e stores information on a connection destination when requesting transport of a product from the production facility 340, in which the distributed production planning and instruction device 100 having the distributed plan input information storage unit 117 is installed, to the production facility identified in the facility ID column 117a via the network 370. If transport request via the network 370 is not required or transport is not possible, the column is left blank.

[0151] The type column 117f stores temporary attribute information of the production equipment specified in the equipment ID column 117a. The information in the type column 117f is generated by the information management unit 121 and used by the plan change determination unit 122, the distribution plan range calculation unit 123, and the distribution plan generation unit 124.

[0152] Return to Figure 2 The processing unit 120 of the distributed production planning and instruction device 100 includes an information management unit 121, a plan change determination unit 122, a distributed plan range calculation unit 123, a distributed plan generation unit 124, a production instruction change and management unit 125, and an alarm information management unit 126.

[0153] The information management unit 121 inquires the production management device 200, the production planning device 210, and the production equipment 340 equipped with the distributed production planning and instruction device 100 and set as the target through the communication unit 130 at a predetermined frequency (for example, every 12 hours) or when specified, obtains the information stored in the production instruction storage unit 111, the group production instruction storage unit 112, the group production status storage unit 113, the group abnormality storage unit 114, and the distributed plan input information storage unit 117, generates necessary information, and updates the information stored in each storage unit.

[0154] In addition, the information management unit 121 inquires the production management device 200 and the production equipment 340 set as the target and equipped with a distributed production planning and instruction device 100 via the communication unit 130 at a predetermined frequency (for example, every 30 seconds) or when specified, obtains and updates the information stored in the group production status storage unit 113 and the group abnormality storage unit 114, and executes the processing of the plan change determination unit 122 based on the updated content.

[0155] Furthermore, based on the result of the determination of whether or not to change the plan, the information management unit 121 executes the processing of the distributed plan range calculation unit 123, the distributed plan generation unit 124, and the production instruction change and management unit 125, thereby generating information to be stored in the production instruction change storage unit 116. Furthermore, based on the execution result of the production instruction change and management unit 125, the alarm information management unit 126 executes the processing.

[0156] Specifically, if there is a production instruction for which the start time of the next process cannot meet the scheduled start time of the next process among the uncompleted production instructions, the plan change determination unit 122 determines that a plan change is required.

[0157] The distributed plan range calculation unit 123 determines the production equipment (target equipment) to be used in the replanning of the distributed plan generated by the distributed plan generation unit 124, the replanning period, and the uncompleted production instructions that are the subject of the replanning, and then transfers these to the distributed plan generation unit 124. Specifically, the distributed plan range calculation unit 123 sets the period containing the latest production instruction among the uncompleted production instructions for which the time at which the next process can be started is later than the scheduled start time of the next process as the distributed plan period. Furthermore, the distributed plan range calculation unit 123 identifies the uncompleted production instructions for which the time at which the next process can be started is later than the scheduled start time of the next process as the uncompleted production instructions subject to the distributed plan. Furthermore, the distributed plan range calculation unit 123 identifies equipment that can be substituted from the equipment-process relationship storage unit 115 as the equipment subject to the distributed plan.

[0158] The distributed plan generating unit 124 re-plans the schedule for recovering from the delay of the production instruction. Specifically, the distributed plan generating unit 124 generates a schedule that minimizes the total number of delayed items and the total delay time from the latest start date as the re-schedule.

[0159] The production instruction change and management unit 125 registers the replan generated by the distributed plan generation unit 124 as a production instruction change. Specifically, the production instruction change and management unit 125 determines whether the number of uncompleted production instructions for which the next process start time falls short of the scheduled start time of the next process has decreased in the replan generated by the distributed plan generation unit 124. If so, it registers the number in the production instruction change storage unit 116. Furthermore, the production instruction change and management unit 125 transfers the production instruction data for the production facility that has assumed processing responsibility after the production instruction change to the production instruction change and management unit 125 of the distributed production planning and instruction device, and issues a delivery request to the delivery request destination for the manufactured product to the production facility.

[0160] The alarm information management unit 126 transmits production plan non-achievement alarm information to the production planning device 210 and the production management device 200 for overall factory production management, for production instructions in which there is a possibility that the plan may not be achieved.

[0161] The communication unit 130 transmits and receives various information to and from other devices via a network.

