System and method for establishing integrated production plan for vehicle

Abstract

The present invention relates to a system and method for establishing an integrated production plan for a vehicle. Introduced is a system for establishing an integrated production plan for a vehicle, the system comprising: a production plan establishment unit for establishing a production plan for a vehicle; a work data measurement unit for measuring work data of a facility when the facility is working according to the production plan established by the production plan establishment unit; a facility data prediction unit that accumulates and learns the work data of the facility measured by the work data measurement unit and predicts facility data of the facility according to the production plan on the basis of the learned work data; and a facility anomaly prediction unit that receives the facility data predicted by the facility data prediction unit and predicts an anomaly of the facility on the basis of the predicted facility data.

Description

System and method for establishing an integrated production plan for vehicles

[0001] The present invention relates to a system and method for establishing an integrated production plan for a vehicle, and more particularly, to a system and method for establishing an integrated production plan for a vehicle for minimizing productivity loss of a vehicle by predicting future equipment abnormalities at the time of establishing a production plan.

[0002] The production activities of a company must be equipped with a system that supplies the basic items, the required quantity, and the required time, and a production management system such as Patent Application No. 10-2006-0007732 is being proposed for this purpose.

[0003] In addition, the recent corporate production planning system is carried out by comprehensively managing the series of information flows from parts shipment / purchase to product delivery by organizing the production plan when an order is usually received through IT-based technology, and various solutions such as SCM (supply chain management), ERP (enterprise resource planning), MRP (materials requirement planning), and CRM (customer relationship management) have been developed, and each company is building its own system using these technologies.

[0004] Most manufacturers utilize production planning systems like the Advanced Planning System (APS) to develop optimal production plans tailored to their specific manufacturing environment. Optimizing production plans presents a challenge, requiring consideration of diverse and complex factors such as customer delivery dates, manufacturing costs, and available factory resources. Therefore, information on each of these factors is typically used as input to the production planning system, which typically considers these complex factors to develop production plans.

[0005] However, production planning systems rely solely on input information, and thus fail to reflect future production conditions after the production plan is established. For example, there's a lack of accurate information about potential breakdowns or repairs to numerous pieces of equipment within a production plant.

[0006] These issues not only significantly reduce productivity across the entire factory, but can also have a greater impact on factories that have recently adopted smart factories and production automation.

[0007] Accordingly, a method is needed to predict equipment abnormalities in advance based on prognostics and health management (PHM) to diagnose the current status of the equipment and predict failures used in the equipment field.

[0008] The matters described as background technology above are only intended to enhance understanding of the background of the present invention, and should not be taken as an admission that they correspond to prior art already known to those skilled in the art.

[0009] The present invention provides a system and method for establishing an integrated production plan for a vehicle to minimize productivity loss of a vehicle by predicting future equipment abnormalities at the time of establishing a production plan.

[0010]

[0011] The technical problems to be achieved in the present invention are not limited to the technical problems mentioned above, and other technical problems not mentioned can be clearly understood by a person having ordinary skill in the technical field to which the present invention belongs from the description below.

[0012] As a means for solving the above technical problem, the present invention configures an integrated production plan establishment system for a vehicle, including: a production plan establishment unit for establishing a production plan for a vehicle; a work data measurement unit for measuring work data of equipment when equipment performs work according to the production plan established by the production plan establishment unit; a facility data prediction unit for accumulating and learning work data of equipment measured by the work data measurement unit, and predicting facility data of equipment according to the production plan based on the learned work data; and a facility abnormality prediction unit for receiving the facility data predicted by the facility data prediction unit and predicting a facility abnormality based on the predicted facility data.

[0013] For example, the work data measurement unit can measure work data of the equipment, including the equipment's work time, work sequence, and work details.

[0014] For example, the equipment data prediction unit can predict equipment data of the equipment, including equipment performance data, temperature data and vibration data inside the equipment.

[0015] For example, the equipment failure prediction unit transmits the predicted equipment failure to the production planning unit, and the production planning unit can modify the vehicle production plan by reflecting the equipment failure received from the equipment failure prediction unit.

[0016] For example, the production planning department repeatedly establishes production plans for vehicles, and can reflect equipment abnormalities received from the equipment abnormality prediction department in each establishment of the vehicle production plan.

