Management system for production facility

Abstract

To provide a management system for a production facility including a plurality of devices, configured to generate a new production plan when work shift of an operator is changed.SOLUTION: A management system 10 for generating a production plan in a production facility 100 comprises: a production-facility information storage unit 16 that stores production facility information pertaining to production facilities; a work shift storage unit 30 that stores a work shift of an operator who works in the production facility; an order storage unit 14 that stores order information including the type of workpiece, the number of produced workpieces, and a delivery date; an input unit 12 that performs inputs to the order storage unit and the work shift storage unit; a production plan generation unit 34 that generates a production plan on the basis of the production facility information, the order, and the work shift, and collates the generated production plan with the delivery date; a production plan storage unit 36 that stores a result of collating the generated production plan with the delivery date; and a display unit 32 that displays the generated production plan, the result of collation with the delivery date, and the work shift.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a management system for generating a production plan for a production facility including a machine tool, a transport device, and a setup device. [Background technology]

[0002] Patent Document 1 describes a production management method that receives an order and generates a production plan taking into consideration the load status of the manufacturing line. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] International Publication No. 2011 / 121703 Summary of the Invention [Problem to be solved by the invention]

[0004] In the production management method described in Patent Document 1, manufacturing conditions including the products to be ordered, the number of orders, the desired delivery date, and the manufacturing period are input, and orders are allocated to each day based on the production plan stored in the production plan storage unit and the manufacturing resource information stored in the manufacturing resource information storage unit so as to minimize the difference in the load on the manufacturing line for each day included in the manufacturing period. However, because the production plan is not generated in relation to the operator's work shifts, there is a problem in that an appropriate production plan cannot be generated when, for example, the work shift is changed.

[0005] The present invention aims to solve these problems of the conventional technology by generating a production plan taking into account the work shifts of operators and making it possible to generate a production plan again if the work shifts change, thereby improving the work efficiency of production managers involved in determining production plans. [Means for solving the problem]

[0006] In order to achieve the above-mentioned object, according to the present invention, a management system for generating a production plan for a production facility including a machine tool, a conveying device, and a setup device includes a production facility information storage unit that stores production facility information related to the production facility, a work shift storage unit that stores work shifts of operators working at the production facility, an order storage unit that stores orders including work types, production quantities, and delivery dates, an input unit that inputs the orders to the order storage unit and inputs the work shifts to the work shift storage unit, a production plan generation unit that generates a production plan based on at least the production facility information, the orders, and the work shifts and compares the completion time of the generated production plan with the delivery date, a production plan storage unit that stores the generated production plan and a comparison result against the delivery date, and a display unit that displays the generated production plan, the comparison result against the delivery date, and the work shifts, The production plan generating unit may be configured to generate a production plan again when a change in the work shift is input. [Effects of the Invention]

[0007] According to the present invention, the comparison result between the generated production plan and the delivery date and the work shifts are displayed, and when the work shifts are changed, the production plan is generated again, so if the delivery date cannot be met, it is possible to increase the work shifts of the insufficient operators in order to meet the delivery date.Furthermore, according to the present invention, if the delivery date can be met, it is possible to reduce the burden on individual operators or to reduce excess work shifts in order to reduce labor costs. [Brief explanation of the drawings]

[0008] [Figure 1] 1 is a block diagram illustrating a preferred embodiment of the management system of the present invention. [Figure 2] 2 is a schematic diagram showing an example of a production facility to which the management system of FIG. 1 is applied. [Figure 3] FIG. 10 is a diagram illustrating an example of order information. [Figure 4]FIG. 10 is a diagram showing an example of machine tool information. [Figure 5] FIG. 10 is a diagram illustrating an example of setup device information. [Figure 6] FIG. 10 is a diagram illustrating an example of palette information. [Figure 7] FIG. 10 is a diagram illustrating an example of transport device information. [Figure 8] FIG. 10 is a diagram illustrating an example of work information. [Figure 9] FIG. 10 is a diagram illustrating an example of work shift pattern information. [Figure 10] FIG. 10 is a diagram illustrating an example of work shift information. [Figure 11] 10 is a flowchart showing a production plan generation process. [Figure 12] FIG. 10 is a diagram illustrating an example of a generated production plan. [Figure 13] FIG. 2 is a diagram showing an example of a Gantt chart as a production plan displayed on a display unit. [Figure 14] 10A and 10B are diagrams showing an example of a Gantt chart displayed on the display unit when the delivery date can be met, and a sub-window displaying that the delivery date can be met. [Figure 15] 10A and 10B are diagrams illustrating an example of a Gantt chart displayed on the display unit when the delivery date cannot be met, and a sub-window displaying that the delivery date cannot be met. [Figure 16] FIG. 10 is a diagram showing an example of a work shift change dialog box that is displayed superimposed on a Gantt chart when a work shift is changed. [Figure 17] 10A and 10B are diagrams showing another example of a Gantt chart displayed on the display unit when the delivery date can be met, and a sub-window displaying that the delivery date can be met. [Figure 18] 10A and 10B are diagrams showing another example of a Gantt chart displayed on the display unit when the delivery date cannot be met, and a sub-window displaying that the delivery date cannot be met. [Figure 19] FIG. 10 is a diagram showing yet another example of a Gantt chart displayed on the display unit when the delivery date can be met, and a sub-window displaying that the delivery date can be met. [Figure 20]10 is a diagram showing an example in which, when a delivery date cannot be met, a Gantt chart is displayed on a display unit, and information indicating that the delivery date cannot be met is displayed in separate non-overlapping windows or areas. FIG. [Figure 21] FIG. 2 is a block diagram showing a notification unit. DETAILED DESCRIPTION OF THE INVENTION

[0009] Hereinafter, preferred embodiments of the present invention will be described with reference to the accompanying drawings. FIG. 1 shows a schematic block diagram of a production facility 100 to which the present invention is applied and a management system 10 for managing the production facility. In FIG. 2, the production facility 100 includes, as its main components, at least one machine tool 102, 104, at least one setup device 106, 108, a pallet stocker 112, and a conveying device 110. In the example shown in FIG. 2, the machine tools 102, 104 are horizontal machining centers having a main rotary spindle S, and include a table (not shown) for fixing a pallet P1, a pallet changer PC, and a feeder (not shown) for moving the table and the main rotary spindle S relatively in at least three orthogonal axes, X, Y, and Z. The feeder may also include a rotary feeder (not shown). The pallet changer exchanges a pallet P1 carrying a machined workpiece with a pallet P2 carrying an unmachined workpiece.

