Computer System and Method for Generating Product Input Plan

Abstract

To generate a product inputting plan for a production line including an inspection lane for random inspection of a product.SOLUTION: The present invention is directed to a computer system for generating a product inputting plan representing an inputting order of products in a production line. The production line includes an inspection lane where a product is inspected. The computer system generates, based on inspection lane arrangement information relating to an arrangement of the inspection lane, an inspection status as a mathematical model representing a state of a flow of products on the inspection lane, generates, when receiving input of product information relating to a product to be input to the production line, a mathematical plan model for use in generation of the product inputting plan defined by state variables relating to a state of the production line and made for achieving a predetermined objective in the production plan, based on the inspection status and the product information, and generates the product inputting plan by using the mathematical plan model.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present invention relates to a system and method for generating a product input plan indicating the input order of products in a production line including an inspection lane for extracting and inspecting products.

Background Art

[0002] In the manufacturing industry, in order to achieve improvements in production efficiency and the like, a plan for the input order of products into a production line using mathematical programming may be generated. For example, the technique described in Patent Document 1 is known.

[0003] Patent Document 1 describes "an input unit 1 for inputting vehicle information to be manufactured, an arithmetic unit 3 for determining an optimal input order based on the vehicle information input to the input unit 1, and an output unit 5 for outputting the input order plan obtained by the arithmetic unit 3 to the outside. The arithmetic unit 3 creates an input order for the vehicles, and based on the constraint conditions at the time of work input input from the input unit 1, obtains the dissatisfaction degree of the created input order as a penalty value. While creating a plurality of input orders, the penalty value for the constraint conditions for each input order is obtained, and the input order with the minimum penalty is obtained."

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0005] The manufacturing process in the manufacturing industry usually includes sampling inspection. In sampling inspection, the product to be inspected is sent to an inspection lane and inspected.

[0006] By formulating the input order using mathematical programming methods including the selection of products to be inspected, a plan closer to on-site operation can be made, and it is expected that production efficiency will be improved.

[0007] There are constraints on the inspection lane, such as the time required for inspection and the upper limit of the number that can be held as a buffer until inspection starts after sampling. When products are input and inspected according to a product input plan that does not consider the state such as the number of products buffered in the inspection lane and the presence or absence of products being inspected, buffer overflow will occur, making it impossible to manufacture products as planned. Therefore, in order to generate a product input plan that can be executed at the production site, it is necessary to prepare a mathematical programming model that takes into account the state of the product flow in the inspection lane.

[0008] However, since the structure of the inspection lane differs for each production line, it is necessary to generate a mathematical programming model according to the inspection lane. Therefore, it takes man-hours to generate the mathematical programming model.

[0009] The present invention has been made in view of the above circumstances, and one of its objects is to provide a system and method for generating a mathematical programming model for determining the input order of products in a production line including an inspection lane.

Means for Solving the Problems

[0010] A typical example of the invention disclosed in the present application is as follows. That is, a computer system that generates a product input plan representing the input order of products in a production line, including at least one computer having a processor and a storage device connected to the processor. The production line includes an inspection lane where product inspection is performed. The at least one computer generates an inspection status, which is a mathematical model representing the state of the product flow in the inspection lane, based on the inspection lane structure information regarding the structure of the inspection lane, stores it in the storage device, and when receiving an input of product information regarding the product to be input into the production line, generates a mathematical planning model defined by state variables regarding the state of the production line based on the inspection status and the product information, stores it in the storage device, generates the product input plan using the mathematical planning model, and stores it in the storage device.

Advantages of the Invention

[0011] According to the present invention, a product input plan can be generated using a mathematical planning model that takes into account the state of the product flow in the inspection lane. As a result, a plan suitable for on-site operation can be provided. Problems, configurations, and effects other than those described above will be clarified by the description of the following embodiments.

Brief Description of the Drawings

[0012]

Figure 1

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Figure 6A

Figure 6B

Figure 6C

Figure 7

Figure 8

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Figure 12

Figure 13

Embodiments for Carrying Out the Invention

[0013] Hereinafter, embodiments of the present invention will be described with reference to the drawings. However, the present invention is not to be construed as being limited to the description of the embodiments shown below. It will be readily understood by those skilled in the art that the specific configuration can be changed without departing from the spirit or gist of the present invention.

