1. Field of the Invention
The present invention relates to a production schedule creating method that creates a production schedule with high accuracy in a short time for a planning operation of a production schedule of a make-to-order product such as an industrial machine, a motor, and an elevator. The present invention also relates to an apparatus for this method.
2. Description of the Related Art
In the case of make-to-order products such as an industrial machine, a motor, and an elevator, it is important to create a production schedule so as to produce and deliver the product by due date requested by a client. Conventionally, a technique for creating a production schedule utilizes a production line simulator to evaluate production capacity of each production line. Then, the technique has been creating a production schedule to meet due date of the client. For example, Japanese Patent Application Laid-Open Publication No. 2003-288476 employs a production line simulator for a semiconductor product as a target to evaluate production capacity of a production line, thus creating a production schedule and a production instruction.
However, in the case where a difference occurs between the production schedule and the operation record due to variation in operation time, arrival delay of a component, and a similar reason, this may cause delivery delay. In this case, a process sequence of operations in progress for each process is changed to meet due date. This is called dispatching. The dispatching method includes a First-In First-Out (FIFO) method that processes an operation on an earlier arrival time, a Shortest Process-ing Time (SPT) method that processes an operation with shorter processing time, an Earliest Due Date (EDD) method that processes an operation closer to the due date, and a similar method. For example, Japanese Patent Application Laid-Open Publication No. 2004-295679 employs a critical ratio method that sequentially processes an operation with a smaller critical ratio, which is calculated with a ratio of time remaining until due date to remaining processing time until completion of the final process as a production instruction method, thus eliminating delivery delay.
However, the make-to-order products such as an industrial machine, a motor, an elevator, and an escalator have different product specifications depending on an order of the client. It is rare to repeatedly produce the same component. Some products with the same name may each have a different design specification, and have a different operation time and a different process to be operated. Accordingly, in order to meet due date, it is preferred to acquire a daily operation record for each process and change the production sequence to instruct an operation.
In contrast, in the case where the production line simulator in Japanese Patent Application Laid-Open Publication No. 2003-288476 is used to change the production sequence, addition of a resource such as overtime hours allows eliminating progress delay. However, this method plans the production schedule of all processes again after changing the production sequence. This takes a long calculation time and is not practical.
The dispatching method in Japanese Patent Application Laid-Open Publication No. 2004-295679 determines a process sequence operation in progress of the target process. Its calculation time is short, which is an advantage. However, production capacity after this process is not considered. Thus, a problem arises in that delivery delay may occur when the determined process sequence is performed. Additionally, the dispatching method has a different aim such as an aim focusing on due date and an aim focusing on throughput depending on a type of the selected dispatching method. This changes influence on the production line. Accordingly, it is difficult for operator of the production schedule to select an appropriate dispatching method correspond to production status.
The present invention has been made to solve the above-described problems, and it is an object of the present invention to provide a production schedule creating method that acquires daily operation record for each process and change the production sequence to instruct an operation in order to meet due date. Another object of the present invention is to provide an apparatus for this method.
In order to achieve the aforementioned objects, a production schedule creating apparatus according to the present invention plans a production schedule of a production process. The production process includes a plurality of operation processes. The production schedule creating apparatus includes a delivery delay detection simulation unit, a dispatching rule information storage unit, a production schedule creating unit, a production schedule evaluating unit, and a dispatching instruction unit. The delivery delay detection simulation unit is configured to estimate a future status of delivery delay using a current status of the production process. The dispatching rule information storage unit is configured to register a plurality of dispatching rules. The production schedule creating unit is configured to use the plurality of dispatching rules registered in the dispatching rule information storage unit, so as to perform a production simulation of the production process where the future delivery delay is estimated by the delivery delay detection simulation unit. The production schedule evaluating unit is configured to select a most appropriate dispatching method with respect to a threshold value of a production management index such as an on-time delivery rate and total overtime hours based on a result of the production simulation performed by the production schedule creating unit. The dispatching instruction unit is configured to provide a production instruction to the production process using the dispatching method. The dispatching method is selected by the production schedule evaluating unit.
Further, in order to achieve the aforementioned objects, a production schedule creating method according to the present invention plans a production schedule of a production process. The production process includes a plurality of operation processes. The production schedule creating method estimates a future status of delivery delay using a current status of the production process, performs a production simulation using a plurality of dispatching rules on a production process where the future delivery delay is estimated by this estimation, selects a most appropriate dispatching method with respect to a threshold value of a production management index such as an on-time delivery rate and total overtime hours based on a result of the performed production simulation, and provides a production instruction to the production process using the selected dispatching method.
The present invention minimizes operation time to be added in the event that delivery delay of the make-to-order product such as an industrial machine, a motor, an elevator, and an escalator occurs. This allows accurately creating a production schedule in a short time to meet due date.
A description will be given of one embodiment according to the present invention below.
The order processing apparatus 120 receives an order from a client, and controls order information such as product specification, client information, and due date. The order processing apparatus 120 sends the received order information to the production schedule creating apparatus 110 at a predetermined timing or corresponding to a request from the production schedule creating apparatus 110. One production line management apparatus 130 may control operation record information of all production lines. Multiple production line management apparatuses 130 may be installed corresponding to the number of production lines. Then, the production line management apparatus 130 sends the operation record information to the production schedule creating apparatus 110 at a predetermined timing or corresponding to a request from the production schedule creating apparatus 110. The production information management apparatus 140 controls process route information such as production capacity for each process, a process route for each product, and an available facility for processing. The production information management apparatus 140 sends the production capacity and the process route information to the process design and production schedule creating apparatus 110 at a predetermined timing or corresponding to a request from the production schedule creating apparatus 110.
