Production fast-forwarding device

Abstract

To provide a production management system and device in a make-to-order production scheme in which the end time of day of a final step corresponds to the production-completion date (loading date-and-hour) or shipment-completion date (shipment date).SOLUTION: A method includes: table-expanding object-of-production progress / partly-finished data 1 on a computer 2 to process step-ordered progress; using designated work time of a packet 8 in a step-ordered step to connect step personal computers 3 perfectly copying actual production steps together through a LAN; and perfectly copying, within a device, actual-production step order and work-time passage by exchanging information of step acceptance date-and-time 9 and step work commencement / completion date-and-time 10, so that the device can execute one month, or 30 date (43,200 minutes), in 3-hour of daily-life required time when a fast-forward designation for fast execution with a fast-forward designation to a device timepiece is 240 times. By utilizing a fast-forward designation of actual-object progress movement to the device timepiece on the personal-computer LAN copied a factory layout, a total result of production is forecast with a progress movement of information.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a production management system for made-to-order production, and relates to production schedule and management accuracy, i.e., accuracy of replying to ultimate completion dates, when a large number of products are produced for a large number of customers, in a large variety of processes, using a plurality of facilities. [Background technology]

[0002] To meet the quality characteristics required by customers, we repeatedly design prototype processes and implement the PDCA cycle to determine the process procedures. An online real-time processing system has been created that uses computers to issue production instructions to each process based on process design information in line with each customer's order (standards and specifications) and receives information on work completion.

[0003] Each manufacturing company is striving to improve QCD by managing production using production management tools and proprietary techniques, but when it comes to D (delivery date), a huge amount of information needs to be processed due to the large number of customers and product varieties, and many companies have not yet realized a system that can predict and prevent delivery delays or instantly determine the impact on other items when handling rush orders. [Prior art documents] [Patent documents]

[0004] Even when searching for production management, waiting time, and completion date, nothing was found that met the gist of this invention. [Non-patent literature]

[0005] Even when searching for production management, waiting time, and completion date, nothing was found that met the gist of this invention. Summary of the Invention [Problem to be solved by the invention]

[0006] The time required to pass through each piece of equipment (process) (waiting time for processing + processing time) is the result of a huge number of combinations of production permutations, and this combination changes each time. The single largest factor in fluctuations in the time required to pass through is the actual waiting time for processing (hereafter referred to as work-in-progress waiting time). In order to provide highly accurate future production forecast results, there was no prior art that automatically calculates the work-in-progress waiting time for all factory equipment using logical means, and that the work-in-progress time, processing time, start and finish times for all processes in the production details, in other words the finish time of the final process, becomes the production completion date (warehouse entry date and time) or shipping completion date (shipping date).

[0007] Providing technology that is as cost-effective as possible. [Means for solving the problem]

[0008] The data to be processed is high-precision process design information for quality assurance purposes, and the processing time of the process equipment that passes through that process design. The host computer stores specific times for each item, including pre- and post-setup times that reflect differences in weight even for the same specifications and standards. The production target progress and in-process process sequence data 1 of the actual production factory is received from the host computer and displayed in a table on computer 2, which processes the progress of the process sequence. Process computer 3, which is a complete copy of the production equipment (processing and assembly) process, is connected via LAN, and operation start and end dates and times, a fast-forward clock 14 double speed specification, and an all-process maintenance plan are manually entered in 2 and transmitted from 2 to 3 via LAN, preparing the overall time management environment of the present invention. Exactly the same operations as actual production are reproduced by linking 2 and 3, and the process acceptance, start, and completion dates and times are quickly updated to all processes 7 of all details 4 using the fast-forward time 14 from the specified start and end dates. Details 4, where the receiving process and shipping process have been completed, are output as production and shipping completion data 11, and the work results of 3 are also output as process work schedule data 12 each time they are completed. The start time of this device can be made continuity by matching it to the time when production target progress and in-process process sequence data 1 of the actual production factory were created.

[0009] Based on

[0008] , the host computer sends detailed process sequence data as production object progress / in-process process sequence data 1 to computer 2, which processes the process sequence in Figure 1, and the data is expanded into a table in 2. In addition, a process computer 3, which is a complete copy of the actual production equipment (processing / assembly) process, is connected via LAN, and the maintenance date and time for all processes, the double speed setting for the equipment clock 14, the end date and time in actual equipment time, additional changes to priority settings, and the operation start time in daily time setting are transmitted via LAN by key input 7 in 2, preparing an overall time management environment. It is essential that the start date and time in actual equipment time be aligned with the time when production object progress / in-process process sequence data 1 was created in order to ensure continuity.

