Production management system, production management method and program

Abstract

This production management system comprises: a manufacturing time acquisition unit (304); and a production plan information creation unit (305). The manufacturing time acquisition unit (304) acquires manufacturing time necessary for manufacturing each of a plurality of products. The production plan information creation unit (305) creates production plan information indicating manufacturing start time point for starting manufacturing of each of the products, in accordance with the manufacturing time of said product acquired by the manufacturing time acquisition unit (304), manufacturing order information indicating the preset order for manufacturing the products, and scheduled operation start time point or scheduled operation end time point on an operation day at a product plant for manufacturing the products. The manufacturing time acquisition unit (304) acquires an actual value of time required for manufacturing one of the plurality of products as manufacturing time of said product, when the one of the products is already manufactured.

Description

[Technical Field]

[0001] The present disclosure relates to a production management system, a production management method, and a program. [Background technology]

[0002] There are known technologies that support users who manage the production of products in factories. For example, Patent Document 1 discloses a device that predicts the arrival times of components, determines the order in which each product should be manufactured according to the arrival times of the components, and creates a production plan for the products according to this order. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Laid-Open No. 2006-72746 Summary of the Invention [Problem to be solved by the invention]

[0004] However, if the actual manufacturing conditions of a product deviate from the conditions assumed when the manufacturing plan was created using the device described in Patent Document 1, the created manufacturing plan may not be useful to the user. For example, if the product is manufactured at a faster manufacturing pace than assumed when the plan was created, or if components do not arrive at the predicted arrival time, it becomes impossible to manufacture the product according to the created manufacturing plan. In this case, the device described in Patent Document 1 cannot provide the user with information useful for managing product manufacturing, which is inconvenient for the user.

[0005] The present disclosure has been made in consideration of the above circumstances, and aims to enable appropriate management of product manufacturing. [Means for solving the problem]

[0006] To achieve the above object, the production management system according to the present disclosure includes a manufacturing time acquisition means and a production plan information creation means. The manufacturing time acquisition means acquires the manufacturing time required to manufacture each of a plurality of products. The production plan information creation means creates production plan information indicating the manufacturing start time for each product, based on the manufacturing time for each product acquired by the manufacturing time acquisition means, manufacturing sequence information indicating a predetermined order in which the products are to be manufactured, and a scheduled start time or scheduled end time for operations on an operating day of a product factory that manufactures the plurality of products. When one of the plurality of products has already been manufactured, the manufacturing time acquisition means acquires, as the manufacturing time of the one product, the actual value of the time required to manufacture the one product. When one of the plurality of products has not yet been manufactured and other products of the same model as the one product have not yet been manufactured, the manufacturing time acquisition means acquires, as the manufacturing time of the one product, a predetermined predicted manufacturing time that is a predicted value of the time required to manufacture the one product. The manufacturing time acquisition means acquires, when one of the plurality of products has not yet been manufactured, and other products of the same model as the one product have been manufactured among the plurality of products, and the manufacturing conditions of the one product satisfy a predetermined reference condition, a representative value of the actual value of the time required to manufacture the other products as the manufacturing time of the one product.When one of the plurality of products has not yet been manufactured, and other products of the same model as the one product have been manufactured among the plurality of parts, and the manufacturing conditions of the one product do not satisfy the reference condition, the manufacturing time acquisition means acquires, when one of the plurality of products has not yet been manufactured, and other products of the same model as the one product have been manufactured among the plurality of parts, and the manufacturing conditions of the one product do not satisfy the reference condition, a predicted manufacturing time of the one product as the manufacturing time of the one product. [Effects of the Invention]

[0007] The production management system having the above configuration acquires the manufacturing time of a product according to the manufacturing performance of the product, and creates and outputs production plan information according to the acquired manufacturing time of the product. This provides the user with production plan information according to the manufacturing performance of the product, which is useful information for managing the manufacturing of the product. This makes it possible to appropriately manage the manufacturing of the product. [Brief explanation of the drawings]

[0008] [Figure 1] FIG. 1 is a diagram illustrating a configuration of a production management system according to an embodiment of the present disclosure. [Figure 2] FIG. 1 is a diagram illustrating hardware configurations of a worker terminal, a production plan information creation device, a berth availability detection device, a parts delivery predicted time calculation device, and a missing-stock determination device according to an embodiment of the present disclosure. [Figure 3] FIG. 1 is a diagram illustrating a hardware configuration of an in-vehicle device according to an embodiment of the present disclosure. [Figure 4] FIG. 1 is a diagram illustrating a hardware configuration of a bus monitoring device according to an embodiment of the present disclosure. [Figure 5] FIG. 1 is a diagram illustrating a functional configuration of a worker terminal according to an embodiment of the present disclosure. [Figure 6] FIG. 1 is a diagram illustrating an example of manufacturing performance information according to an embodiment of the present disclosure. [Figure 7] FIG. 1 is a diagram illustrating a functional configuration of a production plan information creation device according to an embodiment of the present disclosure. [Figure 8] FIG. 10 is a diagram illustrating an example of predicted manufacturing time information according to an embodiment of the present disclosure. [Figure 9] FIG. 1 is a diagram illustrating an example of manufacturing sequence information according to an embodiment of the present disclosure. [Figure 10] FIG. 1 is a diagram illustrating an example of production plan information according to an embodiment of the present disclosure. [Figure 11] 1 is a diagram showing a functional configuration of an in-vehicle device according to an embodiment of the present disclosure; [Figure 12] FIG. 1 is a diagram illustrating a functional configuration of a bus monitoring device according to an embodiment of the present disclosure. [Figure 13] FIG. 1 is a diagram illustrating a functional configuration of a berth vacancy detection device according to an embodiment of the present disclosure. [Figure 14] FIG. 1 is a diagram illustrating an example of entrance / exit information according to an embodiment of the present disclosure. [Figure 15] FIG. 1 is a diagram illustrating an example of vehicle owner information according to an embodiment of the present disclosure. [Figure 16] FIG. 10 is a diagram illustrating an example of average stay time information according to an embodiment of the present disclosure. [Figure 17] FIG. 1 is a diagram illustrating a functional configuration of a part delivery predicted time calculation device according to an embodiment of the present disclosure. [Figure 18]FIG. 10 is a diagram illustrating an example of part loading information according to an embodiment of the present disclosure. [Figure 19] FIG. 10 is a diagram illustrating an example of predicted part delivery time information according to an embodiment of the present disclosure. [Figure 20] FIG. 1 is a diagram illustrating a functional configuration of a missing item determination device according to an embodiment of the present disclosure. [Figure 21] FIG. 1 is a diagram illustrating an example of model information according to an embodiment of the present disclosure. [Figure 22] FIG. 1 is a diagram illustrating an example of component part information according to an embodiment of the present disclosure. [Figure 23] FIG. 10 is a diagram illustrating an example of missing-stock determination information according to an embodiment of the present disclosure. [Figure 24] FIG. 1 is a sequence diagram illustrating the operation of a production management system according to an embodiment of the present disclosure. [Figure 25] 1 is a flowchart illustrating a production plan information creation process executed by a production plan information creation device according to an embodiment of the present disclosure. [Figure 26] FIG. 1 is a sequence diagram illustrating the operation of a production management system according to an embodiment of the present disclosure. [Figure 27] A flowchart for explaining a berth vacancy detection process executed by a berth vacancy detection device according to an embodiment of the present disclosure. [Figure 28] FIG. 1 is a sequence diagram illustrating the operation of a production management system according to an embodiment of the present disclosure. DETAILED DESCRIPTION OF THE INVENTION

[0009] Hereinafter, a production management system, a production management method, and a program according to an embodiment of the present disclosure will be described with reference to the drawings. In the drawings, identical components are denoted by the same reference numerals.

[0010] (Overall configuration of production management system) The production management system 100 shown in FIG. 1 supports a user who manages the production of products in a product factory AA. In the product factory AA, multiple models of products are manufactured using a JIT (Just In Time) production method. Hereinafter, the multiple products manufactured in the product factory AA will be collectively referred to as target products. The target product is an example of multiple products. The user of the production management system 100 is the production manager of the product factory AA. In FIG. 1, the dashed arrow BB indicates the flow of product parts.

[0011] Product parts are manufactured at parts factories CC owned by each parts manufacturer, then loaded onto transport vehicles DD and transported from parts factories CC or wholesalers to product factory AA. Berth EE is located on the site of product factory AA, and berth EE has three parking spaces FF for transport vehicles DD to park in. Parts unloaded from transport vehicles DD parked in parking spaces FF are inspected and divided into predetermined batches before being transported to manufacturing area HH, located inside building GG of product factory AA, where the target product is manufactured. Manufacturing area HH is equipped with one workbench for workers to work on. In manufacturing area HH, one worker manually manufactures the target product from the parts that have been transported in.

[0012] The production management system 100 creates and outputs production plan information indicating the production start time for each target product to be manufactured in the manufacturing area HH, based on the manufacturing performance of the product in the manufacturing area HH.

[0013] Furthermore, the production management system 100 creates and outputs predicted part delivery time information indicating the predicted part delivery time, which is a predicted value of the time when the parts unloaded from the transport vehicle DD at berth EE will be delivered to the manufacturing area HH and will be able to be input into the product manufacturing process. The production management system 100 creates the predicted part delivery time information depending on whether the transport vehicle DD will be able to park at the berth EE and unload the parts from the transport vehicle DD at the berth EE at the predicted vehicle arrival time, which is a predicted value of the time when the transport vehicle DD will arrive at the product factory AA.

[0014] In addition, the production management system 100 determines whether or not parts for each product have been delivered to the production area HH at the production start time of that product, based on the production plan information and the predicted parts delivery time information, and creates and outputs stockout determination information indicating the results of the determination.

[0015] The production management system 100 comprises a worker terminal 200 that accepts information input by workers, a production plan information creation device 300 that creates production plan information according to product manufacturing results, an on-board device 400 mounted on each transport vehicle DD that transports parts to the product factory AA, a berth monitoring device 500 that monitors the entry and exit of transport vehicles DD at berth EE, a berth availability detection device 600 that detects whether the transport vehicle DD will be parked at berth EE at the predicted vehicle arrival time and whether parts can be unloaded from the transport vehicle DD at berth EE, a parts delivery prediction time calculation device 700 that calculates the predicted parts delivery time, and a stockout determination device 800 that determines whether product parts have been delivered to the production area HH at the production start time of each product.

[0016] The worker terminal 200, the production plan information creation device 300, the berth availability detection device 600, the parts delivery predicted time calculation device 700, and the stockout determination device 800 are installed inside building GG of the product factory AA. The berth monitoring device 500 is installed in berth EE of the product factory AA.

[0017] (Hardware configuration of production management system) The worker terminal 200, the production plan information creation device 300, the berth availability detection device 600, the parts delivery predicted time calculation device 700, and the stockout determination device 800 are information processing devices such as PCs (Personal Computers) and tablet terminals, and as shown in FIG. 2, each includes a processor 1 that executes various processes, a main memory unit 2 that functions as a work area for the processor 1, an auxiliary memory unit 3 that stores data and programs used by the processor 1 for various processes, an operation unit 4 that accepts input of various instructions, a display unit 5 that displays various images, a communication unit 6 that communicates with external devices, a timing unit 7 that keeps time, and a system bus 8 that interconnects the processor 1 to the timing unit 7.

[0018] 3, the in-vehicle device 400 is a car navigation device and includes a processor 9 that executes various processes, a main memory unit 10 that functions as a work area for the processor 9, an auxiliary memory unit 11 that stores data and programs used by the processor 9 for various processes, an operation unit 12 that accepts input of various instructions, a display unit 13 that displays various images, a communication unit 14 that communicates with external devices, a timing unit 15 that keeps time, a positioning unit 16 that detects the current position of the transport vehicle DD on which the device is mounted, and a system bus 17 that interconnects the processor 9 to the positioning unit 16. The positioning unit 16 includes an antenna, receives positioning signals from multiple positioning satellites, and detects the current position of the transport vehicle DD according to the received positioning signals.

[0019] 4, the berth monitoring device 500 includes a processor 18 that executes various processes, a main memory unit 19 that functions as a work area for the processor 18, an auxiliary memory unit 20 that stores data and programs used by the processor 18 for various processes, a communication unit 21 that communicates with external devices, an imaging unit 22 that captures images, and a system bus 23 that interconnects the processor 18 and the imaging unit 22. The imaging unit 22 is disposed in a position where it can capture images of transport vehicles DD entering and leaving the berth EE.

