Production simulation device, production system, production simulation method, and program

Abstract

A production simulation device (100) has: an acquisition unit (101) that acquires production order information indicating contents of a production order from an MES (300) that instructs production for each process in accordance with a production order for a production line including a plurality of processes included in a production plan; and a simulation execution unit (102) that calls a simulation model corresponding to a process for executing a production order involved in the production order information acquired by the acquisition unit (101) before the MES (300) instructs production for each process in accordance with the production order, and executes simulation using the called simulation model. The MES (300) instructs production for each process in accordance with a production order that reflects a simulation result.

Description

Technical Field

[0001] This invention relates to production simulation devices, production systems, production simulation methods, and programs. Background Technology

[0002] Previously, a production scheduler was known to create production plans for producing products on a production line. Typically, the production scheduler uses a Master Production Schedule (MPS) and material requirements calculated in a Material Requirements Planning (MRP) system to create a small schedule for the production plan that is then used by the Manufacturing Execution System (MES) to issue production instructions.

[0003] The accuracy of production planning helps improve the productivity of the production line, and therefore various techniques for enabling production schedulers to create accurate production plans have been disclosed. For example, Patent Document 1 discloses a production planning device that calculates the degree of influence of the deviation between the standard time set for each process and the actual operation time on production indicators, and creates a production plan taking into account the degree of influence.

[0004] Patent Document 1: Japanese Patent Application Publication No. 2017-162044 Summary of the Invention

[0005] Such technologies do not reflect the load conditions of the production floor in the production plan, and therefore cannot, for example, create production plans that take into account the actual waiting time between processes on the production line. On the other hand, in order to improve productivity and calculate accurate delivery dates, there is a need for technologies that can issue production instructions based on production plans that take into account the load conditions of the production floor.

[0006] The present invention is made in view of the above circumstances, and its purpose is to provide a production simulation device, production system, production simulation method and program capable of performing simulations, which are used to create production plans that take into account the load conditions of the production site, or to execute production instructions that take into account the load conditions of the production site.

[0007] To achieve the above objectives, the production simulation device of the present invention has the following features: The acquisition unit acquires production order information representing the contents of a production order from a production execution system, which instructs production for each process according to the production order for a production line comprising multiple processes; and The simulation execution unit, before the production execution system instructs production for each of the processes according to the production order, calls the simulation model corresponding to the process of the production order involved in the production order information obtained by the acquisition unit, and performs simulation using the called simulation model. The production execution system instructs production for each of the processes according to the production orders that reflect the simulation results executed by the simulation execution unit.

[0008] The effects of the invention

[0009] According to the present invention, a production simulation apparatus, production system, production simulation method and program are provided that can perform simulations, the simulation being used to create production plans that take into account the load conditions of the production site, or to execute production instructions that take into account the load conditions of the production site. Attached Figure Description

[0010] Figure 1 This is a diagram illustrating the production system involved in Implementation Method 1.

[0011] Figure 2 This is a diagram illustrating the transaction flow in the production system involved in Implementation Method 1.

[0012] Figure 3 This is a block diagram showing the hardware structure of the production simulation device involved in Implementation Method 1.

[0013] Figure 4 This is a diagram showing the functional structure of the production simulation device involved in Implementation Method 1.

[0014] Figure 5 This is a diagram showing the production order table involved in Implementation Method 1.

[0015] Figure 6 This is a graph showing the simulation results table related to Implementation Method 1.

[0016] Figure 7 This is a diagram showing the functional structure of the production scheduler involved in Implementation Method 1.

[0017] Figure 8 This is a flowchart illustrating the production instruction processing performed by the production system involved in Implementation 1.

[0018] Figure 9 This is a diagram showing the functional structure of the production simulation device involved in Implementation Method 2.

[0019] Figure 10 This is a graph showing the result table of parameter adjustments involved in Implementation Method 2.

[0020] Figure 11This is a flowchart illustrating the production instruction processing performed by the production system involved in Implementation 2. Detailed Implementation

[0021] (Implementation Method 1)

[0022] The production system 1 described in Implementation 1 is a system for producing products in a production line that includes multiple processes. For example... Figure 1 As shown, the production system 1 has a production simulation device 100, a production scheduler 200, a MES 300, an MRP 400, and a control device 500, which are connected to each other via network cables or wirelessly (not shown).

[0023] The production system 1 has: a planning layer 1A, which creates the major and intermediate schedules of the production plan; an execution layer 1B, which instructs production based on the minor schedules of the production plan by the MES 300; and a control layer 1C, which controls the equipment to produce products by the control device 500 based on the instructions of the MES 300.

[0024] Production planning is used to plan the production of products on the production line, including logistics such as purchasing parts based on inventory. Production planning defines large schedules, medium schedules, and small schedules, each set based on efficient management principles. For example, a "large schedule" is approximately 3 to 12 months, a "medium schedule" is approximately 1 to 3 months, and a "small schedule" is approximately 1 week to 1 month, but these vary depending on the industry of the products being produced and the production environment. The large and medium schedules of the production plan are created based on a baseline production plan, while the small schedules are created by the production scheduler 200, as described later.

