Production plan drafting system and program

Abstract

To visualize the degree of production capacity under a predetermined condition with respect to the number of requested orders.SOLUTION: A production plan drafting system drafts a production plan for each prescribed period consisting of a plurality of days when producing a plurality of kinds of products by a plurality of production machines. The production plan drafting system comprises: a calculation unit which calculates the number of production plans for each product to output the production plans in each of the plurality of production machines for each prescribed period, by using an objective function, on the basis of, at least, a constraint condition including the products which can be manufactured, production performance per unit time, and an upper limit operating time per one day, for each production machine, the number of orders for each product, and the objective function which aims at maximizing a total production number of the plurality of products; and a control unit which displays the production plan on a display unit.SELECTED DRAWING: Figure 4

Description

[Technical field]

[0001] The present embodiment relates to a production planning system and a program. [Background technology]

[0002] Conventionally, there are cases where multiple types of products are produced (manufactured) using multiple manufacturing machines (production lines) in one or more manufacturing plants. In such cases, each manufacturing machine has different constraints such as the products it can produce, production performance per unit time, and maximum operating hours per day. Then, a long-term (e.g., 2-year, 5-year, etc.) production plan is made based on such constraints and the number of orders for each product.

[0003] In such cases, there is a method in which the user manually creates a production plan using a spreadsheet program on a PC (Personal Computer).Specifically, a plan is created so that each product can be produced using a manufacturing machine with the highest possible output (production efficiency) based on, for example, a production output table that is a correspondence table between product numbers and manufacturing machine capacities, or the maximum operating hours per day for each manufacturing machine.

[0004] However, this method has the following problems. First, it takes time. Secondly, because the plans are made based on the user's intuition, it is not possible to comprehensively evaluate all possible plan combinations. Also, because the experience and ability of planners differ, plans vary and standardization is not possible. As a result, methods have been developed that use computers to automatically make production plans.

[0005] For example, there is a conventional technique in which, when a production plan pattern for a new car that involves changes in production volume within a month is input, the production plan volume for that month is calculated, the peak value of the production volume for that month is detected, and the production plan quantity and resource allocation are determined using the production plan pattern as a constraint condition.

[0006] In addition, for example, when creating a production plan for vehicle parts, there is a conventional technology that performs optimization processing in the order of a step of minimizing the number of unproductive units, a step of maximizing the number of units produced at a priority location, and a step of minimizing the total inventory amount, and that uses artificial intelligence to adjust production capacity and overtime for orders that could not be fulfilled in the above steps, and then performs optimization again until the orders can be fulfilled. [Prior art documents] [Patent documents]

[0007] [Patent Document 1] JP 2002-123310 A [Patent Document 2] JP 2020-140307 A Summary of the Invention [Problem to be solved by the invention]

[0008] However, the above-mentioned conventional technology does not allow visualization of the degree of production capacity under specified conditions for the requested number of orders, and there is room for improvement in terms of convenience, etc.

[0009] Therefore, one of the objectives of this embodiment is to provide a production planning system and program capable of visualizing the degree of production capacity under specified conditions for the requested number of orders. [Means for solving the problem]

[0010] The present embodiment is a production planning system that creates a production plan for a predetermined period consisting of multiple days when multiple types of products are produced by multiple manufacturing machines, and is equipped with a calculation unit that uses an objective function to calculate the planned production quantity for each of the products in each of the multiple manufacturing machines for the predetermined period and outputs the production plan based on at least constraint conditions including the products that can be manufactured by each of the manufacturing machines, production performance per unit time, and maximum operating time per day, the number of orders for each of the products, and an objective function aimed at maximizing the total production number of the multiple products, and a control unit that displays the production plan on a display unit.

[0011] According to this configuration, by displaying on the display unit a production plan calculated using an objective function aimed at maximizing the total number of units produced for a plurality of products, it is possible to visualize the degree of production capacity under specified conditions for the requested number of orders.

