Planning system, production management system, planning method, and planning program

Abstract

To formulate an optimal work schedule.SOLUTION: A planning system includes a processor that executes a program, and a storage device storing the program. The storage device stores a production plan, work shift, and production capability, the production plan specifying a first item and production quantity of a product of the first item, the work shift specifying a worker and work time in which the worker works, and the production capability specifying work time for preparation required for the worker in charge of the production of the first item. The processor optimizes a production schedule including the first item, the worker who works in the work time, and the production quantity, based on the production plan, the work shift, and the production capability, so as to minimize the preparation work time for the production quantity, and outputs the optimized production schedule.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a planning system for creating a plan, a production management system, a planning method, and a planning program. [Background technology]

[0002] There are many different types of production losses that hinder productivity improvement at production sites. Furthermore, formulating measures to improve these production losses requires deep knowledge of the site. In particular, there are losses that arise from planning, such as setup losses that occur when preparing for the production process, so it is important to optimize schedules that take into account worker capabilities and process plans.

[0003] The improvement measure recommendation device in Patent Document 1 stores work performance information and correspondence information that associates measures with measure perspectives in a storage device. The work performance information is information in which work performance data indicating the worker, product, work time period, and work location within the warehouse for each order is associated with variation factors that indicate worker attributes, work time period attributes, product attributes, and location attributes. Based on the work performance information, the processor calculates a basic unit that includes at least one of work frequency, work volume, and unit time for each elemental work that makes up the warehouse work for each category of variation factors. Based on the calculation results of the same variation factor calculated for different categories, the processor extracts specific combinations that will cause work loss from the set of combinations of elemental work, basic units, and variation factors. Based on the specific combination, the processor identifies a specific measure perspective and, by referring to the correspondence information, determines a measure that corresponds to the specific measure perspective.

[0004] The work instruction device of Patent Document 2 includes a memory unit that stores on-site data including production performance information for each product manufactured at the manufacturing site, worker activity information obtained from sensors attached to workers at the manufacturing site, and information on the operation history of equipment at the manufacturing site; a production loss occurrence pattern extraction unit that analyzes the on-site data using a predetermined method to generate a production loss occurrence pattern; and a work instruction generation unit that estimates the occurrence of production loss from a work plan for work corresponding to the date, time, equipment, and worker that correspond to the production loss occurrence pattern, and generates work instruction information including information on the cause of the production loss. [Prior art documents] [Patent documents]

[0005] [Patent Document 1] International Publication No. WO2018 / 193512 [Patent Document 2] Japanese Patent Publication No. 2022-14574 Summary of the Invention [Problem to be solved by the invention]

[0006] In the above-mentioned conventional technology, there are a variety of types of production losses that hinder the productivity of equipment, such as losses caused by the actions of on-site workers, losses caused by production planning and process allocation, and losses caused by product design.

[0007] In order to develop improvement measures for production losses, it is necessary to have the knowledge and man-hours to accurately classify the causes of losses included in the production losses. The above-mentioned conventional technology does not take into consideration the classification of the multiple losses.

[0008] An object of the present invention is to create an optimal work schedule. [Means for solving the problem]

[0009] A planning system according to one aspect of the invention disclosed in this application is a planning system having a processor that executes a program and a storage device that stores the program, wherein the storage device stores a production plan, worker shifts, and production capacity, wherein the production plan specifies a first item and the number of products to be produced of the first item, the worker shifts specify workers and the working hours that the workers will work, and the production capacity specifies the setup work time required when the workers are in charge of producing the first item, and the processor executes an acquisition process that acquires the production plan, the worker shifts, and the production capacity, an optimization process that optimizes a production schedule including the first item, the workers who will work within the working hours, and the production number based on the production plan, worker shifts, and production capacity acquired by the acquisition process so as to minimize the setup work time for the number of products to be produced, and an output process that outputs the production schedule optimized by the optimization process. [Effects of the Invention]

[0010] According to the exemplary embodiment of the present invention, an optimal work schedule can be created. Problems, configurations, and effects other than those described above will become apparent from the following description of the embodiment. [Brief explanation of the drawings]

[0011] [Figure 1] FIG. 1 is an explanatory diagram showing a system configuration example 1 of a production management system. [Figure 2] FIG. 2 is a block diagram showing an example of the hardware configuration of the computer in the system. [Figure 3] FIG. 3 is an explanatory diagram showing an example of a production plan. [Figure 4] FIG. 4 is an explanatory diagram showing an example of a worker shift. [Figure 5] FIG. 5 is a block diagram illustrating an example of the functional configuration of the loss analysis system. [Figure 6] FIG. 6 is an explanatory diagram illustrating an example of the operation detection DB. [Figure 7] FIG. 7 is an explanatory diagram illustrating an example of the facility operation state DB. [Figure 8] FIG. 8 is an explanatory diagram illustrating an example of a loss analysis definition table. [Figure 9] FIG. 9 is an explanatory diagram showing an example of the setup loss DB. [Figure 10] FIG. 10 is an explanatory diagram showing an example of loss analysis by the loss analysis system. [Figure 11] FIG. 11 is a block diagram illustrating an example of the functional configuration of a manufacturing execution system. [Figure 12] FIG. 12 is an explanatory diagram illustrating an example of an SOP definition table. [Figure 13] FIG. 13 is an explanatory diagram illustrating an example of the work record DB. [Figure 14] FIG. 14 is a block diagram illustrating an example of a functional configuration of the planning system. [Figure 15] FIG. 15 is a flowchart illustrating an example of a procedure for analyzing worker-attributed loss by the worker-attributed loss analysis unit. [Figure 16] FIG. 16 is an explanatory diagram showing an example of worker-attributed loss analysis display information. [Figure 17] FIG. 17 is an explanatory diagram showing an example of a worker-attributed loss analysis view. [Figure 18] FIG. 18 is an explanatory diagram illustrating an example of the setup loss time improvement prospect DB. [Figure 19] FIG. 19 is a flowchart illustrating an example of a production capacity update process procedure performed by the production capacity update unit. [Figure 20] FIG. 20 is an explanatory diagram showing an example of production capacity. [Figure 21] FIG. 21 is a flowchart illustrating an example of a production schedule calculation process procedure performed by the production schedule calculation unit. [Figure 22] FIG. 22 is an explanatory diagram showing an example of a production schedule. [Figure 23] FIG. 23 is an explanatory diagram showing a second example of the system configuration of the production management system. DETAILED DESCRIPTION OF THE INVENTION

[0012] <Figure 1 System configuration example 1> FIG. 1 is an explanatory diagram showing a system configuration example 1 of a production management system. In this embodiment, a "system" is composed of one or more computers. The production management system 100 is composed of a core system 101, a loss analysis system 102, a manufacturing execution system 103, a planning system 104, manufacturing equipment 105, and a surveillance camera 106.

