Production management device, production management method and program

Abstract

To generate a further appropriate production plan, process plan, and resource control information change plan if a deviation occurs between a production plan and a production result.SOLUTION: A production management device performs production management of a product by using production plan information of the product, process plan information related to a production process of the product, and resource control information that defines an operation of a production resource that is a manufacturing facility. If a deviation occurs between a production plan of the product and a production result indicating a progress of production while the production management is performed using the first production plan information, the first process plan information, and the first resource control information, the production management device determines to use, instead of the first process plan information and the first resource control information, second process plan information and second resource control information different from the first process plan information and the first resource control information.SELECTED DRAWING: Figure 1

Description

[Technical Field]

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

[0002] In conventional production management, when a discrepancy occurs between the production plan and actual production, the production plan is changed to match the actual production, thereby reducing the discrepancy.

[0003] On the other hand, with the recent advances in mass customization and personalized production, orders for small-lot production of a wide variety of products are on the rise. In order to address the problem of discrepancies between production plans and actual production results in light of this trend, it is necessary to reconsider the allocation of production resources (production equipment) to product varieties.

[0004] Furthermore, the diversification of workers and the introduction of general-purpose robots have led to an increase in work delays and equipment malfunctions. In order to address the problem of discrepancies between production plans and actual production results in light of these trends, it is necessary to reconsider information related to the operation control of production resources.

[0005] As described above, it is becoming difficult to achieve the target production efficiency by simply addressing the problem of discrepancies between production plans and actual production results by changing only the production plans.

[0006] Patent Document 1 discloses a technique for supporting editing of work plans to obtain appropriate process plans. Specifically, the document describes that when a task assigned to a human is changed to a robot arm, a warning is output if the robot's working time after the change is longer than the human's working time. [Prior art documents] [Patent documents]

[0007] [Patent Document 1] Japanese Patent Application Publication No. 2019-148958 Summary of the Invention [Problem to be solved by the invention]

[0008] As mentioned above, the technology in Patent Document 1 reviews the work plan by changing the work assignment destination in order to obtain an appropriate process plan. However, this technology does not take into consideration the impact on the overall product manufacturing, such as how the change in the work plan will change the production volume of the product.

[0009] Typically, the overall production volume (or production efficiency) of a product is determined through the interrelationship and coordination of a production plan regarding the production period and production volume, an equipment configuration indicated by the type and number of equipment used on the production line, a process plan regarding the allocation and work content of production resources on the production line, and resource control information regarding the operation control of each production resource. In other words, simply reviewing the work plan does not allow for an appropriate assessment of the impact on the overall production volume. Therefore, even if the technology of Patent Document 1 is applied when a discrepancy occurs between the production plan and actual production results, it is difficult to achieve the target production efficiency.

[0010] Furthermore, as mentioned above, conventional production management, which responds by changing only the production plan, has the problem that if a discrepancy occurs between the production plan and actual production results, the target production efficiency cannot be achieved.

[0011] The present invention has been made in view of the above-mentioned problems, and has an object to generate more appropriate change proposals for production plans, process plans, and resource control information when a discrepancy occurs between the production plan and the actual production results. [Means for solving the problem]

[0012] The present application includes a plurality of means for solving at least part of the above-mentioned problems, examples of which are as follows: A production management device according to one aspect of the present invention for solving the above-mentioned problems is a production management device that performs product production management using production plan information for a product, process plan information related to a production process of the product, and resource control information that defines the operation of production resources that are manufacturing equipment, and when a discrepancy occurs between the product production plan and actual production results that indicate the progress of production while performing the production management using first the production plan information, first the process plan information, and first the resource control information, the production management device determines to use second the process plan information and second the resource control information that are different from the first process plan information and first the resource control information instead of the first process plan information and the first resource control information. [Effects of the Invention]

[0013] According to the present invention, when a deviation occurs between the production plan and the production results, it is possible to generate more appropriate changes to the production plan, process plan, and resource control information. [Brief explanation of the drawings]

[0014] [Figure 1] 1 is a diagram showing an example of a schematic configuration of a production management device according to an embodiment of the present invention; [Figure 2] FIG. 10 is a diagram showing an example of production performance information. [Figure 3] FIG. 2 is a diagram showing an example of production plan information. [Figure 4] FIG. 10 is a diagram showing an example of process plan information. [Figure 5] FIG. 10 is a diagram illustrating an example of resource control information. [Figure 6] FIG. 10 is a diagram showing an example of production volume information. [Figure 7] FIG. 10 is a diagram illustrating an example of part shape information. [Figure 8] FIG. 10 is a flow diagram showing an example of a production management process. [Figure 9] FIG. 2 is a diagram illustrating an example of a hardware configuration of a production management device. DETAILED DESCRIPTION OF THE INVENTION

[0015] Hereinafter, an embodiment of the present invention will be described with reference to the drawings.

