JPH11320343A - Production planning method and device - Google Patents

Abstract

(57) [Summary] [PROBLEMS] In the case of a complex and large-scale factory where the number of production devices and the number of processes are large and the same product is repeatedly produced, production capacity data of all devices and transfer time between processes are provided. It is necessary to obtain statistical values from past results and make several adjustments in the planning process to adjust the values that match the actual conditions of the factory into the system by examining data such as
Reduce the time required for this. In a production planning method for creating a production plan for an entire factory by applying a procedure specified in advance for each process, a detailed planning procedure for determining a production device and a production time for a predetermined number of product lots. And the basic data;
A production plan is created by using transition time calculation means for calculating the production time of the lot from process time data relating to the time required for production in each process.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a production planning method for producing a production plan and an apparatus therefor.

[0002]

2. Description of the Related Art In recent years, with the technological innovation and changes in the consumer structure, the manufacturing industry has rapidly changed its form of production activities such as high-mix low-volume production, shortened delivery time, and shortened product life cycle. I have. In order to cope with such changes, computerization of computerized production has been advanced in the manufacturing industry. When creating a production plan,
In order to create a highly accurate and efficient production plan, computerized automation is becoming indispensable.

In particular, in a complicated process in which the same apparatus is used a plurality of times and a similar process is repeated a plurality of times, as represented by thin film processing of a semiconductor or a liquid crystal, a large amount of data is handled. Therefore, there are a wide variety of manufacturing restrictions that must be considered in order to create a production plan, and it is difficult to create an accurate plan in a short time by hand.

In the conventional production plan creation, as shown in FIG. 6, a production plan is created according to a given production plan creation program 100 using a central processing unit 101 having a computer. The central processing unit 101 stores basic data necessary for planning a production plan of a product, arrangement of devices in a process of producing a product, and device capability data relating to a time required for processing in each device. A storage device 102 for storing is connected. The storage device 102 further includes inter-device time data relating to the transfer time of the product from the production device of the previous process to the production device of the next process, between the devices that continuously produce, and An assignment rule describing whether to assign in order is stored. Then, a production plan is made based on the stored data. The planning result is stored in the storage device.

[0005] An input device 104 is connected to the central processing unit 101 so that known data required for a target process can be input. The central processing unit 101 is also connected to a display device 106 for displaying the planning result and a printing device 108 for printing the planning result. In the production plan creation, all the lots of a predetermined number of products are allocated to the respective devices based on the basic data, the device capability data, and the required time data between the devices, according to an allocation rule common to the previous process. The production manager statistically examines data such as the capacity of all the devices and the transport time of lots between the devices from past results, and updates the data in order to match these data with the current entity of the factory. .

Further, an allocation rule that can be commonly used in the preceding process is created by trial and error while dividing the case, and a production plan for the preceding process is drafted. In addition, after planning, in processes that require different processing to be performed using the same device or in processes with high load, review the production plan to fill the idle time of the device while checking the load of the next work. The production instructions are given only for the main processes based on the production plan.

[0007]

However, in the case of a complex and large-scale factory where the number of production devices and the number of processes are large and the same product is repeatedly produced, as described above, the production capacity of all the devices is increased. It is necessary to examine the data and the data such as the inter-process transfer time in detail, and reflect a value that matches the actual substance of the factory in the system. For that purpose, it is necessary to obtain a statistical value from past results or to make adjustments by performing planning processing several times, which requires a great deal of time. Further, in a manual inspection process, an unstable device, or the like, there are many uncertainties in the production time, and it is difficult to match detailed data to the actual substance.
Further, in the above-mentioned conventional method, when a certain process is repeated a plurality of times when viewed in individual lots, the same device is used in the process of repeating the device used in the previous process again thereafter. Since no consideration is given to the constraint such as the need to perform, a viable production plan cannot be made.

In the conventional method, when one or a plurality of steps are repeated a plurality of times, the quantity of the work-in-progress lot under production is averaged for each of the repeated times.
It was not possible to make a production plan to keep the number of completed lots daily. Further, in a process with a high load, it has not been possible to formulate an optimal production plan in response to a request from a producer, such as leveling the production load of a device in a subsequent process and increasing the operation rate of the device. The present invention provides a production planning method that can quickly and optimally plan an optimal production plan in consideration of the constraints of individual processes in a complex and large-scale process in which the number of devices and the number of processes are large and similar processing is repeatedly performed. It is an object to provide a method and an apparatus thereof.