[0017] For example, the production planning department may further include a work production department that receives a production plan established by reflecting equipment abnormalities and produces vehicles according to the received production plan.

[0018] For example, the production planning department may be an Advanced Planning and Scheduling (APS) system, and the work production department may be a Manufacturing Execution System (MES) system.

[0019] For example, the equipment abnormality prediction unit may include a PHM (Prognostics and Health Management) server that predicts equipment abnormalities by performing equipment condition diagnosis based on predicted equipment data, predicting equipment failure or lifespan, and calculating equipment replacement timing.

[0020] For example, the equipment failure prediction unit can receive predicted equipment data and predict equipment failures through data mining.

[0021]

[0022] As a method for solving the above technical problem, the present invention comprises a method for establishing an integrated production plan for a vehicle, including: a step of establishing a production plan for a vehicle in a production planning unit; a step of measuring work data of equipment when equipment performs work according to the production plan established in the production planning unit by a work data measuring unit; a step of accumulating and learning work data of equipment measured by the work data measuring unit by a equipment data prediction unit; a step of predicting equipment data of equipment according to the production plan based on the work data learned by the equipment data prediction unit; and a step of receiving equipment data predicted by the equipment data prediction unit and predicting equipment abnormality based on the equipment data by a equipment abnormality prediction unit.

[0023] For example, the equipment abnormality prediction unit may further include a step of transmitting the predicted equipment abnormality to the production planning unit; and a step of the production planning unit modifying the vehicle production plan by reflecting the equipment abnormality received from the equipment abnormality prediction unit.

[0024] For example, the work production department may further include a step of receiving a production plan established by the production planning department that reflects equipment abnormalities and producing vehicles according to the production plan.

[0025] For example, the step of predicting an abnormality in equipment may include a step of receiving predicted equipment data and predicting an abnormality in equipment through data mining.

[0026] According to the integrated production plan establishment system and method for the vehicle of the present invention, it is possible to increase customer trust by predicting future equipment abnormalities at the time of establishment of the production plan, and to minimize productivity loss of the vehicle.

[0027]

[0028] The effects that can be obtained from the present invention are not limited to the effects mentioned above, and other effects not mentioned can be clearly understood by a person having ordinary skill in the art to which the present invention belongs from the description below.

[0029] Figure 1 is a block diagram of an integrated production plan establishment system for a vehicle according to an embodiment of the present invention.

[0030] FIG. 2 is a drawing showing the configuration of an integrated production plan establishment system for a vehicle according to an embodiment of the present invention.

[0031] Figure 3 is a flowchart illustrating the operation of an integrated production plan establishment system for a vehicle according to an embodiment of the present invention.

[0032] Hereinafter, embodiments disclosed in this specification will be described in detail with reference to the attached drawings. Regardless of the drawing numbers, identical or similar components are given the same reference numbers and redundant descriptions thereof will be omitted.

[0033] The suffixes "module" and "part" used for components in the following description are given or used interchangeably only for the convenience of writing specifications, and do not have distinct meanings or roles in themselves.

[0034] In describing the embodiments disclosed in this specification, if it is determined that a detailed description of related known technology may obscure the gist of the embodiments disclosed in this specification, the detailed description thereof will be omitted. In addition, the attached drawings are only intended to facilitate easy understanding of the embodiments disclosed in this specification, and the technical ideas disclosed in this specification are not limited by the attached drawings, and it should be understood that they include all modifications, equivalents, and substitutes included in the spirit and technical scope of the present invention. Terms including ordinal numbers, such as first, second, etc., may be used to describe various components, but the components are not limited by the terms. The terms are used only for the purpose of distinguishing one component from another.

[0035] When a component is referred to as being "connected" or "connected" to another component, it should be understood that it may be directly connected or connected to that other component, but that there may be other components intervening. Conversely, when a component is referred to as being "directly connected" or "connected" to another component, it should be understood that there are no other components intervening.

[0036] Singular expressions include plural expressions unless the context clearly indicates otherwise.

[0037] In this specification, terms such as “include” or “have” are intended to specify the presence of a feature, number, step, operation, component, part or combination thereof described in the specification, but should be understood not to exclude in advance the possibility of the presence or addition of one or more other features, numbers, steps, operations, components, parts or combinations thereof.