[0014] In the configuration of the invention described below, the same or similar configurations or functions are denoted by the same reference numerals, and duplicate descriptions are omitted.

[0015] In this specification and the like, notations such as "first", "second", "third", etc. are attached to identify components and do not necessarily limit numbers or order.

[0016] The positions, sizes, shapes, and ranges, etc. of each component shown in the drawings and the like may not represent the actual positions, sizes, shapes, and ranges, etc. in order to facilitate understanding of the invention. Therefore, the present invention is not limited to the positions, sizes, shapes, and ranges, etc. disclosed in the drawings and the like.

Example

[0017] FIG. 1 is a diagram showing a configuration example of the computer system of Example 1. FIG. 2 is a diagram showing an example of the hardware configuration of the computer constituting the system of Example 1.

[0018] The computer system is composed of an inspection status generation system 101, a mathematical programming model generation system 102, a product input plan generation system 103, and an operation terminal 104. The inspection status generation system 101, the mathematical programming model generation system 102, the product input plan generation system 103, and the operation terminal 104 are connected to each other via a network (not shown). The network is a WAN (Wide Area Network), a LAN (Local Area Network), etc., and the connection method may be either wired or wireless.

[0019] The operation terminal 104 is a general-purpose computer, a smartphone, etc. The inspection status generation system 101, the mathematical programming model generation system 102, and the product input plan generation system 103 are composed of a computer 200 as shown in FIG. 2.

[0020] The computer 200 has a CPU (Central Processing Unit) 201, a storage device 202, and a network interface 203.

[0021] The CPU 201 executes the programs stored in the storage device 202. By executing the processing according to the programs, the CPU 201 operates as a functional unit that realizes specific functions. In the following description, when explaining the processing with the functional unit as the subject, it indicates that the CPU 201 is executing the program that realizes the functional unit. The storage device 202 is a ROM (Read Only Memory) or the like, and stores the programs executed by the CPU 201 and the information used by the programs. Also, the storage device 202 is used as a work area. The network interface 203 communicates with other devices or systems via the network.

[0022] Note that the computer 200 may have a temporary storage device such as a RAM (Random Access Memory), and a non-temporary storage device such as an HDD (Hard Disk Drive) and an SSD (Solid State Drive). Also, the computer 200 may have input devices such as a keyboard, a mouse, and a touch panel, and output devices such as a display.

[0023] Note that the inspection status generation system 101, the mathematical programming model generation system 102, and the product input plan generation system 103 may include a storage system, a switch, and the like.

[0024] The operation terminal 104 inputs information related to the products to be put into the production line (product information) and information related to the structure of the inspection lanes in the production line (inspection lane structure information), etc.

[0025] The inspection status generation system 101 generates an inspection status, which is a mathematical model representing the flow of products in the inspection lanes.

[0026] The mathematical programming model generation system 102 generates a mathematical programming model for determining the product input order in the production line (for generating a product input plan) using the inspection status.

[0027] The product input plan generation system 103 generates an optimal product input plan to achieve the objective using a mathematical programming model.

[0028] In this embodiment, each of the inspection status generation system 101, the mathematical programming model generation system 102, the product input plan generation system 103, and the operation terminal 104 is managed by different operators, but they may also be managed by the same operator. Also, the independent systems may be integrated into one system.

[0029] Here, the functional configuration of the inspection status generation system 101 will be described.

[0030] The inspection status generation system 101 includes an inspection lane structure information acquisition unit 111, an inspection module generation unit 112, an inspection status generation unit 113, and an inspection status output unit 114. The above-described functional units are realized by the CPU 201 executing a program stored in the storage device 202.

[0031] The inspection lane structure information acquisition unit 111 acquires the inspection lane structure information input by the operation terminal 104. The inspection module generation unit 112 generates an inspection module based on the inspection lane structure information. Details of the inspection module will be described later. The inspection status generation unit 113 generates an inspection status using the inspection module. The inspection status output unit 114 outputs the inspection status to the mathematical programming model generation system 102.

[0032] Regarding the functional units of the inspection status generation system 101, a plurality of functional units may be grouped into one module, or one functional unit may be divided into a plurality of functional units for each function.

