JPH0594447A - Production process scheduling table preparing device - Google Patents

Abstract

(57) [Summary] [Purpose] To provide a production process plan table preparation device in a molding line having a plurality of molding machines in consideration of the usable number of each mold in each working time zone. [Configuration] A second storage unit 14 that stores the types of molds and the number of each type as a number that can be used simultaneously, and each product is assigned to one of a plurality of molding machines according to the priority order of the production request. The process allocation processing unit 22 and the molds for molding the products allocated to each molding machine during a certain period of time are classified according to their types, and the number of the classified molds used is determined for a certain period of time. Of the actually used number for each type of die in the above-mentioned step, and the actually used number for each type of die thus obtained and for each type of die stored in the second storage section 14. Compare with the available number,
When the actually used number of arbitrary molds exceeds the usable number, the allocation change processing unit 25 for changing the allocation position of the product is provided.

Description

Detailed Description of the Invention

The present invention is applied to a molding line in which a plurality of products of different kinds are simultaneously produced in parallel by a plurality of molding machines equipped with a plurality of molds corresponding to those products. More specifically, when the actual number of molds used in a given working time exceeds the usable number, the actual number of molds used must not exceed the usable number. The present invention relates to a production process plan table preparation device for avoidance.

[0002]

2. Description of the Related Art Recently, due to the development of computers and the like due to the progress of semiconductor technology, the planning of the molding process in a plastic molding plant, which has conventionally relied on human experience,
It can be done by computer.

As an example of such a process planning device, there is, for example, an interactive schedule planning device disclosed in Japanese Patent Laid-Open No. 56-162713.

This interactive schedule planning device inputs the conditions of each given work (work amount, workable date, delivery date, etc.), and the work amount of each work is smoothed under the conditions. The schedule is created, and the schedule is corrected according to the instruction of the operator (operator) to create a final schedule, and the schedule is output.

[0005]

However, in the above-mentioned conventional apparatus, only the delivery date is set as the constraint condition, and the constraint condition generated in the manufacturing process (for example,
There is a problem in that it is not possible to create a detailed itinerary, since the supply capacity of the raw material supply device for each work time period, etc. is not considered at all.

Further, in the above-mentioned conventional apparatus, a schedule is created in a single molding line, and a production system in which a plurality of different kinds of products are simultaneously produced in parallel in a plurality of molding lines. There was also a problem that it could not be applied to.

The present invention has been made in view of the above circumstances, and its object is to improve not only the man-machine interface but also the constraints on the sales side such as the delivery date, as well as the constraints that occur in the manufacturing process, especially each work time. An object of the present invention is to provide a production process plan table preparation device in consideration of the usable number of the same molds for each band.

[0008]

In order to solve the above-mentioned problems, the production process plan table creating apparatus of the present invention has a plurality of products of different types and a plurality of molds corresponding to the products. In a molding line that is simultaneously produced in parallel by a plurality of mounted molding machines, a mold to be mounted on each of the plurality of molding machines installed on the molding line when creating a production process plan table for a unit period. Type and the number of each type as a number that can be used at the same time, and a process allocation process of allocating each product to one of the plurality of molding machines in accordance with a predetermined priority of the production request Parts and the molds that mold the products assigned to each molding machine within a certain period of time are classified according to their types, and the number of the classified molds used is the type of mold during that certain period of time. The actual used quantity calculation unit for obtaining the actual used quantity of the mold, the actual used quantity for each mold type obtained by the actual used quantity calculation unit, and the usable number for each mold type stored in the storage unit. When the actual number of used molds exceeds the usable number,
By changing the allocation position of the products produced by the dies that exceed it according to the priority of the production request, the allocation change that avoids the constraint so that the actual number of dies used does not exceed the usable number. And a processing unit.

[0009]

When the production process schedule table for a unit period such as one week or one month is created, the storage unit stores the types of molds installed in each of the plurality of molding machines installed in the molding line and The number of each type is stored in advance as the number that can be used simultaneously.

In the process allocation processing section, each product is sequentially allocated to one of a plurality of molding machines in accordance with a predetermined priority order of production requirements.

