Production plan optimization system and production plan optimization method

Abstract

To provide an optimized planning supported by in-process inventory and inventory balance at a decoupling point in a parent-child relationship, taking account of various conditions and restrictions in the parent-child relationship between a product and its constituent elements such as semifinished products and / or components.SOLUTION: A production plan optimization system 100 comprises: a memory device 110 that stores task information, linking information indicating whether a task is linked to a parent or a child and its parent-child relationship, priority information of the task, DP inventory balance information indicating the inventory balance at a decoupling point where the child is stored as a task in process, and KPI information that is an objective function for optimizing a production plan; and a processor 150 that creates the production plan by giving an optimization engine 132 at least the task information, the linking information, the priority information, the DP inventory balance information, the KPI information, and a work schedule necessary for the production plan and resource information.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present invention relates to a production plan optimization system and a production plan optimization method. [Background technology]

[0002] Industrial production is carried out according to production plans that are formulated based on various conditions. Production plans are also classified according to their time span.

[0003] According to the Japanese Industrial Standards (JIS) JIS Z 8141: 2001 (3302), production plans are classified into major schedules, medium schedules, and short schedules. According to this definition, major schedules are long-term production plans that serve as the master for production schedules and determine monthly production volumes. Medium schedules determine production plans by department based on the major schedule. Short schedules determine daily work schedules over even shorter spans.

[0004] Additionally, according to documents such as ANSI / ISA-95.00.01-2010 (IEC 62264-1 Mod) defined by the American National Standards Institute (ANSI), Marcela Vegetti and Gabriela Henning: "ISA-88 Formalization. A Step Towards its Integration with the ISA-95 Standard", Proceedings of the 6th Workshop on Formal Ontologies meet Industry, Rio de Janeiro, Brazil, 22-SEP-2014, production planning is broadly divided into planning and scheduling, and in comparison with the aforementioned JIS Z 8141: 2001 (3302), the former corresponds to large-scale and medium-scale planning, and the latter corresponds to small-scale planning.

[0005] Hereinafter in this specification, the major schedule and the mid-term schedule will be referred to as "planning," and the minor schedule will be referred to as "scheduling."

[0006] In the rest of this specification, parts and modules in a finished product are referred to as children, and the finished product or semi-finished product (a product in the process of being made into a finished product by combining modules) is referred to as a parent.

[0007] In the past, production planning was carried out by creating an optimized plan based on some KPI (Key Performance Indicator). Minimization, etc.

[0008] In this context, a technology has been proposed as a conventional technology for creating a production plan, which determines the production volume for each span for each process design by solving an optimization problem in which a constraint is added regarding the appropriate range of work-in-process inventory in an optimal product mix calculation unit and a variable representing the deviation of work-in-process inventory from the appropriate range is added as a penalty to the evaluation index (see Patent Document 1). The technology refers to the process load unit for each process for each process design calculated by a process load unit calculation unit based on the production route information in a production route information storage unit, the incurred cost unit for each process design calculated by an incurred cost unit calculation unit based on the incurred variable costs in an incurred cost information storage unit, and the production volume information, raw material and selling price information storage unit, equipment information storage unit, evaluation index setting unit, term and span information setting unit, and appropriate work-in-process inventory volume storage unit, and adds a constraint regarding the appropriate range of work-in-process inventory in an optimal product mix calculation unit.

[0009] In addition, as a technology for easily creating a production plan that aims to level out manufacturing volumes and optimize inventory and inventory days without causing delivery delays or shortages in the case of a mixture of mass-shipped products and small-volume or low-frequency shipped products, a production planning device for a batch plant that manufactures products through a single or multiple processes includes a production planning condition setting unit that sets production planning conditions according to the characteristics of the product, and a production planning condition setting unit that sets production planning conditions according to the characteristics of the product based on an order shipment schedule, finished and semi-finished product inventory results, and the production planning conditions. A production planning device (see Patent Document 2) has been proposed, which is characterized by having a production planning basic data calculation unit that creates production planning jobs, a configurable optimal manufacturing capacity table that stores a correspondence table of manufacturing capacity corresponding to manufacturing process loads, a manufacturing capacity calculation unit that calculates a leveling target capacity of the manufacturing process load based on the production planning jobs and the optimal manufacturing capacity table, and a production plan determination unit that determines a production plan for allocating the production planning jobs to each day based on the leveling target capacity.

[0010] Further, there is provided a push-pull mixed type optimal composite production planning method for creating an optimal production plan in a composite production system capable of composite production of order items and forecast items in the same process, comprising a first step of creating a production plan for a first planning period and outputting data on the progress of in-process inventory levels at each time point, and a second step of scheduling for a second planning period that is shorter than the first planning period based on the progress of in-process inventory level transition data output from the first step, and determining a target in-process inventory level by process at the end of the planning period, and determining a target in-process inventory level by process at the end of the planning period based on the production plan data in the latest production plan. A mixed push-pull optimal composite production planning method (see Patent Document 3) has also been proposed in which inventory level data for a time slot corresponding to the beginning of a production plan is extracted from data on inventory levels by item in the latest schedule and used as inventory level data at the end of the period for the newly created schedule, inventory level data for a time slot corresponding to the beginning of a production plan is extracted from data on inventory levels by item in the latest schedule and used as inventory level data at the beginning of the production plan, and inventory level data for a time slot corresponding to the beginning of the next scheduling period is extracted from data on inventory levels by item in the latest schedule and used as inventory level data at the beginning of the next scheduling period.