[0010] The machine tools 102, 104 may further include a tool magazine (not shown) that stores a plurality of tools used in machining, an automatic tool changer (not shown) that changes tools between the tool magazine and the rotary spindle S, a coolant supplying device (not shown) that supplies coolant to the machining area of the machine tools 102, 104, etc. The machine tools 102, 104 may further include an NC device that controls the drive motor of the rotary spindle S and the drive motor of the feed axis device, and a machine control device that controls peripheral devices such as the pallet changer, tool magazine, automatic tool changer, and coolant supplying device.

[0011] In the setup devices 106 and 108, an operator can perform setup work by attaching or detaching workpieces, which are processed objects or workpieces, to or from pallets. The pallet stocker 112 can include shelves for storing pallets P with workpieces W attached thereto or pallets P without workpieces W attached thereto. The transport device 110 transports pallets P with workpieces W attached thereto between the machine tools 102 and 104, the pallet stocker 112, and the setup devices 106 and 108. The transport device 110 may be configured to transport only pallets P without workpieces W attached thereto, or to directly transport workpieces W not attached to pallets P. The transport device 110 may also transport items other than workpieces W or pallets P, such as tools. The transport device 110 and the setup devices 106 and 108 can each be equipped with a control device (local control device).

[0012] The production facility 100 is controlled by a management system 10. The management system 10 can include, as its main components, an input unit 12, an order storage unit 14, a production facility information storage unit 16, a work shift storage unit 30, a display unit 32, a production plan generation unit 34, a production plan storage unit 36, and a production execution unit 38. The production facility information storage unit 16 can include a machine tool information storage unit 18, a setup device information storage unit 20, a pallet information storage unit 22, a transport facility information storage unit 24, a work information storage unit 26, and a work shift pattern storage unit 28.

[0013] The management system 10 can be configured from a computer device and associated software, including a CPU (central processing unit), memory devices such as RAM (random access memory) and ROM (read-only memory), storage devices such as SSDs (solid state drives), network communication devices, input / output ports, and a bidirectional bus that interconnects these. The management system 10 can be connected to the NC devices or machine control devices of the machine tools 102 and 104, the transport device 110, and the local control devices of the setup devices 106 and 108 via a communication network (not shown) that complies with communication standards such as IEEE802.3 (Ethernet) or IEEE802.11 (wireless LAN).

[0014] The input unit 12 can be configured with input devices such as a keyboard (not shown) or a touch panel (not shown) connected to an input / output port. The input unit 12 may also be configured with a server (not shown) or a personal computer on a communication network connected to a network communication device. The order storage unit 14, the production equipment information storage unit 16, the work shift storage unit 30, and the production plan storage unit 36 can be configured with memory areas or storage areas partitioned in the above-mentioned memory devices or storage devices.

[0015] The display unit 32 can be configured by a display device (not shown) of a computer device that constitutes the management system 10. The display unit 32 may include a program that generates images and characters to be displayed on the display device. The display unit 32 may be a display device such as a touch panel provided on a control panel (not shown) of the production facility 100 that is production-managed by the management system 10 or on a control panel (not shown) of each machine tool 102, 104 of the production facility 100. In this case, the input unit 12 may include the touch panel of the control panel.

[0016] The order storage unit 14 stores information (order information) related to orders input via the input unit 12. The order information can be stored in the order storage unit 14 in the form of a table, as shown in FIG. 3, for example. In FIG. 3, the order information includes an "order number," which is a number assigned to each order to identify the order; a "production workpiece," which is an identification name (such as a designation or product number) of the workpiece to be produced; a "production quantity," which is the number of workpieces to be produced; a "production start date," which is the time when production of the workpieces should begin; and a "delivery date," which is the deadline by which all of the workpieces indicated by the "production quantity" should be produced. The "delivery date" can be defined as the time when processing of the workpieces is completed, the time when the processed workpieces are removed from the pallet, the time when the produced workpieces are ready for shipment from the factory, or the like. In the example of FIG. 3, the "production start date" and "delivery date" are specified as a date and time, but they may also be simply a date. The order information may also include other information related to the order.

[0017] The machine tool information storage unit 18 stores information (machine tool information) related to all machine tools 102, 104 equipped in the production facility 100 whose production is managed by the management system 10. The machine tool information can be input from the input unit 12. The machine tool information can be stored in the machine tool information storage unit 18 in the form of a table, as shown in FIG. 4 as an example. In FIG. 4, the machine tool information includes an "identification name," a "model name," and an "operating status." The "identification name" is the name of the machine tools 102, 104 in the production facility 100, and in this embodiment, the identification names MC1 and MC2 correspond to the machine tools 102, 104 in FIG. 2, respectively. The "model name" is the model of the machine tool, and can be, for example, a model number, an item number, or a product number.

[0018] The "operating status" indicates whether the machine tool is in a state where it can be used. Although only "operating" is shown as the "operating status" in Fig. 4, the "operating status" can also include, for example, "stopped," which indicates that the machine tool cannot be used for reasons such as breakdown, repair, or maintenance. The "operating status" can be input by an operator, or can be input from the NC device or machine control device of the machine tools 102, 104 via a communication network.