[0013] The core system 101 is an existing system that enables a user company to improve the efficiency of its business operations. In this example, the core system 101 includes a production plan 111 and a worker shift 112. The core system 101 can communicate with a manufacturing execution system 103 and a planning system 104.

[0014] The loss analysis system 102 is an existing system that analyzes 4M losses. 4M refers to people (huMan), machines (Machines), materials (Materials), and methods (Methods), or data related to these. 4M losses are production losses that occur at manufacturing sites and are identified through analysis of data related to the 4Ms. In this example, the loss analysis system 102 analyzes setup losses, which are one type of production loss.

[0015] The setup is the work of the worker w from the time when the operation of the manufacturing equipment 105 is stopped until the time when the operation is restarted. The setup is classified into a production setup and a changeover setup.

[0016] Production setup is a setup related to production, such as the work of attaching and detaching a cut workpiece when repeatedly producing the same item. In cutting processing, the work of attaching and detaching a workpiece is required as a setup for each workpiece produced. Specifically, for example, the setting work of worker w who sets up the manufacturing equipment 105 from the time one product of the item is processed on the manufacturing equipment 105 until the time the second product is processed is a production setup. In other words, production setup is a setup when there is no changeover of items.

[0017] Switching setup is setup related to switching, such as changing tools such as jigs and blades, when switching between items to be produced. Specifically, when switching items in a manufacturing process (hereinafter simply referred to as a process) in which manufacturing equipment 105 is operating, switching setup is the time taken by worker w from stopping the operation of manufacturing equipment 105 in that process to starting it up with the changed item. Setup loss is loss caused by setup (for example, the time required for setup).

[0018] The loss analysis system 102 is communicatively connected to a planning system 104, a manufacturing facility 105, and a surveillance camera 106.

[0019] The manufacturing execution system 103 is an existing system that understands and manages the manufacturing process, gives instructions and support to workers w, and can, for example, be linked to each manufacturing process on a factory production line. The manufacturing execution system 103 has various management functions such as work procedure management, receipt and shipping management, quality control, and maintenance management. In this example, the manufacturing execution system 103 executes work records according to SOPs (Standard Operating Procedures). The manufacturing execution system 103 is connected to the core system 101, planning system 104, and manufacturing equipment 105 so that they can communicate with each other.

[0020] The planning system 104 is a system that formulates a production plan. The planning system 104 analyzes losses caused by workers w, updates production capacity, and calculates a production schedule. The planning system 104 is communicably connected to the core system 101, the loss analysis system 102, and the manufacturing execution system 103.

[0021] The manufacturing equipment 105 is equipment that manufactures products in accordance with a production plan 111. The manufacturing equipment 105 is operated by an operator w. The manufacturing equipment 105 is connected to the loss analysis system 102 and the manufacturing execution system 103 so that they can communicate with each other.

[0022] The monitoring camera 106 captures images of the manufacturing equipment 105 and the worker w, and transmits the captured image data (which may be a still image or a video image) to the loss analysis system 102. The worker w performs work according to a worker shift 112.

[0023] The site 110 is a location where a worker w is stationed in the manufacturing facility 105, and is photographed by the surveillance camera .

[0024] <Figure 2 Example of the hardware configuration of the computer in the system> FIG. 2 is a block diagram showing an example of the hardware configuration of a computer in the system. The computer 200 includes a processor 201, a storage device 202, an input device 203, an output device 204, and a communication interface (communication IF) 205. The processor 201, the storage device 202, the input device 203, the output device 204, and the communication IF 205 are connected via a bus 206. The processor 201 controls the computer 200. The storage device 202 serves as a working area for the processor 201. The storage device 202 is a non-transitory or temporary recording medium that stores various programs and data. Examples of the storage device 202 include a read-only memory (ROM), a random access memory (RAM), a hard disk drive (HDD), and a flash memory. The input device 203 inputs data. Examples of the input device 203 include a keyboard, a mouse, a touch panel, a numeric keypad, a scanner, a microphone, and a sensor. The output device 204 outputs data. The output device 204 includes, for example, a display, a printer, and a speaker. The communication IF 205 connects to a network and transmits and receives data.

[0025] <Figure 3 Production Plan 111> FIG. 3 is an explanatory diagram showing an example of a production plan 111. The production plan 111 is information indicating a plan for producing a product to be produced. The production plan 111 has fields including a production lot number 301, an item 302, a delivery date 303, and a production quantity 304. The production lot number 301 is a number that uniquely identifies a production lot. A production lot is a unit of products manufactured under the same conditions.

[0026] Item 302 is an item into which the product identified by production lot number 301 is classified. Delivery date 303 is the date by which the product identified by production lot number 301 should be delivered. Production quantity 304 is the number of products identified by production lot number 301 to be produced.

[0027] <Figure 4 Worker Shift 112> FIG. 4 is an explanatory diagram showing an example of a worker shift 112. The worker shift 112 has fields of a person in charge 401, a start date and time 402, and an end date and time 403. The person in charge 401 is a worker w in charge of a task. The start date and time 402 is the date and time when the person in charge 401 starts the task. The end date and time 403 is the date and time when the person in charge 401 finishes the task. The time from the start date and time 402 to the end date and time 403 on the same date is the working time of the person in charge 401 in one day.