[0025] The production simulation device 100 is a device for simulating production in a production line built in an IT space. The production simulation device 100 has a simulator (hereinafter referred to as "production simulator") for simulating production in the production line.

[0026] Before production is instructed by the MES 300, the production simulation device 100 simulates each process of the production line, reflecting the simulation results in the production plan. A process is any step within the production line, such as casting, extrusion, surface treatment, machining, packaging, or shipping. The production simulator has a simulation model for each process, and the production simulation device 100 simulates production on the production line by using these simulation models. Furthermore, the production simulation device 100 uses information collected by the MES 300 representing the actual production performance of the production line (hereinafter referred to as "performance information") for simulation. Performance information is information required for production management on the production line, including various information related to the production status of processes, such as the time required for process processing, waiting time until process processing is completed, operator-related conditions, and fault-related conditions. By using performance information for simulation, the production simulation device 100 can implement simulations that further reflect the current state of the production site.

[0027] The production scheduler 200 uses the material requirements plan created by MRP 400 as the shipping plan.

[0028] The MES 300 issues production instructions to the control device 500 of the control layer 1C according to the production orders contained in the production schedule. A production order is an instruction for production according to the production plan, represented by production units such as parts or products to be produced, and includes information such as the processes to be performed and the sequence of those processes. Additionally, a production order number is assigned to each production order, which is used to identify the production order. Before outputting production instructions to the control device 500 of the control layer 1C according to the actual production orders, the MES 300 outputs the production order information to the production simulation device 100. Furthermore, the MES 300 has a monitoring function for monitoring the production status on the production line, enabling monitoring of information related to the operating status of the equipment on the production line, production performance, and quality performance. The MES 300 collects performance information for processes 1 to N of the control layer 1C through its monitoring function. This performance information collection is performed at any timing required for production management. Subsequently, the MES 300 sends the collected performance information to the production simulation device 100.

[0029] In addition, the MES 300 considers production orders for which production instructions have been executed to the control device 500 of the control layer 1C as processed production orders. The MES 300 stores information on the production order numbers of processed production orders, and determines whether the production orders included in the sub-schedule of the production plan have been processed by checking the stored production order numbers.

[0030] MRP 400 creates a material requirements plan based on information from the parts list, inventory information, and baseline production plan, and issues purchase orders to suppliers for the purchase of materials.

[0031] The control device 500 controls the equipment for each process of the production line, for example, a programmable logic controller (PLC).

[0032] exist Figure 2 The transaction flow in production system 1 is illustrated. In the planning layer 1A, information on the baseline production plan, inventory management, and shipping plan is processed, providing the production scheduler 200 with information on the major or minor schedules of the baseline production plan, inventory management information, and shipping reservation information. In the execution layer 1B, information on the minor schedules of the production plan related to production, performance data, and inbound performance data are processed. This information is used for traceability implementation, quality management, and monitoring. Performance data used to achieve traceability is represented, for example, by production date and time, part number, equipment number, and operator number. Performance data used in quality management is represented, for example, by the quality information of inbound parts, the processing quality information of equipment, and the results of inspections after processing. Additionally, inbound performance data is represented, for example, by the inbound performance data of parts and the inbound performance data of semi-finished products.

[0033] exist Figure 3 The device has a hardware structure for a production simulation device 100.

[0034] The production simulation device 100 includes: a processor 11 that performs various processes; a main storage unit 12 that serves as the working area of ​​the processor 11; an auxiliary storage unit 13 that stores various data used in the processing of the processor 11; a communication unit 14 for communicating with external devices; an input unit 15 that receives input information; and an output unit 16 that displays various information. The main storage unit 12, auxiliary storage unit 13, communication unit 14, input unit 15, and output unit 16 are all connected to the processor 11 via a bus 17.

[0035] The processor 11 includes a CPU (Central Processing Unit). The processor 11 executes programs stored in the auxiliary storage unit 13, thereby realizing various functions of the production simulation device 100.

[0036] The main storage unit 12 contains RAM (Random Access Memory). Programs are loaded into the main storage unit 12 from the secondary storage unit 13. Furthermore, the main storage unit 12 is used as the working area of ​​the processor 11.

[0037] The auxiliary storage unit 13 includes non-volatile memory, such as EEPROM (Electrically Erasable Programmable Read-Only Memory). In addition to programs, the auxiliary storage unit 13 also stores various data used in the processing of the processor 11. Following instructions from the processor 11, the auxiliary storage unit 13 supplies the processor 11 with the data to be used by the processor 11 and stores the data supplied from the processor 11.

[0038] The communication unit 14 includes a network interface circuit for communicating with external devices. The communication unit 14 receives signals from external devices and outputs data represented by those signals to the processor 11. Additionally, the communication unit 14 transmits signals representing data output from the processor 11 to external devices.

