Production plan creation method and production plan creation device

Abstract

In this production plan creation method for creating a production plan to produce multiple product types (Q1)-(Q8) by using multiple production lines (L1) and (L2), on the basis of production information regarding parts attached to a workpiece of each product type (Q1)-(Q8), inventory information regarding parts inventory, arrival information regarding the arrival of parts, and setup information regarding setup groups of the multiple product types (Q1)-(Q8), and if there is a shortage of parts for a first product type (product type (Q6)), a production plan is created in which some or all of a second product type (product type (Q8)), which is of the same setup group as the first product type and for which there is no shortage of parts, is produced before some or all of the first product type is produced, and some or all of the first product type is produced after a parts arrival date (e.g., 4 February, 20:00).

Description

Production planning method and production planning device

[0001] The present disclosure relates to a production planning method and a production planning device for creating a production plan for producing products of a plurality of varieties by a production line.

[0002] In a production line equipped with production facilities such as a mounting device for mounting components on a substrate, while performing setup changes to change the configuration of the production facilities or model changes to change production programs used in the production facilities, products of a plurality of varieties are produced. In the production line, a production plan is created in consideration of the inventory of components to be mounted on the substrate so that products of a plurality of varieties can be produced at a predetermined production quantity by a predetermined production due date. In Patent Document 1, the inventory of components is sequentially allocated to the production plan for each planned variety, and whether it is an allocated state where all components have been allocated or a state with shortages where there are shortages in the necessary components is displayed on a display unit. When a production plan in a state with shortages where the scheduled arrival date of the components with shortages is later than the production start time is selected, the production plan is changed so that a production plan that can be produced earlier than the selected production plan is executed first. A production management device is disclosed.

[0003] Japanese Patent Application Laid-Open No. 2023-29021

[0004] However, in the conventional technology including Patent Document 1, although it is possible to avoid creating a production plan that becomes impossible due to a shortage of necessary components, there is still room for further improvement in order to create a production plan with high production efficiency while avoiding shortages of necessary components.

[0005] Therefore, an object of the present disclosure is to provide a production planning method and a production planning device that can appropriately create a production plan for a production line in consideration of the inventory and incoming parts of the components to be mounted.

[0006] The production planning method of the present disclosure is a production planning method for producing multiple types of products using multiple production lines equipped with production facilities, and the method creates a production plan based on production information including information on parts attached to workpieces for each type, inventory information including information on the inventory of the parts, incoming information including information on the arrival of the parts, and setup information including information on setup groups of the multiple types, such that if there is a shortage of the parts for a first type, the production plan is created to produce some or all of a second type that is in the same setup group as the first type and does not have a shortage of the parts before the production of some or all of the first type, and to produce some or all of the first type after the arrival date of the parts.

[0007] Another production planning method of the present disclosure is a production planning method for producing multiple types of products using multiple production lines equipped with production facilities, and the production planning method is created based on production information including information on parts attached to workpieces for each type, inventory information including information on the inventory of the parts, arrival information including information on the arrival of the parts, and delivery information including information on the delivery date for each type, and if there is a shortage of the parts for the first type and the production of the first type is delayed by the delivery date, the first type is divided and distributed to multiple production lines, and part or all of the first type is produced after the arrival date of the parts.

[0008] Another production planning method of the present disclosure is a production planning method for producing multiple types of products using multiple production lines equipped with production facilities, and the method includes production information including information on parts attached to workpieces for each type, inventory information including information on the inventory of the parts, and arrival information including information on the arrival of the parts, and if there is a shortage of the parts for the first type, the method divides the second type, which is produced before the first type, and distributes it to the multiple production lines, and creates a production plan so that part or all of the first type is produced after the arrival date of the parts.

[0009] The production planning device of the present disclosure is a production planning device that creates a production plan for producing multiple types of products using multiple production lines equipped with production facilities, and includes a production planning unit that, when there is a shortage of the parts for a first type, creates a production plan to produce some or all of a second type, which is the same as the first type and is in the same setup group but does not have a shortage of the parts, before the production of some or all of the first type, and produces some or all of the first type after the date on which the parts arrive.

[0010] Other production planning devices of the present disclosure are production planning devices that create a production plan for producing multiple types of products using multiple production lines equipped with production facilities, and include a production planning unit that, based on production information including information about parts attached to workpieces of each type, inventory information including information about the inventory of the parts, arrival information including information about the arrival of the parts, and delivery information including information about the delivery date for each type, if there is a shortage of the parts for the first type and the production of the first type is delayed by the delivery date, divide the first type and distribute it to the multiple production lines, and create a production plan so that part or all of the first type is produced after the arrival date of the parts.

