Management device, management system, and management method

Abstract

Appropriately manage the margins of systems with multiple processes, taking into account various changes in circumstances. [Solution] The management device of the present invention identifies savings points that require savings between processes from a series of processes leading up to the shipment of a product, divides the series of processes into multiple sub-processes based on the identified savings points, sets the sub-processes that are chronologically later than the savings points as subsequent processes, and sets the sub-processes chronologically earlier than the savings points as previous processes, accepts a shipping plan including a target value for the product's shipping volume and shipping time, calculates the input and output required by the subsequent process based on the response capacity of the subsequent process, the response capacity of the previous process, and the shipping plan, then calculates the input and output required by the previous process, calculates the savings amount at the savings points between the subsequent process and the previous process based on the calculated input required by the subsequent process and the output required by the previous process, and outputs the calculated result.

Description

[Technical Field]

[0001] The present invention relates to a management device, a management system, and a management method for managing a system having a plurality of processes. [Background technology]

[0002] In production systems or logistics / transportation systems that consist of multiple processes, it is common to have some form of "slack" to ensure smooth coordination between each process. In recent years, attention has been focused on "asset-light management," which minimizes owned assets, and there is a need to reduce this "slack" as much as possible.

[0003] Patent Document 1 describes a technology for reducing "slack." This publication states that "the process control device includes an event information management unit that checks the occurrence status of an event in a subsequent process that affects the production capacity of the subsequent process, which is the subsequent process of two adjacent processes, and a conveyance amount adjustment unit that adjusts the allocation of intermediate products produced in the previous process, which is the previous process of the two adjacent processes, to each worker, based on personal data indicating the production capacity for each event occurrence status of each worker working in the subsequent process and the confirmation results by the event information management unit." [Prior art documents] [Patent documents]

[0004] [Patent Document 1] International Publication No. 2020 / 225995 Summary of the Invention [Problem to be solved by the invention]

[0005] However, Patent Document 1 does not disclose how to deal with bottlenecks that are not caused by worker variability, making it difficult to deal with variability in the number of product shipments. The bottlenecks referred to here include, for example, busy periods in a logistics warehouse, or problems caused by machine breakdowns, as described below. Therefore, the present invention aims to appropriately manage the slack in a system with multiple processes, taking into account various changes in the situation. [Means for solving the problem]

[0006] The management device of the present invention is characterized by comprising: an identification unit that identifies savings points between processes that require savings from a series of processes up to the shipment of a product; a division unit that divides the series of processes into a plurality of sub-processes based on the identified savings points; a setting unit that sets, between the divided sub-processes, a sub-process that is chronologically after the savings point as a subsequent process and a sub-process that is chronologically before the savings point as a previous process; an input processing unit that accepts a shipping plan including a target value and shipping time for the product; a calculation unit that calculates the input and output required by the subsequent process based on the response capacity of the subsequent process, the response capacity of the previous process and the shipping plan, and then calculates the input and output required by the previous process, and calculates the savings amount at the savings point between the subsequent process and the previous process based on the calculated input required by the subsequent process and the output required by the previous process; and an output processing unit that outputs the results calculated by the calculation unit. Other means will be described in the detailed description of the invention. [Effects of the Invention]

[0007] According to the present invention, the margin of a system having a plurality of processes can be appropriately managed in consideration of various changes in circumstances. [Brief explanation of the drawings]

[0008] [Figure 1] FIG. 1 is a diagram illustrating a manufacturing and transportation system. [Figure 2A] FIG. 10 is a diagram illustrating margins in a plurality of processes. [Figure 2B] FIG. 10 is a diagram illustrating margins in a plurality of processes. [Figure 2C] FIG. 10 is a diagram illustrating margins in a plurality of processes. [Figure 3A] FIG. 10 is a diagram illustrating margins in a plurality of processes. [Figure 3B] FIG. 10 is a diagram illustrating margins in a plurality of processes. [Figure 3C] FIG. 10 is a diagram illustrating margins in a plurality of processes. [Figure 4] FIG. 2 is a configuration diagram of a management device. [Figure 5A] FIG. 10 is a diagram illustrating a combination of a previous process, a storage location, and a subsequent process. [Figure 5B] FIG. 10 is a diagram illustrating a combination of a previous process, a storage location, and a subsequent process. [Figure 6A] FIG. 1 is a diagram illustrating the dynamic characteristics of a process. [Figure 6B] FIG. 1 is a diagram illustrating the dynamic characteristics of a process. [Figure 6C] FIG. 1 is a diagram illustrating the dynamic characteristics of a process. [Figure 7] 1 is a flowchart of a processing apparatus when the dynamic characteristics of each process do not change in a single sequence. [Figure 8] FIG. 10 is a diagram illustrating details of processing by a calculation unit. [Figure 9A] FIG. 10 is a diagram illustrating a change in the dynamic characteristics of a process. [Figure 9B] FIG. 10 is a diagram illustrating a change in the dynamic characteristics of a process. [Figure 10] FIG. 10 is a diagram illustrating a method for changing the dynamic characteristics of a process. [Figure 11A] FIG. 2 is a diagram illustrating a charging system as a management target of a management device. [Figure 11B] FIG. 2 is a diagram illustrating a charging system as a management target of a management device. [Figure 11C] FIG. 2 is a diagram illustrating a charging system as a management target of a management device. [Figure 12] FIG. 1 is a diagram illustrating n sequences in parallel. [Figure 13]10A and 10B are diagrams illustrating details of processing by a calculation unit that takes into account capacity adjustment of each process. [Figure 14] 10 is a flowchart of the management device when the dynamic characteristics of each process change. [Figure 15] FIG. 10 is a diagram illustrating an example in which two sequences share a saving location. [Figure 16] FIG. 10 is a diagram illustrating an example in which two sequences share a saving location. [Figure 17] FIG. 10 is a diagram illustrating details of processing by a calculation unit to which an inter-process surplus management unit has been added. DETAILED DESCRIPTION OF THE INVENTION

[0009] An embodiment of a management device of the present invention will be described below with reference to the drawings. The management device manages a system that undergoes multiple processes to produce a final output, manages the processing capacity of each process, and determines instructions to devices that control the output of each process. Note that the management device of the present invention does not necessarily have to be installed at the site of the managed object; for example, results calculated on the cloud may be transmitted to the site.

[0010] (Embodiment 1) The first embodiment is an example in which the management device 1 manages a manufacturing and transport system that connects the inside and outside of a factory and manufactures and transports products.

