This case relates to an information processing device, a specifying method, and a non-transitory computer-readable recording medium storing a specifying program.
Techniques for automatically providing information regarding a work plan regarding a work line such as a manufacturing line are disclosed (for example, refer to Patent Documents 1 to 3).
Examples of the related art include: [Patent Document 1] Japanese Laid-open Patent Publication No. 2020-047301; [Patent Document 2] Japanese Laid-open Patent Publication No. 2005-301653; and [Patent Document 3] Japanese Laid-open Patent Publication No. 2015-087803.
According to an aspect of the embodiments, there is provided a non-transitory computer-readable recording medium storing a specifying program for causing a computer to perform processing, the processing including: obtaining first information that indicates a processing order of processing a plurality of objects, the plurality of objects including a plurality of types; obtaining second information that indicates a type that is processable by each of a plurality of work devices, among the plurality of types; distributing, based on the first information and the second information, each of the plurality of objects to any of the plurality of work devices; obtaining a result of a simulation regarding processing of the plurality of work devices based on a result of the distributing each of the plurality of objects to any of the plurality of work devices; counting a number N1 that corresponds to a number of objects which have moved to another work device although processing is capable of being executed on an object to be distributed next, for each of the plurality of work devices from the result of the simulation, and counting a number N2 that corresponds to a number of objects which are caused to wait since processing is executed on another object although processing is capable of being executed on the object to be distributed next, under conditions such that each of the plurality of objects waits when the work device that is capable of executing the processing on the object is executing processing on another object; and specifying a work device to be increased or decreased with respect to the plurality of work devices, according to at least any of the number N1 or the number N2.
The object and advantages of the invention will be realized and attained by means of the elements and combinations particularly pointed out in the claims.
It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory and are not restrictive of the invention.
For example, by switching a processing order of objects in a work line and performing a simulation, it is considered to search for the processing order so that a key performance indicator (KPI) such as a work completion time or a work cost satisfies a desired condition. However, as a result of searching for the processing order, there are some cases where the KPI does not satisfy the desired condition. In this case, it is required to improve the KPI by increasing or decreasing the number of work devices.
In one aspect, an object of the present disclosure is to provide an information processing device, a specifying method, and a specifying program that can provide information regarding increase or decrease of the number of work devices.
First, an outline of a manufacturing line will be described as an example of a work line.
In recent years, a wide variety of products in small quantities are manufactured. Therefore, a manufacturing process to be performed is different for each product number (type of product). For example, as illustrated in
For example, as illustrated in
For example, although a manufacturing device a can perform manufacturing processes of products #1 and #3, the manufacturing device a cannot manufacture products #2 and #4. Although a manufacturing device b can perform a manufacturing process of the product #2, the manufacturing device b cannot manufacture the products #1, #3, and #4. A manufacturing device c can perform manufacturing processes of all the products #1 to #4.
If all the manufacturing devices, which can perform a necessary manufacturing process on the product that is transferred to the head of the standby region, are performing a manufacturing process of another product, the product waits at the head of the standby region. In a case where the another product moves from the manufacturing device, the product that is waiting at the head moves to the manufacturing device. Note that, in a case where there is a plurality of manufacturing devices to which products can be distributed from the standby region, a distribution destination is selected according to a predetermined rule. For example, a manufacturing device of which a process time is short, a manufacturing device of which a manufacturing cost is low, or the like is selected. Note that, since the products are sequentially distributed to each manufacturing device from the leading product in the standby region, if the leading product waits, the other products also wait.
Note that, if a general-purpose device that can perform manufacturing processes of a large number of types of products is used, an operation efficiency of each manufacturing device is improved, and a waiting time for each product is shortened. However, the general-purpose device tends to be expensive and take a longer manufacturing process time. The manufacturing process is lengthened, for example, because a setting change work (changeover work) or the like according to the type of the product is caused. On the other hand, a dedicated device that can perform manufacturing processes of a small number of types of products tends to be inexpensive and take a shorter manufacturing process time. However, the dedicated device cannot perform a manufacturing process for another type of product. In this way, since each of the general-purpose device and the dedicated device has advantages and disadvantages, the general-purpose devices and the dedicated devices are mixed in the manufacturing line.