[0012] Furthermore, this embodiment is a production planning system that creates a production plan for a predetermined period consisting of multiple days when multiple types of products are produced by multiple manufacturing machines, and is equipped with a calculation unit that calculates the planned production quantity for each of the products in each of the multiple manufacturing machines for the predetermined period based on constraint conditions including at least the products that can be manufactured by each of the manufacturing machines, production performance per unit time, and maximum operating time per day, the number of orders for each of the products, and an objective function aimed at minimizing the total operating time of the multiple manufacturing machines, using the objective function, and outputs the production plan, and a control unit that displays the production plan on a display unit.

[0013] According to this configuration, by displaying a production plan calculated using an objective function aimed at minimizing the total operating time of multiple manufacturing machines on the display unit, it is possible to visualize the degree of production capacity under specified conditions for the requested number of orders.

[0014] Moreover, this embodiment is a production planning system that creates a production plan for a predetermined period consisting of a number of days when a plurality of types of products are produced by a plurality of manufacturing machines, and is equipped with a calculation unit that calculates a production plan number for each of the plurality of manufacturing machines for the predetermined period using the first objective function based on constraint conditions including at least the products that can be manufactured by each of the manufacturing machines, production performance per unit time, and an upper limit operation time per day, the number of orders for each of the products, a first objective function that aims to maximize the total production number of the plurality of products, and a second objective function that aims to minimize the total operation time of the plurality of manufacturing machines, and when it is determined that there is a capacity to produce the order number for all of the products, calculates a production plan number for each of the plurality of manufacturing machines for the predetermined period using the second objective function and outputs the production plan, and a control unit that displays the production plan on a display unit.

[0015] According to this configuration, by displaying the production plan calculated using the above-mentioned two objective functions on the display unit, it is possible to visualize the degree of production capacity under specified conditions for the requested number of orders.

[0016] Furthermore, this embodiment is a program for causing a computer that creates a production plan for a predetermined period consisting of multiple days when multiple types of products are produced using multiple manufacturing machines to function as a calculation unit that calculates the planned production quantity for each of the multiple manufacturing machines for each of the multiple manufacturing machines for the predetermined period based on at least constraints including the products that can be manufactured by each of the manufacturing machines, production performance per unit time, and maximum operating time per day, the number of orders for each of the products, and an objective function aimed at maximizing the total number of units produced of the multiple products, and outputs the production plan using the objective function, and a control unit that displays the production plan on a display unit.

[0017] According to this configuration, by displaying on the display unit a production plan calculated using an objective function aimed at maximizing the total number of units produced for a plurality of products, it is possible to visualize the degree of production capacity under specified conditions for the requested number of orders. [Brief description of the drawings]

[0018] [Figure 1] FIG. 1 is a block diagram showing a functional configuration of a production planning system according to an embodiment. [Diagram 2] FIG. 2 is a diagram showing (a) an example of a display screen for a production plan according to the prior art and (a) an example of a display screen for a production plan according to the present embodiment. [Diagram 3] FIG. 3 is a diagram illustrating an example of input data according to the embodiment. [Figure 4] FIG. 4 is a flowchart showing a first process performed by the production planning system according to the embodiment. [Diagram 5] FIG. 5 is a flowchart showing a second process by the production planning system according to the embodiment. [Figure 6] FIG. 6 is a flowchart showing a third process by the production planning system according to the embodiment. [Figure 7] FIG. 7 is a diagram illustrating an example of input data in the case of production line apportionment optimization according to the embodiment. [Figure 8] FIG. 8 is a diagram showing an example of a display screen for the production line allocation optimization according to the embodiment. [Figure 9] FIG. 9 is a diagram showing an example of a display screen of a production plan for each manufacturing machine according to the embodiment. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0019] DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, a production planning system and a program according to an embodiment of the present invention will be described with reference to the drawings.

