Production simulation device, production system, production simulation method and program

Abstract

The production simulation device (100) includes an acquisition unit (101) that acquires production order information indicating the contents of a production order from an MES (300) that instructs production for each process according to a production order for a production line including a plurality of processes included in a production plan, and a simulation execution unit (102) that calls a simulation model corresponding to a process for executing the production order related to the production order information acquired by the acquisition unit (101) before the MES (300) instructs production for each process according to the production order, and executes a simulation using the called simulation model. The MES (300) instructs production for each process according to the production order in which the simulation result is reflected.

Description

[Technical field]

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

[0002] Conventionally, there is known a production scheduler that creates a production plan for manufacturing products on a production line. In general, the production scheduler uses a master production schedule (MPS) and material requirements calculated in a material requirements planning system (MRP) to create a short schedule for the production plan that a manufacturing execution system (MES) issues production instructions.

[0003] Since the accuracy of the production plan contributes to improving the productivity of the production line, various techniques have been disclosed for a production scheduler to create an accurate production plan. For example, Patent Document 1 discloses a production planning device technology that calculates the degree of influence on production indexes due to the deviation between the standard time set for each process and the actual work time, and creates a production plan taking the degree of influence into consideration. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Patent Publication No. 2017-162044 Summary of the Invention [Problem to be solved by the invention]

[0005] The above-mentioned technologies do not reflect the load situation at the production site in the production plan, and therefore cannot create a production plan that takes into account, for example, the actual waiting time between processes on the production line. On the other hand, in order to improve productivity and calculate accurate delivery dates, there is a demand for a technology that enables production instructions to be given based on a production plan that takes into account the load situation at the production site.

[0006] The present disclosure has been made in consideration of the above circumstances, and aims to provide a production simulation device, a production system, a production simulation method, and a program that are capable of creating a production plan that takes into account the load situation at the production site, or performing a simulation for executing production instructions that take into account the load situation at the production site. [Means for solving the problem]

[0007] In order to achieve the above object, a production simulation device according to the present disclosure includes: an acquisition means for acquiring production order information indicating the content of a production order from a production execution system that instructs production for each process according to a production order for a production line including a plurality of processes, before the production execution system instructs production for each process according to the production order; a simulation execution means for calling up a simulation model corresponding to a process for executing the production order related to the production order information acquired by the acquisition means, before the production execution system instructs production for each process in accordance with the production order, and for executing a simulation using the called simulation model, The production execution system instructs production for each process according to a production order that reflects a result of a simulation executed by the simulation execution means. death , The production order includes information on the processes to be performed and information on the sequence of the processes to be performed. . Effect of the Invention

[0008] According to the present disclosure, it is possible to provide a production simulation device, a production system, a production simulation method, and a program capable of creating a production plan taking into account the load situation at the production site, or performing a simulation for executing production instructions taking into account the load situation at the production site. [Brief description of the drawings]

[0009] [Figure 1] FIG. 1 is a diagram showing a production system according to a first embodiment. [Diagram 2] FIG. 1 is a diagram showing a transaction flow in a production system according to a first embodiment. [Diagram 3] FIG. 1 is a block diagram showing a hardware configuration of a production simulation device according to a first embodiment. [Figure 4] FIG. 1 is a diagram showing a functional configuration of a production simulation device according to a first embodiment. [Diagram 5] FIG. 1 is a diagram showing a production order table according to the first embodiment. [Figure 6] FIG. 1 is a diagram showing a simulation result table according to the first embodiment. [Figure 7] FIG. 1 is a diagram showing a functional configuration of a production scheduler according to a first embodiment. [Figure 8] 1 is a flowchart showing a production instruction process executed by the production system according to the first embodiment. [Figure 9] FIG. 13 is a diagram showing a functional configuration of a production simulation device according to a second embodiment. [Figure 10] FIG. 13 is a diagram showing a parameter adjustment result table according to the second embodiment. [Figure 11] 11 is a flowchart showing a production instruction process executed by a production system according to a second embodiment. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0010] (Embodiment 1) The production system 1 according to the first embodiment is a system for producing products in a production line including a plurality of processes. As shown in Fig. 1, the production system 1 has a production simulation device 100, a production scheduler 200, an MES 300, an MRP 400, and a control device 500, which are connected to each other so as to be able to communicate with each other via a network cable or wirelessly (not shown).

[0011] The production system 1 has a planning layer 1A that creates major and mid-term schedules for the production plan, an execution layer 1B in which the MES 300 instructs production based on the minor schedules of the production plan, and a control layer 1C in which the control device 500 controls equipment to produce products based on instructions from the MES 300.

[0012] A production plan is a plan for producing products on a production line, including logistics such as purchasing parts based on inventory. A production plan specifies plans for a major schedule, a medium schedule, and major and minor schedules, and the duration of each is set from the perspective of efficient management. For example, a "major schedule" is about 3 to 12 months, a "medium schedule" is about 1 to 3 months, and a "minor schedule" is about 1 week to 1 month, but these differ depending on the industry in which the product is produced, the production environment, etc. The major schedule and medium schedule of the production plan are created based on a master production plan, and the minor schedule of the production plan is created by production scheduler 200, as described below.