[0011] (Manufacturing and transport system configuration) FIG. 1 is a diagram illustrating the manufacturing and transportation system 3. The manufacturing and transportation system 3 is composed of a manufacturing system 3a and a transportation system 3b. The manufacturing system 3a is composed of three sub-processes: a parts manufacturing process 201 for manufacturing parts, a parts shelf 202 for temporarily storing parts, and a finished product manufacturing process 203 for manufacturing finished products using parts. The transportation system 3b is composed of five sub-processes: a finished product shelf 204 for temporarily storing manufactured finished products, and a shipping process 205 for shipping finished products outside the factory. Hereinafter, for convenience of explanation, a series of processes consisting of multiple processes may be referred to as a "sequence."

[0012] (Margins in multiple processes) Figures 2A, 2B, and 2C are diagrams that explain slack in multiple processes. For example, consider a manufacturing system that produces a finished product by combining two parts, part A and part B, as shown in Figure 2A. In the finished product manufacturing process, one unit of each of part A and part B is required to produce the finished product. In such a manufacturing system, if a problem occurs in the part B manufacturing process, as shown in Figure 2B, part B will not be available for the finished product manufacturing process, and production will halt. To avoid this situation, as shown in Figure 2C, a shelf is prepared after the part A manufacturing process and part B manufacturing process, but before the finished product manufacturing process. By storing parts on the shelf, production of the finished product can continue even if a problem occurs in the part manufacturing process. The parts stored on this shelf correspond to the "slack."

[0013] Figures 3A, 3B, and 3C are also diagrams that explain the slack in multiple processes. The conveying system shown in Figure 3A has loading and unloading processes. Conveying equipment such as forklifts is used to carry out these processes. Conveying systems that transport general cargo must transport large volumes of cargo during short-term peak periods, such as mid-year gift sales and Christmas. Therefore, in order to transport cargo smoothly, multiple conveying equipment must be used, as shown in Figure 3B. On the other hand, as shown in Figure 3C, during off-peak periods, the volume of cargo decreases, potentially allowing for the use of only one conveying equipment. However, if only one conveying equipment is owned during off-peak periods, it will not be able to handle the volume during peak periods. For this reason, it is desirable to own a number of conveying equipment in anticipation of peak periods. The conveying equipment unused during off-peak periods corresponds to "slack."

[0014] Although not shown, as an example of a transport system, a large number of transport robots, ranging from tens to hundreds, are used in an automated logistics warehouse. The number of these robots is determined to correspond to the maximum volume of goods being transported, or to the number that will not impede normal operations even if a particular robot breaks down, and it is rare that all of the robots are used at the same time. In other words, a large number of robots are left unused and waiting as "surplus."

[0015] Note that while the above examples concern "margins" related to the number of specific objects, "margins" are not necessarily integer values. For example, a buffer tank used to stabilize air pressure by supplementing the compressed air output from an air compressor is an example of "margin." Also, a capacitor used to efficiently balance the power generated by a generator with the power used by a prime mover is a type of "margin." The air volume and power mentioned above are real numbers, not integers.

[0016] "Slack" is essential for responding to changes in circumstances, but it does not directly contribute to the creation of economic value in manufacturing, transportation, etc. In other words, "slack" is considered to be surplus assets during normal operations when no problems are occurring. In recent years, attention has been focused on "asset-light management," which minimizes assets held, and there is a desire to reduce "slack" as much as possible.

[0017] (Configuration of management device) FIG. 4 is a configuration diagram of the management device 1. The management device 1 is a general-purpose computer (such as a personal computer or a server). The management device 1 includes a central control unit 11, an input device 12 such as a mouse or keyboard, an output device 13 such as a display, a main memory device 14, an auxiliary memory device 15, and a communication device 16. The storage processing unit 21, the identification unit 22, the division unit 23, the setting unit 24, the input processing unit 25, the calculation unit 26, the system control unit 27, and the output processing unit 28, which are stored in the main memory device 14, are programs. In the following description, when an operating entity is described as "XX unit," this means that the central control unit 11 reads each program from the auxiliary memory device 15 to the main memory device 14 and executes the processing previously described in each program. The management device 1 may be configured as a single unit as shown in FIG. 4, or may be configured as multiple units.

[0018] In addition to the management device 1, there is a manufacturing / transportation system 3 (see Figure 1) and other systems 4. The manufacturing / transportation system 3 and other systems 4 each correspond to a "managed system" that is managed by the management device 1. An example of the other system 4 is a charging system, which will be described later. The management device 1 and the managed system constitute a management system. The management device 1 is connected to the manufacturing / transportation system 3 and other systems 4 via a network 2. The management device 1 receives target values ​​and the like related to the operation of the manufacturing / transportation system 3 and other systems 4 from them. The management device 1 transmits control signals and the like related to the operation of the manufacturing / transportation system 3 and other systems 4.

[0019] The storage processing unit 21 records a series of processes of the manufacturing and transport system 3 in the auxiliary storage device 15. The "series of processes" is a concept that includes all the processes that make up the manufacturing and transport system 3, as well as some of the consecutive processes. In this embodiment, the series of processes is from the parts manufacturing process 201 to the shipping 205. The identification unit 22 identifies a location in the series of processes where storage is required, that is, a storage location. The identification unit 22 may automatically identify the storage location, or may accept a storage location specified by an administrator. In this embodiment, the parts shelf 202 and the finished product shelf 204 are storage locations. Furthermore, if there are multiple conveyance devices to be used for shipment 205 and there is unused conveyance device, the location where the unused conveyance device is stored is also a storage location.

[0020] The dividing unit 23 divides a series of processes into a plurality of sub-processes based on the storage locations identified by the identifying unit 22. In this embodiment, the part manufacturing process 201, the finished product manufacturing process 203, and the shipping 205 have already been divided into sub-processes. The setting unit 24 defines the preceding process and the following process using the storage location as the starting point. With the parts shelf 202 as the storage location, the parts manufacturing process 201 that precedes it in the chronological order is the preceding process, and the finished product manufacturing process 203 that follows it in the chronological order is the following process. Also, with the finished product shelf 204 as the storage location, the finished product manufacturing process 203 that precedes it in the chronological order is the preceding process, and shipping 205 that follows it in the chronological order is the following process. In this way, a preceding process in one division may become a following process in another division.

[0021] The input processing unit 25 receives a shipping plan from the manufacturing and transportation system 3 via the network 2. The shipping plan includes a target value for the shipping quantity and shipping time of the required products. The shipping plan is determined by the administrator who operates the manufacturing and transportation system 3. A typical process performed by the calculation unit 26 is as follows (details will be described later). The calculation unit 26 calculates the input and output required by the subsequent process based on the response capacity of the subsequent process, the response capacity of the previous process, and the shipping plan, and then calculates the input and output required by the previous process. The "response capacity" here refers to the output capacity of each process based on the input to each process, and is expressed as a function of input and output by Equation 1, which will be described later. The calculation unit 26 calculates the amount of savings in the savings location between the subsequent process and the preceding process based on the calculated input required by the subsequent process and the calculated output required by the preceding process.