[0009]

SUMMARY OF THE INVENTION In order to solve the above-mentioned problems, a production planning method according to the present invention is directed to a production plan for a plurality of processes and an arrangement of devices in a process for producing the products in a factory. Basic data on the items necessary for planning, equipment performance data on the time required for processing in each equipment, and the continuous production equipment between the production equipment of the previous process and the next process A predetermined number of product lots are determined based on inter-device required time data on the travel time of products to the production devices and data on allocation rules that describe which products are allocated to which devices in each device group and in what order. And a detailed planning procedure for determining the production time. Then, from the basic data and the process time data relating to the time required for production in each process, the process is designated for each process using a transition calculation procedure for calculating the production time of a predetermined lot and the detailed planning procedure. It is characterized in that a production plan for the entire factory is created by applying the set procedure.

In the production planning method of the present invention, basic data, equipment capacity data, required time data between apparatuses, data of an allocation rule, and required time data of a process are input as known data. The basic data is data relating to items necessary when planning, such as a production plan or an arrangement of devices in a production process, among a plurality of processes. The device capability data is data relating to the time required for production by each device relating only to the process of creating a production plan in the detailed planning procedure.
The required time data between devices is
This is data relating to the transfer time of a product from a production device in a previous process to a production device in a next process. The allocation rule is a rule that describes, for each device group, which product is to be allocated to which device and in what order. The process required time data is data relating to the time required for production in each process of creating a production plan by the transition calculating means.

In the detailed planning procedure, the production equipment and production time of the lot are determined based on the basic data, the equipment performance data, and the required time data between the equipments, using an allocation rule defined for each equipment group to be allocated. I do. In the transition calculation procedure, the production time in each process of the lot is determined using the basic data and the process required time data. In this way, by using the procedure determined for each process, the production plan is created while switching between the detailed planning procedure and the transition calculation procedure depending on the process to be planned, so that the production plan suited to the actual substance of the factory can be quickly changed. Can be planned.

[0012] In the case of the detailed planning procedure, the lot production apparatus and the lot production apparatus are allocated by using an allocation rule determined for each apparatus group to be allocated based on the basic data of storage contents, the apparatus capacity data, and the required time data between apparatuses. The production time is determined, and the result is stored in the storage device as production plan data. In the case of the transition calculation procedure, the production time in each process of the lot is determined using the basic data of the storage contents and the process required time data, and is stored in the storage device as production plan data. While switching between the detailed planning procedure and the transition calculation procedure in the planning step, all lots to be allocated and the planning of the step are automatically and simply achieved by inputting initial known data. can do.

A production planning method according to another aspect of the present invention is a method for preparing a pre-process out of a plurality of processes related before and after each lot, and then preparing the previously created allocation data of the pre-process and a plurality of processes. The same equipment as the equipment assigned in the specified previous process can be used in the subsequent process based on the same equipment usage constraint data that specifies the process in which the same equipment must be used when performing production with the same equipment group. A production plan is created based on an assignment rule that preferentially selects and assigns a post-process.

According to the production planning method of the other aspect of the present invention, of a plurality of processes related before and after a process for each lot, a production plan of a preceding process is preferentially drafted, and then a process of the preceding process is performed. Using the already created allocation data and the same device use constraint data that specifies the process in which the same device must be used, the process specified to use the same device is allocated. In this case, by preferentially selecting and allocating the devices used in the designated previous process, it is possible to draft a production plan so that the same device is used between the processes related to the preceding and following processes.

According to another aspect of the present invention, there is provided a production planning method, which is based on data indicating a section of a process to be repeatedly produced and in-process data indicating a location of a lot being planned. Statistical processing means for creating statistical data including lot quantities is used, and a production plan is created based on an assignment rule for appropriately adjusting the quantity of lots present in a process section based on the statistical data.

In this method, for a process to be produced by repeating the same process, the planning of the repeated process section is first performed based on the data of the section of the repeated process and the in-process data indicating the location of the lot being planned. Statistical processing of the distribution of lots inside. On the basis of the statistical results, the in-process lots are preferentially assigned to the process sections in which the lot distribution is large, so that the number of daily production completions can be equalized.

Further, a production planning method according to another aspect of the present invention includes a step of performing assignment based on sequence data of a lot production process, device data usable in each process, and the in-process data. After determining the lots that can be produced in the process, the quantity of in-process lots in the post-process is calculated for the lots, and a production plan is created based on an assignment rule that assigns a lot with a smaller number of in-process lots. I do.

