Method and apparatus for forming a production plan

• US 6,738,747 B1
• Filed: 02/09/2000
• Issued: 05/18/2004
• Est. Priority Date: 03/29/1999
• Status: Expired due to Fees

• Current Assignee: Matsushita Electric Industrial Company Limited (Panasonic Holdings Corporation)
• Original Assignee: Matsushita Electric Industrial Company Limited (Panasonic Holdings Corporation)
• Inventors: Tanaka, Masayuki, Yamamura, Satoru, Shintani, Kazuhiro, Yamada, Itsuhiro
• Primary Examiner(s): Hafiz, Tariq R.
• Assistant Examiner(s): Boyce, Andre D
• Application Number:
  US09/500,652
• Time in Patent Office: 1,560 Days
• Field of Search: 705/9, 705/7, 700/95, 700/121
• US Class Current: 705/7.22
• CPC Class Codes: G05B 19/41865 characterised by job scheduling, process planning, material flow
• CPC Class Codes: G06Q 10/06 Resources, workflows, human or project management; Enterprise or organisation planning; Enterprise or organisation modelling
• CPC Class Codes: G06Q 10/06312 Adjustment or analysis of established resource schedule, e.g. resource or task levelling, or dynamic rescheduling
• CPC Class Codes: G06Q 10/06314 Calendaring for a resource
• CPC Class Codes: G06Q 10/06316 Sequencing of tasks or work
• CPC Class Codes: G06Q 10/0633 Workflow analysis
• CPC Class Codes: Y02P 90/02 Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]

Abstract

According to the present invention, a production plan forming apparatus is provided with a constitution wherein based on basic data necessary for forming a production plan and state data changing with time stored in a memory unit (11), an event receiving part (2) receives a change of production state as an event, a pseudo event generation part (4) generates a pseudo event (14a) at a time when it should be processed for an event of which times when it occurred and when a production indication is carried out are different, a dispatching part (3) determines a manufacturing apparatus and a production lot in connection with the event from the event (14) or the pseudo event (14a), and a formed production plan is displayed by a display unit (12).

Claims

1. Method for forming a production plan comprising:

an event receiving process for receiving, as an event (14), a change of production state as required, based on basic data (21) necessary for forming a production procedure of production lots or a production plan having information on manufacturing apparatus necessary for production, and state data (22) changing with time indicating state of said production lots and said manufacturing apparatus;

an event analyzing process for analyzing contents of events received in said event receiving process;

an event reservation process for determining a time when a production indication is carried out and contents of an event generated at the determined time, and for forming event data on basis of the contents of the event;

a pseudo event generation process for generating a pseudo event (14a) for carrying out a production indication, on the basis of referring to said event data at a certain time interval, in case a production indication has to be carried out at a different time from a time when said event occurred;

a process for carrying out a production indication by determining a production lot produced with said manufacturing apparatus by said pseudo event at a different time from a time when said event occurred, by using a dispatching part (3) which determines a production lot to be produced with a manufacturing apparatus in connection with said event, and determines a manufacturing apparatus to produce next to a production lot in connection with said event, from said event or said pseudo event;

a between-process in-process number calculation process for calculating out a production lot number being in process between said manufacturing processes from an in-process control data having recorded manufacturing processes where production in a particular production lot is stopped when a production lot number between manufacturing processes in connection with a production order has reached a maximum production lot number that can be held between said manufacturing processes, and in-process lot data showing positions of manufacturing processes where said production lots are in process in the production order;

an introduction lot control process for controlling an introduction to the manufacturing process relating to said production lot in accordance with said production lot number being in process and said in-process control data; and

a process for carrying out a production indication for maintaining the in-process lot number between the manufacturing processes within a predetermined number using the dispatching part.