[0162] The input unit 140 is displayed and operated on a screen, for example, and receives input information inputted by operating a keyboard or a mouse.

[0163] The output unit 150 , for example, creates screen information including information outputted as a result of performing predetermined processing, and outputs the information to the production instruction terminal 320 via the communication unit 130 .

[0164] Figure 10 This figure shows an example of the hardware structure of a distributed production planning and instruction device. The distributed production planning and instruction device 100 can be implemented by a general computer 900 having a processor (e.g., a CPU or GPU) 901, a memory such as RAM (Random Access Memory) 902, an external storage device 903 such as a hard disk device (HDD) or SSD, a reader 905 for reading information from a removable storage medium 904 such as a CD or DVD, an input device 906 such as a keyboard, mouse, barcode reader, or touch panel, an output device 907 such as a display, and a communication device 908 for communicating with other computers via a communication network such as a LAN or the Internet, or a network system having multiple such computers 900. In addition, the reader 905 can also write to the removable storage medium 904 in addition to reading.

[0165] For example, the information management unit 121, the plan change determination unit 122, the distributed plan range calculation unit 123, the distributed plan generation unit 124, the production instruction change and management unit 125, and the alarm information management unit 126 included in the processing unit 120 can be implemented by loading a predetermined program stored in the external storage device 903 into the memory 902 and executing it by the processor 901, the input unit 140 can be implemented by the processor 901 using the input device 906, the output unit 150 can be implemented by the processor 901 using the output device 907 or the communication device 908, the communication unit 130 can be implemented by the processor 901 using the communication device 908, and the storage unit 110 can be implemented by the processor 901 using the memory 902 or the external storage device 903.

[0166] The predetermined program may be downloaded from a removable storage medium 904 via a reader 905 or from a network via a communication device 908 to an external storage device 903, and then loaded into the memory 902 for execution by the processor 901. Alternatively, the predetermined program may be directly loaded from a removable storage medium 904 via a reader 905 or from a network via a communication device 908 to the memory 902 for execution by the processor 901.

[0167] In addition, the performance input terminal 310 and the production instruction terminal 320 can also be used to Figure 10 The general computer 900 shown is implemented.

[0168] Figure 11 The production instruction update process is started at a predetermined frequency (for example, every 12 hours) or when it is specified, or when the decentralized production planning and instruction device 100 is instructed to start the process.

[0169] First, the information management unit 121 performs initialization processing (step S101). Specifically, the initialization processing of the information management unit 121 described later is performed.

[0170] Next, the information management unit 121 obtains production instructions for the production equipment 340 (the production equipment) under its control from the production planning device 210 within a predetermined period (for example, 24 hours), and stores the instructions in the production instruction storage unit 111 (step S102).

[0171] Then, the information management unit 121 performs the processing of steps S104 to S106 for each of the work instructions of the production equipment 340 under its control acquired in step S102 (steps S103 and S107 ).

[0172] The information management unit 121 obtains the equipment information of the next process in the production instruction (step S104). Specifically, the information management unit 121 obtains information from the production management device 200 regarding the equipment ID in the next process equipment ID column 111k of the production instruction, sets "next process" in the type column 117f, and stores it in the distributed plan input information storage unit 117.

[0173] The information management unit 121 then obtains the device ID that can be substituted (step S105). Specifically, the information management unit 121 refers to the device-process relationship storage unit 115, extracts data in both the product ID column 115a and the process ID column 115b that match the production instructions, and obtains the device ID that can be substituted, other than the device ID in the extracted data.

[0174] The information management unit 121 then associates all devices that can be substituted with "groups" (step S106). Specifically, the information management unit 121 sets "group" in the type column 117f for all device IDs acquired in step S105. For devices not stored in the distributed plan input information storage unit 117, the information management unit 121 acquires information from the production management device 200 to supplement the information and stores it in the distributed plan input information storage unit 117 (step S106).

[0175] The information management unit 121 obtains production instructions for the equipment in the "group" from the production planning device 210 (step S108). Specifically, the information management unit 121 obtains production instructions for a predetermined period (e.g., 24 hours) from the production planning device 210 for all equipment IDs whose type column 117f is "group" through the distributed planning input information storage unit 117, and stores them in the group production instruction storage unit 112.