[0020] 1 is a block diagram showing a functional configuration of a production planning system 1 according to an embodiment. The production planning system 1 is a system that creates a production plan for each predetermined period consisting of multiple days when multiple types of products are produced by multiple manufacturing machines. The production planning system 1 is a computer device, and includes a processing unit 2, a storage unit 3, an input unit 4, a display unit 5, and a communication unit 6.

[0021] The storage unit 3 is realized by, for example, a random access memory (RAM), a read only memory (ROM), a solid state drive (SSD), a hard disk drive (HDD), etc., and stores various information. The storage unit 3 stores, for example, the operation program of the processing unit 2, various setting values, objective functions, calculation results, etc.

[0022] The input unit 4 is a means for a user to input information, and is realized by, for example, a keyboard and a mouse.

[0023] The display unit 5 is a means for displaying information, and is realized by, for example, an LCD (Liquid Crystal Display).

[0024] The communication unit 6 is a communication interface for communicating with an external device (not shown).

[0025] The processing unit 2 is realized by, for example, a CPU (Central Processing Unit) and executes various information processes. The processing unit 2 includes, for example, an acquisition unit 21, a setting unit 22, a calculation unit 23, and a control unit 24 as functional components.

[0026] The acquisition unit 21 acquires various pieces of information from an external device or the input unit 4. The acquisition unit 21 acquires, for example, various input data and setting values ​​from the external device or the input unit 4 operated by a user.

[0027] The setting unit 22 performs settings based on various input data and setting values ​​acquired by the acquisition unit 21 .

[0028] The calculation unit 23 executes various calculations. For example, the calculation unit 23 uses the objective function based on constraint conditions including at least the products that can be manufactured by each manufacturing machine, the production performance per unit time, and the upper limit operation time per day, the number of orders for each product, and an objective function that aims to maximize the total production number of multiple products, to calculate the production plan number for each product in each of the multiple manufacturing machines for a predetermined period and output a production plan (FIG. 4). In addition, an objective function that aims to minimize the total operation time of the multiple manufacturing machines may be used as the objective function (FIG. 5).

[0029] In addition, the calculation unit 23 first calculates the production plan number for each product in each of the multiple manufacturing machines for a predetermined period using the first objective function based on, for example, constraint conditions including at least the products that can be manufactured by each manufacturing machine, production performance per unit time, and the upper limit operation time per day, the number of orders for each product, a first objective function for maximizing the total production number of multiple products, and a second objective function for minimizing the total operation time of the multiple manufacturing machines. Then, when the calculation unit 23 determines that the calculation result has the capacity to produce the ordered number for all products, it uses the second objective function to calculate the production plan number for each product in each of the multiple manufacturing machines for a predetermined period and outputs the production plan (FIG. 6).

[0030] The control unit 24 executes various controls. For example, the control unit 24 displays the production plan calculated by the calculation unit 23 on the display unit 5.

[0031] Here, FIG. 2 is a diagram that shows (a) an example of a display screen for a production plan according to the prior art, and (a) an example of a display screen for a production plan according to this embodiment.

[0032] In Figures 2(a) and (b), the horizontal axis is time, the vertical axis is the number of orders or the number of units produced, and the bar graph is the number of orders. Line L1 indicates the estimated number of units produced when seven manufacturing machines are used and there is no overtime. Line L2 indicates the estimated number of units produced when seven manufacturing machines are used and there is overtime. Line L3 indicates the estimated number of units produced when nine manufacturing machines are used and there is overtime. Note that although lines L1 to L3 are shown in Figure 2(b) to allow comparison with Figure 2(a), they do not appear on the actual screen.

[0033] In Fig. 2(a), the number of orders is shown for all products, not for each product. As can be seen from Fig. 2(a), in the conventional technology, for example, by comparing the number of orders with lines L1, L2, and L3, it is possible to recognize the approximate shortage of production capacity, but the accuracy of the information obtained is not high.

[0034] On the other hand, in Figure 2(b), P1 is an upward phase (a phase in which the number of orders is increasing), P2 is the maximum demand phase, and P3 is a downward phase (a phase in which the number of orders is decreasing). The number of orders is shown for each product. G3 indicates the total capacity shortage (the total number of products that cannot be produced).