[0039] The input unit 15 includes input devices such as input keys and pointing devices. The input unit 15 acquires information input by the user of the production simulation device 100 and notifies the processor 11 of the acquired information.

[0040] The output unit 16 includes output devices such as an LCD (Liquid Crystal Display) and a speaker. The output unit 16 can also be configured as a touchscreen integrated with the pointing device constituting the input unit 15. The output unit 16 displays various information to the user according to the instructions of the processor 11.

[0041] exist Figure 4 The functional structure of the production simulation device 100 of this embodiment is shown in the figure.

[0042] The production simulation device 100 has the following functions: an acquisition unit 101, which acquires production order information and performance information; a simulation execution unit 102, which executes the simulation; a sending unit 103, which sends the simulation results to the production scheduler 200; and a production simulation DB unit 104, which stores the simulation models of each process.

[0043] The acquisition unit 101 acquires production order information representing the content of the production order and performance information representing the production line performance from the MES 300. The MES 300 instructs production for each process according to the production order for the production line, which includes multiple processes. The acquisition unit 101 is implemented by the processor 11 and the communication unit 14. Furthermore, the acquisition unit 101 is an example of an acquisition unit.

[0044] Here, the acquisition unit 101 generates a production simulation order for performing simulation through a simulation model, based on the production order information involved in the production order.

[0045] A production simulation order is a production order built on a production line in the IT space, and is a simulation execution instruction executed by the production simulation device 100.

[0046] For example, if the acquisition unit 101 obtains production order information related to the production order of "part A" from the MES 300, it generates production simulation order information representing the production simulation order related to "part A". Furthermore, the acquisition unit 101 stores the production order information and the production simulation order information in the production simulation DB unit 104 in association.

[0047] exist Figure 5 This shows an example of a production order table that records production order information and production simulation order information in association. Figure 5 The production order information shows the contents of the production orders contained in the small schedule of the production plan received by MES 300 from the production scheduler 200. Figure 5 The production simulation order information displays the contents of the production orders executed by the production simulator in the production simulation device 100. For example, the production order information and production simulation order information include order number, process, document number, product type, production instruction drawing number, and predetermined quantity. The production simulation device 100 can use the production order table to manage the processes of the production orders executed by the MES 300 in association with the processes of the production orders simulated in the production simulation device 100.

[0048] Furthermore, the acquisition unit 101 can also directly use production order information as production simulation order information. In this case, Figure 5 In the production order table, production simulation order information is omitted, and production order information is managed as production simulation orders used in the production simulator.

[0049] Before the MES 300 instructs production for each process according to the production order, the simulation execution unit 102 calls the simulation model corresponding to the process of the production order involved in the production order information obtained by the acquisition unit 101, and performs simulation using the called simulation model and the performance information obtained by the acquisition unit 101. The simulation execution unit 102 is implemented by the processor 11 and the communication unit 14. Furthermore, the simulation execution unit 102 is an example of a simulation execution unit.

[0050] The simulation execution unit 102 is a production simulator built on the software platform of the production simulation device 100. The production simulation device 100 has an execution environment, i.e., a software platform, for running software, and can build one production simulator on the software platform, or can collaboratively build multiple production simulators through the software platform.

[0051] If the simulation execution unit 102 receives a production simulation order, it executes the simulation based on the order. Specifically, the simulation execution unit 102 retrieves the simulation model corresponding to the process for executing the production simulation order from the storage area of ​​the production simulation database unit 104. Then, the simulation execution unit 102 executes the simulation using the retrieved simulation model according to the process sequence specified in the production simulation order, and obtains the simulation results. Here, the simulation execution unit 102 inputs the performance information obtained from the MES 300 into the retrieved simulation model to perform the simulation. This allows for the acquisition of simulation results that reflect the on-site load conditions.

[0052] Simulation results primarily include whether simulation is feasible and the production time for each process. Furthermore, in the event of an anomaly during production, the simulation results may also include the following information: production time including the intermediate process from interruption to recovery, the time the anomaly occurred, information indicating the process where the anomaly occurred, and error codes indicating the content of the anomaly. Production anomalies are a general term for situations where actions different from the intended actions occur before the simulation execution unit 102 begins executing the simulation of each process. Examples include situations where the simulation does not end within the intended time, the intended simulation is interrupted midway, and the intended simulation is interrupted but resumes after meeting predetermined conditions.

[0053] Furthermore, when the simulation execution unit 102 executes simulation models for multiple processes consecutively, it can utilize the simulation results obtained from the simulation models of previous processes. That is, the simulation execution unit 102 uses the simulation results output by the simulation model of a certain process for the simulation model of the next process, and performs simulation using the simulation model of the next process. As a result, the simulation execution unit 102 can perform simulations that take into account the actions between processes.