The output unit 113 outputs information. The communication unit 114 sends and receives information through the network 190. The storage unit 115 includes an order information storage unit 1151, a work-in-progress information storage unit 1152, an operation record information storage unit 1153, a process route information storage unit 1154, a facility operation information storage unit 1155, and a dispatching rule information storage unit 1156.
The production schedule creating apparatus 110 in
Next, a description will be given of a processing program executed by the production schedule creating apparatus 110 according to the present invention by referring to
First, the information acquiring unit 1111 of the control unit 111 reads scheduling target product, facility information, production capacity information, process route information, and operating time calendar information as input data from the storage unit 115 (S10).
Subsequently, the delivery delay detection simulation unit 1112 of the control unit 111 performs a production simulation from present to future based on the order information stored in the order information storage unit 1151, work-in-progress information stored in the work-in-progress information storage unit 1152, and an operation record stored in the operation record information storage unit 1153. Then, the delivery delay detection simulation unit 1112 estimates whether production meets due date for each product (S20). As a result of the estimation (S25), the process simply terminates in the case where delivery delay does not occur. In the case where delivery delay occurs, the process proceeds to Step S30.
Step S20 will be described by referring to
Step S30 will be described by referring to
Subsequently, the production schedule creating unit 1114 of the control unit 111 outputs a simulation result, which is performed at Step S30, from the output unit 113 (S40).
The output result of Step S40 will be described by referring to
Subsequently, the production schedule evaluating unit 1115 of the control unit 111 selects the most appropriate dispatching method for the output result at Step S40 using threshold values such as an on-time delivery rate, which is preliminarily set, and total overtime hours (S50).
Subsequently, the dispatching instruction unit 1116 of the control unit 111 sends the dispatching method, which is selected at Step S50, to the production line management apparatus 130 through the network 190, and changes dispatching methods of all apparatuses into the dispatching method selected this time (S60).
First, the delivery delay detection simulation unit 1112 of the control unit 111 acquires information of a target product and a target process stored in the storage unit 115 (S201).
Subsequently, the delivery delay detection simulation unit 1112 determines an order of product process based on the dispatching rule (S202).
Subsequently, the delivery delay detection simulation unit 1112 repeats processes of Steps S204 to S209 for the number of all products in order to plan schedules of all products stored in the order information storage unit 1151 (S203).
Subsequently, the delivery delay detection simulation unit 1112 repeats processes of Steps S205 to S207 for the number of all processes in order to plan a schedule of the target product (S204).
Subsequently, the delivery delay detection simulation unit 1112 confirms whether an available facility exists on date and time assigned to the target product and the target process (S205).
Subsequently, the delivery delay detection simulation unit 1112 makes the process to proceed to Step S206 in the case where an available facility does not exist. The delivery delay detection simulation unit 1112 then increments the assigned date and time by unit time (S206). The process proceeds to Step S205. In the case where an available facility exists, the delivery delay detection simulation unit 1112 makes the process to proceed to Step S207. The delivery delay detection simulation unit 1112 then assigns the target product to the available facility, and increments the assigned date and time by the operating time (S207).
The delivery delay detection simulation unit 1112 repeats the processes of Steps S205 to S207 for the number of all processes in order to plan a schedule of the target product (S208). Finally, the delivery delay detection simulation unit 1112 checks whether delay of the target product with respect to due date occurs (S209).
The delivery delay detection simulation unit 1112 repeats the processes of Steps S204 to S209 for the number of all processes in order to plan schedules of all target products (S210).
Clicking a determination button 1207 in a state where these conditions are selected and the respective input items are input allows performing the process at Step S20. As a result, a time change of the on-time delivery rate is displayed on the graph 1210. On the graph 1210, a thick line 1213 is displayed corresponding to the set threshold value.
First, the production simulation unit 1113 acquires information stored in the storage unit 115 regarding the target product that is late for delivery at Step S20 (S301).
Subsequently, the production simulation unit 1113 repeats processes of Steps S303 to S309 based on the number of the dispatching rules stored in the dispatching rule information storage unit 1156 (S302).
Subsequently, the production simulation unit 1113 repeats processes of Steps S304 to S308 for the number of all target products that are late for delivery at Step S20 (S303).
Subsequently, the production simulation unit 1113 repeats processes of Steps S305 to S307 for the number of all processes in order to plan a schedule of the target product (S304).
Subsequently, the production simulation unit 1113 increments the operating time of the target product and the target process by unit time (S305).
Subsequently, the production simulation unit 1113 performs a production simulation (S306). At Step S306, for example, a process similar to the process that detects the delivery delay at Step S20 in
Subsequently, the production simulation unit 1113 confirms the elimination of the delivery delay. In the case where the delivery delay is eliminated, the process proceeds to Step S309. In the case where the delivery delay is not eliminated, the process proceeds to Step S308 (S307).
The production simulation unit 1113 repeats the processes of Steps S305 to S307 for the number of all processes in order to plan a schedule of the target product (S308).
The production simulation unit 1113 repeats the processes of Steps S304 to S308 for the number of all processes in order to plan schedules of all target products (S309). The production simulation unit 1113 repeats the processes of Steps S303 to S309 with all the dispatching rules (S310).
Finally, an output of the simulation result of Step S40 will be described.
Assume that in the output screen 1000 of
On the output screen 1000 in
On the output screen 1000 in
Number | Date | Country | Kind |
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2010-201886 | Sep 2010 | JP | national |
Filing Document | Filing Date | Country | Kind | 371c Date |
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PCT/JP2011/064015 | 6/20/2011 | WO | 00 | 1/22/2013 |