[0011] Other production planning devices of the present disclosure are production planning devices that create production plans for producing multiple types of products using multiple production lines equipped with production facilities, and include a production planning unit that, based on production information including information about parts attached to workpieces of each type, inventory information including information about the inventory of the parts, arrival information including information about the arrival of the parts, and delivery information including information about the delivery date for each type, divides a second type of product that is produced before the first type and distributes it to the multiple production lines, and creates a production plan so that part or all of the first type of product is produced after the arrival date of the parts.

[0012] According to this disclosure, it is possible to appropriately create a production plan for a production line that takes into account the inventory and arrival of the parts to be installed.

[0013] A diagram illustrating the configuration of a component mounting system according to one embodiment of this disclosure. A block diagram showing the configuration of a control device (production plan creation device) according to one embodiment of this disclosure. An explanatory diagram of an example of product type information used in the control device (production plan creation device) according to one embodiment of this disclosure. An explanatory diagram of an example of component information used in the control device (production plan creation device) according to one embodiment of this disclosure. An explanatory diagram of an example of setup information used in the control device (production plan creation device) according to one embodiment of this disclosure. An explanatory diagram showing product type information used in the control device (production plan creation device) according to one embodiment of this disclosure in chronological order. An explanatory diagram showing component information used in the control device (production plan creation device) according to one embodiment of this disclosure in chronological order. A flowchart of a production plan creation method according to one embodiment of this disclosure. An explanatory diagram of an example of a provisional plan created by the production plan creation method according to one embodiment of this disclosure. An explanatory diagram of an example of a provisional plan created by the production plan creation method according to one embodiment of this disclosure. An explanatory diagram of an example of a provisional plan created by the production plan creation method according to one embodiment of this disclosure.

[0014] An embodiment of this disclosure will be described in detail below with reference to the drawings. The configurations, shapes, etc. described below are illustrative examples for illustrative purposes and can be modified as appropriate according to the specifications of the component mounting system, production line, mounting equipment, management equipment (production planning equipment), etc. In the following, all corresponding elements are denoted by the same reference numerals in all drawings, and redundant explanations are omitted.

[0015] First, the configuration of the component mounting system 1 will be explained with reference to Figure 1. The component mounting system 1 consists of two production lines L1 to L2 located on the production floor PF, connected by a wired or wireless communication network 2 and managed by a control device 3. Production lines L1 to L2 are configured by connecting production equipment including mounting devices M1 to M6. Production lines L1 to L2 have the function of producing mounted boards (products) by sequentially passing boards (workpieces) between the production equipment and mounting components onto the boards using mounting devices M1 to M6. Note that the component mounting system 1 does not necessarily have to have two production lines L1 to L2; it may have one line or three or more lines.

[0016] The control device 3 has the function of creating data and parameters necessary for the operation of the production equipment on production lines L1 to L2 and transmitting them to each production piece of equipment. In addition, the control device 3 also functions as a production planning device that creates a production plan for producing multiple types of mounted circuit boards (products) using multiple production lines L1 to L2 equipped with production equipment.

[0017] In Figure 1, production lines L1 to L2 are configured by connecting multiple production equipment, including six mounting devices M1 to M6, in series from upstream (left side of the page) to downstream (right side of the page) in the substrate transport direction. In other words, production lines L1 to L2 are equipped with multiple production equipment and have the function of producing mounted substrates (products) by sequentially passing substrates (workpieces) between the production equipment. Note that production lines L1 to L2 are a group of production equipment connected via a communication network 2, and the production equipment does not necessarily have to be physically connected to each other.

[0018] The mounting devices M1 to M6 are production equipment that transports substrates by a conveyor belt, picks up components supplied by component supply devices such as tape feeders and tray feeders using nozzles attached to mounting heads, and mounts the components onto the substrates (workpieces). Note that the mounting devices M1 to M6 in production lines L1 to L2 do not necessarily have to be six units; there may be one to five units, or seven or more units.

[0019] In Figure 1, when switching between the types of mounted circuit boards (products) produced by production lines L1 to L2, setup changes are performed, including replacing the nozzles of mounting devices M1 to M6, changing the arrangement of components supplied by the component supply device, and changing the width of the conveyor belt.

[0020] Next, with reference to Figure 2, the configuration of the management device 3 will be described. Here, among the multiple functions of the management device 3, the function as a production planning device will be described, focusing on the production plan for multiple types of mounted circuit boards (products) using multiple production lines L1 to L2, taking into account the inventory and arrival schedule of components to be mounted on the circuit boards (workpieces). The management device 3 comprises a processing unit 10, a storage unit 12, an input unit 17, a display unit 18, and a communication unit 19.

[0021] The input unit 17 is an input device such as a keyboard, touch panel, or mouse, and is used when entering operation commands or data. The display unit 18 is a display device such as a liquid crystal panel, which displays various data stored in the storage unit 12, as well as various information such as operation screens and input screens for operations performed by the input unit 17. The communication unit 19 is a communication interface that transmits and receives data between the communication network 2 and the production equipment (such as mounting devices M1 to M6) that make up the production lines L1 to L2.

