Production planning system and production planning method

Abstract

To make a production plan of minimizing an environmental load such as power consumption even in the case where multi-product mixed flow production is carried out.SOLUTION: A production planning system includes an arithmetic unit and memory unit. The memory unit preserves production plan information, work instruction information, jig information, preparation time information, and power consumption information. The arithmetic unit classifies products, which are supplied during a predetermined period, into product groups, each of which can be produced using the same jig, on the basis of the production plan information and work instruction information. Based on the jib information, the arithmetic unit creates plural drafts of a set of jigs, which are installed in a production facility in order to produce products of each group. Based on the preparation time information and power consumption information, the arithmetic unit creates a set of jigs and an order of supplying products of each group, which make at least one of a sum total of preparation times and a sum total of power consumption values smaller by referencing the plural drafts.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present invention relates to a technology for assisting in formulating a production plan for products.

Background Art

[0002] As the background art of the present invention, there are JP-A-2018-116988 (Patent Document 1) and JP-A-2020-203303 (Patent Document 2).

[0003] Patent Document 1 describes that "in two or more component mounting lines L1 and L2 in which a plurality of component mounting devices are connected, based on the number of workers assigned to production on the component mounting lines L1 and L2 in each time period and the number of workers required for the setup work necessary when switching the mounting substrates V1 to V6 on the component mounting lines L1 and L2, the setup work time (internal setup work times Tc1 to Tc4) required to perform the setup work on the component mounting lines L1 and L2 is calculated, the production completion time Tf0 when the production of all the mounting substrates V1 to V6 to be produced, including the setup work time, is completed is calculated, and within a predetermined period, groups G1 to G4 are determined so that the production completion time Tf0 on the component mounting lines L1 and L2 is shortened."

[0004] Patent Document 2 describes that "the processing order determination method is such that a computer acquires information on a plurality of die setups used for bending components (S10), determines the order of die setup changeovers between the respective die setups based on the die changeover time between the die setups (S11 to 13), and determines the processing order for performing a series of bending processes using the plurality of die setups based on the determined order of changeovers (S14)."

Prior Art Documents

Patent Documents

[0005]

Patent Document 1

Patent Document 2

[0006] In social infrastructure system products such as control panels, multi-product mixed-model production is employed. In multi-product mixed-model production, the variety of products produced is large and frequently changes. Traditionally, efforts have been made to optimize planning for highly efficient multi-product mixed-model production, including workload leveling. However, in recent years, with increasing environmental awareness, it has become crucial to develop production plans that reduce environmental impact, such as power consumption and CO2 emissions.

[0007] As an example of a production process, consider the bending process. The majority of the time a bending machine is operating is spent on setup (i.e., selecting the parts to be processed and changing the molds) before the parts are loaded into the machine. This trend is not limited to bending machines; it is common for all production equipment. Therefore, reducing equipment idling time by improving setup efficiency is required to improve production efficiency and reduce power consumption.

[0008] As technologies for streamlining setup, both Patent Documents 1 and 2 described above include techniques for streamlining setup. However, Patent Document 1 does not describe designing combinations of jigs and fixtures (e.g., dies in bending machines) used in the equipment to streamline setup. Patent Document 2 does not describe designing the input sequence of parts to streamline setup. Furthermore, neither document describes relaxing the selection criteria for jigs and fixtures to streamline setup. [Means for solving the problem]

[0009] To solve at least one of the above problems, the present invention provides a production planning system comprising a calculation unit and a storage unit, wherein the storage unit holds production planning information, work instruction information, jig and fixture information, setup time information, power consumption information, and actual information, the production planning information includes the items of products to be put into the production equipment and the time at which the products are put into the production equipment, the work instruction information includes information instructing the jigs and fixtures to be installed in the production equipment for the production of each item of product, the jig and fixture information includes the specifications of the jigs and fixtures that can be installed in the production equipment, the setup time information includes the time required to set up the jigs and fixtures in the production equipment, the power consumption information includes the power required to set up the jigs and fixtures in the production equipment and for production using the jigs and fixtures, the actual information includes information indicating the jigs and fixtures that have been used in the past for the production of each item of product, and the calculation unit creates selection conditions for the jigs and fixtures to be used for the production of each item of product based on the actual information, and the production planning information, the work instruction information and the selection Based on the conditions, the products to be introduced during a predetermined period are classified into groups of products that can be produced by the same jigs and fixtures; based on the jigs and fixtures information, multiple combinations of jigs and fixtures to be installed in the production equipment to produce the products of each group are created; based on the setup time information and the power consumption information, a combination of jigs and fixtures that minimizes at least one of the total setup time and the total power consumption, and the input order of the groups are created from the multiple options; the production equipment is equipment that performs bending; the jigs and fixtures are dies for the bending process; the work instruction information includes information that instructs the dies to be installed in the production equipment for bending the products for each product item; the jigs and fixtures information includes information indicating the width of each die; the performance information includes information indicating the dies that have been used in the past for bending each product item; the selection conditions include information indicating the width conditions of the dies used for bending each product item; and the calculation unit has a track record of being used for bending each product item. 1 or more The width of the aforementioned mold TotalThe selection criteria are created so that the range is included in the selection target, the products to be introduced during the predetermined period are classified into groups of products that can be produced by the same fixture so that products of multiple items for which at least part of the selection criteria overlap are included in the same group, and as multiple options for combinations of fixtures, an option is created for installing one or more molds whose total width satisfies the selection criteria. [Effects of the Invention]

[0010] According to one aspect of the present invention, even in cases of mixed-model production of multiple product types, it is possible to formulate a production plan that reduces environmental burdens such as power consumption by reducing setup time. Problems, configurations, and effects other than those described above will be clarified by the following description of the embodiments. [Brief explanation of the drawing]

