JPH05314145A - Lot organizing device - Google Patents

Abstract

PURPOSE:To obtain the lot organizing device which can execute automatically a lot organization corresponding to its production state/target. CONSTITUTION:The device is constituted of an order received data input circuit 2 for inputting the standard number of days P for manufacture required for until manufacture is completed and the time of delivery Q from a process for organizing a lot with regard to various orders O, an arithmetic circuit 3 for calculating a start scheduled day R, based on P and Q, a lot size input circuit 4 for inputting lot size S, a first lot organizing circuit 5 for executing a lot organization so that orders OL1 of the same size in orders in which R is within a prescribed period are collected and become S, a deciding circuit 6 for deciding whether an odd order DELTAS exists or not, a second lot organizing circuit 7 for combining orders OL2, OL3,... of different sizes, in the case it is decided that DELTAS exists, a third lot organizing circuit 8 for containing orders OM1, OM2,... in which R is outside of the prescribed period, a third lot organizing circuit 9 for varying the lot size, and a display device 10 for displaying the combination of the orders O by a second - a fourth lot organizing circuits.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a lot forming apparatus,
More specifically, the present invention relates to a lot organization device used in a manufacturing process for collectively manufacturing various orders up to a predetermined process in a predetermined lot size.

[0002]

2. Description of the Related Art Conventionally, at a production site where lot production is carried out, the lot size is fixed up to a certain manufacturing stage from the viewpoint of equipment restrictions and productivity when receiving various orders and producing them. Often does not change often. Then, in this lot size, so-called lot organization is often carried out in which the same order is put together until the lot production stage of the manufacturing process. In order to organize lots, it is optimal from the viewpoint of productivity and delivery date if they are grouped into lots so that orders of the same size and delivery date will match the lot size as much as possible, but it is impossible in reality. Therefore, until now,
Experts were loosening their constraints on product size, delivery time, and weight constraints in their heads while forming lots.

[0003]

In the conventional lot formation as described above, the lot formation depends on the expert's method, or the lot formation according to the production situation / target at that time is performed objectively. There was a problem that I could not. The present invention has been made in order to solve the problems in the prior art as described above, and an object of the present invention is to provide a lot formation device capable of automatically forming a lot according to a production situation and a target. That is.

[0004]

In order to achieve the above object, the present invention relates to the above-mentioned order in a lot forming apparatus used in a manufacturing process for collectively manufacturing various orders up to a predetermined process in a predetermined lot size. Order data input means for inputting the production standard number of days from the process of forming lots to completion of production and the delivery date, and the scheduled start date is calculated based on the production standard number of days and the delivery date input by the order data inputting means. The calculation means, the lot size input means for inputting the lot size, and the orders of the same size among the orders having the scheduled start date calculated by the calculation means within a predetermined period become the lot size. The first lot forming means for performing lot formation as described above, and the half formation that does not fall within the lot size by the lot formation by the first lot forming means And determination means for determining the presence or absence of order,
When the determination unit determines that there is an odd order, the second lot formation unit that combines the order of the same size and the order of different sizes to form the lot size, and the above-described determination Third lot organization means for performing lot organization so that the scheduled start date includes the order size including the order outside the predetermined period when it is determined by the means that there is an odd order, and the determination means. When it is determined that there is an odd order, the fourth lot forming means for forming a lot so that the lot size is changed by a predetermined value, and the second, third, and fourth lots. It is configured as a lot knitting apparatus characterized by comprising display means for displaying the contents of a combination of orders by the knitting means.