[0011] The technology in Patent Document 1 proposes planning that minimizes deviation from the range of work-in-process inventory for each target time, product type, and intermediate product, while the technology in Patent Document 2 proposes planning that aims to minimize product inventory by determining the number of productions when the product inventory for each day falls below the shipping volume. In addition, the technology in Patent Document 3 proposes scheduling that minimizes echelon inventory costs simultaneously with other costs while observing inventory transitions for each time slot in a configuration in which ordered items, i.e., parents, and expected items, i.e., children, are produced in the same process. [Prior art documents] [Patent documents]

[0012] [Patent Document 1] JP2007-115169A [Patent Document 2] Japanese Patent Application Publication No. 8-174385 [Patent Document 3] JP2005-092726A Summary of the Invention [Problem to be solved by the invention]

[0013] However, the conventional technology has not proposed a planning technology that optimizes the work-in-process amount and inventory balance at the decoupling point (the inventory point between parent and child) by planning the parent and child simultaneously based on the linking information between the parent and child. Note that the optimization mentioned above means reducing or reducing the work-in-process amount and inventory balance to zero, or keeping the work-in-process amount and the corresponding inventory setting within a range specified by the user while considering the safety stock.

[0014] Furthermore, the prior art does not propose a planning technique that uses conditions that are often used in practice as constraints, such as the delay tolerance according to the priority of the parent, i.e., the ordered item.

[0015] Furthermore, the prior art has not proposed any planning technology that takes into account design constraints and production management conditions, such as when the parent:child ratio is 1:N, or when the child process that synchronizes with the parent (process) is the start process or intermediate process of the parent.

[0016] The present invention has been made in consideration of these problems, and one of its objectives is to provide technology that supports planning that optimizes work-in-process quantities and inventory balances at the decoupling points between parent and child products, taking into account various conditions and constraints in the parent-child relationships between products and the semi-finished products and parts that make up the products. [Means for solving the problem]

[0017] The production plan optimization system of the present invention that solves the above-mentioned problems is a production plan optimization system having a processor and a storage device connected to the processor, the storage device storing the following information: case information of a case for which a production plan is to be created, linking information indicating whether the case is a parent that is a final product or a child that constitutes the parent and indicating the parent-child relationship, priority information of the case, DP inventory balance information indicating how much inventory will be generated at the decoupling point where the child is stored as work in process, and KPI information which is an objective function for optimizing the production plan. At least one of the following information is included: minimization of the number of stagnant personnel at decoupling points throughout the production planning period; minimization of the total value of inventory stock throughout the production planning period; minimization of the total value of stagnant periods at decoupling points of each item; and maximization of the delivery compliance rate taking into account the priority of the item; and delay tolerance information indicating the number of days or hours for which delays can be tolerated according to the priority information. and the processor holds: The project information, the parent-child linking information, the priority information, the DP inventory information, the delay allowance information, the KPI information, and information regarding processes and resources required for the production plan, Generate production plans by feeding them into a given optimization engine and for a production plan generated by selecting at least one of the KPI information, the selected KPI value, the value of the KPI information that was not selected, the number of stalled workers at the decoupling point for each day of the production plan period, and the value of the inventory at the decoupling point for each day of the production plan period are displayed. The present invention is characterized in that it is

[0018] In addition, in the production plan optimization method of the present invention, in a production plan optimization system, a storage device stores: case information of a case for which a production plan is to be created; linking information indicating whether the case is a parent that is a final product or a child that constitutes the parent and indicating the parent-child relationship; priority information of the case; DP inventory balance information indicating how much inventory will be generated at a decoupling point where the child is stored as work in process; and KPI information which is an objective function for optimizing the production plan. At least one of the following information is included: minimization of the number of stagnant personnel at decoupling points throughout the production planning period; minimization of the total value of inventory stock throughout the production planning period; minimization of the total value of stagnant periods at decoupling points of each item; and maximization of the delivery compliance rate taking into account the priority of the item; and delay tolerance information indicating the number of days or hours for which delays can be tolerated according to the priority information. and the processor: The project information, the parent-child linking information, the priority information, the DP inventory information, the delay allowance information, the KPI information, and information regarding processes and resources required for the production plan, Generate production plans by feeding them into a given optimization engine and for a production plan generated by selecting at least one of the KPI information, the selected KPI value, the value of the KPI information that was not selected, the number of stalled workers at the decoupling point for each day of the production plan period, and the value of the inventory at the decoupling point for each day of the production plan period are displayed. The present invention is characterized by the above. Effect of the Invention

[0019] According to the present invention, it is possible to perform planning that minimizes the amount of work in process and inventory balance at the decoupling point, taking into consideration conditions commonly used in practice, design constraints, and production management conditions.