[0013] The production simulation device 100 is a device that simulates production in a production line constructed in an IT space. The production simulation device 100 has a simulator for simulating production in the production line (hereinafter, referred to as a "production simulator").

[0014] The production simulation device 100 performs a simulation for each process of the production line before the MES 300 issues a production instruction, and reflects the simulation results in the production plan. A process is a process included in the production line, such as casting, extrusion, surface treatment, processing, packaging, and shipping. The production simulator has a simulation model for each process, and the production simulation device 100 simulates production in the production line by executing a simulation using the simulation model for each process. The production simulation device 100 also performs a simulation using information indicating the production results of the production line (hereinafter referred to as "performance information") collected by the MES 300. The performance information is information necessary for production management in the production line, and includes various information on the production status of the process, such as the time required to process the process, the waiting time until the process is executed, the status of the worker, and the status of the trouble. The production simulation device 100 performs a simulation using the performance information, and can therefore perform a simulation that better reflects the current situation of the production site.

[0015] The production scheduler 200 uses the material requirements plan created by the MRP 400 as a shipping plan.

[0016] The MES300 issues production instructions to the control device 500 of the control layer 1C according to the production order included in the short schedule of the production plan. The production order is an instruction for carrying out production based on the production plan, and is indicated by a production unit such as a part or product to be produced, and includes, for example, information on the process to be performed and information on the sequence of the process to be performed. A production order number is also assigned to the production order, and the production order is identified by the production order number. Before outputting a production instruction to the control device 500 of the control layer 1C according to the actual production order, the MES300 outputs information on the production order to the production simulation device 100. The MES300 also has a monitoring function for monitoring the production status in the production line, and enables monitoring of information on the operating status of the equipment devices in the production line, production results, quality results, and the like. The MES300 collects performance information of processes 1 to N of the control layer 1C by the monitoring function. The performance information is collected at any timing required for production management. The MES300 then transmits the collected performance information to the production simulation device 100.

[0017] Furthermore, the MES300 regards a production order for which a production instruction has been issued to the control device 500 in the control layer 1C as a processed production order. The MES300 stores information on the production order numbers of processed production orders, and by checking the stored production order numbers, determines whether a production order included in a subschedule of a production plan has been processed.

[0018] The MRP 400 creates a material requirements plan based on the information in the parts list, inventory information, and the master production schedule, and issues a purchase order to a supplier to purchase materials.

[0019] The control device 500 controls devices for each process of the production line, and is, for example, a programmable logic controller (PLC).

[0020] FIG. 2 shows the flow of transactions in the production system 1. In the planning layer 1A, information on the master production plan, inventory management, and shipping plan is handled, and information on the master production plan's major or mid-term schedule, inventory management, and shipping schedule is provided to the production scheduler 200. In the execution layer 1B, information on the minor schedule of the production plan related to production, actual results information, information on arrival results, etc. are handled, and these pieces of information are used for realizing traceability, quality control, and monitoring. The actual results information used to realize traceability is indicated by, for example, production date and time, part number, equipment number, and worker number. The actual results information used for quality control is indicated by, for example, quality information on incoming parts, information on the processing quality of equipment, and information on the results of inspection after processing is completed. Furthermore, information on arrival results is indicated by, for example, the arrival results of parts and the arrival results of semi-finished products.

[0021] FIG. 3 shows the hardware configuration of the production simulation device 100.

[0022] The production simulation device 100 has a processor 11 that executes various processes, a main memory unit 12 used as a working area for the processor 11, an auxiliary memory unit 13 that stores various data used in the processes of the processor 11, a communication unit 14 for communicating with external devices, an input unit 15 that acquires input information, and an output unit 16 that presents various information. The main memory unit 12, the auxiliary memory unit 13, the communication unit 14, the input unit 15, and the output unit 16 are all connected to the processor 11 via a bus 17.

[0023] The processor 11 includes a CPU (Central Processing Unit). The processor 11 executes programs stored in the auxiliary storage unit 13 to realize various functions of the production simulation device 100.

[0024] The main memory unit 12 includes a RAM (Random Access Memory). Programs are loaded into the main memory unit 12 from the auxiliary memory unit 13. The main memory unit 12 is used as a working area for the processor 11.

[0025] The auxiliary storage unit 13 includes a non-volatile memory such as an EEPROM (Electrically Erasable Programmable Read-Only Memory). In addition to programs, the auxiliary storage unit 13 stores various data used in the processing of the processor 11. In accordance with instructions from the processor 11, the auxiliary storage unit 13 supplies the processor 11 with data used by the processor 11 and stores the data supplied from the processor 11.

[0026] The communication unit 14 includes a network interface circuit for communicating with an external device. The communication unit 14 receives a signal from the external device and outputs data indicated by the signal to the processor 11. The communication unit 14 also transmits a signal indicating the data output from the processor 11 to the external device.

[0027] The input unit 15 includes input devices such as an input key, a pointing device, etc. The input unit 15 acquires information input by a user of the production simulation device 100, and notifies the processor 11 of the acquired information.

