Production plan generation system and production plan generation method

Abstract

Regardless of who is responsible for the planning, it can generate an optimal production plan tailored to the production environment, and it can also flexibly and quickly respond to changes in production conditions, enabling improvements to the production plan. [Solution] This production plan generation system 10 includes a data collection unit 11 that collects production performance data D1 relating to the production performance of multiple types of products and equipment operation data D2 relating to the operating status of multiple production facilities 15; a production capacity master calculation unit 12 that calculates a production capacity master O1 indicating the production capacity of each production facility 15 for various products based on the production performance data D1, equipment operation data D2, and required production quantity data D3 relating to the required production quantity of various products for a predetermined period; a production allocation calculation unit 13 that calculates the production allocation O2 of various products to the production facilities 15 based on the production capacity master O1 and the required production quantity data D3; and a production sequence calculation unit 14 that calculates the production sequence O4 of two or more products from multiple types of products that are allocated to each production facility 15.

Description

Technical Field

[0001] The present invention relates to a production plan generation system and a production plan generation method.

Background Art

[0002] Conventionally, as a production plan generation system, there is known a system that refers to information such as the component configuration, lead time for each production item, and production capacity of equipment, takes order information and inventory information as input, and outputs a production plan such as a daily plan or a weekly plan (see, for example, Patent Document 1).

[0003] In addition, in this type of production plan generation system, information on the equipment for producing each product and the production capacity (production time, production volume) of the product by the equipment are input in advance as production master data, and by referring to these production master data, it is possible to generate production plans for various products (see, for example, Patent Document 2).

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Patent Document 2

Summary of the Invention

Problems to be Solved by the Invention

[0005] On the other hand, in the conventional production plan generation system, as described above, it was necessary for an operator to input information on production capacity (production master data) in advance. In this case, since the input information is set based on the knowledge, experience, and know-how of the operator, there was a problem that the inputters (setters) were limited. Also, with such an input mode, it was difficult to flexibly and quickly change the production plan according to changes in the actual production site situation.

[0006] In light of the above circumstances, this specification aims to address the technical challenge of generating an optimal production plan tailored to the production environment, regardless of who is responsible for its creation, and improving the production plan in a flexible and rapid manner in response to changes in production conditions. [Means for solving the problem]

[0007] The aforementioned problem is solved by the production plan generation system according to the present invention. Specifically, this system is characterized by comprising: a data collection unit that collects production performance data relating to the production performance of multiple types of products and equipment operation data relating to the operating status of multiple production facilities; a production capacity master calculation unit that calculates a production capacity master indicating the production capacity of each production facility for various products based on the production performance data, equipment operation data, and required production quantity data relating to the required production quantity of various products for a predetermined period; a production allocation calculation unit that calculates the production allocation of various products to production facilities based on the production capacity master and required production quantity data; and a production sequence calculation unit that calculates the production sequence of two or more products among multiple types of products that are allocated to each production facility.

[0008] As described above, the production plan generation system according to the present invention includes a data collection unit that collects data on the production performance of multiple types of products to be produced (production performance data) and data on the operating status of multiple production facilities capable of producing those products (equipment operation data). It also includes a production capacity master calculation unit that calculates master data (production capacity master) indicating the production capacity of each production facility for various products based on the collected data and data on the required production volume of various products for a predetermined period (required production volume data). By configuring the production plan generation system in this way, production performance data and equipment operation data can be collected automatically, and the production capacity master can be calculated automatically based on the collected data. Therefore, it becomes possible for any person to formulate an appropriate production plan, regardless of their level of knowledge or experience. Furthermore, since the production capacity master calculation unit can calculate a production capacity master that reflects the production performance data and equipment operation data that fluctuate and are updated daily, it becomes possible to generate appropriate production allocations and, consequently, appropriate production plans that reflect the actual situation on the production floor.

[0009] Furthermore, in the production plan generation system according to the present invention, the production capacity master calculation unit may be configured to select a number of recommended production facilities with high priority as allocation destinations for each type of product from among a number of production facilities based on the calculated production capacity master, and the production allocation calculation unit may be configured to allocate each type of product to the corresponding recommended production facility.

[0010] By selecting multiple recommended production facilities that have a high priority as allocation destinations for each type of product—in other words, preferred as allocation destinations—it becomes possible to allocate production to production facilities more easily and appropriately.