[0020] (Functional configuration of worker terminal 200) As shown in FIG. 5, the worker terminal 200 shown in FIG. 1 functionally includes a manufacturing performance information creation unit 201 that creates manufacturing performance information indicating the manufacturing performance of products in the manufacturing area HH, a manufacturing performance information storage unit 202 that stores the manufacturing performance information created by the manufacturing performance information creation unit 201, and a manufacturing performance information transmission unit 203 that transmits the manufacturing performance information to the production plan information creation device 300.

[0021] The manufacturing performance information creation unit 201 and the manufacturing performance information transmission unit 203 are realized by the processor 1 of the worker terminal 200. The processor 1 functions as these units by executing programs stored in the auxiliary storage unit 3. The manufacturing performance information storage unit 202 is realized by the auxiliary storage unit 3. In other words, the manufacturing performance information storage unit 202 is constructed in a storage area of ​​the auxiliary storage unit 3.

[0022] 6 shows an example of the manufacturing performance information created by the manufacturing performance information creation unit 201. The manufacturing performance information shows, for each target product manufactured in the manufacturing area HH, a manufacturing number which is a product identifier, a manufacturing status of the product, i.e., whether or not the manufacturing of the product has been completed, an actual manufacturing start time which is an actual value of the time when the manufacturing of the product started, an actual manufacturing end time which is an actual value of the time when the manufacturing of the product ended, and an actual manufacturing time which is an actual value of the time required to manufacture the product, all of which are associated with one another.

[0023] The production performance information creation unit 201 creates production performance information according to information input by the worker to the worker terminal 200. Specifically, when starting production of a product, the worker operates the operation unit 4 of the worker terminal 200 to input production start information indicating that production of the product has started. The production performance information creation unit 201 detects the time when the production start information is input as the production start performance time. When production of the product is completed, the worker operates the operation unit 4 to input production end information indicating that production of the product has ended. When the production end information is input, the production performance information creation unit 201 detects that production of the product has been completed. The production performance information creation unit 201 detects the time when the production end information is input as the production end performance time. The production performance information creation unit 201 detects the time when the production end information is input as the production end performance time. The production performance information creation unit 201 detects the time from the production start performance time to the production end performance time as the production end performance time. Every time a worker inputs information to the worker terminal 200, the manufacturing performance information creation unit 201 creates manufacturing performance information in accordance with the input information and stores it in the manufacturing performance information storage unit 202, thereby updating the manufacturing performance information stored in the manufacturing performance information storage unit 202.

[0024] Returning to FIG. 5 , when the manufacturing performance information transmitting unit 203 receives a manufacturing performance information transmission request requesting transmission of manufacturing performance information from the production plan information creation device 300 via the communication unit 6, the manufacturing performance information transmitting unit 203 transmits the manufacturing performance information read out from the manufacturing performance information storage unit 202 to the production plan information creation device 300 via the communication unit 6.

[0025] (Functional configuration of production plan information creation device 300) 7, the production plan information creation device 300 shown in FIG. 1 functionally comprises: a production performance information acquisition unit 301 that acquires production performance information from the worker terminal 200; a predicted production time information storage unit 302 that stores predicted production time information that indicates, for each model, a predetermined predicted production time that is a predicted value of the time required to manufacture each product to be manufactured in the production area HH; a production sequence information storage unit 303 that stores production sequence information that indicates the predetermined sequence in which each product will be manufactured; a production time acquisition unit 304 that acquires the production time required to manufacture each product; a production plan information creation unit 305 that creates production plan information; a production plan information output unit 306 that outputs the production plan information created by the production plan information creation unit 305; a production plan information storage unit 307 that stores the production plan information created by the production plan information creation unit 305; and a production plan information transmission unit 308 that transmits the production plan information to the stockout determination device 800.

[0026] The manufacturing performance information acquisition unit 301, the manufacturing time acquisition unit 304 to the production plan information output unit 306, and the production plan information transmission unit 308 are realized by the processor 1 of the production plan information creation device 300. The processor 1 functions as each of these units by executing programs stored in the auxiliary storage unit 3. The predicted manufacturing time information storage unit 302, the manufacturing sequence information storage unit 303, and the production plan information storage unit 307 are realized by the auxiliary storage unit 3. In other words, each of these units is constructed in the storage area of ​​the auxiliary storage unit 3.

[0027] The manufacturing time acquisition unit 304 is an example of a manufacturing time acquisition means. The production plan information creation unit 305 is an example of a production plan information creation means.

[0028] The manufacturing performance information acquisition unit 301 transmits a manufacturing performance information transmission request to the worker terminal 200 via the communication unit 6, and receives the manufacturing performance information from the worker terminal 200 via the communication unit 6.

[0029] FIG. 8 shows an example of predicted production time information stored in the predicted production time information storage unit 302. The predicted production time information shows the model and the predicted production time for each model, with the model and the predicted production time associated with each other. In this embodiment, the average of the actual times required for a plurality of workers to manufacture a product of one model, calculated by simulation, is set as the predicted production time for that product. By setting the predicted production time for each product model in this manner, predicted production time information is created and stored in the predicted production time information storage unit 302.

[0030] 9 shows an example of production sequence information stored in the production sequence information storage unit 303. The production sequence information indicates, for each target product produced in the production area HH, the order in which the products are produced, the production number, the model, the number of units (i.e., the number of units of that model to be produced), and the worker who produces the product, in correspondence with one another. The production plan information creation device 300 generates production sequence information by accepting operations by the user via the operation unit 4, and stores the information in the production sequence information storage unit 303.

[0031] Returning to FIG. 7 , the manufacturing time acquisition unit 304 acquires the manufacturing time of each product in accordance with the manufacturing performance information acquired by the manufacturing performance information acquisition unit 301, the predicted manufacturing time information stored in the predicted manufacturing time information storage unit 302, and the manufacturing sequence information stored in the manufacturing sequence information storage unit 303.

[0032] Specifically, when one of the target products has been manufactured, the manufacturing time acquisition unit 304 acquires the actual manufacturing time of the one product as the manufacturing time of the one product. The manufacturing time acquisition unit 304 identifies whether or not a product has been manufactured and the actual manufacturing time of the one product by referring to the manufacturing history information.

[0033] When one of the target products has not yet been manufactured and other products of the same model as the one of the target products have not yet been manufactured, the manufacturing time acquisition unit 304 acquires the predicted manufacturing time of the one product as the manufacturing time of the one product. The manufacturing time acquisition unit 304 identifies the model of each product by referencing the manufacturing sequence information. The manufacturing time acquisition unit 304 identifies the predicted manufacturing time of the one product model by referencing the predicted manufacturing time information, and acquires the identified predicted manufacturing time as the predicted manufacturing time of the one product.

[0034] When one of the target products has not yet been manufactured, at least one other product of the same model as the target product has already been manufactured, and the one product is manufactured by the same worker who manufactured the other product, the manufacturing time acquisition unit 304 acquires the average value of the actual manufacturing time of each of the other products as the manufacturing time of the one product. The average value of the actual manufacturing time of each of the other products is an example of a representative value of the actual manufacturing time of each of the other products. The manufacturing time acquisition unit 304 identifies the worker who will manufacture each product by referencing the manufacturing sequence information. An example of a reference condition is that a product is of the same model as the one product and is manufactured by the same worker who manufactured at least one other product that has already been manufactured. The manufacturing time acquisition unit 304 identifies the actual manufacturing time of each product by referencing the manufacturing history information.

[0035] When one of the target products has not yet been manufactured, at least one other product of the same model as the one of the target products has already been manufactured, and the one product is manufactured by a worker different from the worker who manufactured the other product, the manufacturing time acquisition unit 304 acquires the predicted manufacturing time of the one product as the manufacturing time of the one product. When a product is manufactured by a worker different from the worker who manufactured at least one other product of the same model as the one product and that has already been manufactured, this is an example of the manufacturing conditions of the one product not satisfying the reference conditions.

[0036] The production plan information creation unit 305 creates production plan information in accordance with the production performance information acquired by the production performance information acquisition unit 301, the production sequence information stored in the production sequence information storage unit 303, and the production time of each product acquired by the production time acquisition unit 304.

[0037] FIG. 10 shows an example of production plan information. The production plan information indicates, for each product, the order in which the products are to be manufactured, the serial number, and the start time of manufacture, with the order corresponding to each other. The production plan information indicates the start time of manufacture for each product scheduled to be manufactured in the manufacturing area HH, as well as the start time of manufacture for each product that has already been manufactured. The start time of manufacture for a product scheduled to be manufactured is the predicted time at which manufacture of that product will begin. The start time of manufacture for a product that has already been manufactured is the actual time at which manufacture of that product began.

[0038] If the first product in the production order indicated by the production sequence information has already been produced, the production plan information creation unit 305 sets the actual production start time of this product as the production start time of this product. The production plan information creation unit 305 determines whether the first product in the production order has already been produced and the actual production start time of this product by referring to the production result information. If the first product in the production order has not yet been produced, the production plan information creation unit 305 sets the scheduled start time of operations on a preset operating day of product factory AA as the production start time of this product. The scheduled start time of operations is the scheduled time when production of the target product will begin in production area HH. The scheduled start time of operations can be set arbitrarily.

[0039] After setting the production start time for the first product in the production order, the production plan information creation unit 305 sequentially sets the production start time for each product that is second in the production order and thereafter according to the following formula (1): In formula (1), N represents any natural number, TN+1 represents the production start time for the (N+1)th product in the production order, TN represents the production start time for the Nth product in the production order, and XN represents the production time acquired by the production time acquisition unit 304 for the Nth product in the production order.

[0040] TN+1=TN+XN (1)

[0041] The production plan information creation unit 305 creates production plan information by setting the manufacturing start time of each product using the method described above, and stores the information in the production plan information storage unit 307 .

[0042] Returning to FIG. 7, the production plan information output unit 306 outputs the production plan information by causing the display unit 5 to display an image representing the production plan information.

[0043] When the production plan information transmission unit 308 receives a production plan information transmission request requesting the transmission of production plan information from the out-of-stock determination device 800 via the communication unit 6, it transmits the production plan information read from the production plan information storage unit 307 to the out-of-stock determination device 800 via the communication unit 6.

[0044] (Functional Configuration of In-Vehicle Device 400) As shown in FIG. 11, the on-board device 400 shown in FIG. 1 functionally comprises a position change information creation unit 401 that creates position change information indicating the time change in the position of the transport vehicle DD on which the device is mounted, a position change information memory unit 402 that stores the position change information created by the position change information creation unit 401, a movement speed calculation unit 403 that calculates the movement speed of the transport vehicle DD, a transport route information memory unit 404 that stores transport route information indicating the transport route that the transport vehicle DD will take when transporting parts from the parts factory CC to the product factory AA, a vehicle arrival predicted time information transmission request receiving unit 405 that receives a vehicle arrival predicted time information transmission request from the parts delivery predicted time calculation device 700 requesting the transmission of vehicle arrival predicted time information indicating the vehicle arrival predicted time, a vehicle arrival predicted time calculation unit 406 that calculates the vehicle arrival predicted time, and a vehicle arrival predicted time information transmission unit 407 that transmits the vehicle arrival predicted time information indicating the vehicle arrival predicted time calculated by the vehicle arrival predicted time calculation unit 406 to the parts delivery predicted time calculation device 700.

[0045] The position transition information creation unit 401, the travel speed calculation unit 403, and the units from the vehicle arrival estimated time information transmission request reception unit 405 to the vehicle arrival estimated time information transmission unit 407 are realized by the processor 9 of the in-vehicle device 400. The processor 9 functions as each of these units by executing programs stored in the auxiliary storage unit 11. The position transition information storage unit 402 and the transportation route information storage unit 404 are realized by the auxiliary storage unit 11. That is, each of these units is constructed in a storage area of ​​the auxiliary storage unit 11.

[0046] 11 shows only the functional configuration related to the characteristic parts of the present disclosure among the functional configurations of the in-vehicle device 400. In addition to the functional configurations shown in Fig. 11, the in-vehicle device 400 has a functional configuration for realizing various functions of a general car navigation device, including a function of guiding the driver of the transport vehicle DD along a route to a destination.

[0047] The position transition information creating unit 401 causes the positioning unit 16 to detect the position of the transport vehicle DD every time a preset positioning period has elapsed, and creates position transition information by associating the detected position of the transport vehicle DD with the current time measured by the timing unit 15. The position transition information creating unit 401 stores the created position transition information in the position transition information storage unit 402, thereby updating the position transition information stored in the position transition information storage unit 402. The positioning period can be set arbitrarily.