[0020] Problems, configurations and effects other than those described above will become apparent from the following description of the embodiments. [Brief description of the drawings]

[0021] [Figure 1] 1 is a block diagram showing a configuration example of a production plan optimization system according to an embodiment of the present invention. [Diagram 2] 10 is an explanatory diagram illustrating an example of a parent-child linking information storage table in the present embodiment. FIG. [Diagram 3] 1 is an explanatory diagram illustrating an example of a delay allowance definition information storage table in the present embodiment. [Figure 4] FIG. 2 is an explanatory diagram illustrating an example of a KPI information storage table in the present embodiment. [Diagram 5] FIG. 2 is an explanatory diagram illustrating an example of a case information storage table according to the present embodiment. [Figure 6] FIG. 4 is an explanatory diagram showing an example of a process / resource table in the present embodiment. [Figure 7] FIG. 2 is an explanatory diagram illustrating an example of a production plan storage table in the present embodiment. [Figure 8] FIG. 2 is an explanatory diagram illustrating an example of a KPI storage table in this embodiment. [Figure 9] FIG. 11 is an explanatory diagram showing an example of a DP stagnant number / shelf remaining storage table in this embodiment. [Figure 10] FIG. 2 is an explanatory diagram showing an example of a production plan information input screen output by the production plan optimization system of the present embodiment. [Figure 11] FIG. 11 is an explanatory diagram showing an example of a production plan creation result output screen output by the production plan optimization system of the present embodiment. [Figure 12] 4 is a flowchart showing an example of a main routine process of a program in the production plan optimization system according to the present embodiment. [Figure 13] 5 is a flowchart showing an example of processing of a model generation program in the production plan optimization system of the present embodiment. [Figure 14] 5 is a flowchart showing an example of the processing of an optimization engine program, a parallel calculation execution management program, and a calculation time / solution management program in the production plan optimization system of this embodiment. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0022] DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS An embodiment of the present invention will now be described with reference to the drawings. Fig. 1 is a block diagram showing an example of the configuration of a production plan optimization system 100 according to this embodiment.

[0023] <System configuration example> The production plan optimization system 100 is a system for planning that minimizes the amount of work in process and inventory balance at the decoupling point, taking into consideration conditions commonly used in practice, design constraints, and production management conditions.

[0024] The production plan optimization system 100 in this embodiment includes a production plan optimization device 101 and a network 190.

[0025] The production plan optimization device 101 includes a storage device 110, a processor 150 including a central processing unit (CPU (Central Processing Unit)) and the like, a RAM (Random Access Memory) 165, an input device 170, an output device 175, a recording medium reader 180, and a communication interface. The optical fiber 180 has an interface 185.

[0026] The storage device 110 is a device that stores information necessary for planning to minimize the amount of work in progress and inventory balance at the decoupling point, taking into consideration conditions commonly used in practice, design constraints, and production management conditions.

[0027] Such a storage device 110 is, for example, a device such as a HDD (Hard Disk Drive). However, the storage device 110 is a solid state drive (SSD) using a flash memory or the like. ) may also be used.

[0028] The storage device 110 has, as tables 120, at least a parent-child linking information storage table 121, a delay allowance definition information storage table 122, a KPI information storage table 123, an item information storage table 124, a process / resource table 125, a production plan storage table 126, a KPI storage table 127, and a DP stagnant number / shelf remaining storage table 128. Note that DP is an abbreviation for decoupling point, and the same will be used hereinafter.

[0029] The storage device 110 also has at least a model generation program 131, an optimization engine program 132, a parallel calculation execution management program 133, a calculation time / solution management program 134, an output information generation program 135, and a production plan evaluation program 136 as programs 130.

[0030] The processor 150 is a calculation device that executes programs, etc. The processor 150 of this embodiment includes a parent-child information processing unit 151, a variety of model processing unit 152, and a parent-child collective maximum processing unit 154. The system includes an optimal production planning unit 153, a KPI value calculation unit 154, a DP stagnation number calculation unit 155, an output information processing unit 156, and a calculation management unit 157. Each of these units can be said to be a function implemented by the processor 150 executing the program 130.

[0031] The RAM 165 is a memory that stores the programs executed by the processor 150, data necessary for executing the programs, and the like.

[0032] The input device 170 is a device for a user to input various instructions to the production plan optimization system 100. The input device 170 includes, for example, a keyboard, a mouse, and a microphone.

[0033] The output device 175 is a device that outputs a production plan information input screen, etc. The output device 175 is, for example, a device such as a CRT (Cathode Ray Tube) display, an LCD (Liquid Crystal Display) or an organic EL (Electro-Luminescence) display, a speaker, Printers and the like are examples of this.

[0034] The recording medium reading device 180 is a device that reads out information from a portable storage medium having portability. Examples of the portable storage medium include a flexible disk, a CD-ROM, a DVD-ROM, a semiconductor memory, a server, and a communication path such as a LAN. The recording medium reading device 180 may be built into the production plan optimization device 101 or may be attached externally.

[0035] The model generation program 131, the optimization engine program 132, the parallel calculation execution management program 133, the calculation time / solution management program 134, the output information generation program 135, and the production plan evaluation program 136 are loaded from the program 130 into the RAM 165 and executed by the processor 150, thereby realizing the processing of each program.

[0036] The processes to be implemented are shown in Figures 12, 13, and 14, and will be described in detail later. Note that the above programs are, for example, application programs that can be executed on an OS (Operating System) program.

[0037] Furthermore, the above programs may be, for example, programs input from the network 190 via the communication interface 185 and then installed.

[0038] Note that a part or the whole of the production plan optimization device 101 may be realized as hardware using a circuit or the like.

[0039] FIG. 2 is an explanatory diagram showing an example of the parent-child linking information storage table 121 in this embodiment.

[0040] 2 is a table for registering linking information of parent-child relationships for each case, and is composed of a case CD210, a parent-child 220, a parent case CD230, a synchronous process 240, etc. One record is generated for each case.

[0041] The case CD210 is information that uniquely identifies each case that is the target of the production plan. Parent-child 220 is information that identifies for each case whether it is a parent or a child. Parent case CD230 is information that identifies the parent-child link for each case by displaying the parent case CD for the case that is a child, or a hyphen for the case that is a parent.