[0028] <Figure 5: Example of functional configuration of loss analysis system 102> 5 is a block diagram showing an example of the functional configuration of the loss analysis system 102. The loss analysis system 102 includes an operation detection DB 501, an equipment operation status DB 502, a loss analysis definition table 503, a setup loss DB 504, an operation detection unit 511, a collection unit 512, and a setup loss analysis unit 513. The operation detection DB 501, the equipment operation status DB 502, the loss analysis definition table 503, and the setup loss DB 504 are specifically realized, for example, by the storage device 202 shown in FIG. 2. The operation detection unit 511, the collection unit 512, and the setup loss analysis unit 513 are specifically realized, for example, by having the processor 201 execute programs stored in the storage device 202 shown in FIG. 2.

[0029] The work detection unit 511 detects work from the video data from the monitoring camera 106 and records the detection result in the work detection DB 501.

[0030] The collection unit 512 collects information on the operating status of the manufacturing equipment 105 from the manufacturing equipment 105 and records the collected information in the equipment operating status DB 502 .

[0031] The setup loss analysis unit 513 analyzes setup losses by referring to the loss analysis definition table 503 based on the data in the work detection DB 501 and the equipment operating state DB 502, and records the setup loss information that is the analysis result in the setup loss DB 504.

[0032] [Figure 6 Work detection DB 501] 6 is an explanatory diagram showing an example of the work detection DB 501. The work detection DB 501 has the following fields: detection date and time 601, equipment 602, whether work was performed 603, and abnormality data 604. A combination of values ​​in each field in the same row is registered as an entry indicating the work detection result.

[0033] The detection date and time 601 is the date and time when the video data of the surveillance camera 106 that detected the work of the worker w on the manufacturing equipment 105 was captured. In this example, it is detected in one-minute increments. The equipment 602 is identification information that uniquely identifies the manufacturing equipment 105. The work execution status 603 is information indicating whether or not the worker w is working. The work execution status 603 is determined by analyzing the video data from the surveillance camera 106, such as skeletal detection that identifies the positional relationship between the manufacturing equipment 105 and the worker w and the behavior of the worker w.

[0034] The anomaly data 604 is data indicating an anomaly detected by analyzing the video data from the surveillance camera 106. The anomaly data 604 may be, for example, a flag that uniquely identifies the anomaly, or the date and time when the anomaly occurred. The anomaly data 604 may also include video data for a period based on the detection date and time 601 (in this example, one minute, since entries are recorded in one-minute increments).

[0035] [Figure 7 Equipment operation status DB502] 7 is an explanatory diagram showing an example of the equipment operation status DB 502. The equipment operation status DB 502 has fields: collection date and time 701, equipment 602, and equipment operation status 703. A combination of values ​​in each field in the same row is registered as an entry indicating the equipment operation status collection result. The collection date and time 701 is time information indicating when the equipment operation status 703 was collected from the equipment 602. The equipment operation status 703 indicates the operation status (operating or stopped) of the equipment 602 at the time 701.

[0036] [Figure 8 Loss analysis definition table 503] 8 is an explanatory diagram showing an example of a loss analysis definition table 503. The loss analysis definition table 503 is preset information and has fields: work execution status 801, equipment operation status 802, and setup loss 803. Work execution status 801 specifies two possibilities: whether the work is executed or not. Equipment operation status 802 specifies two possibilities: whether the equipment 602 is operating or stopped. Setup loss 803 specifies two possibilities: whether a setup loss exists or not. In other words, the loss analysis definition table 503 shows the correspondence between all possible combinations (4 possibilities: 2 x 2) of work execution status 801 and equipment operation status 802 and the setup loss 803.

[0037] Specifically, for example, when the work execution status 801 is "executed" and the equipment operation status 802 is "operating," it indicates that the worker w is performing some work and the equipment 602 is operating, so it is estimated that production work is being performed. Therefore, with this combination of the work execution status 801 and the equipment operation status 802, the setup loss 803 has not occurred, and the setup loss 803 is set to "absent."

[0038] Furthermore, when the work execution status 801 is "Yes" and the equipment operation status 802 is "Stopped", it indicates that the worker w is performing some work and the equipment 602 is stopped, so it is estimated that a setup work is being performed rather than a production work. Therefore, with this combination of the work execution status 801 and the equipment operation status 802, a setup loss 803 has occurred, and the setup loss 803 is set to "Yes".

[0039] Furthermore, when the work execution status 801 is "absent" and the equipment operation status 802 is "operating," it indicates that the worker w is not performing the work but the equipment 602 is operating, and therefore it is estimated that production work is being performed. Therefore, with this combination of the work execution status 801 and the equipment operation status 802, the setup loss 803 has not occurred, and the setup loss 803 is set to "absent."

[0040] Furthermore, when the work execution status 801 is "absent" and the equipment operation status 802 is "stopped," it indicates that the worker w is not performing the work and the equipment 602 is stopped, so it is estimated that neither production work nor setup work is being performed. Therefore, with this combination of the work execution status 801 and the equipment operation status 802, the setup loss 803 has not occurred, and the setup loss 803 is set to "absent."

[0041] [Figure 9 Setup loss DB504] 9 is an explanatory diagram showing an example of the setup loss DB 504. The setup loss DB 504 has fields of date and time 901, equipment 602, and setup loss 903. A combination of values ​​in each field in the same row is registered as an entry indicating setup loss information, which is the analysis result.

[0042] The date and time 901 is either the detection date and time 601 or the collection date and time 701. The setup loss 903 is the setup loss 803 in the entry of the loss analysis definition table 503 that matches the combination of the operation execution status 603 and the equipment operation status 703.

[0043] [Figure 10 Example of loss analysis] 10 is an explanatory diagram showing an example of loss analysis by the loss analysis system 102. The loss analysis system 102 combines the work detection results in the work detection DB 501 with the equipment operation status in the equipment operation status DB 502 for the same date and time and for the same equipment, to generate combined data 1000. The combined data 1000 has fields such as date and time 901, equipment 602, whether work is being performed 603, and equipment operation status 703.