[0048] The moving speed calculation unit 403 specifies the time transition of the position of the transfer vehicle DD from a time a preset calculation range time before the current time to the current time by referring to the position transition information stored in the position transition information storage unit 402, and calculates the moving speed of the transfer vehicle DD according to the specified time transition of the position. The calculation range time can be set arbitrarily.

[0049] The in-vehicle device 400 creates transport route information by accepting an operation by the driver of the transport vehicle DD via the operation unit 12 and stores the transport route information in the transport route information storage unit 404 .

[0050] The vehicle arrival predicted time information transmission request receiving unit 405 receives the vehicle arrival predicted time information transmission request from the parts delivery predicted time calculation device 700 via the communication unit 14.

[0051] In response to the reception of the predicted vehicle arrival time information transmission request by the predicted vehicle arrival time information transmission request receiver 405, the predicted vehicle arrival time calculation unit 406 calculates the predicted vehicle arrival time.

[0052] The vehicle arrival predicted time calculation unit 406 calculates the vehicle arrival predicted time according to the position change information stored in the position change information storage unit 402, the movement speed of the transport vehicle DD calculated by the movement speed calculation unit 403, and the transport route information stored in the transport route information storage unit 404.

[0053] Specifically, the vehicle arrival predicted time calculation unit 406 determines the length of the route from the current position of the transfer vehicle DD indicated by the position transition information and the transfer route indicated by the transfer route information. The vehicle arrival predicted time calculation unit 406 calculates the time required for the transfer vehicle DD to move from the current position to the product factory AA by dividing the determined route length by the travel speed of the transfer vehicle DD. The vehicle arrival predicted time calculation unit 406 calculates the time that is the calculated time after the current time as the vehicle arrival predicted time.

[0054] The predicted vehicle arrival time calculation unit 406 generates predicted vehicle arrival time information indicating the calculated predicted vehicle arrival time.

[0055] The vehicle arrival predicted time information transmitting unit 407 transmits the vehicle arrival predicted time information created by the vehicle arrival predicted time calculation unit 406 to the parts delivery predicted time calculation device 700 via the communication unit 14 .

[0056] (Functional configuration of berth monitoring device 500) The berth monitoring device 500 shown in FIG. 1 functionally comprises an imaging control unit 501 that controls imaging by the imaging unit 22 of the berth monitoring device 500, and an image transmission unit 502 that transmits the image captured by the imaging unit 22 to the berth vacancy detection device 600, as shown in FIG. 12.

[0057] The imaging control unit 501 and the captured image transmission unit 502 are realized by the processor 18 of the bus monitoring device 500. The processor 18 executes a program stored in the auxiliary storage unit 20 to function as each of these units.

[0058] The imaging control unit 501 causes the imaging unit 22 to capture an image of the berth EE to generate a captured image. The captured image transmission unit 502 transmits the captured image generated by the imaging unit 22 to the berth vacancy detection device 600 via the communication unit 21 in real time.

[0059] (Functional configuration of berth vacancy detection device 600) The berth availability detection device 600 shown in FIG. 1 functionally includes, as shown in FIG. 13, an entrance / exit monitoring unit 601 for monitoring the entrance / exit of the transfer vehicle DD at the berth EE, an entrance / exit information storage unit 602 for storing entrance / exit information indicating the entrance / exit status of the transfer vehicle DD at the berth EE, a vehicle owner information storage unit 603 for storing vehicle owner information indicating the parts manufacturer that owns or uses the transfer vehicle DD, an average stay time information creation unit 604 for creating average stay time information that stores average stay time information indicating the average stay time that is the average value of the actual values ​​of the stay time of the transfer vehicle DD at the berth EE, an average stay time information storage unit 605 for storing the average stay time information created by the average stay time information creation unit 604, and a parts delivery predicted time calculation unit for making an inquiry as to whether the transfer vehicle DD will be able to park at the berth EE at the vehicle arrival predicted time and to unload parts from the transfer vehicle DD at the berth EE. a berth availability detection unit 607 that detects whether the transport vehicle DD will be able to park at the berth EE at the predicted vehicle arrival time and unload parts from the transport vehicle DD at the berth EE; a predicted departure time calculation unit 608 that calculates the predicted departure time which is a predicted value for the time when the transport vehicle DD will leave the berth EE; a berth availability time acquisition unit 609 that acquires the berth availability time which is the earliest time when the transport vehicle DD that is later than the predicted vehicle arrival time can park at the berth EE and unload parts from the transport vehicle DD at the berth EE; a berth availability information creation unit 610 that creates berth availability information which indicates the results of detection by the berth availability detection unit 607; and a berth availability information transmission unit 611 that transmits the berth availability information created by the berth availability information creation unit 610 to the parts delivery predicted time calculation device 700.

[0060] The entrance / exit monitoring unit 601, average stay time information creation unit 604, inquiry receiving unit 606 to berth vacancy information transmission unit 611 are realized by the processor 1 of the berth vacancy detection device 600. The processor 1 functions as each of these units by executing programs stored in the auxiliary storage unit 3. The entrance / exit information storage unit 602, vehicle owner information storage unit 603 and average stay time information storage unit 605 are realized by the auxiliary storage unit 3. In other words, each of these units is constructed in the storage area of ​​the auxiliary storage unit 3.

[0061] The berth availability detection unit 607 is an example of a berth availability detection means. The predicted departure time calculation unit 608 is an example of a predicted departure time calculation means. The berth availability time acquisition unit 609 is an example of a berth availability time acquisition means.

[0062] The entrance / exit monitoring unit 601 receives the captured images transmitted from the berth monitoring device 500 in real time via the communication unit 6, and detects the entrance / exit of the transport vehicle DD at the berth EE from the received captured images. The entrance / exit monitoring unit 601 creates entrance / exit information according to the detection result and stores it in the entrance / exit information storage unit 602.

[0063] 14 shows an example of entry / exit information. The entry / exit information shows, in association with one another, the vehicle registration number written on the license plate of the transport vehicle DD, which is the identifier of the transport vehicle DD, the actual entry time, which is the actual value of the time when the transport vehicle DD entered the berth EE, the actual exit time, which is the actual value of the time when the transport vehicle DD left the berth EE, and the actual stay time, which is the actual value of the time the transport vehicle DD stayed at the berth EE. When the transport vehicle DD has entered the berth EE but has not yet left, information indicating that the transport vehicle DD is staying at the berth EE is stored in the entry / exit information in association with the vehicle registration number of the transport vehicle DD.

[0064] The entrance / exit monitoring unit 601 acquires the time when the entry of the transfer vehicle DD is detected as the actual entry time, and acquires the time when the exit of the transfer vehicle DD is detected as the actual exit time. The entrance / exit monitoring unit 601 detects the time from the actual entry time to the actual exit time as the actual stay time. The entrance / exit monitoring unit 601 reads the vehicle registration number written on the license plate of the transfer vehicle DD entering or exiting the berth EE from the captured image received from the berth monitoring device 500. Every time the entrance / exit monitoring unit 601 detects the entry or exit of the transfer vehicle DD, it creates entrance / exit information and stores it in the entrance / exit information storage unit 602, thereby updating the entrance / exit information stored in the entrance / exit information storage unit 602.

[0065] 15 shows an example of vehicle owner information stored in the vehicle owner information storage unit 603. The vehicle owner information indicates, for each transport vehicle DD, the automobile registration number of the transport vehicle DD and the parts manufacturer that owns or uses the transport vehicle DD, i.e., the parts manufacturer corresponding to the transport vehicle DD, in association with each other. The berth vacancy detection device 600 creates vehicle owner information by accepting information input by the user via the operation unit 4, and stores the vehicle owner information in the vehicle owner information storage unit 603.

[0066] 16 shows an example of average stay time information created by the average stay time information creation unit 604. The average stay time information shows, for each component manufacturer, a component manufacturer and a transport vehicle DD owned or used by the component manufacturer, i.e., the average stay time of the transport vehicle DD corresponding to the component manufacturer, in association with each other.

[0067] The average stay time information generating unit 604 generates average stay time information according to the entrance / exit information stored in the entrance / exit information storage unit 602 and the vehicle owner information stored in the vehicle owner information storage unit 603 .

[0068] Specifically, the average stay time information creation unit 604 identifies the parts manufacturer that owns or uses each transport vehicle DD by referring to the vehicle owner information, and extracts from the entry / exit information information indicating the actual stay time of the transport vehicles DD owned or used by that one parts manufacturer that entered and exited the berth EE from a day a preset extraction period before the current day until the current day. The average stay time information creation unit 604 calculates the average value of the actual stay times of each transport vehicle DD indicated by the extracted information as the average stay time of the transport vehicles DD owned or used by that one parts manufacturer. In this embodiment, the extraction period is set to one month. Note that this is just an example, and the extraction period can be set arbitrarily.

[0069] Every time the entrance / exit information stored in the entrance / exit information storage unit 602 is updated by the entrance / exit monitoring unit 601, the average stay time information creation unit 604 creates average stay time information in accordance with the updated entrance / exit information and stores it in the average stay time information storage unit 605. In this way, the average stay time information stored in the average stay time information storage unit 605 is updated.

[0070] Returning to FIG. 13, the inquiry receiving unit 606 receives an inquiry including information indicating the predicted vehicle arrival time from the parts delivery predicted time calculation device 700 via the communication unit 6.

[0071] In response to the inquiry received by the inquiry receiving unit 606, the berth availability detection unit 607 detects whether the transport vehicle DD will be able to park at the berth EE at the predicted vehicle arrival time indicated by the inquiry and whether parts can be unloaded from the transport vehicle DD at the berth EE.

[0072] Specifically, if the number of transfer vehicles DD currently staying at the berth EE is smaller than the number of parking spaces FF provided at the berth EE, i.e., if at least one parking space FF is not currently parked by a transfer vehicle DD, the berth availability detection unit 607 determines that a transfer vehicle DD will be parked at the berth EE and parts will be able to be unloaded from the transfer vehicle DD at the predicted vehicle arrival time. The berth availability detection unit 607 identifies the number of transfer vehicles DD currently staying at the berth EE, i.e., the number of transfer vehicles DD that have entered the berth EE but have not yet exited the berth EE, by referring to the entry and exit information stored in the entry and exit information storage unit 602.

[0073] If the number of transport vehicles DD currently staying in the berth EE matches the number of parking spaces FF, i.e., if transport vehicles DD are currently parked in all parking spaces FF, the berth vacancy detection unit 607 causes the predicted departure time calculation unit 608 to calculate the predicted departure time of each transport vehicle DD currently staying in the berth EE.

[0074] If at least one of the calculated predicted departure times of each transport vehicle DD is before the predicted vehicle arrival time, the berth availability detection unit 607 determines that the transport vehicle DD will be parked at the berth EE at the predicted vehicle arrival time and will be able to unload parts from the transport vehicle DD.If all of the calculated predicted departure times of each transport vehicle DD are after the predicted vehicle arrival time, the berth availability detection unit 607 determines that the transport vehicle DD will not be parked at the berth EE at the predicted vehicle arrival time and will not be able to unload parts from the transport vehicle DD.

[0075] The predicted departure time calculation unit 608 calculates the predicted departure time of the transport vehicle DD according to the entry / exit information stored in the entry / exit information storage unit 602, the vehicle owner information stored in the vehicle owner information storage unit 603, and the average stay time information stored in the average stay time information storage unit 605.

[0076] Specifically, the predicted departure time calculation unit 608 identifies the actual entry time of one transport vehicle DD by referring to the entry / exit information, and identifies the parts manufacturer that owns or uses the one transport vehicle DD by referring to the vehicle owner information. The predicted departure time calculation unit 608 identifies the average stay time of the transport vehicles DD owned or used by the parts manufacturer by referring to the average stay time information, and calculates the time that is the average stay time later than the actual entry time as the predicted departure time of the one transport vehicle.

[0077] The berth availability time acquisition unit 609 acquires the berth availability time when the berth availability detection unit 607 determines that the transport vehicle DD will be parked at the berth EE at the predicted vehicle arrival time and will not be able to unload parts at the berth EE. The berth availability time acquisition unit 609 acquires the earliest of the predicted departure times of each transport vehicle DD currently parked at the berth EE, calculated by the predicted departure time calculation unit 608, as the berth availability time.