[0011] [Figure 1] This is a block diagram showing the configuration of the production planning system in Embodiment 1 of the present invention. [Figure 2] This is an explanatory diagram showing the production plan held by the production planning system of Embodiment 1 of the present invention. [Figure 3] This is an explanatory diagram showing the work instruction information held by the production planning system in Embodiment 1 of the present invention. [Figure 4] This is an explanatory diagram showing the tooling information held by the production planning system in Embodiment 1 of the present invention. [Figure 5A] This is an explanatory diagram showing the setup time unit cost information held by the production planning system of Embodiment 1 of the present invention. [Figure 5B] This is an explanatory diagram showing the power consumption unit information held by the production planning system of Embodiment 1 of the present invention. [Figure 6] This is an explanatory diagram showing the input group information held by the production planning system of Embodiment 1 of the present invention. [Figure 7] This is an explanatory diagram showing the proposed tool and fixture combinations held by the production planning system of Embodiment 1 of the present invention. [Figure 8]It is an explanatory diagram showing the determined input order and jig combination held by the production planning system according to Example 1 of the present invention. [Figure 9] It is a flowchart showing the process executed by the production planning system according to Example 1 of the present invention. [Figure 10] It is an explanatory diagram showing the output screen displayed by the production planning system according to Example 1 of the present invention. [Figure 11] It is a block diagram showing the configuration of the production planning system according to Example 2 of the present invention. [Figure 12] It is an explanatory diagram showing the production results held by the production planning system according to Example 2 of the present invention. [Figure 13] It is an explanatory diagram showing the jig selection rules held by the production planning system according to Example 2 of the present invention. [Figure 14] It is an explanatory diagram showing the input group information held by the production planning system according to Example 2 of the present invention. [Figure 15] It is an explanatory diagram showing the jig combination plan held by the production planning system according to Example 2 of the present invention. [Figure 16] It is an explanatory diagram showing the determined input order and jig combination held by the production planning system according to Example 2 of the present invention. [Figure 17] It is a flowchart showing the process executed by the production planning system according to Example 2 of the present invention. [Figure 18] It is an explanatory diagram showing the output screen displayed by the production planning system according to Example 2 of the present invention.

Embodiments for Carrying Out the Invention

[0012] Hereinafter, embodiments of the present invention will be described based on the drawings.

Examples

[0013] FIG. 1 is a block diagram showing the configuration of the production planning system according to Example 1 of the present invention.

[0014] The production planning system 100 is a device that includes a personal computer (PC) such as a server or terminal, and software implemented on the PC, and comprises an input / output unit 101, a storage unit 102, and a calculation unit 103. The production planning system 100 is connected to systems such as a design system 105 and a work instruction device 106 via a network 104.

[0015] The input / output unit 101 is for acquiring data necessary for processing in the arithmetic unit 103 and for displaying the processing results. It is configured to include, for example, input devices such as a keyboard and mouse, a communication device for communicating with the outside, a recording and playback device for a disk-type storage medium, and an output device such as an LCD monitor.

[0016] The storage unit 102 includes input information 107 used in the processing of the arithmetic unit 103 and output information 108 for storing the processing results, and is composed of a storage device such as an HDD (hard disk drive) or SSD (solid state drive) and memory.

[0017] Input information 107 includes production plan 111, work instruction information 112, tooling information 113, and unit cost information 114. Unit cost information 114 includes setup time unit cost information 115 (Figure 5A) and power consumption unit cost information 116 (Figure 5B). Output information 108 includes production plan information 121, input group information 122, production method for each input group 123, proposed tooling combinations 124, setup time calculation results for each tooling combination condition 125, and confirmed input order and tooling combinations 126. This information will be described later.

[0018] The arithmetic unit 103 includes a memory unit 130 and an arithmetic processing unit 131. The memory unit 130 is for temporarily holding data acquired from the input / output unit 101 and the input information 107 of the storage unit 102, as well as the results processed by the arithmetic processing unit 131.

[0019] The calculation processing unit 131 consists of a data acquisition unit 132, an input group creation unit 133, a tool and fixture combination planning unit 134, an input order and tool and fixture combination calculation unit 135, and a display control unit 136. The processing performed by each of the above units will be described later.

[0020] Next, we will explain input information 107.

[0021] Figure 2 is an explanatory diagram showing the production plan 111 held by the production planning system 100 of Embodiment 1 of the present invention.

[0022] The production plan 111 is information for managing the production plan of a product, and includes, for example, input date 201, required deadline 202, and part name 203. The input date 201 indicates the scheduled date on which the parts constituting the product are put into the process. The required deadline 202 indicates the deadline by which each process is required to be completed. The part name 203 is information that identifies the part to be put into the process.

[0023] Figure 2 shows, as an example, the production plan for four types of parts identified by part names "A-1," "A-2," "A-3," and "A-4," along with their respective input dates and required deadlines. In the following explanation, these parts may simply be referred to as part "A-1" through part "A-4."

[0024] Figure 3 is an explanatory diagram showing the work instruction information 112 held by the production planning system 100 of Embodiment 1 of the present invention.

[0025] The work instruction information 112 shown in Figure 3 includes part name 301, material 302, plate thickness 303, bending angle 304, processing width 305, processing area 306, mold (upper) 307, and mold (lower) 308. Part name 301 is information that identifies the part to be fed into the process. Material 302 and plate thickness 303 indicate the material and plate thickness of each part. Processing area 306 is information that identifies the part to be processed in the process in which each part is fed. Processing width 305 and bending angle 304 are information that identifies the processing performed in each processing area. Figure 3 shows an example of bending, and the width and bending angle of the part to be bent are specified. Mold (upper) 307 and mold (lower) 308 are information that identifies the mold used for processing each processing area.

[0026] For example, the first entry in the work instruction information 112 in Figure 3 indicates an instruction to bend a part "A-1" with a material "a" and a plate thickness of "t1", specifically a processed section "A-1-1" with a width of "150 mm", by 90 degrees, using a combination of the upper die "P-1" and the lower die "D-2".

[0027] Figure 3 shows an example where bending is performed as a process operation, but this embodiment can also be applied to process operations other than bending. For example, when punching is performed, information specifying the shape and size of the part to be punched out may be included instead of the bending angle 304 and processing width 305. Also, the mold (upper) 307 and mold (lower) 308 are examples of information specifying jigs and fixtures attached to the equipment for the process operation. In this embodiment, a mold for performing bending is shown as a jig and fixture, but jigs and fixtures according to the type of process are used in the equipment, and information specifying that jig and fixture is held in the work instruction information 112. For example, information specifying a mold for performing punching, or a jig for indicating the working position of a part may be held.