[0038] According to one embodiment of the present invention, it is proposed to increase customer trust and minimize productivity loss of vehicles by predicting future equipment abnormalities at the time of establishing production plans.

[0039]

[0040] Figure 1 is a block diagram of an integrated vehicle production planning system according to an embodiment of the present invention. Figure 1 primarily illustrates components related to this embodiment; however, it should be understood that an actual vehicle integrated production planning system may include fewer or more components.

[0041] Referring to FIG. 1, an integrated production plan establishment system (100) for a vehicle according to one embodiment may include a production plan establishment unit (110), a work data measurement unit (120), a facility data prediction unit (130), and a facility abnormality prediction unit (140).

[0042] The production planning unit (110) can repeatedly establish a production plan for vehicles. The production plan can be divided into a daily or weekly quantity plan and a daily input sequence plan. The quantity plan plans the quantity of each product to be produced on a daily or weekly basis, and the input sequence plan plans the order in which each product will be input and produced. Since the production planning unit (110) utilizes work organization information when establishing the quantity plan and input sequence plan, the production plan can include work organization information. In addition, work organization information refers to a work list, work order, and work time information organized by each process for all work contents required to ship each product, which is exemplary and not necessarily limited thereto. Here, the production planning unit (110) may be an APS (Advanced Planning and Scheduling) system.

[0043] This is explained in more detail with reference to Fig. 2.

[0044] FIG. 2 is a drawing showing the configuration of an integrated vehicle production plan establishment system (100) according to an embodiment of the present invention.

[0045] Referring to FIG. 2, the integrated production planning system may be referred to as a server computer and may be comprised of a memory device (101), a communication unit (102), and a power supply unit (103). First, the production planning establishment unit (110) establishes a mid- to long-term production plan (115) using input information (111) for establishing a production plan, and then establishes a short-term plan (115). The established production plan may be displayed as an interface (117).

[0046] In addition, the work data measurement unit (120) can measure the work data of the equipment when the equipment performs work according to the production plan established by the production plan establishment unit (110). This is so that the equipment data prediction unit (130), which will be described later, can build a model that predicts equipment data that will occur at a future production point based on the work data measured by the work data measurement unit (120). As can be seen in Fig. 2, the work data measurement unit (120) may be an ERP (Enterprise Resource Planning, 120) system. The work data measurement unit (120) measures the input production performance and work data (121) based on data input from the IIOT (Industrial Internet of Things, 10).

[0047] The work data measurement unit (120) can measure work data generated during the vehicle production process according to the production plan and production performance according to the vehicle production results. Each facility performs assigned work according to the production plan established by the production plan establishment unit (110), and the work data measurement unit (120) measures the production performance and work data generated during the facility's work process.

[0048] Here, production performance refers to performance information generated during product production. Examples of performance information may include start and end time information for each task, production volume information, input (production) sequence information, work sequence information, and work-specific allocation process information. Therefore, the information elements included in production performance may be considered identical to the production plan, but may have different values ​​than those indicated by the production plan information. In addition, equipment work data may include equipment work time, work sequence, and work details. Through such detailed information, the accuracy of future equipment abnormality prediction by the equipment abnormality prediction unit (140) described below can be improved.

[0049] Below, the equipment data and equipment abnormality prediction are described.

[0050] The equipment data prediction unit (130) can learn by accumulating the production performance and equipment operation data measured by the work data measurement unit (120). Referring to Fig. 2, the equipment data prediction unit (130) and the equipment abnormality prediction unit (140) can be performed by a single server. The equipment data prediction unit (130) transmits information (131) such as a production plan to the equipment data prediction module, and the predicted equipment data is transmitted to the equipment abnormality prediction unit (140) so that equipment abnormalities can be determined as described below. In addition, the production performance (141) through the equipment data can be transmitted again to the equipment data prediction module so that it can be taken into account when predicting the equipment data.

[0051] More specifically, the equipment data prediction unit (130) utilizes work data to power the equipment data prediction module, and can predict future equipment data through the prediction module. Furthermore, based on learned work data, the equipment data prediction module can predict equipment data according to the production plan.

