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

Abstract

A production simulation device (100) comprises: an acquisition unit (101) that acquires production order information indicating the content of a production order, from an MES (300) that directs production for each process of a plurality of processes according to a production order for a production line including the plurality of processes and included in a production plan; and a simulation execution unit (102) that, before the MES (300) directs production for each process according to a production order, calls a simulation model corresponding to the process for executing the production order indicated by the production order information acquired by the acquisition unit (101), and executes a simulation using the called simulation model. The MES (300) directs production for each process according to a production order that reflects the simulation result.

Description

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

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

[0002] Conventionally, production schedulers that create production plans for producing products on a production line are known. Generally, production schedulers use a master production schedule (MPS) and material requirements calculated in a material requirements planning system (MRP) to create a subschedule of the production plan that a manufacturing execution system (MES) uses to issue production instructions.

[0003] Since the accuracy of production plans contributes to improving the productivity of production lines, various techniques have been disclosed that enable production schedulers to create accurate production plans. For example, Patent Document 1 discloses a production planning device technology that calculates the degree of impact on production indicators caused by the deviation between standard times set for each process and actual work times, and creates a production plan taking the degree of impact into consideration.

[0004] JP 2017-162044 A

[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 accurately calculate delivery dates, there is a demand for technology that enables production instructions to be issued 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, production system, production simulation method, and program that are capable of creating a production plan that takes into account the load situation at the production site, or performing a simulation to execute production instructions that take into account the load situation at the production site.

[0007] In order to achieve the above object, the production simulation device according to the present disclosure comprises: an acquisition means for acquiring production order information indicating the contents of a production order from 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 simulation execution means that, before the production execution system instructs production for each process in accordance with the production order, calls a simulation model corresponding to the process for executing the production order related to the production order information acquired by the acquisition means and executes a simulation using the called simulation model; and the production execution system instructs production for each process in accordance with the production order in which the simulation results of the simulation executed by the simulation execution means are reflected.

[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 that are capable of creating a production plan that takes into account the load situation at the production site, or performing a simulation to execute production instructions that take into account the load situation at the production site.

[0009] FIG. 1 shows a production system according to embodiment 1. FIG. 2 shows a transaction flow in the production system according to embodiment 1. Block diagram showing the hardware configuration of the production simulation device according to embodiment 1. FIG. 3 shows a functional configuration of the production simulation device according to embodiment 1. FIG. 4 shows a production order table according to embodiment 1. FIG. 5 shows a simulation result table according to embodiment 1. FIG. 6 shows a functional configuration of the production scheduler according to embodiment 1. Flowchart showing production instruction processing executed by the production system according to embodiment 1. FIG. 7 shows a functional configuration of the production simulation device according to embodiment 2. FIG. 8 shows a parameter adjustment result table according to embodiment 2. Flowchart showing production instruction processing executed by the production system according to embodiment 2.

[0010] A 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 includes 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 medium-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 approximately 3 to 12 months, a "medium schedule" is approximately 1 to 3 months, and a "minor schedule" is approximately 1 week to 1 month, but these differ depending on the industry in which the product is produced, the production environment, etc. The major and medium schedules of a production plan are created based on a master production plan, and the minor schedule of a production plan is created by production scheduler 200, as will be described later.

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

[0014] The production simulation device 100 performs a simulation of each process on the production line before the MES 300 issues a production command 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, machining, packaging, and shipping. The production simulator has a simulation model for each process, and the production simulation device 100 simulates production on the production line by running 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. Performance information is information necessary for production management on the production line and includes various information related to the production status of each process, such as the time required to process the process, the wait time until the process is executed, the status of the workers, and the status of any problems. By using the performance information to perform a simulation, the production simulation device 100 can perform a simulation that better reflects the current situation at the production site.

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

[0016] The MES 300 issues production instructions to the control device 500 of the control layer 1C according to production orders included in the subschedule of the production plan. A production order is an instruction for carrying out production based on the production plan. It is indicated by a production unit such as a part or product to be produced, and includes, for example, information on the processes to be performed and the order in which the processes should be performed. Furthermore, a production order number is assigned to each production order, and the production order is identified by the production order number. The MES 300 outputs production order information to the production simulation device 100 before outputting production instructions to the control device 500 of the control layer 1C according to the actual production order. The MES 300 also has a monitoring function for monitoring the production status on the production line, enabling monitoring of information related to the operating status of equipment on the production line, production results, quality results, etc. The MES 300 uses its monitoring function to collect performance information for processes 1 to N of the control layer 1C. Performance information is collected at any timing required for production management. Then, the MES 300 transmits the collected performance information to the production simulation device 100 .