Here, as an example of determining the priority order of the production demands, various products having production demands are categorized based on the reference data categorized according to the similarity of the sales trend depending on the season, and the categorized product group This is done by determining the allocation order (1, 2, 3 ...). The allocation order (1, 2, 3 ...) is the order in which the production demand is high, and the product group to which the order (hereinafter referred to as priority) 1 is added is a product that is immediately required. group,
The product groups to which the priority level 2 is attached indicate the product groups that are required immediately after the production of the priority level 1 product group. Also, the priority n
The product group to which is attached indicates the product group that is required immediately after the production of the product group of priority n-1.

In the actually used quantity calculation unit, the process allocation processing unit performs a certain period as described above (for example, 8 hours from 9:00 am at the start of work to 5:00 pm at the end of work).
Molds for molding the products allocated to each molding machine during are classified by type, and the number of classified molds used is determined as the actual number of molds used for each type within a certain period. ..

For example, products A to D are allocated from the beginning of work to the end of work. The product A is molded by the mold 1 by the molding machine 1 and the molding machine 3, and the product B is molded by the mold 2. In the machine 2, the product C is formed by the mold 3 in the molding machine 3,
When the product D is molded by the molding machine 1 and the molding machine 2 respectively by the mold 1, the actual number of molds 1 used to mold the products A and D is 2 during this period, and the mold used to mold the product B. The actually used number of the mold 2 is one, and the actually used number of the mold 3 for molding the product C is one.

The allocation change processing unit compares the actual use number for each mold type obtained by the actual use number calculating unit with the usable number for each mold type stored in the storage unit. Then, based on the comparison result, for example, the actual number of used molds 4 (for example, two) is usable (for example, two).
1), the product E produced by the surpassing mold 4 in accordance with the priority of the production request.
By changing the allocation position of, the constraint is avoided so that the actual number of molds 4 used does not exceed the usable number.

For example, from a fixed period from the start of work to the end of work, from 5:00 p.m. at the end of work to 1: 0 am the next day.
The allocation position is changed in the next fixed period until 0. As a result, the actual number of molds 4 used during the fixed period from the start of work to the end of work becomes one, which is within the range of one, which is the usable number.

[0016]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS An embodiment of the present invention will be described below with reference to the drawings.

FIG. 1 is a block diagram showing an electrical configuration of a production process plan table preparation apparatus according to the present invention.

In FIG. 1, the production process plan table preparation apparatus of the present invention is roughly divided into a personal computer 10 for screen operation and a workstation 20 for automatically planning a production process.
0 and the workstation 20 are connected by a LAN (LOCAL Area Network) via a repeater (not shown).

That is, a unit period (for example, one week)
The output of a production plan data input unit (hereinafter, simply referred to as an input unit) 11 for inputting the production plan data for each hit is led to a main control unit 12 that controls the operation of each unit of the personal computer 10, and the main control is performed. The unit 12 and the first storage unit 13 and the second storage unit 14, which are external databases, are bidirectionally connected.

The first storage unit 13 stores calendar data in which items such as a date, a day of the week, a working time zone, and a number of a molding machine installed on each molding line are allocated for each unit period. ..

FIG. 2 shows an example of calendar data per unit period stored in the first storage unit 13. In the figure, in the case of the present embodiment, 1 shift refers to a work time zone from 9:00 am to 5:00 pm, and 2 shifts refers to work from 5:00 pm to 1:00 am the next day. It refers to the time zone, and the third shift is the working time zone from 1:00 am to 9:00 am on that day. In addition, this embodiment shows a case where three molding machines 1 to 3 are in operation.

The second storage unit 14 also stores data indicating the number of molds (not shown) that can be used simultaneously.

FIG. 3 shows an example of simultaneously usable number data of the respective molds stored in the second storage section 14.
In the present embodiment, five types of dies are used according to the product, and the usable number of dies is two for die 1, one for die 2, two for die 3, and one for die 4. The number of dies and the number of dies 5 are one.

Further, the output of the process correction section 15 for correcting the production process plan table created by this apparatus is led to the main control section 12 and provided with a CRT or the like for displaying the created production process plan table. The display unit 16 and the main control unit 12 are bidirectionally connected.

The main control unit 12 is adapted to modify the necessary parts of the production process plan table displayed on the display unit 16 based on the modification instruction from the process modification unit 15. Further, the output of the main control unit 12 which sends out the data showing the production process plan table displayed on the display unit 16 is led to the printer 17, so that the printer 17 prints out the production process plan table. It has become.