[0028] The output unit 16 includes output devices such as an LCD (Liquid Crystal Display) and a speaker. The output unit 16 may be configured as a touch screen integrally formed with a pointing device constituting the input unit 15. The output unit 16 presents various information to the user according to instructions from the processor 11.

[0029] FIG. 4 shows the functional configuration of the production simulation device 100 of this embodiment.

[0030] The production simulation device 100 functionally comprises an acquisition unit 101 that acquires production order information and performance information, a simulation execution unit 102 that executes a simulation, a transmission unit 103 that transmits the simulation results to the production scheduler 200, and a production simulation DB unit 104 in which a simulation model of each process is stored.

[0031] The acquiring unit 101 acquires production order information indicating the contents of the production order and performance information indicating the performance of the production line from the MES 300, which instructs production for each process according to a production order for a production line including multiple processes. The acquiring unit 101 is realized by the processor 11 and the communication unit 14. The acquiring unit 101 is an example of an acquiring means.

[0032] Here, the acquisition unit 101 generates a production simulation order for executing a simulation using a simulation model for the production order related to the production order information.

[0033] The production simulation order is a production order in a production line constructed in an IT space, and is an instruction to execute a simulation performed by the production simulation device 100 .

[0034] For example, when the acquisition unit 101 acquires production order information of a production order related to "part A" from the MES 300, the acquisition unit 101 generates production simulation order information indicating a production simulation order related to "part A." Then, the acquisition unit 101 stores the production order information and the production simulation order information in the production simulation DB unit 104 in association with each other.

[0035] Fig. 5 shows an example of a production order table in which production order information and production simulation order information are registered in association with each other. The production order information in Fig. 5 indicates the contents of a production order included in the short schedule of the production plan received by the MES 300 from the production scheduler 200, and the production simulation order information in Fig. 5 indicates the contents of a production order executed by the production simulator in the production simulation device 100. For example, the production order information and the production simulation order information include an order number, a process, a slip number, a production item, a production instruction drawing number, and a scheduled quantity. The production simulation device 100 can use the production order table to manage the processes of a production order executed by the MES 300 and the processes of a production order simulated in the production simulation device 100 in association with each other.

[0036] The acquisition unit 101 may use the production order information as it is as production simulation order information. In this case, the production simulation order information is omitted from the production order table in Fig. 5, and the production order information is managed as a production simulation order to be used in the production simulator.

[0037] Before the MES 300 issues an instruction to perform production for each process in accordance with the production order, the simulation execution unit 102 calls up a simulation model corresponding to a process for executing the production order related to the production order information acquired by the acquisition unit 101, and executes a simulation using the called simulation model and the performance information acquired by the acquisition unit 101. The simulation execution unit 102 is realized by the processor 11 and the communication unit 14. The simulation execution unit 102 is an example of a simulation execution means.

[0038] The simulation execution unit 102 is a function of a production simulator built on a software platform possessed by the production simulation device 100. The production simulation device 100 has a software platform that is an execution environment for running software, and can build one production simulator on the software platform or build multiple production simulators in cooperation with each other via the software platform.

[0039] When a production simulation order is acquired, the simulation execution unit 102 executes a simulation based on the production simulation order. Specifically, the simulation execution unit 102 calls up a simulation model corresponding to a process for executing the production simulation order from a storage area in the production simulation DB unit 104 in which the simulation models are stored. Then, the simulation execution unit 102 executes a simulation using the called simulation model in the order of the processes specified by the production simulation order, and acquires a simulation result. Here, the simulation execution unit 102 inputs performance information acquired from the MES 300 into the called simulation model to execute the simulation. This makes it possible to acquire a simulation result that reflects the load situation at the site.

[0040] The simulation result mainly includes, for example, whether the simulation is possible and the production time of each process. Furthermore, if a malfunction occurs during production, the simulation result may include the production time including the intermediate process from interruption to recovery, the time when the malfunction occurred, information indicating the process in which the malfunction occurred, an error code indicating the content of the malfunction, etc. The production malfunction is, for example, a general term for a case in which an operation different from the operation assumed before the simulation execution unit 102 starts executing the simulation for each process occurs, and refers to, for example, a case in which the simulation does not end within the assumed time, a case in which the assumed simulation is interrupted midway, a case in which the assumed simulation is interrupted midway and a predetermined condition is satisfied and the simulation is restored, etc.

[0041] Furthermore, when the simulation execution unit 102 executes simulation models of multiple processes consecutively, it can use the simulation results of the simulation model of the previous process. That is, the simulation execution unit 102 executes a simulation using the simulation model of the next process by using the simulation results output by the simulation model of a certain process for the simulation model of the next process. This allows the simulation execution unit 102 to execute a simulation that takes into account the operations between processes.

[0042] For example, when a work delay in a previous process is calculated as a simulation result, the simulation execution unit 102 can obtain a simulation result in the next process that takes into account the work delay in the previous process. This is particularly effective in cases where a work delay is tolerable or unavoidable depending on the cause of the delay. The causes of delays include, for example, a shortage of parts, equipment failure, a short stop where equipment or production is temporarily stopped or idled, a long stop where equipment or production is stopped or idled for a long period of time, and a lack of worker power due to a worker's sudden absence from work.