[0078] When the berth availability detection unit 607 determines that the transport vehicle DD will be parked at a berth EE at the predicted vehicle arrival time and will not be able to unload parts, the berth availability information creation unit 610 creates berth availability information that indicates the result of the determination by the berth availability detection unit 607 and the berth availability time acquired by the berth availability time acquisition unit 609. When the berth availability detection unit 607 determines that the transport vehicle DD will be parked at a berth EE at the predicted vehicle arrival time and will be able to unload parts, the berth availability information creation unit 610 creates berth availability information that indicates the result of the determination by the berth availability detection unit 607 and does not include information indicating the berth availability time.

[0079] The berth availability information transmitting unit 611 transmits the berth availability information created by the berth availability information creating unit 610 to the parts delivery predicted time calculation device 700 via the communication unit 6 .

[0080] (Functional Configuration of Parts Delivery Prediction Time Calculation Device 700) As shown in FIG. 17, the parts delivery predicted time calculation device 700 shown in FIG. 1 functionally includes a parts loading information storage unit 701 that stores parts loading information indicating the transport vehicles DD on which each part included in each product manufactured in the manufacturing area HH is loaded, a vehicle arrival predicted time information acquisition unit 702 that acquires vehicle arrival predicted time information from the on-board device 400, a berth availability information acquisition unit 703 that acquires berth availability information from the berth availability detection device 600, and a predicted value of the time required from when the parts are unloaded at the berth EE until they are delivered to the manufacturing area HH. a part delivery predicted time calculation unit 705 that calculates the predicted part delivery time of each part; a part delivery predicted time information output unit 706 that outputs part delivery predicted time information that indicates the part delivery predicted time of each part calculated by the part delivery predicted time calculation unit 705; a part delivery predicted time information storage unit 707 that stores the part delivery predicted time information; and a part delivery predicted time information transmission unit 708 that transmits the part delivery predicted time information to the stockout determination device 800.

[0081] The predicted vehicle arrival time information acquisition unit 702, the berth availability information acquisition unit 703, the parts delivery predicted time calculation unit 705, the parts delivery predicted time information output unit 706, and the parts delivery predicted time information transmission unit 708 are realized by the processor 1 of the parts delivery predicted time calculation device 700. The processor 1 functions as each of these units by executing programs stored in the auxiliary storage unit 3. The parts loading information storage unit 701, the predicted delivery required time information storage unit 704, and the parts delivery predicted time information storage unit 707 are realized by the auxiliary storage unit 3. That is, each of these units is constructed in the storage area of ​​the auxiliary storage unit 3.

[0082] The parts delivery predicted time calculation unit 705 is an example of a berth availability determination means and a parts delivery predicted time calculation means. The predicted delivery time is an example of a reference time.

[0083] 18 shows an example of part loading information stored in the part loading information storage unit 701. The part loading information indicates, for each part, the part, the vehicle registration number of the transport vehicle DD on which the part is loaded, the number of parts, and the communication address of the on-board device 400 mounted on the transport vehicle DD, in association with each other. The part delivery predicted time calculation device 700 creates part loading information by accepting an operation by the user via the operation unit 4, and stores the part loading information in the part loading information storage unit 701.

[0084] Returning to FIG. 17, the vehicle arrival predicted time information acquisition unit 702 transmits a request for transmitting vehicle arrival predicted time information via the communication unit 6, and receives vehicle arrival predicted time information from the in-vehicle device 400 via the communication unit 6.

[0085] The berth availability information acquisition unit 703 transmits an inquiry to the berth availability detection device 600 via the communication unit 6 as to whether the transport vehicle DD will be able to park at the berth EE and unload parts from the transport vehicle DD at the predicted vehicle arrival time indicated by the predicted vehicle arrival time information acquired by the predicted vehicle arrival time information acquisition unit 702. This inquiry includes information indicating the predicted vehicle arrival time. The berth availability information acquisition unit 703 receives the berth availability information from the berth availability detection device 600 via the communication unit 6.

[0086] In this embodiment, the predicted required delivery time is set as the sum of the predicted values ​​of the time required for unloading work to unload parts from the transport vehicle DD, inspection work to inspect the unloaded parts, and subdivision work to subdivide the inspected parts into smaller units, and predicted required delivery time information indicating this predicted required delivery time is stored in predicted required delivery time information storage unit 704. Specifically, in this embodiment, the average values ​​of the actual values ​​of the time required for each of the unloading work, inspection work, and subdivision work obtained by simulation are acquired as the predicted value of the time required for each work, and the sum of these predicted values ​​is set as the predicted required delivery time.

[0087] The parts delivery predicted time calculation unit 705 calculates the parts delivery predicted time for each part according to the vehicle arrival predicted time information acquired by the vehicle arrival predicted time information acquisition unit 702, the berth availability information acquired by the berth availability information acquisition unit 703, and the predicted delivery required time information stored in the predicted delivery required time information storage unit 704.

[0088] When calculating the predicted part delivery time of a part, the part delivery predicted time calculation unit 705 causes the vehicle arrival predicted time information acquisition unit 702 to acquire vehicle arrival predicted time information indicating the vehicle arrival predicted time of the transport vehicle DD on which the part is loaded. The vehicle arrival predicted time information acquisition unit 702 identifies the communication address of the on-board device 400 mounted on the transport vehicle DD by referring to the part loading information stored in the part loading information storage unit 701, transmits a request to transmit vehicle arrival predicted time information to the identified communication address, and receives the vehicle arrival predicted time information from the on-board device 400.

[0089] The parts delivery predicted time calculation unit 705 inquires of the berth availability information acquisition unit 703 as to whether or not parts can be unloaded at the berth EE at the predicted vehicle arrival time of the transport vehicle DD indicated by the acquired vehicle arrival predicted time information, and acquires the berth availability information.

[0090] The parts delivery predicted time calculation unit 705 refers to the berth availability information acquired by the berth availability information acquisition unit 703 to determine whether the transport vehicle DD will be able to park at the berth EE at the predicted vehicle arrival time and whether parts will be able to be unloaded from the transport vehicle DD.

[0091] When it is determined that the transport vehicle DD will be parked at the berth EE at the predicted vehicle arrival time of the transport vehicle DD and that the part can be unloaded from the transport vehicle DD, the parts delivery predicted time calculation unit 705 calculates a time that is the predicted required delivery time after the predicted vehicle arrival time as the predicted part delivery time for the one part. The parts delivery predicted time calculation unit 705 specifies the predicted required delivery time by referring to the predicted required delivery time information.

[0092] If the part delivery predicted time calculation unit 705 determines that the transport vehicle DD will be parked at the berth EE at the predicted vehicle arrival time of the transport vehicle DD and that the part cannot be unloaded from the transport vehicle DD, it calculates the predicted part delivery time for the part to be a time that is the predicted delivery time after the berth vacancy time indicated by the acquired berth vacancy information.

[0093] The part delivery predicted time calculation unit 705 creates part delivery predicted time information indicating the calculated part delivery predicted time for each part, and stores this information in the part delivery predicted time information storage unit 707. Fig. 19 shows an example of part delivery predicted time information. The part delivery predicted time information indicates, for each part, the part and the part's predicted delivery time in association with each other.

[0094] Returning to Figure 17, the parts delivery predicted time information output unit 706 outputs the parts delivery predicted time information by displaying on the display unit 5 an image representing the parts delivery predicted time information created by the parts delivery predicted time calculation unit 705.

[0095] When the parts delivery predicted time information transmission unit 708 receives a parts delivery predicted time information transmission request requesting the transmission of parts delivery predicted time information from the stockout determination device 800 via the communication unit 6, it transmits the parts delivery predicted time information read from the parts delivery predicted time information storage unit 707 to the stockout determination device 800 via the communication unit 6.

[0096] (Functional configuration of missing item determination device 800) As shown in FIG. 20, the out-of-stock determination device 800 shown in FIG. 1 functionally comprises a production plan information acquisition unit 801 that acquires production plan information from the production plan information creation device 300, a parts delivery predicted time information acquisition unit 802 that acquires parts delivery predicted time information from the parts delivery predicted time calculation device 700, a model information storage unit 803 that stores model information indicating the model of each product manufactured in the manufacturing area HH, a component part information storage unit 804 that stores component part information indicating the parts that each model of product is equipped with, a out-of-stock determination unit 805 that determines whether all parts that a product has have been delivered to the manufacturing area HH at the manufacturing start time of each product and whether manufacturing of the product can be started, and a out-of-stock determination information output unit 806 that outputs out-of-stock determination information indicating the result of the determination by the out-of-stock determination unit 805.

[0097] The production plan information acquisition unit 801, the parts delivery predicted time information acquisition unit 802, the stockout determination unit 805, and the stockout determination information output unit 806 are realized by the processor 1 of the stockout determination device 800. The processor 1 functions as each of these units by executing programs stored in the auxiliary storage unit 3. The model information storage unit 803 and the component information storage unit 804 are realized by the auxiliary storage unit 3. In other words, each of these units is constructed in the storage area of ​​the auxiliary storage unit 3.

[0098] The production plan information acquisition unit 801 and the part delivery predicted time information acquisition unit 802 are examples of an information acquisition unit. The stockout determination unit 805 is an example of a stockout determination unit.

[0099] The production plan information acquisition unit 801 transmits a production plan information transmission request to the production plan information creation device 300 via the communication unit 6, and receives production plan information from the production plan information creation device 300 via the communication unit 6.

[0100] The parts delivery predicted time information acquisition unit 802 sends a parts delivery predicted time information transmission request to the parts delivery predicted time calculation device 700 via the communication unit 6, and receives the parts delivery predicted time information from the parts delivery predicted time calculation device 700 via the communication unit 6.

[0101] 21 shows an example of model information stored in the model information storage unit 803. The model information indicates, for each product, a serial number and a model, in association with each other. The out-of-stock determination device 800 creates model information by accepting an operation by a user via the operation unit 4, and stores the model information in the model information storage unit 803.

[0102] 22 shows an example of component information stored in the component information storage unit 804. The component information indicates, for each model, the model of components included in the product of that model, and the number of those components included in the product, in association with each other. The missing-stock determination device 800 creates component information by accepting an operation by the user via the operation unit 4, and stores the information in the component information storage unit 804.

[0103] Returning to Figure 20, the stockout determination unit 805 makes the above-mentioned determination based on the production plan information acquired by the production plan information acquisition unit 801, the predicted part delivery time information acquired by the predicted part delivery time information acquisition unit 802, the model information stored in the model information storage unit 803, and the component part information stored in the component part information storage unit 804.

[0104] Specifically, the stockout determination unit 805 identifies the model of one of the target products by referencing model information, and identifies the parts that the identified model of the product has by referencing component part information. If the predicted part delivery times of each of the identified parts are all before the production start time of the product, the stockout determination unit 805 determines that all of the parts that the product has will have been delivered to the production area HH at the production start time of the product, and that production of the product can be started. The stockout determination unit 805 identifies the predicted part delivery times of each part by referencing predicted part delivery time information. The stockout determination unit 805 identifies the production start time of the product by referencing production plan information.

[0105] If at least one of the predicted part delivery times for each identified part is later than the production start time of the product, the stockout determination unit 805 determines that at least some of the parts that the product has have not been delivered to the production area HH at the production start time of the product, and that production of the product cannot be started.

[0106] The out-of-stock determination unit 805 creates out-of-stock determination information indicating the determination result. Fig. 23 shows an example of the out-of-stock determination information. The out-of-stock determination information indicates, for each target product, the serial number, the determination result, and the out-of-stock parts whose predicted part delivery time is later than the production start time of the product, i.e., parts that have not been delivered to the production area HH at the production start time, in association with each other.

[0107] Returning to FIG. 20, the out-of-stock determination information output unit 806 outputs the out-of-stock determination information by causing the display unit 5 to display an image representing the out-of-stock determination information created by the out-of-stock determination unit 805.

[0108] (Production control system operation) Next, the operation of the production management system 100 having the above-mentioned hardware configuration and functional configuration will be described with reference to Figs. 24 to 28. Some of the parts necessary to manufacture a product have been carried into the manufacturing area HH, and workers have started manufacturing the product. The production plan information creation device 300 creates predicted manufacturing time information and manufacturing sequence information by accepting operations from the user, and stores them in the predicted manufacturing time information storage unit 302 and the manufacturing sequence information storage unit 303, respectively.

[0109] The on-vehicle device 400 is mounted on each transport vehicle DD. A position transition information creating unit 401 of the on-vehicle device 400 creates position transition information by causing the positioning unit 16 to detect the position of the transport vehicle DD on which the device is mounted every time a positioning period elapses, and sequentially stores the position transition information in a position transition information storage unit 402. The on-vehicle device 400 creates transport route information by accepting operations by the driver of the transport vehicle DD, and stores the transport route information in a transport route information storage unit 404.