The main control unit 12 and the control unit 21 which is a constituent element of the workstation 20 are bidirectionally connected by a communication line 31.

The control unit 21 controls the operation of each unit of the workstation 20, and the control unit 21, the process allocation processing unit 22, the actual usage number calculation unit 23, and the allocation change processing unit 25 are respectively provided. It is a bidirectional connection. Further, the control unit 21 is a third database that is an external database.
The storage unit 26 and the fourth storage unit 27 are each bidirectionally connected.

In the third storage unit 26, the items of date, day of the week, and work time zone are allocated for each unit period, and the vertical axis of each work time zone region indicates the mold of each mold. Items indicating types are allocated, and the horizontal axis stores calendar data in which items such as a usage flag indicating whether or not a mold is used in each molding machine and the number of molds in use in each mold are allocated.

FIG. 4 shows an example of calendar data per unit period stored in the third storage section 26. In this embodiment, five types of molds 1 to 1 are provided in each work time zone area.
5 and 3 types of molding machines 1 to 3 are allocated.

The process allocation processing unit 22 allocates the production plan data per unit period input from the input unit 11 to the calendar data per unit period read from the first storage unit 13.

The actually used quantity calculation unit 23 uses a certain work time zone (for example, February 1) assigned by the process assignment processing unit 22.
The molds 1 to 5 for molding the products A to E allocated to the molding machines 1 to 3 during the first shift of the day are classified according to their types, and the classified molds 1 to 5 are classified. The used number is obtained as the actual used number for each type of molds 1 to 5 in the fixed period, and this is entered in the corresponding portion of the calendar data read from the third storage unit 26.

The allocation change processing unit 25 uses the actual use number for each mold 1 to 5 obtained by the actual use number calculating unit 23 and the usable number for each mold 1 to 5 stored in the second storage unit 14. Compare with. Then, based on the comparison result, when the actual number of molds used exceeds the number that can be used, the allocation position of any product is changed according to the priority order of the production request, so that the actual molds of any mold are changed. Constraint avoidance processing is performed so that the number of used pieces does not exceed the usable number.

Calendar data showing the production process plan table thus avoided (in other words, the calendar data shown in FIG. 2 to which the allocation process is performed in the process allocation processing unit 22 and the actual number of pieces used are entered. The calendar data shown in FIG. 4 is associated with the fourth storage unit 27.
It is supposed to be stored in.

The calendar data indicating the production process schedule is displayed on the display unit 28 via the control unit 21 and the display unit 1 via the communication line 31 and the main control unit 12.
6 is displayed on the screen.

The input unit 11 and the process correction unit 1 described above are used.
Reference numeral 5 is composed of a keyboard and a mouse provided with a numeric keypad and the like.

Next, the operation of the production process plan table preparation device having the above configuration will be described.

In creating the production process plan table, the operator (operator) first operates the input unit 11 to input the production plan data for a unit period (for example, one week).

The production plan data includes production request data such as which product, how many, and by what time, the manufacturing time for each product, and the forming machines 1 to 3 of each molding line. It is created based on basic data such as die setup change time. Further, the production requirement data is classified according to a certain standard, and the production allocation order of each classification is determined.

Here, to classify by a certain standard means, for example, classification based on the similarity of intended use of products (for example,
Products used in the kitchen, products used for sports, etc. ) Classification based on the similarity of sales trends according to seasons (for example, a product group that sells well in early spring, a product group that sells well in summer, etc.). Also, the production allocation order 1,
2, 3, ... means the order in which the production requirements are high, and order 1: I want it immediately.

Sequence 2: Want immediately after sequence 1.

Sequence 3: Want immediately after sequence 2.

[0042] It means that.

The production planning data that is classified and created according to such criteria is input to the process allocation processing unit 22 via the main control unit 12, the communication line 31, and the control unit 21. Here, the production order of the produced production plan data is assumed to be product A, product B, product C, product D, product E, .... here,
The products A and D are molded by the mold 1, the product B is molded by the mold 2, the product C is molded by the mold 3, and the product E is molded by the mold 4.