[0019] 4 shows that the machine tools 102 and 104 in the production facility 100 have the identification names MC1 and MC2, respectively, are the same model of machine tools with the model name a71nx, and are both in a usable state. The machine tool information may also include other information related to the machine tools 102 and 104.

[0020] The setup device information storage unit 20 stores information (setup device information) about all setup devices 106, 108 equipped in the production facility 100. The setup device information can be input from the input unit 12. The setup device information can be stored in the setup device information storage unit 20 in the form of a table, as shown in FIG. 5 as an example. In FIG. 5, the setup device information includes an "identification name" and an "operating status." The "identification name" is the name of the setup devices 106, 108 in the production facility 100, and in this embodiment, the identification names WSS1 and WSS2 correspond to the setup devices 106, 108 in FIG. 2, respectively.

[0021] The "operating status" indicates whether the setup device is in a usable state. Although FIG. 5 only shows "operating" as the "operating status," the "operating status" can also include, for example, "stopped," which indicates that the setup device is unavailable due to reasons such as a malfunction, repair, or maintenance. The "operating status" can be input by an operator or can be input from the local control devices of the setup devices 106 and 108 via a communication network. As an example, the setup device information shown in FIG. 5 indicates that the setup devices 106 and 108 of the production facility 100 are in a usable state. The setup device information may also include other information related to the setup devices 106 and 108.

[0022] The pallet information storage unit 22 stores information (pallet information) related to all pallets P equipped in the production equipment 100. The pallet information can be input from the input unit 12. The pallet information can be stored in the pallet information storage unit 22 in the form of a table, as shown in FIG. 6 as an example. In FIG. 6, the pallet information includes an "identification name," "corresponding work," "storage location," and "operating status." The "identification name" is the name of each pallet P in the production equipment 100. In FIG. 6 as an example, P1, P2, P3, P4, ... mean pallet number 1, pallet number 2, pallet number 3, pallet number 4, .... The "identification name" may simply be 1, 2, 3, 4, ... instead of P1, P2, P3, P4, ....

[0023] Typically, a specialized jig for attaching workpieces is fixed to each pallet P. "Corresponding Work" is information that identifies the workpieces that can be attached to each pallet P. In FIG. 6, which shows an example, the "Corresponding Work" field contains the name of the workpiece to be attached to the pallet P, i.e., information on the "production workpiece." "Storage Location" is the storage location of the pallet P in the pallet stocker 112, and can be, for example, an address assigned to each storage location. "Operating Status" indicates whether the pallet is ready for use. Note that while FIG. 6 only shows "Available" as the "Operating Status," the "Operating Status" can also include, for example, "Unusable," which indicates that the pallet cannot be used for reasons such as breakdown, repair, maintenance, or preparation.

[0024] 6 shows that pallets P1, P2, P3, P4, ... on which workpieces A, B, C, B, ... are mounted are all usable and are stored in storage locations S1-9, S1-5, S1-8, S1-1, ... of the pallet stocker 112. In this embodiment, the pallet stocker is configured with two levels and ten rows, and the storage location "S1-9" for pallet P1 indicates that pallet P1 is stored in the "ninth row of the first level."

[0025] The conveyance device information storage unit 24 stores information (conveyance device information) related to the conveyance devices 110 equipped in the production facility 100. The conveyance device information can be input from the input unit 12. Referring to FIG. 7, the conveyance device information can include an "identification name" which is the name of the conveyance device 110 in the production facility 100, a "model name" which indicates the model of the conveyance device 110, an "operation status" which indicates whether the conveyance device 110 is available for use, and a "transport time" which is the time required to transport a pallet. The "identification name" is the name of the conveyance device 110 in the production facility 100. The "model name" is the model of the conveyance device 110 and can be, for example, a model number, item number, or product number.

[0026] The "operating state" indicates whether the transport device 110 is in a state where it can be used. Although only "operating" is shown as the "operating state" in FIG. 7, the "operating state" can also include, for example, "stopped," which indicates that the transport device 110 is not available for use due to reasons such as a breakdown, repair, or maintenance. The "operating state" can be input by an operator or input from a local control device of the transport device 110 via a communication network.

[0027] "Transport time" is the time required for the transport device 110 to transport a pallet between devices in the production facility 100. FIG. 7 shows the time required to transport a pallet between the machine tool 102 (MC1) and the setup device 106 (WSS1). Note that while FIG. 7 only shows the "transport time" required to transport a pallet between the machine tool 102 (MC1) and the setup device 106 (WSS1), the transport device information can include the "transport time" required to transport a pallet between the machine tool 102 (MC1) and the setup device 108 (WSS2), the "transport time" required to transport a pallet between the machine tool 104 (MC2) and the setup device 106 (WSS1), and the "transport time" required to transport a pallet between the machine tool 104 (MC2) and the setup device 108 (WSS2). The "transport time" between the machine tools 102, 104 or setup devices 106, 108 and the pallet stocker 112 may also be included.

[0028] 7 shows that the transport device 110 of the production facility 100 has an identification name AGV1, is a transport device with a model name of PZ1-AGV, is in an available state, and takes one minute to transport a pallet between the machine tool 102 (MC1) and the setup device 106 (WSS1). The transport device information may include other information related to the transport device 110.

[0029] The workpiece information storage unit 26 stores information related to the workpiece to be machined (workpiece information). Referring to FIG. 8, the workpiece information shown as an example includes "identification name," "machining program number," "machining time," "mounting time," "removal time," "MC1 machining," "MC2 machining," "WSS1 setup," and "WSS2 setup." The workpiece information can be input from the input unit 12. In this specification, "mounting time" and "removal time" are also collectively referred to as "setup time."

