Production planning device, production planning system, and production planning method

Abstract

To update a process plan, a work plan and a production plan for a production change event in a short time for flexible correspondence of the production change.SOLUTION: A process plan relating to a production process for products, includes: a process plan development section for developing a plurality of process plans including alternative process plans; a work plan development section for developing work plans corresponding to each of the process plans; a production plan development section for developing production plans using the plurality of process plans and the work plans; and a production plan re-planning section for re-planning production plans using the plurality of process plans and the work plans when a production change event occurs.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present invention relates to a production planning device, a production planning system, and a production planning method. [Background technology]

[0002] Patent Document 1, with regard to manufacturing systems, states that "When a replan is instructed by the server in response to a determination that the conditions for implementing the replan have been met, the production control measure replans the production plan using a production simulator and assigns the replanned production plan to each production facility in the factory.This makes it possible to maintain an optimal state without affecting future production plans even if a delay in the plan occurs." [Prior art documents] [Patent documents]

[0003] [Patent Document 1] JP 2020-98541 A Summary of the Invention [Problem to be solved by the invention]

[0004] When a production change event occurs in a factory, such as a product type change based on a productivity analysis or equipment failure, it is necessary to devise measures to solve the problem and update the process plan, work plan, and production plan based on these measures.

[0005] On the other hand, developing such countermeasures and updating production plans requires manual work by the factory's production managers and production engineers based on operation data of the factory's productivity, which means that productivity is hindered during the period in which countermeasures are developed, making it difficult to respond flexibly to production fluctuations.

[0006] Patent Document 1 discloses a technology for re-planning a production plan using a production simulator when a problem occurs. However, in the production system of this document, only the production plan is re-planned, and the process plan and the work plan are not re-planned. In other words, in the production system of Patent Document 1, since a problem is dealt with only by re-planning the production plan without re-planning the process plan and the work plan, the scope of the response is limited, and as a result, problems such as delays in the production plan may occur.

[0007] The present invention has been made in consideration of the above problems, and has an object to quickly update process plans, work plans, and production plans in response to production fluctuation events, thereby flexibly responding to production fluctuations. [Means for solving the problem]

[0008] The present application includes a plurality of means for solving at least part of the above-mentioned problems, examples of which are as follows. A process evaluation unit that calculates a predetermined process evaluation index for each production process of the product; The system comprises: a process plan generating unit that generates a plurality of process plans, including alternative process plans, for process plans relating to a production process of a product; a work plan generating unit that generates a work plan corresponding to each of the process plans; a production plan generating unit that generates a production plan using the plurality of process plans and the work plan; and a production plan re-planning unit that re-plans a production plan using the plurality of process plans and the work plan when a production fluctuation event occurs. The process plan generation unit evaluates the production process for specified attributes based on the process evaluation index, calculates the number of equipment candidates to be allocated to the production process based on the evaluation, and generates multiple process plans based on pairs of the production process and equipment candidates in a number corresponding to the number of equipment candidates. Effect of the Invention

[0009] According to the present invention, process plans, work plans and production plans can be updated in a short time in response to production fluctuation events, making it possible to flexibly respond to production fluctuations. [Brief description of the drawings]

[0010] [Figure 1] 1 is a diagram showing an example of a schematic configuration of a production planning system according to an embodiment of the present invention; [Diagram 2] FIG. 11 is a diagram showing an example of production performance information. [Diagram 3] FIG. 11 is a diagram showing an example of product CAD information. [Figure 4] FIG. 11 is a diagram showing an example of part shape information. [Diagram 5] FIG. 11 is a diagram showing an example of production volume information. [Figure 6] FIG. 2 is a diagram showing an example of factory layout information. [Figure 7] FIG. 1 is a diagram showing an example of a process plan. [Figure 8] FIG. 13 is a diagram showing an example of a work plan. [Figure 9] FIG. 1 is a diagram illustrating an example of a production plan. [Figure 10] FIG. 11 is a flow diagram showing an example of a production planning process. [Figure 11] FIG. 11 is a flow diagram showing an example of a process evaluation process. [Figure 12] FIG. 11 is a flow diagram illustrating an example of a calculation process of the number of alternative processes. [Figure 13] FIG. 1 illustrates an example of a work partial order graph. [Figure 14] FIG. 2 is a diagram illustrating an example of a hardware configuration of a first production planning device. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0011] Hereinafter, an embodiment of the present invention will be described with reference to the drawings.

[0012] 1 is a diagram showing an example of a schematic configuration of a production planning system 1000 according to this embodiment. As shown in the figure, the production planning system 1000 has a first production planning device 100 and a second production planning device 200. The first production planning device 100 and the second production planning device 200 are connected to each other so as to be able to communicate with each other via a network N, such as a public network such as the Internet, a LAN (Local Area Network), or a WAN (Wide Area Network).

[0013] In addition, the first production planning device 100 and the second production planning device 200 are communicatively connected via the network N to an external device 300 that is used to transmit instructions to these devices to execute processing and information used in the processing of each device.

[0014] The first production planning device 100 is a device that creates a production plan for products to be manufactured on a production line in a factory. The first production planning device 100 is realized, for example, by a server device placed in a cloud environment. The second production planning device 200 is a device that issues product manufacturing instructions to each piece of equipment that constitutes the production line of the factory using the production plan acquired from the first production planning device 100. The second production planning device 200 is realized, for example, by a server device placed in an edge environment such as a factory.