[0033] The data structure of the information processed by the system will be described with reference to FIGS. 3, 4, and 5.

[0034] FIG. 3 is a diagram showing an example of inspection lane structure information input by the operation terminal 104 in the first embodiment. FIG. 4 is a diagram showing an example of product information input by the operation terminal 104 in the first embodiment.

[0035] The inspection lane structure information 300 includes an inspection field number 301 and structure data 302. The inspection field number 301 is a field for storing the number of inspection fields included in the inspection lane. The structure data 302 is a field for storing structure data including parameters “maximum number of products in waiting for inspection” and “inspection length” indicating the characteristics of each inspection field. In the structure data 302 in FIG. 3, two pieces of structure data of “inspection field 1” and “inspection field 2” are stored.

[0036] The “maximum number of products in waiting for inspection” is a parameter representing the maximum value of the accumulated number of products scheduled to be input to the inspection field, and the “inspection length” is a parameter representing the time required for inspection at the inspection field. In the “inspection length” of this embodiment, the number of time slots of a predetermined length is set. For example, if 1 slot is 10 seconds and “10” is set in the “inspection length”, it indicates that the inspection at the inspection field takes 100 seconds.

[0037] The product information 400 stores entries including a product ID 401, a sampling 402, and an option 403. There is one entry for one product. Note that the fields included in the entry are not limited to those described above. It may not include any of the above-described fields, or may include other fields. For example, a field for storing skills required for the business may be included.

[0038] The product ID 401 is a field that stores the ID of the product. The sampling 402 is a field that stores a value indicating whether the product is the one to be inspected. In the sampling 402 of this embodiment, either "True" indicating that the product is the one to be inspected or "False" indicating that the product is not the one to be inspected is stored. The option 403 is a field that stores a value indicating whether the product has any characteristics. In the option 403 of this embodiment, either "True" indicating that the product has any characteristics or "False" indicating that the product has no characteristics is stored.

[0039] When generating the mathematical programming model, constraint conditions regarding either the sampling 402 or the option 403 can be set. For example, constraint conditions such as not selecting products with the sampling 402 being "False" and not continuously inputting more than n products with the option 403 being "True" can be considered.

[0040] FIG. 5 is a diagram showing an example of the product input plan generated by the product input plan generation system 103 of Example 1.

[0041] The product input plan 500 stores entries including the input order 501, the product ID 502, and the sampling 503. One entry corresponds to one product. Note that the fields included in the entry are not limited to those described above. It may not include any of the fields described above, or may include other fields. For example, a field for storing the skills required for the business may be included.

[0042] The input order 501 is a field that stores the input order of the product to the production line. In this embodiment, it is assumed that the products are input to the production line in order from "1". The product ID 502 and the sampling 503 are the same fields as the product ID 401 and the sampling 402.

[0043] Based on the product input plan 500, the control system of the manufacturing line inputs the products with sampling 503 being "False" into the normal lanes of the manufacturing line, and inputs the products with sampling 503 being "True" into the inspection lane.

[0044] Note that in this embodiment, it is assumed that a product input plan 500 is generated in which products are input every one time slot.

[0045] The structure of the manufacturing line will be described with reference to FIG. 6.

[0046] FIG. 6A, FIG. 6B, and FIG. 6C are diagrams showing an example of the structure of the manufacturing line.

[0047] The manufacturing line shown in FIGS. 6A, 6B, and 6C includes a normal lane 601 and an inspection lane 602.

[0048] The inspection lane 602 is composed of at least one inspection area and at least one inspection waiting area. The inspection area is a space where product inspection is performed. The inspection waiting area is a space where products to be inspected wait, and functions as a buffer for products in the inspection lane 602. In this embodiment, it is assumed that one product can be inspected in one inspection area and one product can be buffered in one inspection waiting area.

[0049] The inspection lane 602 shown in FIGS. 6A, 6B, and 6C is composed of two inspection areas 611, 612 and three inspection waiting areas 621, 622, 623.

[0050] As shown in FIG. 6B, products that are not inspection targets are input into the normal lane 601. Also, as shown in FIG. 6C, products that are inspection targets are input into the inspection lane 602.

[0051] The overall processing flow of the computer system will be described.