[0017] Furthermore, the MES 300 regards a production order for which a production instruction has been issued to the control device 500 of the control layer 1C as a processed production order. The MES 300 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 the subschedule of the 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 plan, and issues a purchase order to a supplier to purchase materials.

[0019] The control device 500 controls devices for each process on 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. The planning layer 1A handles information on the master production plan, inventory management, and shipping plan, and provides information on the master production plan's major or mid-term schedule, inventory management, and shipping schedule to the production scheduler 200. The execution layer 1B handles information on the production plan's minor schedule, actual results, and arrival results, etc., related to production, and this information is used to achieve traceability, quality control, and monitoring. The actual results information used to achieve 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, information on the quality of incoming parts, information on the processing quality of equipment, and information on the results of inspection after processing is completed. Furthermore, arrival results information is indicated by, for example, the arrival results of parts and 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 work 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 input keys, 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 in accordance with instructions from the processor 11.

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

[0030] 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, a transmission unit 103 that transmits the simulation results to the production scheduler 200, and a production simulation DB unit 104 that stores a simulation model of each process.

[0031] The acquisition unit 101 acquires production order information indicating the content of a production order and performance information indicating the performance of production on 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 acquisition unit 101 is realized by the processor 11 and the communication unit 14. The acquisition unit 101 is an example of an acquisition 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 for a production line constructed in an IT space, and is an instruction to execute a simulation executed by the production simulation device 100 .

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

[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 content of a production order included in the subschedule of the production plan received by MES 300 from production scheduler 200, and the production simulation order information in Fig. 5 indicates the content of a production order to be executed by the production simulator in production simulation device 100. For example, the production order information and production simulation order information include an order number, a process, a slip number, a production item, a production instruction drawing number, and a planned quantity. Using the production order table, the production simulation device 100 can manage the process of a production order to be executed by MES 300 and the process of a production order to be simulated in 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 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 included in the production simulation device 100. The production simulation device 100 has a software platform that is an execution environment for running software, and it is possible to build a single production simulator on the software platform, or to 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 the process for executing the production simulation order from a storage area in the production simulation DB unit 104 where the simulation models are stored. The simulation execution unit 102 then executes a simulation using the called-up simulation model in the order of the processes specified by the production simulation order, and acquires the simulation results. Here, the simulation execution unit 102 inputs performance information acquired from the MES 300 into the called-up simulation model and executes the simulation. This makes it possible to acquire simulation results that reflect the load status of the site.

[0040] The simulation results mainly include, for example, whether the simulation was successful and the production time for each process. Furthermore, if a malfunction occurs during production, the simulation results may include the production time including the time from interruption to recovery, the time when the malfunction occurred, information indicating the process where the malfunction occurred, an error code indicating the content of the malfunction, etc. A production malfunction is a general term for, for example, an occurrence of an operation that differs from the operation assumed before the simulation execution unit 102 starts executing a simulation for each process, and refers to, for example, a case where the simulation does not end within the assumed time, a case where the assumed simulation is interrupted midway, or a case where the assumed simulation is interrupted midway and the simulation is restored when a predetermined condition is met, 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 one 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 for the next process that takes into account the work delay in the previous process. This is particularly effective in cases where work delay is tolerable or unavoidable depending on the cause of the delay. Examples of causes of delay include 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 an extended period of time, and a lack of worker power due to a worker's sudden absence.

[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 through re-learning. "Replacing a simulation model" refers to replacing a simulation model with a new one. "Adding a simulation model" refers to adding a simulation model corresponding to a new process when a new process is added to the production line being simulated, or to installing a new simulation model to supplement the simulation accuracy of an existing simulation model.

[0045] Simulation models have limitations in their specifications, such as the number of parameters and calculation formulas, and therefore have limitations in their ability to completely simulate the real world. Therefore, simulation accuracy can be supplemented by creating a simulation model that uses parameters not handled by the existing simulation model and linking the existing simulation model with the new simulation model. An example of a case in which a new simulation model supplements an existing simulation model is when an existing simulation model that simulates the processes of a production line is supplemented with a new simulation model of the equipment that makes up the production line.

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

[0047] After carrying out a simulation for each process of the production simulation order, the simulation execution unit 102 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] 6 shows an example of a simulation result table in which simulation results are registered. In the simulation result table, the order number of the production simulation order information and the production simulation order, i.e., the simulation results for each process for executing the production order, are registered in association with each other. In the example of FIG. 6, the simulation results for each process include a simulation success / failure indicating whether the simulation was successful or not, and the production time.