[0054] For example, if the simulation execution unit 102 calculates the operation delay as a simulation result in a previous process, it can obtain the simulation result in the next process that takes into account the operation delay in the previous process. In particular, depending on the cause of the delay, sometimes the operation delay can be tolerated, and sometimes the operation delay cannot be avoided, and this is effective in such cases. Furthermore, causes of delay include, for example, shortage of parts, equipment failure, short-term shutdowns of equipment or production that are temporarily stopped or idled, long-term shutdowns of equipment or production that are stopped or idled for a long time, and insufficient operator capacity due to sudden absence of operators.

[0055] Here, the simulation execution unit 102 can update, replace, or add to the simulation model for each process.

[0056] Updates to the simulation model refer to situations where the simulation model is updated through relearning. Replacements to the simulation model refer to replacing the existing simulation model with a new one. Additions to the simulation model refer to adding a new simulation model to supplement the simulation accuracy of an existing model when a new process is added to the production line being simulated.

[0057] Due to limitations in specifications such as the number of parameters and calculation formulas, simulation models cannot fully simulate the real world. Therefore, supplementary simulation models are used, employing parameters not covered in existing models. By having the existing and new simulation models work together, simulation accuracy is improved. One example of this supplementation is using a new simulation model of the equipment constituting a production line to complement an existing simulation model simulating production line processes.

[0058] Furthermore, the timing for updating, replacing, and adding to the simulation model for each process can be appropriately specified by the user of the production simulation device 100. For example, in the case of actually modifying the processes of the production line, the simulation model can be updated, replaced, or added before the modification. Alternatively, if various adjustments to the production plan are desired, but the processes of the production line cannot be actually rearranged, the simulation model can be updated, replaced, or added when rearranging the processes in virtual space.

[0059] If the simulation execution unit 102 performs simulation for each process in the production simulation order, it stores the simulation results in the storage area of ​​the production simulation DB unit 104 used to store the simulation model results. Here, the simulation execution unit 102 manages the simulation results for each process used to execute the production order.

[0060] exist Figure 6 This example shows a simulation results table that records simulation results. In the simulation results table, the order number of the production simulation order information and the simulation results for each step used to execute the production simulation order are recorded together. Figure 6 In the example, the simulation results for each process include whether the simulation was successful and the production time.

[0061] If simulation results are registered in the simulation results table, the simulation execution unit 102 sends the simulation results and related information to the sending unit 103. Hereinafter, the simulation results and related information will be referred to as "simulation result related information." The simulation result related information includes, for example, production simulation order information and process names. The production simulation database unit 104 stores the process name, process ID used to identify the process, simulation model of the process, model ID used to identify the simulation model of the process, production simulation order information, production simulation order number used to determine the production simulation order, simulation start and end times, simulation results, prior process ID used to identify a prior process of a certain process, and subsequent process ID used to identify a subsequent process of a certain process. The simulation execution unit 102, referring to the production simulation database unit 104, sends the simulation result related information to the sending unit 103.

[0062] The sending unit 103 sends the simulation results executed by the simulation execution unit 102 to the production scheduler 200, which creates a production plan containing production orders. The sending unit 103 is implemented by the processor 11 and the communication unit 14. Furthermore, the sending unit 103 is an example of a sending unit.

[0063] For example, if the transmitting unit 103 receives information related to the simulation results, it will refer to... Figure 5 The production order table is modified so that the production simulation order information in the simulation result information is replaced with the production order information corresponding to the simulation order information. Furthermore, after the replacement, the sending unit 103 sends the simulation result information containing the production order information to the production scheduler 200.

[0064] exist Figure 7 The functional structure of the production scheduler 200 in this embodiment is shown.

[0065] The production scheduler 200 has the following functions: an input / output unit 201, which sends and receives information with other devices; a main information management unit 202, which manages main information; a planning information management unit 203, which manages the input information used to create production plans and the information of the production plans; a planning engine unit 204, which automatically calculates the production plans; and a modification unit 205, which modifies the automatically calculated production plans.

[0066] The input / output unit 201 transmits and receives information with other devices such as the production simulation device 100 and the MES 300.

[0067] For example, the input / output unit 201 receives simulation result-related information from the production simulation device 100. Additionally, the input / output unit 201 receives performance information from the MES 300. Furthermore, the input / output unit 201 sends a short schedule of the production plan to the MES 300.

[0068] The Master Information Management Department 202 manages master information and information related to constraints when creating a production plan. Master information includes inherent information about the production base and inherent information about the products to be produced. It is used when the Planning Engine Department 204 calculates the production plan and when outputting the calculated results to screens or reports. Information inherent to the production base includes, for example, the equipment and facilities on the production line, as well as the working hours and capabilities of the operators. Information inherent to the product includes, for example, the parts list, the processes involved, and the production method.

[0069] The Planning Information Management Department 203 manages the input information used to create production plans and the information related to the production plans themselves. The input information used to create production plans includes order information, production performance information, and inventory information. Order information includes details such as product category, quantity, and delivery date. Production performance information includes details such as the start / completion date and time, progress rate, and production time for each process. Inventory information includes information on inventory counts, receiving, and shipping.