[0022] In Figure 2, the processing unit 10 is an arithmetic unit such as a CPU. The processing unit 10 includes a production plan creation unit 11 as an internal processing unit. The internal processing unit may be composed of independent hardware assets or of a common CPU and programs for each information processing. The storage unit 12 is a storage device that stores various types of information. The storage unit 12 is implemented by, for example, flash memory or HDD (Hard Disk Drive). The storage unit 12 stores information such as product type information 13, parts information 14, setup information 15, and production plan 16.

[0023] Furthermore, the management device 3 does not need to be composed of a single computer, but may be composed of multiple devices. In addition, all or part of the functions of the processing unit 10 and the storage unit 12 may be configured in the cloud.

[0024] In Figures 2 and 3, the product type information 13 stores information about the mounted circuit boards (products) produced on multiple production lines L1 to L2, for each of the 20 product types of mounted circuit boards. Specifically, the product type information 13 stores production information 13a, delivery date information 13b, etc. Production information 13a includes information (mounted component information 24) about the components to be mounted on each of the 20 product types of mounted circuit boards (workpieces) produced on multiple production lines L1 to L2. Delivery date information 13b includes information about the delivery date 23 for each of the 20 product types.

[0025] Here, with reference to Figures 3 and 6, an example of product type information 13 will be explained. Figure 6 displays the product type information 13 in chronological order. In Figure 6, the trailing end of the rectangles representing product types Q1 to Q8 represents the delivery date 23, and the length of the rectangles represents the total production time (production time 22 multiplied by the number of units produced 21). Product type information 13 includes product type 20, number of units produced 21, production time 22, delivery date 23, and mounted component information 24. Product type 20 is information that identifies the type of mounted circuit board (board type) produced on multiple production lines L1 to L2. In this example, product type information 13 includes information on eight types of mounted circuit boards, from "Q1" to "Q8". Hereafter, a mounted circuit board with product type 20 "Q1" will simply be referred to as "product type Q1", etc.

[0026] The production quantity 21 is the number of mounted boards produced, which is "1,000 pieces" for product types Q1 to Q6 and "500 pieces" for product types Q7 to Q8. The production time 22 is the production time per mounted board, which is "36 seconds / piece" for all product types Q1 to Q8. The delivery date 23 is the date and time when the production of mounted boards should be completed, which is "February 4th, 8:00" for product types Q1 to Q3, "February 5th, 8:00" for product types Q4 to Q6, and "February 6th, 8:00" for product types Q7 to Q8.

[0027] In Figure 3, the component information 24 shows the type of component to be mounted on the board (component type) and the number of components per mounting board. Here, only components that should be considered when creating the production plan 16 are shown. Hereafter, components with component type "A" will be simply referred to as "component A," etc. For example, one mounting board of product type Q2 will have 30 components B and 10 components X mounted on it.

[0028] In Figures 2 and 4, the component information 14 stores information about the status of components to be mounted on mounting boards (products) produced on multiple production lines L1 to L2, for each component type 25. Specifically, the component information 14 stores inventory information 14a, incoming information 14b, etc. Inventory information 14a includes information about the inventory of components (inventory quantity 26). Incoming information 14b includes information about the arrival of components (arrival date and time 27, arrival quantity 28).

[0029] Here, with reference to Figures 4 and 7, an example of component information 14 will be explained. Figure 7 displays the component information 14 in chronological order. In Figure 7, the ends of the rectangles representing components A to F and X to Y indicate the date and time when the inventory quantity 26 was confirmed, or the arrival date and time 27. Component information 14 includes component type 25, inventory quantity 26, arrival date and time 27(1), arrival quantity 28(1), arrival date and time 27(2), and arrival quantity 28(2). Component type 25 is information that identifies the type of component to be mounted on the circuit board produced on multiple production lines L1 to L2. In Figures 3 and 4, only components A to F and X to Y, which should be considered when creating the production plan 16, are displayed.

[0030] The inventory count 26 represents the current number of units of a part that can be used on multiple production lines L1 to L2. For example, there are 30,000 units of part A in stock, and no units of part Y in stock (0 units). The arrival date and time 27 is the date and time when parts used on multiple production lines L1 to L2 will arrive, and the arrival quantity 28 is the number of parts to arrive. For example, 10,000 units of part Y are scheduled to arrive on February 3rd at 8 PM, and 20,000 units on February 4th at 8 PM.

[0031] In Figures 2 and 5, the setup information 15 is information about setup groups of multiple types 20 of mounted circuit boards (products) produced on multiple production lines L1 to L2, and includes information about setup ID 29 that identifies the type 20 belonging to a setup group that can be produced without performing a setup change operation to switch between the types 20 mounted circuit boards produced on production lines L1 to L2.