[0028] Furthermore, although the example in Figure 3 shows only one machining area for a single part, a single part may have multiple machining areas. In that case, multiple entries with the same part name 301 value are registered in the work instruction information 112, and in each entry, the machining content of each machining area and the jigs and fixtures used for it are specified.

[0029] Figure 4 is an explanatory diagram showing the tooling information 113 held by the production planning system 100 of Embodiment 1 of the present invention.

[0030] The fixture information 113 includes information indicating the specifications and quantity of fixtures that can be attached to the equipment for the work of the process. The fixture information 113 shown in Figure 4 includes the mold name 401, width 402, bending angle 403, and quantity 404. The mold name 401 is information that identifies the fixture (a mold in the example of Figure 4). The width 402 indicates the width of the mold. The bending angle 403 indicates the angle of the bending process performed by the mold. The quantity 404 indicates the number of molds being held.

[0031] For example, the first entry in the tooling information 113 in Figure 4 indicates that the die name is P-1, the width of the die is 100 mm, the bending angle is 90 degrees (i.e., it can be used for bending at 90 degrees), and there are three of these dies (i.e., three of the same die can be used simultaneously). In the example in Figure 4, dies "P-1" to "P-3" are the upper dies used for bending, and dies "D-1" to "D-3" are the lower dies.

[0032] Although not shown in Figure 4, the jig and fixture information 113 may also include information specifying the material and plate thickness of the parts for which each die can be used. Furthermore, the jig and fixture information 113 may also include information regarding jigs and fixtures for processes other than bending.

[0033] Figures 5A and 5B are explanatory diagrams showing the unit cost information 114 held by the production planning system 100 of Embodiment 1 of the present invention.

[0034] The unit cost information 114 includes setup time unit cost information 115, which serves as the basis for calculating the time required for process setup, and power consumption unit cost information 116, which serves as the basis for power consumption for each operating state of each piece of equipment. Figure 5A shows an example of setup time unit cost information in a process using a mold. Specifically, the setup time unit cost information 115 shown in Figure 5A includes the mold name 501, mold installation 502, mold removal 503, and mold transport 504. The example in Figure 5A shows that it takes 60 seconds to install mold P-1, 30 seconds to remove the mold, and 180 seconds to transport the mold. Figure 5B shows an example of power consumption unit cost information for each operating state. Specifically, the power consumption unit cost information 116 shown in Figure 5B shows that for equipment M-001, 5kWh is required for equipment startup, 4kWh for equipment idling, and 8kWh during production.

[0035] Next, we will explain output information 108.

[0036] Figure 6 is an explanatory diagram showing input group information 122 held by the production planning system 100 of Embodiment 1 of the present invention.

[0037] As will be described later, in this embodiment, among the multiple parts that are fed into the equipment based on the production plan, parts that can be produced using the same jig and fixture are grouped together. Such groups of input parts are also referred to as input groups. Based on the production plan for a predetermined period (for example, one day), the multiple parts that are fed into the same equipment during that period are classified into several input groups, and the results are stored as input group information 122.

[0038] The input group information 122 shown in Figure 6 includes the input date 601, the deadline 602, the part name 603, the input group 604, the material 605, the plate thickness 606, the bending angle 607, and the processing width 608. Input date 601 to part name 603 correspond to input date 201 to part name 203 in the production plan 111. Material 605 to processing width 608 hold the values ​​for material 302 to processing width 305 corresponding to each part. Input group 604 is information that identifies the input group to which each part is classified. The generation of input groups will be described later.

[0039] Figure 7 is an explanatory diagram showing a proposed jig and tool combination 124 held by the production planning system 100 of Embodiment 1 of the present invention.

[0040] The proposed jig and fixture combination 124 is information that shows proposed combinations of jigs and fixtures to be installed on the equipment for each input group. The proposed jig and fixture combination 124 shown in Figure 7 includes input group 701, material 702, plate thickness 703, bending angle 704, processing width 705, die (upper) 706, and die (lower) 708. Input group 701 is information that identifies each input group and corresponds to input group 604 in Figure 6. Material 702, plate thickness 703, bending angle 704, and processing width 705 correspond to material 605, plate thickness 606, bending angle 607, and processing width 608 for each input group, respectively. Die (upper) 706 and die (lower) 708 are information that identifies the die for processing corresponding to material 605, plate thickness 606, bending angle 607, and processing width 608 for each input group. A specific example shown in Figure 7 will be described later.

[0041] Figure 8 is an explanatory diagram showing the fixed input sequence and tool combination 126 held by the production planning system 100 of Embodiment 1 of the present invention.

[0042] As described later, the production planning system 100 calculates the setup time when one of the generated tooling combination proposals 124 is adopted, identifies the tooling combination proposal 124 that shortens the setup time, and the input order of parts when that proposal is adopted, and stores this information as the final input order and tooling combination 126.

[0043] The finalized input sequence and tool combination 126 shown in Figure 8 includes the input date 801, the deadline 802, the part name 803, the input group 804, the input sequence 805, the upper mold 806, and the lower mold 807. Input dates 801 to input group 804 correspond to input dates 601 to input group 604 in the input group information 122. Input sequence 805 corresponds to the upper mold 705 and lower mold 707 in the tool combination proposal 124 identified by the production planning system 100 as having a shorter setup time. A specific example shown in Figure 8 will be described later.

[0044] Figure 9 is a flowchart showing the processes performed by the production planning system 100 of Embodiment 1 of the present invention.

[0045] First, the data acquisition unit 132 acquires the input information 107 (step S901). This acquires the production plan 111, work instruction information 112, tooling information 113, and unit cost information 114.

[0046] Next, the input group creation unit 133 groups together parts that can perform the process using the same jigs and fixtures, based on the input information 107 (step S902). For example, if the production of parts "A-1", "A-2", "A-3", and "A-4" is planned as shown in Figure 2, and the molds used to produce each part are specified as shown in Figure 3, then parts "A-1" and "A-2" can be produced using the same mold, and are therefore classified into the same input group (e.g., input group "Gr.1"). Similarly, parts "A-3" and "A-4" are each classified into their own input group (e.g., input groups "Gr.2" and "Gr.3"). As a result, input group information 122, such as that shown in Figure 6, is generated.

[0047] Next, the tool combination planning unit 134 plans the tool combination for each input group based on the input information 107 and the generated input group information 122 (step S903).