The process allocation processing unit 22 allocates the derived production plan data per unit period to the calendar data per unit period read from the first storage unit 13 which is an external database. Allocation to calendar data is performed for each work time zone (that is, for each shift).

Further, in the actually used quantity calculating unit 23, every time one process (product) is allocated in the process allocation processing unit 22, the used quantity of the products allocated to the respective molding machines 1 to 3 is obtained for each mold. At the same time, the obtained number of dies used for each die is obtained as the actual number of dies used for each die during the working time period, and this is entered in the corresponding portion of the calendar data read from the third storage unit 26. Is going.

Further, in the allocation change processing unit 25, every time one process (product) is allocated in the process allocation processing unit 22, the actual used number entered in the in-use number of the calendar data and the second storage unit 14 are stored. The number of molds stored is compared with the usable number, and the constraint avoidance process is performed when necessary.

Hereinafter, the operation of the process allocation processing unit 22, the operation of the actually used number calculation unit 23, and the operation of the allocation change processing unit 25 will be sequentially referred to the allocation state to the calendar data on a certain day shown in FIGS. 5 to 10. And explain. However, the calendar data shown in FIGS. 5 to 10 shows one shift on February 1.

That is, the process allocation processing unit 22 allocates the first product A in the production plan data to the molding machine 1.

At this time, in the actually used quantity calculating unit 23, since the mold of the product A is the mold 1, the mold 1 of the molding machine 1 is
Whether the mold 1 is already in use by the molding machine 1 is checked by checking the use flag of. In this case, since it is not in use, the use flag of the mold 1 in the molding machine 1 is set to "in use", and the number of molds 1 in use is increased by 1. In this case, the number in use is 1.

In the allocation change processing unit 25, the number in use entered in the in-use number column of the calendar data shown in FIG. 4 (in this case, 1, 0, 0, 0, 0 from the top of the chart)
And the usable number of each mold stored in the second storage unit 14 are compared. In this case, the usable number of each mold stored in the second storage unit 14 is two molds 1 and two molds 2.
1 mold, 2 molds 3, 2 molds 4, 1 mold 5, and the actual number of molds used for each mold entered in the number-in-use column indicated by reference numeral 44 is In this case, the constraint avoidance process is not performed because the number of usable molds is lower than that of the corresponding molds.

Next, the process allocation processing unit 22 allocates the product B next to the production plan data to the molding machine 2.

At this time, in the actually used quantity calculating unit 23, since the mold of the product B is the mold 2, the mold 2 of the molding machine 2 is
It is checked whether the mold 2 is already being used by the molding machine 2 by checking the usage flag of. In this case, since it is not in use, the use flag of the mold 2 in the molding machine 2 is set to "in use", and the number of molds 2 in use is increased by 1. In this case, the number in use is 1.

In the allocation change processing section 25, the number in use entered in the number in use column of the calendar data shown in FIG. 4 (in this case, 1, 1, 0, 0, 0 from the top of the chart)
And the usable number of each mold stored in the second storage unit 14 are compared. In this case, since the actual number of pieces used for each die entered in the in-use number column indicated by reference numeral 44 is less than the usable number of corresponding die, in this case, the constraint avoidance process is not performed. Not performed.

Next, the process allocation processing unit 22 allocates the product C next to the production plan data to the molding machine 3.

At this time, in the actually used quantity calculating unit 23, since the mold of the product C is the mold 3, the mold 3 of the molding machine 3 is used.
Whether the mold 3 is already in use by the molding machine 3 is checked by checking the use flag of. In this case, since it is not in use, the use flag of the mold 3 in the molding machine 3 is set to "in use", and the number of molds 3 in use is increased by 1. In this case, the number in use is 1. Further, FIG. 5 shows the calendar data when the products A to C are allocated.

The allocation change processing unit 25 compares the in-use number entered in the in-use number column indicated by reference numeral 44 with the usable number for each die stored in the second storage unit 14. In this case, since the actual number of molds used for each mold entered in the in-use number column indicated by reference numeral 44 is lower than the usable number of corresponding molds, in this case, the constraint avoidance process is not performed. Not performed.

Next, the process allocation processing unit 22 allocates the product A of the production plan data to the molding machine 3 this time.