[0022] The system control unit 27 outputs the calculation result of the calculation unit 26 to the manufacturing and transport system 3. More generally, the system control unit 27 may perform arbitrary control of the equipment for each process by outputting various signals to the manufacturing and transport system 3. For example, adjustment of the number of parts manufactured in the part manufacturing process 201 and adjustment of the number of finished products manufactured in the finished product manufacturing process 203 correspond to this control. Such adjustments can be made by changing instructions to the control device of the manufacturing and transport system 3. The output processing unit 28 outputs the calculation result of the calculation unit 26 to a GUI (Graphical User Interface) such as the output device 13 of the management device 1, or to the auxiliary storage device 15. The output processing unit 28 may output not only the storage amounts on the parts shelf 202 and the finished product shelf 204, but also the number of unused transportation equipment in shipment 205.

[0023] (Combination of pre-process, storage area and post-process) 5A and 5B are diagrams explaining combinations of a pre-process, a saving point, and a post-process. As in FIG. 5A, one combination of a pre-process, a saving point, and a post-process can be expressed as a block diagram in which a process (P: Process) is placed before and after a buffer (B: Buffer). When there are multiple saving points, saving points and processes are added sequentially in the latter stages, as in FIG. 5B.

[0024] (Calculation section processing) Hereinafter, the processing executed by the calculation unit 26 will be explained using Equations 1 to 6. Each process can be expressed as a mathematical model such as Equation 1, in which an output y is output when an input u is applied. This mathematical model has dynamic characteristics and corresponds to the "response capability" mentioned above. The subscript i in Equation 1 corresponds to the subscript of process P. The k in Equation 1 means the time (processing step) for each control cycle.

[0025]

number

[0026] For example, in the case of a manufacturing system, dynamic characteristics express the time response from when a manufacturing order is received until the finished product is produced. In the case of a manufacturing system, input and output are integer values ​​(e.g., units). In the case of systems that handle processes such as chemical plants and power plants, input and output are real numbers other than integers, such as concentration (%) or power (w).

[0027] The input processing unit 25 accepts input of the shipping plan via the input device 12. The shipping plan here includes target values ​​for the shipping amounts (including the numbers) of products required at at least N+1 times during the period from time k (the current time) to time k+N. The shipping plan may also include shipping amounts of products required at each time before and after the period. The target value at time k is given by r[k]. In the following calculations, attention is focused only on the target value r from time k to time k+N.

[0028] The calculation unit 26 calculates the control input u2[k] that minimizes the evaluation function J2 of Equation 2 so that the output y2[k] matches the target value r[k] as closely as possible at each time k in the finished product manufacturing process P2. Q2 and R2 in Equation 2 are weighting matrices and adjustment parameters.

[0029]

number

[0030] Equation 2 is a general formulation of model predictive control (MPC). The calculation unit 26 uses the MPC to calculate the required input u2[k] at each time k. Note that a general MPC calculates a time-series input U2={u2[k], ..., u2[k+N]}, which is time-series data of the input u2[k], and uses only the first step of the time series, i.e., u2[k]. However, the calculation unit 26 of this embodiment effectively utilizes inputs up to N steps ahead. Note that the time-series input U2 is the result of an optimization calculation, and therefore may be called an "optimal control time-series input," but for simplicity, it will be referred to as a "time-series input" hereinafter. The same applies to the time-series input U1, which will be described later.

[0031] Based on the relationship between the subsequent process and the previous process, calculation unit 26 may set the minimum number of parts to be stored in storage location B12 to be equal to or greater than U2. To satisfy this condition, the evaluation function of Equation 3 and the constraint of Equation 4 are prepared.

[0032]

number

[0033] Equation 3 means that the output y1[k] of the previous process P1 is made as close as possible to the value obtained by adding the surplus δu2[k] to the input u2[k] of the next process.

[0034]

number

[0035] Equation 4 means that the surplus δu2[k] is a positive value, which means that there is no shortage of input required to execute the subsequent process P2 at each time point k.

[0036] MPC can calculate control inputs that minimize an evaluation function under constraint conditions. Therefore, the calculation unit 26 can use the MPC framework to calculate the time-series input U1={u1[k], ..., u1[k+N]}, which is the time-series data of the input u1[k] of the previous process P1.

[0037] As described above, the calculation unit 26 can use MPC to create a plan to manufacture the necessary products in the final process while minimizing the surplus δu2. However, to perform the above calculation, the constraint condition of Equation 5 must be satisfied.

[0038]

number

[0039] 5a in Equation 5 expresses that the target value r of the product at each time k is the maximum value y of the output y2 of the subsequent process P2. 2maxThis means that it will not exceed . 5b in Equation 5 indicates that the input u2 required by the subsequent process is the maximum value y of the output y1 of the previous process P1. 1max This means that it will not exceed . The constraints 5a and 5b in Equation 5 relate to the rated output of the manufacturing and transport system 3. For example, if a manufacturing and transport system 3 has an upper limit of 10 units per hour, and is required to produce 20 units per hour, the requirement cannot be met. 5a and 5b in Equation 5 are intended to avoid designs that cannot be realized in this way.

[0040] 5c in Equation 5 means that the time series change in the target value (r[t+1]-r[t]) does not exceed the time series change in the output of the subsequent process P2 (y2[t+1]-y2[t]). 5d in Equation 5 means that the time series change in the input required by the subsequent process P2 (u2[t+1]-u2[t]) does not exceed the time series change in the output of the previous process (y1[t+1]-y1[t]). The constraints 5c and 5d in Equation 5 relate to the dynamic characteristics of the manufacturing and transportation system 3.

[0041] (Dynamic characteristics) 6A, 6B, and 6C are diagrams illustrating the dynamic characteristics of the process. The dynamic characteristics are the time when the output of each process is equal to the rated output y max As shown in Figure 6A, it takes time for the output to reach the rated output y max The output of a typical manufacturing / transport system 3 remains below the rated output until time ts, at which point the temperature reaches 1000°C. In particular, in processes requiring heat treatment, chemical reactions, etc., the value of ts is large.

[0042] If only the rated output, as in 5a and 5b of Equation 5, is considered without taking such dynamic characteristics into account, a plan that cannot be realized due to the dynamic characteristics will be calculated, and an accumulated error corresponding to the hatched area in Figure 6B may occur. As shown in Figure 6C, even when reducing the output to the target value yr from time te, the dynamic characteristics have an effect, and the output does not change immediately. For this reason, absolute values ​​(||) are used in 5c and 5d of Equation 5.

[0043] When the dynamic characteristics of each process do not change, the storage processing unit 21 records the dynamic characteristics in advance, and the calculation unit 26 uses the dynamic characteristics as constraint conditions in the optimization calculation. When Formula 5 is used as a constraint condition, the optimization problem for the subsequent process P2 is summarized as Formula 6. The calculation unit 26 calculates U2 that minimizes J2 using the three formulas after "subject to" as constraint conditions.