[0176] The information management unit 121 then obtains production status information for the equipment under its control and the equipment in the "group" (step S109). Specifically, the information management unit 121 obtains production status information from the production management device 200 and the production equipment itself for the equipment IDs of the production equipment under its control and for all equipment IDs for which "group" is stored in the type column 117f of the distributed plan input information storage unit 117, and stores the information in the group production status storage unit 113.

[0177] The information management unit 121 then obtains abnormality information for the equipment under its control and the equipment in the "group" (step S110). Specifically, the information management unit 121 obtains abnormality information from the production management device 200 and the production equipment itself for the equipment IDs of the production equipment under its control and for all equipment IDs for which the "group" is stored in the type column 117f of the distributed plan input information storage unit 117, and stores the information in the group abnormality storage unit 114.

[0178] The above is an example of the flow of the production instruction update process. According to the production instruction update process, the update of the production instruction can be reflected.

[0179] Figure 12 1 is a diagram showing an example of the flow of the initialization process of the information management unit 121. The initialization process of the information management unit 121 starts at step S101 of the production instruction update process.

[0180] First, the information management unit 121 deletes all data stored in the production instruction storage unit 111 (step S111 ).

[0181] Then, the information management unit 121 deletes all the data stored in the group production instruction storage unit 112 (step S112).

[0182] Then, the information management unit 121 deletes all the data stored in the group production status storage unit 113 (step S113).

[0183] Then, the information management unit 121 deletes all the data stored in the group abnormality storage unit 114 (step S114 ).

[0184] Then, the information management unit 121 deletes all the data stored in the production instruction change storage unit 116 (step S115).

[0185] Then, the information management unit 121 deletes all data except for the data whose type column 117f is "this" among the information stored in the distributed plan input information storage unit 117 (step S116).

[0186] The above is an example of the flow of the initialization process of the information management unit 121. According to the initialization process of the information management unit 121, it is possible to initialize the data set for updating various production instructions.

[0187] Figure 13 1 is a diagram showing an example of a flow of a periodic update process. The periodic update process is started at a predetermined frequency (for example, every 30 seconds) or when it is specified, or when an instruction to start the process is given to the distributed production planning and instructing device 100.

[0188] First, the information management unit 121 collects operation status information (step S121). Specifically, the information management unit 121 obtains production status and abnormality information from the production management device 200 or the production equipment 340 under its control, and updates the data in the group production status storage unit 113 and the group abnormality storage unit 114 respectively.

[0189] The information management unit 121 then determines whether the process completion information for the production equipment 340 or the group of production equipment under its control has been updated (step S122). Specifically, in step S121, the information management unit 121 determines whether the device ID information for the production equipment 340 or the group of production equipment under its control has been updated. If the information has not been updated (if the answer is "No" in step S122), the information management unit 121 terminates the regular update process.

[0190] If the update is successful (if the answer is yes in step S122), the information management unit 121 updates the completion column of the process of the production equipment under its control and the group (step S123). Specifically, the information management unit 121 obtains information from the production management device 200 or the production equipment 340 under its control, and updates the completion column 111m of the production instruction storage unit 111 and the completion column 112m of the group production instruction storage unit 112 of the completed process of the corresponding production equipment to the completed state.

[0191] Then, the information management unit 121 executes a plan change necessity determination process described later (step S124 ).

[0192] Then, the information management unit 121 determines whether a plan change is necessary based on the result of step S124 (step S125). If a plan change is not necessary (No in step S125), the information management unit 121 ends the regular update process.

[0193] Then, when the plan change is necessary (in the case of YES in step S125 ), the information management unit 121 executes a dispersion plan range calculation process (step S126 ) described later.

[0194] Then, the information management unit 121 executes a distribution plan generation process (step S127 ) to be described later.

[0195] Then, the information management unit 121 executes instruction change output processing (step S128 ) to be described later.

[0196] The information management unit 121 then determines whether there is an estimate of delayed recovery based on the results of the production instruction change management process (step S129). Specifically, if a replan has been created that allows all production instructions to be completed within the distributed planning range (period, equipment, and production volume), it is determined that there is an estimate of recovery. If there is an estimate of recovery (if the answer is yes in step S129), the information management unit 121 terminates the periodic update process.

[0197] If there is no prediction of recovery (NO in step S129 ), the information management unit 121 executes an alarm process (step S130 ).