If a standby time for each product increases, a time required to complete manufacturing of all the products (manufacturing lead time) increases. Alternatively, a manufacturing cost varies according to an installation cost of each manufacturing device, an operation time of each manufacturing device, or the like. Therefore, it is required for a plurality of KPIs to satisfy a predetermined condition. As the plurality of KPIs, the number of changeovers of each manufacturing device, a delivery date delay time of each product, the number of times of delays of each product, and the like are exemplified, in addition to the manufacturing lead time and the manufacturing cost.
Therefore, by performing a simulation while switching the input order of the product to a manufacturing line model by using a line simulator or the like, it is considered to optimize the input order so that the KPI satisfies the predetermined condition. The line simulator performs simple model calculation for dividing the manufacturing line model into fine cells and transferring a product to the cell in a case where one cell ahead becomes vacant.
By using the line simulator, the input order can be optimized so that an objective function that is determined according to the input order satisfies a predetermined condition, using the KPI such as the manufacturing lead time or the manufacturing cost as the objective function. The number of objective functions may be one or equal to or more than two. In a case where the number of objective functions is one, single-objective optimization is performed. In a case where the number of objective functions is equal to or more than two, multi-objective optimization is performed. From among the obtained results, an input plan that satisfies a desired condition is adopted. However, in a case where no result satisfies the desired condition of the KPI, for example, it is required to adjust the type and the number of manufacturing devices. At this time, it is required to increase or decrease the number of manufacturing devices.
Hereinafter, an information processing device, a specifying method, and a specifying program that can provide information used to increase or decrease the number of manufacturing devices in order to obtain a desired KPI will be described.
The central processing unit (CPU) 101 is a central processing unit. The CPU 101 includes one or more cores. The random access memory (RAM) 102 is a volatile memory that temporarily stores a program to be executed by the CPU 101, data to be processed by the CPU 101, or the like. The storage device 103 is a nonvolatile storage device. As the storage device 103, for example, a read only memory (ROM), a solid state drive (SSD) such as a flash memory, a hard disk to be driven by a hard disk drive, or the like may be used. The storage device 103 stores the specifying program according to the present embodiment. The input device 104 is an input device such as a mouse or a keyboard. The display device 105 is a display device such as a liquid crystal display. The display device 105 displays a result output by the result output unit 90. Each unit in
The manufacturing line model storage unit 10 stores the manufacturing line model as illustrated in
The manufacturing master storage unit 20 stores a manufacturing master in which a type of each product is associated with a manufacturing device that can perform a manufacturing process for each type of the product.
The input order storage unit 30 stores an initial input order as illustrated in
Hereinafter, optimization processing will be described with reference to the flowchart in
Next, the optimization execution unit 60 performs the optimization calculation using the information acquired by the acquisition unit 50 in step S1 (step S2). The optimization calculation here performs a line simulation according to the input order and acquires the manufacturing lead time and the manufacturing cost as objective functions, regarding the simulation result before all the products reach the goal from the start of the product input into the start. With an evolutionary algorithm (for example, genetic algorithm (GA)), the input order is optimized so that the designated objective function becomes excellent.
Next, for each manufacturing device, in a case where a product arrives at the head of the standby region, the count unit 70 counts the number N1 of products that have moved to another manufacturing device although a manufacturing process can be performed and is not performed on the product. Furthermore, for each manufacturing device, in a case where the product arrives at the head of the standby region, the count unit 70 counts the number N2 of products that is caused to wait since the manufacturing process is performed on another product although the manufacturing process can be performed on the product (step S3). Note that, here, waiting means to stop at the head of the standby region for a specified time (0≥0) or more.
For example, as illustrated in
In this case, in a case where a product arrives at the head of the standby region, the manufacturing device d is in a state where the product has moved to another manufacturing device although the manufacturing process is not performed and can be performed on the product. Therefore, as illustrated in
The product #3 has moved to the manufacturing device a so that the product #2 moves to the head of the standby region, as illustrated in
In this case, in a case where a product arrives at the head of the standby region, the manufacturing devices b and c cause the product to wait since the manufacturing processes are performed on the other products although the manufacturing process can be performed on the product. Therefore, as illustrated in
Next, the specification unit 80 determines whether or not a KPI satisfies a predetermined condition for a result of the line simulation in an optimum input order obtained by performing step S2 (step S4). In a case where it is determined as “Yes” in step S4, since the desired KPI is obtained, it is not necessary to add or delete a manufacturing device. Therefore, in a case where it is determined as “Yes” in step S4, the result output unit 90 displays the result in step S2, the result in step S3, or the like on the display device 105 (step S5). Thereafter, the execution of the flowchart ends.