[0052] The equipment data prediction module can refer to the established production plan, such as the work schedule information for each vehicle performed in each cell, and check the future production performance and equipment work data through the learned production performance and equipment work data, and predict how equipment data that will occur in the future production plan section will be generated. Here, the equipment data of the equipment can include equipment performance data, temperature data and vibration data inside the equipment according to the work that will occur in each equipment. The equipment data prediction unit (130) can transmit the predicted equipment data to the equipment abnormality prediction unit (140) and use it as an input value for predicting equipment failures for the established production plan section and additional sections.

[0053] Through this, the integrated production planning system (100) according to the present invention can predict and prevent issues that may arise in the production environment at a future point in time, thereby increasing customer trust and improving productivity.

[0054] The equipment abnormality prediction unit (140) can predict equipment abnormalities based on predicted equipment data received from the equipment data prediction unit (130). Referring to FIG. 2, the equipment abnormality prediction unit (140) may be a PHM (Prognostics and Health Management) server. The PHM server is responsible for predicting equipment abnormalities by performing equipment condition diagnosis based on predicted equipment data, predicting equipment failure or lifespan, and calculating equipment replacement timing.

[0055] The equipment abnormality prediction unit (140) can predict whether equipment will be abnormal in the planned section and additional section based on each equipment data predicted in the production plan section to be established, and can decide whether to perform preemptive maintenance and inspection of the equipment before performing production work based on the prediction result. The equipment abnormality prediction of the equipment abnormality prediction unit (140) can predict equipment abnormalities through data mining based on equipment data. Data mining is a process of systematically and automatically analyzing statistical rules or patterns in large-scale stored data to extract valuable information, and by analyzing the rules and patterns of equipment data among a large amount of equipment data, data necessary for predicting equipment abnormalities can be extracted.

[0056] Through this, the equipment failure prediction unit (140) can predict future equipment failures at the time of establishing production plans prior to work execution, thereby increasing customer trust and minimizing vehicle productivity losses. In this case, if the equipment failure prediction unit (140) predicts that future equipment failures will not occur, the prediction process can be terminated without prior equipment maintenance or inspection.

[0057] In addition, when the equipment abnormality prediction unit (140) predicts an equipment abnormality, it transmits it to the production plan establishment unit (110), and the production plan establishment unit (110) can modify the vehicle production plan by reflecting the equipment abnormality received from the equipment abnormality prediction unit (140). The production plan establishment unit (110) can reflect the equipment abnormality received from the equipment abnormality prediction unit (140) in the process of repeatedly establishing the production plan, thereby being able to predict and prevent issues that may occur in the production environment at a future point in time in advance.

[0058] In addition, the work production department (150) can directly instruct the equipment to produce vehicles according to the established production plan. For example, the work production department (150) can receive a production plan established by reflecting equipment abnormalities from the production planning department (110) and produce vehicles according to the received production plan. Here, the work production department (150) can improve productivity by accurately managing the status of production plan execution at the production site in real time as an MES (Manufacturing Execution System).

[0059]

[0060] Based on the integrated production plan establishment system (100) for the vehicle described above, a method for establishing an integrated production plan for a vehicle according to an embodiment is described with reference to FIGS. 3 and 4.

[0061] Figure 3 is a flowchart showing the operation of an integrated vehicle production plan establishment system (100) according to an embodiment of the present invention.

[0062] Referring to Figure 3, the system can be broadly divided into a production planning unit (110), a production site (work data measurement unit, 120), and a PHM system (130, 140). First, the production planning unit (110) can establish a production plan for a vehicle (S301). Thereafter, the established production plan can be transmitted to the equipment data prediction unit (130) (S303).

[0063] Separately, when vehicle production has started according to the established production plan (S305), the work data measurement unit (120) can collect work data and production performance according to production and transmit them to the PHM system (130, 140) (S307, S309). The equipment data measurement unit can receive work data and production performance according to production and accumulate and learn them (S313, S315). Thereafter, the equipment data prediction unit (130) can predict equipment data of the equipment according to the production plan based on the learned work data (S317). Thereafter, the equipment abnormality prediction unit (140) receives the equipment data predicted by the equipment data prediction unit (130) and predicts an abnormality of the equipment based on the predicted equipment data (S319). If an abnormality of the equipment is predicted (Y of S319), the equipment abnormality prediction unit (140) can cause maintenance work to be performed on the equipment before establishing the production plan (S311).