[0198] The above is an example of the flow of the periodic update process. According to the periodic update process, when a delay or abnormality occurs in the production situation, re-planning using localized alternative production equipment is carried out, and production reflecting the changes in the production plan can be started quickly.

[0199] Figure 14 1 is a diagram showing an example of the flow of the plan change determination process. The plan change determination process is started in step S124 of the periodic update process.

[0200] First, the plan change determination unit 122 identifies uncompleted production instructions (step S201). Specifically, the plan change determination unit 122 refers to the production instruction storage unit 111 and identifies data with an empty completion column 111m as uncompleted production instructions.

[0201] Then, the plan change determination unit 122 reflects the start time and the scheduled end time for the uncompleted production instruction, i.e., the "in progress" production instruction (step S202). Specifically, the plan change determination unit 122 obtains data from the group production status storage unit 113 whose equipment ID matches the production equipment used in the uncompleted production instruction identified in step S201. If the status column 113b indicates "in progress", the plan change determination unit 122 reflects the corresponding data in the scheduled start time column 111g and the scheduled end time column 111h of the uncompleted production instruction.

[0202] Next, the plan change determination unit 122 calculates the equipment downtime period due to the abnormality for the production equipment that has experienced an abnormality and for which no countermeasures have been taken (step S203). Specifically, if data in the group abnormality storage unit 114 indicates the same equipment ID as the production equipment under its control in the equipment ID column 114a and "Not" in the countermeasure status column 114e, the plan change determination unit 122 retrieves this data and calculates the equipment downtime period from the time of occurrence in the time column 114c to the time of scheduled recovery in the time column 114d.

[0203] The plan change determination unit 122 then performs a simulation while maintaining the outstanding production instructions (step S204). Specifically, the plan change determination unit 122 performs a time rollback, such that no new operations are initiated during the equipment downtime period, but operations are resumed after the equipment downtime period ends. The plan change determination unit 122 then allocates execution periods for all outstanding production instructions for the period preceding the current time. The plan change determination unit 122 then calculates the scheduled start and end times for the allocated outstanding production instructions using the data in the device capacity column 117b for the device ID obtained from the distributed plan input information storage unit 117.

[0204] Then, the plan change determination unit 122 calculates the start time of the next process for each of the unfinished production instructions of the simulation object (step S205). Specifically, the plan change determination unit 122 uses the next process equipment ID column 111k of the production instruction storage unit 111 to determine the production equipment of the next process, and uses the information in the delivery time column 117d of the distributed plan input information storage unit 117 to determine the delivery time to the production equipment of the next process. Alternatively, in the event of an abnormality in the production equipment, the delivery time may be made longer than usual (for example, twice). Then, the plan change determination unit 122 calculates the start time of the next process by adding the delivery time to the scheduled end time of the current process.

[0205] Next, the plan change determination unit 122 calculates a judgment item J for each of the uncompleted production instructions of the simulation object, to determine whether the available start time of the next process can meet the scheduled start time (step S206). Specifically, the plan change determination unit 122 calculates the judgment item J = (scheduled start time of the next process) - (available start time of the next process) for each of the uncompleted production instructions.

[0206] Then, the plan change necessity determination unit 122 determines whether or not there is one or more data with J<0 in the uncompleted production instructions (step S207 ).

[0207] When there is one data showing J<0 (YES in step S207 ), the plan change determination unit 122 determines that a plan change is necessary and transfers the information of the unfinished production instruction to the distributed plan range calculation unit 123 (step S209 ).

[0208] If there is no data with J < 0 (if the answer is NO in step S207), the plan change determination unit 122 determines that a plan change is not necessary. If there is data updated in step S121 of the regular update process in the group abnormality storage unit 114, "Not necessary" is stored in the countermeasure status column 114e of the data (step S209). In other words, the plan change determination unit 122 determines that a plan change is not necessary if the production instructions can be followed, taking into account the downtime period of the production element caused by the abnormality.

[0209] The above is an example of a plan change determination process flow. This process can determine whether there are processes that would be delayed if production were to continue without a plan change. Furthermore, if an abnormality occurs, it can be determined that a plan change is not necessary if production instructions can be followed, taking into account the downtime of production elements caused by the abnormality.

[0210] Figure 151 is a diagram showing an example of the flow of the distributed plan range calculation process. The distributed plan range calculation process starts in step S126 of the periodic update process.