[0070] For example, if the input / output unit 201 receives simulation result-related information from the production simulation device 100, the planning information management unit 203 reflects the received simulation result-related information in the production performance information. For example, if the planning information management unit 203 manages the production time "TA0" as production performance information for "process A1", and if the simulation result-related information includes the production time "TA1" for "process A1", then it updates the production time "TA1" for "process A1" and manages the production performance information accordingly.

[0071] The planning engine unit 204 automatically calculates the production plan based on predefined rules and input information managed by the planning information management unit 203. Here, if the planning engine unit 204 of the production scheduler 200 receives simulation result-related information, it corrects the production plan created without using the simulation results, based on the simulation results sent by the sending unit 103. That is, the input information managed by the planning information management unit 203 includes information on production performance obtained through simulation using actual performance information; therefore, the planning engine unit 204 automatically calculates the production plan by taking into account the actual on-site equipment, operator workload, and operating time.

[0072] Based on user instructions, the Change Department 205 modifies the automatically calculated production plan. Specifically, the Change Department 205 visualizes the production plan calculated by the Planning Engine Department 204 from multiple perspectives, such as production resources and orders, and uses screen functions to assist users in making decisions regarding changes to the start date and time, production lines, etc. in the production plan.

[0073] If the input / output unit 201 receives simulation result-related information from the transmission unit 103 of the production simulation device 100, the planning engine unit 204 uses the latest input information, i.e., the simulation result information, managed by the planning information management unit 203, to revise the production plan. Then, the input / output unit 201 sends the revised production plan to the MES 300.

[0074] MES 300 instructs production for each process according to the production orders contained in the production plan revised by the production scheduler 200, thereby instructing production for each process according to the production orders reflecting the simulation results. For example, MES 300 starts processing by specifying the parameters of the equipment performing each process based on the revised production plan received from the production scheduler 200.

[0075] Next, use Figure 8 The flowchart illustrates the production instruction processing performed by the production system 1 according to this embodiment. Figure 8 The production instruction processing is the process that the MES 300 performs when it obtains a small schedule of production plans from the production scheduler 200.

[0076] Here, relative to the production schedule instructing each process according to the production order, the MES 300 sends a simulation start instruction to the production simulation device 100 at a pre-determined required time. Then, if the production simulation device 100 receives the simulation start instruction, it executes the processing of each functional unit.

[0077] The MES 300 produces according to the production orders in the production plan created by the production scheduler 200. However, when the production simulation device 100 performs the simulation, the production start time may sometimes arrive before the simulation ends, resulting in the inability to utilize the simulation results. Therefore, since the MES 300 can determine the production start time according to the production orders included in the production plan, the MES 300 sends a pre-determined time, taking into account the simulation time required, to the production simulation device 100 relative to the production start time.

[0078] The predetermined required time is set considering the time needed for the production simulation device 100 to perform the simulation, the time for the production scheduler 200 to reflect the simulation results in the production order, and the time needed to respond based on the simulation results. The time needed to respond based on the simulation results is, for example, the time required to replenish parts when the operator confirms the simulation results and knows that parts are depleted. Furthermore, if the predetermined required time is underestimated, the production instruction time may sometimes be reached before the simulation ends. In this case, the difference between the predetermined required time and the simulation end time is collected as a log, and the predetermined required time is readjusted.

[0079] The MES 300 determines whether the simulation should begin at the pre-determined time (step S101). If the MES 300 determines that the simulation should begin at the pre-determined time (step S101; YES), it proceeds to step S102. On the other hand, if the MES 300 determines that the simulation should not begin at the pre-determined time (step S101; NO), it waits.

[0080] The MES 300 determines whether the production orders included in the sub-schedule of the production plan have not yet been processed (step S102). If the MES 300 determines that the production orders included in the sub-schedule of the production plan have not yet been processed (step S102; YES), the acquisition unit 101 of the production simulation device 100 acquires the production order information representing the production orders (step S103). On the other hand, if the MES 300 determines that the production orders included in the sub-schedule of the production plan are not unprocessed (step S102; NO), it proceeds to step S110. The MES 300 considers the processed production orders as the completion of the simulation corresponding to the process, reflects the simulation results to the production plan, and executes the instructions of the production orders according to the sub-schedule of the production plan obtained from the production scheduler 200.

[0081] The simulation execution unit 102 of the production simulation device 100 retrieves the simulation model corresponding to the process of the production order involved in the production order information obtained by the acquisition unit 101 from the storage area of ​​the simulation model in the production simulation DB unit 104 (step S104). Then, the simulation execution unit 102 performs the simulation using the retrieved simulation model (step S105) and stores the simulation results in the simulation result storage area of ​​the production simulation DB unit 104 (step S106).

[0082] The simulation execution unit 102 determines whether the simulation execution of all processes used to execute unprocessed production orders has been completed (step S107). If the simulation execution unit 102 determines that the simulation execution of all processes has been completed (step S107; YES), the sending unit 103 notifies the production scheduler 200 of the simulation result information (step S108). On the other hand, if the simulation execution unit 102 determines that the simulation execution of all processes has not been completed (step S107; NO), it returns to step S104 and performs step S104 and subsequent processing on the processes for which the simulation execution has not been completed.