[0043] Here, the simulation execution unit 102 can update, replace, or add a simulation model for each process.

[0044] "Updating a simulation model" refers to updating a simulation model by re-learning. "Replacing a simulation model" refers to replacing a simulation model with another new simulation model. "Adding a simulation model" refers to adding a simulation model corresponding to a new process when a new process is added to a production line to be simulated, or to installing a new simulation model to supplement the simulation accuracy of an existing simulation model.

[0045] A simulation model has limitations in terms of the number of parameters, calculation formulas, and other specifications of the simulation model, and thus has limitations in terms of completely simulating the real world. Therefore, a simulation model using parameters not handled by the existing simulation model is installed side by side, and the existing simulation model and the new simulation model are linked to supplement the simulation accuracy. An example of a case in which a new simulation model supplements an existing simulation model is when an existing simulation model that mimics the process of a production line is supplemented with a new simulation model of the equipment that constitutes the production line.

[0046] The timing for updating, replacing, and adding the simulation model for each process can be appropriately specified by the user of the production simulation device 100. For example, the simulation model can be updated, replaced, and added before actually modifying the processes of a production line, or when various adjustments to a production plan are to be tried but the processes of the production line cannot be actually rearranged, and therefore the processes are to be rearranged in a virtual space.

[0047] When the simulation execution unit 102 executes a simulation for each process of the production simulation order, it stores the simulation results in a storage area for storing simulation model results in the production simulation DB unit 104. Here, the simulation execution unit 102 manages the simulation results for each process for executing the production order.

[0048] An example of a simulation result table in which simulation results are registered is shown in Fig. 6. In the simulation result table, the order number of the production simulation order information and the production simulation order, i.e., the simulation result for each process for executing the production order, are registered in association with each other. In the example of Fig. 6, the simulation result includes, for each process, a simulation success or failure indicating whether the simulation was successful or not, and a production time.

[0049] When the simulation execution unit 102 registers the simulation result in the simulation result table, it transmits the simulation result and information related to the simulation result to the transmission unit 103. Hereinafter, the simulation result and information related to the simulation result are referred to as "simulation result related information". The information related to the simulation result included in the simulation result related information is, for example, production simulation order information, process name, etc. The production simulation DB unit 104 stores the process name, a process ID for identifying the process, a simulation model of the process, a model ID for identifying the simulation model of the process, production simulation order information, a production simulation order number for identifying the production simulation order, simulation start and end times, simulation results, a previous process ID for identifying a previous process of a certain process, a subsequent process ID for identifying a subsequent process of a certain process, etc. The simulation execution unit 102 refers to the production simulation DB unit 104 and transmits the simulation result related information to the transmission unit 103.

[0050] The transmitting unit 103 transmits the simulation result from the simulation executed by the simulation executing unit 102 to the production scheduler 200 that creates a production plan including the production order. The transmitting unit 103 is realized by the processor 11 and the communication unit 14. The transmitting unit 103 is an example of a transmitting means.

[0051] For example, when the transmitting unit 103 receives the simulation result related information, it replaces the production simulation order information in the simulation result related information with production order information corresponding to the production simulation order information by referring to the production order table in Fig. 5. Then, after the replacement, the transmitting unit 103 transmits the simulation result related information including the production order information to the production scheduler 200.

[0052] FIG. 7 shows the functional configuration of the production scheduler 200 of this embodiment.

[0053] Functionally, the production scheduler 200 comprises an input / output unit 201 that transmits and receives information to and from other devices, a master information management unit 202 that manages master information, a plan information management unit 203 that manages input information and production plan information for creating a production plan, a plan engine unit 204 that automatically calculates the production plan, and a modification unit 205 that modifies the automatically calculated production plan.

[0054] The input / output unit 201 transmits and receives information to and from other devices such as the production simulation device 100 and the MES 300 .

[0055] For example, the input / output unit 201 receives simulation result related information from the production simulation device 100. The input / output unit 201 also receives performance information from the MES 300. The input / output unit 201 also transmits a short schedule of the production plan to the MES 300.

[0056] The master information management unit 202 manages master information and information related to constraint conditions for creating a production plan. The master information is information specific to a production base, information specific to a product to be produced, etc., and is used when the planning engine unit 204 calculates a production plan and when the calculation results are output to a screen or a report. Information specific to a production base is, for example, the equipment and machines on the production line and the operating hours and capabilities of workers. Information specific to a product is, for example, a parts list, a passing process, a production method, etc.

[0057] The plan information management unit 203 manages input information and production plan information for creating a production plan. Input information for creating a production plan includes order information, production performance information, inventory information, etc. Order information is information indicating, for example, item, quantity, and delivery date. Production performance information is information indicating, for example, arrival and completion date and time for each process, progress rate, and production time. Inventory information is information indicating inventory, arrival, and shipment.