[0211] First, the distributed plan range calculation unit 123 receives input of all uncompleted production instructions as a result of the plan change determination process (step S301 ).

[0212] The dispersion plan range calculation unit 123 then sets the dispersion plan period (step S302). Specifically, the dispersion plan range calculation unit 123 obtains the latest next process start time from the production instructions with J < 0, and sets the period from the current time to the next process start time as the dispersion plan period.

[0213] The distributed planning range calculation unit 123 then sets the distributed planning target production instructions (step S303). Specifically, the distributed planning range calculation unit 123 extracts the production instruction with the latest scheduled start time from the production instructions with J < 0, and the unfinished production instructions for the distributed planning target with a scheduled start time before the latest scheduled start time, and sets them as the distributed planning target production instructions.

[0214] The distributed planning range calculation unit 123 then sets the equipment to be distributed (step S304). Specifically, for each production instruction to be distributed, the distributed planning range calculation unit 123 extracts the data that matches both the item ID column 115a and the process ID column 115b from the equipment-process relationship storage unit 115, obtains the equipment ID other than the equipment ID in the production instruction from the equipment column 115c, and sets the target equipment for the financing as the equipment to be distributed.

[0215] Then, the distributed plan range calculation unit 123 transfers the distributed plan period, the distributed plan target production instruction, and the distributed plan target equipment to the distributed plan generation unit 124 (step S305 ).

[0216] The above is an example of the flow of the distributed planning range calculation process. According to the distributed planning range calculation process, the localized range to be the target of the distributed planning, particularly the period, production instruction, and production equipment, can be determined.

[0217] Figure 16 1 is a diagram showing an example of the flow of the distributed plan generation process. The distributed plan generation process starts in step S127 of the periodic update process.

[0218] First, the distributed plan generating unit 124 receives as input the distributed plan period, the distributed plan target production instruction, and the distributed plan target equipment, which are the results of the distributed plan range calculation process (step S401 ).

[0219] The distributed plan generation unit 124 then adds the uncompleted production instructions for the distributed plan target equipment to the distributed plan target production instructions (step S402). Specifically, the distributed plan generation unit 124 retrieves data with an empty column 112m for each equipment ID included in the distributed plan target equipment from the group production instruction storage unit 112, matches it with the existing distributed plan target production instructions, and re-sets them as the distributed plan target production instructions.

[0220] The distributed plan generation unit 124 then determines the operation start status of the equipment in the distributed plan production instruction (step S403). Specifically, the distributed plan generation unit 124 obtains data in the equipment ID column 113a associated with the distributed plan production instruction from the group production status storage unit 113. If the status column 113b indicates "Starting," the data is reflected in the corresponding data in the distributed plan production instruction.

[0221] The distributed plan generation unit 124 then determines the delivery time to the next process for all distributed plan-targeted production instructions (step S404). Specifically, the distributed plan generation unit 124 identifies the next process equipment by referring to the next process equipment ID column 111k and the next process equipment ID column 112k for all distributed plan-targeted production instructions, and reads the delivery time column 117d in the distributed plan input information storage unit 117 to determine the delivery time to the next process.

[0222] The distributed plan generation unit 124 then determines the latest start time for all distributed plan-targeted production instructions (step S405). Specifically, the distributed plan generation unit 124 calculates the difference between the scheduled start time and the scheduled completion time for all distributed plan-targeted production instructions as the scheduled processing period, and determines the latest start time as the time that is calculated by looking back the transport time and the scheduled processing period from the scheduled start time of the next process.

[0223] Then, the distributed plan generating unit 124 determines the earliest start time for all the distributed plan-targeted production instructions (step S406). Specifically, the distributed plan generating unit 124 determines the scheduled start time as the earliest start time for all the distributed plan-targeted production instructions.

[0224] The distributed plan generation unit 124 then generates a distributed production plan (step S407). Specifically, during the distributed plan period, the distributed plan generation unit 124 generates a schedule that minimizes the total number of delayed items and the total delay time from the latest start date for all work instructions for the equipment in the distributed plan target production instructions, while also utilizing the target equipment. This schedule is then transferred to the production instruction modification and management unit 125.

[0225] The above is an example of the flow of the distributed plan generation process. According to the distributed plan generation process, a distributed production plan optimized within a localized range can be created.

[0226] Figure 17 1 is a diagram showing an example of the flow of the instruction change output process. The instruction change output process starts in step S128 of the periodic update process.