[0032] Here, referring to Figure 5, an example of setup information 15 will be explained. Setup information 15 includes product type 20, setup ID 29, and setup time 30. Setup ID 29 is information that identifies the setup group. Hereafter, a setup group with setup ID 29 "R1" will simply be referred to as "setup group R1," etc. For example, product type Q4 and product type Q7 belong to the same setup group R4, and product type Q6 and product type Q8 belong to the same setup group R6. Setup time 30 is the time required for the setup change operation. The setup time 30 is "30 minutes" for all product types Q1 to Q8.

[0033] In Figure 2, the production plan creation unit 11, based on product type information 13, component information 14, and setup information 15, creates a production plan 16 that efficiently executes the production of mounted circuit boards (products) by reducing delivery delays caused by shortages of components to be mounted on the mounted circuit boards (products) produced on multiple production lines L1 to L2, and stores it in the storage unit 12. The created production plan 16 is displayed on the display unit 18 or the like.

[0034] Next, following the flow chart in Figure 8 and referring to Figures 9 through 11, we will explain a method for creating a production plan 16 for producing multiple types 20 mounted circuit boards (products) using multiple production lines L1 to L2 equipped with production facilities. Here, we will explain an example in which the production plan creation unit 11 of the management device 3 (production plan creation device) allocates the production of multiple types Q1 to Q8 mounted circuit boards to two production lines L1 to L2 to create a production plan 16, based on the type information 13 shown in Figures 3 and 6, the component information 14 shown in Figures 4 and 7, and the setup information 15 shown in Figure 5.

[0035] In Figure 8, first, the production planning unit 11 takes into account the production information 13a and delivery date information 13b included in the product information 13, the inventory information 14a and receiving information 14b included in the parts information 14, and the setup information 15 to create a preliminary plan (1) in which product types Q1 to Q8 for which parts are ready and can be produced are assigned to two production lines L1 to L2 in a preliminary order (ST1: preliminary plan creation process). Specifically, the production planning unit 11 extracts multiple product types Q1 to Q8 to be produced in a predetermined period (for example, one week) from the product information 13, and assigns product types Q1 to Q8 for which parts to be installed are ready to two production lines L1 to L2 in a preliminary order in order of earliest delivery date 23.

[0036] Now, referring to Figure 9, an example of a provisional plan (1) created by the production planning unit 11 will be explained. First, the production planning unit 11 assigns product Q2 (part B: 30,000 units, part X: 10,000 units), which has parts ready (inventory 26 is greater than or equal to the required number of parts) as of "February 3rd, 8:00" out of product Q1 to Q3 with a delivery date 23 of "February 4th, 8:00", to production line L1.

[0037] For product type Q1 (part A: 40,000 units), the inventory of part A is 26 units, but at "February 3rd, 8:00 AM", the inventory is "30,000 units", which is insufficient. Also, for product type Q3 (part C: 30,000 units, part Y: 10,000 units), the inventory of part C is 26 units, which is "30,000 units", and the required number is ready at "February 3rd, 8:00 AM", but the inventory of part Y is "0", which is insufficient. Therefore, production of product types Q1 and Q3 cannot start at "February 3rd, 8:00 AM". Accordingly, the production planning unit 11 assigns product type Q4 (part D: 30,000 units), for which the required "30,000 units" of part D are ready at "February 3rd, 8:00 AM", to production line L2. Furthermore, the production planning unit 11 adds a setup change operation with a setup time of "30 minutes" before the start of production for product Q2 and product Q4, and calculates the total production time for product Q2 and product Q4.

[0038] In Figure 9, the production planning unit 11 then schedules the production of product Q1, which will be ready to begin when production of product Q2 is finished, based on the arrival of 10,000 units of part A at 8 PM on February 3rd, and adds a setup changeover before production of product Q1 begins. Similarly, the production planning unit 11 schedules the production of product Q3, which will be ready to begin when production of product Q4 is finished, based on the arrival of 10,000 units of part Y at 8 PM on February 3rd, and adds a setup changeover before production of product Q3 begins.

[0039] Next, the production planning department 11 assigns product Q5 (parts E: 40,000 units, parts X: 20,000 units), which has an earlier delivery date 23, with 10,000 units of part E arriving on February 3rd at 8:00 PM and 20,000 units of part X arriving on February 4th at 8:00 AM, so that all the necessary parts will be ready by the time production of product Q1 is finished, after product Q1, and adds a changeover operation before production of product Q5 begins. Next, it assigns product Q7 (parts D: 15,000 units), which has all the necessary parts D ready by the time production of product Q5 is finished, after product Q5, and adds a changeover operation before production of product Q7 begins.

[0040] Furthermore, the production planning unit 11 assigns product Q8 (part F: 15,000 units), which can begin production at the end of production of product Q3, to product Q6, which is short of part Y at the end of production of product Q3, after product Q3, and adds setup work before the start of production of product Q8. Next, the production planning unit 11 assigns product Q6 after product Q8. Note that product Q6 (part F: 30,000 units, part Y: 20,000 units) will receive 20,000 units of part Y at 8 PM on February 4th, and will be able to begin production at the end of production of product Q8. Also, since product Q6 and product Q8 belong to the same setup group R6, the production planning unit 11 does not add any setup change work before the start of production of product Q6.