[0042] The synchronization process 240 is information for each case that indicates which parent process it will synchronize with if it is a child, and indicates a hyphen to identify the synchronization process if it is a parent.

[0043] Here, "synchronization" refers to when the child is completed, goes through the final process, is stored as work in progress, and is then delivered to the process where the parent is assembled.

[0044] FIG. 3 is an explanatory diagram showing an example of the delay allowance definition information storage table 122 in this embodiment.

[0045] The allowable delay definition information storage table 122 of this embodiment is a table for registering an allowable delay according to the priority of an item, and is composed of a priority 310, an allowable delay [days] 320, etc. One record is generated for each priority.

[0046] Priority 310 is information for identifying the priority of each item, such as actual order item, tentative order item, inventory adjustment item, etc. Allowable delay amount [days] 320 is information for identifying how many days of delay are allowable for each priority.

[0047] FIG. 4 is an explanatory diagram showing an example of the KPI information storage table 123 in this embodiment.

[0048] The KPI information storage table 123 of this embodiment is a table for registering KPIs (objective functions) for optimization, and is composed of a KPI ID 410, a KPI name 420, etc. One record is generated for each KPI.

[0049] The KPI ID 410 is information for uniquely identifying each KPI, and the KPI name 420 is information for identifying the name registered by the user of the production plan optimization system 100 for identification of each KPI.

[0050] FIG. 5 is an explanatory diagram showing an example of the case information storage table 124 in this embodiment.

[0051] The case information storage table 124 of this embodiment is a table for registering various information related to cases, and is composed of case CD 510, priority 520, possible start date 530, due date 540, quantity 550, DP stock [k yen / unit] 560, etc. One record is generated for each case CD.

[0052] The item CD 510 is information for uniquely identifying each item that is the subject of the production plan, and the priority 520 is the priority of each item, and is selected from the priorities 310 .

[0053] The possible start date 530 is the date on which production of each item can be started, and is determined based on the arrival date of procured items, the acceptance date of outsourced personnel required for production, and the like.

[0054] A delivery date 540 is a delivery date for each item CD and is determined according to the order. A quantity 550 is information for identifying how many of the same product are to be produced for each item CD.

[0055] DP inventory [k￥ / unit] 560 is information that identifies how much will be generated per unit as inventory when each child exists as work in progress in the DP.

[0056] FIG. 6 is an explanatory diagram showing an example of the process / resource table 125 in this embodiment.

[0057] The process / resource table 125 of this embodiment is a table for registering various information related to the processes and resources required for the production of each item, and is composed of items CD 610, processes 620, routings 630, resources 640, consumption values ​​650, and upper capacity values ​​per time bucket of the resources 660. One record is generated for each item CD, process, and resource.

[0058] The item CD 610 is information for uniquely identifying each item that is the subject of the production plan, and the process 620 is information for identifying the process required for the production of the item CD of the record.

[0059] The process order 630 is information for identifying the order of the process for the project CD of the record. The resources 640 are information for identifying resources required for the process of the project CD of the record, such as machines, people, tools, and areas.

[0060] Furthermore, if multiple resources are consumed for each case CD and process, for example when an area and people are consumed, then multiple records are registered for each case CD and process.

[0061] The consumption value 650 is information that identifies how much of the resource registered in the record is consumed in the case CD and process of the record, and values ​​such as time for a specific machine or person, number of people for a specific tool, and area for an area are registered.

[0062] The capacity upper limit value 660 of the resource per time bucket indicates the capacity upper limit value of the resource registered in the record per time bucket (the smallest unit of planning granularity such as a day or morning / afternoon).

[0063] In addition, in terms of implementation, it is possible to set this value by preparing a separate master, but for the sake of simplicity, it is described in the process and resource table 125. Also, this value does not have to be a fixed value, and a separate master may be prepared and changed for each time bucket.

[0064] 7 is an explanatory diagram showing an example of the production plan storage table 126 in this embodiment. The production plan storage table 126 in this embodiment is a table for registering the results of creating an optimal production plan, and is composed of a plan number 710, an item CD 720, a process 730, a start date 740, an end date 750, etc. One record is generated for each plan number, item CD, and process.

[0065] The plan number 710 is a number issued each time a plan is registered, and is information that uniquely identifies the plan. The case CD 720 is information that uniquely identifies each case that is the target of the production plan. The process 730 is information that uniquely identifies each process of each case CD.

[0066] Also, a start date 740 and an end date 750 are information for identifying the start date and end date of the case CD and process of the record, respectively.

[0067] 8 is an explanatory diagram showing an example of the KPI storage table 127 in this embodiment. The KPI storage table 127 in this embodiment is a table for registering the results of calculating each KPI value for the result of creating an optimal production plan, and is composed of a plan number 810, a KPI ID 820, a designated KPI flag 830, a value 840, etc. One record is generated for each plan number and KPI ID.

[0068] The plan number 810 is a number that is issued each time a plan is registered, and is information that uniquely identifies the plan. The KPI ID 820 is information that uniquely identifies each KPI.

[0069] The designated KPI flag 830 is information for identifying the KPI designated on the input screen when planning, and 1 is registered for the designated KPIID, and 0 is registered for the undesignated KPIID. The value 840 is registered with the value of each KPIID for the plan of each plan number.