In a case where it is determined as “No” in step S4, the specification unit 80 sets a threshold for each of the number N1 of products and the number N2 of products (step S6). Next, the specification unit 80 determines whether or not the number N1 of products is equal to or more than the threshold set in step S6, for each manufacturing device (step S7). In a case where there is a manufacturing device that is determined as “Yes” in step S7, the specification unit 80 deletes the manufacturing device from the manufacturing line model, as illustrated in
Next, the specification unit 80 determines whether or not the number N2 of products is equal to or more than the threshold set in step S6, for each manufacturing device (step S9). In a case where there is a manufacturing device that is determined as “Yes” in step S9, the specification unit 80 adds one more manufacturing device to the manufacturing line model, as illustrated in
Note that, in a case where it is determined as “No” in step S7, step S9 is performed without performing step S8. In a case where it is determined as “No” in step S9, the processing is performed again from step S1 without performing step S10.
According to the present embodiment, by counting the number N1 of products and the number N2 of products, a manufacturing device to be increased or decreased can be specified. For example, since the number of times when the product cannot be distributed can be counted by counting the number N1 of products, the number N1 of products can be assumed as an index for necessity of each manufacturing device. Furthermore, since the number of times when the product is caused to wait can be counted by counting the number N2 of products, the number N2 of products can be assumed as an index for necessity of each manufacturing device. By comparing the number N1 of products with the threshold, a manufacturing device to be deleted can be specified. Furthermore, by comparing the number N2 of products with the threshold, a manufacturing device to be added can be specified.
With reference to
It is assumed that the number N2 of products be obtained as illustrated in
As a type of the manufacturing device to be added, a manufacturing device of which the number N2 of products is larger than a threshold (for example, average value) is set as a candidate. In the example in
However, it is preferable to consider a cost to be increased by adding the manufacturing device.
In the example described above, the products #1 to #5 are examples of a plurality of objects including a plurality of types. The input order of the products into the manufacturing line is an example of a processing order for processing the plurality of objects including the plurality of types. The manufacturing device is an example of a work device.
The acquisition unit 50 is an example of an acquisition unit that acquires first information that indicates the processing order for processing the plurality of objects including the plurality of types and acquires second information that indicates a type that can be processed by each of the plurality of work devices, among the plurality of types. The count unit 70 is an example of a count unit that obtains a result of a simulation regarding processing of the plurality of work devices, based on a result of distributing each of the plurality of objects to any one of the plurality of work devices, based on the first information and the second information, counts the number N1 of objects that have moved to another work device although processing can be executed on an object to be distributed next, for each of the plurality of work devices, from the result of the simulation, and counts the number N2 of objects that are caused to wait since processing is executed on another object although the processing can be executed on the object to be distributed next, under conditions such that each of the plurality of objects waits if the work device that can execute the processing on the object is executing the processing on another object. The specification unit 80 is an example of a specification unit that specifies the work device to be increased or decreased with respect to the plurality of work devices, according to at least one of the number N1 of objects and the number N2 of objects.
While the embodiment of the present invention has been described above in detail, the present invention is not limited to such a specific embodiment, and various modifications and alterations may be made within the scope of the present invention described in the claims.
All examples and conditional language provided herein are intended for the pedagogical purposes of aiding the reader in understanding the invention and the concepts contributed by the inventor to further the art, and are not to be construed as limitations to such specifically recited examples and conditions, nor does the organization of such examples in the specification relate to a showing of the superiority and inferiority of the invention. Although one or more embodiments of the present invention have been described in detail, it should be understood that the various changes, substitutions, and alterations could be made hereto without departing from the spirit and scope of the invention.
This application is a continuation application of International Application PCT/JP2020/048768 filed on Dec. 25, 2020 and designated the U.S., the entire contents of which are incorporated herein by reference.
Number | Date | Country | |
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Parent | PCT/JP2020/048768 | Dec 2020 | US |
Child | 18307844 | US |