[0044]

number

[0045] Similarly, the optimization problem for the front-end process P1 is summarized as in Equation 7. The calculation unit 26 calculates U1 that minimizes J1 using the six equations after "subject to" as constraints.

[0046]

number

[0047] (Flowchart when the dynamic characteristics of each process do not change in a single sequence) 7 is a flowchart of a processing system when the dynamic characteristics of each process in a single sequence do not change. In the following explanation, "Step SXXX" refers to the order of information processing in the flowchart, and is a different concept from the "processing step" as a time for each control cycle described above. In step S000, the input processing unit 25 determines whether or not the administrator has input that the initial settings have been completed via the input device 12. If the initial settings have been completed (YES), the input processing unit 25 proceeds to step S005, and if the initial settings have not been completed (NO), the input processing unit 25 proceeds to step S001.

[0048] In step S001, the storage processing unit 21 reads information about a series of steps stored as the contents of the initial settings from the auxiliary storage device 15. The storage processing unit 21 may also receive this information from the input device 12. In step S002, the identification unit 22 identifies the saving location based on the information read in step S001. In step S003, the dividing unit 23 divides the series of steps into sub-steps based on the saving locations identified in step S002. In step S004, the setting unit 24 sets a previous process and a subsequent process based on the division process in step S003 and with the saving location identified in step S002 as the starting point.

[0049] The above-described processing from step S001 to step S004 is repeatedly executed every time the processes of the manufacturing and transport system 3 are rearranged. "Process rearrangement" means changing the order of multiple processes belonging to a certain sequence, or the merging and branching points. In step S005, the input processing unit 25 reads the shipment plan that was input to the input device 12 and stored in the auxiliary storage device 15. The shipment plan is time-series data. Therefore, if there is time-series data from the current time to a time sufficiently in the future, the input processing unit 25 does not need to additionally read the shipment plan.

[0050] In step S006, the calculation unit 26 determines whether the shipping plan is feasible. Specifically, the calculation unit 26 determines whether the target value r is smaller than the rated output y 2max That is, the calculation unit 26 determines whether 5a of the mathematical expression 5 is satisfied. In step S007, the calculation unit 26 branches the process depending on the result of the determination in step S006. The calculation unit 26 determines whether the shipping plan is feasible, that is, whether the target value r is smaller than the rated output y 2max If the target value r is less than or equal to the rated output y of the subsequent process (YES), the calculation unit 26 proceeds to step S008.2max If it is not equal to or less than this (NO), the process proceeds to step S013.

[0051] In step S008, the calculation unit 26 uses the target value r to calculate a time-series input U2 required in a subsequent process according to Equation 2. In step S009, the calculation unit 26 calculates the time series input U1 required in the previous process according to Equations 3 and 4, using the time series input U2 of the subsequent process calculated in step S008.

[0052] In step S010, the calculation unit 26 determines whether the subsequent process and the preceding process are executable for U2 and U1 calculated in steps S008 and S009, respectively. Specifically, the calculation unit 26 checks whether 5b to 5d of Formula 5 are true. If the subsequent process and the preceding process are executable (YES), that is, if 5b to 5d of Formula 5 are true, the calculation unit 26 proceeds to step S011. On the other hand, if the subsequent process and the preceding process are not executable (NO), the calculation unit 26 proceeds to step S013.

[0053] In the above, the calculation unit 26 determines whether the constraint conditions are satisfied after minimizing the evaluation function. However, the calculation unit 26 may minimize the evaluation function under the constraint conditions by following Equation 6 in step S008 and Equation 7 in step S009. In this case, the calculation unit 26 does not go through step S010 "NO".

[0054] In step S011, the system control unit 27 outputs the calculation result of the calculation unit 26 to the managed system. That is, the system control unit 27 transmits the time-series input U1, the time-series input U2, and the storage amount as control signals to the manufacturing / transportation system 3, etc. In step S012, the output processing unit 28 outputs the calculation result of the calculation unit 26 to the output device 13. That is, the output processing unit 28 displays the time series input U1, the time series input U2, and the savings amount to the manager.

[0055] Step S013 is a process performed when it is determined in step S007 or step S010 that execution is impossible. Even when it is determined that execution is impossible, if there is a surplus in the savings location, it is possible to temporarily continue output, or to output less than the plan. Therefore, in step S013, the output processing unit 28 notifies the manager in advance via the output device 13 that, as a result of such a situation occurring, for example, a change will occur in the amount saved in the savings location.

[0056] In step S014, if the input processing unit 25 receives an operation from the administrator to continue operation of the manufacturing / transportation system 3 (YES), it proceeds to step S011, and if it receives an operation to not continue operation (NO), it proceeds to step S012.

[0057] 8 is a diagram for explaining details of the processing by the calculation unit 26. The calculation unit 26 is made up of a post-process capacity management unit 601, a post-process planning unit 602, a pre-process capacity management unit 603, and a pre-process planning unit 604.

[0058] The downstream process capacity management unit 601 calculates the time series target values ​​R={r[k], r[k+1], ..., r[k+N]} to be output in the downstream process from the current time k to N steps ahead based on the time series target value r obtained from the input processing unit 25. The downstream process capacity management unit 601 calculates the time series target values ​​R by multiplying the maximum value y of the output of the downstream process P2 by the time series target values ​​R. 2max By comparing the maximum output of the subsequent process with the target value, the subsequent process capability management unit 601 determines whether the maximum output of the subsequent process is equal to or greater than the target value. Furthermore, by determining whether 5c of Equation 5 is satisfied, the subsequent process capability management unit 601 determines whether the capability of the subsequent process corresponding to the time-series change in output is equal to or greater than the time-series change in the target value. If the maximum output of the subsequent process is not equal to or greater than the target value, or if the capability of the subsequent process corresponding to the time-series change in output is not equal to or greater than the time-series change in the target value, the subsequent process capability management unit 601 notifies the output processing unit 28 of this fact. The output processing unit 28 displays this fact to the manager via the output device 13. Note that R here is unrelated to R1 and R2 (weighting matrices) on the right-hand sides of Equation 2 and Equation 3.

[0059] The subsequent process planning unit 602 plans a time-series input U2 of a subsequent process for the time-series target value R. At this time, the subsequent process planning unit 602 plans at least one of the input quantity and the input time as U2. Furthermore, the subsequent process planning unit 602 transmits the first step u2[k] of the planned time-series input U2 to the system control unit 27.