[0030] The "identification name" is the same information as the "production work" in the order above. The "machining program number" is the number of the machining program for machining the work. The "machining time" is the time required to machine the work. The "mounting time" is the time required to mount the unmachined work on the pallet P in the setup device WSS1 (106) or WSS2 (108). The "removal time" is the time required to remove the machined work from the pallet P in the setup device WSS1 (106) or WSS2 (108). In this specification, the "mounting work" of the work on the pallet and the "removal work" from the pallet are also simply referred to as "setup."

[0031] "MC1 machining" and "MC2 machining" indicate whether the workpiece can be machined by machine tool MC1 (102) and / or MC2 (104), i.e., the suitability of the machine tool for the workpiece. "WSS1 setup" and "WSS2 setup" indicate whether the workpiece can be set up on pallet P by setup device WSS1 (106) and / or WSS2 (108), i.e., the suitability of the setup device for the workpiece.

[0032] 8 shows that the workpieces to be machined by production equipment 100 are workpieces A, B, and C, and that it takes 30, 45, and 60 minutes to machine one workpiece, respectively; 5, 15, and 15 minutes to attach the unmachined workpiece to pallet P; 5, 10, and 12 minutes to remove the machined workpiece from pallet P; workpieces A and B can be machined by machine tools MC1 and MC2; workpiece C can be machined by machine tool MC1 but not by machine tool MC2; workpieces A and B can be set up for pallet P by setup devices WSS1 and WSS2; and workpiece C can be set up for pallet P by setup device WSS1 but cannot be set up by setup device WSS2. Furthermore, the workpiece information may include process information consisting of tasks required to produce the workpieces and their order. Process information consists of three pieces of information: the tasks required to produce the workpiece, the order of the tasks, and the equipment on which the tasks are executed, such as "1: Installation (setup equipment) → 2: Transport (transport equipment) → 3: Processing (machine tool) → 4: Transport (transport equipment) → 5: Removal (setup equipment)." Work information may also include other information related to the workpiece.

[0033] The work shift pattern storage unit 28 stores information related to the work shift patterns of operators, that is, the normal working patterns of operators engaged in work related to the production facility 100. The work shift pattern information can be input from the input unit 12. Referring to FIG. 9, the work shift pattern information shown as an example includes "pattern," "working hours 1," and "working hours 2."

[0034] "Pattern" is the name given to the working style at the production facility 100 or at the factory where the production facility 100 is installed. In the example shown in FIG. 8, "pattern" includes day shifts, night shifts, and overtime. "Working hours 1" and "Working hours 2" are the times when the operator is engaged in work related to the production facility 100. A break can be set between "Working hours 1" and "Working hours 2."

[0035] The work shift pattern information shown in Figure 9 includes the following work styles: day shift 1, which works from 8:00 (8:00 AM) to 12:00 (noon), followed by a one-hour break, and then works from 1:00 PM (1:00 PM) to 5:00 PM (5:00 PM); night shift 1, which works from 4:00 PM (4:00 PM) to 8:00 PM (8:00 PM), followed by a one-hour break, and then works from 9:00 PM (9:00 PM) to 1:00 AM (1:00 AM); overtime 1, which works from 5:15 PM (5:15 PM) to 7:15 PM (7:15 PM); and overtime 2, which works from 5:15 PM (5:15 PM) to 9:15 PM (9:15 PM). The work shift pattern information may also include other work styles, such as early shifts that start before 8:00 (8:00 a.m.), late shifts that start in the afternoon, and late-night shifts that start after 25:00 (1:00 a.m.).

[0036] The work shift memory unit 30 stores work shift information related to the work shifts of operators engaged in work related to the production equipment 100. The work shift information can be input through the input unit 12. The work shift information can be input by the production manager, or can be input via a communication network from an attendance management server (not shown) in the factory where the production equipment 100 is installed. The work shift information stored in the work shift memory unit 30 can be displayed as a work shift table on the display unit 32. Note that the production manager refers to the person who both manages and operates the management system in this invention, but the operator may also serve as the production manager.

[0037] Referring to FIG. 10, the work shift information shown as an example includes "working date," "operator," "working time 1," and "working time 2." "Working date" is the date on which each operator works on the production equipment 100. "Operator" is the name of the working operator. "Working time 1" and "working time 2" are the times when the operator works on the production equipment 100. A break can be set between "working time 1" and "working time 2."

[0038] The work shift information shown in Figure 10 indicates that on September 15, 2023, operator OP1 will work from 8:00 (8:00 AM) to 12:00 (noon) and from 13:00 (1:00 PM) to 17:00 (5:00 PM), operator OP2 will work from 16:00 (4:00 PM) to 20:00 (8:00 PM) and from 21:00 (9:00 PM) to 25:00 (1:00 AM the next day), and on September 16, 2023, operator OP1 will work from 8:00 (8:00 AM) to 12:00 (noon) and from 13:00 (1:00 PM) to 17:00 (5:00 PM), and operator OP2 will work from 16:00 (4:00 PM) to 20:00 (8:00 PM) and from 21:00 (9:00 PM) to 25:00 (1:00 AM the next day).

[0039] The operation of this embodiment will be described below with reference to FIG. After the production manager inputs a new order from the input unit 12, the production plan generation unit 34 generates a production plan, which is a collection of tasks required to produce the production work specified in the order and is the work procedure for each device in the production facility 100. When the production manager commands the generation of a production plan (step S10), the production plan generation unit 34 generates a production plan, which is the work procedure for each device in the production facility 100 (step S12). The generation of the production plan may be started automatically when an order is input. Furthermore, a production plan can be generated when, for example, the operating status of a machine tool is changed or when the status of the production facility is changed, such as when a pallet is added.