[0015] In order to flexibly respond to the occurrence of production fluctuation events, the first production planning device 100 generates in advance a plurality of process plans including alternative process plans and work plans corresponding to each process plan, and uses these to create a production plan. The first production planning device 100 also transmits the production plan, the plurality of process plans including the alternative process plans, and the work plans corresponding to each process plan to the second production planning device 200.

[0016] The second production planning device 200 analyzes whether a production fluctuation event has occurred depending on the factory production line status, and if it determines that the production plan should be re-planned, it re-plans the production plan using the multiple process plans obtained from the first production planning device 100 and their corresponding work plans, and issues manufacturing instructions to each piece of equipment based on the re-planned production plan.

[0017] An example of each functional configuration of the first production planning device 100 and the second production planning device 200 will be described below.

[0018] As shown in FIG. 1, the first production planning device 100 includes a processing unit 110, a storage unit 120, an input unit 130, an output unit 140, and a communication unit 150.

[0019] The processing unit 110 is a functional unit that executes various processes performed in the first production planning device 100. Specifically, the processing unit 110 has a process evaluation unit 111, a process evaluation graph generation unit 112, a process plan generation unit 113, a work plan generation unit 114, and a production plan generation unit 115.

[0020] The process evaluation unit 111 is a functional unit that evaluates the work process of the component parts that make up the target product. Specifically, the process evaluation unit 111 calculates evaluation indexes (process evaluation indexes) of the dimensional variation and work time variation of the component parts (including similar components). In addition, the process evaluation unit 111 calculates the operation rate of the equipment used in the process that handles the component parts (including similar components).

[0021] The process evaluation graph generating unit 112 calculates alternative process number reference values ​​based on evaluation indexes such as dimensional variation, using a graph showing the partial order relationship of the product (hereinafter, sometimes referred to as a "partial order graph"). In addition, the process evaluation graph generating unit 112 generates a process evaluation graph in which the alternative process number reference values ​​are assigned to nodes showing the corresponding components or processes.

[0022] The process plan generating unit 113 is a functional unit that generates a process plan. Specifically, the process plan generating unit 113 calculates the number of alternative processes for the corresponding process based on the alternative process number reference value. In addition, the process plan generating unit 113 generates a process plan (including an alternative process plan) using a set of each process and equipment to which equipment in a number corresponding to the number of alternative processes is assigned.

[0023] The work plan generating unit 114 is a functional unit that generates a work plan corresponding to each of the process plans.

[0024] The production plan generating unit 115 is a functional unit that generates a production plan using a process plan and a work plan.

[0025] The storage unit 120 is a functional unit that stores various information. Specifically, the storage unit 120 has production performance information 121, product CAD (Computer-Aided Design) information 122, part shape information 123, production volume information 124, and factory layout information 125.

[0026] FIG. 2 is a diagram showing an example of the production performance information 121. The production performance information 121 is information related to past production performance. The product ID 121a in the production performance information 121 is information for identifying a product. The part ID 121b is information for identifying a part. The process ID 121c is information for identifying a process. The production resource ID 121d is information for identifying a production resource. The date and time 121e is information indicating the date and time of implementation of a predetermined process, for example, assembling a part of the corresponding part ID 121b, in the production of a product identified by the associated product ID 121a. The start time 121f is information indicating the start time of the process identified by the associated process ID 121c. The end time 121g is information indicating the end time of the process.

[0027] When a process specified by a process ID 121c for an object specified by a product ID 121a and a part ID 121b is completed, information on the object is registered and updated in the production performance information 121.

[0028] 3 is a diagram showing an example of the product CAD information 122. The product CAD information 122 includes information including the partial order relationship of components and other attribute information.

[0029] FIG. 4 is a diagram showing an example of part shape information 123. Part shape information 123 is information on the shapes of components that make up a product. Part ID 123a in part shape information 123 is information for identifying a part. Part name 123b is information indicating the name of the part. Shape characteristics 123c is information indicating the shape characteristics of a part, such as a cylinder, a rectangle, or a column. Width 123d, length 123e, diameter 123f, and weight 123g are information indicating the width, length, diameter, and weight of the part, respectively.

[0030] 5 is a diagram showing an example of the production volume information 124. The production volume information 124 is information on the volume of a product or part to be produced. The product ID 124a in the production volume information 124 is information for identifying a product. Moreover, the monthly production volume 124b is information indicating the production volume of a target product or component part in a specified target period.

[0031] 6 is a diagram showing an example of the factory layout information 125. The factory layout information 125 is information indicating areas (cells) in a factory for arranging equipment, positions of conveyors, and the like.

[0032] Each piece of information in the storage unit 120 does not have to be stored in advance in the storage unit 120, and may be acquired from the external device 300 when the first production planning device 100 executes the process.

[0033] Returning to Fig. 1, the input unit 130 is a functional unit that accepts input of instructions and information from an operator via an input device included in the first production planning device 100. The input unit 130 also accepts input of instructions and information from the second production planning device 200 or the external device 300 via the communication unit 150.

[0034] The output unit 140 is a functional unit that generates display information and displays the display information on a display device (display) provided in the first production planning device 100 or the second production planning device 200 and the external device 300.

[0035] The communication unit 150 is a functional unit that performs information communication with the second production planning device 200 or the external device 300 .