[0060] The upstream process capacity management unit 603 calculates the time series input U2 planned by the downstream process planning unit 602 as the maximum value y of the output of the upstream process P1. 1max By comparing the maximum output of the previous process with the input planned by the next process planning unit 602, the previous process capacity management unit 603 determines whether the capacity of the previous process to respond to time-series changes in the output is equal to or greater than the time-series changes in the input planned by the next process planning unit 602 by determining whether 5d of Equation 5 is satisfied. If the maximum output of the previous process is not equal to or greater than the input planned by the next process planning unit 602, or if the capacity of the previous process to respond to time-series changes in the output is not equal to or greater than the time-series changes in the input planned by the next process planning unit 602, the previous process capacity management unit 603 notifies the output processing unit 28 that a change will occur in the amount of storage in the storage location due to this. The output processing unit 28 displays this information to the manager via the output device 13.

[0061] The pre-process planning unit 604 plans a time-series input U1 for the pre-process. At this time, the pre-process planning unit 604 plans at least one of the input quantity and the input time as U1. Furthermore, the pre-process planning unit 604 transmits the first step u1[k] of the planned time series U1 to the system control unit 27.

[0062] Up to this point, it has been assumed that there is a single sequence and that the dynamic characteristics of each process do not change. The present invention can also handle situations where there are two parallel sequences (when there is a parallel sequence in which two (multiple) sequences exist in parallel) and the dynamic characteristics of the process change. In particular, if the dynamic characteristics of the process can be changed at the manager's discretion, the dynamic characteristics of the process can be optimized by changing the calculation procedure of the calculation unit 26.

[0063] (Example 1 of dynamic characteristics change) 9A and 9B are diagrams for explaining changes in the dynamic characteristics of a process. As an example of a process whose dynamic characteristics can be changed, consider the transport process from the parts manufacturing process 201 to the parts shelf 202 in the manufacturing and transport system 3 of FIG. 1. As shown in FIG. 9A, there are two parts manufacturing lines, and a transport process is prepared for each parts manufacturing line. The respective processes are designated as P11 and P12. The transport equipment used in the transport process is the same type of robot.

[0064] In the situation of Figure 9A, since both processes P11 and P21 use five robots each, the transport capacity (≒ rated output) of y 11max and y 21max Both are "5". Robots of the same specifications can easily change their operating locations. Now, as shown in Figure 9B, one robot is moved from process P11 to process P21. Then, the transport capacity y 11max changes to "4" and y 21max changes to "6." In this way, by dynamically adjusting the number of robots in use, it is possible to change the capacity according to the increase or decrease in the production plan for each parts manufacturing line.

[0065] FIG. 10 is a diagram illustrating a method for changing the dynamic characteristics of a process. In FIG. 10, two sequences exist in parallel (parallel sequences). Sequence 1, which constitutes this parallel sequence, uses the transport system in the upper part of FIGS. 9A and 9B. Sequence 2, which constitutes the parallel sequence, uses the transport system in the lower part of FIGS. 9A and 9B. The previous process of Sequence 1 is P11, and the next process is P12. The previous process of Sequence 2 is P21, and the next process is P22. Because it is assumed that a robot will move between the previous processes of the two sequences, bidirectional arrows are drawn between the previous processes P11 and P21.

[0066] To implement an optimal allocation plan for the transport robots, the calculation unit 26 first calculates the time-series input U 11 and U 21 Then, the calculation unit 106 calculates the obtained time series input U 11 and U 21 The output time series Y obtained by applying 11 and Y 21 The output time series Y 11 and Y 21 is the carrying capacity y 11max and y 21max The calculation unit 26 adjusts the number of robots so that the number does not exceed y 11max and y 21max The total value of is a fixed constant, and therefore, calculation results that exceed this value are not permitted. "Without explicitly considering Formula 5" means that some degree of success can be expected even in optimization that does not use Formula 5 as a constraint (Formula 5 is optional).

[0067] The above example is a rearrangement of the number of transport robots, and the rated output y max However, the present invention can also be used to adjust the capacity of a process whose dynamic characteristics can be changed significantly.

[0068] (Example 2 of Dynamic Characteristics Change: Embodiment 2 / Charging System) 11A, 11B, and 11C are diagrams illustrating a charging system to be managed by the management device 1. FIG. 11A shows a charging system for electric vehicles (EVs). The charging system stores electricity generated by a wind power generator 801, a small gas turbine 802, and a solar power generator 803 in capacitors 804 and 805, or transmits the electricity directly to charging stations 806 and 807 to charge the EVs. In the charging system, the capacitors can be considered as storage locations, the power generation process as a pre-process, and the EV charging process as a post-process. Generally, because capacitors deteriorate with repeated charging and discharging, it is desirable to transmit electricity to charging stations without using the capacitors whenever possible. This is similar to the desire to minimize shelf inventory in the manufacturing and transportation system 3 described above.

[0069] The amount of power generated by wind power generation 801 and solar power generation 803 varies greatly depending on the weather. Therefore, to compensate for the shortage of power generation, a small gas turbine 802 is used. In Fig. 11A, there is sufficient wind volume but insufficient sunlight, and the small gas turbine 802 is connected to a battery 805 and a charging station 807.

[0070] On the other hand, in Figure 11B, there is sufficient sunlight but insufficient wind, and the small gas turbine 802 is connected to a battery 804 and a charging station 806. The amount of power generated by the small gas turbine 802 must also be changed appropriately in response to such changes in the situation. However, since the amount of power generated by the small gas turbine 802 changes due to changes in the turbine rotation speed caused by gas combustion, this change will have dynamic characteristics as shown in Figure 6A. For this reason, a capacity adjustment method that takes into account the dynamic characteristics of the small gas turbine 802 is required. Note that, as shown in Figure 11C, the power generated by the small gas turbine 802 may supplement both the wind power generation 801 and the solar power generation 803.

[0071] Figure 10 also corresponds to an example of a charging system. Sequence 1 mainly uses wind power generation. Sequence 2 mainly uses solar power generation. Since it is assumed that the connection destination of the small gas turbine 802 will be changed, bidirectional arrows are drawn between the respective previous processes P11 and P21.

[0072] A method for operating a charging system to which the present invention is applied will be described. First, the calculation unit 26 calculates the time-series input U 12 and U 22 Furthermore, the calculation unit 26 calculates these time series inputs U 12 and U 22 Utilizing this, for the previous process P11 and the previous process P21, the time series input U 11 and U 21 The calculation unit 26 calculates the control input U 11 ~U 22 By solving in the forward direction, each output time series Y 11 ~Y 22 The calculation unit 26 adjusts the connection destination of the small gas turbine so that the output time series obtained here satisfies the limit on the rated output corresponding to 5b in Formula 5 and the limit on the dynamic power generation capacity corresponding to 5d in Formula 5.

[0073] The above explanation is an example of recombination of the upstream steps P11 and P21, but the same applies to the downstream step. Furthermore, in the above explanation, the upstream step and the downstream step are included in two sequences (i.e., both sequences have a storage location), but the scope of application of the present invention is not limited to this.

[0074] 12 is a diagram illustrating n sequences executed in parallel. As shown in FIG. 12, the managed system may be a system in which n sequences (n is an integer) are executed in parallel.

