Production fast forward device

Abstract

To provide a production management system and device in a make-to-order production scheme in which the end time of day of a final step corresponds to the production-completion date (loading date-and-hour) or shipment-completion date (shipment date).SOLUTION: A method includes: table-expanding object-of-production progress / partly-finished data 1 on a computer 2 to process step-ordered progress; using designated work time of a packet 8 in a step-ordered step to connect step personal computers 3 perfectly copying actual production steps together through a LAN; and perfectly copying, within a device, actual-production step order and work-time passage by exchanging information of step acceptance date-and-time 9 and step work commencement / completion date-and-time 10, so that the device can execute one month, or 30 date (43,200 minutes), in 3-hour of daily-life required time when a fast-forward designation for fast execution with a fast-forward designation to a device timepiece is 240 times. By utilizing a fast-forward designation of actual-object progress movement to the device timepiece on the personal-computer LAN copied a factory layout, a total result of production is forecast with a progress movement of information.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a production management system for made-to-order production, and relates to production schedule and management accuracy, i.e., accuracy of replying to ultimate completion dates, when a large number of products are produced for a large number of customers, in a large variety of processes, using a plurality of facilities. [Background technology]

[0002] To meet the quality characteristics required by customers, we repeatedly design prototype processes and implement the PDCA cycle to determine the process procedures. An online real-time processing system has been created that uses computers to issue production instructions to each process based on process design information in line with each customer's order (standards and specifications) and receives information on work completion.

[0003] Each manufacturing company is striving to improve QCD by managing production using production management tools and proprietary techniques, but when it comes to D (delivery date), a huge amount of information needs to be processed due to the large number of customers and product varieties, and many companies have not yet realized a system that can predict and prevent delivery delays or instantly determine the impact on other items when handling rush orders. [Prior art documents] [Patent documents]

[0004] Even when searching for production management, waiting time, and completion date, nothing was found that met the gist of this invention. [Non-patent literature]

[0005] Even when searching for production management, waiting time, and completion date, nothing was found that met the gist of this invention. Summary of the Invention [Problem to be solved by the invention]

[0006] The time required to pass through each piece of equipment (process) (waiting time for processing + processing time) is the result of a huge number of combinations of production permutations, and this combination changes each time. The single largest factor in fluctuations in the time required to pass through is the actual waiting time for processing (hereafter referred to as work-in-progress waiting time). In order to provide highly accurate future production forecast results, there was no prior art that automatically calculates the work-in-progress waiting time for all factory equipment using logical means, and that the work-in-progress time, processing time, start and finish times for all processes in the production details, in other words the finish time of the final process, becomes the production completion date (warehouse entry date and time) or shipping completion date (shipping date).

[0007] Providing technology that is as cost-effective as possible. [Means for solving the problem]

[0008] The data to be processed is high-precision process design information for quality assurance purposes, and the processing time of the process equipment that passes through that process design. The host computer stores specific times for each item, including pre- and post-setup times that reflect differences in weight even for the same specifications and standards. The production progress and in-process process sequence data 1 of the actual production factory is received from the host computer, and is displayed in a table on computer 2 that processes the progress of the process sequence. This is then connected to process computer 3, which is a complete copy of the production equipment (processing and assembly) process, via LAN. The computer 2. Manually input the operation start date and time, end date and time, and the fast-forward clock 14 times speed, and the entire process maintenance plan. The computer From 2 All the above processes PC 3 via LAN, prepare the entire time management environment of this invention, and perform the same operations as in actual production. Based on the items entered on Computer 2 above , The computer 2 and The above process computer Reproduced by linking 3, the process is fast-forwarded from the specified start date and time to the end date and time in 14 steps. Work in progress date and time , start Date and Time The completion date and time is updated to all processes 7 of all details 4 in a short time, and the details 4 for which the receiving process and shipping process have been completed are output as production and shipping completion data 11, Process PCEach time the work results of 3 are completed, they are output as process work schedule data 12. By matching the start time of this device with the time when the production target progress and in-process production target progress and in-process process sequence data 1 of the actual production factory and work-in-process factory were created, continuity can be maintained.

[0009] Based on

[0008] , the host computer sends detailed process sequence data as production object progress / in-process process sequence data 1 to computer 2, which processes the process sequence in Figure 1, and the data is expanded into a table in 2. In addition, a process computer 3, which is a complete copy of the actual production equipment (processing / assembly) process, is connected via LAN, and the maintenance date and time for all processes, the double speed setting for the equipment clock 14, the end date and time in actual equipment time, additional changes to priority settings, and the operation start time in daily time setting are transmitted via LAN by key input 7 in 2, preparing an overall time management environment. It is essential that the start date and time in actual equipment time be aligned with the time when production object progress / in-process process sequence data 1 was created in order to ensure continuity.