[0016] 1 is a diagram showing an example of the schematic configuration of a production management device 100 according to this embodiment. When a discrepancy occurs between a production plan and actual production results that indicate progress against the production plan, the production management device 100 generates proposed changes to process plan information and corresponding resource control information, and formulates proposed changes to the production plan in coordination with proposed changes to the process plan, etc., so that predetermined production KPIs (Key Performance Indicators) such as manufacturing cost and production throughput are optimized.

[0017] As shown in FIG. 1, such a production management device 100 includes a processing unit 110, a storage unit 120, an input unit 130, an output unit 140, and a communication unit 150.

[0018] The processing unit 110 is a functional unit that performs various processes executed by the production management device 100. Specifically, the processing unit 110 has an actual result deviation detection unit 111, a plan change necessity determination unit 112, a plan information generation unit 113, a resource control information generation unit 114, and a plan linkage optimization unit 115.

[0019] The actual result deviation detection unit 111 is a functional unit that detects a deviation between the production plan and the actual production results. Specifically, the actual result deviation detection unit 111 detects a deviation in the number of days delay or a deviation in the production volume.

[0020] More specifically, the actual result deviation detection unit 111 identifies the difference between a planned value (for example, the end time of a process identified from the production plan information 122) and an actual result value (for example, the end time of a process identified from the production result information 121) for the same target product using the production plan information 122 and the production result information 121. Furthermore, if the identified difference is equal to or greater than a predetermined threshold (for example, one day or more), the actual result deviation detection unit 111 determines that a deviation between the production plan and the production result (a deviation with a delay in the number of days) has been detected.

[0021] Furthermore, the actual result deviation detection unit 111 identifies the ratio of the difference between the planned value (for example, the planned production quantity identified from the production plan information 122 and the production quantity information 125) and the actual value (the actual predicted production quantity identified from the production result information 121) for the same target product using the production plan information 122, the production result information 121, and the production quantity information 125. Furthermore, if the ratio of the identified difference is less than a predetermined threshold, the actual result deviation detection unit 111 determines that a deviation between the production plan and the actual production (deviation in production quantity) has been detected.

[0022] The plan change necessity determination unit 112 is a functional unit that determines whether or not a coordinated change of the process plan and the production plan is necessary based on the magnitude of the deviation between the production plan and the actual production results. Specifically, the plan change necessity determination unit 112 determines that a coordinated change of the process plan and the production plan is necessary when the magnitude of the deviation is equal to or greater than a predetermined threshold.

[0023] The plan information generating unit 113 is a functional unit that generates various types of plan information. Specifically, the plan information generating unit 113 generates production plan information 122, process plan information 123, and proposed changes thereto.

[0024] The resource control information generating unit 114 is a functional unit that generates the resource control information 124. Specifically, the resource control information generating unit 114 generates the resource control information 124 that defines the operation of the production resources and a proposed change thereto.

[0025] The plan collaboration optimization unit 115 is a functional unit that collaborates and optimizes multiple plans. Specifically, the plan collaboration optimization unit 115 collaborates and creates proposed changes to the production plan using proposed changes to the process plan information 123 and the resource control information 124.

[0026] Next, a description will be given of the storage unit 120. The storage unit 120 is a functional unit that stores various types of information used in various processes executed by the processing unit 110. Specifically, the storage unit 120 has production performance information 121, production plan information 122, process plan information 123, resource control information 124, production quantity information 125, part shape information 126, and cost information 127.

[0027] FIG. 2 is a diagram showing an example of production performance information 121. Information indicating performance (progress results) corresponding to a production plan is registered in the production performance information 121. Specifically, the product ID 121a in the production performance information 121 is information for identifying a product. The part ID 121b is information for identifying a part. The process ID 121c is information for identifying a process. The production resource ID 121d is information for identifying a production resource. The date and time 121e is information indicating the date and time when a predetermined process, such as assembling a part with the corresponding part ID 121b, was carried out in the production of a product identified by the associated product ID 121a. The start time 121f is information indicating the time when the process identified by the associated process ID 121c started. The end time 121g is information indicating the time when the process ended.

[0028] FIG. 3 is a diagram showing an example of production plan information 122. The production plan information 122 stores information indicating production timing, such as the date and time, start time, and end time of each process in product manufacturing. Specifically, the product ID 122a in the production plan information 122 is information for identifying the product to be manufactured. The part ID 122b is information for identifying the parts that make up the product. The process ID 122c is information for identifying the process. The production resource ID 122d is information for identifying the production resource. The date and time 122e is information indicating the date and time of a specific process, such as assembling a part with the corresponding part ID 122b, in the manufacture of a product identified by the associated product ID 122a. The start time 122f is information indicating the planned start time of the process identified by the associated process ID 122c. The end time 122g is information indicating the planned end time of the process.

[0029] Each item in the production plan information 122 corresponds to each item in the production performance information 121, and when a process identified by a process ID 122c is completed for an object identified by a product ID 122a and a part ID 122b in the production plan information 122, information about the object is registered in the production performance information 121 as a production performance.