[0049] After registering the simulation results in the simulation result table, the simulation execution unit 102 sends the simulation results and information related to the simulation results to the transmission unit 103. Hereinafter, the simulation results and information related to the simulation results will be referred to as "simulation result-related information." Information related to the simulation results included in the simulation result-related information includes, for example, production simulation order information and process names. The production simulation DB unit 104 stores the process name, a process ID for identifying the process, a simulation model for the process, a model ID for identifying the simulation model for the process, production simulation order information, a production simulation order number for specifying the production simulation order, simulation start and end times, simulation results, a previous process ID for identifying a process previous to a certain process, and a subsequent process ID for identifying a process subsequent to a certain process. The simulation execution unit 102 references the production simulation DB unit 104 and sends the simulation result-related information to the transmission unit 103.

[0050] The transmitting unit 103 transmits the simulation results from the simulation executed by the simulation executing unit 102 to the production scheduler 200, which 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. 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 subschedule of the production plan to the MES 300.

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

[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, the 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 information on actual production results. For example, when the plan information management unit 203 manages the information on actual production results with the production time "TA0" for "process A1," if the production time "TA1" for "process A1" is included in the simulation result-related information, the plan information management unit 203 updates the production time for "process A1" to "TA1" and manages the information on actual production results.

[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 that was created without using the simulation results, based on the simulation results transmitted by the transmission unit 103. In other words, the input information managed by the planning information management unit 203 includes information on actual production results obtained by a simulation using actual performance information, so the planning engine unit 204 automatically calculates a production plan taking into account the loads and operating hours of the equipment and workers at the actual site.

[0060] The change unit 205 changes the automatically calculated production plan based on a user's instruction. 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 to change the start date and time, input line, etc. in the production plan.

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

[0062] MES 300 instructs production for each process according to the production order that reflects the simulation results, by instructing production for each process according to the production order included in the production plan corrected by production scheduler 200. For example, MES 300 specifies parameters for the equipment that executes the processing for 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 subschedule of the 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 issuing an instruction to start production for each process in accordance with the production order. Then, upon receiving the simulation start instruction, the production simulation device 100 executes the processing of each functional unit.

[0065] MES 300 issues a production instruction in accordance with 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 production instruction may arrive before the simulation ends, resulting in the simulation results being unusable. Therefore, MES 300 can identify the timing at which to issue a production instruction in accordance with the production order included in the production plan, and so MES 300 transmits a simulation start instruction to production simulation device 100 a predetermined required time before the timing at which the production instruction is issued, taking into account the time required for the simulation.

[0066] The "predetermined required time" is set taking into consideration 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 results in the production order, the time required for a response based on the simulation results, and the like. The time required for a response based on the simulation results is, for example, the time required for a worker to check the simulation results and realize that a part is out of stock, and then perform the work of replenishing the part. Note that if the set value for the predetermined required time is too optimistic, the timing to issue a production instruction may arrive before the simulation is completed. In such cases, 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 MES 300 determines whether it is time to start a simulation that is a predetermined required time before (step S101). If the MES 300 determines that it is time to start a simulation that is a predetermined required time before (step S101; YES), the MES 300 proceeds to step S102. On the other hand, if the MES 300 determines that it is not time to start a simulation that is a predetermined required time before (step S101; NO), the MES 300 remains on standby.

[0068] The MES 300 determines whether any production orders included in the subschedule of the production plan are unprocessed (step S102). If the MES 300 determines that any production orders included in the subschedule of the production plan are 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 MES 300 determines that any production orders included in the subschedule of the production plan are not unprocessed (step S102; NO), the process proceeds to step S110. The MES 300 considers that the execution of a simulation corresponding to a process has been completed for a processed production order, and that the simulation results have been reflected in the production plan, and executes the instructions for the production order in accordance with 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 the 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 results in the storage area for the simulation results in the production simulation DB unit 104 (step S106).

[0070] The simulation execution unit 102 determines whether or not the execution of simulations for all processes for executing the unprocessed production order has been completed (step S107). If the simulation execution unit 102 determines that the execution of simulations for 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 determines that the execution of simulations for all processes has not been completed (step S107; NO), the process returns to step S104, and the processes from step S104 onwards are performed for the processes for which the execution of simulations has not been completed.