[0070] 9 is an explanatory diagram showing an example of the DP backlog number / shelf stock storage table 128 in this embodiment. The DP backlog number / shelf stock storage table 128 in this embodiment is a table for registering the results of calculating the DP backlog number and shelf stock values ​​for each day of the planning period for the results of creating an optimal production plan, and is composed of a plan number 910, date 920, number of backlogged personnel 930, shelf stock [k￥] 940, etc. One record is generated for each plan number and date.

[0071] The plan number 910 is a number that is issued each time a plan is registered, and is information that uniquely identifies the plan. The date 920 indicates each day of the plan period, and is registered in one-day increments from the first day to the last day of the plan period.

[0072] Further, the number of backlogged workers 930 and the stock on hand [k￥] 940 are the totals of the number of backlogged workers and the stock on hand for each plan number and date, respectively, and are calculated from the job information storage table 124 and the production plan storage table 126 .

[0073] <Example of output screen> FIG. 10 is an explanatory diagram showing an example of a production plan information input screen 1000 output by the production plan optimization device 101 of this embodiment.

[0074] A production plan information input screen 1000 in FIG. 10 is a screen displayed by, for example, the output device 175 of the production plan optimization device 101 in order to receive input from a user of the production plan optimization system 100.

[0075] The production plan information input screen 1000 in this embodiment includes a planning button 1010 and a close button 1020. When the planning button 1010 is operated (for example, pressed using a mouse or a touch sensor), a model generation program 131, an optimization engine program 132, a parallel computation execution management program 133, and a computation time / solution management program 134, which will be described later, are executed. When the close button 1020 is operated, the production plan information input screen 1000 is closed.

[0076] Furthermore, the production plan information input screen 1000 displays a reference table of planned item information 1030 and allowable delay amount 1040. The planned item information 1030 corresponds to FIG. 2 and FIG. 5, and the allowable delay amount 1040 corresponds to FIG.

[0077] Furthermore, the production plan information input screen 1000 displays a calculation thread number input section 1050, a calculation time upper limit 1060, and a KPI selection section 1070. The KPI selection section 1070 corresponds to Fig. 4. These are present so that a user who has referred to the production plan information input screen 1000 can input information by operating the input device 170, and when the plan creation 1010 is operated, an optimal production plan is created based on each of the conditions.

[0078] FIG. 11 is an explanatory diagram showing an example of a production planning result output screen 1100 output by the production plan optimization device 101 of this embodiment.

[0079] A production plan creation result output screen 1100 in FIG. 11 is a screen displayed by, for example, the output device 175 of the production plan optimization device 101 in order to output the results of the optimal production plan created by the production plan optimization system 100.

[0080] The production planning result output screen 1100 includes a register button 1110 , a print button 1115 , and a close button 1120 .

[0081] When the registration button 1110 is operated (e.g., pressed using a mouse or a touch sensor), the main routine of the program is executed and the results of the production plan are stored in FIG. 7, each KPI value is stored in FIG. 8, and the number of DPs that are backlogged and the values ​​of inventory are stored in FIG. 9.

[0082] When the print button 1115 is operated, the information on the production planning result output screen 1100 is output. When the close button 1120 is operated, the production planning result output screen 1100 is closed.

[0083] Furthermore, the production planning result output screen 1100 displays process chart information 1130 of the production planning result, load pile result 1140, KPI value 1150, DP stagnation number / stock 1160, and result label 1170.

[0084] The process chart information 1130 is generated from Fig. 7, and the load pile result 1140 is generated from Fig. 6 and Fig. 7. Also, the KPI value 1150 and the number of DPs stuck and in stock 1160 correspond to Fig. 8 and Fig. 9, respectively.

[0085] Result label 1170 displays label information of an optimal solution or a feasible solution included in the result of the process described later with reference to FIG. 14, or, if a feasible solution cannot be obtained, the result of problem analysis as label information.

[0086] <Production plan optimization method flow> FIG. 12 is a flowchart showing an example of a main routine process of the program 130 in the production plan optimization device 101 of this embodiment.

[0087] This process is executed by the processor 150 in accordance with a model generation program 131, an optimization engine program 132, a parallel calculation execution management program 133, a calculation time / solution management program 134, an output information generation program 135, and a production plan evaluation program 136 in order to formulate an optimal production plan.

[0088] The processor 150 receives, from the production plan information input screen 1000, an instruction to create and execute an optimal production plan together with the number of threads to be used in parallel processing, the upper limit of the calculation time, and the input values ​​of the selected KPI (S1210).

[0089] The processor 150 executes the model generation program 131 using a parent-child information processing unit 151 and various model processing units 152, and creates a parent-child linking information storage table 121, a delay allowance definition information storage table 122, a KPI information storage table 123, and a case information storage table 124.

[0090] Then, the process and resource table 125 is read, and a model required for formulating an optimal production plan is generated according to a model generation process, the details of which will be described with reference to FIG. 13 (S1220).

[0091] The processor 150 executes the optimization engine program 132, the parallel calculation execution management program 133, and the calculation time / solution management program 134 using the parent-child batch optimal production plan planning unit 153 and the calculation management unit 157, and based on the information acquired in S1210 (the number of threads to be used in parallel processing, the upper limit of calculation time, and the selected KPI), plans a production plan in accordance with the production plan optimization process, the details of which will be described in FIG. 14, and simultaneously calculates the value of the selected KPI (S1230).