[0227] First, the production instruction change and management unit 125 receives a distributed production plan from the distributed plan generation unit 124 (step S501 ).

[0228] Then, the production instruction change and management unit 125 extracts only the production instructions of the production equipment 340 under the management of the decentralized production plan, recalculates J, and determines the number of production instructions with J<0 and its change (step S502).

[0229] Then, based on the result of step S502, the production instruction change and management unit 125 determines whether the number of production instructions with J < 0 has decreased (step S503). If the number of production instructions with J < 0 has not decreased (if the answer is No in step S503), the production instruction change and management unit 125 advances control to step S505.

[0230] If the number of production instructions with J < 0 decreases (if the answer is yes in step S503), the production instruction change and management unit 125 registers all production instructions with J < 0 in a waiting state for change management (step S504). Specifically, the production instruction change and management unit 125, through the processing of the distributed plan generation unit 124, sets the change status column 116p to "Not" for all production instructions with J < 0, and stores them in the production instruction change storage unit 116 along with the pre-change equipment ID.

[0231] Then, the production instruction change and management unit 125 sets the status to "estimated delayed recovery" when the number of items with J < 0 is 0, and sets the status to "no estimated delayed recovery" when the number of items with J < 0 is 1 or more (step S505). Specifically, the production instruction change and management unit 125 sets the status to "estimated delayed recovery" when the number of items with J < 0 is 0, and stores "completed" in the countermeasure status column 114e of the corresponding data in the group abnormality storage unit 114. When the number of items with J < 0 is 1 or more, the status is "no estimated delayed recovery".

[0232] The above is an example of the flow of the instruction change output process. According to the instruction change output process, when there is no delay in the prepared distributed production plan, it is determined that there is an expectation of delay recovery and a change instruction is issued, and otherwise no change instruction is issued.

[0233] Figure 18 1 is a diagram showing an example of the flow of the instruction generation process. The instruction generation process starts immediately after the instruction change output process.

[0234] First, the production instruction change and management unit 125 extracts data whose change status column 116p is "not" from the change data stored in the production instruction change storage unit 116 (step S511).

[0235] The production instruction change and management unit 125 then applies the change data to the production instructions of the production equipment under its control (step S512). Specifically, the production instruction change and management unit 125 extracts the change data whose post-change device ID 116b matches the ID of the equipment under its control from all the extracted data and uploads the corresponding data to the production instruction storage unit 111. The production instruction change and management unit 125 then changes the value of the change status column 116p to "Complete."

[0236] The production instruction change and management unit 125 then deletes any production instructions that are not for the production equipment 340 under its control and registers them as group production instructions (step S513). Specifically, the production instruction change and management unit 125 extracts any production instructions whose changed equipment ID 116b is not the equipment ID from all the extracted data, deletes the corresponding production instruction data from the production instruction storage unit 111, and adds the changed production instruction data to the group production instruction storage unit 112.

[0237] The production instruction change and management unit 125 then forwards the production instruction that is not directed to the production facility 340 under its control to the production instruction change and management unit 125 of the distributed production planning and instruction device 100 of the facility to be changed (step S514). Specifically, the production instruction change and management unit 125 obtains the information in the connection information column 117c of the distributed plan input information storage unit 117, identifies the distributed production planning and instruction device 100 of the facility to be changed, and forwards the production instruction data to the production instruction change and management unit 125 of the distributed production planning and instruction device 100 of the facility to be changed.

[0238] The production instruction change and management unit 125 then sends a delivery request to the distributed production planning and instruction device 100 designated as the delivery request destination (step S515). Specifically, the production instruction change and management unit 125 retrieves the information in the delivery request destination information column 117e from the distributed plan input information storage unit 117, identifies the distributed production planning and instruction device 100 designated as the delivery request destination, and sends the delivery request. Furthermore, the production instruction change and management unit 125 changes the value in the change status column 116p to "Complete."

[0239] The above is an example of the flow of the instruction generation process. According to the instruction generation process, the actual production instructions are updated according to the prepared distributed production plan, and the production and delivery can also be appropriately updated when the production and delivery are transferred to other production equipment in the group.

[0240] Figure 19 1 is a diagram showing an example of a flow of a change instruction reception process. When a change in a production instruction is output in the instruction change output process, the change instruction reception process is started in the distributed production planning and instruction device 100 at the change destination.