[0005]

According to the present invention, by inputting the standard production days and the delivery date from the process of forming the lot to the completion of the production for various orders by the order data input means, the production standard days and the delivery date are calculated by the calculating means. The scheduled start date is calculated based on and. Next, if the lot size is input by the lot size input means, the first lot organization means collects the orders of the same size among the orders whose scheduled start date is within a predetermined period, and sets the lot size as the above lot size. Lot formation is performed. The determination means determines whether there is an odd order that does not fit in the lot size in the lot organization. If the determination means determines that there is an odd order, the second lot organization means combines the order of the same size and the order of different sizes to perform the lot organization to obtain the lot size. The third lot organization means performs the lot organization so that the lot size includes the orders whose scheduled start date is outside the predetermined period, and the fourth lot organization means changes the lot size by a predetermined value. Lot formation is performed so that the changed lot size is obtained. Then, the display means displays the contents of the order combination by the second, third and fourth lot organization means.

[0006]

Embodiments of the present invention will be described below with reference to the accompanying drawings for the understanding of the present invention. The following embodiments are examples of embodying the present invention and are not of the nature to limit the technical scope of the present invention. Here, FIG. 1 is a block diagram showing a schematic configuration of a lot organization device 1 according to an embodiment of the present invention, FIG. 2 is a flowchart showing an operation procedure of the lot organization device 1, and FIG. 3 is a result of a case study (1). 4 is a list showing the results of the case study (2), FIG. 5 is a list showing the results of the case study (3), and FIG. 6 is a list showing the results of the case study (4). is there.

As shown in FIG. 1, the lot forming apparatus 1 according to the present embodiment receives an order data input circuit 2 for inputting the standard production days P from the process of forming lots for various orders O to the completion of production and the delivery date Q. (Corresponds to order data input means)
And a calculation circuit 3 (corresponding to a calculation means) for calculating the scheduled start date R based on the standard production days P and the delivery date Q input by the order data input circuit 2, and a lot size input circuit for inputting the lot size S 4 (corresponding to the lot size input means) and the lot size S is obtained by collecting the orders O _L1 of the same size among the orders having the scheduled start date R calculated by the calculation circuit 3 within the predetermined period. Lot size S by the first lot organization circuit 5 (corresponding to the first lot organization means) for performing
Judgment circuit 6 for judging whether there is an odd order ΔS that does not fit in
(Corresponding to the determination means) and the determination circuit 6 makes an odd order Δ
If it is determined that there is S, the second lot formation circuit 7 (the second lot formation circuit 7 that performs the lot formation so that the order O _{L1 of the} same size and the orders O _L2 , O _L3 , ... (Corresponding to lot lottery means 2) and the determination circuit 6
If it is determined that there is an odd order ΔS, the third lot formation circuit performs the lot formation so that the scheduled start date R includes the orders O _M1 , O _M2 , ... 8 (corresponding to the third lot organization means), and when the determination circuit 6 determines that there is an odd order ΔS, the lot size S is changed by a predetermined value to form a lot size S ′. A fourth lot formation circuit 9 (corresponding to a fourth lot formation means) and a display device 10 (corresponding to a display means) for displaying the contents of a combination of orders by the second, third and fourth lot formation circuits 7, 8 and 9. ) And is composed of.

Each of the circuits described above includes a software procedure for achieving those functions, and a hardware configuration that is temporarily configured in the computer to achieve those functions. The work procedure of the apparatus 1 will be described in the order of steps S1, S2, ... With reference to FIG. First, the standard production days P and the delivery date Q are input for each of the ordered orders O (S1), and the scheduled start date R is calculated based on these (S2). Next, the lot size S is input (S3), and the ordered size O _L1 having the scheduled start date R within L days is collected and set as the lot size S (S).
4). The lot size S is composed of an upper limit value S ₁ and a lower limit value S ₂ , and the lot formation completion determination formula is given by the following formula. S ₁ ≦ (n ₁ × OL ₁ ) ≦ S ₂ (n ₁ = 1,2, ...) (1) If the above formula (1) is satisfied, the lot formation is completed, but if it is not satisfied (ie, , If it is determined that there is an odd order ΔS (S5), the same size order O _L1 and different sizes O _L2 , O _L3 , ... Are combined to form the lot size S (S6). For example, if O _L2 and O _L3 are orders with different tolerances and different wall thicknesses, the lot formation completion determination formulas are given in the order of the following formulas (2) to (4) (that is, regulations are gradually weakened). .. Since these judgment formulas consist only of orders whose scheduled start date is within L days, they correspond to the case where the delivery date is prioritized. _{S 1 ≦ (n 1 × O} L1) ≦ S 2 ··· (2) ( combination of n ₂ × O _L1 and _{m 2 × O L2) S 1} ≦ ≦ S 2 ··· (3) S 1 ≦ (Combination of n ₃ × OL ₁ and m ₃ × OL ₃ ) ≦ S ₂ (4)