[0040] In order to produce the workpieces described in the order information, the production plan generation unit 34 can generate a production plan, which is the work procedures for the machine tools 102, 104, setup devices 106, 108, pallet P, and transport device 110 of the production facility 100, in the form of a table (FIG. 12), as shown as an example in FIG. 12, based on the order information stored in the order memory unit 14, the machine tool information, setup device information, pallet information, transport device information, and workpiece information stored in the production facility information memory unit 16, and the work shift stored in the work shift memory unit 30. The production plan generated by the production plan generation unit 34 is stored in the production plan memory unit 36 (step S14).

[0041] 12 includes a "task," a "workpiece-processing number," an "order," a "pallet," a "scheduled task start time," a "scheduled task end time," and an "equipment." A "task" is a term used to refer to an operation performed by an apparatus constituting the production facility 100. In this example, the "tasks" include an "attachment operation" in which an operator attaches an unmachined workpiece to a pallet P in the setup device 106 or 108; a "transport 1" in which the workpiece W attached to the pallet P is transported together with the pallet P from the setup device 106 or 108 to the machine tool 102 or 104 by the transport device 110; a "processing" operation in which the transported workpiece W is processed in the machine tool 102 or 104; a "transport 2" operation in which the machined workpiece W is transported together with the pallet P from the setup device 106 or 108 to the setup device 106 or 108 by the transport device 110; and a "removal operation" in which the machined workpiece W is removed from the pallet P in the setup device 106 or 108.

[0042] "Workpiece-processing number" is information that indicates the number of the workpiece among the "production workpiece" and "production quantity" listed in the order information. The "workpiece-processing number" shown as an example in Figure 12 is a combination of (production workpiece)-(number)-(production quantity). "Order" is the "order number" listed in the order information. "Pallet" is the "identification name" of the pallet P to be used (see Figure 6). "Scheduled task start time" is the time starting point of the "task" in the production plan, "scheduled task end time" is the time ending point of the "task" in the production plan, and "equipment" is the "identification name" of the equipment used to execute the "task" (see Figures 4, 5, and 7).

[0043] In the example of Figure 12, the production plan for production work A with order number PO-A-0915 in Figure 3 is as follows: (1) From 8:00 AM on September 15, 2023 to 8:05 AM on September 15, 2023, an operator performs the work of attaching the first production work A, unprocessed work A-1-10, to pallet P1 at setup device WSS1. (2) From 8:05 AM on September 15, 2023 to 8:06 AM on September 15, 2023, workpiece A-1-10 attached to pallet P1 is transported from setup device WSS1 to machine tool MC1 by transport device AGV1, (3) From 8:06 AM on September 15, 2023 to 8:36 AM on September 15, 2023, workpiece A-1-10 is machined using machine tool MC1. (4) From 8:36 AM on September 15, 2023 to 8:37 AM on September 15, 2023, the machined workpiece A-1-10 is transported from the machine tool MC1 to the setup device WSS1 by the transport device AGV1. (5) From 8:37 AM on September 15, 2023 to 8:42 AM on September 15, 2023, an operator removes the machined workpiece A-1-10 from pallet P1 at setup device WSS1. (6) From 8:42 AM on September 15, 2023 to 8:47 AM on September 15, 2023, an operator performs the work of attaching the unprocessed work A-2-10, which is the second production work A, to pallet P1 at setup device WSS1. (7) From 8:47 AM on September 15, 2023 to 8:48 AM on September 15, 2023, workpiece A-2-10 attached to pallet P1 is transported from setup device WSS1 to machine tool MC1 by conveyance device AGV1, (8) From 8:48 AM on September 15, 2023 to 9:18 AM on September 15, 2023, workpiece A-2-10 is machined using machine tool MC1. After performing further tasks not shown in the figure, (9) From 15:48 (3:48 PM) on September 15, 2023 to 15:53 (3:53 PM) on September 15, 2023, the operator removes the processed workpiece A-10-10, which is the tenth production workpiece A, from pallet P1 in setup device WSS1.

[0044] The production plan generation unit 34 compares (step S16) the time point at which all work on the production work A in the production facility 100 is completed, which is the completion point of the generated production plan; in the example of FIG. 12, the scheduled task end time at which the last work A-10-10 is removed from pallet P1 (15:53 (3:53 PM) on September 15, 2023), with the delivery date stated in the order information (8:00 (8 AM) on September 20, 2023). The comparison result is stored in the production plan storage unit 36.

[0045] As will be explained below, the display unit 32 accesses the production plan storage unit 36 and displays the production plan together with the collation results. When displaying the production plan, the display unit 32 may display the production plan in the form of a table as shown in FIG. 12, but it is preferable to display the production plan in the form of a Gantt chart as shown in FIG. 13. When the production plan involves a long schedule or when there are many devices to be displayed, it is preferable to be able to enlarge or reduce the display and to switch the display vertically and horizontally using a scroll bar. Furthermore, by always displaying the last task of the last work when the production plan is first generated and displayed, it becomes easier to confirm that the delivery date will be met.

[0046] 13, the Gantt chart 50 as a production plan displayed on the display unit 32 includes, for example, a work time chart 52, a processing plan chart 54, a transportation plan chart 56, a setup plan chart 58, and an operator work time chart 60. The Gantt chart 50 showing the production plan further includes an icon (completion icon) 62 indicating the completion point of the generated production plan, in this case, the completion time of the production plan. In FIGS. 13 to 19, the completion icon 62 indicates the time when processing of the final production workpiece A is completed and the removal of the workpiece W from the pallet P is completed, but it may also indicate the time when processing of the final production workpiece A is completed. Note that, although the delivery date and completion date are expressed in minutes in this embodiment, both or either of the delivery date and completion date may be expressed in other units, such as months only, days and months, time in hours, or time in seconds.

