JPH07192057A - Production equipment verification simulator - Google Patents

Abstract

(57) [Summary] [Purpose] In a production process with multiple steps, increase resources from the present to the future and enable verification by accurate simulation of the steps to improve production efficiency. [Structure] From the planned sales plan data and the past shipment record data from the past shipment record database unit 24, the product number-specific shipment prediction unit 21 obtains product number-specific / predetermined interval-specific shipment prediction data for which product number-specific / monthly shipment is predicted . The key process simulation unit 22 is configured to match the key process capability, which is a process in which the capability enhancement cannot be changed, from the product number-specific / predetermined interval-based shipment forecast data and the process capability data from the key process capability database unit 25. The production plan quantity data for each predetermined interval / product in which the load of the process is adjusted is obtained in. Further, from the production plan quantity data and the other process capability data from the other process capability database section 26, the capacity balance calculation section 23 obtains data in which the consistency of the process load is calculated.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a production facility verification simulator for verifying the process of increasing the resources of facilities and humans and the load thereof in the production process of a housing unit or member having a plurality of processes, from present to future. Regarding

[0002]

2. Description of the Related Art Conventionally, in a standardized house in which various types of housing units are assembled at a construction site, various plastic building materials used for this housing unit are produced in a factory. The simulation verifies the capability and the matching state of the load process, which is the machining of the work in this production facility. This verification is an individual simulation for each step in the production process (see, for example, Japanese Patent Application Laid-Open No. 4-19050).

[0003]

As described above, in the above-mentioned conventional example, verification is performed by individual simulation for each step in the production process. In this case, the basis for calculating the load of each process is insufficient, and further, the grasp of the relation between the processes is inaccurate. For this reason, the production capacity will be increased more than necessary, or the production capacity will be increased at an incorrect time, making it impossible to verify the present and future facilities and human resources in the production process by an accurate simulation. There is a drawback that.

The present invention has been made in view of the above circumstances, and it is possible to verify the present process and future facility of a production process having a plurality of steps, the increase of human resources, and the process of the load by an accurate simulation. Is possible,
The purpose is to provide a production facility verification simulator that can contribute to the improvement of production efficiency.

[0005]

In order to solve the above-mentioned problems, is the invention according to claim 1 capable of production using the current equipment resources from the present to the subsequent in a production process having a plurality of steps? In the production equipment verification simulator for verifying whether or not the product sales are based on the planned sales plan data and the previously known past shipment result data, classified by product number / time, day, month,
Product number-specific shipment prediction means for obtaining product number-specific / predetermined interval-specific shipment prediction data that predicts shipment by any predetermined interval of the year,
Process to match the key process capability, which is a process in which capacity enhancement cannot be changed, from product number-specific / predetermined interval-specific shipment prediction data obtained by product number-specific shipment prediction means, and previously known process capability data Process based on the key process simulation means for obtaining the production plan quantity data for each predetermined interval / product by adjusting the load of the process, the production plan quantity data obtained by the key process simulation means, and the other process capability data known in advance. It is characterized in that it is provided with a capability matching calculation means for obtaining data in which the matching of the load of is calculated.

The invention according to claim 2 is the production facility verification simulator according to claim 1, which comprises a process load adjustment for matching with the key process capability in the key process simulation means, and a capability matching calculation means. The calculation of the consistency of the process load is performed, and a pile indicating the production time of the load process at predetermined intervals is performed, and if the production time of the load process exceeds the production capacity by this pile, the production is performed at the previous predetermined interval. The feature is that the loading process is adjusted forward.

[0007]

According to the production facility verification simulator of claim 1 or 2, the sales plan data and the past shipment result data which are known in advance are used to determine the product number and the predetermined interval of any one of time, day, month and year. Shipment forecast data by product number / predetermined interval for which shipment is predicted is obtained. Furthermore, the load process is adjusted so as to match with the key process capability, which is a process in which the capability enhancement cannot be changed, based on the shipment forecast data by product number / predetermined interval and the process capability data that is known in advance. The production plan quantity data by predetermined interval / product is obtained. Further, data in which the consistency of the process load is calculated is obtained from the production plan quantity data and the previously known other process capability data.

In this case, the adjustment of the process load and the calculation of the consistency of the process load are carried out by accumulating the production time of the load process, and when the production time of the load process exceeds the production capacity by this accumulation, the previous predetermined interval We are adjusting the load process to carry out production ahead of schedule. Therefore, the equipment from the present to the future in the production process having multiple steps, the enhancement of human resources,
Also, it is possible to verify the process through accurate simulation.