[0052] FIG. 7 is a sequence diagram for explaining the overall processing flow of the computer system of Embodiment 1.

[0053] In FIG. 7, the process flow from when a product input plan is generated based on the information input from the operation terminal 104 until it is output to the operation terminal 104 will be described.

[0054] The user uses the operation terminal 104 to transmit inspection lane structure information to the inspection status generation system 101 (step S701).

[0055] The inspection status generation system 101 generates an inspection status based on the inspection lane structure information (step S702), and transmits the inspection status to the mathematical programming model generation system 102 (step S703). Details of the inspection status generation process will be described later.

[0056] The mathematical programming model generation system 102 registers the inspection status received from the inspection status generation system 101 (step S704). Further, the mathematical programming model generation system 102 transmits a registration completion notification notifying the operation terminal 104 that the inspection status has been registered (step S705).

[0057] The user uses the operation terminal 104 to transmit product information to the mathematical programming model generation system 102 (step S706).

[0058] The mathematical programming model generation system 102 generates a mathematical programming model based on the inspection status and product information (step S707), and transmits the mathematical programming model to the product input plan generation system 103 (step S708). Details of the mathematical programming model generation process will be described later.

[0059] The product input plan generation system 103 generates a product input plan by searching for the optimal product input order (optimal solution of the mathematical programming model) using the mathematical programming model (step S709), and transmits the product input plan to the operation terminal 104 (step S710).

[0060] Note that the inspection status generation system 101 may send a registration completion notice. Also, the registration completion notice may not be sent.

[0061] Note that the user may send product information to the mathematical programming model generation system 102 before registering the inspection status.

[0062] Note that the sequence shown in FIG. 7 is an example and is not limited thereto. As long as it is a procedure for generating a mathematical programming model, the processing procedures from step S701 to step S706 may be interchanged.

[0063] FIG. 8 is a flowchart for explaining an example of the inspection status generation process executed by the inspection status generation system 101 of Example 1. FIG. 9 is a diagram showing an example of an inspection module generated by the inspection status generation system 101 of Example 1. FIG. 10 is a flowchart showing the transition rule of the state variable of the inspection module generated by the inspection status generation system 101 of Example 1. FIG. 11 is a diagram showing an example of the transition of the state variable of the inspection module of Example 1. FIG. 12 is a diagram showing an example of the method for generating the inspection status of Example 1.

[0064] The inspection lane structure information acquisition unit 111 acquires the inspection lane structure information transmitted from the operation terminal 104 (step S801).

[0065] Here, it is assumed that the inspection lane structure information 300 shown in FIG. 3 is acquired. The inspection lane structure information shown in FIG. 3 corresponds to the inspection lane 602 having the structure shown in FIG. 6A. In the inspection lane 602, there are two inspection fields: an inspection field 611 (inspection field 1) and an inspection field 612 (inspection field 2). Since the upper limit value of the number of products waiting for inspection in the inspection field 611 is "2", there are two inspection waiting fields 621 and 622 in front of the inspection field 611. Since the upper limit value of the number of products waiting for inspection in the inspection field 612 is "1", there is one inspection waiting field 623 in front of the inspection field 612.

[0066] The inspection module generation unit 112 divides the inspection lane into blocks composed of an inspection site and a waiting area for inspection that exists between the manufacturing lane and the inspection site or between inspection sites, and generates an inspection module that is a mathematical model representing the state of the product flow in each block (step S802). Here, the blocks and the inspection module will be described with reference to FIG. 9.

[0067] The inspection module of the block including inspection site i (i is an integer) consists of six state variables: sampling parameter Q i [t], inspection waiting parameter X i [t], inspection site usage parameter S i [t], inspection site input parameter I i [t], inspection site output parameter O i [t], and inspection count parameter C i [t]. In the inspection module, the waiting areas for inspection included in the block are aggregated and managed as one.

[0068] The sampling parameter Q i [t] is a state variable representing the presence or absence of products carried into the inspection waiting area at time t. If there are products carried into the inspection waiting area, Q i [t] becomes "1", and if there are no products carried into the inspection waiting area, Q i [t] becomes "0".

[0069] The inspection waiting parameter X i [t] is a state variable representing the number of products buffered in the inspection waiting area at time t. X i [t] is an integer greater than or equal to 0.