(N ₂ , n ₃ , m ₂ , m ₃ = 1, 2, ...) Next, includes orders O _M1 , O _M2 , and O _M3 whose scheduled start date R is outside L days (M days). Lot size S (S
7). For example, O _M1 , O _M2 , and O _M3 have the same size,
For orders with different tolerances and different wall thicknesses, the judgment formulas for lot formation completion are given in the order of the following formulas (5) to (8) (that is, regulations are gradually weakened). Since these judgment formulas preferentially combine orders of the same size, they correspond to the case where productivity is prioritized. S ₁ ≦ (n ₁ × O _L1 ) ≦ S ₂・ ・ ・ (5) S ₁ ≦ (combination of n _2a × and m _2a × O _M1 ) ≦ S ₂・ ・ ・ (6) S ₁ ≦ (n _3a × O combination of _L1 and m _3a × O _M2) combination of _{≦ S 2 ··· (7) S} 1 ≦ (n 4a × O L1 and _{m 4a × O M3) ≦ S} 2 ··· (8 ) (N _2a , n _3a , n _4a , m _2a , m _3a , m _4a = 1, 2, ...) Next, the lot size S is changed by a predetermined value. That is, S _{1
→ S 1 ', S 2 →} S 2' above as (2) to apply the judgment formula of ~ (8) (S8). This case corresponds to a case where an odd order ΔS is constantly generated due to changes in the manufacturing environment (order quantity, changes in factory equipment, etc.). Then, the combination content of each order O, which is the lot organization result of steps S6 to S8, is displayed (S9). The operator selects the combination used in the actual manufacturing process based on the displayed contents. In this way, lot organization according to the production status and goals can be performed automatically without relying on a specialist. As a result, the optimum lot can be obtained quickly and stably. In the above embodiment, different sizes are shown as different tolerances and different wall thicknesses. However, in actual use, there is no problem even if the outer diameter and the inner diameter are included within a range that does not cause a problem in the manufacturing process. .. In the above embodiment, the operating procedure is S1, S2, ... In order, but in actual use, the remaining steps S2, S4, S5 to S9 are executed after the steps S1 and S3 for each input are completed first. But there is no problem. In the above embodiment, steps S6 to S9 for forming a lot when there is an odd order ΔS.
Were sequentially executed, but in actual use, there is no problem even if the order is changed or executed simultaneously. It should be noted that in the above-mentioned embodiment, the judgment formula when there is an odd order ΔS is (2)-
Although it is given by the equation (8), in actual use, a more appropriate lot organization can be performed by executing a total combination by applying, for example, a determination equation having only different sizes.

Next, a case study in a pipe factory using the lot forming apparatus 1 will be described below. In this pipe factory, copper pipes are melted-extruded-rolled-drawn-
The products are manufactured in the order of finishing processes, and the final product size (outer diameter, inner diameter, wall thickness, tolerance) is processed in the drawing process (almost the same size up to the rolling process). Therefore, it is better to work with copper tubes of the same size as a lot in the drawing process.
Workability improves because the size change setup is reduced. However, because the order size is very large (straight tube type x outer diameter x inner diameter x tolerance = about 6 x 40 x 40 x 4) and the order weight is different, the orders are grouped in a given lot size. It's difficult. In the case study, the lot formation in this drawing process is targeted, and the orders O having the scheduled start date R as close as possible are summarized by the given lot size S.
Here, the scheduled start date R is the scheduled date planned weekly based on the value obtained by performing the above calculation on the host computer,
It is given on a weekly basis. The lot size S is given by 240 kg × N (N: integer) which is a work unit from melting to drawing.