2. Method for forming a production plan comprising:

an event receiving process for receiving, as an event (14), a change of production state as required, based on basic data (21) necessary for forming a production procedure of production lots or a production plan having information on manufacturing apparatus necessary for production, and state data (22) changing with time indicating state of said production lots and said manufacturing apparatus;

an event analyzing process for analyzing contents of events received in said event receiving process;

an event reservation process for determining a time when a production indication is carried out and contents of an event generated at the determined time, and for forming event data on basis of the contents of the event;

a pseudo event generation process for generating a pseudo event (14a) for carrying out a production indication, on the basis of referring to said event data at a certain time interval, in case a production indication has to be carried out at a different time from a time when said event occurred;

a process for carrying out a production indication by determining a production lot produced with said manufacturing apparatus by said pseudo event at a different time from a time when said event occurred, by using a dispatching part (3) which determines a production lot to be produced with a manufacturing apparatus in connection with said event, and determines a manufacturing apparatus to produce next to a production lot in connection with said event, from said event or said pseudo event;

a grouping process for forming grouping data dynamically by being related to a production lot having completed production for each manufacturing unit based on a predetermined rule;

a representative lot judgment process for designating a production lot representing a group of the related production lots as a representative lot from said grouping data;

a representative lot control process for determining a particular production procedure for said representative lot;

a same group control process for carrying out an introduction control to a following manufacturing process depending on state of the representative lot for a production lot of the same group other than said representative lot; and

a process for distinguishing a product procedure and for carrying out a production indication of the representative lot of production lots dynamically grouped using the dispatching means, and production lots of the same group, based on determination of said representative lot control process and said same group control process.

3. A production plan forming apparatus comprising:

an input unit for inputting basic data (21) necessary for forming a production procedure of production lots or a production plan having information on manufacturing apparatuses necessary for production, unit control data (31) for controlling automation of a production indication for each manufacturing apparatus, process control data (32) for controlling automation of a production indication for each production process in a production procedure, lot control data (33) for controlling automation of lot progress for each production lot or product type, event control data (34) for controlling automation of a production indication for each event forming a production plan;

a memory unit (11) for storing each type of said data inputted from said input unit, state data (22) changing with time indicating state of production lots and manufacturing apparatuses, event data (23) relating to different events from a time production state changes, irregular flow data (24) relating to a production procedure of production lots violating a limitation time, limitation time data (26) relating to a holding time limitation of production lots between manufacturing processes in connection with production orders, and production history data (27) relating to production histories of production lots, limitation time state data (25) relating to a limitation state by an entire lot holding time, in-process limitation data relating to a production lot number that can be in process between manufacturing processes and a manufacturing process an introduction control is carried out by that, in-process lot data (28) relating to positions where production lots are in process, grouping data (30) relating to production lot group related to a lot having completed in production for each manufacturing apparatus;

a central processing unit (1) comprising;

an event receiving part (2) for receiving an event of which production state changes, a pseudo event generation part (4) for forming said event data and for generating a pseudo event, a holding-time limitation observation part (5) for changing a production procedure of production lots violating a holding limitation time between manufacturing processes utilizing said irregular flow data, limitation time data, production history data, and limitation time state data, in-process number introduction control part (6) for carrying out introduction limitation of production lots to said manufacturing apparatus to maintain an in-process lot number between manufacturing processes within a predetermined number utilizing said in-process control data and in-process lot data, dynamic lot group control part (7) for distinguishing a representative lot of a production lot group grouped dynamically from a production procedure of other production lots utilizing said grouping data, an automatic planning control part (8) for determining outputs of a production indication and for determining progress of production lots by receiving said unit control data, process control data, lot control data, event control data from said input unit, a dispatching part (3) for carrying out a production indication by determining lots produced in said manufacturing apparatus among in-process lots; and

a display unit (12) for displaying contents and forming state of the production plan;

wherein said pseudo event generation part (4) comprises;

an event analyzing part (9) for analyzing contents of the event received at said event receiving part;

an event reservation part (42) for forming event data (23) by determining a time when a production indication is carried out and an event generated at the determined time in case a production indication has to be carried out at a different time from a time when the analyzed event occurred; and

an event generation part (41) for generating and outputting a pseudo (14a), referring to said event data at a certain time interval, with respect to the event data at the time when the production indication is carried out;

wherein, said central processing unit carries out

a between-process in-process number calculation procedure for calculating out a production lot number being in process between said manufacturing processes from an in-process control data having recorded manufacturing processes where production in a particular production lot is stopped when a production lot number between manufacturing processes in connection with a production order has reached a maximum production lot number that can be held between said manufacturing processes, and in-process lot data showing positions of manufacturing processes where said production lots are in process in the production order;

an introduction lot control procedure for controlling an introduction to the manufacturing process relating to said production lot in accordance with said production lot number being in process and said in-process control data; and

a procedure for carrying out a production indication for maintaining the in-process lot number between the manufacturing processes within a predetermined number using the dispatching part.