[0075] 13 is a diagram illustrating details of the processing performed by the calculation unit 26 in consideration of capacity adjustment for each process. The calculation unit 26 shown in FIG. 13 is composed of a post-process capacity management unit 601, a post-process planning unit 602, a pre-process capacity management unit 603, a pre-process planning unit 604, a post-process inter-operation management unit 605, and a pre-process inter-operation management unit 606.

[0076] The post-process capability management unit 601 calculates the target value r i Based on this, the time series target value R to be output in the next process from the current time k to N steps ahead is i ={r i [k], r i [k+1], …, r i [k+n]} is calculated. Here, the subscript i=1...n is a number corresponding to the process. Furthermore, the post-process capability management unit 601 calculates the time-series target value R i In the same manner as described above, it is determined whether the capacity of each subsequent process (P12, P22, ..., Pn2) is sufficient for the R. The subsequent process capacity management unit 601 also performs the process described in FIG. i is independent of R1 and R2 (weighting matrices) on the right-hand sides of Equation 2 and Equation 3.

[0077] The post-process inter-operation management unit 605 determines the target value r i By adjusting the surplus or shortage of capacity of each subsequent process, the target value r i Specifically, when the downstream process capacity management unit 601 determines that the maximum output of a downstream process in a specific sequence is not equal to or greater than the target value, or that the capacity of a downstream process in a specific sequence that responds to time-series changes in output is not equal to or greater than the time-series changes in the target value, the downstream inter-process operations management unit 605 determines to provide at least a part of the capacity of a downstream process in another sequence to the downstream process in the specific sequence. In other words, the downstream inter-process operations management unit 605 determines that a downstream process (r <y 2max ) capacity of the subsequent process (r>y 2max) is provided. Regardless of the capacity allocation, the target value r i If the above cannot be realized, the post-process inter-operation control unit 605 notifies the output processing unit 28 of this fact. The output processing unit 28 displays this fact to the manager via the output device 13.

[0078] The subsequent process planning unit 602 plans the time series input U2 of the subsequent process based on the output results of the subsequent process capacity management unit 601 and the subsequent process inter-operation management unit 605. Furthermore, the subsequent process planning unit 602 plans the time series input U2 of the subsequent process based on the calculated time series U i2 The first step of i2 [k] is transmitted to the system control unit 27.

[0079] The upstream process capacity management unit 603 determines whether the capacity of each upstream process (P11, P21, ..., Pn1) is sufficient for the time-series input U2 planned by the downstream process planning unit 602. The upstream process capacity management unit 603 also performs the processing described in FIG.

[0080] The front-end inter-process operations management unit 606 adjusts the surplus or shortage of capacity of each front-end process for the time-series input U2 determined by the front-end process capacity management unit 603, thereby exchanging capacity between each front-end process between different sequences so as to realize the time-series input U2. Specifically, when the front-end process capacity management unit 603 determines that the maximum output of the front-end process in a specific sequence is not equal to or greater than the input planned by the back-end process planning unit 602, or that the capacity of the front-end process in a specific sequence to respond to the time-series change in output is not equal to or greater than the time-series change in input planned by the back-end process planning unit 602, the front-end inter-process operations management unit 606 decides to provide at least a part of the capacity of the front-end process in another sequence to the front-end process in the specific sequence. In other words, the front-end inter-process operations management unit 606 determines that there is surplus capacity (u2) in another sequence. <y 1max ) Part of the capacity of the previous process is insufficient in a specific sequence (u2>y 1max) to the preceding process. If the time-series input U2 cannot be realized no matter what kind of capacity accommodation is performed, the inter-preceding process operations control unit 606 notifies the output processing unit 28 of this fact. The output processing unit 28 displays this fact to the manager via the output device 13.

[0081] The pre-process planning unit 604 plans the time-series input U1 of the pre-process based on the output results of the pre-process capacity management unit 603 and the pre-process inter-operation management unit 606. Furthermore, the pre-process planning unit 604 plans the time-series input U1 of the pre-process based on the calculated time-series input U i1 The first step of i1 [k] is transmitted to the system control unit 27.

[0082] (Flowchart when the dynamic characteristics of each process change) Fig. 14 is a flowchart of the control device when the dynamic characteristics of each process change. The flowchart in Fig. 14 has many similarities to the flowchart in Fig. 7, so only the differences will be explained.

[0083] The initial check in step S100 corresponds to the processing from step S000 to step S005. In step S101, the downstream process capability management unit 601 calculates the time-series target value R i It is determined whether each subsequent process has the capability to carry out the above. In step S102, the downstream process capability management unit 601 branches the process based on the result of the determination in step S101. If the downstream process capability management unit 601 has the capability to execute (YES), the process proceeds to step S103, and if the downstream process capability management unit 601 does not have the capability to execute (NO), the process proceeds to step S104.

[0084] In step S103, the subsequent process planning unit 602 performs operation planning for the subsequent process. This process is similar to step S008. In step S104, the post-process inter-operation management unit 605 determines whether or not the processing of each post-process can be continued by sharing capacity. Here, as described above, the post-process inter-operation management unit 605 determines whether or not part of the capacity of a post-process with surplus capacity can be diverted to the capacity of another post-process with insufficient capacity between different sequences. If the post-process inter-operation management unit 605 determines that the processing of each post-process can be continued by sharing capacity (YES), it proceeds to step S105, and if the processing of all post-processes cannot be continued even by sharing capacity (NO), it proceeds to step S106.

[0085] In step S105, the post-process inter-operation control unit 605 determines to provide the capacity of the post-process Pj2 in which surplus capacity occurs to the post-process Pi2 in which capacity shortage occurs. The processes in steps S106 and S107 are similar to those in steps S013 and S014.

[0086] In step S108, the upstream process capacity management unit 603 calculates the time-series input U i2 The preceding process determines whether it has the capability to carry out the above. The subsequent processing from step S109 to step S113 is the same as the processing from step S102 and step S104 to step S107 related to the post-processing process, and therefore description thereof will be omitted. However, in steps S109, S110, and S111, the "post XX part" in steps S102, S104, and S105 is replaced with "front XX part," and "post process Pi2" and "post process Pj2" are replaced with "front process Pi1" and "front process Pj1," respectively. The processes in steps S114 and S115 are similar to those in steps S011 and S012.

[0087] (Sharing of storage locations) The above explanation is an example in which each sequence has its own dedicated storage location between its pre-process and post-process. However, the present invention is not limited to this configuration, and multiple sequences can share a storage location.

[0088] 15 and 16 are diagrams illustrating an example in which two sequences share a saving location. Specific processing details will be explained below using an example in which two sequences share one saving location B, as shown in FIG. 15. This embodiment can also be extended to a system in which multiple (N) sequences run in parallel, similar to FIG. 12.