[0044] The loss analysis system 102 refers to the loss analysis definition table 503 to identify a combination of work execution status 801 and equipment operation status 802 that matches the combination of work execution status 603 and equipment operation status 703 in the combined data 1000, and identifies the setup loss 803 that corresponds to the identified combination of work execution status 801 and equipment operation status 802.

[0045] The loss analysis system 102 combines the identified setup loss 803 with the date / time 901 and equipment 602 of the combined data 1000 as a setup loss 903 to generate setup loss information, and registers it as an entry in the setup loss DB 504 .

[0046] <Figure 11: Example of functional configuration of manufacturing execution system 103> 11 is a block diagram showing an example of the functional configuration of the manufacturing execution system 103. The manufacturing execution system 103 has an SOP definition table 1100, a work record DB 1101, a setup history DB 1102, and an SOP work recording unit 1102. The SOP definition table 1100, the work record DB 1101, and the setup history DB 1102 are specifically realized, for example, by the storage device 202 shown in FIG. 2. The SOP work recording unit 1102 is specifically realized, for example, by having the processor 201 execute a program stored in the storage device 202 shown in FIG. 2.

[0047] The SOP work recording unit 1102 acquires the manufacturing lot number 301, the work 1203, the item 302, the equipment 602, the person in charge 401, as well as the work start date and time and the work end date and time as manufacturing execution information from the manufacturing equipment 105.

[0048] [Figure 12 SOP definition table 1100] 12 is an explanatory diagram showing an example of an SOP definition table 1100. The SOP definition table 1100 is a table in which an SOP is defined in advance, and has fields of an item 302, a process 1201, an operation type 1202, and an operation 1203. The process 1201 is the order of operations in the manufacturing facility 105. For example, a product of item Ia is produced by executing the processes in the order X⇒Y⇒Z.

[0049] The work type 1202 indicates the type of work within the process 1201. For example, "switching work (start)" indicates a setup work for switching from a product in the previous process 1201 to another product. "Production work" indicates that work in the process 1201 is being performed by the operation of the manufacturing equipment 105. "Switching work (end)" indicates a setup work for switching from a product in the current process 1201 to another product.

[0050] The work 1203 indicates the execution order of the work types 1202 within the process 1201. The work 1203 defines the execution order of the work types 1202 in ascending order starting from 1 of the branch numbers of the process 1201 symbols.

[0051] [Figure 13 Work record DB1101 and setup history DB1102] 13 is an explanatory diagram showing an example of the work record DB 1101 and the setup history DB 1102. The work record DB 1101 has the following fields: production lot number 301, work 1203, item 302, work start date and time 1301, work end date and time 1302, equipment 602, and person in charge 401. A combination of values ​​in each field in the same row is registered in the work record DB 1101 as an entry indicating work record information.

[0052] The work start date and time 1301 is the date and time when the work 1203 to produce the product of item 302 by the equipment 602 that the person in charge 401 is in charge of started, and is acquired as manufacturing execution information from the manufacturing equipment 105. The work end date and time 1302 is the date and time when the work 1203 to produce the product of item 302 by the equipment 602 that the person in charge 401 is in charge of ended, and is acquired as manufacturing execution information from the manufacturing equipment 105.

[0053] The setup history DB 1102 has fields of a pre-switching production lot number 1311, a pre-switching item 1312, a post-switching production lot number 1313, and a post-switching item 1314. The pre-switching production lot number 1311 is the pre-switching production lot number 301. The pre-switching item 1312 is the pre-switching item 302. The post-switching production lot number 1313 is the post-switching production lot number 301. The post-switching item 1314 is the post-switching item 302.

[0054] The work record DB 1101 and the setup history DB 1102 are associated with each other by the production lot number 301 , the pre-switching production lot number 1311 , and the post-switching production lot number 1313 .

[0055] <Figure 14 Planning System 104> 14 is a block diagram showing an example of the functional configuration of the planning system 104. The planning system 104 has a worker-attributed loss analysis unit 1401, a production capacity update unit 1402, and a production schedule calculation unit 1403. Specifically, the worker-attributed loss analysis unit 1401, the production capacity update unit 1402, and the production schedule calculation unit 1403 are realized, for example, by having the processor 201 execute programs stored in the storage device 202 shown in FIG.

[0056] [Figure 15: Worker-caused loss analysis process] FIG. 15 is a flowchart showing an example of the worker-attributed loss analysis processing procedure performed by the worker-attributed loss analysis unit 1401.

[0057] (Step S1501) The worker-attributed loss analysis unit 1401 acquires the work results. The work results are setup loss information from the setup loss DB 504 and work record information from the work record DB 1101.

[0058] (Step S1502) The worker-attributed loss analysis unit 1401 executes worker-attributed loss analysis. The worker-attributed loss analysis is a process that calculates the actual time required for setup work for each task 1203 based on setup loss information and work record information, and generates worker-attributed loss analysis display information 1410.

[0059] (Step S1503) The worker-attributed loss analysis unit 1401 displays the worker-attributed loss analysis display information 1410 as a worker-attributed loss analysis view 1411 on a display, which is an example of the output device 204 .

[0060] (Step S1504) The worker-attributed loss analysis unit 1401 determines whether there is room for improvement in an operation. Specifically, for example, the worker-attributed loss analysis unit 1401 automatically determines whether there is room for improvement in an operation based on the variation (variance) of operation time. If the variance is greater than a threshold, the worker-attributed loss analysis unit 1401 determines that there is room for improvement in the operation (step S1504: Yes), and if the variance is equal to or less than the threshold, it determines that there is no room for improvement in the operation (step S1504: No).

[0061] The worker-attributed loss analysis unit 1401 may also receive input from the input device 203 as to whether there is room for improvement in the work. The worker-attributed loss analysis unit 1401 may also model deviation behavior in advance, and display a warning when it detects deviation behavior by worker w. In this case, the worker-attributed loss analysis unit 1401 may display the number of deviation behaviors detected and the total deviation time, and prompt the user to determine whether there is room for improvement.