[0058] For example, when the input / output unit 201 receives simulation result related information from the production simulation device 100, the plan information management unit 203 reflects the received simulation result related information in the production performance information. For example, when the plan information management unit 203 manages the production performance information for "process A1" with the production time "TA0", if the simulation result related information includes the production time "TA1" for "process A1", the plan information management unit 203 updates the production time for "process A1" to "TA1" and manages the production performance information.

[0059] The planning engine unit 204 automatically calculates a production plan based on predefined rules and input information managed by the planning information management unit 203. Here, when the planning engine unit 204 of the production scheduler 200 receives simulation result related information, it modifies the production plan created without using the simulation results, based on the simulation results transmitted by the transmission unit 103. In other words, since the input information managed by the planning information management unit 203 includes information on actual production results obtained by a simulation using actual result information, the planning engine unit 204 automatically calculates a production plan taking into account the load and operation time of the equipment and workers at the actual site.

[0060] The change unit 205 changes the production plan that has been automatically calculated based on the user's instructions. Specifically, the change unit 205 visualizes the production plan calculated by the planning engine unit 204 from multiple perspectives, such as by production resource or by order, and supports the user's decision-making by using a screen function, such as by changing the start date and time in the production plan and the input line.

[0061] When the input / output unit 201 receives the simulation result related information from the transmission unit 103 of the production simulation device 100, the plan engine unit 204 modifies the production plan using the latest input information managed by the plan information management unit 203, i.e., the simulation result information. Then, the input / output unit 201 transmits the modified production plan to the MES 300.

[0062] MES300 instructs production for each process according to the production orders that reflect the simulation results by instructing production for each process according to the production orders included in the production plan corrected by production scheduler 200. For example, MES300 specifies parameters of the equipment that executes the processing of each process based on the corrected production plan received from production scheduler 200, and starts the processing.

[0063] Next, the production instruction process executed by the production system 1 according to this embodiment will be described with reference to the flowchart in Fig. 8. The production instruction process in Fig. 8 is executed when the MES 300 acquires a minor schedule of a production plan from the production scheduler 200.

[0064] Here, the MES 300 transmits a simulation start instruction to the production simulation device 100 a predetermined required time before the timing of instructing production for each process according to the production order. Then, upon receiving the simulation start instruction, the production simulation device 100 executes the processing of each functional unit.

[0065] MES300 issues a command to start production according to the production order in the production plan created by production scheduler 200, but when a simulation is executed in production simulation device 100, depending on the timing at which the simulation ends, the timing to issue a command to start production may arrive before the simulation ends, resulting in a problem that the simulation results cannot be used. Therefore, since MES300 can identify the timing at which to issue a command to start production according to the production order included in the production plan, MES300 transmits a command to start a simulation to production simulation device 100 a predetermined required time before the timing at which the production command is issued, taking into account the time required for the simulation.

[0066] The predetermined required time is set in consideration of the time required for the production simulation device 100 to perform the simulation, the time required for the production scheduler 200 to reflect the simulation result in the production order, the time required for a response based on the simulation result, etc. The time required for a response based on the simulation result is, for example, the time required for an operator to perform work to replenish parts when he or she confirms the simulation result and realizes that a part is out of stock. If the set value of the predetermined required time is too optimistic, the timing to instruct production may arrive before the simulation is completed. In such a case, the difference between the predetermined required time and the time the simulation is completed is collected as a log, and the predetermined required time is readjusted.

[0067] The MES300 determines whether it is time to start a simulation before a predetermined required time (step S101). If the MES300 determines that it is time to start a simulation before a predetermined required time (step S101; YES), the MES300 proceeds to step S102. On the other hand, if the MES300 determines that it is not time to start a simulation before a predetermined required time (step S101; NO), the MES300 waits as it is.

[0068] The MES300 determines whether a production order included in the subschedule of the production plan is unprocessed (step S102). If the MES300 determines that a production order included in the subschedule of the production plan is unprocessed (step S102; YES), the acquisition unit 101 of the production simulation device 100 acquires production order information indicating the production order (step S103). On the other hand, if the MES300 determines that a production order included in the subschedule of the production plan is not unprocessed (step S102; NO), the MES300 proceeds to step S110. The MES300 regards a processed production order as one in which execution of a simulation corresponding to a process has been completed and the simulation results have been reflected in the production plan, and executes instructions for the production order according to the subschedule of the production plan acquired from the production scheduler 200.

[0069] The simulation execution unit 102 of the production simulation device 100 calls up a simulation model corresponding to a process for executing the production order related to the production order information acquired by the acquisition unit 101 from a storage area for the simulation model in the production simulation DB unit 104 (step S104). Then, the simulation execution unit 102 executes a simulation using the called simulation model (step S105), and stores the simulation result in a storage area for the simulation result in the production simulation DB unit 104 (step S106).

[0070] The simulation execution unit 102 judges whether or not the execution of simulations of all processes for executing the unprocessed production order has been completed (step S107). If the simulation execution unit 102 judges that the execution of simulations of all processes has been completed (step S107; YES), the transmission unit 103 notifies the production scheduler 200 of the simulation result related information (step S108). On the other hand, if the simulation execution unit 102 judges that the execution of simulations of all processes has not been completed (step S107; NO), the process returns to step S104, and the process from step S104 onwards is performed for the processes for which the execution of simulations has not been completed.