[0089] The basic processing contents are the same as those of the previous embodiments in the configuration of Fig. 15. However, in this embodiment, by sharing the saving location, it is possible to avoid the situation where continuation is not possible in step S113 of Fig. 14.

[0090] In Figure 16, time t a From time t a+1 In this case, the control input u of the post-process P12 12 is the rated output y of the previous process P11 11max The excess amount is δu 12 At time t a From time t a+1 In this case, the control input u of the post-process P22 22 is the rated output y of the previous process P21 21max The excess amount is δu 22 If the amount of savings at the saving point B does not change, then at time t a In this case, the outputs of the subsequent processes P12 and P22 are below the expected level because the inputs from the previous processes P11 and P21 are insufficient.

[0091] Therefore, the target value r i The input u of the next process obtained by sequentially calculating i2 is the maximum output y i1max The time t exceeds aIf the pre-process capacity management unit 603 determines that there is a surplus between processes, the inter-process surplus management unit 607 calculates the total excess amount (δu 12 +δu 22 ) and calculate the sum of them at the previous time t a-1 This can be easily achieved by applying the sum of the excess amounts to δu2 in Equation 3 relating to the optimization calculation in the previous step.

[0092] 17 is a diagram illustrating details of the processing by the calculation unit 26 to which an inter-process surplus management unit 607 has been added. In order for the calculation unit 26 to perform the above functions, the inter-process surplus management unit 607 is added to the functional blocks in FIG.

[0093] The front-end process capacity management unit 603 detects a capacity shortage (δu in FIG. 16). 12 and δu 22 ) has occurred, the inter-process surplus management unit 607 modifies the plan to be executed in the preceding process. If a surplus has occurred in a specific sequence, the pre-process inter-process operations management unit 606 compensates for the capacity shortage by adjusting the capacity of each preceding process. If the capacity shortage cannot be compensated for, the inter-process surplus management unit 607 adjusts the predicted shortage δu 12 and δu 22 The plan requested to the pre-process planning unit 604 is changed so that the above-mentioned items can be stored in the storage location in advance.

[0094] When using a shared storage location, the number of preceding processes does not have to match the number of succeeding processes. For example, if there are two succeeding processes and three preceding processes, the inter-process surplus management unit 607 calculates the total value of the inputs of the succeeding processes (U 12 +U 22 ) is the total output value of the previous process (Y 11 +Y 21 +Y 31 ) and adjust your savings accordingly.

[0095] In other words, when the upstream process capacity management unit 603 determines that the maximum output of the upstream process in a specific sequence is not greater than the input planned by the downstream process planning unit 602, or that the capacity of the upstream process in a specific sequence to respond to time-series changes in output is not greater than the time-series changes planned by the downstream process planning unit 602, and when it is not possible to plan the input required by the downstream process even if at least a portion of the capacity of the upstream process in another sequence with surplus capacity is provided to the upstream process in a specific sequence with insufficient capacity, the inter-process surplus management unit 607 calculates the savings amount in the savings location.

[0096] In this case, if the upstream process capacity management unit 603 determines, taking into account the savings calculated by the inter-process surplus management unit 607, that the maximum output of the upstream process in a specific sequence is not greater than the input planned by the subsequent process planning unit 602, or that the capacity of the upstream process in a specific sequence to respond to time-series changes in output is not greater than the time-series changes in input planned by the subsequent process planning unit 602, the upstream inter-process operations management unit 606 decides to provide at least a portion of the capacity of the upstream process in another sequence to the upstream process in the specific sequence. Furthermore, the pre-process planning unit 604 calculates the input required by the pre-process after the decision by the pre-process inter-process operation management unit 606, based on the target value obtained by adding the input planned by the post-process planning unit 602 to the savings amount calculated by the inter-process surplus management unit 607.

[0097] (Effects of the embodiment) According to the first and second embodiments, it is possible to dynamically calculate the capacity that each process should satisfy as the situation changes, and minimize the surplus between processes. For example, it is possible to minimize the inventory of intermediate products between serially linked processes. Furthermore, it is possible to realize asset-light operations by sharing the work capacity (machines, etc.) between parallel processes.

[0098] The present invention is not limited to the above-described embodiments and includes various modifications. 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 those including all of the described configurations. Furthermore, it is possible to replace part of the configuration of one embodiment with the configuration of another embodiment, or to add the configuration of another embodiment to the configuration of one embodiment. Furthermore, it is possible to add, delete, or replace part of the configuration of each embodiment with other configurations.

[0099] Furthermore, the above-mentioned configurations, functions, processing units, processing means, etc. may be partly or entirely implemented in hardware, for example, by designing them as integrated circuits. The above-mentioned configurations, functions, etc. may also be implemented in software, with a processor interpreting and executing a program that implements each function. Information such as the programs, tables, and files that implement each function can be stored in a memory, a recording device such as a hard disk or SSD (Solid State Drive), or a recording medium such as an IC card, SD card, or DVD. 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 in the product. In reality, it can be assumed that almost all components are interconnected. [Explanation of symbols]

[0100] 1 Management device 2 Network 3 Manufacturing and transport systems 3a Manufacturing System 3b Conveyor system 4 Other Systems 11 Central control unit 12 Input Devices 13 Output Devices 14 Main memory 15 Auxiliary storage 16. Communications equipment 21 Memory Processing Unit 22 Specific section 23 Division 24 Setting section 25 Input processing section 26 Calculation section 27 System Control Unit 28 Output Processing Section P1 Pre-process P2 Post-process B12 Savings point

Claims

1. an identifying unit that identifies a saving point between processes that requires saving from a series of processes up to the shipment of a product; a division unit that divides the series of processes into a plurality of sub-processes based on the identified saving location; a setting unit that sets a sub-process that is chronologically subsequent to the storage location as a subsequent process and a sub-process that is chronologically subsequent to the storage location as a previous process among the divided sub-processes; an input processing unit that receives a shipping plan including a target value of the shipping quantity and a shipping time of the product; Calculating the input and output required by the subsequent process based on the response capacity of the subsequent process, the response capacity of the previous process, and the shipping plan, and then calculating the input and output required by the previous process; a calculation unit that calculates a saving amount of the saving location between the subsequent process and the preceding process based on the calculated input required by the subsequent process and the calculated output required by the preceding process; an output processing unit that outputs the result calculated by the calculation unit; A management device comprising:

2. The calculation unit a downstream process capability management unit that determines whether or not the maximum output of the downstream process is equal to or greater than the target value, and determines whether or not the capability of the downstream process to respond to time-series changes in output is equal to or greater than the time-series changes in the target value; a post-process planning unit that plans inputs required by the post-process according to the shipping plan; a front-end process capability management unit that determines whether or not the maximum output of the front-end process is equal to or greater than the input planned by the back-end process planning unit, and determines whether or not the capability of the front-end process to respond to time-series changes in output is equal to or greater than the time-series changes in input planned by the back-end process planning unit; a front-end process planning unit that plans inputs required for the front-end process in accordance with the inputs planned by the back-end process planning unit; The management device according to claim 1 , further comprising:

