Production sequence planning system

Abstract

To provide a production sequence planning system that merges products in correct order even if a planned product merging sequence changes during an upstream process.SOLUTION: A production sequence planning system for planning an order to merge inspected products, which have been manufactured with a plurality of specifications in a production line having a plurality of manufacturing processes and sampled at an inspection process, back into a production line, is configured to: compare a target serial number nx of a product that has reached a point before an inspection product merges with a confirmed serial number na for which a production instruction to merge has been fixed; and determine whether the product with the target serial number is within a planned production sequence, based on the serial number of the product following the target serial number. If the product with the target serial number is within the planned production sequence, the system compares the target serial number with a serial number n of the inspection product to determine whether the inspected product can be merged, and updates the serial number of the merged inspection product to the fixed serial number. If the product with the target serial number is outside the planned production sequence, the system does not merge the inspection product, but merges the product with the target serial number and does not update the confirmed serial number.SELECTED DRAWING: Figure 2

Description

[[Technical Field]]

[0001] The present invention relates to a production sequence planning system, and more particularly to a production sequence planning system for planning a sequence for merging products sampled in an inspection process back into a production line, where products with a plurality of specifications are produced on the production line having a plurality of manufacturing processes. [[Background Art]]

[0002] Generally, in a production line that produces products of multiple specifications through multiple manufacturing processes, products manufactured in the manufacturing processes are sampled in an inspection process, and inspection is performed to check whether there is any problem in proceeding to the next manufacturing process. Further, when an inspected product sampled in the inspection process has no problem and can proceed to the next manufacturing process, it is necessary to merge the inspected product back into the production line in accordance with the planned sequence. Conventionally, in order to merge the inspected products sampled in the inspection process, merging is performed when the merging point of a product with a serial number larger than that of the inspected product is reached.

[0003] Patent Document 1 discloses a technology in which inspected products sampled from a production line for products of multiple specifications are merged at a sequence replacement point for replacement. However, Patent Document 1 does not mention the point of merging inspected products in the correct sequence. [[Prior Art Documents]] [[Patent Documents]]

[0004] [[Patent Document 1]] Japanese Unexamined Patent Publication No. 2022-133944 [[Summary of the Invention]] [[Problem to be Solved by the Invention]]

[0005] However, in production lines that produce products with multiple specifications through multiple manufacturing processes, the planned merging sequence may be changed upstream of the inspection process. In conventional methods, where products with a higher serial number than the inspected product are merged when they reach the merging point, there is a concern that the inspected product may merge at a time that does not match the planned sequence. When inspected products merge at a time that does not match the planned sequence, there is a concern that production efficiency will decrease in the subsequent processes after merging.

[0006] This invention has been made in view of the above circumstances, and aims to provide a production sequence planning system that ensures products are merged in the correct order even if the planned order of product merging in the upstream process is changed. [Means for solving the problem]

[0007] To solve the aforementioned problems, this invention provides a production sequence planning system for producing products of multiple specifications on a production line having multiple manufacturing processes, and for planning the sequence in which inspected products sampled in the inspection process are brought into the production line, wherein the acquired production sequence The sequential number of the product in the production line, which is the number of the product in the production line where the inspected products extracted in the inspection process are combined, is planned and determined in advance. Flow planning sequence number information Report Based on this, the sequence number of products whose production instructions to merge have been confirmed is defined as the confirmed sequence number, the sequence number of products that have reached a point before the inspection product merges is defined as the target sequence number, the target sequence number and the confirmed sequence number are compared, and it is determined whether the product with the target sequence number is within the planned production sequence based on the sequence number of products after the target sequence number, if the product with the target sequence number is within the planned production sequence, the target sequence number and the sequence number of the inspection product are compared to determine whether the inspection product can merge, the sequence number of the merged inspection product is updated to the confirmed sequence number, and if the product with the target sequence number is outside the planned production sequence, the inspection product is not merged, the product with the target sequence number is merged, and the confirmed sequence number is not updated.

[0008] In this invention, the determination of whether the product with the target serial number is within the planned production order is made if the target serial number is larger than the next higher serial number of the confirmed serial number, then within the range of the difference between the confirmed serial number and the target serial number. Product number The consecutive numbers were overtaken. The test is performed based on the presence or absence of the product, and if the result is "yes", The aforementioned sequential numbering was unexpected. , in cases where the judgment result is none The result is judged to be within the planned timeframe. that preferable.