[0071] When the production scheduler 200 receives the simulation results from the production simulation device 100, it creates a subschedule of the production plan that reflects the received simulation results, and transmits the created subschedule of the production plan to the MES 300 (step S109). Then, the MES 300 executes production instructions according to the production order included in the received subschedule of the production plan (step S110).

[0072] According to this embodiment, a simulation is performed for each process of the production line, and a production plan reflecting the simulation results is created, thereby improving the accuracy of the production plan. As a result, rather than relying on the abilities of on-site workers, such as intuition, experience, and courage, a major schedule, a medium schedule, and a minor schedule that takes into account the situation on-site can be formulated. This makes it possible to produce based on an optimal production plan, thereby improving productivity and realizing planned production that makes it easier to determine delivery dates.

[0073] Moreover, according to this embodiment, a simulation of each process is performed using actual results information from the production site. Therefore, if there is a delay in the production line, the simulation result is a result that reflects the impact of the delay on production. Therefore, by having the production scheduler create a production plan using the simulation result, it is possible to create a realistic production plan that matches the load situation, rather than a production plan in an ideal state. Conventionally, the MES executed production instructions based on a production plan that did not consider the load situation at the site, which resulted in unreasonable production instructions, and problems occurred in which products could not be produced as planned. However, according to this embodiment, the production scheduler corrects the production plan, and the MES executes production instructions based on a production plan that considers the load situation at the site, so that products can be produced as planned.

[0074] Furthermore, according to this embodiment, by generating a production simulation order for executing the production order in a simulator, it is possible to provide an environment in which operations including the issuance of the production order are executed. This makes it possible to execute a simulation including the timing of issuing the production order, thereby further improving the accuracy of the simulation.

[0075] Furthermore, according to this embodiment, the production scheduler receives simulation result information obtained from the production simulation device as production performance information and creates a production plan, so the production scheduler can utilize the simulation results simply by having the same configuration as conventional production schedulers.

[0076] (Embodiment 2) The production system 1 according to the second embodiment includes a production simulation device 100, a production scheduler 200, an MES 300, an MRP 400, and a control device 500, similar to the first embodiment, but the functional configuration of the production simulation device 100 is different from that of the first embodiment.

[0077] FIG. 9 shows the functional configuration of the production simulation device 100 of this embodiment.

[0078] Functionally, the production simulation device 100 comprises an acquisition unit 101 that acquires production order information and performance information, a simulation execution unit 102 that executes a simulation, an adjustment unit 105 that adjusts parameters to be issued to equipment on the production line, and a production simulation DB unit 104 in which a simulation model of each process is stored.

[0079] The following describes the functions that differ from the first embodiment.

[0080] The acquisition unit 101 acquires, from the MES 300, production order information indicating a production order for a production line including a plurality of processes, performance information indicating the production performance of the production line, and information on parameters that the MES 300 instructs the equipment of the production line.

[0081] When the simulation execution unit 102 executes a simulation for each process for the production simulation order, it registers the simulation results in a simulation result table stored in the production simulation DB unit 104. Here, the simulation results include, for each process, a simulation success / failure indicating whether the simulation was successful or not, a production time, and information indicating execution contents indicating how the processing of the equipment installed on the production line is executed on the production simulator in accordance with the execution of a production instruction by the MES 300. The execution contents indicate the physical operation contents of the equipment installed on the production line that are generated by the execution of a production instruction by the MES 300. The execution contents are, for example, the operating state and control instruction contents of the control device 500, the operation contents of the controlled device that operates in response to a control instruction from the control device 500, etc.

[0082] The adjustment unit 105 adjusts parameters to be specified for devices that execute process processing based on the simulation results, and transmits the adjusted parameters to the MES 300. The adjustment unit 105 is realized by the processor 11 and the communication unit 14. The adjustment unit 105 is an example of an adjustment means.

[0083] For example, the device that executes the process is the control device 500, and the parameters designated to the device indicate the contents of the control instructions of the control device 500.

[0084] Specifically, after a simulation of all processes for executing a production order included in a subschedule of a production plan has been performed, the adjustment unit 105 refers to the simulation result table stored in the production simulation DB unit 104 and adjusts the parameters included in the production instructions executed by the MES 300 for each process.

[0085] For example, the adjustment unit 105 judges whether or not a malfunction has occurred in the production line based on the performance information acquired by the acquisition unit 101 from the MES 300. If the adjustment unit 105 judges that a malfunction has occurred in the production line, the adjustment unit 105 searches for parameters based on the simulation results to identify adjusted parameters. An example of the search is shown below.