[0070] The inspection site usage parameter S i [t] is a state variable representing the presence or absence of products at the inspection site at time t. If there are products at the inspection site, S i [t] becomes "1", and if there are no products at the inspection site, S i [t] becomes "0".

[0071] The inspection site input parameter I iI[t] is a state variable representing the presence or absence of products carried into the inspection area at time t. If there are products carried into the inspection area, I i [t] becomes "1", and if there are no products carried into the inspection area, I i [t] becomes "0".

[0072] Inspection area output parameter O i O[t] is a state variable representing the presence or absence of products carried out from the inspection area at time t. If there are products carried out from the inspection area, O i [t] becomes "1", and if there are no products carried out from the inspection area, O i [t] becomes "0".

[0073] Inspection count parameter C i C[t] is a state variable representing the inspection elapsed time of products present in the inspection area at time t. C i [t] is an integer greater than or equal to 0.

[0074] Inspection waiting parameter X i For X[t], the relational expression of Equation (1) holds. Here, W i represents the upper limit value of the number of products waiting for inspection in inspection area i.

[0075]

Equation

[0076] Inspection count parameter C i For C[t], the relational expression of Equation (2) holds. Here, T i represents the inspection length of inspection area i.

[0077]

Equation

[0078] Inspection waiting parameter X i The time transition of X[t] is defined by Equation (3). As shown in Equation (3), X at time t i[t] is X at time (t - 1). i At [t - 1], add Q at time t i [t], and further subtract I at time t i [t] to obtain.

[0079] [Number]

[0080] Inspection site usage parameter S i The time transition of [t] is defined by Equation (4). As shown in Equation (4), S at time t i [t] is S at time (t - 1). i [t - 1], add I at time t i [t], and further subtract O at time t i [t] to obtain.

[0081] [Number]

[0082] Also, the state variable transitions according to the branch conditions as shown in Figure 10.

[0083] C at time (t - 1). i [t - 1] is T i If it is smaller (step S1001 is YES), that is, if the inspection elapsed time of the product at the inspection site is smaller than the inspection length, the inspection is not completed and the product is not carried out of the inspection site, so O i [t] is "0" (step S1002). Also, if there is a product at the inspection site at time t, that is, S i is "1" (step S1003 is YES), the value obtained by adding 1 to C i [t - 1] at time (t - 1) is C i [t] (step S1004). On the other hand, if there is no product at the inspection site at time t (step S1003 is NO), C i [t] becomes "0".

[0084] C at time (t-1) i [t-1] is T i In the above case (step S1001 is NO), that is, when the inspection elapsed time of the product at the inspection site is equal to or longer than the inspection length, the inspection is completed and the product is carried out from the inspection site, so O i [t] is "1" (step S1006). Also, when there is a product carried into the inspection site at time t, that is, I i is "1" (step S1007 is YES), a product is carried into the inspection site and the inspection is started, so S i [t] becomes "1", and C i [t] becomes "1" (step S1008). On the other hand, when there is no product carried into the inspection site at time t, that is, I i is "1" (step S1007 is NO), no product is carried into the inspection site and the inspection is not started, so S i [t] becomes "0", and C i [t] becomes "0" (step S1009).

[0085] As described above, the inspection module is defined by formulas (1) to (4) and the transition rules of state variables.

[0086] Here, FIG. 11 shows a transition example of state variables of an inspection module of a production line including an inspection lane composed of one inspection site. Here, the upper limit value of the number of products waiting for inspection is 2, and the inspection length is 3 time slots. Also, it is assumed that products are input into the production line in units of 1 time slot.

[0087] When a product is carried into inspection lane 602 at time t1, since the product is carried into the inspection waiting area, Q[t1] becomes "1". Since there is no product in the inspection site, the product carried into the inspection waiting area is carried into the inspection site without being buffered. Therefore, X[t1] is "0", I[t1] is "1", S[t1] is "1", and C[t1] is "1". Also, since no product is carried out from the inspection site, O[t1] is "0".

[0088] When a product is carried into the normal lane 601 at time t2, Q[t2], X[t2], and I[t2] each become "0". Since C[t1] is smaller than the inspection length, O[t2] becomes "0". Since there is a product being inspected in the inspection waiting area, S[t2] is "1". Therefore, C[t2] becomes "2".