3. The post-process planning unit The post-process planning unit plans the planned input time, The front-end process planning unit The pre-process planning unit plans the input time; 3. The management device according to claim 2, wherein:

4. When the upstream process capability management unit determines that the maximum output of the upstream process is not equal to or greater than the input planned by the downstream process planning unit, or that the capability of the upstream process to respond to time-series changes in output is not equal to or greater than the time-series changes in input planned by the downstream process planning unit, The output processing unit notifying the user that a change will occur in the amount of savings in the savings location; 3. The management device according to claim 2, wherein:

5. When the preceding process and the succeeding process are included in a plurality of parallel sequences, The calculation unit a downstream process capability management unit that determines whether or not the maximum output of the downstream process is equal to or greater than the target value, and determines whether or not the capability of the downstream process to respond to time-series changes in output is equal to or greater than the time-series changes in the target value; a downstream inter-process operations management unit that determines, when the downstream process capability management unit determines that the maximum output of the downstream process in a specific sequence is not equal to or greater than the target value, or that the capability of the downstream process in a specific sequence to respond to time-series changes in output is not equal to or greater than the time-series changes in the target value, to provide at least a part of the capability of the downstream process in another sequence to the downstream process in the specific sequence; a post-process planning unit that plans inputs required by the post-process according to the shipping plan in the post-process after the decision by the post-process inter-operation management unit; a front-end process capability management unit that determines whether or not the maximum output of the front-end process is equal to or greater than the input planned by the back-end process planning unit, and determines whether or not the capability of the front-end process to respond to time-series changes in output is equal to or greater than the time-series changes in input planned by the back-end process planning unit; an inter-front-end process operations management unit that determines, when the front-end process capacity management unit determines that the maximum output of the front-end process in a specific sequence is not equal to or greater than the input planned by the back-end process planning unit, or that the capacity of the front-end process in a specific sequence to respond to time-series changes in output is not equal to or greater than the time-series changes in input planned by the back-end process planning unit, to provide at least a part of the capacity of the front-end process in another sequence to the front-end process in the specific sequence; a front-end process planning unit that plans an input required for the front-end process in accordance with the input planned by the back-end process planning unit in the front-end process after the determination by the front-end inter-process operations management unit; The management device according to claim 2 , further comprising:

6. When the preceding process and the succeeding process are included in a plurality of parallel sequences, The calculation unit a downstream process capability management unit that determines whether or not the maximum output of the downstream process is equal to or greater than the target value, and determines whether or not the capability of the downstream process to respond to time-series changes in output is equal to or greater than the time-series changes in the target value; a downstream inter-process operations management unit that determines, when the downstream process capability management unit determines that the maximum output of the downstream process in a specific sequence is not equal to or greater than the target value, or that the capability of the downstream process in a specific sequence to respond to time-series changes in output is not equal to or greater than the time-series changes in the target value, to provide at least a part of the capability of the downstream process in another sequence to the downstream process in the specific sequence; a post-process planning unit that plans inputs required by the post-process according to the shipping plan in the post-process after the decision by the post-process inter-operation management unit; a front-end process capability management unit that determines whether or not the maximum output of the front-end process is equal to or greater than the input planned by the back-end process planning unit, and determines whether or not the capability of the front-end process to respond to time-series changes in output is equal to or greater than the time-series changes in input planned by the back-end process planning unit; an inter-process surplus management unit that calculates a savings amount of the saving location when the upstream process capacity management unit determines that the maximum output of the upstream process in a specific sequence is not equal to or greater than the input planned by the downstream process planning unit, or that the capacity of the upstream process in a specific sequence to respond to time-series changes in output is not equal to or greater than the time-series changes in input planned by the downstream process planning unit, and when the input required by the downstream process cannot be planned even if at least a part of the capacity of the upstream process in another sequence is provided to the upstream process in the specific sequence; an inter-process operations management unit that determines, when the front-end process capacity management unit determines, in consideration of the savings calculated by the inter-process surplus management unit, that the maximum output of the front-end process in a specific sequence is not equal to or greater than the input planned by the back-end process planning unit, or that the capacity of the front-end process in a specific sequence to respond to time-series changes in output is not equal to or greater than the time-series changes in input planned by the back-end process planning unit; and a front-end process planning unit that calculates an input required by the front-end process in accordance with a target value obtained by adding the input planned by the back-end process planning unit to the savings amount calculated by the inter-process surplus management unit in the front-end process after the determination by the front-end inter-process operations management unit; The management device according to claim 2 , further comprising:

7. The calculation unit calculating inputs required by the subsequent process and the previous process by model predictive control using only the dynamic characteristics and constraint conditions of the previous process and the subsequent process set by the setting unit and the shipping plan received by the input processing unit from the current time to a predetermined time ahead; The management device according to claim 1 .

8. A management system including a management device and a managed system managed by the management device, The management device an identifying unit that identifies a saving point between processes that requires saving from a series of processes up to the shipment of a product; a division unit that divides the series of processes into a plurality of sub-processes based on the identified saving location; a setting unit that sets a sub-process that is chronologically subsequent to the storage location as a subsequent process and a sub-process that is chronologically subsequent to the storage location as a previous process among the divided sub-processes; an input processing unit that receives a shipping plan including a target value of the shipping quantity and a shipping time of the product; Calculating the input required by the subsequent process based on the response capacity of the subsequent process, the response capacity of the previous process, and the shipping plan, and then calculating the input required by the previous process; a calculation unit that calculates a saving amount of the saving location between the subsequent process and the previous process based on the calculated input required by the subsequent process and the input required by the subsequent process; a system control unit that outputs the result calculated by the calculation unit to the managed system; A management system comprising:

9. The specifying unit of the management device Identify the points in the process that require savings between processes from the series of processes leading up to product shipment, The division unit of the management device Dividing the series of processes into a plurality of sub-processes based on the identified saving points; The setting unit of the management device Among the divided sub-processes, a sub-process that is later than the saving point in time series is set as a subsequent process, and a sub-process that is earlier than the saving point in time series is set as a previous process, The input processing unit of the management device receiving a shipping plan including a target value for the shipping quantity and a shipping time of the product; The calculation unit of the management device Calculating the input required by the subsequent process based on the response capacity of the subsequent process, the response capacity of the previous process, and the shipping plan, and then calculating the input required by the previous process; calculating a storage amount of the storage location between the subsequent process and the previous process based on the calculated input required by the subsequent process and the input required by the previous process; The output processing unit of the management device outputting the result calculated by the calculation unit; A management method characterized by:

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