[0062] (Step S1505) The worker-attributed loss analysis unit 1401 records the setup loss time improvement prospect information in the setup loss time improvement prospect DB. Specifically, for example, when the worker-attributed loss analysis unit 1401 receives approval input from the input device 203, it confirms the work time improvement prospect and records the setup loss time improvement prospect information in the setup loss time improvement prospect DB 1412.

[0063] [Figure 16: Display information for worker-attributable loss analysis 1410] 16 is an explanatory diagram showing an example of worker-attributed loss analysis display information 1410. The worker-attributed loss analysis display information 1410 has as fields the production lot number 301, the operation 1203, the item 302, the operation start date and time 1301, the operation end date and time 1302, the equipment 602, the person in charge 401 in the work record DB 1101, and an actual operation time 1600. The actual operation time 1600 is the actual time required for the setup work calculated for each operation 1203 in step S1502.

[0064] Specifically, for example, the worker-attributed loss analysis unit 1401 identifies entries included in the time period from the task start date / time 1301 (2023 / 10 / 1 10:00:00) to the task end date / time 1302 (2023 / 10 / 1 10:05:00) in the entry 1601 of a certain task 1203 (for example, "X-1") from the setup loss DB 504. In this example, entries 1611 to 1615 are identified. It is assumed that the date / time 901 is recorded in one-minute increments.

[0065] Then, the worker-attributed loss analysis unit 1401 identifies entries 1611, 1613 to 1615 in which the setup loss 904 is "yes" from the identified entries 1611 to 1615. Since the date and time 901 is in one-minute units, the time during which the setup loss 904 is "yes" in the four entries 1611, 1613 to 1615 is four minutes. The worker-attributed loss analysis unit 1401 records "4" in the actual work time 1600.

[0066] [Figure 17 Worker-attributable loss analysis view 1411] 17 is an explanatory diagram showing an example of the worker-attributed loss analysis view 1411. The worker-attributed loss analysis view 1411 is a screen that displays a graph of the display target in the SOP. Specifically, for example, the worker-attributed loss analysis view 1411 displays an SOP selection section 1701, a display target selection section 1702, and a graph 1703.

[0067] The SOP selection section 1701 is a graphical user interface that displays a selectable SOP from a plurality of SOPs. Fig. 17 shows a state in which "task X-1" has been selected as the SOP. The display object selection section 1702 is a graphical user interface that displays a selectable display object from a plurality of display objects. Fig. 17 shows a state in which "actual setup work time" has been selected as the display object.

[0068] Graph 1703 is a group of plot points in time series relating to the display objects in the SOP for each person in charge 401. The horizontal axis of graph 1703 represents elapsed time, and the vertical axis represents the display objects selected in the display object selection unit 1702. That is, the plot points marked with black triangles (×) represent the actual work time 1600 required by person in charge Ra at the work start date and time 1301 on the horizontal axis, and the plot points marked with crosses (▲) represent the actual work time 1600 required by person in charge Rb at the work start date and time 1301 on the horizontal axis. Plot point 1730 corresponds to entry 1601 in the work-related loss analysis view 1412. That is, plot point 1730 is the intersection of the work start date and time 1301 (2023 / 10 / 1 10:00:00) on the horizontal axis and "4" minutes, which is the actual work time 1600 on the vertical axis.

[0069] Marker 1740 indicates an abnormality detected at the plot point to the left of it. The abnormality is assigned by abnormality data 604 associated with the combination of detection date and time 601 and equipment 602 in the work detection DB 501 that matches the combination of work start date and time 1301 and equipment 602.

[0070] For example, if the abnormal data 604 is "tool dropped," when the marker 1740 is specified with the input device 203, "tool dropped" is displayed as a speech bubble 1741. Although not shown, if the abnormal data 604 includes video data, the worker attributable loss analysis unit 1401 may play the video data. This allows the user to compare the differences between normal and abnormal work and identify points that need improvement, thereby promoting the reduction of setup work time.

[0071] The dotted line T(Ra) is the average value of the actual work time 1600 of the person in charge Ra, and the dotted line T(Rb) is the average value of the actual work time 1600 of the person in charge Rb. The worker-attributed loss analysis unit 1401 may also use these average values ​​to calculate the variation (variance) of the actual work time 1600 for each worker. This allows the worker-attributed loss analysis unit 1401 to automatically determine whether there is room for improvement in the work.

[0072] In FIG. 17, the graphs are drawn for the responsible persons Ra and Rb, but the worker w can be selected, although not shown.

[0073] [Figure 18 Setup loss time improvement prospect DB1412] 18 is an explanatory diagram showing an example of the setup loss time improvement prospect DB 1412. The setup loss time improvement prospect DB 1412 has the following fields: production lot number 301, operation 1203, item 302, actual operation time 1600, operation time improvement prospect 1800, equipment 602, and person in charge 401. A combination of values ​​in each field in the same row is registered in the setup loss time improvement prospect DB 1412 as an entry that defines setup loss time improvement prospect information. The operation time improvement prospect 1800 is the expected time by which the actual operation time 1600 is improved, and is received by input from the input device 203.

[0074] [Figure 19 Production capacity update process] FIG. 19 is a flowchart showing an example of a production capacity update process performed by the production capacity update unit 1402.

[0075] (Step S1901) The production capacity update unit 1402 acquires information on the expected improvement in setup loss time, which is an entry in the expected improvement in setup loss time field 1412 .

[0076] (Step S1902) The production capacity update unit 1402 calculates and updates the production capacity 1413. The production capacity 1413 is the capacity to produce products at the site 110, and specifically, is composed of, for example, a required production time and a required changeover time.

[0077] [Figure 20 Production capacity 1413] 20 is an explanatory diagram showing an example of the production capacity 1413. The production capacity 1413 has a required production setup time 2001 and a required switching setup time 2002. The required production setup time 2001 specifies an improved production setup standard work time 2010 for each person in charge 401 when the production of a product of a certain item 302 is processed in a certain facility 602 in a process 1201.