[0030] FIG. 4 is a diagram showing an example of the process plan information 123. Information related to the manufacturing process of a product is registered in the process plan information 123. Specifically, the product ID 123a in the process plan information 123 is information for identifying the product to be manufactured. The part ID 123b is information for identifying the parts that make up the product. The process ID 123c is information for identifying each process. The production resource ID 123d is information for identifying the production resources used in each process.

[0031] FIG. 5 is a diagram showing an example of the resource control information 124. The resource control information 124 stores control information for defining the operation of production resources. Specifically, each record of the resource control information 124 stores information such as the operation trajectory (e.g., the moving trajectory of an arm) and the maximum operation speed when a production resource (e.g., a facility such as a manufacturing robot) identified by a production resource ID 124d performs a process operation identified by a process ID 124c. More specifically, the product ID 124a and the part ID 124b are information for identifying the product and part that are the target of the process operation identified by the process ID 124c. The process ID 124c is information for identifying the operation of the process. The production resource ID 124d is information for identifying the production resource that performs the process operation. The operation trajectory 124e is information indicating the operation trajectory of the production resource, and information indicating coordinate values ​​in a predetermined coordinate system is registered. The maximum operation speed 124f is information indicating the maximum operation speed of the production resource.

[0032] 6 is a diagram showing an example of production volume information 125. The production volume information 125 is information indicating the planned production volume for each period of a product manufactured according to a production plan. Specifically, the product ID 125a in the production volume information 125 is information for identifying the product. Furthermore, the monthly production volume 125b is information indicating the planned production volume of the target product for a predetermined target period.

[0033] FIG. 7 is a diagram showing an example of part shape information 126. Part shape information 126 is information about the shapes of the components that make up a product. Specifically, part ID 126a in part shape information 126 is information for identifying the part. Component name 126b is information indicating the name of the part. Shape characteristics 126c is information indicating the shape characteristics of the part, such as a cylinder, rectangle, or column. Width 126d, length 126e, diameter 126f, and weight 126g are information indicating the width, length, diameter, and weight of the part, respectively.

[0034] The cost information 127 is information in which various costs are registered. The cost information 127 also registers costs incurred due to changes in, for example, production plans and process plans. Specifically, the cost information 127 includes, for example, equipment costs incurred in changing the layout of equipment such as production resources in a factory layout, operation costs of production resources, profit rates on production output, outsourcing costs including worker costs per unit time and worker overtime costs, penalty costs related to product delivery delays, penalty costs related to work delays, etc.

[0035] Returning to Fig. 1, the input unit 130 is a functional unit that accepts input of instructions and information from a user (operator) of the production management device 100 via an input device included in the production management device 100. The input unit 130 also accepts input of instructions and information from an external device 200 via the communication unit 150.

[0036] The output unit 140 is a functional unit that generates output information (including display information) and displays the display information on the output device 320 (including a display) provided in the production management device 100 or the external device 200. The output unit 140 also generates control instruction information for controlling the operation of the production resources and outputs (transmits) the control instruction information to each production resource in the production line via the communication unit 150.

[0037] The communication unit 150 is a functional unit that performs information communication with the external device 200. Specifically, the communication unit 150 transmits and receives various information to and from the external device 200 via a network (communication line network) N such as the Internet or a LAN (Local Area Network).

[0038] An example of the schematic configuration (functional blocks) of the production management device 100 has been described above.

[0039] [Explanation of operation] Next, the production management process executed by the production management device 100 will be described.

[0040] 8 is a flow diagram showing an example of production management processing. In the production management processing, when a discrepancy occurs between a production plan and actual production results that indicate progress against the production plan, a change plan is generated for each of the process plan information 123 and the corresponding resource control information 124, and a change plan for the production plan is formulated in conjunction with the change plan for the process plan, etc., so that predetermined KPIs such as manufacturing cost and production throughput are optimized.

[0041] The production management process is executed, for example, when an execution instruction is received from a user (operator) of the production management device 100, or at a fixed cycle (for example, once a day or once a week).

[0042] When the process starts, the actual result deviation detection unit 111 determines whether or not a deviation between the production plan and the actual production has been detected (step S010). Specifically, the actual result deviation detection unit 111 acquires the actual production information 121 and the production plan information 122 from the storage unit 120, and compares the actual value of the actual production information 121 with the planned value of the production plan information 122 for the same target.

[0043] More specifically, the actual performance deviation detection unit 111 identifies records in the production performance information 121 for which the processing of this step has not been performed. The actual performance deviation detection unit 111 also identifies the product ID 121a, part ID 121b, process ID 121c, and production resource ID 121d of each identified record. The actual performance deviation detection unit 111 also identifies records in the production plan information 122 in which the same IDs as the identified IDs are registered.