[0064]

[0065] According to the embodiments of the present invention described so far, it is possible to increase customer trust by predicting future equipment abnormalities at the time of establishing a production plan, and to minimize productivity loss of vehicles.

[0066]

[0067] Although the present invention has been illustrated and described with respect to specific embodiments thereof, it will be apparent to those skilled in the art that the present invention may be variously improved and modified without departing from the technical spirit of the invention as defined by the following claims.

[0068]

[0069] [Explanation of symbols]

[0070] 100: Integrated Production Planning System

[0071] 110: Production Planning Department

[0072] 120: Work data measurement unit

[0073] 130: Equipment Data Prediction Department

[0074] 140: Equipment failure prediction department

Claims

1. Production planning department that establishes production plans for vehicles; A work data measurement department that measures the work data of equipment when equipment performs work according to the production plan established by the production planning department; A facility data prediction unit that learns by accumulating the facility work data measured in the facility work data measurement unit and predicts the facility data of the facility according to the production plan based on the learned facility work data; and A vehicle integrated production plan establishment system including a facility abnormality prediction unit that receives predicted facility data from a facility data prediction unit and predicts facility abnormalities based on the predicted facility data.

2. In claim 1, The work data measurement unit is an integrated production plan establishment system for vehicles, characterized by measuring the work data of the equipment, including the equipment's work time, work sequence, and work history.

3. In claim 1, A vehicle integrated production plan establishment system characterized in that the facility data prediction unit predicts facility data including facility performance data, facility internal temperature data, and facility vibration data.

4. In claim 1, The equipment failure prediction department sends the predicted equipment failure to the production planning department. An integrated vehicle production plan establishment system characterized in that the production plan establishment department modifies the vehicle production plan by reflecting equipment abnormalities received from the equipment abnormality prediction department.

5. In claim 4, An integrated vehicle production plan establishment system characterized in that the production plan establishment department repeatedly establishes production plans for vehicles and reflects equipment abnormalities received from the equipment abnormality prediction department at each establishment of the vehicle production plan.

6. In claim 5, A vehicle integrated production plan establishment system characterized by further including a work production department that receives a production plan established by reflecting equipment abnormalities from a production plan establishment department and produces vehicles according to the received production plan.

7. In claim 6, An integrated vehicle production planning system characterized by the production planning department being an APS (Advanced Planning and Scheduling) system and the work production department being an MES (Manufacturing Execution System) system.

8. In claim 1, A vehicle integrated production plan establishment system characterized by including a PHM (Prognostics and Health Management) server that predicts equipment abnormalities by performing equipment status diagnosis based on predicted equipment data, predicting equipment failure or lifespan, and calculating equipment replacement time.

9. In claim 1, An integrated vehicle production plan establishment system characterized in that the equipment abnormality prediction unit receives predicted equipment data and predicts equipment abnormalities through data mining.

10. The stage where the production planning department establishes a production plan for the vehicle; The work data measurement section is a step for measuring the work data of equipment when the equipment performs work according to the production plan established by the production planning section; The equipment data prediction unit is a step for accumulating and learning equipment work data measured by the work data measurement unit; A step for predicting equipment data of equipment according to a production plan based on work data learned in the equipment data prediction section; and A method for establishing an integrated production plan for a vehicle, comprising: a step of the equipment abnormality prediction unit receiving equipment data predicted by the equipment data prediction unit and predicting equipment abnormalities based on the equipment data; 11. In claim 10, The equipment failure prediction unit transmits the predicted equipment failure to the production planning unit; and A method for establishing an integrated production plan for a vehicle, characterized in that it further includes a step of the production plan establishment unit revising the vehicle production plan by reflecting the equipment abnormality received from the equipment abnormality prediction unit.

12. In claim 10, A method for establishing an integrated production plan for a vehicle, characterized in that it further includes a step of the work production department receiving a production plan established by reflecting equipment abnormalities from the production planning department and producing vehicles according to the production plan.

13. In claim 10, The steps to predict equipment abnormalities are: A method for establishing an integrated production plan for a vehicle, characterized by including a step of receiving predicted facility data and predicting facility abnormalities through data mining.

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