[0078] The improved production setup standard work time 2010 is the standard work time required for the production setup after the improvement. The production setup is a setup related to production, such as the work of attaching and detaching a cut workpiece when repeatedly producing the same item 302. In cutting processing, the work of attaching and detaching a workpiece is required as a setup each time a workpiece is made.

[0079] The improved production setup standard work time 2010 is, for example, the sum of the values ​​obtained by subtracting the expected work time improvement 1800 from the actual work time 1600 for the same item 302, process 1201, equipment 602, and person 401.

[0080] Specifically, for example, referring to SOP definition table 1100, "X" in process 1201 (hereinafter referred to as process X) is composed of X-1, X-2, X-3, and X-4 in tasks 1203 (hereinafter referred to as tasks X-1, X-2, X-3, and X-4), of which the "production tasks" are tasks X-2 and X-3.

[0081] Therefore, in the case of item 302 "Ia" (hereinafter, item Ia), equipment 602 "Ma" (equipment Ma), process X, and person in charge 401 "Ra" (hereinafter, person in charge Ra) in FIG. 18, the improved production setup standard working time 2010 of entry 2011 is the sum of 4 (= 5 - 1), which is obtained by subtracting the expected working time improvement of 1800 from the actual working time of 1600 for task X-2, and 2 (= 4 - 2), which is obtained by subtracting the expected working time improvement of 1800 from the actual working time of 1600 for task X-3.

[0082] If there are multiple combinations of item Ia, equipment Ma, process X, and person in charge Ra, the average value of the above totals becomes the improved production setup standard work time 2010 for that combination.

[0083] The required switching setup time 2002 specifies the improved switching setup standard work time 2020 for each person in charge 401 when switching from the production of a product of a certain item 302 (pre-switching item 1312) to the production of a product of another item 302 (post-switching item 1314) in a certain process 1201 of a certain facility 602.

[0084] The improved changeover setup standard work time 2020 is the standard work time required for changeover setup after the improvement. The changeover setup is a setup related to changeover, such as the work of replacing tools such as jigs and blades when switching the item 302 to be produced.

[0085] The setup history DB 1102 is referenced to identify the pre-switching production lot number 1311 corresponding to the pre-switching item 1312. Once the pre-switching production lot number 1311 is identified, the work record DB 1101 is referenced to identify the work end date and time 1302 of the production lot number 301 that matches the pre-switching production lot number 1311.

[0086] Similarly, the setup history DB 1102 is referenced to identify the post-switching production lot number 1313 corresponding to the post-switching item 1314. When the post-switching production lot number 1313 is identified, the work record DB 1101 is referenced to identify the work start date and time 1301 of the production lot number 301 that matches the post-switching production lot number 1313.

[0087] The time from the work end date and time 1302 to the work start date and time 1301 is calculated as the improved changeover setup standard work time 020. If there are multiple combinations of the same pre-change item 1312, post-change item 1314, process 1201, equipment 602, and person in charge 401, the average value of the time from each work end date and time 1302 to the work start date and time 1301 is calculated as the improved changeover setup standard work time 020.

[0088] [Figure 21 Production schedule calculation process] FIG. 21 is a flowchart showing an example of a production schedule calculation process procedure performed by the production schedule calculation unit 1403.

[0089] (Step S2101) The production schedule calculation unit 1403 acquires the production plan 111 , the worker shift 112 , and the production capacity 1413 .

[0090] (Step S2102) The production schedule calculation unit 1403 optimizes a production schedule 1414 that includes a production sequence and a manpower allocation plan. Specifically, for example, the production schedule calculation unit 1403 solves an optimization problem (MIP (Mixed Integer Programming) model). The variables and constants used in the optimization problem are defined below.

[0091] i is the manufacturing lot number 301, j is the item 302, k is the equipment 602, l is the person in charge 401, s is the process 1201, and t is the one shift period of worker w.

[0092] P i is the quantity to be produced in production lot number i (production number 304), and Di is the delivery date 303 (the period elapsed from the starting date) of manufacturing lot number i, and J i is the item 302 produced in production lot number i.

[0093] T1 j,k,l,s is the production setup required time 2001 when person in charge l is in charge of producing item j at facility k in process s, specifically, the improved production setup standard work time 2010.

[0094] T2 j,j´,k,l,s is the required changeover setup time 2002 when person in charge l changes from item j (item before changeover 1312) to item j' (item after changeover 1314) at equipment k in process s, specifically, the improved changeover setup standard work time 2020.

[0095] S l,t takes the value 1 if the person in charge l is in the worker shift 112 in the period t, and takes the value 0 if the person in charge l is not in the worker shift 112 in the period t.

[0096] L k,s takes the value 1 if equipment k belongs to process s, and 0 if it does not belong to process s.

[0097] H l,s takes the value 1 if worker w is able to take charge of process s as person in charge l, and 0 if not.

[0098] Θ is the period length of period t.

[0099] x i,j,k,l,s,t takes the value of 1 if production of item j of manufacturing lot number i by person l at facility k in process s is carried out in period t, and 0 otherwise.

[0100] xs i,j,k,l,s,t takes the value of 1 when production of item j with manufacturing lot number i by person l at facility k in process s is carried out at the beginning of period t, and 0 otherwise.

[0101] xe i,j,k,l,s,ttakes the value of 1 if production of item j of manufacturing lot number i by person l at equipment k in process s is carried out at the end of period t, and 0 otherwise.

[0102] y i,i´,j,j´,k,l,s,t takes the value of 1 if a switch from item j to item j' occurs in period t due to a switch from production lot number i to production lot number i' by person in charge l at equipment k in process s, and 0 otherwise.

[0103] z l,s, t takes the value 1 if worker l is in charge of process s in period t, and 0 otherwise.

[0104] The production schedule calculation unit 1403 solves the following equation (1) as an optimization problem.