[0041] In this way, the production planning unit 11 creates a production plan 16 based on production information 13a, which includes information on the components to be mounted on each substrate (workpiece) of each of the 20 product types (mounted component information 24); inventory information 14a, which includes information on the inventory of components (inventory quantity 26); incoming information 14b, which includes information on the arrival of components (arrival date and time 27, arrival quantity 28); and setup information 15, which includes information on setup groups R1 to R6 of multiple product types 20 (setup ID 29). If component Y for the first product type (product type Q6) is in short supply, the unit creates a production plan 16 to produce some or all of the second product type (product type Q8), which has the same setup group R6 as the first product type and does not have a shortage of component F, before the production of some or all of the first product type, and to produce some or all of the first product type after the arrival date of component Y (February 4, 8pm).

[0042] In Figure 8, the production plan creation unit 11 then determines whether there are any product types 20 that will be late for delivery date 23 in the created provisional plan (1) (ST2: delivery date determination process). In the provisional plan (1) shown in Figure 9, product types Q1, Q3, and Q6 are late for delivery date 23. If there are product types 20 that will be late for delivery date 23 (Yes in ST2), the production plan creation unit 11 divides the production quantity 21 of product type 20, taking into account the delivery date information 13b included in the product type information 13 and the incoming information 14b included in the parts information 14 (ST3: division process). Next, the production plan creation unit 11 rearranges the production order of the divided product types 20 or creates a provisional plan (2) that distributes them to multiple production lines L1 to L2 (ST4: distribution process).

[0043] Next, the delivery date determination process (ST2) is executed. If there are any product types 20 that will be late for delivery date 23 in the provisional plan (2) (Yes in ST2), the division process (ST3) and the sorting process (ST4) are repeated. If there are no product types 20 that will be late for delivery date 23 in the provisional plan (No in ST2), the production plan creation unit 11 stores the last provisional plan as the production plan 16 in the storage unit 12. If there are still product types 20 that will be late for delivery date 23 even after repeating the division process (ST3) and the sorting process (ST4) a predetermined number of times (Yes in ST2), the production plan creation unit 11 stores the provisional plan with the fewest product types 20 that will be late for delivery date 23, or the provisional plan with the smallest total delay time, as the production plan 16 in the storage unit 12.

[0044] Referring to FIG. 10 here, an example of the tentative plan (2) created by changing the tentative plan (1) shown in FIG. 9 by the production plan creation unit 11 will be described. In the tentative plan (2), varieties Q5 to Q8 are changed from the tentative plan (1), and the delivery delay of variety Q6 occurring in the tentative plan (1) is eliminated. Hereinafter, only the change of varieties Q5 to Q8 will be described.

[0045] In FIG. 10, first, the production plan creation unit 11 divides variety Q5 into "500 sheets" and "500 sheets" (ST3), and assigns them after variety Q1 on production line L1 and variety Q3 on production line L2, respectively (ST4). In addition, setup change operations are respectively added before the production start of variety Q5 on production line L1 and production line L2.

[0046] At the end of the production of variety Q5 on production line L1 and variety Q5 on production line L2, for variety Q6, the necessary parts F and Y are prepared and production can start. Therefore, the production plan creation unit 11 divides variety Q6 into "500 sheets" and "the 500 sheets" (ST3), and assigns them after variety Q5 on production line L1 and variety Q5 on production line L2, respectively (ST4). In addition, setup change operations are respectively added before the production start of variety Q6 on production line L1 and production line L2.

[0047] In FIG. 10, next, the production plan creation unit 11 assigns variety Q7 after variety Q6 on production line L1 and adds a setup change operation before the production start of variety Q7. In addition, the production plan creation unit 11 assigns variety Q8 of the same setup group R6 after variety Q6 on production line L2. That is, in the tentative plan (2), since there is a margin in the delivery date of variety Q8, the production order of variety Q6 and variety Q8 in the same setup group R6 is changed from variety Q8 → variety Q6 in the tentative plan (1) to variety Q6 → variety Q8, so as to accelerate the start of production of variety Q6. As a result, in the tentative plan (2), the production of variety Q6 is completed before the delivery date 23 (8:00 on February 5th), and the delivery delay occurring in the tentative plan (1) is eliminated.

[0048] In this way, when the production planning unit 11 determines that the production of the first product type (product type Q6) is delayed until the due date 23 (8:00 on February 5) due to a shortage of component Y for the substrates (workpieces) of each product type 20, the production planning unit 11 divides the first product type and allocates it to a plurality of production lines L1 to L2, and creates a production plan 16 so that part or all of the first product type is produced after the arrival date (20:00 on February 4) of component Y, based on the production information 13a including information on components (mounted component information 24) to be mounted on the substrates (workpieces) of each product type 20, the inventory information 14a including information on the inventory of components (inventory quantity 26), the incoming shipment information 14b including information on the incoming shipment of components (arrival date and time 27, incoming shipment quantity 28), and the due date information 13b including information on the due date 23 of each product type 20.