[0048] For example, when the input group information 122 shown in Figure 6 is generated, the machining width in input group "Gr.1" is 150 mm. Therefore, as instructed by the work instruction information 112, dies "P-2" and "D-2" with a width of 150 mm can be used for that machining. However, it is also possible to use a combination of dies "P-1" and "P-3" or a combination of dies "D-1" and "D-3" whose combined width is 150 mm, or a combination of three dies "P-3" or a combination of three dies "D-3" whose combined width is 150 mm. In this way, the tooling combination planning unit 134 generates multiple proposed tooling combinations that can be used for the generated input group and stores them as tooling combination proposals 124.

[0049] For example, the first entry in tooling combination proposal 124 in Figure 7 shows a proposal in which, for machining input group "Gr.1", the combination of dies "P-1" and "P-3" is used as the upper die, and the combination of dies "D-1" and "D-3" is used as the lower die.

[0050] Next, the input order and tool combination calculation unit 135 calculates the setup time for each of the multiple tool combination proposals 124 based on the input information 107 and the generated tool combination proposals 124, and identifies the tool combination proposal 124 and the input order at that time that results in the shortest setup time (step S904). For example, the input order and tool combination calculation unit 135 may calculate the setup time based on the unit cost information 114 while changing the input order of the input group for each of the multiple tool combination proposals 124, identify the tool combination proposal 124 and the input order at that time that results in the shortest setup time, and retain the result as the finalized input order and tool combination 126.

[0051] Figure 8 shows an example of the tooling combinations and input sequence identified in this manner. In this example, parts "A-1" and "A-2" from input group "Gr.1" are input first, followed by part "A-3" from input group "Gr.2", and then part "A-4" from input group "Gr.3". For machining parts "A-1" and "A-2", a combination of molds "P-1" and "P-3" and a combination of molds "D-1" and "D-3" are used, which have a total width of 150 mm, contrary to the instructions given in work instruction information 112. For machining part "A-4", a combination of two molds "P-3" and a combination of two molds "D-3" are used, which have a total width of 100 mm, contrary to the instructions given in work instruction information 112.

[0052] According to this example, after setting up molds "P-1", "P-3", "D-1", and "D-3" before processing the first part, it is not necessary to remove molds "P-3" and "D-3" until all parts have been processed. Molds "P-1" and "D-1" can be removed when loading part "A-3", and molds "P-3" and "D-3" can be added and set up when loading part "A-4".

[0053] In this way, parts that can perform the process using the same jig and fixture (parts "A-1" and "A-2" in the example above) are fed in succession, and the combination of jigs and fixtures used and the order in which parts are fed are determined so as to minimize the total time required for setting up, removing, and transporting the jigs and fixtures. This minimizes setup time and, as a result, reduces the power consumption required for product production.

[0054] In the above example, the combination of fixtures and the input order of parts are determined to minimize the total setup time, but they may also be determined to minimize power consumption. For example, the production planning system 100 may maintain information indicating power consumption according to the state of the equipment (e.g., power consumption unit information 116). Then, in step S904, the production planning system 100 may, for each of the multiple fixture combination proposals 124, change the input order of the input groups, calculate the setup time based on the setup time unit information 115, and further calculate the total power consumption based on the power consumption unit information 116 to identify the fixture combination proposal 124 and the input order at that time that minimizes the total power consumption.

[0055] Next, the input order and tool combination calculation unit 135 modifies the work instruction information 112 based on the determined input order and tool combination 126 (step S905). For example, the display control unit 136 may display an output screen containing the determined input order and tool combination 126 and related information on the input / output unit 101, and if a correction is input, the input order and tool combination calculation unit 135 may modify the work instruction information 112 after reflecting the correction. Examples of information displayed by the display control unit 136 will be described later.

[0056] This completes the processing performed by the production planning system 100 in Example 1.

[0057] Figure 10 is an explanatory diagram showing the output screen displayed by the production planning system 100 of Embodiment 1 of the present invention.

[0058] The output screen 1000 shown in Figure 10 includes a production plan display area 1001, an input group display area 1002, an input sequence and tooling information display area 1003, an analysis condition input area 1004, an effect display area 1005, a pre-change work instruction information input area 1006, a work instruction modification input area 1007, and a work instruction issuance area 1008.

[0059] In the example shown in Figure 10, when a user of the production planning system 100 (for example, an operator or manager who performs process tasks using production equipment) enters information specifying the analysis target date and the equipment to be analyzed into the analysis condition input area 1004 and operates the group execution button, the execution of the process shown in Figure 9 begins.

[0060] The production plan display area 1001 displays the production plan for the parts to be loaded into the specified equipment for analysis on the specified analysis date. This corresponds to the production plan information 121 in the output information 108, and is the information from the production plan 111 acquired in step S901 that corresponds to the analysis date and the equipment for analysis.

[0061] The input group display area 1002 displays the input groups created in step S902. For example, information similar to the input group information 122 shown in Figure 6 may be displayed. The user may refer to the input group display area 1002 and, if they determine that modifications are necessary, input the modifications and then input instructions for planning the input sequence. As a result, steps S903 and S904 are executed.

[0062] The input sequence and tooling information display area 1003 displays information obtained during steps S903 and S904, or information obtained as a result thereof. For example, when a user inputs planning conditions and operates the display button, the planned tooling combination and input sequence according to those conditions are displayed. The planning conditions may be any conditions, such as minimizing setup time, minimizing power consumption required for production, shortening production time, or equalizing the frequency of use of multiple tools.

[0063] The information displayed in the input sequence and tooling information display area 1003 may be the same as that shown in Figure 8, but it is displayed as a preliminary draft until the user gives a confirmation instruction, and the user can select one of the drafts or change the contents of the draft. Of the information displayed in the input sequence and tooling information display area 1003, the mold information corresponding to the input group corresponds to the production method 123 for each input group in the output information 108.

[0064] As a result of designing a combination of jigs and fixtures that satisfies predetermined conditions (e.g., minimizing setup time), the combination of jigs and fixtures instructed by the work instruction information 112 in the input information 107 may be changed. In the example in Figure 10, the molds corresponding to parts "A-1", "A-2", and "A-4" have been changed, similar to the example in Figure 8. The input sequence and jig and fixture information display area 1003 may also display such changes (e.g., highlighting the changed parts).