[0089] When a product is carried into the normal lane 601 at time t3, Q[t3], X[t3], and I[t3] each become "0". Since C[t2] is smaller than the inspection length, O[t3] becomes "0". Since there is a product being inspected in the inspection waiting area, S[t3] is "1". Therefore, C[t3] becomes "3".

[0090] When a product is carried into the normal lane 601 at time t4, Q[t4], X[t4], and I[t4] each become "0". Since C[t3] is equal to the inspection length, O[t4] becomes "1". Since I[t4] is "0", S i [t4] and C[t4] become "0".

[0091] When a product is carried into the inspection lane 602 at time t5, each state variable becomes the same value as at time t1.

[0092] When a product is carried into the inspection lane 602 at time t6, since a product is carried into the inspection waiting area, Q[t6] becomes "1". Since there is a product in the inspection area, the carried-in product is buffered in the inspection waiting area. Therefore, X[t6] becomes "1" and I[t6] becomes "0". Since C[t5] is smaller than the inspection length, O[t3] becomes "0". Since there is a product being inspected in the inspection waiting area, S[t6] is "1". Therefore, C[t6] becomes "2".

[0093] When a product is carried into the inspection lane 602 at time t7, since the product is carried into the inspection waiting area, Q[t7] becomes "1". Since there is a product in the inspection area, the carried-in product is buffered in the inspection waiting area. Therefore, X[t7] becomes "2" and I[t7] becomes "0". Since C[t6] is smaller than the inspection length, O[t6] becomes "0". Since there is a product under inspection in the inspection waiting area, S[t7] is "1". Therefore, C[t7] becomes "3".

[0094] By defining the relational expressions of each parameter based on the number of inspection waiting areas included in the block and the time required for inspection, inspection modules (mathematical models) of various inspection areas can be generated.

[0095] The above is the description of the block and the inspection module. Return to the description of Figure 8.

[0096] The inspection module generation unit 112 of this embodiment divides the inspection lane 602 into a block 901 composed of an inspection area 611 and inspection waiting areas 621, 622, and a block 902 composed of an inspection area 612 and an inspection waiting area 623. The inspection module generation unit 112 generates inspection modules 911, 912 from each of the blocks 901, 902.

[0097] Next, the inspection status generation unit 113 generates an inspection status using the inspection module (step S803).

[0098] Specifically, the inspection status generation unit 113 defines a relational expression in which the inspection area output parameter O i [t] of the front inspection module and the sampling parameter Q j [t] of the rear inspection module match, thereby connecting the two inspection modules. When three or more inspection modules are generated, the inspection status generation unit 113 generates pairs of inspection modules along the flow of the product, and defines relational expressions for each pair of inspection modules to connect the inspection modules.

[0099] FIG. 12 shows an inspection status 1200 generated by connecting inspection module 911 and inspection module 912. Inspection module 911 and inspection module 912 are connected by defining a relational expression in which O1[t] of inspection module 911 and O2[t] of inspection module 912 match.

[0100] By dividing the inspection lane 602 in block units, generating inspection modules corresponding to the blocks, and further connecting the inspection modules, a mathematical model representing the state of the product flow in the inspection lane can be generated. By adjusting the parameters of the inspection modules and the connection between the inspection modules, inspection statuses (mathematical models) of various inspection lanes can be generated.

[0101] Next, the inspection status output unit 114 transmits the inspection status to the mathematical programming model generation system 102 (step S804).

[0102] FIG. 13 is a flowchart for explaining an example of the mathematical programming model generation process executed by the mathematical programming model generation system 102 of the first embodiment.

[0103] The mathematical programming model generation system 102 acquires the inspection status from the inspection status generation system 101 and also acquires the product information from the operation terminal 104 (step S1301).

[0104] Based on the inspection status and the product information, the mathematical programming model generation system 102 generates a mathematical programming model for generating a product input plan defined by the state variables of the production line and achieving a predetermined objective (step S1302). Since the generation of the mathematical programming model may use known techniques, detailed description is omitted. The inspection status is incorporated, for example, as a constraint condition in the mathematical programming model.

[0105] The mathematical programming model generation system 102 transmits the mathematical programming model to the product input plan generation system 103 (step S1303).