[0036] An example of the functional configuration of the first production planning device 100 has been described above.

[0037] As shown in FIG. 1, the second production planning device 200 includes a processing unit 210, a storage unit 220, an input unit 230, an output unit 240, and a communication unit 250.

[0038] The processing unit 210 is a functional unit that executes various processes performed in the second production planning device 200. Specifically, the processing unit 210 has a manufacturing instruction unit 211, a production plan update time determination unit 212, a production line analysis unit 213, and a production plan re-planning unit 214.

[0039] The production instruction unit 211 is a functional unit that transmits production instructions to each piece of equipment in the factory. Specifically, the production instruction unit 211 executes the production of products by outputting, via the communication unit 250, to each piece of equipment in the factory, operation instructions (production instructions) according to a work plan corresponding to the production plan generated by the first production planning device 100.

[0040] The production plan update time determination unit 212 is a functional unit that determines when to update the production plan. Specifically, the production plan update time determination unit 212 determines whether or not it is time to review the configuration of the production line or to formulate a production plan. Note that information regarding these times may be stored in the storage unit 220 in advance.

[0041] The production line analysis unit 213 is a functional unit that analyzes the status of the production line. Specifically, the production line analysis unit 213 acquires and analyzes information indicating the status of the production line from each piece of equipment in the factory connected via the communication unit 250.

[0042] The production plan re-planning unit 214 is a functional unit that re-plans a production plan. Specifically, the production plan re-planning unit 214 re-plans a production plan using the process plans acquired from the first production planning device 100 and the work plans corresponding to each process plan.

[0043] The storage unit 220 is a functional unit that stores various information. Specifically, the storage unit 220 has a process plan 221 including an alternative process plan acquired from the first production planning device 100, a work plan 222, a production plan 223, and production performance information 224.

[0044] 7 is a diagram showing an example of a process plan 221. Information related to a manufacturing process of a product is registered in the process plan 221. Note that a product ID 221a in the process plan is information for identifying a target product. A process ID 221b is information for identifying a process. A production resource ID 221c is information for identifying a production resource.

[0045] 8 is a diagram showing an example of the work plan 222. Information indicating the work content to be performed in each process is registered in the work plan 222. Note that the work ID 222a of the work plan 222 is information for identifying the work, and is information linked to each process ID 221b of the process plan 221. The work plan ID 222b is information for identifying the work plan, and an ID indicating the content of the work plan (e.g., assembly work, etc.) is registered. The work time 222c is information indicating the work time when equipment (production resource) assigned to the process identified by the work ID 222a performs the work content identified by the work plan ID 222b.

[0046] It is assumed that the work plan ID 222b is associated with a robot program for implementing the work content to be performed in each process and is stored in the storage unit 120. The robot program is generated in accordance with each process plan based on known technology using predetermined information (not shown) related to the arrangement of the robot in the cell. Specifically, the robot program is generated by the work plan generation unit 114 using information related to the arrangement pattern of the cells in the factory (for example, information having predetermined parameter values ​​such as the position and posture of the robot and the operating speed). It is assumed that the work content corresponding to the work plan ID 222b is registered in advance in the predetermined information (not shown) stored in the storage unit 120.

[0047] FIG. 9 is a diagram showing an example of the production plan 223. Information on the production plan of a product is registered in the production plan 223. The product ID 223a in the production plan is information for identifying a product. The part ID 223b is information for identifying a part. The process ID 223c is information for identifying a process. The production resource ID 223d is information for identifying a production resource. The date and time 223e is information indicating the date and time of a predetermined process, for example, assembling a part of the corresponding part ID 223b, in the production of a product identified by the associated product ID 223a. The scheduled start time 223f is information indicating the scheduled start time of the process identified by the associated process ID 223c. The scheduled end time 223g is information indicating the scheduled end time of the process.

[0048] The production performance information 224 in the memory unit 220 is common information with the production performance information 121 stored in the memory unit 120 of the first production planning device 100, and is updated successively as products are manufactured based on the production plan.

[0049] Moreover, the input unit 230 and the output unit 240 are similar to those in the first production planning device 100, and therefore a detailed description thereof will be omitted.

[0050] The communication unit 250 is a functional unit that performs information communication with the first production planning device 100 or the external device 300 .

[0051] An example of the functional configuration of the second production planning device 200 has been described above.

[0052] [Explanation of operation] 10 is a flow diagram showing an example of the production planning process. As described later, in the production planning process, the first production planning device 100 executes the processes of steps S010 to S050, and the second production planning device 200 executes the processes of steps S060 to S100. The production planning process is started when an instruction to execute the process is received from a user via the input unit 130 in the first production planning device 100, for example.

[0053] When the process starts, the first production planning device 100 acquires various information (step S010). Specifically, the process evaluation unit 111 acquires production performance information 121, product CAD information 122, part shape information 123, production quantity information 124, and factory layout information 125 from the storage unit 120.

[0054] Next, the process evaluation unit 111 calculates an evaluation index for each process based on the past production results (step S020).

[0055] 11 is a flow diagram showing an example of the process evaluation processing corresponding to step S020. When this processing is started, the process evaluation unit 111 repeatedly executes the processing of the following steps S021 to S024 for all components of all products (loop processing 1-1 to 1-2, loop processing 2-1 to 2-2).