[0065] The effect display area 1005 displays values ​​for indicators that show the effect of optimizing the combination and input sequence of jigs and fixtures. In the example in Figure 10, the setup time and power consumption for each proposed combination and input sequence of jigs and fixtures, devised according to each condition, are displayed, but values ​​for other indicators may also be displayed. The information displayed in the effect display area 1005 corresponds to the setup time calculation results 125 for each jigs and fixture combination condition in the output information 108.

[0066] The user can display the work instructions for a part before the change by entering the part name in the pre-change work instruction information input area 1006 and operating the display button. The user can then refer to the pre-change work instructions, the input sequence and the changes displayed in the jig and fixture information display area 1003, and the effects of the proposed options corresponding to each condition displayed in the effect display area 1005 to decide which option to select and whether to modify the options. If it is determined that modification is necessary, the user can modify at least one of the input sequence or the jig and fixture combination by operating the work instruction modification input area 1007.

[0067] When the user selects one of several options, makes modifications if necessary, and operates the confirm button in the work order issuance area 1008, the selected option is confirmed and a work order corresponding to it is issued. [Examples]

[0068] Next, Embodiment 2 of the present invention will be described. Except for the differences described below, each part of the system in Embodiment 2 has the same function as each part denoted by the same reference numerals in Embodiment 1, so their descriptions will be omitted.

[0069] Figure 11 is a block diagram showing the configuration of the production planning system in Embodiment 2 of the present invention.

[0070] In the production planning system 100 shown in Figure 11, the input information 107 further includes production results 1101. The calculation processing unit 131 further includes a tool selection rule creation unit 1103 and a tool selection criterion modification unit 1104. The output information 108 further includes tool selection rules 127. In addition, the input group information 122, the production method 123 for each input group, the proposed tool combination 124, the setup time calculation results 125 for each tool combination condition, and the confirmed input order and tool combination 126 may differ from those in Example 1. The differences described above will be explained below.

[0071] Figure 12 is an explanatory diagram showing the production results 1101 held by the production planning system 100 of Embodiment 2 of the present invention.

[0072] Production record 1101 is a collection of information on jigs and fixtures used in actual production in the past. Production record 1101 shown in Figure 12 includes input date 1201, part name 1202, material 1203, plate thickness 1204, bending angle 1205, processing width 1206, processing section 1207, mold (upper) 1208, and mold (lower) 1209.

[0073] Input Date 1201 indicates the date on which each part was actually put into the equipment for the process. Part Name 1202 to Processing Section 1207 indicate the name, material, plate thickness, bending angle, processing width, and processing section of the part that was actually put into the equipment. Mold (Upper) 1208 and Mold (Lower) 1209 are information that identifies the jigs and fixtures (in this example, molds) that were actually used to process each part.

[0074] In the example in Figure 12, parts "A-1", "A-2", and "A-4" are loaded on day "X", and molds "P-2" and "D-2" are used for all of them. The use of molds "P-2" and "D-2" for processing parts "A-1" and "A-2" is specified in work instruction information 112.

[0075] On the other hand, while work instruction information 112 specifies the use of molds "P-1" and "D-1" for processing part "A-4", in reality, different molds "P-2" and "D-2" are used. For example, such discrepancies can occur if a worker on site decides to use a mold different from that specified in work instruction information 112. In the above example, the processing width of part "A-4" is 100 mm, while the widths of molds "P-1" and "P-2" are 150 mm. Generally, there are cases where it is not a problem to use a mold with a width wider than the processing width for processing, so if it is not a problem to use a mold intended for processing parts that are fed before or after, the decision may be made to use that mold.

[0076] In other words, this example demonstrates that it was possible to use molds "P-2" and "D-2," which have a width of 150 mm, to process part "A-4," which has a processing width of 100 mm.

[0077] Furthermore, in the example in Figure 12, parts "A-1," "A-2," and "A-4" are loaded on day "Y." In this example, one mold "P-1" and one mold "D-1" were used for processing part "A-4," as specified in work instruction information 112. On the other hand, two molds "P-1" and two molds "D-1" were used for processing parts "A-1" and "A-2," contrary to what was specified in work instruction information 112. This is based on the judgment of the workers on site, as in the example on day "X."

[0078] In other words, this example demonstrates that it was possible to use two molds "P-1" and two molds "D-1", with a total width of 200 mm, to process parts "A-1" and "A-2", which have a processing width of 150 mm.

[0079] Figure 13 is an explanatory diagram showing the tool selection rules 1102 held by the production planning system 100 of Embodiment 2 of the present invention.

[0080] The tool selection rule 1102 is created by the tool selection rule creation unit 1103, as will be described later. The tool selection rule 1102 shown in Figure 13 includes part name 1301, material 1302, plate thickness 1303, bending angle 1304, machining width 1305, machining area 1306, die width 1307, and die constraint 1308. Of these, part name 1301 to machining area 1306 are the same information as part name 301 to machining area 308 in the work instruction information 112. The die width 1307 and die constraint 1308 indicate the selection conditions for the tool for machining each newly selected part. A specific example of the tool selection rule 1102 shown in Figure 13 will be described later.

[0081] Figure 14 is an explanatory diagram showing input group information 122 held by the production planning system 100 of Embodiment 2 of the present invention.

[0082] The input group information 122 in Example 2 shown in Figure 14, including the input date 601, the request deadline 602, the part name 603, and the input group 604, are the same as those shown in Figure 6. However, the value of input group 604 may differ from that in Example 1. Furthermore, the input group information 122 in Example 2 includes the selected mold width 1401 corresponding to the parts classified into each input group. A specific example of the input group information 122 shown in Figure 14 will be described later.

[0083] Although omitted in Figure 14, the input group information 122 of Example 2 may further include the material 605, plate thickness 606, bending angle 607, and processing width 608 of the parts of each input group shown in Figure 6.

[0084] Figure 15 is an explanatory diagram showing a proposed jig and tool combination 124 held by the production planning system 100 of Embodiment 2 of the present invention.