[0092] The processor 150 executes the production plan evaluation program 136 using each KPI value calculation unit 154 and DP stagnation number / stock calculation unit 155 to calculate KPI values ​​other than the DP stagnation number, stock, and KPIs to be optimized (S1240).

[0093] The processor 150 uses the output information processing unit 156 to execute the output information generation program 135 and generate a table of the process schedule, load pile results, DP stagnation number, inventory backlog, and values ​​of each KPI that matches the format of the production planning result output screen 1100 (S1250).

[0094] The processor 150 displays the process chart, the load pile result, the DP stagnation number, the stock, and a table of the values ​​of each KPI on the production planning result output screen 1100 (S1260).

[0095] When the processor 150 receives an operation of the registration button 1110 on the production planning result output screen 1100, it registers information in the production plan storage table 126, the KPI storage table 127, and the DP stagnant number / shelf remaining storage table 128 (S1270), and terminates the processing.

[0096] FIG. 13 is a flowchart showing an example of the processing of the model generation program 131 in the production plan optimization device 101 of this embodiment.

[0097] The processor 150 reads the parent-child linking information storage table 121, the delay allowance definition information storage table 122, the KPI information storage table 123, the case information storage table 124, and the process / resource table 125, and passes the information to the parent-child information processing unit 151 and the various model processing unit 152 (S1310).

[0098] TIFF0007662462000001.tif28170

[0099] Here, a time bucket is an arbitrary period such as a day or morning and afternoon, and is the smallest unit of the time axis of a production plan. Also, t is a time bucket, p is processing time, job is a case or process, and proj is a case. , proc is a process, and x is a 0-1 decision variable that takes the value 1 if a job (proj, proc) starts in time bucket t and 0 if it does not start.

[0100] The parent-child information processing unit 151 refers to the synchronous process of each parent and child in the parent-child linking information storage table 121 and the processing time for each case and process in the process and resource table 125, and sets the constraint condition of the following formula (1) that the difference between the start of the final process of the child and the start of the synchronous process of the parent is equal to or longer than the processing time of the final process of the child. Note that T represents the target period (whole) of the production plan.

[0101] [Number 1] TIFF0007662462000002.tif22170

[0102] TIFF0007662462000003.tif32170

[0103] The parent-child information processing unit 151 also refers to the case information storage table 124, and stores the number of stalls of the DP of each parent and child in ascending order of the cases CD of the parent and child in a matrix (a list in implementation) m, and We introduce a matrix i that stores the stock values ​​of DP in ascending order of parent and child cases CD.

[0104] TIFF0007662462000004.tif34170

[0105] [Number 2] TIFF0007662462000005.tif22170

[0106] The various model processing unit 152 sets constraint conditions in the Resource Constrained Project Scheduling Problem (hereinafter referred to as RCPSP), which is a general optimization method for planning (S1350).

[0107] For example, the constraint is one in which the load of each case is piled up within a range that does not exceed the upper capacity value of each resource in any time bucket, as shown in formula (3).

[0108] TIFF0007662462000006.tif21170

[0109] As described in the explanation of the process / resource table 125, the upper limit value of each resource may be changed for each time bucket, and this condition is taken into consideration and introduced as a function of t. J represents the universal set of cases and processes.

[0110] Note that the range of the variable x is set so that it is 1 during the processing period of each item and process. The definition of a decision variable that takes the value 1 in the start time bucket of each project or process and 0 otherwise remains unchanged.

[0111] Furthermore, by referring to the process / resource table 125, similar to formula (1), a constraint condition is set that for each case / process, the time from the start of the process with the larger process order to the start of the process with the smaller process order is equal to or longer than the processing time of the process with the smaller process order.

[0112] TIFF0007662462000007.tif14170

[0113] [Number 3] TIFF0007662462000008.tif50170

[0114] TIFF0007662462000009.tif20170

[0115] The various model processing unit 152 sets a KPI for minimizing the DP stagnation period (S1370). For example, using the variables introduced above, it can be written as in formula (4). That is, for each parent and child, it is the difference between the time bucket in which the parent's synchronization process starts and the time bucket in which the child's final process ends.

[0116] [Number 4] TIFF0007662462000010.tif22170

[0117] TIFF0007662462000011.tif22170

[0118] The amount of delay is the end time bucket of the final step of each case, i.e., the start time bucket (decision variable) of the final step of each case plus the processing time of the final step of each case minus the due date of each case.

[0119] The various model processing unit 152 sets KPIs in the RCPSP (S1390). For example, the makespan shown in formula (5), that is, the lead times of all products that are the subject of the production plan, is set.

[0120] Here, the final dummy case and dummy process are the dummy cases set after the final process of all the parents.

[0121] The processing time is 0 and is a variable that is not related to the delivery date.

[0122] [Number 5] TIFF0007662462000012.tif15170

[0123] FIG. 14 is a flowchart showing an example of the processing of the optimization engine program 132, the parallel computation execution management program 133, and the computation time / solution management program 134 in the production plan optimization device 101 of this embodiment.

[0124] The processor 150 passes the information acquired in S1210 (the number of threads to be used for parallel processing, the upper limit of calculation time, and the selected KPI) and the model generated in S1220 to the parent-child batch optimal production planning unit 153 and the calculation management unit 157 (S1410).

[0125] The calculation management unit 157 executes the parallel calculation execution management program 133, and manages the parallel processing in the optimization calculation based on the number of threads used for the parallel processing obtained in S1210. It also executes the calculation time / solution management program 134, and manages the calculation time up to the upper limit value of the calculation time obtained in S1210, and secures an area of ​​the RAM 165 for storing solutions in the subsequent processing, and also manages the labels for the solutions (S1420).