[0011] Furthermore, in the production plan generation system according to the present invention, the production capacity master calculation unit may be configured to update the production capacity master based on the latest production performance data and equipment operation data, and the production allocation calculation unit may be configured to calculate the allocation of various products to production equipment based on the updated production capacity master.

[0012] By configuring the system in this way, even after the production capacity master has been calculated, it is possible to update the master to reflect the latest production results and equipment operating status. Therefore, by calculating the production allocation to production equipment based on this updated production capacity master, it becomes possible to continuously improve the production plan.

[0013] Furthermore, the aforementioned problems can also be solved by the production plan generation method according to the present invention. Specifically, this method is characterized by comprising: a data collection step of collecting production performance data relating to the production performance of multiple types of products and equipment operation data relating to the operating status of multiple production facilities; a production capacity master calculation step of calculating a production capacity master indicating the production capacity of each production facility for various products by executing a first program based on the production performance data, equipment operation data, and required production quantity data relating to the required production quantity of various products for a predetermined period; a production allocation calculation step of calculating the production allocation of various products to production facilities by executing a second program based on the production capacity master and required production quantity data; and a production sequence calculation step of calculating the production sequence of two or more products among multiple types of products that have been allocated to each production facility.

[0014] The production plan generation method according to the present invention, like the production plan generation system according to the present invention, can automatically collect production performance data and equipment operation data, and can automatically calculate a production capacity master based on the collected data. Therefore, it becomes possible for any person to formulate an appropriate production plan, regardless of their level of knowledge or experience. Furthermore, in this production capacity master calculation process, a production capacity master that reflects the production performance data and equipment operation data that fluctuate and are updated daily can be calculated, making it possible to generate an appropriate production allocation and, consequently, an appropriate production plan that reflects the actual situation on the production floor. [Effects of the Invention]

[0015] As described above, according to the present invention, it is possible to generate an optimal production plan according to the production environment, regardless of who is planning it, and to flexibly and quickly respond to changes in production conditions to improve the production plan. [Brief explanation of the drawing]

[0016] [Figure 1] This is a conceptual diagram showing the overall configuration of a production plan generation system according to one embodiment of the present invention. [Figure 2] The flowchart for the production plan generation method using the system shown in Figure 1 is shown below. [Figure 3] This flowchart shows the flow of a production plan generation method according to another embodiment of the present invention. [Modes for carrying out the invention]

[0017] One embodiment of the present invention will be described below with reference to the drawings.

[0018] Figure 1 shows the overall configuration of the production plan generation system 10 according to this embodiment. As shown in Figure 1, the system 10 mainly comprises a data collection unit 11, a production capacity master calculation unit 12, a production allocation calculation unit 13, and a production sequence calculation unit 14.

[0019] The data collection unit 11 is configured to collect production performance data D1 relating to the production performance of multiple types of products to be produced, and equipment operation data D2 relating to the operating status of multiple production facilities 15 capable of producing the above-mentioned multiple types of products.

[0020] In this embodiment, the data collection unit 11 is communicably connected to the daily report system 16, and can transfer data D1 regarding the production results of various products in a unit period (for example, the number actually produced by each production facility 15 in the most recent one day) input to the daily report system 16 for each unit period. Further, in this embodiment, the data collection unit 11 is communicably connected to the operation information collection system 17. The operation information collection system 17 is communicably connected to at least a plurality of production facilities 15 targeted by this system 10, and can transfer data D2 regarding the operation information of these plurality of production facilities 15 (for example, the operation time, operation rate, availability, equipment utilization rate, time required for setup, etc. of each production facility 15 in the most recent one day). The transfer of these data D1 and D2 is automatically performed based on a periodic request of the data collection unit 11. The transferred data D1 and D2 are stored and accumulated in the data collection unit 11. That is, the production result data D1 and the equipment operation data D2 are automatically collected by the data collection unit 11.

[0021] [ Based on the production result data D1, the equipment operation data D2, and the required production volume data D3 regarding the required production volume of various products in a predetermined period (for example, one year), the production capacity master calculation unit 12 is configured to be able to calculate (output) a production capacity master O1 indicating the production capacity of each production facility 15 for various products.

[0022] The production capacity master O1 mentioned here is data regarding the production capacity possessed by each production facility 15, and includes data related to the quantity that can produce various products to be produced in a predetermined period. Further, the quantity that can be produced here includes not only the number but also the quantity in lot units.