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

[0072] According to this embodiment, a simulation is performed for each process on the production line, and a production plan is created that reflects the simulation results, thereby improving the accuracy of the production plan. As a result, rather than formulating a production plan that depends on the abilities of on-site workers, such as intuition, experience, and courage, it is possible to formulate a major schedule, a medium schedule, and a minor schedule that takes into account the situation on-site. Therefore, production based on an optimal production plan is possible, and systematic production can be realized, such as improved productivity and easier determination of delivery dates.

[0073] Furthermore, according to this embodiment, a simulation of each process is performed using actual production information from the production line. Therefore, if there is a delay on the production line, for example, the simulation results reflect the impact of the delay on production. Therefore, by having the production scheduler create a production plan using the simulation results, it is possible to create a realistic production plan that matches the load situation, rather than a production plan based on an ideal state. Conventionally, the MES executed production instructions based on a production plan that did not take into account the load situation on the production line, resulting in unreasonable production instructions and problems such as products not being produced as planned. However, according to this embodiment, the production scheduler modifies the production plan, and the MES executes production instructions based on a production plan that takes into account the load situation on the production line, so products can be produced as planned.

[0074] Furthermore, according to this embodiment, an environment can be provided in which operations, including the issuance of a production order, are executed by generating a production simulation order for executing the production order in a simulator. This allows a simulation to be performed that includes the timing of issuing the production order, further improving the accuracy of the simulation.

[0075] Furthermore, according to this embodiment, the production scheduler receives the 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] (Second embodiment) 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 simulations, an adjustment unit 105 that adjusts parameters to be instructed to equipment on the production line, and a production simulation DB unit 104 that stores simulation models for each process.

[0079] The following describes 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 multiple processes, performance information indicating the production performance of the production line, and information on parameters that the MES 300 instructs the equipment on the production line.

[0081] After the simulation execution unit 102 performs a simulation for each process of 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 indicator indicating whether the simulation was successful, the production time, and information indicating the execution content indicating how the processing of the equipment installed on the production line will be executed on the production simulator in accordance with the execution of the production instructions by the MES 300. The execution content indicates the physical operation content of the equipment installed on the production line that occurs as a result of the execution of the production instructions by the MES 300. The execution content includes, for example, the operating status and control instruction content of the control device 500, and the operation content of the controlled device that operates in response to the control instructions issued by the control device 500.

[0082] The adjustment unit 105 adjusts parameters to be assigned to the devices that execute the process 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 specified for the device indicate the contents of the control instructions of the control device 500.

[0084] Specifically, after simulating all processes for executing the production orders included in the subschedule of the production plan, 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 determines whether 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 determines that a malfunction has occurred in the production line, it searches for parameters based on the simulation results to identify adjusted parameters. An example of the search is shown below.

[0086] For example, if an error occurs during a simulation, the cause of the error is identified, and parameters related to the error cause are identified. If there are multiple candidate error causes, multiple parameters related to the candidate error causes are identified. Then, parameter values ​​of parameters unrelated to the error cause are fixed, and optimal parameter values ​​are searched for for the identified parameters. If multiple parameters are identified, optimal parameter values ​​are searched for in an arbitrary order. The optimal parameter value is searched for by setting parameter values ​​obtained by adding or subtracting a predetermined value to or from the current parameter value and running the simulation again. If the re-run simulation shows an improvement in the error, the predetermined value is reduced, and the parameter value obtained by adding or subtracting the reduced value is set and run again. This simulation with the changed parameter value is repeated until the improvement in the error converges, and the search ends when the improvement converges. Note that the search also ends if no trend in improvement is observed even after changing the parameter value. Furthermore, when searching for multiple parameters, after completing the search for the parameter value of a certain parameter, the parameter is set to the optimal parameter value found by the search, and optimal parameter values ​​for the other parameters are searched for. In this way, 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 a parameter adjustment table in which adjusted parameters are registered. In the parameter adjustment table, production simulation order information and parameters before and after adjustment 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, the adjustment unit 105 transmits the adjusted parameters to the MES 300. The MES 300 instructs production for each process according to the adjusted parameters transmitted by the adjustment unit 105, thereby instructing production for each process according to the production order that reflects the simulation results. In other words, when the MES 300 receives the adjusted parameters, the parameters that the MES 300 instructs the equipment on the production line become the adjusted parameters. This enables the MES 300 to issue production instructions that take into account the load status of 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 the same as the processes in steps S101 to S107 in Fig. 8.