[0083] If the production scheduler 200 receives simulation results from the production simulation device 100, it creates a sub-schedule reflecting the received simulation results and sends the created sub-schedule to the MES 300 (step S109). Furthermore, the MES 300 executes production instructions according to the production orders contained in the received sub-schedule (step S110).

[0084] According to this embodiment, simulations are performed on each process of the production line, and a production plan reflecting the simulation results is created, thereby improving the accuracy of the production plan. Thus, production plans can be formulated not based on the intuition, experience, or courage of on-site operators, but rather on large schedules, medium schedules, and small schedules based on on-site conditions. This allows production to be carried out based on the optimal production plan, thereby achieving planned production with increased productivity and easier determination of delivery dates.

[0085] Furthermore, according to this embodiment, simulations of each process are performed using actual on-site performance information. Therefore, for example, in the event of delays in the production line, the simulation results reflect the impact of these delays on production. Thus, by having the production scheduler create a production plan using the simulation results, a realistic production plan matching the load conditions is created, rather than an ideal one. Previously, because the MES (Manufacturing Execution System) executed production instructions based on a production plan that did not consider on-site load conditions, unreasonable production instructions were generated, leading to problems such as products not being produced as planned. However, according to this embodiment, by correcting the production plan through the production scheduler, the MES executes production instructions based on a production plan that takes into account on-site load conditions, thus enabling products to be produced according to the production plan.

[0086] Furthermore, according to this embodiment, a production simulation order is generated for executing production orders in the simulator, thereby providing an environment for performing actions including the issuance of production orders. This enables simulations including the timing of production order issuance, further improving simulation accuracy.

[0087] Furthermore, according to this embodiment, the production scheduler receives information from the simulation results obtained from the production simulation device as information on production performance and creates a production plan. Therefore, as long as the production scheduler has the same structure as the conventional production scheduler, it can utilize the simulation results.

[0088] (Implementation Method 2)

[0089] The production system 1 involved in Embodiment 2 is similar to that in Embodiment 1, including a production simulation device 100, a production scheduler 200, a MES 300, an MRP 400, and a control device 500, but the functional structure of the production simulation device 100 is different from that in Embodiment 1.

[0090] exist Figure 9 The functional structure of the production simulation device 100 of this embodiment is shown.

[0091] The production simulation device 100 has the following functions: an acquisition unit 101, which acquires production order information and performance information; a simulation execution unit 102, which executes the simulation; an adjustment unit 105, which adjusts the parameters indicated to the equipment on the production line; and a production simulation DB unit 104, which stores simulation models of each process.

[0092] The following describes the functions that differ from those in Implementation Method 1.

[0093] The acquisition unit 101 obtains the following information from the MES 300: production order information, which represents production orders for a production line that includes multiple processes; performance information, which represents the production performance of the production line; and information on the parameters of the equipment on the production line as instructed by the MES 300.

[0094] If the simulation execution unit 102 performs simulation for each production simulation order for each process, it registers the simulation results in the simulation result table stored in the production simulation DB unit 104. Here, the simulation results for each process include information indicating whether the simulation was successful (if so), the production time, and the execution content. This execution content indicates how the processing of the equipment installed on the production line is performed on the production simulator as the production instructions issued by the MES 300 are executed. The execution content shows the physical actions of the equipment installed on the production line resulting from the execution of the production instructions issued by the MES 300. Examples of execution content include, for instance, the operating status of the control device 500 and the content of its control instructions, as well as the actions of the controlled devices that operate due to the control instructions issued by the control device 500.

[0095] Based on simulation results, the adjustment unit 105 adjusts the parameters specified for the equipment performing the process and sends them to the MES300. The adjustment unit 105 is implemented by the processor 11 and the communication unit 14. Furthermore, the adjustment unit 105 is an example of an adjustment unit.

[0096] For example, the equipment that performs the process is a control device 500, and the parameters assigned to the equipment indicate the content of the control instructions of the control device 500.

[0097] Specifically, after the simulation of all processes of the production orders included in the small schedule used to execute the production plan has been performed, the adjustment unit 105 adjusts the parameters included in the production instructions executed by the MES 300 for each process by referring to the simulation result table stored in the production simulation DB unit 104.

[0098] For example, the adjustment unit 105 determines whether an anomaly has occurred on the production line based on the performance information obtained by the acquisition unit 101 from the MES 300. Then, if the adjustment unit 105 determines that an anomaly has occurred on the production line, it explores the parameters based on the simulation results, thereby determining the adjusted parameters. An example of the exploration is shown below.