[0035] As can be seen from FIG. 2(b), in this embodiment, for example, the shortage status of production capacity can be recognized for each time unit by looking at the portion indicated by reference symbol G3, so that the obtained information can be said to be highly accurate.

[0036] Next, a specific formulation will be described. Fig. 3 is a diagram showing an example of input data in the embodiment. Fig. 3(a) is data showing the output (the number of units (quantity) produced per hour) by manufacturing machine by product number (type of product). Parts without numbers indicate that production is not possible.

[0037] Figure 3(b) shows data showing the maximum operating hours per month for each manufacturing machine. FIG. 3(c) shows data showing monthly production numbers (order numbers) by product number (product type).

[0038] (Maximize production volume) When maximizing the number of units produced, the objective function (number of units produced), the required number of units produced (number of orders), and the upper limit of operating hours are as follows:

number

[0039] As can be seen from the formula for the required production quantity (order quantity), the production quantity of each product will never exceed the order quantity, but it may fall short of the order quantity. If it falls short of the order quantity, it means that there is a shortage of production capacity.

[0040] (Minimize total operating time) When minimizing the total operating time, the objective function (total operating time), the required production quantity (number of orders), and the upper limit of operating time are as follows. Note that the variables and parameters are the same as in the case of maximizing the number of units produced.

number

[0041] As can be seen from the formula for production requirement (order quantity), the production quantity of each product will be the same as the order quantity. In other words, this assumes that there is no shortage of production capacity.

[0042] Next, FIG. 4 is a flowchart showing a first process (a process for maximizing the production volume) by the production planning system 1 according to the embodiment.

[0043] First, in step S11, the acquisition unit 21 reads a file, that is, acquires input data (FIG. 3) and the like.

[0044] Next, in step S12, the setting unit 22 checks the input data and the like.

[0045] Next, in step S13, the setting unit 22 sets calculation conditions (setting variables and constraint conditions).

[0046] Next, in step S14, the calculation unit 23 performs a process for maximizing the production volume (performs an optimization calculation).

[0047] Next, in step S15, the control unit 24 displays the calculation result (production plan) on the display unit 5 (FIG. 2(b)).

[0048] Next, FIG. 5 is a flowchart showing a second process (total operation time minimization process) by the production planning system according to the embodiment.

[0049] First, in step S21, the acquisition unit 21 reads a file, that is, acquires input data (FIG. 3) and the like.

[0050] Next, in step S22, the setting unit 22 checks the input data and the like.

[0051] Next, in step S23, the setting unit 22 sets calculation conditions (setting variables and constraint conditions).

[0052] Next, in step S24, the calculation unit 23 performs a process of minimizing the total operating time (performs an optimization calculation).

[0053] Next, in step S25, the control unit 24 displays the calculation result (production plan) on the display unit 5. Note that this process is based on the premise that there is no shortage in production capacity, so the calculation result (production plan) differs from that shown in FIG. 2(b).

[0054] FIG. 6 is a flowchart showing the third process (process for maximizing the production volume and process for minimizing the total operating time) by the production planning system according to the embodiment.

[0055] First, in step S31, the acquisition unit 21 reads a file, that is, acquires input data (FIG. 3) and the like.

[0056] Next, in step S32, the setting unit 22 checks the input data and the like.

[0057] Next, in step S33, the setting unit 22 sets calculation conditions (setting variables and constraint conditions).

[0058] Next, in step S34, the calculation unit 23 performs a process for maximizing the production volume (performs an optimization calculation).

[0059] Next, in step S35, the calculation unit 23 determines the production capacity based on the calculation result in step S34, and if there is capacity (there is no shortage in capacity), the process proceeds to step S36, and if there is no capacity (there is a shortage in capacity), the process proceeds to step S37.

[0060] In step S36, the calculation unit 23 performs a process of minimizing the total operating time (performs an optimization calculation).