[0056] In step S021, the process evaluation unit 111 identifies each component part of the target product and the corresponding process based on the past production results. Specifically, the process evaluation unit 111 identifies each component part of the target product and the corresponding process ID by using the production result information 121.

[0057] If the production record of the target product is not included in the production record information 121, the process evaluation unit 111 identifies parts similar to each component part of the target product and corresponding process IDs. Specifically, the process evaluation unit 111 uses the product CAD information 122 and the part shape information 123 to triangulate the target product, and divides the product into its component parts based on the connection relationships between the meshes and the shape characteristics and sizes of the component parts. The process evaluation unit 111 also identifies the part IDs of parts having the same or similar shape characteristics and size from the part shape information 123, and identifies the process IDs associated with the part IDs from the production record information 121.

[0058] In addition, such processing may be performed using a method similar to the process labeling processing described in Japanese Patent Application No. 2020-144537, for example.

[0059] Next, the process evaluation unit 111 calculates an evaluation index of the dimensional variation of each component part based on the past production results (step S022). Specifically, the process evaluation unit 111 identifies the dimensions of the identified component part during past production using, for example, predetermined information (not shown) in which the component part's part ID and the dimensions are associated and registered. The process evaluation unit 111 also obtains the standard deviation of the dimensional variation, and calculates an evaluation index Cp of the dimensional variation of each component part using the standard deviation of the dimensional variation and constants UTL (upper limit of the dimensional variation tolerance) and LTL (lower limit of the dimensional variation tolerance) according to the following formula (1). Here, σ indicates the standard deviation of the dimensional variation.

[0060]

number

[0061] The process evaluation unit 111 may obtain the average value of the dimensional variation using the above-mentioned predetermined information, and calculate the evaluation index Cpk of the dimensional variation of each component part by the following formula (2): T=(UTL-LTL) / 2, and μ indicates the average value of the dimensional variation.

[0062]

number

[0063] Next, the process evaluation unit 111 calculates an evaluation index for the variation in the work time of each component part from the past production results (step S023). Specifically, the process evaluation unit 111 calculates the work time during past production of the component part based on the difference between the start time and the end time in the production result information 121. The process evaluation unit 111 also obtains the standard deviation of the variation in the work time, and calculates an evaluation index Tp for the variation in the work time of each component part using the standard deviation of the variation in the work time and constants USL (upper tolerance limit of the variation in the work time) and LSL (lower tolerance limit of the variation in the work time) according to the following formula (3). Here, σ indicates the standard deviation of the variation in the work time.

[0064]

number

[0065] The process evaluation unit 111 may obtain the average value of the work time variation using the production performance information 121, and calculate the evaluation index Tpk of the work time variation of each component part by the following formula (4). Note that S=(USL-LSL) / 2, and ε indicates the average value of the work time variation.

[0066]

number

[0067] Next, the process evaluation unit 111 calculates the availability of the equipment allocated to the process that handles each component based on the past production results (step S024). Specifically, the process evaluation unit 111 identifies a record in the production results information 121 in which the component ID and the process ID of the component are associated, and calculates the availability of the equipment allocated to each process based on the difference between the start time and the end time of the record.

[0068] After completing the process of step S024, the process evaluation unit 111 ends this flow.

[0069] Returning to Fig. 10, the first production planning device 100 then calculates the number of alternative processes for each process based on the evaluation index (Step S030).

[0070] 12 is a flow diagram showing an example of the alternative process number calculation process corresponding to step S030. When this process is started, the process evaluation graph generating unit 112 repeatedly executes the following processes of steps S031 to S033 for all products (loop processes 3-1 to 3-2).

[0071] In step S031, the process evaluation graph generating unit 112 uses the product CAD information 122 to generate an operation partial order graph.

[0072] 13 is a diagram showing an example of a task partial order graph. As shown in the figure, the task partial order graph is composed of nodes A1 to A5 indicating components of a product, and arcs indicating assembly relationships, i.e., partial order relationships, between each node. Note that the nodes can also be defined as indicating processes that handle each component. Therefore, in the following description, a component and a process corresponding to such a component may be described as being synonymous.

[0073] Next, the process evaluation graph generating unit 112 generates a process evaluation graph (step S032). Specifically, the process evaluation graph generating unit 112 calculates attribute values ​​of arcs for three attributes, namely, "sum of evaluation indexes of dimensional variations," "sum of evaluation indexes of work time variations," and "sum of equipment operation rates." In addition, the process evaluation graph generating unit 112 clusters arcs whose attribute values ​​are equal to or greater than a predetermined reference value for each attribute.

[0074] First, the process evaluation graph generating unit 112 calculates the attribute value of an arc for the "sum of evaluation indexes of dimensional variation" among the attributes, and clusters arcs whose attribute value is equal to or greater than a reference value. Specifically, the process evaluation graph generating unit 112 assigns an evaluation index of dimensional variation of the corresponding component to each node of the generated operation partial order graph. In addition, the process evaluation graph generating unit 112 calculates the sum of the evaluation indexes assigned to the nodes at both ends, i.e., the sum of the evaluation indexes of dimensional variation of the components at both ends, as the attribute value of the arc between both nodes.

[0075] Furthermore, the process evaluation graph generating unit 112 compares the calculated attribute value of the arc with a predetermined reference value, and clusters the arcs that are equal to or greater than the reference value. As a result, the clustered arcs associate processes (components) that are at both ends of the clustered arc and have a large degree of dimensional variation and are prone to problems, with processes related to those processes that are likely to be affected when a problem occurs.