In this method, first, an assignment step is performed,
The lot that can be produced in the process is determined. For the lot, the number of lots being processed in successive post-processes is totaled. Next, by giving priority to the lot with the smaller number of lots being processed in the post-process, it is possible to create a production plan for leveling the load of the equipment in the post-process.

According to another aspect of the present invention, there is provided a production planning method.
Basic data on matters necessary for planning such as product production plan and equipment arrangement plan in the process of producing goods, and equipment capacity data on the time required for processing in each equipment, continuous production Between the devices, the required time data between the devices related to the transfer time of the product from the production device of the previous process to the production device of the next process, and one that describes in which device the product is allocated and in which order, or And a plurality of allocation rules. The production planning method includes a detailed planning procedure for determining a production apparatus and a production time of a lot according to an allocation rule based on the basic data, the equipment capacity data, and the inter-applied time data; the basic data; And a transition calculation procedure for determining a time required for a lot to pass through each process based on the required process time data relating to the production time required in the above.

In this method, first of all, basic data necessary for planning a production plan of a product or an arrangement of devices in a process of producing a product is input from an input device and stored in a storage device. . In addition, only for the process of creating a production plan in the detailed planning procedure, the equipment capacity data on the time required for production in each equipment and the equipment from the previous production equipment to the next production equipment Using an input device, the required time between devices relating to the movement time of the product and the allocation rule describing which product is to be allocated to which device and in which order for each device group are input and stored in the storage device. Further, with respect to the process of creating a production plan by the transition calculating means, process required time data relating to the time required for production in each process is input from the input device and stored in the storage device.
Based on the stored contents, it is determined whether the allocation procedure for each process is the detailed planning procedure or the transition calculation procedure.

The production planning device of the present invention comprises an input device for the basic data, device capability data, inter-device required time data, and process required time data, a display device for displaying the content of the production plan, and a content of the production plan. And a central processing unit that manages and controls the input device, the storage device, the display device, and the printing device as a whole.

[0022]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS A production plan creating apparatus and a production plan making method using the same as a preferred embodiment of the present invention will be described below with reference to FIGS. FIG. 1 shows a schematic configuration of the apparatus of the present embodiment. The central processing unit 1 having a computer includes a detailed planning procedure 2 and a transition calculation procedure 3 as software for appropriately creating a production plan for each process according to the contents of known data.

The central processing unit 1 is connected to a storage device 11 for storing data necessary for creating a production plan, a display device 12 for displaying the created production plan, and a printing device 13 for printing. ing. An input device 14 for inputting initial known data is connected to the storage device 11. The detailed planning procedure 2 includes basic data 21, device capacity data 22, device-to-device time data 23, and allocation rule 2.
6 is a program for determining a production device and a production time of a predetermined lot based on initially known data such as 6, and creating or updating the production plan data 25. The basic data 21 includes usable device data, model data of a lot to be produced,
This is process flow data or the like indicating which process is to be performed for each model. The production time is a general term for a lot setup start time, a production start time, and a production completion time.

The transition calculation procedure 3 is a program for determining a production time in a process of a predetermined lot on the basis of the basic data and the required process time data 24, and creating or updating the production plan data 25. The initial known data is input to the storage device 11 from the input device 14. Further, the storage device 11 receives and stores the production plan data 25 of the planning result created in the detailed planning procedure 2 and the production plan data 25 of the production plan created in the transition calculation procedure 3. The operation of the above configuration will be described with reference to FIG. FIG. 2 is a flowchart showing a procedure for performing an allocation process using a detailed planning procedure 2 and a transition calculation procedure 3 when a production plan is created by the central processing unit 1.

First, basic data 21 necessary for planning a product production plan and arrangement of devices in a process of producing a product, and device capability data 22 relating to time required for processing in each device are known. The condition is input by the input device 14. In the same manner, between the devices to be processed in the continuous process, the device-to-device time data 22 relating to the transfer time of the product from the production device of the previous process to the production device of the next process.
And an assignment rule 26 describing which product is to be assigned to which device and in what order for each device group, and process required time data 24 relating to the time required for production in each process are known conditions by the input device 14. Is entered. These input data are stored by the storage device 11.