[0061] In step S37, the control unit 24 displays on the display unit 5 the calculation result (production plan) in step S36.

[0062] (Maximize total production volume allocated to manufacturing lines) In addition, the total number of production units can be maximized by the production line allocation. Fig. 7 is a diagram showing an example of input data in the case of optimizing the production line allocation according to the embodiment.

[0063] (a) shows the number of orders per month for each part number (product type) (A to E). (b) shows the number of operating days for each production line. (c) shows the production line. (d) shows the availability rate of each production line.

[0064] (e) shows the number of personnel per CT (Cycle Time) on a production line basis. (f) shows the maximum operating hours per month for each production line. (g) shows the flow conditions for each production line.

[0065] (h) shows the current ratio for each condition. For example, condition (1) of 32% means that, referring to (c) and (g), for manufacturing line 1, the total production volume of products A, D, and F must be 32% or less of the total production volume of products A, B, D, E, and F.

[0066] The formulation is as follows.

[0067] (Maximize total production volume allocated to manufacturing lines) Fastest CT (CT k ) personnel (h k )・Mobility rate (v k ) to find the production volume and shortage for each production line by part number that maximizes the total production volume.

number

[0068] (Minimizing the total operating time of the production line) In addition, the total operating time can be minimized by dividing the production line. k ) personnel (h k )・Mobility rate (v k ) to find the production volume for each production line by part number that minimizes the total operating time. Note that it is assumed that there is no shortage of production capacity. The variables and parameters are the same as in the case of maximizing the production volume allocated to the production line.

number

[0069] 8A to 8C are diagrams showing examples of display screens for the optimization of production line allocation according to the embodiment. As shown in (a1) to (a4), the number of produced units and the number of units in shortfall (symbol G3) could be obtained for each production line.

[0070] In addition, by changing the constraint conditions in various ways, the constraint conditions that satisfy the order quantity can be derived as shown in (b1) to (b4). Note that such work, which would have taken several days in the case of manual work in the prior art, can be completed in a few minutes to several tens of minutes in this embodiment.

[0071] 9A and 9B are diagrams showing examples of a display screen of a production plan for each manufacturing machine according to an embodiment. In (a) and (b), the horizontal axis indicates time, and the vertical axis indicates the number of orders or the number of units produced.

[0072] In (a), for manufacturing machine 1, reference symbol G11 indicates the number of orders for product 1. Reference symbol G12 indicates the capacity without overtime. Reference symbol G13 indicates the capacity with average overtime. Reference symbol G14 indicates the capacity with maximum overtime.

[0073] In (b), the reference characters G11 to G14 are the same as those in (a) for manufacturing machine 2. Reference character G15 indicates the number of orders for product 2. Reference character G16 indicates the total capacity shortage.

[0074] In this way, according to the production planning system 1 of this embodiment, by displaying a production plan calculated (FIG. 4) using an objective function aimed at maximizing the total number of units produced for a plurality of products for a long-term (e.g., two-year, five-year, etc.) production plan on the display unit 5, it is possible to visualize the level of production capacity under specified conditions for the requested number of orders (FIG. 2(b)).

[0075] Furthermore, compared to the manual work of the conventional technology, not only can the time be significantly reduced, but also the effects of being able to comprehensively judge all possible plan combinations and standardize plans can be obtained.

[0076] Furthermore, if the result is a lack of capacity, it is possible to deal with the problem by, for example, increasing the number of manufacturing machines, reducing the number of orders in consultation with the customer, or changing parameters.

[0077] In addition, by displaying on the display unit 5 a production plan calculated using an objective function (FIG. 5) aimed at minimizing the total operating time of multiple manufacturing machines, it is possible to visualize the degree of production capacity under specified conditions for the requested number of orders.

[0078] In addition, by displaying the production plan calculated using the above-mentioned two objective functions (FIG. 6) on the display unit 5, the degree of production capacity under specified conditions for the requested number of orders can be visualized.