[0105]

number

[0106] The first term of the above formula (1) is the sum of the production setup time 2001 for the production quantity 304 minutes, and the second term is the sum of the switchover setup time 2002. The production schedule calculation unit 1403 calculates the production schedule for the production lot numbers i and i', items j and j', equipment k, person in charge l, process s, period t, and quantity P so that the sum of the above formula (1) is minimized. i The production schedule calculation unit 1403 may solve the optimization problem by excluding the equipment k, the person in charge l, the process s, and the period t from the above equation (1).

[0107] The above formula (1) complies with the following constraints (formulas (2) to (15)).

[0108]

number

[0109] Equation (2) above ensures that every production lot produced in period t is either a replacement for a previous production lot or the first production lot produced in period t.

[0110]

number

[0111] Equation (3) above ensures that every production lot produced in period t is either switched over to the next production lot or is the last production lot produced in period t.

[0112]

number

[0113] The above formula (4) guarantees that there is only one production lot that is produced first in period t for each process 1201 and facility 602.

[0114]

number

[0115] The above formula (5) guarantees that there is only one final production lot for each process 1201 and facility 602 in the period t.

[0116]

number

[0117] The above formula (6) guarantees that the equipment 601 only produces the process 1201 to which it belongs.

[0118]

number

[0119] The above formula (7) guarantees that worker w (person in charge l) performs only the tasks 1203 that he or she can handle.

[0120]

number

[0121] The above formula (8) guarantees that worker w (person in charge l) is in charge of only one process 1201.

[0122]

number

[0123] The above formula (9) is x i,j,k,l,s,t and z l,s, t This ensures that z is consistent. l,s, t If it is decided that person l will be in charge of process s in period t, then x i,j,k,l,s,t is also determined in the same way (z l,s, t This means that no work is done in any equipment 602 other than the process 1201 determined in step 1201.

[0124]

number

[0125] The above formula (10) ensures that only the target items are produced in each production lot.

[0126]

number

[0127] The above formula (11) guarantees that the task 1203 will not be assigned if the worker w (person in charge l) is off shift.

[0128]

number

[0129] The above formula (12) guarantees that for every production lot, the production period and worker w (person in charge l) for each process 1201 and facility 602 are determined to be a unique combination.

[0130]

number

[0131] The above formula (13) guarantees the order relationship of the process 1201 of the manufacturing lot.

[0132]

number

[0133] The above formula (14) guarantees that production carried out in period t is completed within period t.

[0134]

number

[0135] The above formula (15) guarantees that the delivery dates 303 of all production lots are met.

[0136] (Step S2103) The production schedule calculation unit 1403 records the production schedule 1414. Specifically, for example, in step S2102, the production schedule calculation unit 1403 identifies the manufacturing lot numbers i and i', items j and j', equipment k, person in charge l, process s, and period t that minimize the sum of the above formula (1).

[0137] [Figure 22 Production Schedule 1414] 22 is an explanatory diagram showing an example of a production schedule. The production schedule calculation unit 1403 registers the identified item j in the item 302, registers the identified process s in the process 1201, registers the identified equipment k in the equipment 602, and calculates the quantity P to be produced for the identified production lot number i. iis registered in the production quantity 2201 , the start date and time of the specified period t is registered in the start date and time 2202 , the end date and time of the specified period t is registered in the end date and time 2203 , and the specified person in charge l is registered in the person in charge 401 .

[0138] The production schedule calculation unit 1403 outputs a production schedule 1414. Specifically, for example, the production schedule calculation unit 1403 displays the production schedule 1414 on a display, which is an example of the output device 204, or transmits it to another computer.

[0139] Although the system configuration example 1 of the production management system 100 is shown in FIG. 1, the following system configuration example 2 may also be used.

[0140] <Fig. 23 System configuration example 2> Fig. 23 is an explanatory diagram showing a second system configuration example of the production management system 100. In the example of Fig. 23, an integrated system 2301 is a system that integrates the loss analysis system 102 and the manufacturing execution system 103. Specifically, for example, the integrated system 2301 performs loss analysis using the worker-attributable loss analysis unit 1401, and the planning system 104 updates the production capacity 1413 using the production capacity update unit 1402 and optimizes the production schedule 1414 using the production schedule calculation unit 1403. Alternatively, the integrated system 2301 may acquire the production capacity 1413 using the production capacity update unit 1402, and the integrated system 2301 may optimize the production schedule 1414 using the production schedule calculation unit 1403.

[0141] As described above, this embodiment contributes to standardization of on-site improvement work and reduction of man-hours because it does not require the on-site knowledge and man-hours required for planning improvement measures. In addition, by performing analysis and rescheduling based on real-time performance information, it becomes possible to realize schedule optimization that takes into account worker capabilities and process plans.

[0142] The present invention is not limited to the above-described embodiments, and includes various modifications and equivalent configurations within the spirit and scope of the appended claims. For example, the above-described embodiments have been described in detail to clearly explain the present invention, and the present invention is not necessarily limited to configurations including all of the described configurations. Furthermore, part of the configuration of one embodiment may be replaced with the configuration of another embodiment. Furthermore, the configuration of another embodiment may be added to the configuration of one embodiment. Furthermore, part of the configuration of each embodiment may be added to, deleted from, or replaced with other configurations.

[0143] Furthermore, the aforementioned configurations, functions, processing units, processing means, etc. may be realized in part or in whole in hardware, for example by designing them as integrated circuits, or may be realized in software by having a processor interpret and execute a program that realizes each function.

[0144] Information such as programs, tables, files, etc. that realize each function can be stored in storage devices such as memory, hard disks, SSDs (Solid State Drives), or recording media such as IC (Integrated Circuit) cards, SD cards, and DVDs (Digital Versatile Discs).