[0099] For example, if an error occurs during simulation, the cause of the error is determined, and the parameters related to the cause are identified. If multiple candidate causes exist, multiple parameters related to these candidate causes are determined. Then, the parameter values ​​of parameters unrelated to the cause are fixed, and the optimal parameter values ​​are explored for the identified parameters. If multiple parameters are identified, the optimal parameter values ​​are explored sequentially in an arbitrary order. The exploration of optimal parameter values ​​is performed by setting a parameter value obtained by adding or subtracting a predetermined value relative to the current parameter value, and then re-running the simulation. If the error is observed to have improved after re-running the simulation, the predetermined value is decreased, and the parameter value obtained by adding or subtracting the decreased value is set, and the simulation is run again. The simulation with the changed parameter values ​​is repeated until the improvement in the error converges; if the improvement converges, the exploration ends. Furthermore, the exploration also ends if no improvement is observed even after changing the parameter values. Additionally, when exploring multiple parameters, after exploring the parameter value of a certain parameter, that parameter is set to the optimal parameter value obtained through exploration, and the optimal parameter values ​​for the other parameters are explored. As mentioned above, the optimal parameter values ​​are explored among combinations of multiple parameters.

[0100] The adjustment unit 105 adjusts the timing parameters when, for example, a device such as a robotic arm malfunctions due to timing errors. Additionally, the adjustment unit 105 adjusts the control angle parameters when an abnormality occurs due to a collision between the control angle of the robotic arm and another robotic arm. The adjustment unit 105 stores the adjusted parameters in the production simulation database 104.

[0101] exist Figure 10An example of a parameter adjustment table is shown, which registers the adjusted parameters. In the parameter adjustment table, for each process used to execute the production simulation order, the production simulation order information is registered in association with the parameters before and after adjustment.

[0102] After registering the adjusted parameters in the parameter adjustment table, the adjustment unit 105 sends the adjusted parameters to the MES 300. The MES 300 instructs production for each process according to the adjusted parameters sent by the adjustment unit 105, thereby instructing production for each process according to the production order reflecting the simulation results. That is, if the MES 300 receives the adjusted parameters, the parameters that the MES 300 instructs for the equipment on the production line become the adjusted parameters. Thus, the MES 300 can implement production instructions that take into account the on-site load conditions.

[0103] Next, use Figure 11 The flowchart illustrates the production instruction processing performed by the production system 1 according to this embodiment. Furthermore, Figure 11 The processing of steps S201 to S207 and Figure 8 The processing steps S101 to S107 are the same.

[0104] Based on the simulation results, the adjustment unit 105 adjusts the parameters specified for the equipment performing the process and sends them to the MES 300 (step S208). Furthermore, if the MES 300 receives the adjusted parameters, it executes the production instruction specified with the adjusted parameters (step S209).

[0105] For example, if the adjustment unit 105 determines that an anomaly has occurred in the production line based on the performance information collected by the MES 300, it adjusts the parameters based on the simulation results. On the other hand, if the adjustment unit 105 does not change the parameters based on the performance information collected by the MES 300 and no anomaly has occurred in the production line, it does not change the parameters. Furthermore, if the MES 300 receives the adjusted parameters, it executes the production instruction specified with the adjusted parameters; if it receives the parameters before adjustment, it executes the production instruction specified with the parameters before adjustment.

[0106] According to this embodiment, simulations are performed for each process of the production line, and based on the simulation results, the parameters specified for executing each process are adjusted. This allows the production execution system to execute production instructions while taking into account the load conditions of the production site. Furthermore, it ensures that production is executed according to the production plan created by the production scheduler, achieving the same effect as creating a production plan that takes into account the load conditions.

[0107] (Variation example)

[0108] The embodiments of the present invention have been described above, but various modifications and applications are possible when implementing the present invention.

[0109] In Embodiment 1, the production simulation device 100 has a sending unit 103. In Embodiment 2, the production simulation device 100 has an adjustment unit 105. However, it is also possible for one production simulation device 100 to have both a sending unit 103 and an adjustment unit 105.

[0110] Furthermore, in the above embodiment, the production simulation device 100 performs simulation using performance information, but it can also perform simulation without using performance information. For example, the production simulation device 100 can perform simulation without obtaining performance information before the production line starts operating. That is, the acquisition unit 101 can also obtain production order information representing the content of the production order from the MES 300, which instructs production for each process according to the production order for the production line containing multiple processes. Before instructing production for each process according to the production order, the simulation execution unit 102 calls up the simulation model corresponding to the process of the production order involved in the production order information obtained by the acquisition unit 101, and performs simulation using the called simulation model.

[0111] Alternatively, by applying the action program to an existing personal computer or information terminal device, the personal computer or information terminal device can be made to function as the production simulation device 100 involved in the above-described embodiment, wherein the action program specifies the operation of the production simulation device 100 involved in the above-described embodiment.

[0112] Furthermore, the distribution method of this program is arbitrary. For example, it can be distributed by storing it on computer-readable recording media such as CD-ROM (Compact Disk Read-Only Memory), DVD (Digital Versatile Disk), or memory card, or it can be distributed via communication networks such as the Internet.