[0076] In addition, the process evaluation graph generating unit 112 also clusters the arcs for the attributes "sum of evaluation indexes of work time variations" and "sum of equipment operation rates" using a similar method.

[0077] In addition, the process evaluation graph generating unit 112 counts the number of clustered arcs CNi among the arcs connected to node i for each attribute of the arc. Specifically, the process evaluation graph generating unit 112 adds CNi to the nodes connected to the clustered arcs for each attribute of the arc. For example, in the case of the attribute "sum of evaluation indexes of dimensional variation", when arc x and arc y are clustered, the CNi of node A3 is "2" obtained by adding arc x = 1 and arc y = 1. In addition, in the case of the attribute "sum of evaluation indexes of work time variation", when arc x and arc z are clustered, the CNi of node 3 is "2" obtained by adding arc x = 1 and arc z = 1. In addition, in the case of the attribute "sum of equipment operation rate", when arc x, arc y and arc z are clustered, the CNi of node 3 is "3" obtained by adding arc x = 1, arc y = 1 and arc z = 1.

[0078] Furthermore, the process evaluation graph generating unit 112 calculates the sum of the values ​​collected for each attribute, and assigns this to each corresponding node as an alternative process number reference value, thereby generating a process evaluation graph.

[0079] It should be noted that the process evaluation graph generating unit 112 only needs to generate a process evaluation graph using at least one of the attributes of the three arcs, and it is not essential to use all of the three attributes.

[0080] Next, the process plan generating unit 113 repeatedly executes the process of the following step S033 for all the component parts of the product (loop process 4-1 to 4-2).

[0081] In step S033, the process plan generating unit 113 calculates the number of alternative steps for the process corresponding to the node by using the process evaluation graph. Specifically, the process plan generating unit 113 calculates the number of alternative steps for the process corresponding to each node according to the ratio of the magnitude of the alternative step number reference value of each node to the average value of CNi of all nodes.

[0082] The process plan generating unit 113 sets the number of alternative processes to "1" for a node to which an alternative process number reference value less than the average value of CNi of all nodes is assigned. In this case, one piece of equipment is allocated to the process corresponding to the node (because each process has a basic equipment number=1), and no other piece of equipment is allocated as an alternative process.

[0083] For a node to which an alternative process number reference value equal to or greater than the average CNi of all nodes is assigned, the process plan generating unit 113 calculates the number of alternative processes = "2" to "n" according to the ratio of the magnitude of the reference value. In this case, the number of pieces of equipment allocated to the process corresponding to the node is the sum of the basic equipment number = 1 and the calculated number of alternative processes.

[0084] Furthermore, when the process plan generating unit 113 has calculated the number of alternative processes for each process for all components of all products, this flow ends.

[0085] Returning to Fig. 10, the first production planning device 100 then generates a plurality of process plans and corresponding work plans (step S040). Note that the method of generating the process plans and work plans is not particularly limited, but an example is shown below.

[0086] First, the process plan generating unit 113 identifies the part IDs of the component parts corresponding to the process and parts similar thereto from the part shape information 123, and identifies the production resources associated with these part IDs from the production performance information 121.

[0087] In addition, the process plan generation unit 113 sets the identified multiple production resources as candidate production resources for the process, and assigns to the process the production resource candidates whose number corresponds to the total number of alternative processes and the number of basic equipment calculated in step S030 and that have the shorter working time for the process.

[0088] In addition, the process plan generation unit 113 performs similar processing for all component parts in all target products, thereby generating multiple process plans for each product in which candidate production resources are assigned to each process corresponding to each component part in a number corresponding to the number of alternative processes.

[0089] In addition, a method for generating such a process plan may use, for example, the technology described in Patent Application No. 2020-144537.

[0090] In addition, the process plan generating unit 113 generates a work plan in which a work ID linked to the process, a work plan ID indicating the work content, and a work time are associated with each other for each generated process plan. Note that the method of generating a work plan based on a process plan is not particularly limited, and any known technology may be used.

[0091] In addition, as another example of a method for generating a process plan, for example, a technology described in Japanese Patent Application No. 2020-030479 may be used. Specifically, the process plan generating unit 113 generates a plurality of sets of processes and equipment in which a number of pieces of equipment (module groups) corresponding to the calculated total number of alternative processes and basic equipment are assigned to the corresponding processes. In addition, the work plan generating unit 114 estimates the work time based on the arrangement and operation rules of such equipment (module groups) in the cell in the factory layout. In addition, the process plan generating unit 113 identifies a predetermined number of sets of processes and equipment that reduce the work time in the cell, and generates a plurality of process plans that take into account the work sequence of all components in all products. Note that when equipment is assigned to a process, the number of pieces of equipment required in each process is determined accordingly. Therefore, the generated process plan includes the equipment configuration of the production line indicated by the type of equipment used in the production line and the number of pieces of equipment. In addition, the work plan generating unit 114 generates a work plan in which each process included in the process plan is associated with the work time of the equipment in the cell for each generated process plan.