[0010] When the operation start time specified in

[0009] arrives, the process information expanded in table 2 that is determined to be in progress (when the previous process has an end date and time and the next process does not, or the next process is in progress) is sent to all process computers 3 via packet 8 at 9 after entering the end date and time of the previous process into the acceptance date and time of process order process 7. This device processes all processes using the end date and time of the previous process as the send date and time to the next process (acceptance date and time in the process computer), and when its turn comes in the process computer work waiting table, the end date and time (the time it can be sent to the next process: start date and time + working time) is determined, and when the end date and time match the equipment clock time, the start date and time and end date and time are returned via transmission 10 and entered into the process order table 7. The exact same operations as actual production are reproduced by the linkages 9 and 10 between 2 and 3, and the process work completion time is calculated as the start date and time + working time in process computer 3 using the fast-forward time at 14 from the start date and time of the equipment clock to the end date and time, and the process is run according to the process order at 4. The process acceptance, start, and completion dates and times are updated in a short time to all processes 7 of all details 4 using the fast-forward time, and the details 4 for which the shipping process has been completed are output as production completion data 11, and the work results of 3 are also output as process work schedule data 12 each time they are completed.

[0011] It is possible to determine delivery delays based on the order delivery date and the end date and time of the shipping process, and output the file and list.

[0012] The processing results of the process PC work waiting table 15 become the work results in the process order table 7, so the processing of 15 is the most important, with maintenance information taking top priority and being at the front of the line, followed by the priority specified in packet 8, and then those without a priority specified, starting with the earliest acceptance date and time. Packets with end dates and times that overlap with the maintenance start and end dates and times will not be executed. If there are packets whose end dates and times do not overlap with the maintenance start and end dates and times, they will be executed over each other. The start and end dates and times of the executed packets are updated in 10 to the start and end dates and times of the sender process 7 using the detail IDX and process IDX of packet 8.

[0013] The waiting priority conditions for the process PC work waiting table 15 were explained in

[0012] , but packets 8 that are already being worked on are unconditionally processed first, but the determination that they are already being worked on is made when the reception date and time of the packet 8 sent to the process PC 3 in

[0010] is the oldest among the waiting packets 8, and is between the end date and time of the latest results for the process PC 4 with the equipment code and the creation time of the production object progress / in-process process sequence data 1, indicating that work is already being done, and the reception date and time of this packet is taken as the start date and time. At the time the production object progress / in-process process sequence data 1 was created, work was already being done at the majority of each process.

[0014] The process computer 3 is available in sequential processing type and batch all-in-one type (for example, annealing furnace), and there are differences in how the end date and time is determined, the start date and time of the next process, and the processing of the work waiting table, with the batch all-in-one type having cooling after removal from the furnace, the removal date and time is calculated using the packet work time, and the start date and time of the next waiting packet (entry date and time) is updated, and once the removal packet is cooled and ready to be sent to the next process, it is processed 10 and deleted from the date and time waiting table. Similar operations can be considered for sequential processing types as well, and can be realized by using the cooling time item.

[0015] This device can be used to identify items that have been delayed by specifying the equipment code and production lot of the process that had the longest waiting time, changing the priority designation, and then executing the process again to resolve the delay and check whether any new delays in delivery have occurred as a result.

[0016] The only programs required are four patterns: a program on the host side to create production progress and in-process process sequence data 1, a sequential processing process computer 3, a batch processing computer (e.g., annealing furnace) process computer 3, and a computer 2 that processes the progress of the process sequence. The load on process computer 3 is extremely small, and it is thought that an inexpensive computer could be used. Computer 2, which processes the progress of the process sequence, needs performance that matches the load of the large number of details and the LAN processing speed required to specify double the speed, so there is also the option of increasing the number of computers. It is thought that the program that creates production target progress and work-in-progress process sequence data 1 on the host side will not impose a large burden on development. [Effects of the Invention]

[0017] Each manufacturing company is trying to improve QCD by managing production using production management tools and proprietary techniques, but when it comes to D (delivery date), a huge amount of information needs to be processed due to the large number of customers and the wide variety of products, and many companies are unable to realize a system that can predict and prevent delivery delays or instantly determine the impact on other items when handling rush items.

[0018] As mentioned in

[0008] to

[0015] , the order of the detailed processes is fixed (100%), but the accuracy of the process work time does not necessarily approach 100%. If the accuracy of the work time for all processes is not nearly 100%, there will be an impact, and all results will be unrealistic. In companies that have no intention of utilizing this accuracy of work time in the first place, it may be left unaddressed, and it may be overlooked in DX issue development, and the issue mentioned in

[0006] will never be resolved, no matter how much time passes. This is an improvement on the current situation.