[0044] Furthermore, the actual result deviation detection unit 111 compares the end times in the identified records of the production result information 121 and the production plan information 122. Then, if there is a record in which the end time of the production result information 121 is delayed from the end time of the production plan by a predetermined threshold value or more (for example, one day or more), the actual result deviation detection unit 111 determines that a deviation (deviation delayed by the number of days) between the production plan and the actual production has been detected.

[0045] Alternatively, the actual result deviation detection unit 111 may use the production result information 121, the production plan information 122, and the production quantity information 125 to detect the deviation (deviation in production quantity) between the planned production quantity based on the production plan and the actual predicted production quantity based on the production result.

[0046] Specifically, the actual performance deviation detection unit 111 acquires actual production information 121, production plan information 122, and production quantity information 125 from the storage unit 120. The actual performance deviation detection unit 111 also identifies records in the production performance information 121 for which the processing of this step has not been performed. The actual performance deviation detection unit 111 also identifies the production quantity for the month in which the product ID 121a of each identified record is registered in the production quantity information 125 as the planned production quantity based on the production plan.

[0047] Furthermore, the actual result deviation detection unit 111 calculates the degree of delay from the production plan based on the end time 121g of each identified record in the production result information 121. Furthermore, based on the degree of delay, the actual result deviation detection unit 111 calculates the actual predicted production quantity based on the production result for the product with the corresponding product ID 121a as the predicted production quantity for the relevant month. Then, if the ratio of the actual predicted production quantity to the planned production quantity is less than a predetermined threshold (for example, less than 90%), the actual result deviation detection unit 111 determines that a deviation between the production plan and the actual production (deviation in production volume) for the product with the product ID 121a has been detected.

[0048] The actual result deviation detection unit 111 performs the determination by either method, and if it determines that a deviation between the production plan and the actual production has not been detected (No in step S010), it performs the process of step S010 again.On the other hand, if it determines that the deviation has been detected (Yes in step S010), the actual result deviation detection unit 111 proceeds to step S020.

[0049] In step S020, the plan change necessity determination unit 112 determines whether or not a coordinated change of the process plan and the production plan is necessary based on the magnitude of the deviation. Specifically, the plan change necessity determination unit 112 determines that a coordinated change of the process plan and the production plan is necessary if the magnitude of the deviation is equal to or greater than a predetermined threshold. Examples of the threshold include a delay of three days or more in the case of a deviation in days, and a ratio of the actual predicted production quantity to the planned production quantity of less than 70% in the case of a deviation in production volume.

[0050] If it is determined that coordinated changes to the process plan and production plan are not necessary (No in step S020), the plan change necessity determination unit 112 proceeds to step S060. In step S060, the plan information generation unit 113 generates a proposed change to the production plan information 122. This is because the discrepancy between the production plan and actual production results is small, and therefore it is possible to address this by changing only the production plan information 122. The plan information generation unit 113 generates the proposed change to the production plan information 122 using publicly known techniques, using the production plan information 122, actual production results information 121, and various other information in the storage unit 120.

[0051] Furthermore, the plan information generating unit 113 changes the production plan information 122 to the revised plan (step S070), and returns the process to step S010.

[0052] On the other hand, if it is determined that a coordinated change of the process plan and the production plan is necessary (Yes in step S020), the plan change necessity determining unit 112 proceeds to step S030.

[0053] In step S030, the plan information generation unit 113 and the resource control information generation unit 114 generate multiple change plans for the process plan information 123 and the resource control information 124 corresponding to each of them. Specifically, the plan information generation unit 113 generates change plans for the process plan information 123 related to the equipment configuration indicated by the types of equipment used in the production line and the number of such equipment, and the allocation of production resources in the production line and the work contents, and change plans for the resource control information 124 corresponding to each change plan for the process plan information 123 and for specifying the operation of each production resource. Note that the method for generating the process plan information 123 (including the change plans) and the resource control information 124 (including the change plans) is not particularly limited, but an example is shown below.

[0054] First, the plan information generating unit 113 identifies the part IDs 126a of the component parts corresponding to the process and parts similar thereto from the part shape information 126, and identifies the production resources associated with these part IDs 126a from the production performance information 121.

[0055] In addition, the plan information generation unit 113 sets the identified multiple production resources as candidate production resources for the process, and allocates to each process a predetermined number (e.g., 10) of candidate production resources that have the shortest working time for the process.

[0056] Furthermore, the plan information generation unit 113 performs the same process for all component parts of all target products, thereby generating multiple sets of process plan information 123 for each product, in which a predetermined number of production resource candidates are assigned to each process corresponding to each component part. Note that the method for generating such process plan information 123 may use, for example, the technology described in Japanese Patent Application No. 2020-144537.