[0110] The berth monitoring device 500 captures images of the berth EE using the imaging unit 22 and transmits the captured images in real time to the berth vacancy detection device 600. The entrance / exit monitoring unit 601 of the berth vacancy detection device 600 constantly monitors the entry and exit of transport vehicles DD at the berth EE based on the captured images received from the berth monitoring device 500. The berth vacancy detection device 600 creates vehicle owner information and average stay time information by accepting operations from the user, and stores them in a vehicle owner information storage unit 603 and an average stay time information storage unit 605, respectively.

[0111] The parts delivery predicted time calculation device 700 creates parts loading information and predicted delivery required time information by accepting operations from the user, and stores them in the parts loading information storage unit 701 and the predicted delivery required time information storage unit 704. The stockout determination device 800 creates model information and component information by accepting operations from the user, and stores them in the model information storage unit 803 and the component information storage unit 804.

[0112] In this state, when the worker inputs production start information or production end information by operating the operation unit 4 of the worker terminal 200, the production performance information creation unit 201 of the worker terminal 200 creates the production performance information exemplified in FIG. 6 according to the input information and stores it in the production performance information storage unit 202 (step S1).

[0113] In addition, when the transport vehicle DD enters or leaves the berth EE, the entry / exit monitoring unit 601 of the berth vacancy detection device 600 detects the entry or exit of the transport vehicle DD at the berth EE based on the captured image received from the berth monitoring device 500 (step S2), and adds the information to the entry / exit information illustrated in Figure 14 (step S3).

[0114] Next, the average stay time information creation unit 604 creates average stay time information as shown in FIG. 16 according to the entry / exit information created in step S3, and stores the information in the average stay time information storage unit 605 (step S4). The average stay time information creation unit 604 identifies the parts manufacturer that owns or uses each transport vehicle DD by referring to the vehicle owner information as shown in FIG. 15 stored in the vehicle owner information storage unit 603. The average stay time information creation unit 604 extracts information indicating the actual stay time of a transport vehicle DD owned or used by a certain parts manufacturer that entered or exited a berth EE from a day that is the extraction period before the current day until the current day, from the entry / exit information. The average stay time information creation unit 604 creates the average stay time information by calculating the average value of the actual stay times of each transport vehicle DD indicated by the extracted information as the average stay time of the transport vehicles DD owned or used by the certain parts manufacturer.

[0115] Next, it is assumed that the reference time for creating production plan information has arrived. In this embodiment, the reference time is set to every hour starting from 8:30 AM. As a result, the production plan information is updated every hour. When the reference time arrives, the manufacturing performance information acquisition unit 301 of the production plan information creation device 300 transmits a manufacturing performance information transmission request to the worker terminal 200 (step S5). When the manufacturing performance information transmission unit 203 of the worker terminal 200 receives the manufacturing performance information transmission request from the production plan information creation device 300, it reads out the manufacturing performance information stored in the manufacturing performance information storage unit 202 and transmits it to the production plan information creation device 300 (step S6). When the manufacturing performance information acquisition unit 301 receives the manufacturing performance information from the worker terminal 200, the production plan information creation device 300 executes a production plan information creation process for creating production plan information (step S7).

[0116] 25, when the production plan information creation process is started, the manufacturing time acquisition unit 304 selects one of the target products to be manufactured in the manufacturing area HH by referring to the manufacturing sequence information exemplified in FIG. 9 and stored in the manufacturing sequence information storage unit 303 (step S101). The manufacturing time acquisition unit 304 determines whether the product selected in step S101 has already been manufactured by referring to the manufacturing performance information received by the manufacturing performance information acquisition unit 301 (step S102). If it is determined that the selected product has already been manufactured (step S102; Yes), the manufacturing time acquisition unit 304 acquires the actual manufacturing time of the product indicated by the manufacturing performance information as the manufacturing time of the product (step S103).

[0117] If it is determined that the product selected in step S101 has not yet been manufactured (step S102; No), the manufacturing time acquisition unit 304 determines whether a product of the same model as the product has already been manufactured by referring to the manufacturing performance information (step S104). The manufacturing time acquisition unit 304 identifies the model of each product by referring to the manufacturing sequence information. If it is determined that a product of the same model has not yet been manufactured (step S104; No), the manufacturing time acquisition unit 304 refers to the estimated manufacturing time information stored in the estimated manufacturing time information storage unit 302, as shown in FIG. 8, identifies the estimated manufacturing time of the product of the model selected in step S101 as the estimated manufacturing time of the product, and acquires the estimated manufacturing time as the manufacturing time of the product (step S105).

[0118] If it is determined that a product of the same model as the product selected in step S101 has already been manufactured (step S104; Yes), the manufacturing time acquisition unit 304 determines whether the worker who manufactures the selected product is the same worker who manufactured the already manufactured product of the same model by referring to the product order information (step S106).If it is determined that the workers are the same (step S106; Yes), the manufacturing time acquisition unit 304 acquires the average value of the actual manufacturing times of the already manufactured products of the same model, which are indicated by the manufacturing performance information, as the manufacturing time of the product selected in step S101 (step S107).

[0119] If it is determined that the workers are different (step S106; No), the manufacturing time acquisition unit 304 refers to the predicted manufacturing time information, identifies the predicted manufacturing time of the product model selected in step S101 as the predicted manufacturing time of the product, and acquires the predicted manufacturing time as the manufacturing time of the product (step S108).

[0120] After executing the process of step S103, S105, S107, or S108, the manufacturing time acquisition unit 304 determines whether all target products to be manufactured in the manufacturing area HH have been selected by referring to the manufacturing sequence information (step S109). If it is determined that there are target products that have not yet been selected (step S109; No), the process returns to step S101, and one of the target products that have not yet been selected is selected (step S101). The manufacturing time acquisition unit 304 acquires the manufacturing time of each product by repeating the processes of steps S101 to S109 until it is determined as Yes in step S109.

[0121] If it is determined in step S109 that all target products have been selected (step S109; Yes), the production plan information creation unit 305 creates the production plan information exemplified in Fig. 10 using the above formula (1) in accordance with the production time, production performance information, and production sequence information of each product acquired in steps S101 to S109, and stores the information in the production plan information storage unit 307 (step S110). Thereafter, the process returns to the process shown in the sequence diagram of Fig. 24.

[0122] 24, after the production plan information creation process of step S7 is executed, the production plan information output unit 306 of the production plan information creation device 300 outputs the production plan information created in step S7 by displaying an image representing the production plan information on the display unit 5 (step S8). Thereafter, the processor 1 of the production plan information creation device 300 transmits a production plan information creation notice notifying that the production plan information has been created to the parts delivery predicted time calculation device 700 via the communication unit 6 (step S9).

[0123] As shown in FIG. 26, when the processor 1 of the parts delivery predicted time calculation device 700 receives a production plan information creation notification from the production plan information creation device 300 via the communication unit 6, the parts delivery predicted time calculation unit 705 selects one of the parts that each product manufactured in the manufacturing area HH has by referring to the parts loading information stored in the parts loading information storage unit 701, as exemplified in FIG. 18 (step S10).

[0124] Next, the vehicle arrival predicted time information acquisition unit 702 transmits a vehicle arrival predicted time information transmission request to the on-board device 400 mounted on the transport vehicle DD loaded with the parts selected in step S10, requesting transmission of vehicle arrival predicted time information indicating the vehicle arrival predicted time of this transport vehicle DD (step S11). The vehicle arrival predicted time information acquisition unit 702 identifies the communication address of the on-board device 400 mounted on the transport vehicle DD loaded with the selected parts by referring to the parts loading information, and transmits the vehicle arrival predicted time information transmission request to this communication address.

[0125] When the vehicle arrival predicted time information transmission request receiving unit 405 of the on-board device 400 receives a vehicle arrival predicted time information transmission request from the part delivery predicted time calculation device 700, the movement speed calculation unit 403 calculates the movement speed of the transport vehicle DD according to the position change information stored in the position change information storage unit 402 (step S12).

[0126] Next, the vehicle arrival predicted time calculation unit 406 calculates the vehicle arrival predicted time according to the travel speed of the transfer vehicle calculated in step S12, the position transition information, and the transfer route information stored in the transfer route information storage unit 404, and creates vehicle arrival predicted time information indicating the calculated vehicle arrival predicted time (step S13). The vehicle arrival predicted time calculation unit 406 identifies the length of the route from the current position to the product factory AA according to the current position of the transfer vehicle DD indicated by the position transition information and the transfer route indicated by the transfer route information. The vehicle arrival predicted time calculation unit 406 calculates the time required for the transfer vehicle DD to travel from its current position to the product factory AA by dividing the identified route length by the travel speed of the transfer vehicle DD. The vehicle arrival predicted time calculation unit 406 calculates the calculated time later than the current time as the vehicle arrival predicted time.

[0127] Thereafter, vehicle arrival predicted time information transmitting unit 407 transmits the vehicle arrival predicted time information created in step S13 to parts delivery predicted time calculation device 700 (step S14).

[0128] When the vehicle arrival predicted time information acquisition unit 702 of the parts delivery predicted time calculation device 700 receives the vehicle arrival predicted time information from the on-board device 400, the berth vacancy information acquisition unit 703 transmits an inquiry to the berth vacancy detection device 600 as to whether the transport vehicle DD will be able to park at the berth EE at the vehicle arrival predicted time indicated by the vehicle arrival predicted time information and whether the transport vehicle DD will be able to unload parts at the berth EE (step S15). This inquiry stores information indicating the vehicle arrival predicted time indicated by the vehicle arrival predicted time information received by the vehicle arrival predicted time information acquisition unit 702.

[0129] When the inquiry receiving unit 606 of the vacant berth detection device 600 receives the inquiry from the predicted parts delivery time calculation device 700, the processor 1 of the vacant berth detection device 600 executes a vacant berth detection process to create vacant berth information (step S16).

[0130] 27, when the berth vacancy detection process starts, the berth vacancy detection unit 607 determines whether the number of transfer vehicles DD currently parked in the berth EE matches the number of parking spaces FF provided in the berth EE, thereby determining whether transfer vehicles are currently parked in all parking spaces FF (step S201). The berth vacancy detection unit 607 identifies the number of transfer vehicles DD currently parked in the berth EE by referring to the entry / exit information stored in the entry / exit information storage unit 602.

[0131] If it is determined that the number of transport vehicles DD parked at the berth EE is less than the number of parking spaces FF, i.e., that no transport vehicles DD are parked in at least one parking space FF (step S201; No), the berth vacancy detection unit 607 determines that the transport vehicles DD will be parked at the berth EE and parts will be able to be unloaded from the transport vehicles DD at the predicted vehicle arrival time indicated in the inquiry received by the inquiry receiving unit 606 (step S206).

[0132] When the berth availability detection unit 607 determines that the number of transport vehicles DD staying in the berth EE matches the number of parking spaces FF, that is, that all parking spaces FF are occupied by transport vehicles DD (step S201; Yes), the predicted departure time calculation unit 608 calculates the predicted departure time of each transport vehicle DD currently staying in the berth EE (step S202). The predicted departure time calculation unit 608 identifies the actual entry time of a transport vehicle DD by referring to the entry / exit information, and identifies the parts manufacturer that owns or uses the transport vehicle DD by referring to the vehicle owner information stored in the vehicle owner information storage unit 603, as shown in FIG. 15. The predicted departure time calculation unit 608 identifies the average stay time of the transport vehicles DD owned or used by the parts manufacturer by referring to the average stay time information stored in the average stay time information storage unit 605, and calculates the time that is later than the actual entry time by the average stay time as the predicted departure time of the transport vehicle.

[0133] Next, the berth availability detection unit 607 determines whether or not any of the predicted departure times of each transport vehicle DD calculated in step S202 is earlier than the predicted vehicle arrival time indicated in the inquiry received by the inquiry receiving unit 606 (step S203). If it is determined that at least one of the calculated predicted departure times of each transport vehicle DD is earlier than the predicted vehicle arrival time (step S203; Yes), the berth availability detection unit 607 determines that the transport vehicle DD can park at the berth EE and unload parts from the transport vehicle DD at the predicted vehicle arrival time (step S206).