[0092] More specifically, the process plan generating unit 113 extracts a number of pieces of equipment (module group candidates) for each process according to the total number of alternative processes and basic equipment. The work plan generating unit 114 also calculates the work time taking into consideration the arrangement, orientation, and operation rules of each module group candidate in the cell. The process plan generating unit 113 also identifies a predetermined number of module group candidates and arrangement plans that reduce the work time in the cell for each module group candidate. The process plan generating unit 113 also generates multiple process plans in which the identified module group candidates are assigned to the corresponding processes. The work plan generating unit 114 also generates a work plan in which, for each process included in the generated process plan, the corresponding work ID is associated with the work time of the module group used in the process.

[0093] When generating a process plan using this method, the necessary information (e.g., part attribute information, module group specification information, module specification information, module operation pattern information, and layout information) may be stored in advance in the memory unit 120, or may be obtained from the external device 300 via the communication unit 150.

[0094] Next, the production plan generating unit 115 generates a production plan using a plurality of process plans and operation plans, and at the same time optimizes the configuration of the production line (step S050). Specifically, the production plan generating unit 115 generates an optimized production plan, allocates cells to each process, and calculates the number of cells by using the generated process plans 221 and operation plans 222, production quantity information 124, factory layout information 125, etc., for all components of all products, so that the production throughput is maximized and the cost of changing the cell configuration is equal to or less than a reference value, by a metaheuristic method such as MIP (Mixed Integer Programming) Solver or GA (Genetic Algorithm). The cost of changing the cell configuration may be stored in the storage unit 120 in advance.

[0095] In addition, after processing step S050, the production plan generation unit 115 transmits the generated production plan 223, multiple process plans (in this case, including multiple alternative process plans not related to the generated production plan) 221, and work plans 222 corresponding to each process plan 221 to the second production planning device 200 via the communication unit 150.

[0096] Next, the second production planning device 200 executes the production of the product based on the acquired production plan 223 (step S060). Specifically, the production instruction unit 211 executes the production of the product by issuing a production instruction to each piece of equipment in the factory using the work plan 222 corresponding to the production plan 223 via the communication unit 250. More specifically, the production instruction unit 211 updates the operation program of each piece of equipment in the factory using a robot program linked to the work plan 222 corresponding to the production plan 223, thereby manufacturing the product according to the production plan 223.

[0097] Next, the production plan update time determination unit 212 determines whether or not it is time to review the configuration of the production line or to formulate a production plan (step S070).

[0098] Then, when it is determined that either of the times has been reached (Yes in step S070), the production plan update time determination unit 212 returns the process to step S010. In this case, the production plan update time determination unit 212 transmits an instruction request regarding the creation of a production plan to the first production plan device 100 via the communication unit 250. On the other hand, when it is determined that neither of the times has been reached (No in step S070), the production plan update time determination unit 212 shifts the process to step S080.

[0099] In step S080, the production line analysis unit 213 analyzes whether or not a production fluctuation event has occurred based on the production results. Specifically, the production line analysis unit 213 compares the production results information 121, which is successively updated as the product is manufactured, with the production plan 223, and analyzes whether or not there is a delay in the manufacture of the product compared to the production plan 223. In addition, the production line analysis unit 213 analyzes whether or not error information indicating a failure has been output from each piece of equipment via the communication unit 250.

[0100] Next, the production line analysis unit 213 judges whether or not to re-plan the production plan (step S090). Specifically, the production line analysis unit 213 judges to re-plan the production plan when the production results are delayed by a predetermined threshold or more with respect to the production plan 223 or when error information is output from the equipment.

[0101] If it is determined that the production plan is not to be re-planned (No in step S090), the production line analysis unit 213 returns the process to step S060. On the other hand, if it is determined that the production plan is to be re-planned (Yes in step S090), the production line analysis unit 213 transitions the process to step S100.

[0102] In step S100, the production plan replanning unit 214 replans (replans) the production plan using a plurality of process plans 221 acquired from the first production planning device 100 and work plans 222 corresponding to each of the process plans 221.

[0103] Specifically, the production plan re-planning unit 214 uses a plurality of process plans 221 and corresponding work plans 222, production quantity information 124, etc. to re-plan an optimized production plan and allocate cells to each process by a metaheuristic method such as a Mixed Integer Programming (MIP) Solver or a Genetic Algorithm (GA) so as to maximize predetermined KPIs (Key Performance Indicators) related to productivity, such as maximizing production throughput and minimizing delivery delays.

[0104] After completing the process of step S100, the production plan replanning unit 214 returns the process to step S060. In this case, the production instruction unit 211 issues production instructions to each facility based on the robot program linked to the replanned production plan and the corresponding work plan.

[0105] The production planning process according to this embodiment has been described above.

[0106] According to such a production planning system, the process plan, the work plan, and the production plan can be updated in a short time in response to a production fluctuation event, and the production fluctuation can be flexibly handled. In particular, in the production planning system, a first production planning device generates a plurality of process plans including an alternative process plan and a work plan corresponding to each process plan in advance, and when a production fluctuation event occurs in a factory, a production plan is re-created using the plurality of process plans and the work plan, in which a predetermined KPI related to productivity such as production throughput is optimized, and manufacturing instructions are given to each facility based on the corresponding work plan. Therefore, according to the production planning system, it is possible to update the production plan without requiring manpower, and flexible production can be realized in response to production fluctuations.

[0107] In addition, according to the first production planning device, the process evaluation index can be used to quantitatively evaluate the dimensional variations of component parts and the variations in work time, and more alternative processes (equipment allocations) can be created for processes that are prone to problems (e.g., work delays or redoing work) or are easily affected by such problems.