[0023] Furthermore, in this embodiment, the production capacity master calculation unit 12 is configured to select (output) a plurality of recommended production facilities O11 with high priority as production allocation destinations for each type of product from among a plurality of production facilities 15 that are subject to allocation. The priority as a production allocation destination, as referred to here, means the level at which production can be carried out without difficulty for the required period and production quantity, in other words, the degree of surplus production capacity for the requirements of each product. In this case, the production capacity master calculation unit 12 calculates a production capacity master O1 for each production facility 15 and also calculates recommended production facilities O11 for each product with a production request.

[0024] The production capacity master calculation unit 12 includes software, which is a program for obtaining predetermined outputs (production capacity master O1, recommended production equipment O11) from predetermined inputs (production performance data D1, equipment operation data D2, required production volume data D3), and hardware capable of executing the processing performed by the software.

[0025] The production allocation calculation unit 13 is configured to calculate the production allocation O2 to the production equipment 15 for various products based on the production capacity master O1 calculated by the production capacity master calculation unit 12 and the required production volume data D3.

[0026] In this embodiment, the production allocation calculation unit 13 is configured to calculate the production allocation O2 for various products to the production equipment 15, as well as the target production quantity (short-term target production quantity O3) for the most recent short-term unit period (e.g., one month) for each product. Furthermore, as in this embodiment, when recommended production equipment O11 is calculated for each product, the production allocation calculation unit 13 is configured to select (output) the production equipment 15 to be allocated from the recommended production equipment O11 for each product, based on the recommended production equipment O11 and the required production quantity data D3.

[0027] The production allocation calculation unit 13 includes software, which is a program for obtaining a predetermined output (production allocation O2, or production allocation O2 and short-term target production quantity O3) from predetermined inputs (required production quantity data D3 and production capacity master O1), and hardware capable of executing the processing performed by the software. In this case, the allocation is calculated, for example, in such a way that the bias in production efficiency (operating time, operating efficiency, equipment utilization rate, etc.) among multiple production facilities 15 is minimized. Alternatively, the allocation is calculated in such a way that the time required for setup (changeover) is minimized. In the latter case, similar products may be allocated to the same production facility 15.

[0028] Furthermore, the above software may include a machine learning algorithm for optimization. In this case, the algorithm uses the above-mentioned required production volume data D3 and production capacity master O1 as training data to generate an optimization model for production allocation O2, or an optimization model for production allocation O2 and short-term target production volume O3.

[0029] The production sequence calculation unit 14 is configured to calculate the production sequence O4 of two or more products assigned to each production equipment 15 from among multiple types of products. In this case, the production sequence calculation unit 14 has software, which is a program for obtaining a predetermined output (the production sequence O4 of two or more products at each production equipment 15) from a predetermined input (production allocation O2, or production allocation O2 and short-term target production quantity O3), and hardware capable of executing the processing by said software. In this case, the calculation of the production sequence O4 is performed, for example, in a way that minimizes the time required for setup (changeover). In the latter case, the products of the same type are arranged in a sequence in which they are produced consecutively.

[0030] Furthermore, the above software may include a machine learning algorithm for optimization. In this case, the algorithm generates an optimization model for the production sequence O4 using the production allocation O2 (or production allocation O2 and short-term target production quantity O3) described above as training data.

[0031] Next, an example of a production plan generation method using the production plan generation system 10 with the above configuration will be explained, mainly based on Figure 2.

[0032] As shown in Figure 2, the production plan generation method according to this embodiment comprises a data collection step S1, a production capacity master calculation step S2, a production allocation calculation step S3, and a production sequence calculation step S4.

[0033] (S1) Data acquisition process In this process S1, the data collection unit 11 shown in Figure 1 is used to collect production performance data D1 and equipment operation data D2 for a predetermined period in the past (for example, 1 to several months). Here, it is not considered whether the production during the predetermined period in the past was carried out based on a production plan generated by the production plan generation system 10 or the production plan generation method according to the present invention.