First, lot formation is performed for orders (for L days) whose scheduled start date R is within a fixed period. For the order ΔS that is not a lot in this L days and is not a lot, lots are formed by using an order (M days worth) whose scheduled start date R is later. In this case study, in order to confirm the effect when M was changed, a total of 20 cases were carried out with the combination of L = 1, 3, 5, 7 M = 0, 1, 3, 5, 7. The lots are organized so as to satisfy the following constraint conditions, and if an odd order ΔS appears, the constraint conditions are relaxed in the order of (1) to (3) below. (1) Knitting with the same outer diameter, the same inner diameter, the same wall thickness, and the same tolerance (2) Same as above, knitting with different tolerances (3) Same as above, knitting with different wall thickness (expansion difference less than 1) Among these, (3) Conducted a case study. Lot size S ground clearance weight (product weight + yield) 1200k
g (5 pieces), and as the lot size S, two types of (1) 1100 kg to 1200 kg (2) 1000 kg to 1200 kg were adopted.

The results of knitting under the above conditions are shown in FIG.
~ Shown in FIG. The case study (1) in FIG. 3 is performed when the lot size S is set to 1100 kg to 1200 kg, and the case study (2) in FIG. 4 relaxes the condition to 1000 to 1200 kg for the order ΔS that was odd in (1). This is the result of lot formation. Case studies (1) and (2) are the results of organization with M = 0. The lot formation rate is 28.1% for one day, but it increases to 71.6% by increasing L to 7. Case study (3) in FIG. 5 is the result of varying M. Here, the number of organized lots (L) is the number of orders that have become lots among the orders for L days, and the number in () is the lot composition rate. Lot formation rate is, for example, L = 3
In case of M = 1, it is 61.7%, and by increasing M = 7, it increases to 75.8%. The case study (4) in FIG. 6 is a case in which the lot size S is further relaxed, and the lot organization rate increases to 81.0% when L = 3 and M = 7.

The number of organized lots (M) is the number of orders placed from M days for lot formation, and the number in [] is the ratio of the ordered orders to the number of orders for L days, that is, M days. It is the amount of excess capacity that occurs because of the transfer from the minute. As can be seen from the case study (3), when L is increased, the lot formation rate is increased and the overage rate is decreased. On the other hand, if L is kept constant and M is increased, the lot formation rate increases but the overage also increases. Furthermore, the smaller the L is, the larger the increase in over is. In other words, (L, M) = (3,3) and (5,5 with a lot composition rate of about 70%.
In the case of 1), although the composition rate is the same, 41% is exceeded when L = 3, while 7% is exceeded when L = 5. Therefore, it is understood that it is desirable to preferentially organize lots of orders for L days even if the orders for M days are included and orders for M days are included. The calculation time is about 1 when L and M = 7 in the maximum case study (2).
It was 0 minutes. The following is a summary of examples of lot organization conditions handled by the device 1. (1) Size constraint (1-1) Same size (1-2) Tolerance difference (1-3) Wall thickness difference (2) Delivery time constraint condition (2-1) L days only (2-2) (3) Weight constraint conditions (3-1) Lot size -10% to lot size (3-2) Lot size -20% to lot size Ideally (1-1 ) AND (2-1) AND (3-
Although it is desirable to perform lot organization in 1), it is not possible in practice. Therefore, the device 1 is provided with a mechanism for relaxing each condition.