[0009] Furthermore, in this invention, when it is determined that the product with the aforementioned serial number is within the planned production order, The number is a number that has been pre-assigned to the product that has been determined to be within the timeframe. If the initial serial number is greater than the serial number of the product being inspected, the serial number of the product being inspected is added to the merged production instruction, and the merged serial number is updated to the final serial number. If the planned serial number is less than the serial number of the product being inspected, the planned serial number is added to the merged production instruction, and the merged serial number is updated to the final serial number. that preferable.

[0010] By configuring the system as described above, the system compares the confirmed serial number of the merged production instruction with the target serial number that reached the point before the merge, and determines whether the product of the target serial number is within the planned production sequence based on the serial number of the product that comes after the target serial number. The determination of whether the product of the target serial number is within the planned production sequence is made by checking whether the target serial number is larger than the next higher serial number of the confirmed serial number, and whether there are any serial numbers that have been overtaken by the target serial number within the range of the difference between the confirmed serial number and the target serial number. If there are, the target serial number is determined to be out of schedule; otherwise, it is determined to be within schedule.

[0011] If, as a result of the above determination, the product with the target serial number is within the planned production sequence, the target serial number and the serial number of the inspection product are compared to determine whether the inspection product can be merged, and the serial number of the merged inspection product is updated to the confirmed serial number. In other words, if the product with the target serial number is determined to be within the planned production sequence, and the planned serial number is greater than the serial number of the inspection product, the serial number of the inspection product is added to the merged production instruction, and the merged serial number is updated to the confirmed serial number. On the other hand, if the planned serial number is less than the serial number of the inspection product, the planned serial number is added to the merged production instruction, and the merged serial number is updated to the confirmed serial number.

[0012] Further, when the product with the target serial number is out of the planned production order, the product with the target serial number is merged without merging the inspection product, and the fixed serial number is not updated. [Effects of the Invention]

[0013] According to the present invention, with the configuration as described above, not only products before merging but also products before and after the merging are evaluated, so that products can be merged in the correct order even if the merging plan order of products is changed in an upstream process. [Brief Description of Drawings]

[0014] [Figure 1] FIG. 1 is a schematic configuration diagram of a merged production instruction creation device that embodies the production order planning system according to the present invention. [Figure 2] FIG. 2 is a flowchart showing a procedure for creating a merged production instruction using the production order planning system according to the present invention. [Figure 3] FIG. 3 is a schematic diagram showing an example of creating a merging plan order for inspection products in the present invention. [Figure 4] FIG. 4 is an explanatory diagram showing a processing procedure for determining the merging plan order of inspection products in the present invention. [Figure 5] FIG. 5 is a diagram explaining the production order and merging plan order serial numbers of branch production instructions in the first embodiment of the present invention. [Figure 6] FIG. 6 is a schematic diagram showing an example of creating a merging plan order for inspection products in the first embodiment of the present invention. [Figure 7] FIG. 7 is a diagram explaining the production order and merging plan order serial numbers of branch production instructions in the first embodiment of the present invention. [Figure 8] FIG. 8 is a diagram explaining the production order and merging plan order serial numbers of the created merged production instruction in the first embodiment of the present invention. [Figure 9] FIG. 9 is a diagram explaining the production order and merging plan order serial numbers of branch production instructions in the second embodiment of the present invention. [Figure 10] FIG. 10 is a schematic diagram showing an example of creating a merging plan order for inspection products in the second embodiment of the present invention. [Figure 11] It is a diagram illustrating the production order and merging plan sequence serial number of a branching production instruction according to a second embodiment of the present invention. [Figure 12] It is a diagram illustrating the production order and merging plan sequence serial number of a created merging production instruction according to a second embodiment of the present invention. MODE FOR CARRYING OUT THE INVENTION

[0015] Hereinafter, modes for carrying out the present invention will be described in detail with reference to the accompanying drawings. Here, a production order system that plans an order for merging inspection products sampled in an inspection process into the production line in a production line that produces products of a plurality of specifications through a plurality of manufacturing processes will be described. The production order planning system according to the present invention is embodied, that is, executed by a production order planning apparatus 20.