[0034] (S2) Production capacity master calculation process In step S2, the production capacity master calculation unit 12 calculates (outputs) a production capacity master O1 indicating the production capacity of each production equipment 15 for various products, based on the production performance data D1, equipment operation data D2, and required production quantity data D3 related to the required production quantity of various products for a predetermined period (e.g., one year) collected by the data collection unit 11. In this embodiment, the production capacity master calculation unit 12 calculates (outputs) the production capacity master O1 and recommended production equipment O11. This output process is automatically executed when the required amount of production performance data D1, equipment operation data D2, and required production quantity data D3 is input.

[0035] (S3) Production allocation calculation process In step S3, the production allocation calculation unit 13 calculates the production allocation O2 for each product to the production equipment 15 based on the production capacity master O1 calculated by the production capacity master calculation unit 12 and the required production volume data D3. In this embodiment, the production allocation calculation unit 13 calculates the short-term target production volume O3 for each product along with the production allocation O2 for each product to the production equipment 15 in a unit period. Furthermore, if the recommended production equipment O11 is calculated in the production capacity master calculation step S2, the production equipment 15 to be allocated O2 is selected (output) from the recommended production equipment O11 for each product based on the recommended production equipment O11 and the required production volume data D3.

[0036] (S4) Production sequence calculation process SL9T-F7T2ST-C9CL In step S4, the production sequence calculation unit 14 is used to calculate the production sequence O4 for two or more products from among multiple product types that are assigned to each production equipment 15. This determines the assignment O2 to the production equipment 15 and the production sequence for that production equipment 15 within a unit period for each type of product to be produced. In other words, a production plan for a unit period is automatically generated for all multiple types of products to be produced.

[0037] Therefore, in this case, for example, based on the production plan for the unit period generated in the above-described steps S1 to S4, steps S1 to S4 are performed again before the production of multiple types of products is completed (step S5 in Figure 2). This automatically generates the production plan for the next unit period.

[0038] In this way, a production plan is generated for each unit period, and production based on that plan is repeatedly carried out, thereby enabling the production of multiple types of products based on the production plan for a predetermined period (see process S6 in Figure 2).

[0039] The timing for starting processes S1-S4 to generate the next production plan for a given unit period can be set until production based on the current production plan for the ongoing unit period is completed. For example, processes S1-S4 for generating the next production plan for a given unit period can be executed when the unit period has elapsed since the latest (most recent) production plan was generated.

[0040] As described above, the production plan generation system 10 according to this embodiment is equipped with a data collection unit 11 that collects production performance data D1, which is data on the production performance of multiple types of products to be produced, and equipment operation data D2, which is data on the operating status of multiple production facilities 15 capable of producing the products. It is also equipped with a production capacity master calculation unit 12 that calculates master data (production capacity master O1) indicating the production capacity of each production facility 15 for various products based on the collected data D1 and D2 and required production quantity data D3, which is data on the required production quantity of various products for a predetermined period. By configuring the production plan generation system 10 in this way, production performance data D1 and equipment operation data D2 can be collected automatically, and the production capacity master O1 can be calculated automatically based on the collected data D1 and D2. Therefore, it becomes possible for any person to formulate an appropriate production plan, regardless of the amount of knowledge or experience they have. Furthermore, this production capacity master calculation unit 12 can calculate a production capacity master O1 that reflects the daily fluctuating and updated production performance data D1 and equipment operation data D2, making it possible to generate appropriate production allocations and, consequently, appropriate production plans that reflect the actual situation on the production floor.

[0041] Furthermore, in the production plan generation method according to this embodiment, in the production capacity master calculation step S2, based on the calculated production capacity master O1, multiple recommended production facilities O11 with high priority as allocation destinations for each type of product are selected (calculated) from among multiple production facilities 15, and in the production allocation calculation step S3, each type of product is allocated to the corresponding recommended production facility O11. By selecting multiple recommended production facilities O11 with high priority as allocation destinations for each type of product, in other words, preferred as allocation destination candidates, it becomes possible to allocate production to the production facilities 15 more easily and appropriately.

[0042] Although one embodiment of the present invention has been described above, the production plan generation system and production plan generation method described above can take other forms as long as they remain within the scope of the present invention.

[0043] For example, in the above embodiment, when producing multiple types of products based on a production plan for a unit period generated in the above-described steps S1 to S4, the production allocation O2, short-term target production quantity O3, and production sequence O4 calculated when the production plan was generated are fixed during the unit period. However, this is by no means limited to this, and for example, these calculated data may be modified to more appropriate values ​​when carrying out production based on the production plan for the unit period.