[0057] As another example of a method for generating a process plan, the technology described in Japanese Patent Application No. 2020-030479 may be used. Specifically, the plan information generation unit 113 generates multiple combinations of processes and equipment by allocating the calculated predetermined number of pieces of equipment (module groups) to the corresponding processes. The plan information generation unit 113 also estimates the work time based on the arrangement and operation rules of the equipment (module groups) within the cell in the factory layout. The plan information generation unit 113 also identifies a combination of a predetermined number of processes and equipment that minimizes the work time within the cell, and generates multiple pieces of process plan information 123 that take into account the work sequence of all component parts for all target products. Note that allocating equipment to processes determines the number of pieces of equipment required for each process. Therefore, the generated process plan information 123 includes the equipment configuration of the production line, which is indicated by the types and quantities of equipment used in the production line.

[0058] When generating the process plan information 123 using this method, the necessary information (e.g., part attribute information, module group specification information, module specification information, module operation pattern information, and layout information) may be stored in advance in the memory unit 120, or may be obtained from the external device 200 via the communication unit 150.

[0059] Furthermore, the resource control information generation unit 114 generates proposed changes to resource control information 124 for causing the production resources to execute the process plan related to the proposed changes, corresponding to each proposed change in the generated process plan information 123. Note that the method for generating the resource control information 124 is not particularly limited, and any known robot trajectory generation method such as a Rapidly-exploring Random Tree (RRT) algorithm may be used.

[0060] The process plan information 123 and the corresponding multiple modification plans for the resource control information 124 may be stored in the storage unit 120 in advance.

[0061] Next, the plan collaboration optimization unit 115 uses a predetermined production KPI as an objective function and creates a change proposal for the production plan by simultaneously optimizing multiple change proposals for the process plan information 123 and resource control information 124 in collaboration with the production plan information 122 (step S040).

[0062] Specifically, the plan linkage optimization unit 115 solves an optimization problem regarding the combination of multiple change proposals for the process plan information 123 and the resource control information 124 with the production plan information 122 so that predetermined production KPIs such as manufacturing cost and production throughput are maximized (optimized), thereby formulating change proposals for the production plan information 122 in coordination with the change proposals for the process plan information 123 and the resource control information 124.

[0063] As an optimization method, a known technique such as a metaheuristic method, for example, a mixed integer programming (MIP) solver or a genetic algorithm (GA), may be used.

[0064] Specifically, the plan collaboration optimization unit 115 uses one of the proposed changes to the process plan information 123 and the corresponding resource control information 124, and various information in the storage unit 120, to perform a production simulation while changing the production timing (e.g., date and time, start time, and finish time) in the production plan information 122, thereby calculating a predetermined production KPI for each timing. The plan collaboration optimization unit 115 also acquires different proposed changes to the process plan information 123 and the resource control information 124 from the storage unit 120, and performs a similar production simulation using the proposed changes and the production plan information 122 to calculate a predetermined production KPI. The plan collaboration optimization unit 115 also repeatedly performs production simulations using the production plan information 122 for all proposed changes to the process plan information 123 and the resource control information 124 in this manner. This allows the plan collaboration optimization unit 115 to create proposed changes to the production plan information 122 that maximize the predetermined production KPI. Furthermore, by such processing, a set of proposed changes to the process plan information 123 and resource control information 124 corresponding to the proposed changes to the production plan information 122 is determined.

[0065] Note that production KPIs are not limited to manufacturing costs and production throughput, and may be set appropriately based on the perspectives that the user values. Therefore, in addition to manufacturing costs and production throughput, production KPIs may also include, for example, product yield rates and other production KPIs.

[0066] Here, we will explain each production KPI and the type of information used to calculate it. Manufacturing costs are costs incurred due to changes in production plans and process plans. Specifically, manufacturing costs include at least one of the following: equipment costs incurred in changing the layout of equipment such as production resources in the factory layout; operating costs of production resources; profit margins on production output; outsourcing costs including worker costs per unit time and worker overtime costs; penalty costs related to product delivery delays; and penalty costs related to work delays. Specific values ​​for these manufacturing costs can be calculated by performing a production simulation using proposed changes to production plan information 122, process plan information 123, and resource control information 124, as well as cost information 127.

[0067] Also, production throughput is the number of units per predetermined time (e.g., 1 month) in a predetermined period of time. This production throughput is the average number of products produced per minute (for example, per minute). Such production throughput can be determined based on a predicted value calculated by performing a production simulation using the production plan information 122, proposed changes to the process plan information 123 and resource control information 124, and the production quantity information 125.

[0068] The plan collaboration optimization unit 115 may use the process plan information 123 and the corresponding resource control information 124 to identify the net work time of the production resource and the setup time for the production resource to work, and calculate the production throughput by taking these net work times and setup times into account. For example, if the net work time associated with each process ID of the production resource is registered in the process plan information 123 (including proposed changes to the process plan information 123) or the resource control information 124 (including proposed changes to the resource control information 124), the plan collaboration optimization unit 115 identifies the net work time of the production resource from this information. Furthermore, the plan collaboration optimization unit 115 may calculate the time interval between each process as the setup time, and calculate the production throughput by performing a production simulation using the identified net work time and setup time. Performing a production simulation that takes such net work time and setup time into account results in a more accurate predicted value of production throughput.