[0134] If it is determined that the calculated predicted departure times of each transport vehicle DD are all after the predicted vehicle arrival time (step S203; No), the berth availability detection unit 607 determines that the transport vehicle DD will not be parked at the berth EE at the predicted vehicle arrival time and will not be able to unload parts from the transport vehicle DD (step S204). Subsequently, the berth availability time acquisition unit 609 acquires the earliest time among the predicted departure times of each transport vehicle DD calculated in step S202 as the berth availability time (step S205).

[0135] After executing the processing of step S205 or S206, the berth availability information creation unit 610 creates berth availability information indicating the result of the determination made in step S204 or S206 (step S207). If it is determined in step S204 that the parts cannot be unloaded at berth EE at the predicted vehicle arrival time, the berth availability information creation unit 610 creates berth availability information including information indicating the berth availability time acquired in step S205. Then, the processing returns to the processing shown in the sequence diagram of FIG.

[0136] As shown in FIG. 26, after the berth availability detection process in step S16 is executed, the berth availability information transmitting unit 611 of the berth availability detection device 600 transmits the berth availability information created in step S16 to the parts delivery predicted time calculation device 700 (step S17).

[0137] When the berth availability information acquisition unit 703 of the part delivery predicted time calculation device 700 receives the berth availability information from the berth availability detection device 600, the part delivery predicted time calculation unit 705 calculates the part delivery predicted time of the part selected in step S10 in accordance with the berth availability information received by the berth availability information acquisition unit 703 (step S18).

[0138] Specifically, the part delivery predicted time calculation unit 705 refers to the berth availability information to determine whether the delivery vehicle DD loaded with the part selected in step S10 will be able to park at the berth EE and unload the part at the predicted vehicle arrival time of the delivery vehicle DD. The part delivery predicted time calculation unit 705 determines the predicted vehicle arrival time by referring to the predicted vehicle arrival time information transmitted from the on-board device 400 in step S14. If the part delivery predicted time calculation unit 705 determines that the delivery vehicle DD will be able to park at the berth EE at the predicted vehicle arrival time and unload the part, it calculates a time that is the predicted vehicle arrival time after the predicted vehicle arrival time by the predicted delivery required time as the part delivery time for the part. The part delivery predicted time calculation unit 705 determines the predicted delivery required time by referring to the predicted delivery required time information stored in the predicted delivery required time information storage unit 704.

[0139] If it is determined that the transport vehicle DD will be parked at the berth EE at the predicted vehicle arrival time and that the transport vehicle DD will not be able to unload the parts, the parts delivery predicted time calculation unit 705 calculates a time that is the predicted delivery time after the berth availability time as the parts delivery predicted time for the part. The parts delivery predicted time calculation unit 705 identifies the berth availability time by referring to the berth availability information.

[0140] Next, by referring to the parts loading information, parts delivery predicted time calculation unit 705 determines whether all parts to be included in each product manufactured in manufacturing area HH have been selected (step S19). If it is determined that there are parts that have not yet been selected (step S19; No), the process returns to step S10, and one of the parts that have not yet been selected is selected (step S10). Parts delivery predicted time calculation device 700 calculates the parts delivery predicted time of each part by repeating the processes of steps S10, S11, S15, S18, and S19 until it is determined Yes in step S19.

[0141] If it is determined in step S19 that all parts have been selected (step S19; Yes), part delivery predicted time calculation unit 705 creates part delivery predicted time information as shown in Fig. 19, which indicates the calculated part delivery predicted time for each part, and stores it in part delivery predicted time information storage unit 707 (step S20). Subsequently, part delivery predicted time information output unit 706 outputs the part delivery predicted time information by displaying an image representing the part delivery predicted time information created in step S20 on display unit 5 (step S21).

[0142] Then, the processor 1 of the part delivery predicted time calculation device 700 sends a part delivery predicted time information creation notification to the missing part determination device 800 via the communication unit 6, notifying that the part delivery predicted time information has been created, as shown in Figure 28 (step S22).

[0143] When the processor 1 of the stockout determination device 800 receives a notification of the creation of predicted part delivery time information from the predicted part delivery time calculation device 700 via the communication unit 6, the production plan information acquisition unit 801 sends a production plan information transmission request to the production plan information creation device 300 (step S23).

[0144] When the production plan information transmission unit 308 of the production plan information creation device 300 receives a production plan information transmission request from the out-of-stock determination device 800, it reads out the production plan information stored in the production plan information storage unit 307 in step S110 and transmits it to the out-of-stock determination device 800 (step S24).

[0145] When the production plan information acquisition unit 801 of the stockout determination device 800 receives production plan information from the production plan information creation device 300, the parts delivery predicted time information acquisition unit 802 sends a parts delivery predicted time information transmission request to the parts delivery predicted time calculation device 700 (step S25).

[0146] When the parts delivery predicted time information transmission unit 708 of the parts delivery predicted time calculation device 700 receives a parts delivery predicted time information transmission request from the missing part determination device 800, it reads out the parts delivery predicted time information stored in the parts delivery predicted time information memory unit 707 in step S20 and transmits it to the missing part determination device 800 (step S26).

[0147] When part delivery predicted time information acquisition unit 802 of stockout determination device 800 receives part delivery predicted time information from part delivery predicted time calculation device 700, part delivery detection unit 805 selects one of the target products manufactured in manufacturing area HH by referring to the model information exemplified in Fig. 21 stored in model information storage unit 803 (step S27). Next, part delivery detection unit 805 executes a stockout determination process to determine whether or not all parts included in the product selected in step S27 have been carried into manufacturing area HH at the manufacturing start time of this product and manufacturing of this product can be started (step S28).

[0148] Specifically, the stockout determination unit 805 identifies the model of the selected product by referencing the model information, and identifies the parts included in the identified model by referencing the component information illustrated in FIG. 22 and stored in the component information storage unit 804. If the predicted part delivery times of each identified part are all before the production start time of the product, the stockout determination unit 805 determines that all parts included in the product have been delivered to the production area HH at the production start time of the product, and that production of the product can be started. The stockout determination unit 805 identifies the production start time of the selected product by referencing the production plan information received by the production plan information acquisition unit 801. The stockout determination unit 805 identifies the predicted part delivery time of each part by referencing predicted part delivery time information received by the predicted part delivery time information acquisition unit 802.

[0149] If at least one of the predicted part delivery times for each identified part is later than the production start time of the product, the stockout determination unit 805 determines that at least some of the parts that the product has have not been delivered to the production area HH at the production start time of the product, and that production of the product cannot be started.

[0150] Next, the out-of-stock determining unit 805 determines whether or not all target products manufactured in the manufacturing area HH have been selected by referring to the model information (step S29). If it is determined that there are target products that have not yet been selected (step S29; No), the process returns to step S27, and one of the target products that have not yet been selected is selected (step S27). The out-of-stock determining unit 805 repeats the processes of steps S27 to S29 until it is determined Yes in step S29, thereby performing out-of-stock determination processing for each product.

[0151] If it is determined in step S29 that all target products have been selected (step S29; Yes), the out-of-stock determination device 800 creates out-of-stock determination information, as illustrated in FIG. 23, which indicates the results of the out-of-stock determination process for each product in step S28 (step S30).

[0152] Thereafter, the out-of-stock determination information output unit 806 outputs the out-of-stock determination information by displaying an image representing the out-of-stock determination information created in step S30 on the display unit 5 (step S31).

[0153] (effect) As described above, the production management system 100 according to this embodiment acquires the manufacturing time of a product according to the manufacturing performance of the product, and creates and outputs production plan information according to the acquired manufacturing time of the product. This provides the user with production plan information according to the manufacturing performance of the product, which is useful information for managing the manufacturing of the product. This makes it possible to appropriately manage the manufacturing of the product.

[0154] Furthermore, the production management system 100 provides the user with information on predicted parts delivery times, which is useful information for managing product production and indicates the predicted parts delivery times calculated depending on whether or not parts can be unloaded from the transport vehicle DD at the berth EE at the predicted vehicle arrival time, thereby enabling appropriate management of product production.

[0155] Furthermore, the production management system 100 determines whether the transport vehicles DD will be parked at the berth EE at the predicted vehicle arrival time and whether the transport vehicles DD will be able to unload parts, based on whether the transport vehicles DD are parked in all parking spaces FF provided in the berth EE and the predicted departure times of the transport vehicles DD parked in the parking spaces FF. With this configuration, it is possible to appropriately manage the production of products.

[0156] Furthermore, the production management system 100 calculates the predicted departure time of a transport vehicle DD according to the average stay time of transport vehicles DD owned or used by the parts manufacturer that owns or uses the transport vehicle DD. With this configuration, it is possible to appropriately manage the production of products.

[0157] Furthermore, if the production management system 100 determines that the transport vehicle DD cannot unload parts at the berth EE at the predicted vehicle arrival time, it acquires the earliest predicted departure time of the transport vehicle DD parked in the parking space FF as the berth availability time. This configuration makes it possible to appropriately manage the production of products.

[0158] Furthermore, the production management system 100 determines whether product parts have been delivered to the manufacturing area HH at the start time of product manufacturing in accordance with the production plan information and parts delivery predicted time information, and outputs stockout determination information indicating the result of the determination. With this configuration, the stockout determination information, which is useful information for managing product manufacturing, is provided to the user. This enables appropriate management of product manufacturing.

[0159] (Variation) Although the embodiments of the present disclosure have been described above, the present disclosure is not limited to the above-described embodiments, and various modifications are possible within the scope of the gist of the present disclosure.

[0160] For example, in the above embodiment, it has been described that products are manufactured manually by workers in the manufacturing area HH, but this is merely an example, and products may also be manufactured using manufacturing equipment installed in the manufacturing area HH.

[0161] In the above embodiment, the worker terminal 200 is described as creating the production performance information by accepting information input by the worker, but this is merely an example, and the production performance information can be created by any method. For example, the production area HH may be captured by an imaging device, and the start and end of product production may be detected from the captured image generated by the imaging device, thereby creating the production performance information.

[0162] In the above embodiment, an example of the reference condition is described in which a certain product is manufactured by the same worker who manufactured at least one other product that is the same model as the certain product and has already been manufactured. However, this is merely an example, and the reference condition can be set arbitrarily. For example, the reference condition may be that a certain product is manufactured on the same workbench as the other product. Alternatively, the reference condition may be that a certain product is manufactured on the same workbench as the other product, by the same worker who manufactured the other product.

[0163] In the above embodiment, the production time acquisition unit 304 of the production plan information creation device 300 is described as acquiring the average value of the actual production times of each of the other products as the production time of the target product when one of the target products has not yet been manufactured, at least one other product of the same model as the target product has already been manufactured, and the target product is manufactured by the same worker who manufactured the other product. However, this is merely an example, and the production time acquisition unit 304 may also acquire a representative value of the actual production times of each of the other products other than the average value as the production time of the target product. For example, the production time acquisition unit 304 may acquire the median of the actual production times of each of the other products as the production time of the target product. Alternatively, the production time acquisition unit 304 may acquire the mode of the actual production times of each of the other products as the production time of the target product.

[0164] In the above embodiment, it has been described that the production plan information creation unit 305 of the production plan information creation device 300 creates production plan information using the above formula (1) in accordance with the production time of each product acquired by the production time acquisition unit 304, the production sequence information stored in the production sequence information storage unit 303, and the scheduled start time of operation set in advance. However, this is merely an example, and the production plan information creation device 300 can create production plan information by any method in accordance with the production time of each product acquired by the production time acquisition unit 304.

[0165] For example, the production plan information creation unit 305 may create production plan information using the following formula (2) based on the production time of each product, production sequence information, and the predetermined scheduled operation end time for the operating day of product factory AA. The scheduled operation end time is the scheduled time when production of the product in production area HH will end. In formula (2), N represents any natural number, TN represents the production start time of the Nth product in the production sequence, TN+1 represents the production start time of the (N+1)th product in the production sequence, and XN represents the production time of the Nth product in the production sequence acquired by the production time acquisition unit 304. The scheduled operation end time can be set arbitrarily.

[0166] TN=TN+1-XN (2)

[0167] In this modified example, the production plan information creation unit 305 sets the production start time of the last product in the production sequence indicated by the production sequence information to a time that is earlier than the scheduled operation end time by the production time of that product acquired by the production time acquisition unit 304. Thereafter, the production plan information creation unit 305 creates production plan information by sequentially setting the production start times of products other than the last product in the production sequence in accordance with the above formula (2).