[0126] The parent-child collective optimal production plan planning unit 153 executes the optimization engine program 132, executes a process of formulating an optimal production plan based on the selected KPI acquired in S1210 and the model generated in S1220, and if a feasible solution or an optimal solution exists, passes the solution to the calculation time / solution management program 134 each time (S1430).

[0127] If there is a solution that the parent-child batch optimal production plan planning unit 153 determines to be the optimal solution before the upper limit of the calculation time is reached (S1440: Yes), the calculation time / solution management program 134 receives the solution, assigns a label as the optimal solution, and stores the production plan in question in the RAM 165 (S1450).

[0128] If there is no solution that the parent-child batch optimal production planning unit 153 has determined to be the optimal solution (S1440: No), the solution is sought until the upper limit of the calculation time is reached (S1460).

[0129] If there is a solution that the parent-child batch optimal production plan planning unit 153 has determined to be a feasible solution (S1470: Yes), the calculation time / solution management program 134 receives the solution, assigns a label of a feasible solution to it, and stores the production plan in question in the RAM 165 (S1480).

[0130] If there is no solution that the parent-child batch optimal production planning unit 153 has determined to be a feasible solution (S1470: No), the calculation time / solution management program 134 receives problem analysis information (for example, no solution exists given the conditions of the given model, or a solution may exist but could not be determined within the upper limit of the calculation time, etc.), assigns a label indicating that there is no feasible solution to the problem analysis information, and stores the information in RAM 165 (S1490).

[0131] By carrying out the above processing in Figures 12, 13, and 14, it is possible to obtain an optimal or feasible production plan and each KPI value, DP stagnation number, inventory stock value, and label information indicating whether the solution is optimal or feasible, or information regarding the reason why the production plan result could not be obtained.

[0132] It should be noted that the present invention is not limited to the above-described embodiment, and various modifications are included. For example, the above-described embodiment has been described in detail for a better understanding of the present invention, and the present invention may be modified in various ways. Furthermore, the present invention is not limited to having all of the configurations described.

[0133] In addition, the above-mentioned configurations, functions, processing units, processing means, etc. may be realized in part or in whole by hardware, for example, by designing them as integrated circuits. In addition, the above-mentioned configurations, functions, etc. may be realized in software by a processor interpreting and executing a program that realizes each function. Information such as a program, table, file, etc. that realizes each function can be stored in a storage device such as a non-volatile semiconductor memory, a hard disk drive, or an SSD (Solid State Drive), or in a computer-readable non-transitory data storage medium such as an IC card, an SD card, or a DVD.

[0134] In addition, the control lines and information lines are shown as those considered necessary for the explanation, and not all control lines and information lines in the product are shown. In reality, it can be considered that almost all components are connected to each other.

[0135] According to this embodiment, it is possible to support planning that optimizes the amount of work in progress and inventory balance at the decoupling point between a product and its constituent products, such as semi-finished products and parts, taking into account various conditions and constraints in the parent-child relationships between the product and the semi-finished products and parts that make up the product.

[0136] The description of this specification makes at least the following clear. That is, in the production plan optimization system of this embodiment, the storage device may further hold delay allowance information indicating the number of days or hours for which a delay is allowable according to the priority information, and may hold at least one of the following as the KPI information: minimization of the number of stagnant personnel at a decoupling point throughout the production plan period, minimization of the total value of inventory stock throughout the production plan period, minimization of the total value of stagnant periods at decoupling points of each job, and maximization of delivery compliance rate taking into account the priority of the job, and the processor may generate a production plan based on the job information, the parent-child linking information, the priority information, the DP inventory stock information, the delay allowance information, the KPI information, and information on processes and resources required for the production plan.

[0137] This makes it possible to develop a production plan that further considers at least one of the following KPIs: minimization of the total inventory value at the decoupling point, minimization of the total stagnation period at the decoupling point of each job, and maximization of the delivery deadline compliance rate taking into account the priority of the jobs.

[0138] In the production plan optimization system of this embodiment, the processor may display, for a production plan generated by selecting at least one of the KPI information, the value of the selected KPI, the value of the KPI information that was not selected, the number of backlogged workers at the decoupling point for each day of the production plan period, and the value of inventory at the decoupling point for each day of the production plan period.

[0139] This makes it possible to provide users who wish to optimize their production plans with appropriate information required for their consideration.

[0140] In the production plan optimization system of this embodiment, the processor may define, for a child in the project information for which there is no parent-child linking information, a period from the end of production of the non-existent child to the last day of the planning period as stagnation, and calculate the total value of the stagnation period at the decoupling points of each of the projects included in the KPI information.

[0141] This makes it possible to calculate information regarding children for which no parent-child linking information exists, i.e., target parts for stock production, etc.

[0142] In the production plan optimization system of this embodiment, the processor may hold a mathematical optimization engine or a metaheuristics engine as the optimization engine, and execute a process of determining whether a solution output by the optimization engine is an optimal solution or a feasible solution, and a process of outputting cause analysis information when a feasible solution is not found.

[0143] This makes it possible to appropriately respond to situations where a feasible solution cannot be found and to provide information that is useful for considering the optimization of production plans.