When the central processing unit 1 operates according to these input data, the process to be planned is determined in step 31 of the planning process determining procedure based on the basic data 21, and the process is detailed in the determination step 32. It is determined whether the processing is based on the planning procedure or the transition calculation procedure. If the planning step is a step to be processed according to the detailed planning procedure, the process proceeds to step 33, where the apparatus to be planned is selected based on the basic data 21, the apparatus capacity data 22, and the required time data 22 between apparatuses. Then, from the devices in the process, one device to be allocated is selected according to the allocation rule 26. Next, one of the lots that can be produced by the apparatus is selected by the allocation rule 26 in the planning lot selection step 34, and the production time of the lot is determined in the step 35 of the first allocation procedure. The assignment rule 26 is
Each step is described by a planning process and different choices are prioritized.

If the planning process is a process to be processed by the transition calculation procedure 3, the production time of the lot is determined by the step 36 of the second allocation procedure based on the basic data 21 and the required process time data 24. The planning result is stored in the storage device 11 as the production plan data 25. The above planning for each process is repeated until all the lots to be allocated are allocated. As described above, by using different allocation procedures for each process, it is possible to quickly and efficiently draft a production plan that meets the actual conditions of the factory. FIG. 3 is a flowchart showing a procedure for drafting a production plan in which the same apparatus is used in each of the steps related to the previous and subsequent steps.

To explain this, after the process to be planned is determined in step 31 of the process determination procedure, the same device use constraint data 43 that specifies that the same device must be used in a plurality of processes is referred to. . In step 41 of the same device constraint determination procedure, it is determined whether or not the process for planning must use the device used previously. If the planning process is a process having the same device usage constraint, the lot is transferred to the same device as the device used in the process defined by the same device usage constraint data 43 by the planning device selection step 33 and the planning lot selection step 34. Choose to assign. Next, allocation is performed in step 35 of the first allocation procedure. By repeatedly performing the same process for all the processes from the input of the lot to the completion through the step 42, it is possible to draft a production plan to use the same apparatus between the processes.

FIG. 4 is a flowchart showing a procedure for drafting a production plan for leveling the number of daily production completions. After the process to be planned is determined in step 31 of the planning process determination procedure, one device to be planned is selected in step 33 of planning device selection. Thereafter, the distribution of the in-process lots for each process section is performed by step 51 of the in-process statistical processing procedure based on the process section data 52 indicating the section in which similar processes are repeated and the in-process data 53 indicating the location of the target lot under planning. Is statistically processed and stored as statistical data 54. Next, based on the statistical data 54,
Lots in process in a lot of lot distribution are selected preferentially in a planning lot selection step 34, and allocation is performed in a step 35 of a first allocation procedure. By repeating the same process for all processes from the input of the lot to the completion through the step 42,
It is possible to draft a production plan in which the number of daily production completions is equalized.

FIG. 5 is a flowchart showing a procedure for drafting a production plan for leveling the load on the apparatus. First, a process to be planned is determined in step 31 of the process determination procedure. Next, based on the work-in-progress data 62 under planning, for the lots that can be planned in the process, the post-process work-in-process lot totaling step 61 totals the quantity of lots in progress in the subsequent post-process, and as work in process statistical data 63 Store. Next, based on the in-process statistical data 63, step 33 for selecting a planning device and step 34 for selecting a planning lot
Thus, a device and a lot with a low load in the post-process are preferentially selected, and allocation is performed in step 35 of the first allocation procedure. By repeatedly performing the same process for all the processes from the input of the lot to the completion through the step 42, it is possible to draft a production plan in which the load of the apparatus is leveled.

[0031]

According to the production planning method of the present invention, the number of apparatuses and the number of processes are large, and even for a large-scale factory that performs production having complicated processes in which similar processing is repeatedly performed, Planning is performed while appropriately switching the planning procedure for each process. Therefore, it is possible to quickly make a production plan that matches the actual situation of the factory. In addition, even when there is a constraint that equipment used in a certain process must be used again in a subsequent process when viewed in an individual lot, it is possible to draft a production plan that satisfies the constraint. .

In the case where a plurality of processes are repeated a plurality of times, a production plan for leveling the number of work-in-progress lots in production for each of the number of times of the repeated processes is established, so that the number of daily production completed lots is kept constant. Can be equalized to the value of In addition, by drafting a production plan in consideration of the work-in-process state of a post-process having a high load, the load on the device can be leveled and the operation rate of the device can be increased.