[0168] In the above embodiment, the production plan information output unit 306 of the production plan information creation device 300 has been described as outputting the production plan information by displaying an image representing the production plan information on the display unit 5, but this is merely an example, and the production plan information output unit 306 can output the production plan information by any method. For example, the production plan information creation device 300 may be equipped with a printer, and the production plan information output unit 306 may output the production plan information by causing this printer to print a print image representing the production plan information on a print medium.

[0169] In the above embodiment, the part delivery predicted time calculation device 700 executes the process of step S15 each time it executes the process of step S10 in the sequence diagram of FIG. 26 , and individually inquires of the berth availability detection device 600, for each part included in each product manufactured in the manufacturing area HH, whether the part can be unloaded at the predicted vehicle arrival time of the transport vehicle DD carrying the part. However, this is merely an example. The part delivery predicted time calculation device 700 may also collectively inquire of the berth availability detection device 600 whether the part can be unloaded at the predicted vehicle arrival time of each transport vehicle DD. This configuration reduces the communication load between the part delivery predicted time calculation device 700 and the berth availability detection device 600.

[0170] In the above embodiment, the predicted delivery time, which is the predicted time required from when parts are unloaded at berth EE to when they are delivered to the manufacturing area HH, is described as the sum of the predicted times required for unloading, inspection, and subdivision. However, this is merely an example, and the predicted delivery time can be set arbitrarily. For example, the predicted delivery time may be set to the sum of the predicted times required for unloading, inspection, and subdivision, plus the predicted time required for other tasks performed from when parts are unloaded to when they are delivered to the manufacturing area HH. Specific examples of such tasks include unpacking parts and depalletizing, which involves removing parts from pallets. In this modified example, the average of the actual times required for each task obtained by simulation is obtained as the predicted time required for each task, and the sum of these predicted values ​​is set as the predicted delivery time.

[0171] In the above embodiment, it has been described that predicted part delivery time information output unit 706 of predicted part delivery time calculation device 700 outputs the predicted part delivery time information by displaying an image representing the predicted part delivery time information on display unit 5, but this is merely an example, and predicted part delivery time information output unit 706 can output the predicted part delivery time information by any method. For example, predicted part delivery time calculation device 700 may be equipped with a printer, and predicted part delivery time information output unit 706 may output the predicted part delivery time information by causing this printer to print a print image representing the predicted part delivery time information on a print medium.

[0172] In the above embodiment, it has been described that the stockout determination device 800 acquires the production plan information created by the production plan information creation device 300 and the predicted part delivery time information created by the predicted part delivery time calculation device 700, and determines whether or not the product parts have been delivered to the production area HH at the product production start time according to this information. However, this is merely an example, and the stockout determination device 800 may acquire only either the production plan information or the predicted part delivery time information, and make a determination according to the acquired information.

[0173] In a modified example in which stockout determination device 800 makes a determination based only on the production plan information, stockout determination device 800 creates information indicating the predicted part delivery time for each part by accepting a user operation and stores the information in advance in auxiliary storage unit 3. Stockout determination unit 805 of stockout determination device 800 makes a determination based on the production plan information acquired from production plan information creation device 300 and the information stored in auxiliary storage unit 3. With this configuration, it is possible to omit predicted part delivery time calculation device 700, which creates predicted part delivery time information, and on-board device 400, berth monitoring device 500, and berth availability detection device 600, which create various information used by predicted part delivery time calculation device 700 to create predicted part delivery time information, and therefore the configuration of production management system 100 can be simplified.

[0174] In a modified example in which the stockout determination device 800 makes a determination based only on the predicted part delivery time, the stockout determination device 800 creates information indicating the production start time of each product by accepting a user operation and stores the information in advance in the auxiliary storage unit 3. The stockout determination unit 805 makes a determination based on the predicted part delivery time information obtained from the predicted part delivery time calculation device 700 and the information stored in the auxiliary storage unit 3. With this configuration, it is possible to omit the production plan information creation device 300 that creates the production plan information and the worker terminal 200 that creates the manufacturing performance information used by the production plan information creation device 300 to create the production plan information, thereby simplifying the configuration of the production management system 100.

[0175] In the above embodiment, it has been described that the out-of-stock determination information output unit 806 of the out-of-stock determination device 800 outputs the out-of-stock determination information by displaying an image representing the out-of-stock determination information on the display unit 5, but this is merely an example, and the out-of-stock determination information output unit 806 can output the out-of-stock determination information by any method. For example, the out-of-stock determination device 800 may include a printer, and the out-of-stock determination information output unit 806 may output the out-of-stock determination information by causing this printer to print a print image representing the out-of-stock determination information on a print medium.

[0176] In the above embodiment, it has been described that three parking spaces FF are provided in the berth EE, but this is merely an example, and any number of parking spaces FF can be provided in the berth EE.

[0177] Note that one of the workers' terminals 200 to the stockout determination device 800 may be configured to perform the functions performed by at least one of the other devices in the above-described embodiments. For example, the stockout determination device 800 may perform the functions performed by the production plan information creation device 300, the berth availability detection device 600, and the predicted part delivery time calculation device 700 in the above-described embodiments. Such a configuration can simplify the configuration of the production management system 100.

[0178] At least some of the functions performed by the on-board device 400 in the above embodiment may be realized by an information processing device, such as a server or PC, that is not mounted on the transport vehicle DD. In this modification, each transport vehicle DD is equipped with a positioning device that detects the current position of the transport vehicle DD, and the information processing device acquires data indicating the current position of the transport vehicle DD from this positioning device. A specific example of the positioning device is a GPS (Global Positioning System) receiving device. With this configuration, the configuration of the devices mounted on each transport vehicle DD can be simplified.

[0179] It is possible to provide a dedicated information processing device that is equipped in advance with the configuration for realizing each function according to the present disclosure as the worker terminal 200 to stockout determination device 800 according to the present disclosure, and also to apply a program to make an existing information processing device function as the worker terminal 200 to stockout determination device 800 according to the present disclosure. That is, by applying a program for realizing each function of the worker terminal 200 to stockout determination device 800 according to the present disclosure so that it can be executed by a processor that controls an existing information processing device, the existing information processing device can be made to function as the worker terminal 200 to stockout determination device 800 according to the present disclosure.

[0180] Such a program can be applied by any method. For example, the program may be stored in a computer-readable non-transitory storage medium such as a flexible disk, a CD (Compact Disc)-ROM (Read Only Memory), a DVD (Digital Versatile Disc)-ROM, or a memory card and applied. Alternatively, the program may be superimposed on a carrier wave and applied via a communication network such as the Internet or a LAN (Local Area Network). Specifically, the program may be posted and distributed on a bulletin board system (BBS) on the communication network. A processor controlling an existing information processing device may then launch the program and execute it under the control of an operating system (OS) in the same way as other application programs, thereby realizing the functions of the worker terminal 200 to the missing item determination device 800 according to the present disclosure.

[0181] Although the embodiments and modifications of the present disclosure have been described above, the present disclosure is not limited to these. The present disclosure includes appropriate combinations of the embodiments and modifications, and appropriate modifications thereto.

[0182] The above describes in detail preferred embodiments, but the present invention is not limited to the above-described embodiments, and various modifications and substitutions can be made to the above-described embodiments without departing from the scope of the claims.

[0183] This application is based on Japanese Patent Application No. 2022-087826, filed on May 30, 2022. The entire specification, claims, and drawings of Japanese Patent Application No. 2022-087826 are incorporated herein by reference.

[0184] Various aspects of the present disclosure are summarized below as appendices.

[0185] (Appendix 1) a manufacturing time acquisition means for acquiring a manufacturing time required for manufacturing each of the plurality of products; a production plan information creation means for creating production plan information indicating a production start time for starting production of each product according to the production time of each product acquired by the production time acquisition means, production sequence information indicating a predetermined order in which the products are to be produced, and a scheduled operation start time or a scheduled operation end time on an operating day of the product factory that manufactures the plurality of products; Equipped with The manufacturing time acquisition means If one of the plurality of products has been manufactured, the actual value of the time required to manufacture the one product is acquired as the manufacturing time of the one product; When one product among the plurality of products has not yet been manufactured and another product of the same model as the one product among the plurality of products has not yet been manufactured, a predetermined predicted manufacturing time, which is a predicted value of the time required to manufacture the one product, is acquired as the manufacturing time of the one product; When one of the plurality of products has not yet been manufactured, and another product of the same model as the one product has been manufactured among the plurality of products, and the manufacturing conditions of the one product satisfy a predetermined reference condition, a representative value of the actual values ​​of the time required to manufacture the other product is acquired as the manufacturing time of the one product; If one of the plurality of products has not yet been manufactured, and another product of the same model as the one of the plurality of products has already been manufactured, and the manufacturing conditions of the one product do not satisfy the reference conditions, acquiring the predicted manufacturing time of the one product as the manufacturing time of the one product; Production management system. (Appendix 2) a berth availability determination means for determining whether or not parts can be unloaded from the transport vehicle at a berth provided at the product factory at a predicted vehicle arrival time when the transport vehicle will arrive at the product factory; a parts delivery predicted time calculation means for calculating a parts delivery predicted time when the parts unloaded from the transport vehicle at the berth will be delivered to the manufacturing area according to the result of the determination by the berth availability determination means; Furthermore, The part delivery predicted time calculation means If the berth availability determination means determines that the parts can be unloaded from the transport vehicle at the berth at the predicted vehicle arrival time, a time that is a reference time later than the predicted vehicle arrival time is calculated as the predicted parts delivery time, When the berth availability determination means determines that the parts cannot be unloaded from the transport vehicle at the berth at the predicted vehicle arrival time, the time that is later than the berth availability time, which is the earliest time at which the parts can be unloaded from the transport vehicle at a berth after the predicted vehicle arrival time, is calculated as the predicted parts delivery time. 1. A production management system as described in Appendix 1. (Appendix 3) a berth availability detection means for detecting whether or not parts can be unloaded from a transport vehicle at a berth at the predicted vehicle arrival time; The berth vacancy detection means If the transport vehicle is not parked in at least one of the parking spaces provided at the berth for the transport vehicle, it is determined that the parts can be unloaded from the transport vehicle at the berth at the predicted vehicle arrival time; When transport vehicles are parked in all parking spaces and at least one of the predicted departure times of the parked transport vehicles from the berth is before the predicted vehicle arrival time, it is determined that parts can be unloaded from the transport vehicles at the berth at the predicted vehicle arrival time; If transport vehicles are parked in all parking spaces and the predicted departure times of the parked transport vehicles are all after the predicted vehicle arrival time, it is determined that parts cannot be unloaded from the transport vehicles at the berth at the predicted vehicle arrival time, the berth availability determination means determines whether or not parts can be unloaded from the transport vehicle at the berth at the predicted vehicle arrival time, in accordance with berth availability information indicating the result of detection by the berth availability detection means. 2. A production management system as described in Appendix 2. (Appendix 4) a predicted departure time calculation means for calculating a predicted departure time, the predicted departure time calculation means calculates a time that is an average stay time, which is an average value of actual values ​​of stay times at the berth of a transport vehicle corresponding to the one transport vehicle, from an actual entry time at which the one transport vehicle entered the berth, as a predicted departure time of the one transport vehicle, the berth availability detection means detects whether or not the parts can be unloaded from the transport vehicle at the berth at the predicted vehicle arrival time, according to the predicted departure time calculated by the predicted departure time calculation means. 1. A production management system as described in Appendix 3. (Appendix 5) a berth availability time acquisition means for acquiring berth availability times, When the berth availability detection means determines that the transport vehicle cannot unload parts at the berth at the predicted vehicle arrival time, the berth availability time acquisition means acquires the earliest predicted departure time of the transport vehicle parked in the parking space as the berth availability time, The berth availability information indicates the berth availability time acquired by the berth availability time acquisition means. 5. The production management system according to claim 3 or 4. (Appendix 6) The system further comprises a stockout determination means for determining whether or not parts for a product have been delivered to the manufacturing area at the manufacturing start time of each product, in accordance with at least one of the production plan information created by the production plan information creation means and parts delivery predicted time information indicating the predicted time when parts unloaded from the transport vehicle at a berth provided in the product factory will be delivered to the manufacturing area. 6. A production management system according to any one of appendices 1 to 5. (Appendix 7) a manufacturing time acquisition step of acquiring a manufacturing time required for manufacturing each of the plurality of products; a production plan information creation step of creating production plan information indicating a production start time for starting production of each product according to the production time of each product acquired in the production time acquisition step; Including, In the manufacturing time acquisition step, a manufacturing time of one product is acquired according to whether or not one product among the plurality of products has been manufactured, whether or not other products of the same model as the one product among the plurality of products have been manufactured, and whether or not manufacturing conditions of the one product satisfy preset reference conditions. Production management methods. (Appendix 8) a berth availability determination step of determining whether the transport vehicle can park in a berth provided at the product factory at a predicted vehicle arrival time when the transport vehicle will arrive at the product factory; a parts delivery predicted time calculation step of calculating a parts delivery predicted time at which the parts unloaded from the transport vehicle at the berth will be delivered to the manufacturing area according to the result of the determination in the berth availability determination step; further comprising: The production control method described in Appendix 7. (Appendix 9) The method further includes a stockout determination step of determining whether or not product parts have been delivered to the manufacturing area at the manufacturing start time of each product, in accordance with at least one of the production plan information created in the production plan information creation step and parts delivery predicted time information indicating a parts delivery predicted time at which parts unloaded from the transport vehicle at a berth will be delivered to the manufacturing area, depending on whether the transport vehicle can park at a berth provided at the product factory at the predicted vehicle arrival time at which the transport vehicle will arrive at the product factory. 9. A production management method according to claim 7 or 8. (Appendix 10) Computer, a manufacturing time acquisition means for acquiring a manufacturing time required for manufacturing each of the plurality of products; a production plan information creation means for creating production plan information indicating a production start time for starting production of each product according to the production time of each product acquired by the production time acquisition means; It functions as the manufacturing time acquisition means acquires the manufacturing time of one product according to whether or not one product among the plurality of products has been manufactured, whether or not other products of the same model as the one product among the plurality of products have been manufactured, and whether or not manufacturing conditions of the one product satisfy preset reference conditions; program. (Appendix 11) Computer, a berth availability determination means for determining whether the transport vehicle can park in a berth provided at the product factory at a predicted vehicle arrival time when the transport vehicle will arrive at the product factory; a parts delivery predicted time calculation means for calculating a parts delivery predicted time when the parts unloaded from the transport vehicle at the berth will be delivered to the manufacturing area according to the result of the determination by the berth availability determination means; To further function as 10. The program described in Appendix 10. (Appendix 12) Computer, and further functioning as a stockout determination means for determining whether or not product parts have been delivered to the manufacturing area at the manufacturing start time of each product, in accordance with at least one of the production plan information created by the production plan information creation means and part delivery predicted time information indicating the part delivery predicted time at which parts unloaded from the transport vehicle at a berth will be delivered to the manufacturing area, depending on whether the transport vehicle can park at a berth provided in the product factory at the predicted vehicle arrival time at the product factory. 12. The program according to claim 10 or 11. [Explanation of symbols]