[0010] When the operation start time specified in

[0009] arrives, computer From the process information displayed in the table in 2, the process information that is judged to be in progress (when the previous process has an end date and time, and the next process does not have an end date and time, and the next process is in progress) is sent to all process computers 3 in the process order of process 7. Device After entering the end date and time of the previous process in the date and time, packet 8 is sent at 9. This device sends the end date and time of the previous process to the next process. Device Everything is processed by date and time (received date and time in the process PC), and when the order comes in the process PC work waiting table, the end date and time (time when it can be sent to the next process: start time + work time) is decided, and when the end date and time match the equipment clock time, the start date and time and end date and time are returned by transmission 10 and the start date and time and end date and time are entered in the process order table 7. It operates exactly the same as actual production. computer 2 and Process PC The linkages 9 and 10 of 3 are reproduced, and the process work completion time is calculated by the process computer 3 using the fast-forward time of 14 from the start date and time of the equipment clock to the end date and time, as the start time + work time, and the process is carried out according to the process order of 4. Work in progress date and time , start Date and TimeThe completion date and time are updated to all processes 7 of all details 4 in a short time, and the details 4 for which the shipping process has been completed are output as production completion data 11, and the work results of 3 are also output as process work schedule data 12 each time they are completed.

[0011] It is possible to determine delivery delays based on the order delivery date and the end date and time of the shipping process, and output the file and list.

[0012] The processing result of the process PC work waiting table 15 becomes the work performance of the process order table 7, so the processing of 15 is the most important, and the maintenance information has the highest priority and is at the front, then the priority specification of packet 8 is next, and the one without priority specification is next. Device The earliest date and time are executed first. Packets with end dates and times that overlap with the maintenance start and end dates and times will not be executed. If there are packets whose end dates and times do not overlap with the maintenance start and end dates and times, they will be executed over them. The start and end dates and times of the executed packet are updated in 10 to the start and end dates and times of the sender process 7 using the detail IDX and process IDX of packet 8.

[0013] The waiting priority conditions of the process PC work waiting table 15 explained in

[0012] have been described, but the packet 8 already being worked on is unconditionally processed first, but the judgment of already being worked on is made by the packet 8 sent to the process PC 3 in

[0010] . Device If the date and time is the oldest among the waiting packets 8 and is between the end date and time of the latest results of 4 with the equipment code of the process computer and the creation time of the production target progress / in-process process sequence data 1, it indicates that work is already in progress, and Device The date and time are the start date and time. At the time when the production progress and work-in-progress process sequence data 1 was created, most of the processes were in progress.

[0014] The process computer 3 is available in sequential processing type and batch processing type (for example, annealing furnace), and there are differences in how the end date and time are decided, the start date and time of the next process, and the processing of the work waiting table. The batch processing type involves cooling after removal from the furnace, and the removal date and time is calculated based on the packet work time, and the start date and time of the next packet (entry date and time) is updated. After the removal packet is cooled, it is processed as 10 when it can be sent to the next process. workThe queue is deleted from the waiting table. Similar operations can be considered for sequential processing, and can be realized by using the cooling time item.

[0015] This device can be used to identify items that have been delayed by specifying the equipment code and production lot of the process that had the longest waiting time, changing the priority designation, and then executing the process again to resolve the delay and check whether any new delays in delivery have occurred as a result.

[0016] The only programs required are four patterns: a program on the host side to create production progress and in-process process sequence data 1, a sequential processing process computer 3, a batch processing computer (e.g., annealing furnace) process computer 3, and a computer 2 that processes the progress of the process sequence. The load on process computer 3 is extremely small, and it is thought that an inexpensive computer could be used. Computer 2, which processes the progress of the process sequence, needs performance that matches the load of the large number of details and the LAN processing speed required to specify double the speed, so there is also the option of increasing the number of computers. It is thought that the program that creates production target progress and work-in-progress process sequence data 1 on the host side will not impose a large burden on development. [Effects of the Invention]

[0017] Each manufacturing company is trying to improve QCD by managing production using production management tools and proprietary techniques, but when it comes to D (delivery date), a huge amount of information needs to be processed due to the large number of customers and the wide variety of products, and many companies are unable to realize a system that can predict and prevent delivery delays or instantly determine the impact on other items when handling rush items.

[0018] As mentioned in

[0008] to

[0015] , the order of the detailed processes is fixed (100%), but the accuracy of the process work time does not necessarily approach 100%. If the accuracy of the work time for all processes is not nearly 100%, there will be an impact, and all results will be unrealistic. In companies that have no intention of utilizing this accuracy of work time in the first place, it may be left unaddressed, and it may be overlooked in DX issue development, and the issue mentioned in

[0006] will never be resolved, no matter how much time passes. This is an improvement on the current situation.

[0019] The result data of this device can be compared with the actual production work results the next day, and whether the process work time is appropriate or not, or whether there is any local on-site rule other than that shown in

[0012] . rule This allows us to investigate whether there are any issues and immediately take action to ensure accuracy. As a result, we can improve the accuracy of work times for all details and processes in just a few months of manpower. Once this environment is in place, we can provide accurate schedules over the long term, opening up endless possibilities for DX, PDCA, QC activities, and more in production management QCD activities.