[0009]

Embodiments 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 facility verification simulator which is an embodiment of the present invention. In FIG. 1, this example shows a computer main body 1 as an engineering workstation (EWS).
And an input / output terminal 2 connected to the computer 1 body
It is roughly composed of and. The configurations of the computer body 1 and the input / output terminal 2 are similar to those of a conventional computer system.

The computer main body 1 has a central processing unit (CPU) 3, a ROM 4 storing a processing program to be executed by the CPU 3, a RAM 5 in which a work area of the CPU 3 is set, and a floppy disk drive (FDD).
6 and an I / O circuit 7. The input / output terminal 2 includes an input device 13 such as a keyboard and a mouse, an output device 14 such as a printer, and a display device 15 including a CRT and the like.
And an external storage device 17 such as a hard disk drive (HDD).

FIG. 2 is a functional block diagram when the present invention is executed with the configuration of FIG. In FIG. 2, this example is provided with a product number-specific shipment prediction unit 21 as the computer main body 1, a key process simulation unit 22, and a capacity balance calculation unit 23.

Further, the past shipment record database unit 24 as the input / output terminal 2, the key process capability database unit 25, the other process capability database unit 26, the database input unit 27, and various input processes such as medium-term sales An input unit 31 for inputting plan data and sending the data to the computer main body 1 is provided. Further, the result display unit 32 for displaying the calculation result from the computer main body 1 on the screen, the result print output unit 33 for outputting the calculation result from the computer main body 1 as a hard copy, and the calculation result from the computer main body 1 temporarily or The storage unit 34 stores the data over a long period of time.

Next, the processing in this embodiment will be described. Here, we verify the present and future equipment, human resource enhancement, and the process in a production process having multiple steps by simulation. Specifically, for example, the description will be made by applying it to a production process of a plastic molded product using an injection molding machine or an extrusion molding machine. Hereinafter, a production process of a plastic molded product by an injection molding machine will be described with the following steps (1), (2) and (3). In this case, products handled in the production process are classified into a plurality of product groups. further,
As the injection molding machine, a plurality of injection molding machines having different molding capacities are used. (1) Raw material process using equipment for supplying plastic raw materials (2) Molding process for manufacturing products by injection molding (3) Post-processing process for packing plastic products after molding

FIG. 3 is a flow chart showing the processing procedure for increasing resources in this step and verifying the step by simulation using the configuration of FIG. 2 and 3, the following processes (1), (2) and (3) are performed here. (1) Make a long-term medium-term sales forecast. In this long-term medium-term sales forecast, by product and time, which is a 5-year medium-term sales forecast for the next few years, for example, a long-term sales forecast of 10 years or more,
Calculate the forecasted number of shipments by day, month, or year, here by month. (2) Perform key process simulation. In this key process simulation, the production load is adjusted so as to match the key (neck) process capability, which is a process in which capacity enhancement cannot be changed. (3) Perform capability consistency (balance) calculation. In this capacity matching (balance) calculation, the production plan quantity for each product by month is matched (balanced) with the load and the other process capacity.

Hereinafter, the processes (1), (2) and (3) will be sequentially described. (1) Mid-term Sales Forecasting In step SP10, the mid-term sales forecast, the product-by-product and monthly-by-month forecasts of shipment, are stored in advance in the mid-term sales plan data and the past shipment record database section 24 in the input / output terminal 2. FIG. 4 shows a subroutine of this step SP10, that is, a flowchart of a detailed processing procedure of the medium-term sales forecast. In step SP10a in FIG. 4, the medium-term sales plan data is calculated. From the input unit 31 of the input / output terminal 2 in FIG. Further, in step SP10b, the past shipment record data from the past shipment record database section 24 in the input / output terminal 2 is supplied to the product number-specific shipment prediction section 21. Next, in step SP10c, the product number-specific shipment forecasting unit 21 performs the shipment forecast (1) and the shipment forecast (2) described with reference to FIG. Create the data.

FIG. 5 is a diagram for explaining the preparation state of the product number / monthly shipment forecast data. The shipment forecast (1) in Fig. 5 is by product group, by combining the sales plan for the next five years and the past results by individual product, by individual product,
Calculate the expected number of shipments by month. In Figure 5, "Product classification FA
Medium-term sales plan data (A) having data such as “XXXX, product classification name XXXX, sales plan XX tons” and “Product classification FAXXXX, April ○%, May ○%… March ○%”
Based on the past shipment record data (B) that includes data such as "Product classification FAXXXX, April tons, May tons ... 3
Shipment forecast data (D) for each product category having data such as "month ton" is created. Next, in the shipping forecast (2) in FIG. 5, shipping forecast data by product category (D) and shipping ratio data by individual product (E) from the past shipping record database unit 24 are used as shipping forecast data by product number / month. The shipping forecast file (F) is created.