At this time, in the actually used quantity calculating unit 23, since the mold of the product A is the mold 1, the mold 1 of the molding machine 3 is
Whether the mold 1 is already in use by the molding machine 3 is checked by checking the usage flag of. In this case, since it is not in use, the use flag of the mold 1 in the molding machine 3 is set to "in use", and the number of molds 1 in use is increased by 1. in this case,
The number of molds 1 in use is 2. The calendar data at this time is shown in FIG.

In the allocation change processing section 25, the number of in-use items entered in the in-use number column indicated by reference numeral 44 (in this case,
(2, 1, 1, 0, 0 from the top in the figure) is compared with the usable number of each mold stored in the second storage section 14. In this case, since the actual number of molds used for each mold entered in the in-use number column indicated by reference numeral 44 is lower than the usable number of corresponding molds, in this case, the constraint avoidance process is not performed. Not performed.

Next, the process allocation processing section 22 allocates the product D next to the production plan data to the molding machine 1.

At this time, in the actually used quantity calculating unit 23, since the mold of the product D is the mold 1, the mold 1 of the molding machine 1 is
Whether the mold 1 is already in use by the molding machine 1 is checked by checking the use flag of. In this case, it can be seen that the product D is in use and the product D satisfies the usable number of molds 1. Therefore, in this case, the product avoidance process is not performed, and the product D is assigned to the molding machine 1. The calendar data at this time is shown in FIG.

Up to the above, if product avoidance processing is unnecessary,
In other words, this is a product allocation process when the number of molds constraint is satisfied.

Next, an example of the case where the product avoidance process is necessary because the constraint on the number of molds is not satisfied will be described.

That is, the process allocation processing section 22 allocates the products D up to the product D as shown in FIG. 7, and then allocates the products D to the molding machine 2 again.

At this time, in the actually used quantity calculating unit 23, since the mold of the product D is the mold 1, the mold 1 of the molding machine 2 is
It is checked whether the mold 1 is already being used by the molding machine 2 by checking the usage flag of. In this case, since it is not in use, the use flag of the mold 1 in the molding machine 2 is set to "in use", and the number of molds 1 in use is increased by 1. in this case,
The number of molds 1 in use becomes three. The calendar data at this time is shown in FIG.

In the allocation change processing unit 25, the number in use (filled in this case) entered in the in-use number column indicated by reference numeral 44 (in this case,
(3, 1, 1, 0, 0 from the top in the figure) and the usable number of each mold stored in the second storage unit 14 are compared. In this case, among the actually used number of each die entered in the in-use number column indicated by reference numeral 44, the actually used number of the die 1 is 3
In this case, any one of the following three patterns of constraint avoidance processing is selected and performed.

That is, in the first pattern 1 of the constraint avoidance processing, as shown in FIG. 9, the production amount of the product B allocated to the molding machine 2 is increased from the broken line to the solid line. As a result, the product D is assigned to the first of the two shifts of the molding machine 2,
The actual number of molds 1 that can be directly used is 2, which is the same as the number that can be used. In this case, if the increase is subtracted from the unallocated products B of the same type, the production of the entire product B will not increase.

The second pattern 2 of the constraint avoidance process
As shown in FIG. 10, the allocation of the product D to the molding machine 2 is stopped and the next product E is allocated to the molding machine 2.

At this time, in the actually used quantity calculating unit 23, since the mold of the product E is the mold 4, the mold 4 of the molding machine 3 is
Whether the mold 4 is already being used by the molding machine 2 is checked by checking the use flag of. In this case, since it is not in use, the use flag of the mold 4 in the molding machine 2 is set to "in use", and the number of molds 4 in use is increased by 1. in this case,
The number of molds 4 in use becomes 1.

In the allocation change processing section 25, the number in use (filled in this case) entered in the in-use number column indicated by reference numeral 44 (in this case,
(2, 1, 1, 1, 0 from the top in the figure) is compared with the usable number of each mold stored in the second storage unit 14. In this case, since the actual number of molds used for each mold entered in the in-use number column indicated by reference numeral 44 is lower than the usable number of corresponding molds, in this case, the constraint avoidance process is not performed. I will not do it.

The third pattern 3 of the constraint avoidance process
In the above, pattern 1 and pattern 2 are given priorities in advance, and when constraint avoidance is required, constraint avoidance processing is performed in accordance with the priority.