[0241] First, the production instruction change and management unit 125 receives change instruction data from the distributed production planning and instruction device that outputs a change in the production instruction (step S521 ).

[0242] Then, the production instruction change and management unit 125 sets the change status column 116p to "not", and stores the received change instruction data in the production instruction change storage unit 116 (step S522).

[0243] The above is an example of the flow of the change instruction reception process. According to the change instruction reception process, when production and transportation are shifted from other production equipment in the group according to the prepared distributed production plan, the change can be appropriately reflected.

[0244] Figure 20 1 is a diagram showing an example of the flow of the alarm process. The alarm process starts in step S130 of the periodic update process.

[0245] First, the alarm information management unit 126 generates production plan non-achievement alarm information (step S601 ).

[0246] Then, the alarm information management unit 126 transmits production plan non-achievement alarm information to the production management device 200 and the production planning device 210 (step S602 ).

[0247] The above is an example of the flow of the alarm processing. According to the alarm processing, it is possible to send the alarm information indicating that the production plan has not been achieved to the production management device 200 and the production planning device 210.

[0248] Figure 21: This is a diagram showing an example of a display screen of a distributed production planning and instruction device. The production instruction screen 400 is an example of a screen that displays the work instructions confirmed by the operator or the on-site reader through the output unit 150 of the distributed production planning and instruction device 100. In the production instruction screen 400, the device ID for identifying the production equipment 340 in which the distributed production planning and instruction device 100 is installed and information related to the status of the production equipment are displayed in the display area 410. In addition, the current time is displayed in the display area 420 of the production instruction screen 400, and the production instruction (initial) indicated by the production planning device 210 and the progress of the production instruction (display of "current" and vertical line) are displayed in the production instruction display area 430. In the production instruction display area 440, the production instruction (re-planned) updated according to the production plan re-planned by the distributed production planning and instruction device 100 is displayed together with the progress of the production instruction.

[0249] The equipment ID input field 450 accepts input of an equipment ID. The display instruction input field 460 accepts input of a display instruction. The associated production instruction display area 470 displays, along with the progress, the operation instructions for the associated production equipment (group equipment) identified by the equipment ID accepted in the equipment ID input field 450. The replanning instruction input field 480 accepts input of a replanning execution instruction. When a replanning execution instruction is entered, the distributed production planning and instruction device 100 begins periodic update processing, and when the production plan is replanned, the information displayed in the production instruction display area 440 is updated.

[0250] The above is an example of the configuration of a decentralized production planning and instruction system according to the first embodiment of the present invention. The decentralized production planning and instruction system 10 of the first embodiment can locally determine whether rescheduling is necessary within a production facility 340 that may not meet the production plan. Based on this determination, the production plan is replanned by narrowing the scope of rescheduling, including the replanning period, the targeted production facilities, and the targeted processes, to the minimum necessary, and production instructions can be issued based on this replan. This allows for the creation of appropriate recovery plans at appropriate times for any production delays, enabling local and autonomous execution without unnecessarily altering the overall plan.

[0251] In the above technology, it is assumed that the manufacturing site (area) 300 is a single one, but the present invention is not limited to this. Even if the manufacturing sites (areas) 300 are dispersed across multiple locations, the same function can be achieved by setting the network 370 to a wide area network such as the Internet (including a 5G wireless communication network).

[0252] The above-mentioned embodiments are described in detail to explain the present invention in an easy-to-understand manner, and are not limited to having all the structures described. A part of the structure of the embodiment can be replaced with another structure. In addition, a part of the structure of the embodiment can also be deleted.

[0253] Furthermore, some or all of the aforementioned components, structures, functions, and processing units may be implemented in hardware, for example, through integrated circuit design. Furthermore, the aforementioned components, structures, functions, and the like may be implemented in software by having a processor interpret and execute programs that implement the respective functions. Information such as programs, tables, and files that implement the respective functions may be stored in a storage device such as a memory or hard disk, or in a storage medium such as an IC card, SD card, or DVD.

[0254] Furthermore, the control lines and information lines described in the above embodiments are shown as necessary for illustration, and do not necessarily represent all control lines and information lines in the product. In practice, it can be assumed that almost all components are interconnected. The above description of the present invention focuses on the embodiments.