4. A production plan forming apparatus comprising:

an input unit for inputting basic data (21) necessary for forming a production procedure of production lots or a production plan having information on manufacturing apparatuses necessary for production, unit control data (31) for controlling automation of a production indication for each manufacturing apparatus, process control data (32) for controlling automation of a production indication for each production process in a production procedure, lot control data (33) for controlling automation of lot progress for each production lot or product type, event control data (34) for controlling automation of a production indication for each event forming a production plan;

a memory unit (11) for storing each type of said data inputted from said input unit, state data (22) changing with time indicating state of production lots and manufacturing apparatuses, event data (23) relating to different events from a time production state changes, irregular flow data (24) relating to a production procedure of production lots violating a limitation time, limitation time data (26) relating to a holding time limitation of production lots between manufacturing processes in connection with production orders, and production history data (27) relating to production histories of production lots, limitation time state data (25) relating to a limitation state by an entire lot holding time, in-process limitation data relating to a production lot number that can be in process between manufacturing processes and a manufacturing process an introduction control is carried out by that, in-process lot data (28) relating to positions where production lots are in process, grouping data (30) relating to production lot group related to a lot having completed in production for each manufacturing apparatus;

a central processing unit (1) comprising;

an event receiving part (2) for receiving an event of which production state changes, a pseudo event generation part (4) for forming said event data and for generating a pseudo event, a holding time limitation observation part (5) for changing a production procedure of production lots violating a holding limitation time between manufacturing processes utilizing said irregular flow data, limitation time data, production history data, and limitation time state data, in-process number introduction control part (6) for carrying out introduction limitation of production lots to said manufacturing apparatus to maintain an in-process lot number between manufacturing processes within a predetermined number utilizing said in-process control data and in-process lot data, dynamic lot group control part (7) for distinguishing a representative lot of a production lot group grouped dynamically from a production procedure of other production lots utilizing said grouping data, an automatic planning control part (8) for determining outputs of a production indication and for determining progress of production lots by receiving said unit control data, process control data, lot control data, event control data from said input unit, a dispatching part (3) for carrying out a production indication by determining lots produced in said manufacturing apparatus among in-process lots; and

a display unit (12) for displaying contents and forming state of the production plan;

wherein said pseudo event generation part (4) comprises;

an event analyzing part (9) for analyzing contents of the event received at said event receiving part;

an event reservation part (42) for forming event data (23) by determining a time when a production indication is carried out and an event generated at the determined time in case a production indication has to be carried out at a different time from a time when the analyzed event occurred; and

an event generation part (41) for generating and outputting a pseudo (14a), referring to said event data at a certain time interval, with respect to the event data at the time when the production indication is carried out;

wherein, said central processing unit carries out

a grouping procedure for forming grouping data dynamically by being related to a production lot having completed production for each manufacturing apparatus based on a predetermined rule;

a representative lot judgment procedure for designating a production lot representing a group of the related production lots as a representative lot from said grouping data;

a representative lot control procedure for determining a particular production procedure for said representative lot;

a same group control procedure for carrying out an introduction control to a subsequent manufacturing process depending on state of the representative lot for a production lot of the same group other than said representative lot; and

a procedure for distinguishing a product procedure and for carrying out a production indication of the representative lot of production lots dynamically grouped using the dispatching part, and production lots of the same group, based on determination of said representative lot control procedure and said same group control procedure.

5. Method for forming a production plan further comprising:

an event receiving process for receiving, as an event (14), a change of production state as required, based on basic data (21) necessary for forming a production procedure of production lots or a production plan having information on manufacturing apparatus necessary for production, and state data (22) changing with time indicating state of said production lots and said manufacturing apparatus;

an event analyzing process for analyzing contents of events received in said event receiving process;

an event reservation process for determining a time when a production indication is carried out and contents of an event generated at the determined time, and for forming event data on basis of the contents of the event;

a pseudo event generation process for generating a pseudo event (14a) for carrying out a production indication, on the basis of referring to said event data at a certain time interval, in case a production indication has to be carried out at a different time from a time when said event occurred;