[0085] The proposed jig and fixture combination 124 of Example 2 contains information on the same items as the proposed jig and fixture combination 124 of Example 1 shown in Figure 7, but its contents differ from those of Example 1. A specific example of the proposed jig and fixture combination 124 shown in Figure 15 will be described later.

[0086] Figure 16 is an explanatory diagram showing the fixed input sequence and tool combination 126 held by the production planning system 100 of Embodiment 2 of the present invention.

[0087] The determined input sequence and tool combination 126 in Example 2 includes information on the same items as the determined input sequence and tool combination 126 in Example 1 shown in Figure 8, but its contents differ from those of Example 1. A specific example of the determined input sequence and tool combination 126 shown in Figure 16 will be described later.

[0088] Figure 17 is a flowchart showing the processes performed by the production planning system 100 in Embodiment 2 of the present invention.

[0089] First, the data acquisition unit 132 acquires the input information 107 (step S1701). This process is the same as step S901 in Figure 9, but the input information acquired in step S1701 also includes production results 1101.

[0090] Next, the tool selection rule creation unit 1103 creates tool selection rules 1102 based on the production results 1101 (step S1702). As a result, tools other than those specified by the work instruction information 112 will be included as selection targets during the planning process in subsequent processing.

[0091] Here, the tool selection rule creation unit 1103 creates tool selection rules 1102 so as to include the width of molds that have been used in the past (i.e., so that combinations of molds whose sum equals that width are included in the selection target).

[0092] For example, if production results 1101 as shown in Figure 12 are obtained, then there is a record of using molds "P-2" and "D-2" with a width of 150 mm to process parts "A-1" and "A-2" with a processing width of 150 mm, and furthermore, there is a record of using two molds "P-1" and two molds "D-1" with a total width of 200 mm. Therefore, the jig and fixture selection rule creation unit 1103 relaxes the jig and fixture selection rule used for processing parts "A-1" and "A-2" by setting the mold width 1307 corresponding to these parts to "150 or more" (see Figure 13).

[0093] Similarly, according to the production record 1101 shown in Figure 12, there is a record of using molds "P-1" and "D-1" with a width of 100 mm to process part "A-4", and further, there is a record of using molds "P-2" and "D-2" with a width of 150 mm. For this reason, the jig and fixture selection rule creation unit 1103 relaxes the jig and fixture selection rule used for processing part "A-4" by setting the mold width 1307 corresponding to part "A-4" to "100 or more" (see Figure 13).

[0094] Furthermore, the mold width 1307 may include information indicating the upper limit of the mold width. Specifically, in the above example, the mold width 1307 for parts "A-1" and "A-2" may be "150 or more and 200 or less" based on actual results. Also, the mold width 1307 for part "A-4" may be "100 or more and 150 or less" based on actual results.

[0095] Next, the input group creation unit 133 groups together parts that can perform the process using the same fixture, based on the input information 107 and the fixture selection rule 1102 (step S1703). This process is performed in the same way as step S902 in Figure 9. However, the difference is that step S902 refers to the work instruction information 112 and the fixture information 113, while step S1703 refers to the fixture selection rule 1102.

[0096] In other words, in step S902, the work instruction information 112 and the tooling information 113 are referenced as information corresponding to the tooling selection rules, whereas in step S1703, the tooling selection rules 1102 that have been modified (i.e., relaxed) based on the production results 1101 are referenced.

[0097] Specifically, in Example 1, parts "A-1" and "A-2" were classified into input group "Gr.1," and parts "A-3" and "A-4" were classified into input groups "Gr.2" and "Gr.3," respectively. In contrast, in Example 2, as described above, the selection rules for jigs and fixtures for producing part "A-4" are relaxed, and a mold with a width of 150 mm can also be selected. Therefore, part "A-4" can be classified into the same input group "Gr.1" as parts "A-1" and "A-2" (see input group 604 in Figure 14).

[0098] Accordingly, the tool selection criteria modification unit 1104 changes the value of the mold width 1401 to be selected for part "A-4" to "150 or more," the same as for parts "A-1" and "A-2."

[0099] Furthermore, by relaxing the tool selection rules as described above, it may be possible to classify a certain part into any of multiple groups. In such cases, the input group creation unit 133 may create input groups in such a way that the total number of input groups is minimized.

[0100] Next, the tooling combination planning unit 134 plans tooling combinations for each input group based on the input information 107 and the generated input group information 122 (step S1704). This is performed in the same way as step S903 in Figure 9, but the planning is based on the fact that part "A-4" has been classified into input group "Gr.1" and that the selection conditions for the mold width of input group "Gr.1" have been relaxed, as shown in Figure 14. As a result, multiple tooling combination plans 124 for input groups "Gr.1" and "Gr.2" are planned, for example, as shown in Figure 15.

[0101] In other words, step S903 creates a proposal for one or more combinations of dies whose total width matches the width of the die specified in the work instruction information 112. In contrast, step S1704 creates a proposal for one or more combinations of dies whose total width satisfies the tool selection rule 1102.

[0102] Next, the input sequence and tool combination calculation unit 135 identifies a tool combination plan 124 that shortens the setup time and the corresponding input sequence (step S1705). This is performed similarly to step S904 in Figure 9, but since it is based on the tool combination plan 124 formulated in step S1704, the result may differ from that of Example 1. The determined input sequence and tool combination 126 shown in Figure 16 is an example of the information obtained as a result of step S1705.

[0103] Here, we will explain the differences between the fixed input sequence and tool combination 126 in Example 2 shown in Figure 16 and the fixed input sequence and tool combination 126 in Example 1 shown in Figure 8. In Example 2, since part "A-4" is classified into input group "Gr.1", the processing of part "A-4" is carried out immediately after the processing of parts "A-1" and "A-2", and the mold is not changed during this time. Note that the processing of parts "A-1", "A-2", and "A-4" can be carried out in any order. As a result, the number of mold changes is further reduced compared to Example 1, and thus setup time and power consumption can be further reduced.

[0104] Next, the input order and tool combination calculation unit 135 modifies the work instruction information 112 based on the determined input order and tool combination 126 (step S1706). This process is performed in the same way as step S905 in Figure 9. An example of the information displayed by the display control unit 136 will be described later.

[0105] This completes the processing performed by the production planning system 100 in Example 2.