[0145] In addition, the control lines and information lines shown are those that are considered necessary for the explanation, and do not necessarily show all the control lines and information lines that are necessary for implementation. In reality, it can be considered that almost all components are interconnected. [Explanation of symbols]

[0146] 100 Production Management System 101 Core System 102 Loss Analysis System 103 Manufacturing Execution System 104 Planning System 105 Manufacturing equipment 106 Surveillance Camera 111 Production Planning 112 Worker Shifts 200 calculator 201 processor 202 Storage Devices 302 items 304 units produced 401 Person in Charge 503 Loss Analysis Definition Table 511 Work detection unit 512 Collection Department 513 Loss Analysis Department 1102 Work Recording Department 1401 Worker-Caused Loss Analysis Department 1402 Production capacity update section 1403 Production schedule calculation section

Claims

1. A planning system comprising a processor for executing a program and a storage device for storing the program, The aforementioned memory device stores the production plan, worker shifts, and production capacity. The aforementioned production plan specifies the first item and the number of products to be produced for the first item, The aforementioned worker shift specifies the workers and the working hours for each worker. The aforementioned production capacity specifies the setup time required when the worker is in charge of producing the first item. The aforementioned processor, An acquisition process for acquiring the production plan, the worker shifts, and the production capacity, Based on the production plan, worker shifts, and production capacity obtained through the acquisition process, an optimization process is performed to optimize the production schedule, including the first item, the workers performing the work within the specified time, and the production quantity, so as to minimize the setup time for the specified production quantity. An output process that outputs the production schedule optimized by the aforementioned optimization process, A planning system characterized by its execution.

2. A planning system according to claim 1, The aforementioned production capacity is determined by specifying the setup time for each process. In the optimization process, the processor optimizes the production schedule, including the first item, the worker, and the production quantity, for each process so that the setup time for the production quantity is minimized for each process. In the output processing, the processor outputs the production schedule for each process. A planning system characterized by the following features.

3. A planning system according to claim 1, The aforementioned production plan specifies the equipment for producing the first product item, The aforementioned production capacity specifies the setup time when the worker is responsible for producing the first item using the aforementioned equipment. In the optimization process, the processor optimizes the production schedule, including the first item, the equipment, the workers performing the tasks within the specified time, and the production quantity, so as to minimize the setup time for the specified number of production units. A planning system characterized by the following features.

4. A planning system according to claim 3, The aforementioned processor, A specific process to identify whether or not setup occurs during the work of the first item, based on whether or not the worker is performing the work and the operating status of the equipment, A calculation process is performed to calculate the production capacity based on the actual setup time required for the aforementioned setup work, A planning system characterized by its execution.

5. A planning system according to claim 4, The aforementioned processor, A display process that generates and displays a graph showing the occurrence or non-occurrence of the aforementioned setup work in chronological order, The system performs an input process that accepts input of an estimated time for improvement to improve the aforementioned actual setup work time, In the calculation process described above, the processor calculates the production capacity based on the actual setup time and the estimated improvement time. A planning system characterized by the following features.

6. A planning system according to claim 5, The aforementioned processor, The detection process is executed to detect abnormalities in the aforementioned worker. In the display process, the processor displays information indicating the worker's abnormality at the time the worker's abnormality is detected by the detection process. A planning system characterized by the following features.

7. A planning system according to claim 6, In the aforementioned display process, the processor performs a playback process that plays a video showing the abnormality of the worker, A planning system characterized by its execution.

8. A planning system according to claim 1, The aforementioned setup time is the production setup time required when repeatedly producing the first item. A planning system characterized by the following features.

9. A planning system according to claim 1, The aforementioned setup time is the time required for the switching setup when switching from the first item to the second item. In the optimization process, the processor optimizes the production schedule, including the first item, the second item, the workers performing the tasks within the time frame, and the production quantity, based on the production plan, the worker shifts, and the production capacity, so as to minimize the setup time for the number of units produced. A planning system characterized by the following features.

10. A planning system according to claim 1, The setup time is the sum of the production setup time required when repeatedly producing the first item and the switching setup time required when switching from the first item to the second item. In the optimization process, the processor optimizes the production schedule, including the first item, the second item, the workers performing the tasks within the time frame, and the production quantity, based on the production plan, the worker shifts, and the production capacity, so as to minimize the setup time for the number of units produced. A planning system characterized by the following features.

11. A production management system in which a first system and a second system are connected in a manner that enables communication, The first system is accessible to a production plan and worker shifts, the production plan specifies a first item and the number of products of the first item to be produced, and the worker shifts specify workers and the working hours for each worker. The second system is An acquisition process is performed to acquire the production capacity that specifies the setup time required when the worker is in charge of producing the first item. The first system is An optimization process that optimizes a production schedule, including the first item, the workers performing the tasks within the specified time, and the production quantity, based on the production plan, the worker shifts, and the production capacity, so as to minimize the setup time for the specified production quantity. An output process that outputs the production schedule optimized by the aforementioned optimization process, A production management system characterized by its execution.

12. A planning method performed by a planning system having a processor for executing a program and a storage device for storing the program, The aforementioned memory device stores the production plan, worker shifts, and production capacity. The aforementioned production plan specifies the first item and the number of products to be produced for the first item, The aforementioned worker shift specifies the workers and the working hours for each worker. The aforementioned production capacity specifies the setup time required when the worker is in charge of producing the first item. The aforementioned processor, An acquisition process for acquiring the production plan, the worker shifts, and the production capacity, Based on the production plan, worker shifts, and production capacity obtained through the acquisition process, an optimization process is performed to optimize the production schedule, including the first item, the workers performing the work within the specified time, and the production quantity, so as to minimize the setup time for the specified production quantity. An output process that outputs the production schedule optimized by the aforementioned optimization process, A planning method characterized by the execution of the following:

13. A planning program that causes a processor to execute planning, The processor has access to a memory device that stores production plans, worker shifts, and production capacity. The aforementioned production plan specifies the first item and the number of products to be produced for the first item, The aforementioned worker shift specifies the workers and the working hours for each worker. The aforementioned production capacity specifies the setup time required when the worker is in charge of producing the first item. The aforementioned processor, An acquisition process for acquiring the production plan, the worker shifts, and the production capacity, Based on the production plan, worker shifts, and production capacity obtained through the acquisition process, an optimization process is performed to optimize the production schedule, including the first item, the workers performing the work within the specified time, and the production quantity, so as to minimize the setup time for the specified production quantity. An output process that outputs the production schedule optimized by the aforementioned optimization process, A planning program characterized by its ability to execute [a specific action].

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