[0047] In Fig. 13, working time chart 52 is a chart that shows the working hours of all operators engaged in production equipment 100 superimposed on one another, and includes working hours shown in white and non-working hours shown in hatched areas. The working hours shown in working time chart 52 in Fig. 13 include 8:00 (8:00 AM) to 12:00 (noon) and 13:00 (1:00 PM) to 17:00 (5:00 PM). Note that in the working hours shown in working time chart 52 in Fig. 13, no operators are working after 17:00 (5:00 PM).

[0048] A machining plan chart 54 can be generated for each of the machine tools MC1 and MC2, but in Fig. 13 it is generated only for the machine tool MC1. The machining plan chart 54 includes a plurality of task icons (machining task icons) arranged in chronological order. In the example of Fig. 13, the machining plan chart 54 for the machine tool MC1 includes machining task icons T1 to T10. The machining task icons T1 to T10 correspond to machining in the machine tool MC1. In the example of Fig. 13, the machining task icons T1 to T10 are assigned the pallet numbers of pallets on which workpieces to be machined by the machine tool MC1 are mounted, but "workpiece-machining number" or "production workpiece" may be assigned instead of the pallet numbers.

[0049] The transportation plan chart 56 includes a plurality of task icons (transport task icons) arranged in chronological order. In the example of Fig. 13, the transportation plan chart 56 includes transport task icons C1 to C20. The transport task icon C(1+2i):i = 0 to 9 corresponds to transport 1 in Fig. 12, that is, the transport operation of an unmachined workpiece from the setup device WSS1 to the machine tool MC1, and the transport task icon C(2i):i = 1 to 10 corresponds to transport 2 in Fig. 12, that is, the transport operation of a machined workpiece from the machine tool MC1 to the setup device WSS1.

[0050] The setup chart 58 includes task icons (setup task icons) WS1 to WS20. The setup task icons WS(1+2i)i=0 to 9 correspond to the installation work in Fig. 12, and the setup task icons WS(2i)i=1 to 10 correspond to the removal work in Fig. 12. Although Figs. 13 to 20 only show the setup in setup device WSS1, the setup in setup device WSS2 can also be displayed in a similar manner.

[0051] The operator working time chart 60 is a chart showing the working hours of each individual operator, and includes working hours shown in white and non-working hours shown in hatched areas. The working hours include 8:00 (8:00 AM) to 12:00 (noon) and 13:00 (1:00 PM) to 17:00 (5:00 PM). In Figure 13, only operator OP1 is working, so the working time chart 52 and the operator working time chart 60 match in terms of the working hours of operator OP1.

[0052] If the delivery date is achievable (Yes in step S16), the display unit 32 displays the production plan together with a message that the delivery date can be met (step S18). Referring to FIG. 14, the display unit 32 displays a sub-window 64 including a message indicating that the delivery date can be met, along with the Gantt chart of FIG. 13. The message indicating that the delivery date can be met, shown as an example in FIG. 14, includes the order number "PO-A-0915" and the delivery date "2023 / 9 / 15 8:00 (8:00 AM on September 15, 2023)." The sub-window 64 also displays buttons 66a and 66b for asking the production manager whether or not to approve the production plan.

[0053] If the delivery date cannot be met (No in step S16), the display unit 32 displays the production plan and a message indicating that the delivery date cannot be met (step S20). Referring to FIG. 15, the Gantt chart displayed on the display unit 32 as a production plan when the delivery date cannot be met includes, similar to the Gantt chart in FIG. 13, a work time chart 52, a processing plan chart 54, a transportation plan chart 56, a setup plan chart 58, and an operator work time chart 60. The Gantt chart in FIG. 15 also includes an icon (delivery date icon) 68 indicating the delivery date with a line and a text box. A line is displayed corresponding to the delivery date, and the date and time of the delivery date are displayed in the text box. The delivery date icon 68 includes the word "delivery date" to clearly indicate that the icon indicates the delivery date. However, it may be an icon of another type, such as an icon of a different color or shape from the completion icon 62. In the Gantt chart in FIG. 15, the completion date icon 62 indicating the completion date is located to the right of the delivery date icon 68, making it easy for the production manager to understand that the completion date has passed the delivery date and the delivery date cannot be met. Furthermore, in the Gantt chart of Figure 15, since the three processing task icons T13 to T15 are located to the right of the delivery date icon 68, the production manager can easily understand that the production of production work A-13-15 to A-15-15 of order PO-A-0918, which corresponds to the processing task icons T13 to T15, will not be in time for the delivery date.

[0054] If the delivery date cannot be met, the display unit 32 displays a sub-window 70 including a message indicating that the delivery date cannot be met, along with a Gantt chart representing the production plan. The message indicating that the delivery date cannot be met, as shown as an example in FIG. 15, includes the order number "PO-A-0918" and the delivery date "2023 / 9 / 18 23:00 (11:00 PM on September 18, 2023)." The sub-window 70 also displays buttons 72a and 72b for asking the production manager whether or not to change the work shift.

[0055] When the production manager taps or clicks the "Yes" button 72a to change the work shift, a work shift change dialog box 74 (Figure 16) appears on the Gantt chart of the production plan. The work shift change dialog box 74 includes a table (current work shift table) 76 showing the current work shifts, a table (additional work shift table) 78 showing work shifts to be added to the current work shifts, an Add button 80, and a Cancel button 82. The current work shift table 76 is generated based on the current work shift information stored in the work shift memory unit 30. The additional work shift table 78 is generated by the production manager selecting operators available for additional work and then inputting or selecting the work dates and working hours. By simultaneously displaying the generated production plan and work shifts on the display unit 32, the management system operator can adjust work shifts while checking the production plan. Here, the additional work shift table 78 initially displays headings for work date, operator, work time 1, and work time 2, as well as input rows with input rules. The production manager can directly input data according to the input rules. For example, an input rule may be that work dates must be in year-month-day format. Furthermore, the input rule may be set by referring to each storage unit of the management system 100. For example, the work shift pattern storage unit 28 may be referenced, and work shift pattern information may be displayed in list form in association with work time 1 or work time 2 of the additional work shift table 78, so that when the production manager selects a desired work shift pattern from the list by tapping or clicking, the selected work shift pattern is input into work time 1 or work time 2 of the additional work shift table 78.