[0106] As described above, according to this embodiment, by using the generated mathematical programming model using the inspection status representing the state of the product flow in the inspection lane, a product input plan considering the product flow in the inspection lane can be generated. Thereby, the effectiveness and productivity of the product input plan of the production line can be improved.

[0107] Note that the present invention is not limited to the above-described embodiments and includes various modifications. For example, the above-described embodiments are those in which the configuration is described in detail for easy understanding of the present invention, and are not necessarily limited to those having all the configurations described. Also, for a part of the configuration of each embodiment, it is possible to add, delete, or replace other configurations.

[0108] In addition, each of the above configurations, functions, processing units, processing means, etc. may be realized in hardware by designing part or all of them, for example, by an integrated circuit. Also, the present invention can be realized by a program code of software that realizes the functions of the embodiments. In this case, a storage medium storing the program code is provided to a computer, and a processor included in the computer reads the program code stored in the storage medium. In this case, the program code itself read from the storage medium realizes the functions of the above-described embodiments, and the program code itself and the storage medium storing it constitute the present invention. As a storage medium for supplying such a program code, for example, a flexible disk, CD-ROM, DVD-ROM, hard disk, SSD (Solid State Drive), optical disk, magneto-optical disk, CD-R, magnetic tape, non-volatile memory card, ROM, etc. are used.

[0109] Also, the program code for realizing the functions described in this embodiment can be implemented in a wide range of programs or script languages such as assembler, C / C++, perl, Shell, PHP, Python, Java (registered trademark), etc.

[0110] Furthermore, the program code of the software that realizes the functions of the embodiments may be distributed via a network, stored in a storage means such as a hard disk or memory of a computer, or a storage medium such as a CD-RW or CD-R, and the processor included in the computer may read and execute the program code stored in the storage means or the storage medium.

[0111] In the above embodiments, the control lines and information lines show those considered necessary for explanation, and not necessarily all the control lines and information lines are shown on the product. All the components may be interconnected.

Explanation of Signs

[0112] 101 Inspection Status Generation System 102 Mathematical Programming Model Generation System 103 Product Input Plan Generation System 104 Operation Terminal 111 Inspection Lane Structure Information Acquisition Unit 112 Inspection Module Generation Unit 113 Inspection Status Generation Unit 114 Inspection Status Output Unit 200 Computer 201 CPU 202 Storage Device 203 Network Interface 300 Inspection Lane Structure Information 400 Product Information 500 Product Input Plan 601 Normal Lane 602 Inspection Lane 611, 612 Inspection Sites 621, 622, 623 Inspection Waiting Areas 901, 902 Blocks 911, 912 Inspection Modules 1200 Inspection Status

Claims

1. A computer system for generating a product input plan representing the order of product input in a manufacturing line, comprising at least one computer having a processor and a storage device connected to the processor, wherein the manufacturing line includes an inspection lane where product inspection is performed, and the at least one computer, generates an inspection status, which is a mathematical model representing the state of product flow in the inspection lane, based on inspection lane structure information regarding the structure of the inspection lane, stores it in the storage device, when receiving an input of product information regarding a product to be input into the manufacturing line, generates a mathematical planning model defined by state variables regarding the state of the manufacturing line based on the inspection status and the product information, for generating the product input plan for achieving a predetermined objective in the manufacturing line, and stores it in the storage device, generates the product input plan using the mathematical planning model and stores it in the storage device. A computer system characterized by the above.

2. The computer system according to claim 1, wherein the inspection lane is composed of one block including an inspection area where inspection of inspection products is performed and at least one inspection waiting area functioning as a buffer for the inspection products to the inspection area, or is composed of a plurality of the blocks, and the at least one computer, generates an inspection module, which is a mathematical model representing the state of product flow in the block, based on the inspection lane structure information, and generates the inspection status using the inspection module. A computer system characterized by the above.

3. The computer system according to claim 2, wherein the inspection module, at a certain time, includes a first state variable indicating whether the inspection product is input into the block, at a certain time, a second state variable indicating the number of the inspection products existing in the inspection waiting area included in the block, at a certain time, a third state variable indicating whether the inspection product exists in the inspection area included in the block, at a certain time, a fourth state variable indicating whether the inspection product is input into the inspection area included in the block, at a certain time, a fifth state variable indicating whether the inspection product is output from the inspection area included in the block. At a certain time, a sixth state variable indicating the time elapsed since the inspection product was input to the inspection site included in the block, A computer system characterized by being a mathematical model using the above as state variables.