[0049] Next, referring to FIG. 11, an example of the tentative plan (3) created by changing the tentative plan (1) shown in FIG. 9 by the production planning unit 11 will be described. In the tentative plan (3), by dividing product types Q2 and Q4 and allocating them to a plurality of production lines L1 to L2, the delay in the due date of product type Q6 that occurred in the tentative plan (1) is eliminated, and the delay in the due dates of product types Q1 and Q3 is reduced.

[0050] In FIG. 11, first, the production planning unit 11 divides product type Q2 into "900 sheets" that can be produced on production line L1 by "20:00 on February 3" when product type Q1 can start production and the remaining "100 sheets" (ST3). Next, the production planning unit 11 allocates product type Q1 after product type Q2 on production line L1 (ST4), and adds a setup change operation before the start of production of product type Q1. As a result, in the tentative plan (3), the start of production of product type Q1 can be made earlier than in the tentative plan (1), and the delay in the due date of product type Q1 can be reduced.

[0051] Next, the production planning unit 11 adds the divided "100 sheets" of product Q2 to production line L2, and divides product Q4 into "800 sheets" that can be produced by "February 3rd, 8pm" when product Q3 becomes ready for production, and the remaining "200 sheets" (ST3). Next, the production planning unit 11 allocates the divided "100 sheets" of product Q2 after the "800 sheets" of product Q4 on production line L2 (ST4), and adds a setup change operation before the start of production of product Q2. Furthermore, the production planning unit 11 allocates product Q3 after product Q2 (100 sheets) on production line L2 (ST4), and adds a setup change operation before the start of production of product Q3. As a result, the provisional plan (3) can start production of product Q3 earlier than the provisional plan (1), and the delivery delay of product Q3 can be reduced.

[0052] In Figure 11, the production planning unit 11 then assigns product Q5 after product Q1 on production line L1, and adds a setup change operation before the start of production of product Q5. The production planning unit 11 also assigns the divided "200 sheets" of product Q4 after product Q3 on production line L2 (ST4), and then assigns product Q7, which belongs to the same setup group R4 as product Q4, after product Q4. This eliminates the need for a setup change operation before the start of production of product Q7. In other words, by assigning product Q7, which belongs to the same setup group R4, immediately after product Q4, which had been divided into "200 sheets" and postponed, the start of production of product Q7 can be brought forward, and the increase in production time due to setup changes can also be reduced.

[0053] Next, the production planning unit 11 divides product Q6 into "500 sheets" and "500 sheets" (ST3) and assigns them after product Q5 on production line L1 and after product Q7 on production line L2, respectively (ST4). It also adds setup changeover work before the start of production of product Q6 on production line L1 and production line L2. As a result, production of product Q6 is completed before the delivery date 23 (February 5th, 8am), and the delivery delay that occurred in the provisional plan (1) is resolved. Next, the production planning unit 11 assigns product Q8 of the same setup group R6 after product Q6 on production line L2. As a result, the setup changeover work before the start of production of product Q8 can be omitted.

[0054] In this way, the production planning unit 11 creates a production plan 16 based on production information 13a, which includes information on the components to be mounted on each of the 20 types of substrates (workpieces) (mounted component information 24); inventory information 14a, which includes information on the inventory of components (inventory quantity 26); and arrival information 14b, which includes information on the arrival of components (arrival date and time 27, arrival quantity 28). If there is a shortage of component A for the first type (type Q1), the unit divides the second type (type Q2), which is produced before the first type, and distributes it to multiple production lines L1 to L2, and creates a production plan 16 so that part or all of the first type is produced after the arrival date and time of component A (February 3rd, 8pm).

[0055] In the above description, the production plan 16 for producing products using multiple production lines L1 to L2 equipped with production equipment was explained using an example where components are attached to a substrate (workpiece) using multiple production lines L1 to L2 equipped with production equipment such as mounting devices M1 to M6 to produce mounted substrates (products). However, the invention disclosed herein is applicable to other situations as well. For example, it is applicable to a production plan 16 for producing home appliances using multiple production lines L1 to L2 equipped with assembly equipment, or to a production plan 16 for producing processed food products using multiple production lines L1 to L2 equipped with food processing equipment.

[0056] As explained above, this disclosure discloses the following technical concepts.