For example, in the case of the priorities of pattern 2 and pattern 1, even if the product to be molded by the molding machine 2 according to the pattern 2 is changed from the product D to the product E, the actual product of an arbitrary mold is obtained. If the number used exceeds the usable number, the operation of pattern 1 may be canceled at that point to return to the original state, and thereafter the operation of pattern 1 may be performed.

The production process plan table for all molding lines is created by sequentially allocating the production plan data per unit period to the calendar data while performing such constraint avoidance processing as necessary. Then, the production process plan table for which allocation of all processes has been completed is stored in the fourth storage unit 27 and displayed on the display unit 16 via the control unit 21 and the control unit 12.

After that, when the operator judges that it is necessary while looking at the production process plan table displayed on the display unit 16, the process correction unit 15 is operated to insert, delete,
Make corrections such as movement.

The final production process plan table corrected in this way is printed out by the printer 17 and given to each manufacturing worker as a manufacturing work instruction.

In the above embodiment, the fixed period is explained as a direct unit, but by making it short (for example, every 4 hours, every 2 hours, etc.), for example, allocation is possible, but allocation is possible. The problem that the avoidance process is performed so as not to exist is solved, and it becomes possible to create a more detailed and efficient production process plan table.

[0077]

The production process plan table preparation apparatus of the present invention, when preparing the process plan table per unit period, if the actual number of used molds exceeds the usable number, the production request By changing the allocation position of any product according to the priority order, it is configured to avoid restrictions so that the actual number of molds used does not exceed the usable number.
It is possible to realize a production process plan table preparation apparatus applicable to almost all cases for a production system of a molding line that uses a plurality of molding machines at the same time. In addition, this production process plan table preparation device can significantly reduce the time required for process planning per unit period, and can produce fine process plan data with good production efficiency. ..

[Brief description of drawings]

FIG. 1 is a block diagram showing an electrical configuration of a production process plan table preparation device of the present invention.

FIG. 2 is a diagram showing an example of calendar data stored in a first storage unit.

FIG. 3 is a diagram showing an example of usable usable number data stored in a second storage unit.

FIG. 4 is a diagram showing an example of calendar data per unit period stored in a third storage section 26.

FIG. 5 is a diagram showing an example of a state of allocation to calendar data on a certain day.

FIG. 6 is a diagram showing an example of a state of allocation to calendar data on a certain day.

FIG. 7 is a diagram showing an example of a state of allocation to calendar data on a certain day.

FIG. 8 is a diagram showing an example of a state of allocation to calendar data on a certain day.

FIG. 9 is a diagram showing an example of a state of allocation to calendar data on a certain day.

FIG. 10 is a diagram showing an example of a state of allocation to calendar data on a certain day.

[Explanation of symbols]

 10 personal computer 11 input unit 12 main control unit 13 first storage unit 15 process correction unit 14 second storage unit 16 display unit 17 printer 20 workstation 21 control unit 22 process allocation processing unit 23 actual usage number calculation unit 25 allocation Change processing unit (including comparison unit) 26 Third storage unit 27 Fourth storage unit 28 Display unit

Claims (1)

[Claims] 1. A plurality of products of different types,
In a molding line that is simultaneously produced in parallel by a plurality of molding machines equipped with a plurality of molds corresponding to those products, it was installed on the molding line when the production process plan table for a unit period was created. A storage unit that stores the types of molds mounted on each of a plurality of molding machines and the number of each type as a number that can be used at the same time, and a plurality of each product according to the priority order of a predetermined production request. The process allocation unit that allocates to one of the molding machines on the stand and the molds that mold the products allocated to each molding machine within a certain period of time are classified according to their types, and the classified metal The actual used quantity calculation unit that obtains the number of used molds as the actual used quantity for each type of mold in the fixed period, and the actual used quantity for each mold type obtained by this actual used quantity calculation unit Compared with the usable number of each type of mold stored in the section, if the actual number of usable molds exceeds the usable number, according to the priority of the production request, the exceeded number of molds Production characterized by having an allocation change processing unit that avoids restrictions by changing the allocation position of the product produced by the mold so that the actual number of molds used does not exceed the usable number Process schedule table creation device.