Claims

1. A decentralized production planning and instruction device, characterized in that: have: a storage unit storing production instructions serving as operation instructions for production factors including production equipment, production resources, and operators of a factory, abnormality status information including an occurrence status of an abnormality in the production factors, production status information including status information indicating a status of each of the production equipment and a start time and an end time, and equipment-process relationship information identifying, for each process performed by the production factors, other production factors that can be performed in place of the process; a plan change determination unit for determining that, when an abnormality in the execution of the production instruction occurs in the production element, the plan change is not necessary if the production instruction can be followed, taking into account a stoppage period of the production element caused by the abnormality; a decentralized planning scope calculation unit that includes the other production factors that can be implemented alternatively in the scope of re-planning; a distributed plan generating unit that replans the production instruction within the generated replanning target range, When an abnormality occurs in the execution of the production instruction in the production factor, the plan change determination unit rewinds the implementation time in such a way that the operation is started after the stop period of the production factor caused by the abnormality ends, and allocates the implementation period of all unfinished and started production instructions in the period before the current time. If the scheduled start time of the next process can be met, it is determined that no plan change is required. The unfinished and started production instructions are identified in the following manner: for each of the production instructions, determine whether the completion information indicating whether the production instruction is completed is empty, and for each piece of production status information of the production equipment determined to be unfinished, determine whether the status information indicates that production has started, and reflect the start time and end time corresponding to the production equipment in the production instruction.

2. The decentralized production planning and instruction device according to claim 1, characterized in that: The distributed production planning and instruction device includes a production instruction changing and managing unit that outputs the production instruction re-planned by the distributed plan generating unit to the production element and the production element that can be implemented alternatively.

3. The decentralized production planning and instruction device according to claim 1, characterized in that: The distributed production planning and instruction device includes an alarm information management unit that sends a predetermined alarm to other devices that manage production of the entire factory when the distributed plan generation unit cannot perform replanning within the replanning target range.

4. The decentralized production planning and instruction device according to claim 2, characterized in that: If the production instructions for the replanned object include a production instruction that cannot meet the scheduled start time of the next process, the production instruction change and management unit determines that it is impossible to replan within the scope of the replanned object. The distributed production planning and instruction device includes an alarm information management unit that sends a predetermined alarm to other devices that manage production of the entire factory when the distributed plan generation unit cannot perform replanning within the replanning target range.

5. The decentralized production planning and instruction device according to claim 1, characterized in that: When there is a production element that replaces the production instruction, the distributed plan generating unit re-plans the production instruction to include a transfer time from the production element to the production element that performs the next process.

6. A decentralized production planning and instruction system comprising a plurality of decentralized production planning and instruction devices provided for each of one or more production equipment in a factory, characterized in that: The decentralized production planning and instructing device has: a communication unit that communicates with each other via a network; a storage unit storing production instructions serving as operation instructions for production factors including production equipment, production resources, and operators of the factory, abnormality status information including an occurrence status of an abnormality in the production factors, production status information including status information indicating a status of each of the production equipment and a start time and an end time, and equipment-process relationship information identifying, for each process performed by the production factors, other production factors that can be performed in place of the process; a plan change determination unit for determining that, when an abnormality in the execution of the production instruction occurs in the production element, the plan change is not necessary if the production instruction can be followed, taking into account a stoppage period of the production element caused by the abnormality; a decentralized planning scope calculation unit that includes the other production factors that can be implemented alternatively in the scope of re-planning; a distributed plan generating unit configured to re-plan the production instructions within the generated re-planning target range; a production instruction change and management unit that outputs the production instruction replanned by the decentralized plan generation unit to the production factor and the production factor that can be implemented instead, and starts production management according to the production instruction upon receiving the production instruction; When an abnormality occurs in the execution of the production instruction in the production factor, the plan change determination unit rewinds the implementation time in such a way that the operation is started after the stop period of the production factor caused by the abnormality ends, and allocates the implementation period of all unfinished and started production instructions in the period before the current time. If the scheduled start time of the next process can be met, it is determined that no plan change is required. The unfinished and started production instructions are identified in the following manner: for each of the production instructions, determine whether the completion information indicating whether the production instruction is completed is empty, and for each piece of production status information of the production equipment determined to be unfinished, determine whether the status information indicates that production has started, and reflect the start time and end time corresponding to the production equipment in the production instruction.

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