4. The computer system according to claim 3, The inspection lane structure information includes a first threshold value representing the upper limit number of the inspection products that can be buffered in the block included in the inspection lane, and a second threshold value representing the time required for inspecting the inspection products. The at least one computer, A conditional expression defined by the second state variable and the first threshold value, A conditional expression defined by the sixth state variable and the second threshold value, A relational expression representing the time transition of the second state variable defined by the first state variable, the second state variable, and the fourth state variable, A relational expression representing the time transition of the third state variable defined by the third state variable, the fourth state variable, and the fifth state variable, A computer system characterized by generating the inspection module defined by the above.

5. The computer system according to claim 4, The at least one computer generates the inspection status by connecting the plurality of inspection modules by defining a relational expression between the fifth state variable of one block and the first state variable of the other blocks connected to the block. A computer system characterized by that.

6. A method for generating a product input plan representing the input order of products in a manufacturing line, which is executed by a computer system, The computer system includes at least one computer having a processor and a storage device connected to the processor, The manufacturing line includes an inspection lane where product inspection is performed, The method for generating the product input plan is as follows. In the first step, the at least one computer generates an inspection status, which is a mathematical model representing the state of the product flow in the inspection lane, based on the inspection lane structure information regarding the structure of the inspection lane, and stores it in the storage device. When the at least one computer receives an input of product information regarding a product to be input into the manufacturing line, it generates a mathematical planning model defined by state variables regarding the state of the manufacturing line based on the inspection status and the product information, and generates a product input plan for achieving a predetermined objective in the manufacturing line, and stores the model in the storage device in a second step; A method for generating a product input plan, comprising: a third step in which the at least one computer generates the product input plan using the mathematical planning model and stores the plan in the storage device. **Claim 7** The method for generating a product input plan according to claim 6, wherein the inspection lane is composed of an inspection site where inspection of inspection products is performed and at least one inspection waiting site that functions as a buffer for the inspection products to the inspection site, or is composed of a plurality of the blocks; The first step is a fourth step in which the at least one computer generates an inspection module, which is a mathematical model representing a state of product flow in the block, based on the inspection lane structure information; a fifth step in which the at least one computer generates the inspection status using the inspection module. A method for generating a product input plan is characterized by including these steps. **Claim 8** The method for generating a product input plan according to claim 7, wherein the inspection module is a first state variable indicating whether the inspection product is input into the block at a certain time; a second state variable indicating the number of the inspection products present in the inspection waiting site included in the block at a certain time; a third state variable indicating whether the inspection product is present in the inspection site included in the block at a certain time; a fourth state variable indicating whether the inspection product is input into the inspection site included in the block at a certain time; a fifth state variable indicating whether the inspection product is output from the inspection site included in the block at a certain time; a sixth state variable indicating the time elapsed since the inspection product was input into the inspection site included in the block at a certain time; A method for generating a product input plan, characterized in that it is a mathematical model having the above as state variables. **Claim 9** The method for generating a product input plan according to claim 8, The inspection lane structure information includes a first threshold value representing the upper limit number of the inspection products that can be buffered in the block included in the inspection lane, and a second threshold value representing the time required for the inspection of the inspection products. The fourth step includes a step in which the at least one computer generates the inspection module defined by a conditional expression defined by the second state variable and the first threshold value, a conditional expression defined by the sixth state variable and the second threshold value, a relational expression representing the time transition of the second state variable defined by the first state variable, the second state variable, and the fourth state variable, and a relational expression representing the time transition of the third state variable defined by the third state variable, the fourth state variable, and the fifth state variable. A method for generating a product input plan, characterized in that it comprises the steps of:

10. A method for generating a product input plan according to claim 9, The fifth step includes a step in which the at least one computer defines a relational expression between the fifth state variable of one of the blocks and the first state variable of the other blocks connected to the block, thereby connecting the plurality of inspection modules to generate the inspection status. A method for generating a product input plan, characterized in that it comprises the steps of:

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