According to the production planning apparatus of the present invention, the constraints of individual processes are taken into consideration for a large-scale factory having a large number of apparatuses and processes and having complicated processes in which similar processes are repeatedly performed. In addition, by appropriately applying the allocation procedure for each process, an optimal production plan can be quickly drafted.

[Brief description of the drawings]

FIG. 1 is a block diagram illustrating a schematic configuration of a production planning device according to an embodiment of the present invention.

FIG. 2 is a flowchart illustrating a procedure for switching a planning procedure for each process and performing an allocation process for processes related to the previous and next processes.

FIG. 3 is a flowchart showing a procedure for drafting a production plan so as to use the same apparatus between processes related to before and after.

FIG. 4 is a flowchart illustrating a procedure for leveling the number of in-process lots in a section of a process in which production is repeated.

FIG. 5 is a flowchart illustrating a procedure for leveling the device load based on the number of in-process lots in a post-process.

FIG. 6 is a block diagram showing a schematic configuration of a conventional production planning device.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Central processing unit 2 Detailed planning procedure 3 Transition calculation procedure 11 Storage device 12 Display device 13 Printing device 14 Input device 21 Basic data 22 Device capability data 23 Inter-device required time data 24 Process required time data 25 Production planning data 26 Allocation rules 31 Planning process determination procedure 33 Planning equipment selection 34 Planning lot selection 35 First allocation procedure 36 Second allocation procedure 37 Termination determination 41 Same equipment restriction determination procedure 43 Same equipment usage constraint data 51 In-process statistical processing procedure 52 Process section data 53 Work in process Data 54 Statistical data 61 Post-process in-process lot aggregation 62 In-process data 63 In-process statistical data

Claims (5)

[Claims] 1. In a factory that performs a process having a plurality of processes, basic data relating to matters necessary when planning a production plan of a product or an arrangement of devices in a process of producing a product,
Equipment capacity data on the time required for processing in each equipment, and inter-equipment time data on the transfer time of the product from the production equipment of the previous process to the production equipment of the next process between the equipment used in the continuous production process A detailed planning procedure for determining a production device and a production time for a predetermined number of product lots from data of an assignment rule that describes which product is assigned to which device and in which order for each device group, Using the basic data, the process time data relating to the time required for production in each process, and the transition calculation procedure for calculating the production time of the lot, applying the procedure specified in advance for each process, A production planning method for creating a production plan. 2. For each lot, after planning a preceding process among a plurality of processes related to the preceding and following processes, a plurality of productions are performed by using the same data as the allocation data created in the preceding process. Assigned in the specified previous process from the same device usage constraint data that specifies the process that must use the same device when performing the process, and the device and the same device usage constraint data that were allocated in the specified previous process 2. The production planning method according to claim 1, wherein the same device as the device is preferentially selected in a post-process, an allocation rule for allocating the post-process is formed, and a production plan is created based on the rule. 3. Statistical data including the number of lots existing in the section of the process is obtained based on data indicating the section of the step of producing the same process repeatedly and in-process data indicating the location of the lot to be planned. 3. The production plan planning according to claim 1, wherein the statistical processing means is used to create a production plan based on an allocation rule for appropriately adjusting the number of lots present in a process section based on the statistical data. Method. 4. A step of performing assignment based on order data indicating an order of a process of producing the lot, device data of a device usable in each process, and the in-process data. 4. The method according to claim 3, wherein after determining a lot that can be produced, the number of in-process lots in the post-process for the lot is totaled, and a production plan is created based on an assignment rule for assigning a lot with a smaller number of in-process lots. Production planning method. 5. Basic data indicating items necessary for planning such as a production plan of a product and an arrangement plan of a device in a process of producing the product, and device capability data relating to a time required for processing in each device. And between the devices used in the continuous production process, the inter-device required time data relating to the transfer time of the product from the production device of the previous process to the production device of the next process, and in which order the product is allocated to which device A detailed planning procedure for determining the production equipment and production time of the lot according to the allocation rule based on one or more allocation rule data describing the above, the basic data, the equipment capacity data and the required inter-equipment time data; A storage device for storing the basic data and process time data relating to the production time required for each process; and a transition calculation procedure for determining the time for the lot to pass through each process. An input device for the basic data, device capability data, inter-device required time data, and process required time data; a display device for displaying the content of the production plan; a printing device for printing the content of the production plan; and the storage device; And a central processing unit that manages and controls the device, the display device, and the printing device as a whole.