In the processing in the product number-specific shipment forecasting section 21, a required input operation is performed from the input section 31, and further, the process display and the result are displayed in the result display section 32, and the result print output section is also provided as necessary. The hard copy printed from 33 is output. Further, the processing is performed by storing it in the storage unit 34 as needed.

(2) Key process simulation In step SP11, a key is a process in which the production load cannot be changed to increase the production load with respect to the product / monthly shipment forecast data created in the medium-term sales forecast in step SP10. (Neck) Adjust to match the process capability,
Simulate monthly process plans.

FIG. 6 shows a flowchart of a detailed processing procedure of the subroutine of step SP11, that is, the key process simulation.
In a, according to the product number obtained by the product number-specific shipment prediction unit 21
The shipment forecast file (F) as monthly shipment forecast data is supplied to the key process simulation unit 22. next,
In step SP11b, the key process capability data is supplied from the key process capability database unit 25 to the key process simulation unit 22. Then, step SP11c
Then, in the key process simulation unit 22 from the product number / monthly shipment forecast data and the key process capability data,
The injection molding machines suitable for molding the product (product) in the monthly shipping forecast data (shipping forecast file (F)) are classified into classes for each molding capacity. Next, in step SP11d, a pile of the production times of the load process for each class of the injection molding machine in the molding process is performed for each month. Further, in step SP11e, when the production time of the load process exceeds the capacity, the load process of carrying out production earlier than the previous month is adjusted.

The processing in the key process simulation unit 22 is performed by a required input operation of the input unit 31, and the process display and the result are displayed on the result display unit 32. Further, if necessary, the result print output unit 33 The printed hard copy is output and, if necessary, stored in the storage unit 34, and the processing is performed.

FIG. 7 (a) is a diagram for explaining the load stacking process in the molding process for injection molding a product, and FIG. 7 (b) is a diagram for explaining the load adjustment process by moving forward in step SP11c. It is a figure. Figure 7
In (a), for molding machine class X, August 1994 (9
The molding capacity is exceeded on 4/8). Therefore,
As shown in (b), the molding process in August 1994 (94/8) is advanced to July 1994 (94/7). If the production time of the load process becomes equal to or less than the capacity due to the advance of the load adjustment processing, the production plan quantity for each product by month is fixed as shown in Table 1 below, for example.

"Table 1" Product name 94/4 94/5 94/6 AAA 1000 2000 2000 3000 BBB 1000 1000 1000 1000 CCC 3000 3000 3000 3000 DDD 5000 5000 5000 5000

(3) Capacity Consistency (Balance) Calculation The capacity balance calculation of the consistency (balance) in the load process between the production plan quantity for each product by month created in step SP12 as shown in Table 1 and other process capacities The calculation is performed by the unit 23.

FIG. 8 is a subroutine of step SP12,
That is, it is a flow chart showing a detailed processing procedure of the capability consistency (balance) calculation. In FIG. 8, in step SP12a, by the fixed monthly product by the key process simulation unit 22 obtained in the above step SP11. The planned production quantity data (Table 1) is supplied to the capacity balance calculation unit 23. Furthermore, step SP12
In b, the other process capability data from the other process capability database unit 26 is supplied to the capability balance calculation unit 23. Next, in step SP12c, the products (AAA, BBB, CCC) in the production plan quantity data for each product by month are classified by raw material and post-process line. Step SP12d
Then, load is piled up for each raw material and each post process. Then, in step SP12e, the production capacity and the load are compared.

The processing in the capacity balance calculation unit 23 is performed by the input unit 31 according to the required input operation, and the process display and the result are displayed on the result display unit 32, and the result print output unit 33 prints the result as required. The hard copy is output and further stored in the storage unit 34 as necessary.
Perform that process.

This product is classified by raw material, for example, raw material type T
When T1 and T2 are classified by product names AAA, BBB, CCC, and DDD, they are as shown in Table 2 below. Therefore,
The required amount of raw material types T1 and T2 is classified by month in April 1994 (9
4/4), May 1994 (94/5), June 1994 (94
/ 6) is summarized in Table 3. That is,
Raw material type T1 is 2000 in April 1994 (94/4)
Tons, 3000 tons in May 1994 (94/5) and 4000 tons in June 1994 (94/6) are required. Also,
From April 1994 (94/4) to June 1994 (94/6), raw material type T2 requires 8,000 tons each.

[Table 2] Product name 94/4 94/5 94/6 Raw material type AAA 1000 2000 2000 3000 T1 BBB 1000 1000 1000 1000 T1 CCC 3000 3000 3000 3000 T2 DDD 5000 5000 5000 5000 T2

[Table 3] Raw material type 94/4 94/5 94/6 T1 2000 3000 4000 T2 8000 8000 8000

FIG. 9 is a diagram for explaining the load pile processing of the production amount of the raw material T1 line. In FIG.
In the production line for raw material T1 shown in Table 3, August 1994 (9
Production capacity will be exceeded on 4/8). In this case as well, the part that exceeds the production capacity in August 1994 (94/8) is moved forward, and the month before the production capacity is exceeded in July 1994 (94
/ 7).