[0057] (Technology 1) A method for creating a production plan 16 for producing multiple product types Q1 to Q8 using multiple production lines L1 to L2 equipped with production equipment (mounting devices M1 to M6), wherein the production plan 16 is created based on production information 13a including information on components A to F and X to Y mounted on workpieces (substrates) for each product type Q1 to Q8, inventory information 14a including information on the inventory of components A to F and X to Y, receiving information 14b including information on the arrival of components A to F and X to Y, and setup information 15 including information on setup groups R1 to R6 for multiple product types Q1 to Q8, and if component Y of the first product type (product type Q6) is in short supply, the production plan 16 is created so that if component Y of the first product type (product type Q6) is in short supply, part or all of the second product type (product type Q8), which has the same setup group R6 as the first product type and does not have a shortage of component F, is produced before part or all of the first product type is produced, and part or all of the first product type is produced after the arrival date of component Y (February 4th, 8pm).

[0058] This makes it possible to appropriately create a production plan 16 for production lines L1 to L2, taking into account the inventory and incoming stock of the parts A to F and X to Y to be installed.

[0059] (Technology 2) A method for creating a production plan 16 for producing multiple types of products Q1 to Q8 using multiple production lines L1 to L2 equipped with production equipment (mounting devices M1 to M6), wherein the production plan 16 is created based on production information 13a including information on components A to F and X to Y mounted on workpieces (substrates) for each type Q1 to Q8, inventory information 14a including information on the inventory of components A to F and X to Y, arrival information 14b including information on the arrival of components A to F and X to Y, and delivery information 13b including information on the delivery date 23 for each type Q1 to Q8, and if component Y for the first type (type Q6) is insufficient and the production of the first type is delayed until the delivery date 23 (February 5th, 8am), the production plan 16 is created to divide the first type and distribute it to multiple production lines L1 to L2, and produce part or all of the first type after the arrival date of component Y (February 4th, 8pm).

[0060] This makes it possible to appropriately create a production plan 16 for production lines L1 to L2, taking into account the inventory and incoming stock of the parts A to F and X to Y to be installed.

[0061] (Technology 3) A method for creating a production plan 16 for producing multiple types of products Q1 to Q8 using multiple production lines L1 to L2 equipped with production equipment (mounting devices M1 to M6), wherein the production plan 16 is created based on production information 13a including information on components A to F and X to Y mounted on workpieces (substrates) for each type Q1 to Q8, inventory information 14a including information on the inventory of components A to F and X to Y, and incoming information 14b including information on the arrival of components A to F and X to Y, and if component A of the first type (type Q1) is in short supply, the second type (type Q2), which is produced before the first type, is divided and distributed to multiple production lines L1 to L2, and a production plan 16 is created so that part or all of the first type is produced after the arrival date of component A (February 3rd, 8pm).

[0062] This makes it possible to appropriately create a production plan 16 for production lines L1 to L2, taking into account the inventory and incoming stock of the parts A to F and X to Y to be installed.

[0063] (Technology 4) A method for creating a production plan as described in any of Technologies 1 to 3, wherein the workpiece is a circuit board and the production equipment is mounting devices M1 to M6 for mounting components A to F and X to Y onto the circuit board.

[0064] This makes it possible to appropriately create production plans 16 for production lines L1 to L2, taking into account the inventory and incoming shipments of components A to F and X to Y that are mounted on the circuit board by mounting devices M1 to M6.

[0065] (Technology 5) A production planning device (management device 3) that creates a production plan 16 for producing multiple types of products Q1 to Q8 using multiple production lines L1 to L2 equipped with production equipment (mounting devices M1 to M6), wherein, based on production information 13a including information on components A to F and X to Y to be mounted on workpieces (substrates) for each type Q1 to Q8, inventory information 14a including information on the inventory of components A to F and X to Y, receiving information 14b including information on the arrival of components A to F and X to Y, and setup information 15 including information on setup groups R1 to R6 for multiple types Q1 to Q8, if component Y of the first type (type Q6) is in short supply, a part or all of the second type (type Q8), which has the same setup group R6 as the first type and does not have a shortage of component F, is produced before the production of a part or all of the first type, and a part or all of the first type is produced on the arrival date of component Y (February 4th) A production planning device (management device 3) is equipped with a production planning unit 11 that creates a production plan 16 to produce after 8 PM.

[0066] This makes it possible to appropriately create a production plan 16 for production lines L1 to L2, taking into account the inventory and incoming stock of the parts A to F and X to Y to be installed.

[0067] (Technology 6) A production planning device (management device 3) that creates a production plan 16 for producing multiple types of products Q1 to Q8 using multiple production lines L1 to L2 equipped with production equipment (mounting devices M1 to M6), wherein the production plan 16 is created based on production information 13a including information on components A to F and X to Y to be mounted on workpieces (substrates) for each type Q1 to Q8, inventory information 14a including information on the inventory of components A to F and X to Y, arrival information 14b including information on the arrival of components A to F and X to Y, and delivery information 13b including information on the delivery date 23 for each type Q1 to Q8, if component Y of the first type (type Q6) is insufficient and the production of the first type is delayed until the delivery date 23 (February 5, 8am), the first type is divided and distributed to multiple production lines L1 to L2, and part or all of the first type is distributed on the arrival date of component Y (February 4, A production planning device (management device 3) is equipped with a production planning unit 11 that creates a production plan 16 to produce after 8 PM.