[0056] The management system 10 may include a work shift calculation unit (not shown) that calculates work shifts to meet delivery deadlines and proposes them to the management system operator, in order to assist the production manager in selecting and inputting operators who are available to work additional shifts. Furthermore, the management system 10 may include an operator information storage unit (not shown) that stores operator information. The operator information may include work availability information for each individual operator (for example, operator OP1 can work overtime up to five hours a week, cannot work night shifts, and cannot work on Sundays), and skill information for each operator (for example, operator OP1 can set up work A and B, but cannot set up work C). Work shift selection, production plan generation, or work shift calculation may be performed based on the operator information.

[0057] In the example of FIG. 16 , if the production manager creates an additional work shift schedule 78 with the following content: work date is September 18, 2023, operator P1, work time 1 is 17:15-21:15 (5:15 PM to 9:15 PM), and work time 2 is not set; and then taps or clicks the Add button 80 (Yes in step S22), the flowchart returns to step S12, and the production plan generation unit 34 generates a new production plan taking the added work shift into account. The generated new production plan is stored in the production plan storage unit 36 (step S14). Next, the production plan generation unit 34 again determines whether the delivery date can be met (step S16). If the delivery date can be met (Yes in step S16), the display unit 32 displays a subwindow 64 including a message indicating that the delivery date can be met, together with a Gantt chart showing the new production plan, as shown in FIG. 17 (step S18).

[0058] If the answer is No in step S16, that is, if the delivery date cannot be met even if the work shift is changed and the production plan is regenerated, the display unit 32 again displays the subwindow 70, which includes a message indicating that the delivery date cannot be met, along with a Gantt chart representing the newly generated production plan (step S20). Here, if the production manager taps or clicks the "Yes" button 72a to change the work shift, the display unit 32 again displays the work shift change dialog box 74. The production manager can then reconsider the work shift.

[0059] Figures 18 and 19 show embodiments different from those of Figures 16 and 17. The work shift change dialog box 74 of Figure 18 includes an additional work shift table 84. In the additional work shift table 78 of Figure 16, operator OP1 works from 17:15 (5:15 PM) to 21:15 (9:15 PM), whereas in the additional work shift table 84 shown in Figure 18, operator OP2 works from 15:20 (3 PM) to 20:00 (8 PM) and from 21:00 (9 PM) to 25:00 (1 AM the next day).

[0060] When the production manager taps or clicks the Add button 80 (Yes in step S22), the flowchart returns to step S12, and the production plan generation unit 34 generates a new production plan taking the added work shift into account. The generated new production plan is stored in the production plan storage unit 36 (step S14). Next, the production plan generation unit 34 again determines whether the delivery date can be met (step S16). If the delivery date can be met (Yes in step S16), the display unit 32 displays a subwindow 64 including a message indicating that the delivery date can be met, along with a Gantt chart showing the new production plan, as shown in FIG. 19 (step S18). In the Gantt chart in FIG. 17, the operator working time chart 60 indicates that only operator OP1 is working, whereas in the Gantt chart in FIG. 19, the operator working time chart 60 indicates that operator OP2 is working in addition to operator OP1.

[0061] If, in step S16, the delivery date cannot be met even with the new production plan, the above process may be repeated until the delivery date can be met, but the process may be interrupted and a dialogue may be displayed prompting the production manager to find a fundamental solution, such as reviewing the order or arranging for production equipment.

[0062] If the delivery date can be met (Yes in step S16), the production manager approves the generated production plan by tapping or clicking the "Yes" button 66a (FIGS. 14, 17, and 19) in the subwindow 64 containing the message indicating that the delivery date can be met (Yes in step S24). This determines whether or not changes to the work shifts were made when the production plan was generated. If no changes to the work shifts were made (No in step S26), an "Execute" button (not shown) is displayed on the display unit 32 (step S30), prompting the production manager to execute the production plan. If changes to the work shifts were made (Yes in step S26), the changes to the work shifts are reflected in the work shifts stored in the work shift storage unit in step S28, and then the production manager is prompted to execute the production plan in step S30.

[0063] When the production manager taps or clicks the execute button to instruct the production execution unit 38 to execute the production plan (Yes in step S32), the production execution unit 38 reads the approved production plan from the production plan storage unit 36 and instructs the production equipment 100 to execute production in accordance with the read production plan (Step S34), and the production plan generation process ends (Step S36). If the production manager does not instruct the production plan to be executed (No in step S32), the production equipment 100 does not execute the production plan, and the production plan generation process ends with the approved production plan stored in the production plan storage unit 36 (Step S36).

[0064] Even if the delivery date can be met, the production manager can choose not to approve the generated production plan (No in step S24). That is, when the subwindow 64 containing the "Delivery date achievable" indication shown in Figures 14, 17, and 19 is displayed, the production manager can tap or click the "No" button 66b included therein to display the work shift change dialog box 74 and change the work shift. This allows further improvements even if the delivery date can be met. For example, to reduce labor costs, it is possible to eliminate redundant work shifts by having one operator meet the delivery date as shown in Figure 17, or to increase the number of operators to reduce the burden on the operators as shown in Figure 19.

[0065] If the "No" button 72b is tapped or clicked in step S22 (if No in step S22), the production plan generation process ends (step S36) with the generated production plan stored in the production plan storage unit 36. In this case, the generated production plan is not executed.