[0016] As shown in FIG. 1, the production order planning apparatus 20 includes: an acquisition unit 21 that acquires information data of a production order and a merging plan sequence serial number, which will be described later; a determination unit 22 that compares a sequence serial number of a product for which a merging production instruction has been determined (hereinafter referred to as a determined serial number) with a sequence number of a product that has reached a point before the inspection product merges (hereinafter referred to as a target serial number), and determines whether or not the product with the target serial number is within the schedule of the production order; a rewriting unit 23 that updates the serial number of the inspection product determined by the determination unit 22 to the determined serial number; and an output unit 24 that includes a display or the like and displays the production order updated by the rewriting unit 23 on the display or the like.

[0017] A procedure for creating a merging production instruction by the production order planning system according to the present invention will be described with reference to FIGS. 2 to 4. First, as shown in FIG. 2, the acquisition unit 21 acquires information data (branching production instruction) of a production order and a merging plan sequence serial number, which will be described later (step S1).

[0018] Based on the production sequence and merging plan sequence number information data (branching production instructions) acquired by the acquisition unit 21, the sequence number of products whose merging production instructions have been confirmed is defined as the confirmed sequence number, and the sequence number of products that have reached the point before the inspection product merges is defined as the target sequence number. Specifically, as shown in Figure 3, the sequence number of products at merging point P0 whose merging production instructions have been confirmed is defined as the confirmed sequence number na, and the sequence number of products that have reached point Pa before the inspection product merges is defined as the target sequence number nx. In Figure 3, the symbol n is the sequence number of the inspection product.

[0019] Next, the determination unit 22 compares the target serial number nx with the confirmed serial number na and determines whether the product with target serial number nx is within the planned production order based on the serial numbers of products that come after the target serial number nx (step S2). Specifically, as shown in Figure 4, if the target sequence number nx is larger than the next higher sequence number of the confirmed sequence number na (hereinafter referred to as the expected value na+1), the target sequence number nx is determined to be unexpected if there is a sequence number that has been overtaken by the target sequence number nx within the range of the difference between the confirmed sequence number na and the target sequence number nx, and within that range if there is, then the target sequence number nx is determined to be within the expected range. Here, the reason why the expected value is the next higher sequence number of the confirmed sequence number na+1 is that the confirmed sequence number na is smaller than the sequence number n of the inspection product to be merged, and therefore, according to the production order, it will reach the merging point P0 before the inspection product.

[0020] If the determination unit 22 determines that the target sequence number nx is unexpected, the target sequence number nx is added to the merged production instruction and the confirmed sequence number is not updated (step S3).

[0021] If the determination unit 22 determines that the target serial number nx is within the planned range, it compares the target serial number nx with the serial number n of the inspection product and determines if it is within the planned range. The number (in this case, the target sequence number nx) Determine whether the value is greater than the sequential number n of the inspected product (Step S4) In this step S4, the decision on whether or not the inspected products can be combined is made as follows:

[0022] If the planned sequence number is greater than the sequence number n of the product being inspected, the sequence number n of the product being inspected is added to the merged production instruction, and the merged sequence number is rewritten and updated by the rewriting unit 23 to the confirmed sequence number (step S5). ). In other words, at this point, the inspected products are combined.

[0023] If the planned sequence number is smaller than the sequence number n of the product being inspected, the planned sequence number is added to the merged production instruction, and the merged sequence number is rewritten and updated by the rewriting unit 23 to the confirmed sequence number (step S6). ). In other words, at this point, the products deemed to be within the planned range (products with planned serial numbers) are sent directly to the production line, and the products to be inspected are not added to them. Instead, the line waits for the next product to be detected as the target serial number.

[0024] The following describes a specific embodiment of the production sequence planning system according to this invention. <First Embodiment> In the first embodiment, as shown in Figure 5, a branch production instruction is created by combining information on the production sequence of the preceding process and the consolidation plan sequence number. This branch production instruction is acquired by the acquisition unit 21 (step S1). In this case, as shown in Figure 5, the branch production instruction is created for production sequences 1, 2, 3, 4, 5, 6, 7...13, and the consolidation plan sequence is created for inspection sequence numbers (005), (001), (002), (003), (004), (008), (004), (006)...(013).