[0108] In addition, the first production planning device quantitatively evaluates equipment operation rates and can create more alternative processes (equipment allocation) for processes that use equipment with high operation rates. This allows processes that use equipment with relatively low operation rates to be created as alternative processes, making it possible to prevent work delays even if a malfunction occurs in equipment with high operation rates.

[0109] Furthermore, according to the production planning system, a first production planning device located in a cloud environment generates multiple process plans including alternative process plans, work plans (including robot programs), and production plans, and when a production change occurs, a second production planning device located in an edge environment such as a factory re-creates the production plan using the alternative process plans and corresponding work plans. Therefore, even if a problem occurs in the cloud environment and the first production planning device cannot be used, the second production planning device in the edge environment can respond to the production change, making it possible to continue manufacturing products.

[0110] In addition, there may be multiple second production planning devices 200, and the first production planning device 100 may simultaneously generate multiple process plans 221 to be transmitted to the multiple second production planning devices 200, corresponding work plans 222, and production plans 223.

[0111] Furthermore, in the production planning system according to the first modified example of the present invention, the second production planning device 200 may have each piece of information in the processing unit and storage unit provided in the first production planning device 100. In this case, instead of the first production planning device 100, the second production planning device 200 in the edge environment may generate a plurality of process plans 221, operation plans 222, and production plans 223, and use the production plan 223 and operation plan 222 to give manufacturing instructions to each piece of equipment, thereby producing products.

[0112] Furthermore, in the production planning system according to the second modified example of the present invention, the first production planning device 100 may have each piece of information in the processing unit and storage unit of the second production planning device 200. In this case, instead of the second production planning device 200, the first production planning device 100 in the cloud environment issues product manufacturing instructions based on the production plan 223 and the operation plan 222 to each piece of equipment connected via the communication unit 150. Furthermore, in response to the occurrence of a production fluctuation event, the first production planning device 100 re-creates a production plan using multiple process plans 221 and operation plans 222.

[0113] Furthermore, the production planning system according to the third modified example of the present invention may be configured so that the first production planning device 100 according to the second modified example and the second production planning device 200 according to the first modified example coexist. That is, the production planning device may be configured so that the same configuration can generate a production plan 223 using a plurality of process plans 221 and operation plans 222, and when a production fluctuation event occurs, re-plan the production plan 223 using an alternative process plan 221 and the corresponding operation plan 222, and coexist in a cloud environment and an edge environment.

[0114] With such a configuration of the second production planning device or the first production planning device, the process plan, operation plan, and production plan can be updated in a short time in response to production fluctuation events, and the production fluctuation can be flexibly dealt with.

[0115] Next, a description will be given of an example of a hardware configuration of the first production planning device 100. Note that the hardware configuration of the second production planning device 200 is similar to that of the first production planning device 100, and therefore a detailed description will be omitted.

[0116] Fig. 14 is a diagram showing an example of a hardware configuration of the first production planning device 100. As shown in the figure, the first production planning device 100 has an input device 410, a display device 420, a processing device 430, a main storage device 440, an auxiliary storage device 450, a communication device 460, and a bus 470 that electrically interconnects these devices.

[0117] The input device 410 is, for example, an input device such as a touch panel, a keyboard, a mouse, etc. The display device 420 is a display device such as a liquid crystal display or an organic display.

[0118] The processing device 430 is, for example, a central processing unit (CPU). The main storage device 440 is a memory device such as a random access memory (RAM) or a read only memory (ROM).

[0119] The auxiliary storage device 450 is a non-volatile storage device capable of storing digital information, such as a so-called hard disk drive, a solid state drive (SSD), or a flash memory.

[0120] The communication device 460 is a wired communication device that performs wired communication via a network N cable, or a wireless communication device that performs wireless communication via an antenna.

[0121] An example of the hardware configuration of the first production planning device 100 has been described above.

[0122] The processing unit 110 of the first production planning device 100 is realized by a program that causes the processing device 430 to perform processing. This program is stored in the main storage device 440 or the auxiliary storage device 450, and is loaded onto the main storage device 440 and executed by the processing device 430 when the program is executed.

[0123] Moreover, the input unit 130 is realized by an input device 410. Moreover, the output unit 140 is realized by a display device 420. Moreover, the storage unit 120 is realized by a main storage device 440, an auxiliary storage device 450, or a combination of these. Moreover, the communication unit 150 is realized by a communication device 460.

[0124] The hardware that realizes each of the processing unit 210, the input unit 230, the output unit 240, the storage unit 220, and the communication unit 250 of the second production planning device 200 is similar to that of the first production planning device 100.

[0125] Furthermore, the above-mentioned configurations, functions, processing units, processing means, etc. of the first production planning device 100 and the second production planning device 200 may be realized in part or in whole by hardware, for example, by designing them as integrated circuits. The above-mentioned configurations and functions may be realized in software by a processor interpreting and executing a program that realizes each function. Information such as the programs, tables, and files that realize each function can be stored in a storage device such as a memory, a hard disk, or an SSD, or in a recording medium such as an IC card, an SD card, or a DVD.

[0126] Furthermore, the present invention is not limited to the above-mentioned embodiment and modified examples, and various modified examples are included within the scope of the same technical idea. For example, the above-mentioned embodiment has been described in detail to explain the present invention in an easy-to-understand manner, and is not necessarily limited to those having all of the configurations described. Furthermore, it is possible to replace a part of the configuration of one embodiment with the configuration of another embodiment, and it is also possible to add the configuration of another embodiment to the configuration of one embodiment. Furthermore, it is possible to add, delete, or replace a part of the configuration of each embodiment with another configuration.