[0066] According to this embodiment, the generated production plan is compared with the delivery date, and the collation results and work shifts are displayed. When the work shifts are changed, the production plan is generated again. If the delivery date cannot be met, work shifts for insufficient operators can be increased to meet the delivery date. If the delivery date can be met, surplus work shifts can be reduced to reduce the burden on operators and cut labor costs.

[0067] Furthermore, the production facility information storage unit 16 stores machine tool information including the operating status of the machine tools 102, 104, setup device information including the operating status of the setup devices 106, 108, pallet information including the type and number of pallets P held by the production facility 100, transport device information including the transport capacity and operating status of the transport device 110, workpiece information including the machining program number for each workpiece type, setup time (mounting time and removal time), machining time, machine tools that can be machined, and setup devices that can be set up, and work shift pattern information including work shift patterns, and the production plan generation unit 34 generates a production plan based on this information. This improves the accuracy of the generated production plan, and when the work shift is changed, the work shift pattern can be displayed to assist in changing the work shift.

[0068] In the embodiment described above, the work shift change dialog box 74 is displayed (popped out) so as to be superimposed on the Gantt chart of the production plan, but the production plan and the work shift may be displayed in separate windows or areas that do not overlap, as shown in Fig. 20. In the embodiment shown in Fig. 20, the production plan display area 90, the work shift display area 92, and the sub-window 70 containing the display of the delivery date not being met are simultaneously displayed on the display unit 32 so as not to overlap each other.

[0069] If a new order is input while a production plan is being generated, there is a possibility that a production plan that the production manager did not anticipate will be generated. To prevent such a situation from occurring, the management system 10 can be provided with a notification unit that notifies the production manager when another order is input to the order storage unit 14 while the production plan generation unit 34 is generating a production plan.

[0070] 21, the notification unit 40 monitors the production plan generation unit 34 and the order storage unit 14, and if an order other than the order related to the production plan is entered into the input unit 12 while the production plan generation unit 34 is generating the production plan, the notification unit 40 puts the input of this order on hold and notifies the production manager that a new order has been entered via the speaker 42, the display unit 32, or a preferably portable terminal 44 such as a smartphone or tablet. After confirming the notification that a new order has been entered, the production manager can choose whether to continue or cancel the entry of this new order.

[0071] If the production manager selects to continue inputting another order, the generation of the production plan currently in progress is forcibly stopped, and if the production manager selects to stop inputting another order, the generation of the production plan currently in progress can be continued. After the generation of the production plan currently in progress is forcibly stopped, the generation of a new production plan that takes into account the other order may be started.

[0072] Furthermore, the production plan may be generated not on the management system 10 attached to the actual production equipment, but on a virtual management system (not shown) that replicates information from various storage units of the management system 10. This allows the production plan to be generated freely in response to various orders and fluctuations in the status and number of production equipment, without interfering with the actual production. [Explanation of symbols]

[0073] 10 Management System 12 Input section 14 Order storage section 16 Production equipment information storage unit 18 Machine tool information storage section 20 Setup device information storage unit 22 Palette information storage section 24 Transport device information storage unit 26 Work information storage unit 28 Work shift pattern memory unit 30 Work shift memory section 32 Display section 34 Production Planning Division 36 Production plan memory section 38 Production Execution Department 40 Information Department 42 speakers 44 terminals 50 Gantt Chart 52 Working Hours Chart 54 Processing plan chart 56 Transportation Planning Chart 58 Setup Planning Chart 60 Operator Working Hours Chart 62 Completion icon 64 subwindows 66a Button 66b Button 68 Delivery Icon 70 Subwindows 72a Button 72b Button 74 Work Shift Change Dialog Box 76 Current work shift schedule 78 Additional Work Shift Schedule 80 Add button 82 Cancel button 84 Additional Work Shift Schedule 90 Production plan display area 92 Work shift display area 102 Machine tools 104 Machine tools 106 Setup device 108 Setup device 110 Conveyor 112 Pallet Stocker

Claims

1. In a management system for generating a production plan for a production facility including a machine tool, a conveyance device, and a setup device, a production facility information storage unit that stores production facility information related to the production facility; a work shift storage unit that stores work shifts of operators working at the production facility; an order storage unit that stores orders including types of workpieces, production quantities, and delivery dates; an input unit that inputs the order to the order storage unit and inputs the work shift to the work shift storage unit; a production plan generating unit that generates a production plan based on at least the production equipment information, the order, and the work shift, and compares the completion time of the generated production plan with the delivery date; a production plan storage unit that stores the generated production plan and a collation result obtained by comparing the production plan with the delivery date; a display unit that displays the generated production plan, a collation result obtained by comparing the production plan with the delivery date, and the work shift; Including, The management system is characterized in that the production plan generation unit generates a production plan again when a change in the work shift is input.

2. 2. The management system according to claim 1, wherein the production equipment information storage unit stores machine tool information including the operating status of the machine tool, transport device information including the transport capacity and operating status of the transport device, setup device information including the operating status of the setup device, pallet information including the types of workpieces that can be attached to pallets held by the production equipment, workpiece information including the machining program number, setup time, machining time, machine tools that can be machined and setup devices that can be set up for each type of workpiece, and work shift pattern information including operator work shift patterns, and the production plan generation unit generates a production plan based on this information.

3. 2. The management system according to claim 1, wherein the generated production plan and work shifts are simultaneously displayed on a display unit.

4. 4. The management system according to claim 3, wherein the generated production plan and work shift are displayed simultaneously in a production plan display area and a work shift display area of the display unit so as not to overlap each other.

5. 2. The management system according to claim 1, further comprising a notification unit that, when an input related to a new, separate order is made to the order storage unit while the production plan generation unit is generating a production plan, holds the input related to the new, separate order and notifies a production manager via a speaker, a display unit, and / or a terminal that an input related to the new, separate order has been made.

Images