However, how to combine these conditions to form a lot depends on the situation at that time. That is, any of the conditions is effective for forming lots of odd orders ΔS. However, under the condition (1), lots of different sizes are mixed, so that setup change time is required.
As for the condition (2), since the orders with different delivery dates are mixed, the delivery date as a whole is delayed. The condition (3) also has a disadvantage that the larger the lot size S, the larger the remaining portion. In other words, conditions (1) and (3) are conditions that the more the conditions are relaxed, the lower the productivity but the delivery time is achieved. Conversely, the conditions (2) are relaxed (the more L and M are increased, the more ), The condition is that the productivity will increase but the delivery date will be off. or,
The condition (3) is to change the lot size S to S'when an odd order ΔS is constantly generated due to a change in manufacturing environment (order quantity, change in factory equipment, etc.). The correspondence between these conditions and the respective judgment formulas in the second, third and fourth lot formation circuits 7, 8, 9 of the lot formation device 1 is as described above. Therefore, the operator can automatically obtain the lot organization result (combination contents of order O) according to the production situation / target, and can select the lot organization used in the manufacturing process based on this. For example, prepare a combination pattern (rule base) of typical constraint relaxation such as delivery priority, production priority, etc., select according to the situation at that time, or run multiple rule bases at night, If the optimum knitting result is obtained from the total combination calculation results, lot knitting according to the situation becomes possible. Then, it becomes clear what kind of combination (rule base) should be used in what kind of situation.

[0015]

Since the lot forming apparatus according to the present invention is configured as described above, it is possible to automatically perform the lot forming according to the production situation and the target without relying on an expert. As a result, the optimum lot can be obtained quickly and stably.

[Brief description of drawings]

FIG. 1 is a block diagram showing a schematic configuration of a lot organization device 1 according to an embodiment of the present invention.

FIG. 2 is a flowchart showing an operation procedure of the lot organization device 1.

FIG. 3 is a list showing the results of case study (1).

FIG. 4 is a list showing the results of Case Study (2).

FIG. 5 is a list showing the results of Case Study (3).

FIG. 6 is a list showing the results of Case Study (4).

[Explanation of symbols]

DESCRIPTION OF SYMBOLS 1 ... Lot organization device 2 ... Order data input circuit (corresponding to order data input means) 3 ... Calculation circuit (corresponding to calculation means) 4 ... Lot size input circuit (corresponding to lot size input means) 5 ... First lot composition circuit (Corresponding to first lot forming means) 6 ... Judgment circuit (corresponding to judging means) 7 ... Second lot forming circuit (corresponding to second lot forming means) 8 ... Third lot forming circuit (third lot forming circuit) 9 ... Fourth lot formation circuit (corresponding to fourth lot formation means) 10 ... Display device (corresponding to display means) O, O _L1 , O _L2 , O _M1 , O _M2 ... Order P ... Manufacturing standard Number of days Q… Delivery date R… Scheduled start date S, S ′… Lot size ΔS… Incomplete order

Claims (1)

[Claims] 1. A lot organization device used in a manufacturing process for collectively manufacturing various orders up to a predetermined process in a predetermined lot size, and a standard production number of days from the lot organization process to completion of production and delivery date for the order. Inputting order data inputting means for inputting, and a calculating means for calculating a planned start date based on the production standard days and the delivery date input by the receiving ordering data inputting means, and a lot size inputting means for inputting the lot size. A first lot forming means for collecting lots of orders of the same size among the orders having the scheduled start date calculated by the calculating means within a predetermined period to make the lot size the lot size; The determination means for determining whether there is an odd order that does not fall within the lot size by the lot formation by the first lot formation means, and the determination means. When it is determined that there is an odd order, the second lot organization means for combining the orders of the same size and the orders of different sizes to achieve the lot size, and the determination means If it is determined that there is a new order, the third lot forming means for forming a lot so that the scheduled start date includes the order outside the predetermined period, and the lot size, and the determination means When it is determined that there is an order, the fourth lot forming means for forming a lot so that the lot size is changed by a predetermined value, and the second, third, and fourth lot forming means A lot organization device comprising display means for displaying the contents of a combination of orders.