[0113] This invention can be implemented in various ways and with variations without departing from the broad spirit and scope of the invention. Furthermore, the above-described embodiments are for illustrative purposes only and are not intended to limit the scope of the invention. That is, the scope of the invention is defined not by the embodiments, but by the claims. Moreover, various modifications implemented within the scope of the claims and their equivalent inventive meaning are considered to fall within the scope of this invention.

[0114] Industrial applicability

[0115] According to the present invention, a production simulation apparatus, production system, production simulation method and program are provided that can perform simulations, the simulation being used to create production plans that take into account the load conditions of the production site, or to execute production instructions that take into account the load conditions of the production site.

[0116] Explanation of the label

[0117] 1 Production System, 11 Processor, 12 Main Storage Unit, 13 Auxiliary Storage Unit, 14 Communication Unit, 15 Input Unit, 16 Output Unit, 17 Bus, 100 Production Simulation Device, 101 Acquisition Unit, 102 Simulation Execution Unit, 103 Transmission Unit, 104 Production Simulation DB Unit, 105 Adjustment Unit, 200 Production Scheduler, 201 Input / Output Unit, 202 Main Information Management Unit, 203 Planning Information Management Unit, 204 Planning Engine Unit, 205 Change Management Unit, 300 MES (Production Execution System), 400 MRP (Material Requirements Planning System), 500 Control Device.

Claims

1. A production simulation device, comprising: The acquisition unit acquires production order information representing the contents of a production order from a production execution system, which instructs production for each process according to the production order for a production line comprising multiple processes; and The simulation execution unit, before the production execution system instructs production for each of the processes according to the production order, calls the simulation model corresponding to the process of the production order involved in the production order information obtained by the acquisition unit, and performs simulation using the called simulation model. The production execution system instructs production for each of the processes according to the production orders that reflect the simulation results executed by the simulation execution unit.

2. The production simulation device according to claim 1, wherein, The acquiring unit acquires performance information representing the production performance of the production line. The simulation execution unit uses the invoked simulation model and the performance information obtained by the acquisition unit to execute the simulation.

3. The production simulation device according to claim 1 or 2, wherein, The system includes a sending unit that sends the simulation results executed by the simulation execution unit to the production scheduler, which creates a production plan containing the production orders. The production scheduler modifies the production plan based on the simulation results sent by the sending unit. The production execution system instructs production for each of the processes according to the production orders contained in the production plan modified by the production scheduler, thereby instructing production for each of the processes according to the production orders reflecting the simulation results.

4. The production simulation device according to claim 1 or 2, wherein, The system includes an adjustment unit that, based on the simulation results, adjusts the parameters of the equipment performing the process, and sends the adjusted parameters to the production execution system. The production execution system instructs production for each process according to the adjusted parameters sent by the adjustment unit, thereby instructing production for each process according to the production order reflecting the simulation results.

5. The production simulation device according to any one of claims 1 to 4, wherein, The acquisition unit generates a production simulation order for the simulation model to execute, based on the production orders involved in the production order information. The simulation execution unit executes the simulation based on the production simulation order and manages the simulation results for each process used to execute the production order.

6. The production simulation device according to any one of claims 1 to 5, wherein, The simulation execution unit can update, replace, or add to the simulation model for each of the aforementioned processes.

7. The production simulation device according to claim 2, wherein, In contrast to the timing of production instructions for each process according to the production order, the production execution system sends a start instruction for the simulation to the production simulation device at a pre-determined required time. If the production simulation device receives the simulation start instruction, the acquisition unit obtains the production order information and the performance information from the production execution system, and the simulation execution unit starts the simulation.

8. A production system comprising a production execution system and a production simulation device, the production execution system instructing production for each process according to a production order for a production line comprising multiple processes. In this production system, The production simulation device has the following features: The acquisition unit acquires production order information representing the content of the production order from the production execution system; and The simulation execution unit, before the production execution system instructs production for each of the processes according to the production order, calls the simulation model corresponding to the process of the production order involved in the production order information obtained by the acquisition unit, and performs simulation using the called simulation model. The production execution system instructs production for each process according to the production order reflecting the simulation results executed by the simulation execution unit.

9. A production simulation method, executed by a production simulation device, wherein, The acquisition unit retrieves production order information representing the content of a production order from the production execution system, which instructs production for each process according to the production order for a production line containing multiple processes. Before the production execution system instructs production for each process according to the production order, the simulation execution unit calls the simulation model corresponding to the process of the production order involved in the production order information obtained by the acquisition unit, and performs the simulation using the called simulation model. The production execution system instructs production for each process according to the production order reflecting the simulation results executed by the simulation execution unit.

10. A program that enables a computer to function as both an acquisition unit and a simulation execution unit. The acquisition unit retrieves production order information representing the content of a production order from the production execution system, which instructs production for each process according to the production order for a production line containing multiple processes. The simulation execution unit calls the simulation model corresponding to the process of the production order involved in the production order information obtained by the acquisition unit, and performs the simulation using the called simulation model. The production execution system instructs production for each process according to the production order reflecting the simulation results executed by the simulation execution unit.

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