[0086] For example, when an error occurs in a simulation, the cause of the error is identified, and a parameter related to the cause of the error is identified. When there are multiple candidates for the cause of the error, multiple parameters related to the candidate error causes are identified. Then, the parameter values ​​of the parameters not related to the cause of the error are fixed, and optimal parameter values ​​are searched for for the identified parameters. When multiple parameters are identified, optimal parameter values ​​are searched for in an arbitrary order. The optimal parameter value is searched for by setting a parameter value obtained by adding or subtracting a predetermined value to the current parameter value and executing the simulation again. When an improvement in the error is observed by executing the simulation again, the predetermined value is reduced, and the parameter value obtained by adding or subtracting the reduced value is set and the simulation is executed. The simulation in which the parameter value is changed in this manner is repeated until the improvement in the error converges, and the search is terminated when the improvement converges. Note that the search is also terminated when no tendency for improvement is observed even if the parameter value is changed. In addition, when searching for multiple parameters, after the search for the parameter value of a certain parameter is completed, the certain parameter is set to the optimal parameter value obtained by the search, and optimal parameter values ​​of the other parameters are searched for. In this manner, optimal parameter values ​​are searched for in a combination of multiple parameters.

[0087] For example, when a malfunction occurs due to the execution timing of a device such as a robot arm, the adjustment unit 105 adjusts the parameters of the execution timing. Also, when a malfunction occurs due to a collision with another robot arm caused by the control angle of the robot arm, the adjustment unit 105 adjusts the parameters of the control angle. The adjustment unit 105 stores the adjusted parameters in the production simulation DB unit 104.

[0088] 10 shows an example of the parameter adjustment table in which adjusted parameters are registered. In the parameter adjustment table, production simulation order information and pre-adjustment and post-adjustment parameters for each process for executing the production simulation order are registered in association with each other.

[0089] After registering the adjusted parameters in the parameter adjustment table, adjustment unit 105 transmits the adjusted parameters to MES 300. MES 300 instructs production for each process according to the adjusted parameters transmitted by adjustment unit 105, thereby instructing production for each process according to the production order in which the simulation results are reflected. In other words, when MES 300 receives the adjusted parameters, the parameters that MES 300 instructs to the equipment on the production line become the adjusted parameters. This enables MES 300 to realize production instructions that take into account the load situation on the site.

[0090] Next, the production instruction process executed by the production system 1 according to this embodiment will be described with reference to the flowchart in Fig. 11. Note that the processes in steps S201 to S207 in Fig. 11 are similar to the processes in steps S101 to S107 in Fig. 8.

[0091] Based on the simulation results, the adjustment unit 105 adjusts parameters to be assigned to the equipment that executes the process, and transmits the adjusted parameters to the MES 300 (step S208). Then, upon receiving the adjusted parameters, the MES 300 executes the production instruction for which the adjusted parameters are specified (step S209).

[0092] For example, when the adjustment unit 105 determines that a malfunction has occurred in the production line based on performance information collected by the MES 300, the adjustment unit 105 adjusts the parameters based on the simulation results. On the other hand, when the adjustment unit 105 determines that no malfunction has occurred in the production line based on performance information collected by the MES 300, the adjustment unit 105 does not change the parameters. Then, when the MES 300 receives the adjusted parameters, the MES 300 executes a production instruction specifying the adjusted parameters, and when the MES 300 receives the unadjusted parameters, the adjustment unit 105 executes a production instruction specifying the unadjusted parameters.

[0093] According to this embodiment, a simulation is performed for each process of the production line, and parameters specified for executing the processing of each process are adjusted based on the simulation results. This makes it possible to have the production execution system execute production instructions while taking into account the load situation at the production site. It is also possible to guarantee that production is executed in accordance with the production plan created by the production scheduler, which has the same effect as creating a production plan that takes into account the load situation.

[0094] (Modification) Although the embodiment of the present disclosure has been described above, various modifications and applications are possible in implementing the present disclosure.

[0095] In embodiment 1, the production simulation device 100 has a transmitting unit 103, and in embodiment 2, the production simulation device 100 has an adjusting unit 105, but one production simulation device 100 may be equipped with the transmitting unit 103 and the adjusting unit 105.

[0096] In the above embodiment, the production simulation device 100 executes a simulation using performance information, but the production simulation device 100 may execute a simulation without using performance information. For example, the production simulation device 100 may execute a simulation before the production line is operated and performance information has not been acquired. That is, the acquisition unit 101 may acquire production order information indicating the contents of the production order from the MES 300 that instructs production for each process according to a production order for a production line including a plurality of processes, and the simulation execution unit 102 may call up a simulation model corresponding to a process for executing the production order related to the production order information acquired by the acquisition unit 101 before instructing production for each process according to the production order, and execute a simulation using the called simulation model.

[0097] In addition, by applying an operating program that specifies the operation of the production simulation device 100 according to the above embodiment to an existing personal computer or information terminal device, it is also possible to cause the personal computer or information terminal device to function as the production simulation device 100 according to the embodiment.

[0098] Furthermore, the method of distribution of such a program is arbitrary; for example, the program may be stored on a computer-readable recording medium such as a CD-ROM (Compact Disk Read-Only Memory), a DVD (Digital Versatile Disk), or a memory card and distributed, or the program may be distributed via a communications network such as the Internet.