[0020] It is expected to be applied to production management operations in many industries, and contributions from an SDG perspective are expected, such as reducing the human labor required for delivery date management and response to delivery date inquiries, reducing work in progress, and utilizing larger trucks and return trips in strategic delivery planning. Increasing the accuracy of product completion dates for export shipments by sea will enable strategic choices and lead to cost reductions. Furthermore, by simultaneously using this system for priority and regular management of customer inquiries, it will be possible to provide reliable answers that include a schedule for the entire process, gaining customer trust and gaining a digital transformation advantage among competitors.

[0021] In addition to the measures to prevent delivery delays explained in

[0015] , by using 11 to aggregate delivery destinations by prefecture, by using priority designation to control completion dates, and by consolidating details, it is possible to increase the size of orders and reduce the number of deliveries. [Brief explanation of the drawings]

[0022] [Figure 1] A diagram showing the relationship between host progress and in-process process sequence data 1, process sequence computer 2, process PC 3, and key input 7. DETAILED DESCRIPTION OF THE INVENTION

[0023] In a small to medium-sized air-conditioned room, process PCs 3 (low-cost) and a high-performance computer are installed, the number of which is equal to the number of processing equipment in the factory, and an operational test of the equipment is carried out at the stage when data creation on the host is completed. Practical application is promoted through the activities shown in

[0019] . [Explanation of symbols]

[0024] 1. Production progress and in-process process data for actual production plants 2. Computer (high performance) to process the progress of the process 3. Process computer that perfectly copies the production equipment (processing and assembly) process (1:1 with on-site equipment) 4 Identify using (Detail IDX) in the process expanded details for each manufacturing lot number expanded in the table in 2. 7 Identify using (Process IDX) in the process expanded in the table 4. 9 Packets from 2 to 3 Device LAN process for sending date and time (sent date and time) 10 LAN process sending start and end dates and times from 3 to 2 11 Data output for completed production and shipping processes and data output for delivery delays 12. The process schedule is output when the process in 3 is completed, the results are returned to 2, and the data is deleted from the waiting table. 14. A device clock (equipped on 2 and 3) that uses the computer clock that keeps accurate daily time and keeps fast-forward time by specifying double speed. 15 Work in progress table [Industrial Applicability]

[0025] It provides functions required by all manufacturing industries. In addition, with regard to the 2024 problem, both the transportation industry and shippers face challenges, with the receivers seeking to reduce driver waiting time by improving their own work efficiency, and the shippers needing to grasp the overall progress of the manufacturing process and make highly accurate arrangements at an early stage to prevent delays in delivery dates and prevent receivers from having to wait for cargo. However, the technology essential to realizing this is lacking, and there is a high possibility that this invention will become a core technology that paves the way.

[0026] In production, if information can be obtained even one day earlier for inventory management, material procurement, customer inquiries, shipping plans, etc., optimal and low-cost measures can be implemented with ample time to spare, and technology that can ensure accuracy up to a considerable distance in the future (about one month) is effective in achieving the SDGs in the global manufacturing supply chain. It is also effective in developing specific issues for DX (digital transformation).

Claims

[Claim 1] A host computer having production target progress and in-process process sequence data (1) including information on completion records and future work processes in an actual production factory that produces a large number of products with a wide variety of processes using multiple facilities; a computer (2) that develops the production object progress and in-process process sequence data (1) provided from the host computer into a table for each product and processes the progress of a plurality of process sequences; a process personal computer (3) connected to the computer (2) via a LAN, which stores a complete copy of the processes to be carried out in the actual production factory and has a process work waiting table provided for each piece of equipment for each process; The four items of the operation start date and time, end date and time, the double speed specification of the fast-forward clock (14), and the schedule of each process for periodic maintenance are manually input into the computer (2) and transmitted from the computer (2) to all the process personal computers (3), thereby preparing an overall time management environment, and the same operations as actual production are reproduced in cooperation with the computer (2) and the process personal computers (3) based on the items input into the computer (2). When the fast-forward time (14) from the operation start date and time to the end date and time, which is the same as the closing day at the end of the month, which is the general closing day in an actual production factory, matches the end time of the work in progress in the work waiting table of the process personal computer (3), the process personal computer (3) sends the start date and end date and time to the computer (2), and the process sequence table (4) is generated. The computer (2) sends the date and time of receipt (in-process) of the process to a personal computer (3) designated by an equipment code, and the process of adding the process work waiting table is continued until the end date and time that is the same as the closing date of the end of the month, and the data in which the end date and time of the final process is recorded in the process sequence table (4) where the receiving process and shipping process are completed is output as production and shipping completion data (11) in which the start date and time, start date and time, and completion date and time of all processes are updated, and the work completion results of the process personal computer (3) are a record of the start date and time, start date and time, and completion date and time of the work in-process of the process, and are output as process work schedule data (12) each time it is completed, and the start date and time, start date and time, and completion date and time of all processes are recorded until the date and time designated by the operation end date and time.

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