[0106] Figure 18 is an explanatory diagram showing the output screen displayed by the production planning system 100 of Embodiment 2 of the present invention.

[0107] The output screen 1800 shown in Figure 18 includes a production plan display area 1801, an input group display area 1802, an input sequence and tooling information display area 1803, an analysis condition input area 1804, an effect display area 1805, a pre-change work instruction information input area 1806, a work instruction modification input area 1807, and a work instruction issuance area 1808. These are basically the same as the production plan display area 1001, input group display area 1002, input sequence and tooling information display area 1003, an analysis condition input area 1004, an effect display area 1005, a pre-change work instruction information input area 1006, a work instruction modification input area 1007, and a work instruction issuance area 1008 of the output screen 1000 of Embodiment 1 shown in Figure 10, but there are the following differences.

[0108] Similar to Example 1, when the user enters information specifying the analysis date and the equipment to be analyzed into the analysis condition input area 1804 and operates the group execution button, the process shown in Figure 17 is started.

[0109] Since the production plan display area 1801 is the same as the production plan display area 1001, its explanation is omitted.

[0110] The input group display area 1802 displays the input groups created in step S1703. For example, information similar to the input group information 122 shown in Figure 14 may be displayed. The user may refer to the input group display area 1802 and, if they determine that modifications are necessary, input the modifications and then input instructions for planning the input sequence. As a result, steps S1704 and S1705 are executed.

[0111] The input order and tooling information display area 1803 displays information obtained during steps S1704 and S1705, or information obtained as a result thereof. For example, as in the first embodiment, when the user inputs the planning conditions and operates the display button, the tooling combination and input order planned according to those conditions are displayed.

[0112] The information displayed in the input order and tooling information display area 1803 may be the same as that shown in Figure 16, but as in Example 1, it is not finalized until the user gives a confirmation instruction. Also, as in Example 1, if the combination of tools and fixtures instructed by the work instruction information 112 is changed by the plan, the changed parts may be clearly indicated.

[0113] The effect display area 1805, similar to the effect display area 1005 in Figure 10, displays an index value indicating the effect of optimizing the combination and input order of jigs and fixtures.

[0114] The operation methods for the pre-change work instruction information input area 1806, the work instruction modification input area 1807, and the work instruction issuance area 1808 are the same as those shown in Figure 10 for the pre-change work instruction information input area 1006, the work instruction modification input area 1007, and the work instruction issuance area 1008, so an explanation is omitted.

[0115] The system of the embodiment of the present invention may be configured as follows, for example.

[0116] (1) A production planning system (e.g., production planning system 100) comprising a calculation unit (e.g., calculation unit 103) and a storage unit (e.g., storage unit 102), wherein the storage unit holds production planning information (e.g., production plan 111), work instruction information (e.g., work instruction information 112), tooling information (e.g., tooling information 113), setup time information (e.g., setup time unit information 115), and power consumption information (e.g., power consumption unit information 116), wherein the production planning information includes the item of the product (e.g., part) to be put into the production equipment (e.g., part name 203) and the time when the product is put into the production equipment (e.g., input date 201), the work instruction information includes, for each item of product, information instructing the tooling to be installed in the production equipment for the production of the product, the tooling information includes the specifications of the tooling that can be installed in the production equipment, and setup time information The report includes the time required to set up jigs and fixtures in the production equipment, and the power consumption information includes the power required to set up jigs and fixtures in the production equipment and to produce using jigs and fixtures. The calculation unit classifies the products to be input during a predetermined period into groups of products that can be produced by the same jigs and fixtures (for example, creating input groups in step S902 or S1703) based on the production plan information and work instruction information, creates multiple options for combinations of jigs and fixtures to be installed in the production equipment to produce the products of each group (for example, step S903 or S1704), and from the multiple options, creates a combination of jigs and fixtures that minimizes at least one of the total setup time and total power consumption, as well as an input order for the groups (for example, step S903 or S1704).

[0117] This makes it possible to create production plans that reduce setup time and environmental impact, such as power consumption, even when multi-product mixed-model production is carried out.

[0118] (2) In (1) above, the memory unit further stores performance information (e.g., production performance 1101) indicating the tools and fixtures used in the production of each product in the past, and the calculation unit creates selection criteria (e.g., tool and fixture selection rules 1102) for the tools and fixtures to be used in the production of each product based on the performance information (e.g., step S1702), and classifies the products to be put into a predetermined period into groups of products that can be produced with the same tools and fixtures (e.g., step S1703).

[0119] This will further reduce setup time.

[0120] (3) In (2) above, the calculation unit classifies the products to be input during a predetermined period into groups of products that can be produced using the same tools, so as to minimize the number of groups.

[0121] This will further reduce setup time.

[0122] (4) In (2) above, the production equipment is equipment for bending, the jigs and fixtures are dies for bending, the work instruction information includes information that instructs the dies to be installed on the production equipment for bending each product item, the jigs and fixtures information includes information that indicates the width of each die, the performance information includes information that indicates the dies that have been used in the past for bending each product item, the selection criteria include information that indicates the width of the dies to be used for bending each product item, the calculation unit creates selection criteria so as to include the width of dies that have been used in the past for bending each product item (for example, step S1702), classifies the products to be introduced during a predetermined period into groups of products that can be produced by the same jigs and fixtures so as to include products of multiple items whose selection criteria overlap in the same group (for example, step S1703), and creates a plan to install one or more dies whose total width satisfies the selection criteria as one of several possible combinations of jigs and fixtures (for example, step S1704).

[0123] This reduces setup time, such as die changes, when bending processes are performed.

[0124] (5) In (1) above, the production equipment is equipment for bending, the jigs and fixtures are dies for bending, the work instruction information includes information that instructs which dies to be installed on the production equipment for bending the product for each product item, the jigs and fixtures information includes information that indicates the width of each die, and the calculation unit creates a plan to install one or more dies as multiple possible combinations of jigs and fixtures, the sum of which matches the width of the dies instructed by the work instruction information (for example, step S903).

[0125] This reduces setup time, such as die changes, when bending processes are performed.