[0099] Various embodiments and modifications of the present disclosure are possible without departing from the broad spirit and scope of the present disclosure. The above-described embodiments are for explaining the present disclosure and do not limit the scope of the present disclosure. In other words, the scope of the present disclosure is indicated by the claims, not the embodiments. Various modifications made within the scope of the claims and the scope of the disclosure equivalent thereto are considered to be within the scope of the present disclosure. [Industrial Applicability]

[0100] According to the present disclosure, it is possible to provide a production simulation device, a production system, a production simulation method, and a program capable of creating a production plan taking into account the load situation at the production site, or performing a simulation for executing production instructions taking into account the load situation at the production site. [Explanation of symbols]

[0101] 1 production system, 11 processor, 12 main memory unit, 13 auxiliary memory unit, 14 communication unit, 15 input unit, 16 output unit, 17 bus, 100 production simulation device, 101 acquisition unit, 102 simulation execution unit, 103 transmission unit, 104 production simulation DB unit, 105 adjustment unit, 200 production scheduler, 201 input / output unit, 202 master information management unit, 203 planning information management unit, 204 planning engine unit, 205 change unit, 300 MES (manufacturing execution system), 400 MRP (material requirements planning system), 500 control device.

Claims

1. an acquisition means for acquiring production order information indicating the content of a production order from a production execution system that instructs production for each process according to a production order for a production line including a plurality of processes, before the production execution system instructs production for each process according to the production order; a simulation execution means for calling up a simulation model corresponding to a process for executing the production order related to the production order information acquired by the acquisition means, and for executing a simulation using the called simulation model, before the production execution system issues an instruction for production for each process in accordance with the production order; the production execution system instructs production for each process in accordance with a production order that reflects the simulation results of the simulation executed by the simulation execution means; Production simulation device.

2. the acquiring means acquires performance information indicating the performance of production on the production line; the simulation execution means executes the simulation using the called simulation model and the performance information acquired by the acquisition means. The production simulation device according to claim 1 .

3. a transmission means for transmitting a simulation result obtained by the simulation execution means to a production scheduler that creates a production plan including the production order; the production scheduler modifies the production plan based on the simulation results transmitted by the transmission means, the production execution system instructs production for each process in accordance with the production order included in the production plan revised by the production scheduler, thereby instructing production for each process in accordance with the production order in which the simulation results are reflected; 3. The production simulation device according to claim 1.

4. an adjustment means for adjusting parameters of equipment that executes the process based on the simulation results and transmitting the adjusted parameters to the production execution system; the production execution system instructs production for each of the processes in accordance with the adjusted parameters transmitted by the adjustment means, thereby instructing production for each of the processes in accordance with a production order in which the simulation results are reflected.

3. The production simulation device according to claim 1.

5. the acquiring means generates a production simulation order for executing a simulation using the simulation model for the production order related to the production order information; the simulation execution means executes the simulation based on the production simulation order, and manages the simulation results for each process for executing the production order.

3. The production simulation device according to claim 1.

6. the simulation execution means is capable of updating, replacing, or adding the simulation model for each of the steps; 3. The production simulation device according to claim 1.

7. the production execution system transmits an instruction to start the simulation to the production simulation device a predetermined required time before a timing at which production is instructed for each process in accordance with the production order; When the production simulation device receives the instruction to start the simulation, the acquiring means acquires the production order information and the performance information from the production execution system, The simulation execution means starts the simulation. The production simulation device according to claim 2.

8. A production system including a production execution system that instructs production for each process in accordance with a production order for a production line including a plurality of processes, and a production simulation device, The production simulation device an acquisition means for acquiring production order information indicating the content of the production order from the production execution system before the production execution system issues an instruction for production for each process in accordance with the production order; a simulation execution means for calling up a simulation model corresponding to a process for executing the production order related to the production order information acquired by the acquisition means, and for executing a simulation using the called simulation model, before the production execution system issues an instruction for production for each process in accordance with the production order; the production execution system instructs production for each process in accordance with a production order that reflects the simulation results of the simulation executed by the simulation execution means; Production system.

9. A production simulation method executed by a production simulation device, comprising: The acquisition means acquires production order information indicating the content of the production order from a production execution system that instructs production for each process according to a production order for a production line including a plurality of processes, before the production execution system instructs production for each process according to the production order; a simulation execution means for calling a simulation model corresponding to a process for executing the production order related to the production order information acquired by the acquisition means, and executing a simulation using the called simulation model, before the production execution system issues an instruction to produce for each process in accordance with the production order; the production execution system instructs production for each process in accordance with a production order that reflects the simulation results of the simulation executed by the simulation execution means; Production simulation methods.

10. Computer, an acquisition means for acquiring production order information indicating the content of a production order from a production execution system that instructs production for each process according to a production order for a production line including a plurality of processes, before the production execution system instructs production for each process according to the production order; before the production execution system issues a production command for each process in accordance with the production order, the production execution system functions as a simulation execution means that invokes a simulation model corresponding to a process for executing the production order related to the production order information acquired by the acquisition means, and executes a simulation using the invoked simulation model; the production execution system instructs production for each process in accordance with a production order that reflects the simulation results of the simulation executed by the simulation execution means; program.

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