[0186] 1,9,18 Processor, 2,10,19 Main memory unit, 3,11,20 Auxiliary memory unit, 4,12 Operation unit, 5,13 Display unit, 6,14,21 Communication unit, 7,15 Timekeeping unit, 8,17,23 System bus, 16 Positioning unit, 22 Imaging unit, 100 Production management system, 200 Worker terminal, 201 Manufacturing performance information creation unit, 202 Manufacturing performance information storage unit, 203 Manufacturing performance information transmission unit, 300 Production plan information creation device, 301 Manufacturing performance information acquisition unit, 302 Estimated manufacturing time information storage unit, 303 Manufacturing sequence information storage unit, 304 Manufacturing time acquisition unit, 305 Production plan information creation unit, 306 Production plan information output unit, 307 Production plan information storage unit, 308 Production plan information transmission unit, 400 In-vehicle device, 401 Location transition information creation unit, 402 location transition information storage unit, 403 movement speed calculation unit, 404 transport route information storage unit, 405 vehicle arrival predicted time information transmission request reception unit, 406 vehicle arrival predicted time calculation unit, 407 vehicle arrival predicted time information transmission unit, 500 berth monitoring device, 501 imaging control unit, 502 captured image transmission unit, 600 berth vacancy detection device, 601 entry / exit monitoring unit, 602 entry / exit information storage unit, 603 vehicle owner information storage unit, 604 average stay time information creation unit, 605 average stay time information storage unit, 606 inquiry reception unit, 607 berth vacancy detection unit, 608 departure predicted time calculation unit, 609 berth vacancy time acquisition unit, 610 berth vacancy information creation unit, 611 berth vacancy information transmission unit, 700 parts delivery predicted time calculation device, 701 parts loading information storage unit, 702 Vehicle arrival predicted time information acquisition unit, 703 Berth availability information acquisition unit, 704 Predicted delivery time information storage unit, 705 Parts delivery predicted time calculation unit, 706 Parts delivery predicted time information output unit, 707 Parts delivery predicted time information storage unit, 708 Parts delivery predicted time information transmission unit, 800 Stockout determination device, 801 Production plan information acquisition unit, 802 Parts delivery predicted time information acquisition unit, 803 Model information storage unit, 804 Component part information storage unit, 805 Stockout determination unit, 806 Stockout determination information output unit, AA Product factory, BB Parts flow, CC Parts factory, DD Transport vehicle, EE Berth, FF Parking space, GG Product factory building, HH Manufacturing area.

Claims

1. a manufacturing time acquisition means for acquiring a manufacturing time required for manufacturing each of the plurality of products; a production plan information creation means for creating production plan information indicating a production start time for starting production of each product according to the production time of each product acquired by the production time acquisition means, production sequence information indicating a predetermined order in which the products are to be produced, and a scheduled operation start time or a scheduled operation end time on an operating day of the product factory that manufactures the plurality of products; Equipped with The manufacturing time acquisition means If one of the plurality of products has been manufactured, the actual value of the time required to manufacture the one product is acquired as the manufacturing time of the one product; When one product among the plurality of products has not yet been manufactured and another product of the same model as the one product among the plurality of products has not yet been manufactured, a predetermined predicted manufacturing time, which is a predicted value of the time required to manufacture the one product, is acquired as the manufacturing time of the one product; When one of the plurality of products has not yet been manufactured, and another product of the same model as the one product has been manufactured among the plurality of products, and the manufacturing conditions of the one product satisfy a predetermined reference condition, a representative value of the actual values ​​of the time required to manufacture the other product is acquired as the manufacturing time of the one product; If one of the plurality of products has not yet been manufactured, and another product of the same model as the one of the plurality of products has already been manufactured, and the manufacturing conditions of the one product do not satisfy the reference conditions, acquiring the predicted manufacturing time of the one product as the manufacturing time of the one product; Production management system.

2. a berth availability determination means for determining whether or not parts can be unloaded from the transport vehicle at a berth provided at the product factory at a predicted vehicle arrival time when the transport vehicle will arrive at the product factory; a parts delivery predicted time calculation means for calculating a parts delivery predicted time when the parts unloaded from the transport vehicle at the berth will be delivered to the manufacturing area according to the result of the determination by the berth availability determination means; Furthermore, The part delivery predicted time calculation means If the berth availability determination means determines that the parts can be unloaded from the transport vehicle at the berth at the predicted vehicle arrival time, a time that is a reference time later than the predicted vehicle arrival time is calculated as the predicted parts delivery time, When the berth availability determination means determines that the parts cannot be unloaded from the transport vehicle at the berth at the predicted vehicle arrival time, the time that is later than the berth availability time, which is the earliest time at which the parts can be unloaded from the transport vehicle at a berth after the predicted vehicle arrival time, is calculated as the predicted parts delivery time. The production management system according to claim 1 .

3. a berth availability detection means for detecting whether or not parts can be unloaded from a transport vehicle at a berth at the predicted vehicle arrival time; The berth vacancy detection means If the transport vehicle is not parked in at least one of the parking spaces provided at the berth for the transport vehicle, it is determined that the parts can be unloaded from the transport vehicle at the berth at the predicted vehicle arrival time; When transport vehicles are parked in all parking spaces and at least one of the predicted departure times of the parked transport vehicles from the berth is before the predicted vehicle arrival time, it is determined that parts can be unloaded from the transport vehicles at the berth at the predicted vehicle arrival time; If transport vehicles are parked in all parking spaces and the predicted departure times of the parked transport vehicles are all after the predicted vehicle arrival time, it is determined that parts cannot be unloaded from the transport vehicles at the berth at the predicted vehicle arrival time, the berth availability determination means determines whether or not parts can be unloaded from the transport vehicle at the berth at the predicted vehicle arrival time, in accordance with berth availability information indicating the result of detection by the berth availability detection means. The production management system according to claim 2 .

4. a predicted departure time calculation means for calculating a predicted departure time, the predicted departure time calculation means calculates a time that is an average stay time, which is an average value of actual values ​​of stay times at the berth of a transport vehicle corresponding to the one transport vehicle, from an actual entry time at which the one transport vehicle entered the berth, as a predicted departure time of the one transport vehicle, the berth availability detection means detects whether or not the parts can be unloaded from the transport vehicle at the berth at the predicted vehicle arrival time, according to the predicted departure time calculated by the predicted departure time calculation means. The production management system according to claim 3 .

5. a berth availability time acquisition means for acquiring berth availability times, When the berth availability detection means determines that the transport vehicle cannot unload parts at the berth at the predicted vehicle arrival time, the berth availability time acquisition means acquires the earliest predicted departure time of the transport vehicle parked in the parking space as the berth availability time, The berth availability information indicates the berth availability time acquired by the berth availability time acquisition means. The production management system according to claim 3 or 4.

6. The system further comprises a stockout determination means for determining whether or not parts for a product have been delivered to the manufacturing area at the manufacturing start time of each product, in accordance with at least one of the production plan information created by the production plan information creation means and parts delivery predicted time information indicating the predicted time when parts unloaded from the transport vehicle at a berth provided in the product factory will be delivered to the manufacturing area. The production management system according to claim 1 or 2.

7. A production management method performed by a production management system, a manufacturing time acquisition step of acquiring a manufacturing time required for manufacturing each of the plurality of products; a production plan information creation step of creating production plan information indicating a production start time for starting production of each product according to the production time of each product acquired in the production time acquisition step; Including, In the manufacturing time acquisition step, a manufacturing time of one product is acquired according to whether or not one product among the plurality of products has been manufactured, whether or not other products of the same model as the one product among the plurality of products have been manufactured, and whether or not manufacturing conditions of the one product satisfy preset reference conditions. Production management methods.

8. a berth availability determination step of determining whether the transport vehicle can park in a berth provided at the product factory at a predicted vehicle arrival time when the transport vehicle will arrive at the product factory; a parts delivery predicted time calculation step of calculating a parts delivery predicted time at which the parts unloaded from the transport vehicle at the berth will be delivered to the manufacturing area according to the result of the determination in the berth availability determination step; further comprising: The production management method according to claim 7.

9. The method further includes a stockout determination step of determining whether or not product parts have been delivered to the manufacturing area at the manufacturing start time of each product, in accordance with at least one of the production plan information created in the production plan information creation step and parts delivery predicted time information indicating a parts delivery predicted time at which parts unloaded from the transport vehicle at a berth will be delivered to the manufacturing area, depending on whether the transport vehicle can park at a berth provided at the product factory at the predicted vehicle arrival time at which the transport vehicle will arrive at the product factory. The production management method according to claim 7 or 8.

10. Computer, a manufacturing time acquisition means for acquiring a manufacturing time required for manufacturing each of the plurality of products; a production plan information creation means for creating production plan information indicating a production start time for starting production of each product according to the production time of each product acquired by the production time acquisition means; It functions as the manufacturing time acquisition means acquires the manufacturing time of one product according to whether or not one product among the plurality of products has been manufactured, whether or not other products of the same model as the one product among the plurality of products have been manufactured, and whether or not manufacturing conditions of the one product satisfy preset reference conditions; program.

11. Computer, a berth availability determination means for determining whether the transport vehicle can park in a berth provided at the product factory at a predicted vehicle arrival time when the transport vehicle will arrive at the product factory; a parts delivery predicted time calculation means for calculating a parts delivery predicted time when the parts unloaded from the transport vehicle at the berth will be delivered to the manufacturing area according to the result of the determination by the berth availability determination means; To further function as The program according to claim 10.

12. Computer, and further functioning as a stockout determination means for determining whether or not product parts have been delivered to the manufacturing area at the manufacturing start time of each product, in accordance with at least one of the production plan information created by the production plan information creation means and part delivery predicted time information indicating the part delivery predicted time at which parts unloaded from the transport vehicle at a berth will be delivered to the manufacturing area, depending on whether the transport vehicle can park at a berth provided in the product factory at the predicted vehicle arrival time at the product factory. The program according to claim 10 or 11.

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