[0069] The product yield rate is the ratio of the actual production volume to the target production volume for a predetermined period (e.g., one month). Such a product yield rate can be calculated by performing a production simulation using, for example, the production plan information 122, proposed changes to the process plan information 123 and resource control information 124, and the production quantity information 125.

[0070] Note that maximizing (optimizing) manufacturing costs means lower manufacturing costs, maximizing (optimizing) production throughput means higher production throughput, and maximizing (optimizing) product yield rate means higher yield rate.

[0071] In addition, the processing of step S040 may be performed so that a proposed change to the production plan information 122 is formulated in coordination with proposed changes to the process plan information 123 and the resource control information 124 so that at least one production KPI is maximized, or the processing may be performed so that any multiple production KPIs are maximized.

[0072] As described above, by adopting proposed changes to the production plan information 122, process plan information 123, and resource control information 124 that maximize the production KPI and managing production based on these proposed changes, production throughput and manufacturing costs are maximized, and the discrepancy between the production plan and actual production results is reduced. For example, proposed changes that maximize production throughput correspond to production plans and process plans that improve production efficiency. Therefore, if production management is carried out based on such proposed changes, delays in days and discrepancies in production volume are reduced, and the target production efficiency is achieved.

[0073] Furthermore, for example, manufacturing costs include the profit margin on production volume, outsourcing costs including the cost per unit of worker time and overtime costs, penalty costs for delayed product delivery, and penalty costs for work delays. Because these costs increase due to delays in the production plan, a change plan that maximizes manufacturing costs (lower manufacturing costs) corresponds to a production plan and process plan with less delay from the original production plan. Therefore, if production management is carried out based on such a change plan, delays in days and deviations in production volume will be reduced, and the target production efficiency will be achieved.

[0074] Next, the plan link optimization unit 115 updates the production plan information 122, the process plan information 123, and the resource control information 124 based on the proposed change to the production plan information 122 and the corresponding proposed changes to the process plan information 123 and the resource control information 124 (step S050). As a result, production management is performed in accordance with the production plan information 122, the process plan information 123, and the resource control information 124 in a state in which the production KPI has been optimized in response to the discrepancy between the production plan and the actual production results.

[0075] Specifically, a predetermined functional unit (e.g., output unit 140) of production management device 100 generates control instruction information for controlling production resources based on updated process plan information 123 and resource control information 124 in accordance with updated production plan information 122, and outputs (transmits) the control instruction information to each production resource in the production line via communication unit 150. In this way, production management device 100 controls the operation of each process by the production resources based on the changed production plan information 122, process plan information 123, and resource control information 124.

[0076] After completing the process of step S050, the plan collaboration optimization unit 115 returns the process to step S010.

[0077] An example of the production management process has been described above.

[0078] According to such a production management device, when a deviation occurs between the production plan and the actual production results, it is possible to generate more appropriate changes to the production plan, process plan information, and resource control information.

[0079] In particular, the production management device works in conjunction with proposed changes to process plan information and resource control information to propose changes to production plan information so as to maximize production KPIs from a predetermined perspective. Therefore, it is possible to generate appropriate production plan information, process plan information, and resource control information that optimizes production KPIs such as manufacturing cost and production throughput while correspondingly reducing the gap between the production plan and actual production. As a result, the production management device makes it possible to reduce the gap between the production plan and actual production and achieve the target production efficiency.

[0080] 9 is a diagram showing an example of the hardware configuration of production management device 100. As shown in the figure, production management device 100 has an input device 310, an output device 320, a processing device 330, a main memory device 340, an auxiliary memory device 350, a communication device 360, and a bus 370 that electrically interconnects these devices.

[0081] The input device 310 is, for example, a touch panel, a keyboard, a mouse, etc. The output device 320 is a display device such as a liquid crystal display or an organic display.

[0082] The processing device 330 is, for example, a central processing unit (CPU). The main storage device 340 is a memory device such as a random access memory (RAM) or a read only memory (ROM).

[0083] The auxiliary storage device 350 is a non-volatile storage device capable of storing digital information, such as a so-called hard disk drive, a solid state drive (SSD), or a flash memory.

[0084] The communication device 360 ​​is a wired communication device that performs wired communication via a network cable, or a wireless communication device that performs wireless communication via an antenna.

[0085] An example of the hardware configuration of the production management device 100 has been described above.

[0086] The processing unit 110 of the production management device 100 is realized by a program that causes the processing device 330 to perform processing. This program is stored in the main memory device 340 or the auxiliary memory device 350, and is loaded onto the main memory device 340 and executed by the processing device 330 when the program is executed.

[0087] The input unit 130 is realized by an input device 310. The output unit 140 is realized by an output device 320. The storage unit 120 is realized by a main storage device 340, an auxiliary storage device 350, or a combination of these. The communication unit 150 is realized by a communication device 360.