[0144] In the production plan optimization method of this embodiment, the storage device may further retain delay allowance information indicating the number of days or hours for which delays are allowable according to the priority information, and may retain at least one of the following as the KPI information: minimization of the number of delayed employees at decoupling points throughout the production planning period, minimization of the total value of inventory stock throughout the production planning period, minimization of the total value of stagnation periods at decoupling points of each job, and maximization of delivery compliance rate taking into account the priority of the jobs; and the processor may generate a production plan based on the job information, the parent-child linking information, the priority information, the DP inventory stock information, the delay allowance information, the KPI information, and information regarding processes and resources required for the production plan.

[0145] In the production plan optimization method of this embodiment, the processor may display, for a production plan generated by selecting at least one of the KPI information, the value of the selected KPI, the value of the KPI information that was not selected, the number of backlogged workers at the decoupling point for each day of the production plan period, and the value of inventory at the decoupling point for each day of the production plan period.

[0146] In the production plan optimization method of this embodiment, the processor may define, for a child of the project information for which there is no parent-child linking information, a period from the end of production of the non-existent child to the last day of the planning period as stagnation, and calculate the total value of the stagnation period at the decoupling points of each of the projects included in the KPI information.

[0147] In the production plan optimization method of the present embodiment, the processor may hold a mathematical optimization engine or a metaheuristics engine as the optimization engine, and execute a process of determining whether a solution output by the optimization engine is an optimal solution or a feasible solution, and a process of outputting cause analysis information when a feasible solution is not found. [Explanation of symbols]

[0148] 100 Production Planning Optimization System 101 Production planning optimization device 110 Storage device 121 Parent-child linking information storage table 122 Delay tolerance definition information storage table 123 KPI information storage table 124 Case information storage table 125 Process and Resource Table 126 Production plan storage table 127 KPI storage table 128 DP stagnation number / shelf remaining storage table 131 Model Generator 132 Optimization Engine Program 133 Parallel Computing Execution Management Program 134 Calculation time and solution management program 135 Output information generation program 136 Production Planning Evaluation Program

Claims

1. A production plan optimization system having a processor and a storage device connected to the processor, the storage device holds: case information of cases for which production planning is to be made; linking information indicating whether the case is a parent that is a final product or a child that constitutes the parent and indicating the parent-child relationship; priority information of the cases; DP stock information indicating the amount of inventory balance that will be generated at the decoupling point where the child is stored as work in progress; KPI information that is an objective function for optimizing the production plan, the KPI information being at least one of minimizing the number of delayed personnel at the decoupling point throughout the production planning period, minimizing the total value of stock throughout the production planning period, minimizing the total value of the stagnation period at the decoupling point of each case, and maximizing the delivery date compliance rate taking into account the priority of the cases; and delay tolerance information indicating the number of days or hours for which delays are tolerable according to the priority information; The processor generates a production plan by providing a predetermined optimization engine with the case information, the parent-child linking information, the priority information, the DP inventory information, the delay allowance information, the KPI information, and information regarding processes and resources required for the production plan, and displays, for a production plan generated by selecting at least one of the KPI information, the value of the selected KPI, the value of the KPI information not selected, the number of delayed personnel at a decoupling point for each day of the production plan period, and the inventory value at a decoupling point for each day of the production plan period. A production planning optimization system comprising:

2. The processor, For a child of the project information that does not have parent-child linking information, a period from the end of production of the child that does not exist to the last day of the planning period is defined as stagnation, and a total value of the stagnation period at the decoupling point of each of the projects included in the KPI information is calculated. The production plan optimization system according to claim 1 .

3. The processor, The optimization engine includes a mathematical optimization engine or a metaheuristics engine, and executes a process of determining whether a solution output by the optimization engine is an optimal solution or a feasible solution, and a process of outputting cause analysis information when a feasible solution is not found. The production plan optimization system according to claim 1 .

4. In the production planning optimization system, a storage device holds: case information of cases for which a production plan is to be created; linking information indicating whether the case is a parent that is a final product or a child that constitutes the parent and indicating the parent-child relationship; priority information of the cases; DP stock information indicating the amount of inventory balance that will be generated at a decoupling point where the child is stored as work in progress; KPI information which is an objective function for optimizing the production plan, the KPI information being at least one of minimizing the number of delayed personnel at the decoupling point throughout the production plan period, minimizing the total value of stock throughout the production plan period, minimizing the total value of stagnation periods at the decoupling points of each case, and maximizing the delivery date compliance rate taking into account the priority of the cases; and delay tolerance information indicating the number of days or hours for which a delay can be tolerated according to the priority information; a processor generates a production plan by providing a predetermined optimization engine with the case information, the parent-child linking information, the priority information, the DP stock information, the delay allowance information, the KPI information, and information regarding processes and resources required for the production plan, and displays, for a production plan generated by selecting at least one of the KPI information, a value of the selected KPI, a value of the KPI information not selected, the number of delayed personnel at a decoupling point for each day of the production plan period, and a value of stock at a decoupling point for each day of the production plan period. A production plan optimization method comprising:

5. The processor, For a child of the project information that does not have parent-child linking information, a period from the end of production of the child that does not exist to the last day of the planning period is defined as stagnation, and a total value of the stagnation period at the decoupling point of each of the projects included in the KPI information is calculated. The production plan optimization method according to claim 4.

6. The processor, The optimization engine includes a mathematical optimization engine or a metaheuristics engine, and performs a process of determining whether a solution output by the optimization engine is an optimal solution or a feasible solution, and a process of outputting cause analysis information when a feasible solution is not found. The production plan optimization method according to claim 4.

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