The production capacity in the post-processing step for packing the molded plastic product in the same manner as the raw material process using the equipment for supplying the plastic raw material and the molding process for injection molding the product as described above. The relationship between the load process and the load process can be simulated and verified. As described above, in this embodiment, the relationship between the production capacity and the load in the molding step of injection molding the raw material process and the product is verified by simulation, and the case where the production capacity is exceeded is clearly identified, and the appropriate response is required. It will be possible and production efficiency will be improved.

Although the embodiment of the present invention has been described in detail above with reference to the drawings, the specific structure is not limited to this embodiment, and there are design changes and the like within the scope not departing from the gist of the present invention. Also included in the present invention. For example, in this embodiment, the production by moving forward (FIGS. 7 and 9) is performed in the previous month, but this is not limited to the month before the production capacity is exceeded, and it may be the previous month.

[0032]

As is apparent from the above description, according to the production facility verification simulator of claims 1 and 2, the sales plan data and the past shipment record data are used to identify the product number and time, day, month, and year. The shipment forecast data by product number / predetermined interval that predicts the shipment by any of the predetermined intervals is obtained. Further, based on the shipment forecast data by product number / predetermined interval and the process capability data, the process load is adjusted so as to match the key process capability, which is a process in which capacity enhancement cannot be changed, by predetermined interval / product. I have another quantity of production plan data.
Further, since the data in which the consistency of the load of the process is calculated is obtained from the production plan quantity data and the other process capability data, the present and future facilities and personnel of the production process having a plurality of processes can be obtained. This has the effect of making it possible to increase resources and verify the process through accurate simulation.

[Brief description of drawings]

FIG. 1 is a block diagram showing an electrical configuration of a production facility verification simulator that is an embodiment of the present invention.

FIG. 2 is a functional block diagram when the present invention is executed with the configuration of FIG.

FIG. 3 is a view showing an increase in resources in the process in the embodiment,
5 is a flowchart showing a processing procedure for verifying the process and its process by simulation.

FIG. 4 is a flowchart showing a processing procedure of a medium-term sales forecast in the embodiment.

FIG. 5 is a diagram for explaining a production state of product number-based / month-based shipping forecast data in the embodiment.

FIG. 6 is a flowchart showing a detailed processing procedure of a key process simulation in the embodiment.

FIG. 7 (a) is a diagram for explaining load pile processing in a molding step of injection molding a product in the same embodiment. (B) is a figure for explaining forward load adjustment processing.

FIG. 8 is a flowchart showing a processing procedure for capacity matching calculation in the embodiment.

FIG. 9 is a diagram for explaining a load stacking process of the production amount of the raw material line in the embodiment.

[Explanation of symbols]

1 Computer Main Body 2 Input / Output Terminal 21 Part Number Shipment Prediction Part (Part Number Shipment Prediction Means) 22 Key Process Simulation Part (Key Process Simulation Means) 23 Capacity Balance Calculator (Capability Consistency Calculator) 24 Past Shipment Performance Database Part ( Past shipment record data) 25 Key process capability database (Key process capability data) 26 Other process capability database section (Other process capability data)

Claims (2)

[Claims] 1. A production equipment verification simulator for verifying whether or not production using the current equipment resources in a production process having a plurality of processes from the present to the future can be performed, and the sales plan data can be determined in advance from the planned sales plan data. Shipment forecasting means by product number, which obtains shipment forecast data by product number / predetermined interval by predicting shipment by product number / hour, day, month, or year by predetermined interval from the past shipment record data Based on the shipment forecast data for each product number / predetermined interval obtained by the separate shipment forecasting means and the process capability data which is known in advance, it is possible to match the key process capability, which is a process in which capacity enhancement cannot be changed. Key process simulation means for obtaining load-adjusted production plan quantity data for each predetermined interval / product; production plan quantity data obtained by the key step simulation means; Therefore, a production facility verification simulator comprising: a capability consistency calculation means for obtaining data in which the process load consistency is calculated from the other process capability data that is known. 2. The adjustment of the process load to be matched with the key process capability by the key process simulation means, and the calculation of the process load consistency by the capability consistency calculation means are performed at predetermined intervals of the production time of the load process. The production facility according to claim 1, wherein the pile shown is performed, and when the production time of the load process exceeds the production capacity in the pile, the production is advanced to a predetermined predetermined interval to adjust the load process. Verification simulator.