[0019] The resulting data from this device can be compared with actual production work results the next day, allowing for investigation into whether process work times are inappropriate or if there are local on-site deviations that do not conform to the rules shown in

[0012] , and immediate action can be taken to ensure accuracy. Therefore, improved work time accuracy for all details and processes can be achieved with a few months of labor-intensive work. Once this environment is in place, accurate schedules can be provided over the long term, opening up endless avenues for DX, PDCA, QC activities, and more in production management QCD activities.

[0020] It is expected to be applied to production management operations in many industries, and contributions from an SDG perspective are expected, such as reducing the human labor required for delivery date management and response to delivery date inquiries, reducing work in progress, and utilizing larger trucks and return trips in strategic delivery planning. Increasing the accuracy of product completion dates for export shipments by sea will enable strategic choices and lead to cost reductions. Furthermore, by simultaneously using this system for priority and regular management of customer inquiries, it will be possible to provide reliable answers that include a schedule for the entire process, gaining customer trust and gaining a digital transformation advantage among competitors.

[0021] In addition to the measures to prevent delivery delays explained in

[0015] , by using 11 to aggregate delivery destinations by prefecture, by using priority designation to control completion dates, and by consolidating details, it is possible to increase the size of orders and reduce the number of deliveries. [Brief explanation of the drawings]

[0022] [Figure 1] A diagram showing the relationship between host progress and in-process process sequence data 1, process sequence computer 2, process PC 3, and key input 7. DETAILED DESCRIPTION OF THE INVENTION

[0023] In a small to medium-sized air-conditioned room, process PCs 3 (low-cost) and a high-performance computer are installed, the number of which is equal to the number of processing equipment in the factory, and an operational test of the equipment is carried out at the stage when data creation on the host is completed. Practical application is promoted through the activities shown in

[0019] . [Explanation of symbols]

[0024] 1. Production progress and in-process process data for actual production plants 2. Computer (high performance) to process the progress of the process 3. Process computer that perfectly copies the production equipment (processing and assembly) process (1:1 with on-site equipment) 4 Identify using (Detail IDX) in the process expanded details for each manufacturing lot number expanded in the table in 2. 7 Identify using (Process IDX) in the process expanded in the table 4. 9 LAN process that sends the packet and the receipt date and time (sent date and time) from 2 to 3 10 LAN process sending start and end dates and times from 3 to 2 11 Data output for completed production and shipping processes and data output for delivery delays 12. The process schedule is output when the process in 3 is completed, the results are returned to 2, and the data is deleted from the waiting table. 14. A device clock (equipped on 2 and 3) that uses the computer clock that keeps accurate daily time and keeps fast-forward time by specifying double speed. 15 Work in progress table [Industrial Applicability]

[0025] It provides functions required by all manufacturing industries. In addition, with regard to the 2024 problem, both the transportation industry and shippers face challenges, with the receivers seeking to reduce driver waiting time by improving their own work efficiency, and the shippers needing to grasp the overall progress of the manufacturing process and make highly accurate arrangements at an early stage to prevent delays in delivery dates and prevent receivers from having to wait for cargo. However, the technology essential to realizing this is lacking, and there is a high possibility that this invention will become a core technology that paves the way.

[0026] In production, if information can be obtained even one day earlier for inventory management, material procurement, customer inquiries, shipping plans, etc., optimal and low-cost measures can be implemented with ample time to spare, and technology that can ensure accuracy up to a considerable distance in the future (about one month) is effective in achieving the SDGs in the global manufacturing supply chain. It is also effective in developing specific issues for DX (digital transformation).

Claims

[Claim 1] The device receives production progress and in-process process sequence data (1) from a host computer in an actual production factory, and displays the data in a table on a computer (2) that processes the progress of the process sequence. A process computer (3) that completely copies the production equipment (processing and assembly) processes is connected via a LAN, and operation start and end dates and times, a designation of double speed for a fast-forward clock (14), and an all-process maintenance plan are manually input via LAN from (2) to (3). The device prepares an overall time management environment of the present invention, and reproduces the exact same operations as actual production by linking (2) and (3). The device quickly updates all processes (7) of all details (4) with the process acceptance, start, and completion dates and times using the fast-forward time from the designated start date and time to the end date and time (14). The device outputs details (4) for which the warehousing process and shipping process have been completed as production and shipping completion data (11), and also outputs the work results of (3) as process work schedule data (12) each time they are completed.

Images