[0126] It should be noted that the present invention is not limited to the embodiments described above, and various modifications are included. For example, the embodiments described above are explained in detail for a better understanding of the present invention, and are not necessarily limited to those having all of the configurations described. Furthermore, it is possible to replace parts of the configuration of one embodiment with the configuration of another embodiment, and it is possible to add configurations from other embodiments to the configuration of one embodiment. In addition, it is possible to add, delete, or replace parts of the configuration of each embodiment with other configurations.

[0127] Furthermore, each of the above configurations, functions, processing units, and processing means may be implemented in hardware, either partially or entirely, by designing them as integrated circuits, for example. Alternatively, each of the above configurations and functions may be implemented in software by a processor interpreting and executing programs that implement each function. Information such as programs, tables, and files that implement each function can be stored in storage devices such as non-volatile semiconductor memory, hard disk drives, and SSDs (Solid State Drives), or in computer-readable non-temporary data storage media such as IC cards, SD cards, and DVDs.

[0128] Furthermore, the control lines and information lines shown are those deemed necessary for explanatory purposes, and do not necessarily represent all control lines and information lines in the actual product. In practice, it can be assumed that almost all components are interconnected. [Explanation of Symbols]

[0129] 100 Production Planning System 101 Input / output section 102 Storage section 103 Arithmetic section 104 Network 105 Design Systems 106 Work instruction device 107 Input Information 108 Output Information 130 Memory section 131 Arithmetic Processing Unit

Claims

1. It is a production planning system, It comprises an arithmetic unit and a memory unit, The aforementioned memory unit holds production plan information, work instruction information, tooling information, setup time information, power consumption information, and actual performance information. The production planning information includes the items of products to be put into the production equipment and the timing at which the products will be put into the production equipment. The work instruction information includes information specifying the jigs and fixtures to be installed in the production equipment for the production of each product item, The aforementioned fixture information includes the specifications of fixtures that can be installed in the production equipment. The aforementioned setup time information includes the time required to set up the jigs and fixtures in the production equipment. The aforementioned power consumption information includes the power required for setting up the jigs and fixtures in the production equipment and for production using the jigs and fixtures. The aforementioned performance information includes information indicating the tools and fixtures used in the past for the production of the aforementioned products for each item. The aforementioned arithmetic unit, Based on the aforementioned performance information, selection criteria for the jigs and fixtures used in the production of the aforementioned products for each item are created. Based on the production plan information, the work instruction information, and the selection criteria, the products to be put into a predetermined period are classified into groups of products that can be produced using the same jigs and fixtures. Based on the tooling information, multiple combinations of tools to be installed in the production equipment to produce the products of each group are created. A production planning system characterized by creating a combination of jigs and fixtures and an input order for the group from among the plurality of options, based on the setup time information and the power consumption information, such that at least one of the total setup time and the total power consumption is small, The aforementioned production equipment is equipment for performing bending processes. The jig and fixture is a die for the bending process, The work instruction information includes, for each product item, information specifying the mold to be installed in the production equipment for bending the product, The tooling information includes information indicating the width of each mold, The aforementioned performance information includes information indicating the molds used in the past for bending the aforementioned products of each item, The selection criteria include information indicating the width of the die used for bending the product of each item, The aforementioned arithmetic unit, The selection criteria are created such that the range of the sum of the widths of one or more molds that have been used for bending the aforementioned products for each item is included in the selection criteria. The products introduced during the predetermined period are classified into groups of products that can be produced by the same tools and fixtures, such that products of multiple items having at least some of the selection criteria overlap are included in the same group. A production planning system characterized by creating a plan for installing one or more molds whose total width satisfies the selection criteria, as one of several proposed combinations of jigs and fixtures.

2. A production planning system according to claim 1, The production planning system is characterized in that the calculation unit classifies the products to be introduced during the predetermined period into groups of products that can be produced by the same jig or tool, so as to minimize the number of groups.

3. A production planning method in which a production planning system is implemented, The production planning system comprises a calculation unit and a storage unit, The aforementioned storage unit contains production plan information, work instruction information, tooling information, setup time information, It stores power consumption information and performance information. The production planning information includes the items of products to be put into the production equipment and the timing at which the products will be put into the production equipment. The work instruction information includes information specifying the jigs and fixtures to be installed in the production equipment for the production of each product item, The aforementioned fixture information includes the specifications of fixtures that can be installed in the production equipment. The aforementioned setup time information includes the time required to set up the jigs and fixtures in the production equipment. The aforementioned power consumption information includes the power required for setting up the jigs and fixtures in the production equipment and for production using the jigs and fixtures. The aforementioned performance information includes information indicating the tools and fixtures used in the past for the production of the aforementioned products for each item. The aforementioned production planning method is, The calculation unit performs a first step of creating selection criteria for the jigs and fixtures used in the production of each product based on the performance information, The calculation unit performs a second step of classifying the products to be put into a predetermined period into groups of products that can be produced using the same jig and fixture, based on the production plan information, the work instruction information, and the selection conditions. A third step in which the calculation unit creates a plurality of proposed combinations of jigs and fixtures to be installed in the production equipment to produce the products of each group, based on the jig and fixture information, The calculation unit includes a fourth step of creating a combination of jigs and fixtures from the plurality of options, based on the setup time information and the power consumption information, such that at least one of the total setup time and the total power consumption is small, and an input order for the group. The aforementioned production equipment is equipment for performing bending processes. The jig and fixture is a die for the bending process, The work instruction information includes, for each product item, information specifying the mold to be installed in the production equipment for bending the product, The tooling information includes information indicating the width of each mold, The aforementioned performance information includes information indicating the molds used in the past for bending the aforementioned products of each item, The selection criteria include information indicating the width of the die used for bending the product of each item, In the first step, the calculation unit creates the selection conditions such that the range of the sum of the widths of one or more molds that have been used for bending the products of each item is included in the selection criteria. In the second step, the calculation unit classifies the products to be introduced during the predetermined period into groups of products that can be produced by the same jig and tool, such that the products of multiple items whose selection conditions overlap by at least a portion are included in the same group. A production planning method characterized in that, in the second step, the calculation unit creates a plan for installing one or more molds whose total width satisfies the selection conditions, as one of several possible combinations of the jigs and fixtures.

4. A production planning method according to claim 3, A production planning method characterized in that, in the second step, the calculation unit classifies the products to be introduced during the predetermined period into groups of products that can be produced by the same jig or tool, such that the number of groups is minimized.

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