[0068] This makes it possible to appropriately create a production plan 16 for production lines L1 to L2, taking into account the inventory and incoming stock of the parts A to F and X to Y to be installed.

[0069] (Technology 7) A production planning device (management device 3) that creates a production plan 16 for producing multiple types of products Q1 to Q8 using multiple production lines L1 to L2 equipped with production equipment (mounting devices M1 to M6), comprising a production planning unit 11 that, based on production information 13a including information on components A to F and X to Y mounted on workpieces (substrates) for each type Q1 to Q8, inventory information 14a including information on the inventory of components A to F and X to Y, and arrival information 14b including information on the arrival of components A to F and X to Y, if component A of the first type (type Q1) is in short supply, divides the second type (type Q2), which is produced before the first type, and distributes it to multiple production lines L1 to L2, and creates a production plan 16 so that part or all of the first type is produced after the arrival date of component A (February 3rd, 8pm).

[0070] This makes it possible to appropriately create a production plan 16 for production lines L1 to L2, taking into account the inventory and incoming stock of the parts A to F and X to Y to be installed.

[0071] The production plan creation method and production plan creation apparatus disclosed herein have the effect of being able to appropriately create a production plan for a production line that takes into account the inventory and arrival of components to be mounted, and are useful in the field of mounting components onto a substrate.

[0072] 3. Management device (production plan creation device) A-F, X-Y Parts L1-L2 Production line M1-M6 Mounting device Q1-Q8 Product type R1-R6 Setup group

Claims

1. A production planning method for creating a production plan for producing multiple types of products using multiple production lines equipped with production facilities, the method comprising: production information including information on parts attached to workpieces for each type; inventory information including information on the inventory of the parts; incoming information including information on the arrival of the parts; and setup information including information on setup groups for multiple types, wherein if there is a shortage of the parts for a first type, the production plan is created to produce some or all of a second type, which is the same as the first type and the setup group but does not have a shortage of the parts, before the production of some or all of the first type, and to produce some or all of the first type after the arrival date of the parts.

2. A method for creating a production plan for producing multiple types of products using multiple production lines equipped with production facilities, the method comprising: production information including information on parts attached to workpieces of each type; inventory information including information on the inventory of the parts; arrival information including information on the arrival of the parts; and delivery information including information on the delivery date for each type, wherein if there is a shortage of the parts for the first type and the production of the first type is delayed by the delivery date, the method creates a production plan to divide the first type and distribute the parts to multiple production lines, and to produce part or all of the first type after the arrival date of the parts.

3. A production plan creation method for creating a production plan for producing multiple types of products using multiple production lines equipped with production facilities, the method comprising: production information including information on parts attached to workpieces for each type; inventory information including information on the inventory of the parts; and arrival information including information on the arrival of the parts, the method for creating a production plan in which, if there is a shortage of the parts for the first type, the second type, which is produced before the first type, is divided and distributed to the multiple production lines, and part or all of the first type is produced after the arrival date of the parts.

4. The production plan creation method according to any one of claims 1 to 3, wherein the workpiece is a circuit board and the production equipment is a mounting device for mounting the components onto the circuit board.

5. A production planning device for creating a production plan for producing multiple types of products using multiple production lines equipped with production facilities, comprising: a production planning unit that, based on production information including information on parts attached to workpieces for each type, inventory information including information on the inventory of the parts, incoming information including information on the arrival of the parts, and setup information including information on setup groups of the multiple types, creates a production plan such that if the parts for a first type are in short supply, a part or all of a second type, which is the same as the first type and the setup group but does not have a shortage of the parts, is produced before the production of a part or all of the first type, and a part or all of the first type is produced after the arrival date of the parts.

6. A production planning device for creating a production plan for producing multiple types of products using multiple production lines equipped with production facilities, comprising: a production planning unit that, based on production information including information on parts attached to workpieces of each type, inventory information including information on the inventory of the parts, arrival information including information on the arrival of the parts, and delivery information including information on the delivery date for each type, creates a production plan such that if there is a shortage of the parts for the first type and the production of the first type is delayed by the delivery date, the first type is divided and distributed to multiple production lines, and part or all of the first type is produced after the arrival date of the parts.

7. A production planning device for creating a production plan for producing multiple types of products using multiple production lines equipped with production facilities, comprising: a production planning unit that, based on production information including information on parts attached to workpieces of each type, inventory information including information on the inventory of the parts, arrival information including information on the arrival of the parts, and delivery information including information on the delivery date for each type, if there is a shortage of the parts for the first type, divides the second type, which is produced before the first type, and distributes it to the multiple production lines, and creates a production plan so that part or all of the first type is produced after the arrival date of the parts.

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