[0044] Figure 3 is a flowchart showing the flow of a production plan generation method according to one example (another embodiment of the present invention). As shown in Figure 3, steps S1 to S4 for generating a new production plan for a unit period are the same as in the embodiment shown in Figure 2, but the steps after generation differ between the two.

[0045] In other words, in the generation method according to this embodiment, after starting production of various products based on the generated production plan, the data collection unit 11 periodically collects production performance data D1 and equipment operation data D2, and if it is deemed necessary based on the collected data D1 and D2, the production capacity master calculation unit 12 updates part or all of the production capacity master O1 (see steps S7 and S8 in Figure 3). When the production capacity master O1 is updated, the production allocation calculation unit 13 recalculates the production allocation O2 and the short-term target production quantity O3 based on the updated production capacity master O1, and the production sequence calculation unit 14 recalculates the production sequence O4 based on the recalculated production allocation O2 (see steps S9 and S10 in Figure 3, respectively).

[0046] Alternatively, even if updating the production capacity master O1 is not necessary, if the production status and the operating status of production equipment 15, such as stagnation in the upstream process due to a shortage of parts or cessation of the downstream process due to a line malfunction, are grasped in real time through production performance data D1 and equipment operation data D2, and if it is determined that correction is necessary considering the above situation, the production allocation calculation unit 13 recalculates the production allocation O2 (see processes S11 and S9 in Figure 3). Alternatively, if it is determined that correction is necessary considering the above situation, the production sequence calculation unit 14 recalculates the production sequence O4 for the specified production equipment 15 (see processes S12 and S10 in Figure 3).

[0047] When the production plan is modified in this way, for example, the day following the modification date is set as the start date of production based on the modified production plan, and production of various products is carried out based on the modified production plan for a unit period from that start date (see process S10 in Figure 3). Therefore, according to the production plan generation method of this embodiment, it is possible to carry out production while modifying the production plan to reflect the latest production status and equipment operating status to the optimal content. [Explanation of Symbols]

[0048] 10 Production planning system 11 Data Collection Unit 12 Production Capacity Master Calculation Unit 13 Calculation Section 14 Production sequence calculation unit 15 Production Equipment 16 Daily Report System 17. Operational Information Collection System D1 Production Performance Data D2 Equipment Operation Data D3 Required Production Volume Data O1 Production Capacity Master O11 Recommended Production Equipment O2 production allocation O3 Short-Term Production Target O4 Production Sequence

Claims

1. A data collection unit that collects production performance data related to the production performance of multiple types of products and equipment operation data related to the operating status of multiple production facilities, A production capacity master calculation unit calculates a production capacity master indicating the production capacity of each production facility for each of the aforementioned products, based on the aforementioned production performance data, the aforementioned equipment operation data, and the aforementioned required production quantity data relating to the required production quantity of each of the aforementioned products for a predetermined period. A production allocation calculation unit calculates the allocation of production of the various products to the production equipment based on the production capacity master and the required production volume data. A production sequence calculation unit that calculates the production sequence of two or more of the aforementioned products that are assigned to each production facility from among the aforementioned multiple types of products, A production plan generation system equipped with this system.

2. The production capacity master calculation unit selects a plurality of recommended production facilities with high priority as allocation destinations for each of the various products from among the plurality of production facilities based on the calculated production capacity master, and the production allocation calculation unit allocates the various products to the corresponding recommended production facilities, as described in claim 1.

3. The production capacity master calculation unit updates the production capacity master based on the latest production performance data and equipment operation data, and the production allocation calculation unit calculates the allocation of the various products to the production equipment based on the updated production capacity master, according to claim 1, for the production plan generation system.

4. A data collection process that collects production performance data related to the production performance of multiple types of products and equipment operation data related to the operating status of multiple production facilities, A production capacity master calculation step calculates a production capacity master indicating the production capacity of each production facility for each of the aforementioned products by executing a first program based on the aforementioned production performance data, the aforementioned equipment operation data, and the aforementioned required production quantity data relating to the required production quantities of each of the aforementioned products for a predetermined period. A production allocation calculation process, which calculates the allocation of production of the various products to the production equipment by executing a second program based on the production capacity master and the required production volume data, A production sequence calculation step that calculates the production sequence of two or more products from among the multiple types of products that are assigned to each production facility, A production plan generation method equipped with a production plan.

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