[0079] As described with reference to Figures 7 and 8, a production plan can be created by optimization calculations under the conditions of maximizing the total number of production units allocated to the manufacturing lines and minimizing the total operating time.

[0080] In addition, a production plan for each manufacturing machine can be displayed as shown in Fig. 9. Drafting such a production plan for each manufacturing machine would take a day even for a rough review using manual work with conventional technology, but in this embodiment, it took about an hour and a half.

[0081] The programs executed by the production planning system 1 of this embodiment can be provided by recording them in an installable or executable file format on a recording medium readable by a computer device, such as a CD (Compact Disc)-ROM (Read Only Memory), a flexible disk (FD), a CD-R (Recordable), or a DVD (Digital Versatile Disk). The programs may also be provided or distributed via a network, such as the Internet.

[0082] Although the embodiment of the present invention has been described above, this embodiment is presented as an example and is not intended to limit the scope of the invention. This new embodiment can be implemented in various other forms, and various omissions, substitutions, and modifications can be made without departing from the gist of the invention. This embodiment and its modifications are included in the scope and gist of the invention, and are included in the scope of the invention and its equivalents described in the claims. [Explanation of symbols]

[0083] Reference Signs List 1: Production planning system, 2: Processing unit, 3: Memory unit, 4: Input unit, 5: Display unit, 6: Communication unit, 21: Acquisition unit, 22: Setting unit, 23: Calculation unit, 24: Control unit

Claims

1. A production planning system that creates a production plan for a predetermined period consisting of multiple days when multiple types of products are produced by multiple manufacturing machines, comprising: a calculation unit that calculates a production plan quantity for each of the plurality of manufacturing machines for each of the predetermined time periods based on constraint conditions including at least the products that can be manufactured by each of the manufacturing machines, production performance per unit time, and an upper limit of operation time per day, the number of orders for each of the products, and an objective function that aims to maximize the total number of production units of the plurality of products, and outputs a production plan using the objective function; A production planning system comprising: a control unit that displays the production plan on a display unit.

2. A production planning system that creates a production plan for a predetermined period consisting of multiple days when multiple types of products are produced by multiple manufacturing machines, comprising: a calculation unit that calculates a production plan quantity for each of the plurality of manufacturing machines for each of the predetermined time periods based on constraint conditions including at least the products that can be manufactured by each of the manufacturing machines, production performance per unit time, and an upper limit of operation time per day, the number of orders for each of the products, and an objective function for minimizing a total operation time of the plurality of manufacturing machines, and outputs a production plan using the objective function; A production planning system comprising: a control unit that displays the production plan on a display unit.

3. A production planning system that creates a production plan for a predetermined period consisting of multiple days when multiple types of products are produced by multiple manufacturing machines, comprising: Based on at least constraints including the products that can be manufactured, production performance per unit time, and upper limit operation time per day for each of the manufacturing machines, the number of orders for each of the products, a first objective function having an objective of maximizing the total number of production units of the multiple products, and a second objective function having an objective of minimizing the total operation time of the multiple manufacturing machines, a calculation unit that calculates a production plan quantity for each of the products in each of the plurality of manufacturing machines for each of the predetermined time periods using the first objective function, and when it is determined that there is a capacity to produce the ordered quantity for all of the products, calculates a production plan quantity for each of the plurality of manufacturing machines for each of the predetermined time periods using the second objective function, and outputs a production plan; A production planning system comprising: a control unit that displays the production plan on a display unit.

4. A computer that creates a production plan for a predetermined period consisting of a plurality of days when a plurality of types of products are produced by a plurality of manufacturing machines, a calculation unit that calculates a production plan quantity for each of the plurality of manufacturing machines for each of the predetermined time periods based on constraint conditions including at least the products that can be manufactured by each of the manufacturing machines, production performance per unit time, and an upper limit of operation time per day, the number of orders for each of the products, and an objective function that aims to maximize the total number of production units of the plurality of products, and outputs a production plan using the objective function; A program for causing the control unit to function as a control unit that displays the production plan on a display unit.

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