[0025] In the first embodiment, as shown in Figure 6, an example is given in which an inspection product with inspection serial number (005) is merged, where the confirmed serial number (003) is the product at the merging point P0 where the production instruction to be merged has been confirmed, and the target serial number (008) is the product that has reached point Pa before the inspection product is merged. For the sake of clarity in the following explanation, in Figures 7 and 8, the confirmed serial number (003), inspection serial number (005), target serial number (008), etc. will be explained as confirmed serial number (3), inspection serial number (5), target serial number (8), etc.

[0026] In the determination unit 22, the confirmed serial number (3) and the target serial number (8) are compared, and it is determined whether the product with target serial number (8) is within the planned production order based on the serial numbers of products that come after the target serial number (8) (step S2). In this determination, the confirmed serial number (3) and the target serial number (8) are compared, and if the target serial number (8) is larger than the next higher serial number of the confirmed serial number (3) (expected value 3+1), the range of the difference between the confirmed serial number (3) and the target serial number (8) is examined. In this case, since the expected value for the target serial number (8) is (3+1=4), the range of the difference is 8-4=4.

[0027] Within the range of the difference, if even one of the sequence numbers (4, 6, 7) has been overtaken by the target sequence number (8), the target sequence number (8) is determined to be unplanned; otherwise, the target sequence number (8) is determined to be within the planned range. In this case, since there is a sequence number (4, 6, 7) that has been overtaken, the target sequence number (8) is determined to be unplanned, and the confirmed sequence number (3) is not updated, and the process moves to the next step. The target sequence number (8) is added to the merged production instruction, and the confirmed sequence number is not updated (step S3).

[0028] Based on the above processing, the merge production instruction shown in Figure 8 is created, and the inspection sequence number (5) merges after the merge plan sequence number (4). The rewriting unit 23 rewrites and updates the merged inspection sequence number (5) to the confirmed sequence number.

[0029] As described above, the production sequence planning system of the first embodiment is used when the target sequence number (8) is larger than the next higher sequence number (expected value 3+1) of the confirmed sequence number (3), and when there are sequence numbers (4, 6, 7) that have been overtaken by the target sequence number (8) within the range of the difference between the verification sequence number (3) and the target sequence number (8). In this case, the target sequence number (8) is determined to be unexpected, the confirmed sequence number is not updated, the inspection sequence number (5) is merged after the merge planning sequence number (4), the inspection sequence number (5) is updated to the confirmed sequence number, and a merge production instruction is created. The created merge production instruction is displayed, for example, on a display by the output unit 24. Therefore, even if the merge planning sequence of products in the upstream process is changed based on the created merge production instruction, the products can be merged in the correct order.

[0030] <Second Embodiment> In the second embodiment, as shown in Figure 9, a branch production instruction is created by combining information on the production sequence of the preceding process and the confluence plan sequence number, and this branch production instruction is acquired by the acquisition unit 21 (step S1). In this case, as shown in Figure 9, the branch production instruction is created for production sequences 1, 2, 3, 4, 5, 6, 7...13, and the confluence plan sequence is created for inspection sequence numbers (005), (001), (002), (003), (006), (007), (008), (004), (009)...(013).

[0031] In the second embodiment, as shown in Figure 10, an example is given in which the inspection product with inspection serial number (005) is merged, where the confirmed serial number (003) is the product at the merging point P0 where the production instruction to be merged has been confirmed, and the target serial number (006) is the product that has reached point Pa before the inspection product is merged. For the sake of clarity in the following explanation, in Figures 11 and 12, the confirmed serial number (003), inspection serial number (005), target serial number (006), etc. will be explained as confirmed serial number (3), inspection serial number (5), target serial number (6), etc.

[0032] In the determination unit 22, the confirmed serial number (3) and the target serial number (6) are compared, and it is determined whether the product with target serial number (6) is within the planned production order based on the serial numbers of products that come after the target serial number (6) (step S2). In this determination, the confirmed serial number (3) and the target serial number (6) are compared, and if the target serial number (6) is larger than the next higher serial number of the confirmed serial number (3) (expected value 3+1), the range of the difference between the confirmed serial number (3) and the target serial number (6) is examined. In this case, since the expected value for the target serial number (6) is (3+1=4), the range of the difference is 6-4=2.