[0091] Based on the simulation results, the adjustment unit 105 adjusts the 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, if the adjustment unit 105 determines that a malfunction has occurred on 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, if the adjustment unit 105 determines that no malfunction has occurred on 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 on the production line, and the parameters specified for executing the processing of each process are adjusted based on the simulation results. This allows the production execution system to execute production instructions while taking into account the load situation at the production site. Furthermore, it is possible to ensure 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] (Modifications) Although the embodiments of the present disclosure have been described above, various modifications and applications are possible when implementing the present disclosure.

[0095] In the first embodiment, the production simulation device 100 has a transmission unit 103, and in the second embodiment, the production simulation device 100 has an adjustment unit 105, but one production simulation device 100 may have both the transmission unit 103 and the adjustment unit 105.

[0096] Furthermore, 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 starts operation 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, which instructs production for each process according to a production order for a production line including multiple processes. Before instructing production for each process according to the production order, the simulation execution unit 102 may call 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 execute a simulation using the called simulation model.

[0097] Furthermore, by applying an operating program that defines 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 make the personal computer or information terminal device 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, it 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 it may be distributed via a communication network such as the Internet.

[0099] The present disclosure allows various embodiments and modifications without departing from the broad spirit and scope of the present disclosure. Furthermore, the above-described embodiments are intended to explain the present disclosure and do not limit the scope of the present disclosure. That is, the scope of the present disclosure is defined by the claims, not the embodiments. Various modifications made within the scope of the claims and the meaning of equivalent disclosures are considered to be within the scope of the present disclosure.

[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 that are capable of creating a production plan that takes into account the load situation at the production site, or performing a simulation to execute production instructions that take into account the load situation at the production site.

[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. A production simulation device comprising: an acquisition means for acquiring production order information indicating the contents of a production order from 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 simulation execution means that, before the production execution system instructs production for each process in accordance with the production order, calls 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 called simulation model; and the production execution system instructs production for each process in accordance with the production order in which the simulation results of the simulation executed by the simulation execution means are reflected.

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

3. The production simulation device according to claim 1 or 2, further comprising a transmission means for transmitting simulation results from the simulation executed by the simulation execution means to a production scheduler that creates a production plan that includes the production order, wherein the production scheduler modifies the production plan based on the simulation results transmitted by the transmission means, and wherein the production execution system instructs production for each of the processes in accordance with the production order that reflects the simulation results by instructing production for each of the processes in accordance with the production order included in the production plan modified by the production scheduler.

4. A production simulation device according to claim 1 or 2, further comprising an adjustment means for adjusting parameters of equipment that executes processing of said process based on said simulation results and transmitting the adjusted parameters to said production execution system, wherein said production execution system instructs production for each of said processes in accordance with the adjusted parameters transmitted by said adjustment means, thereby instructing production for each of said processes in accordance with a production order that reflects said simulation results.

5. The production simulation device according to any one of claims 1 to 4, wherein the acquisition means generates a production simulation order for executing a simulation using the simulation model for the production order related to the production order information, and 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.

6. The production simulation device according to any one of claims 1 to 5, wherein the simulation execution means is capable of updating, replacing, or adding the simulation model for each of the processes.

7. The production simulation device according to claim 2, wherein the production execution system transmits an instruction to start the simulation to the production simulation device a predetermined amount of time before the timing of issuing an instruction to produce for each process in accordance with the production order, and when the production simulation device receives the instruction to start the simulation, the acquisition means acquires the production order information and the performance information from the production execution system, and the simulation execution means starts the simulation.

8. A production system having 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, wherein the production simulation device comprises: an acquisition means that acquires production order information indicating the contents of the production order from the production execution system; and a simulation execution means that, before the production execution system instructs production for each process in accordance with the production order, calls a simulation model corresponding to the process for executing the production order related to the production order information acquired by the acquisition means, and executes a simulation using the called simulation model; and the production execution system instructs production for each process in accordance with the production order in which the simulation results of the simulation executed by the simulation execution means are reflected.

9. A production simulation method executed by a production simulation device, wherein an acquisition means acquires production order information indicating the contents of the production order from 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, a simulation execution means calls a simulation model corresponding to the 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 executes a simulation using the called simulation model, and the production execution system instructs production for each process in accordance with the production order that reflects the simulation results of the simulation executed by the simulation execution means.

10. A program that causes a computer to function as: an acquisition means that acquires production order information indicating the contents of a production order from a production execution system that instructs production for each process in accordance with a production order for a production line including multiple processes; and a simulation execution means that calls a simulation model corresponding to a process for executing a production order related to the production order information acquired by the acquisition means and executes a simulation using the called simulation model; and the production execution system instructs production for each process in accordance with the production order that reflects the simulation results of the simulation executed by the simulation execution means.

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