[0127] In addition, in the above explanation, the control lines and information lines are those that are considered necessary for the explanation, and not all control lines and information lines in the product are necessarily shown. In reality, it can be considered that almost all components are connected to each other. [Explanation of symbols]

[0128] 1000 production planning system, 100 first production planning device, 110 processing unit, 111 process evaluation unit, 112 process evaluation graph generation unit, 113 process plan generation unit, 114 work plan generation unit, 115 production plan generation unit, 120 storage unit, 121 production result information, 122 product CAD information, 123 part shape information, 124 production amount information, 125 factory layout information, 130 input unit, 140 output unit, 150 communication unit, 200 second production planning device, 210 processing unit unit, 211... manufacturing instruction unit, 212... production plan update time determination unit, 213... production line analysis unit, 214... production plan re-planning unit, 220... storage unit, 221... process plan, 222... work plan, 223... production plan, 224... production result information, 230... input unit, 240... output unit, 250... communication unit, 300... external device, 410... input device, 420... display device, 430... processing device, 440... main memory device, 450... auxiliary memory device, 460... communication device, 470... bus, N... network

Claims

1. A process evaluation unit that calculates a predetermined process evaluation index for each production process of a product; a process plan generating unit that generates a plurality of process plans, including alternative process plans, for a production process of a product; a work plan generating unit that generates a work plan corresponding to each of the process plans; a production plan generating unit that generates a production plan using the process plans and the operation plans; a production plan re-planning unit that re-plans a production plan using the plurality of process plans and the plurality of operation plans when a production fluctuation event occurs, The process plan generation unit Evaluating the production process for a predetermined attribute based on the process evaluation index, calculating the number of equipment candidates to be allocated to the production process based on the evaluation, and generating a plurality of the process plans based on a combination of the production process and the equipment candidates, the number of which corresponds to the number of the equipment candidates. A production planning device comprising:

2. The production planning device according to claim 1, The process evaluation unit includes: Calculating the process evaluation index regarding the dimensional variation of the component parts corresponding to the production process A production planning device comprising:

3. The production planning device according to claim 1, The process evaluation unit includes: Calculating the process evaluation index regarding the variation in the work time in the production process A production planning device comprising:

4. The production planning device according to claim 1, The process evaluation index is The attribute is an evaluation index for at least one of the following attributes: dimensional variation of components in the product, work time variation, and availability rate of equipment used in a process that handles the components. A production planning device comprising:

5. The production planning device according to claim 1, The system further includes a communication unit that transmits the process plans, the work plans, and the production plans to a predetermined device that outputs a manufacturing instruction to a predetermined facility based on the production plans and the work plans. A production planning device comprising:

6. The production planning device according to claim 5, The predetermined device is A production plan re-planning unit is provided for re-planning a production plan using the process plans and the operation plans when a production fluctuation event occurs. A production planning device comprising:

7. The production planning device according to claim 6, The predetermined device is a production line analysis unit that analyzes a state of the production line by using the production plan and the updated production record; The production plan re-planning unit Based on the analysis results by the production line analysis unit, the necessity of re-planning the production plan is determined. A production planning device comprising:

8. The production planning device according to claim 1, A production line analysis unit that analyzes a status of the production line by using the production plan and the updated production record, The production plan re-planning unit Based on the analysis results by the production line analysis unit, the necessity of re-planning the production plan is determined. A production planning device comprising:

9. A production planning system having a first production planning device and a second production planning device, The first production planning device is A process evaluation unit that calculates a predetermined process evaluation index for each production process of the product; a process plan generating unit that generates a plurality of process plans, including alternative process plans, for a production process of a product; a work plan generating unit that generates a work plan corresponding to each of the process plans; a production plan generating unit that generates a production plan using the process plans and the operation plans; a communication unit that transmits the process plans, the work plan, and the production plan to the second production planning device, The process plan generation unit Evaluating the production process for a predetermined attribute based on the process evaluation index, calculating a number of equipment candidates to be allocated to the production process based on the evaluation, and generating a plurality of process plans based on a combination of the production process and equipment candidates, the number of which corresponds to the number of equipment candidates; The second production planning device, Manufacture a product using the production plan and the operation plan acquired from the first production planning device; When a production fluctuation event occurs, a production plan is re-created using the plurality of process plans and the operation plans. A production planning system comprising:

10. A production planning method performed by a production planning device, The production planning device includes: A process evaluation index calculation step of calculating a predetermined process evaluation index for each production process of the product; A process plan generating step of generating a plurality of process plans including alternative process plans, the process plans being related to a production process of a product; a work plan generating step of generating a work plan corresponding to each of the process plans; a production plan generating step of generating a production plan using the process plans and the operation plans; a production plan re-planning step of re-planning a production plan using the plurality of process plans and the operation plans when a production fluctuation event occurs; In the process plan generation step, The production process is evaluated for a predetermined attribute based on the process evaluation index, the number of equipment candidates to be allocated to the production process is calculated based on the evaluation, and a plurality of process plans are generated based on a combination of the production process and the equipment candidates, the number of which corresponds to the number of the equipment candidates. A production planning method comprising:

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