[0033] Within the range of the difference, if even one sequence number (4,5) is overtaken by the target sequence number (6), the target sequence number (6) is determined to be unexpected; otherwise, the target sequence number (6) is determined to be within the expected range. In this case, since no sequence numbers have been overtaken, the target sequence number (6) is determined to be within the expected range, the confirmed sequence number is updated to (6), and the process moves to the next step (step S6).

[0034] Based on the above processing, the merge production instruction shown in Figure 12 is created, and the inspection sequence number (5) merges after the merge plan sequence number (4). The rewriting unit 23 rewrites and updates the merged inspection sequence number (5) to the confirmed sequence number.

[0035] As described above, the production sequence planning system of the second embodiment is used when the target sequence number (6) is larger than the next higher sequence number (expected value 3+1) of the confirmed sequence number (3), and there are no sequence numbers (4,5) overtaken by the target sequence number (6) within the range of the difference between the verification sequence number (3) and the target sequence number (6). In this case, the target sequence number (6) is determined to be within the planned range, the target sequence number (6) is updated to the confirmed sequence number, the inspection sequence number (5) merges after the merge planning sequence number (4), and the inspection sequence number (5) is updated to the confirmed sequence number to create a merge production instruction. The created merge production instruction is displayed, for example, on a display by the output unit 24. Therefore, even if the merge planning sequence of products is changed in the upstream process based on the created merge production instruction, the products can be merged in the correct order.

[0036] In the above embodiment, the case described was that inspected products sampled in the inspection process of a production line are merged into the production line from which the inspected products were sampled. However, products sampled in the inspection process of one production line of parallel production lines may be merged into the other production line.

[0037] The production sequence planning system according to this invention is not limited to the above-described embodiment, and the same effects can be obtained by applying it to cases where products that have been sampled in the manufacturing process on the production line for reasons other than inspection are to be reintroduced to the production line. [Explanation of Symbols]

[0038] 20 Production sequence planning device 21 Acquisition Department 22 Judgment section 23 Rewriting section 24 Output section P0 Merging Point Point before the merge at PA n Inspection sequence number na Fixed serial number nx Target sequential number na+1 Expected value

Claims

1. A production sequence planning system for producing products with multiple specifications on a production line having multiple manufacturing processes, and for planning the sequence in which inspected products sampled in the inspection process are merged into the production line, Based on the acquired production sequence and the sequential number information of the planned merge sequence, which is the sequential number of the product in the production line where the inspected products extracted in the inspection process are merged, the sequential number of the product whose production instruction to merge has been confirmed is defined as the confirmed sequential number, and the sequential number of the product that has reached a point before the inspected product merges is defined as the target sequential number. The target serial number and the confirmed serial number are compared, and based on the serial numbers of products that come after the target serial number, it is determined whether or not the product with the target serial number is within the planned production order. If the product with the target serial number is within the planned production sequence, the target serial number and the serial number of the product to be inspected are compared to determine whether the product to be inspected can be merged, and the serial number of the merged product to be updated to the confirmed serial number. If the product with the aforementioned serial number is not part of the planned production sequence, the product with the aforementioned serial number will be merged without merging the inspected product, and the confirmed serial number will not be updated. A production sequence planning system characterized by the following features.

2. A production sequence planning system according to claim 1, A production sequence planning system characterized in that, if the target sequence number is larger than the next higher sequence number of the confirmed sequence number, the determination of whether or not the product of the target sequence number has been overtaken by the product of the target sequence number is made by checking whether or not there is a product of the sequence number that has been overtaken by the product of the target sequence number within the range of the difference between the confirmed sequence number and the target sequence number, and if there is a result of the determination, the target sequence number is determined to be out of schedule, and if there is no result of the determination, it is determined to be within schedule.

3. A production sequence planning system according to claim 1, A production sequence planning system characterized in that, when a product with the aforementioned serial number is determined to be within the planned production sequence, if the planned serial number, which is a number previously assigned to the product determined to be within the planned sequence, is greater than the serial number of the product being inspected, the serial number of the product being inspected is added to the merged production instruction, and the merged serial number is updated to the confirmed serial number.

4. A production sequence planning system according to claim 1, A production sequence planning system characterized in that, when a product with the aforementioned serial number is determined to be within the planned production sequence, if the planned serial number, which is a number previously assigned to the product determined to be within the planned sequence, is smaller than the serial number of the product being inspected, the planned serial number is added to the merged production instruction and the merged serial number is updated to the confirmed serial number.

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