[0088] Furthermore, the above-described configurations, functions, processing units, and processing means of the production management device 100 may be partially or entirely implemented in hardware, for example, by designing them as integrated circuits. The above-described configurations and functions may also be implemented in software, with a processor interpreting and executing programs that implement the respective functions. Information such as programs, tables, and files that implement the respective functions can be stored in storage devices such as memory, hard disks, and SSDs, or in recording media such as IC cards, SD cards, and DVDs.

[0089] Furthermore, the present invention is not limited to the above-described embodiments and modifications, and includes various modifications within the scope of the same technical concept. For example, the above-described embodiments have been described in detail to clearly explain the present invention, and the present invention is not necessarily limited to those including all of the described configurations. Furthermore, it is possible to replace part of the configuration of one embodiment with the configuration of another embodiment, or to add the configuration of another embodiment to the configuration of one embodiment. Furthermore, it is possible to add, delete, or replace part of the configuration of each embodiment with other configurations.

[0090] In addition, in the above explanation, the control lines and information lines are those that are considered necessary for the explanation, and do not necessarily show all the control lines and information lines in the product. In reality, it can be considered that almost all components are interconnected. [Explanation of symbols]

[0091] 100... Production management device, 110... Processing unit, 111... Actual result deviation detection unit, 112... Plan change necessity determination unit, 113... Plan information generation unit, 114... Resource control information generation unit, 115... Plan linkage optimization unit, 120... Storage unit, 121... Production result information, 122... Production plan information, 123... Process plan information, 124... Resource control information, 1 25...Production quantity information, 126...Part shape information, 127...Cost information, 130...Input section, 140...Output section, 150...Communication section, 200...External device, 310...Input device, 320...Output device, 330...Processing device, 340...Main memory device, 350...Auxiliary memory device, 360...Communication device, 370...Bus, N...Network

Claims

1. A production management device that manages the production of a product using production plan information including information on the timing of the production of the product, process plan information regarding the allocation of production resources and work contents related to the production process of the product, and resource control information that specifies specific setting values ​​for controlling the operation of production resources, which are manufacturing facilities, in accordance with the process plan information, When a discrepancy occurs between a product production plan and a production result indicating the progress of production while performing the production management using the first production plan information, the first process plan information, and the first resource control information, If the amount of deviation is equal to or greater than a predetermined threshold, generating a plurality of second process planning information and a plurality of second resource control information, each different from the first process planning information and the first resource control information, using production results; determining which of the second process plan information and the second resource control information to use instead of the first process plan information and the first resource control information so that a predetermined production KPI (Key Performance Indicator) is maximized; using the determined second process plan information and the second resource control information, performing a production simulation multiple times while changing the production timing in the production plan information so as to maximize the production KPI, and creating second production plan information which is a proposed change to the production plan; If the amount of deviation is less than the predetermined threshold, creating the second production plan information, which is a proposed change to the production plan, using the first process plan information, the first resource control information, and the production results; A production management device characterized by:

2. 2. The production management device according to claim 1, The production KPI is: Manufacturing costs including at least one of the following: equipment costs for rearranging equipment such as production resources in a factory layout; operating costs for production resources; profit margins on production output; outsourcing costs including worker costs per unit time and worker overtime costs; penalty costs for product delivery delays and penalty costs for work delays; or a production throughput, which is the number of products produced in a predetermined period of time; The second production plan information is formulated so that the manufacturing cost becomes lower or the production throughput becomes higher. A production management device characterized by:

3. a production plan including information on the timing of product production, a production record showing the progress of production, and a deviation detection unit that detects deviations; a storage unit that stores product production plan information, process plan information relating to the allocation of production resources and work contents related to the product production process, and resource control information that specifies specific setting values ​​for controlling the operation of production resources, which are manufacturing equipment, in accordance with the process plan information; a plan information generating unit that generates, when the deviation is detected and the amount of the deviation is equal to or greater than a predetermined threshold, a plurality of second process plan information and a plurality of second resource control information, each different from the process plan information and the resource control information, using production results; a plan linkage optimization unit that uses the second process plan information and the second resource control information to propose changes to the production plan information so as to maximize a predetermined production KPI (Key Performance Indicator), If the amount of deviation is less than the predetermined threshold, the plan information generation unit uses the first process plan information, the first resource control information, and the production results to create a change plan for the production plan information. A production management device characterized by:

4. 4. The production management device according to claim 3, The plan collaboration optimization unit A production simulation is performed using the proposed changes to the process plan information and the resource control information, and the production plan information, to calculate a predicted value of production throughput, which is the number of products to be produced in a predetermined period of time. A production management device characterized by:

5. 5. The production management device according to claim 4, The plan collaboration optimization unit Identifying the net work time and setup time of the production resource from the proposed change to the process plan information or the proposed change to the resource control information; The production simulation is performed taking into consideration the net work time and setup time, thereby calculating the predicted value of the production throughput. A production management device characterized by:

6. 4. The production management device according to claim 3, an output unit that generates control instruction information for controlling the production resources using the proposed changes to the production plan information, the proposed changes to the process plan information, and the proposed changes to the resource control information, and outputs the control instruction information to the production resources in the production line; A production management device characterized by:

7. 4. The production management device according to claim 3, The production KPI is an evaluation index related to manufacturing costs, including at least one of the following: equipment costs related to rearrangement of equipment such as production resources in a factory layout; operation costs of production resources; profit margins on production output; outsourcing costs including worker costs per unit time and worker overtime costs; penalty costs related to product delivery delays; and penalty costs related to work delays; The plan collaboration optimization unit calculates the production KPI related to the manufacturing cost by performing a production simulation using the production plan information, the process plan information, and the proposed changes to the resource control information. A production management device characterized by:

8. A production management method for a product, which is carried out by a production management device using production plan information including information on the production timing of the product, process plan information regarding the allocation of production resources and work contents related to the production process of the product, and resource control information that specifies specific setting values ​​for controlling the operation of production resources, which are manufacturing equipment, in accordance with the process plan information, The production management device When a discrepancy occurs between a product production plan and a production result indicating the progress of production while performing the production management using the first production plan information, the first process plan information, and the first resource control information, If the amount of deviation is equal to or greater than a predetermined threshold, generating a plurality of second process planning information and a plurality of second resource control information, each different from the first process planning information and the first resource control information, using production results; determining which of the second process plan information and the second resource control information to use instead of the first process plan information and the first resource control information so that a predetermined production KPI (Key Performance Indicator) is maximized; performing a step of executing a production simulation multiple times while changing the production timing in the production plan information using the determined second process plan information and the second resource control information so as to maximize the production KPI, and formulating second production plan information which is a proposal for changing the production plan; If the amount of deviation is less than the predetermined threshold, a step of formulating the second production plan information, which is a proposed change to the production plan, using the first process plan information, the first resource control information, and the production results; A production management method characterized by:

9. A production management method using a production management device, The production management device a production plan including information on the timing of product production, a production record showing the progress of production, and a deviation detection step for detecting deviations; a storage step for storing production plan information for the product, process plan information relating to the allocation of production resources and work contents related to the production process of the product, and resource control information defining specific setting values ​​for controlling the operation of the production resources, which are manufacturing equipment, in accordance with the process plan information; a plan information generating step of generating, when the deviation is detected and the amount of the deviation is equal to or greater than a predetermined threshold, a plurality of second process plan information and a plurality of second resource control information different from the process plan information and the resource control information, using production results; a plan linkage optimization step of formulating a change plan for the production plan information using the second process plan information and the second resource control information so as to maximize a predetermined production KPI (Key Performance Indicator); If the amount of deviation is less than the predetermined threshold, a step of formulating a change plan for the production plan using the first process plan information, the first resource control information, and the production results; A production management method characterized by:

10. A program that causes a computer to function as a production management device, The computer, Execute production management of the product using production plan information including information on the production timing of the product, process plan information regarding the allocation of production resources and work contents related to the production process of the product, and resource control information that specifies specific setting values ​​for controlling the operation of the production resources, which are manufacturing equipment, in accordance with the process plan information; When a discrepancy occurs between a product production plan and a production result indicating the progress of production while performing the production management using the first production plan information, the first process plan information, and the first resource control information, If the amount of deviation is equal to or greater than a predetermined threshold, generating a plurality of second process planning information and a plurality of second resource control information, each different from the first process planning information and the first resource control information, using production results; determining which of the second process plan information and the second resource control information to use instead of the first process plan information and the first resource control information so that a predetermined production KPI (Key Performance Indicator) is maximized; using the determined second process plan information and the second resource control information, executing a production simulation multiple times while changing the production timing in the production plan information so as to maximize the production KPI, and formulating second production plan information which is a proposed change to the production plan, and performing production management; If the amount of deviation is less than the predetermined threshold, The second production plan information, which is a proposed change to the production plan, is prepared using the first process plan information, the first resource control information, and the production results. A program characterized by:

11. A program that causes a computer to function as a production management device, The computer a production plan including information on the timing of product production, production results relating to the allocation of production resources and work contents showing the progress of production, and a deviation detection unit for detecting deviations; a storage unit that stores production plan information for a product, process plan information relating to a production process of the product, and resource control information that defines specific setting values ​​for controlling the operation of production resources, which are manufacturing equipment, in accordance with the process plan information; a plan information generating unit that generates, when the deviation is detected and the amount of the deviation is equal to or greater than a predetermined threshold, a plurality of second process plan information and a plurality of second resource control information, each different from the process plan information and the resource control information, using production results; a planning linkage optimization unit that uses the second process plan information and the second resource control information to propose changes to the production plan information so as to maximize a predetermined production KPI (Key Performance Indicator); If the amount of deviation is less than the predetermined threshold, a program causing the plan information generation unit to function to formulate a change proposal for the production plan by using the first process plan information, the first resource control information, and the production results.

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