a process for carrying out a production indication by determining a production lot produced with said manufacturing apparatus by said pseudo event at a different time from a time when said event occurred, by using a dispatching part (3) which determines a production lot to be produced with a manufacturing apparatus in connection with said event, and determines a manufacturing apparatus to produce next to a production lot in connection with said event, from said event or said pseudo event;

a comparison process for comprising a holding time of entire production lots and a limitation time from limitation time data with respect to a minimum time said production lots have to hold and a maximum time said production lots are able to hold between manufacturing processes in connection with production orders, and production history data having recorded a time of production of each manufacturing process of each of said production lots;

a limitation time judgment process for forming and outputting limitation time state data by judging an observance state of the limitation time based on a result of comparison in said comparison process;

a limitation event generation process for generating a limitation event with respect to a production lot where said holding time violates said limitation time;

a production route determination process for determining a production procedure of a production lot in connection with said limitation event generated from irregular flow data having recorded a production procedure of a production lot violating the limitation time and said limitation time state data;

a process for carrying out a production indication using a dispatching part immediately, in case a holding production lot violates the limitation time based on determination by said production route determination process;

a between-process in-process number calculation process for calculating out a production lot number being in process between said manufacturing processes from an in-process control data having recorded manufacturing processes where production in a particular production lot is stopped when a production lot number between manufacturing processes in connection with a production order has reached a maximum production lot number that can be held between said manufacturing processes, and in-process lot data showing positions of manufacturing processes where said production lots are in process in the production order;

an introduction lot control process for controlling an introduction to the manufacturing process relating to said production lot in accordance with said production lot number being in process and said in-process control data; and

a process for carrying out a production indication for maintaining the in-process lot number between the manufacturing processes within a predetermined number using the dispatching part.

6. Method for forming a production plan comprising:

an event receiving process for receiving, as an event (14), a change of production state as required, based on basic data (21) necessary for forming a production procedure of production lots or a production plan having information on manufacturing apparatus necessary for production, and state data (22) changing with time indicating state of said production lots and said manufacturing apparatus;

an event analyzing process for analyzing contents of events received in said event receiving process;

an event reservation process for determining a time when a production indication is carried out and contents of an event generated at the determined time, and for forming event data on basis of the contents of the event;

a pseudo event generation process for generating a pseudo event (14a) for carrying out a production indication, on the basis of referring to said event data at a certain time interval, in case a production indication has to be carried out at a different time from a time when said event occurred;

a process for carrying out a production indication by determining a production lot produced with said manufacturing apparatus by said pseudo event at a different time from a time when said event occurred, by using a dispatching part (3) which determines a production lot to be produced with a manufacturing apparatus in connection with said event, and determines a manufacturing apparatus to produce next to a production lot in connection with said event, from said event or said pseudo event;

a comparison process for comprising a holding time of entire production lots and a limitation time from limitation time data with respect to a minimum time said production lots have to hold and a maximum time said production lots are able to hold between manufacturing processes in connection with production orders, and production history data having recorded a time of production of each manufacturing process of each of said production lots;

a limitation time judgment process for forming and outputting limitation time state data by judging an observance state of the limitation time based on a result of comparison in said comparison process;

a limitation event generation process for generating a limitation event with respect to a production lot where said holding time violates said limitation time;

a production route determination process for determining a production procedure of a production lot in connection with said limitation event generated from irregular flow data having recorded a production procedure of a production lot violating the limitation time and said limitation time state data;

a process for carrying out a production indication using a dispatching part immediately, in case a holding production lot violates the limitation time based on determination by said production route determination process;

a grouping process for forming grouping data dynamically by being related to a production lot having completed production for each manufacturing unit based on a predetermined rule;

a representative lot judgment process for designating a production lot representing a group of the related production lots as a representative lot from said grouping data;

a representative lot control process for determining a particular production procedure for said representative lot;

a same group control process for carrying out an introduction control to a following manufacturing process depending on state of the representative lot for a production lot of the same group other than said representative lot; and

a process for distinguishing a product procedure and for carrying out a production indication of the representative lot of production lots dynamically grouped using the dispatching means, and production lots of the same group, based on determination of said representative lot control process and said same group control process.

7. A production plan forming apparatus comprising:

an input unit for inputting basic data (21) necessary for forming a production procedure of production lots or a production plan having information on manufacturing apparatuses necessary for production, unit control data (31) for controlling automation of a production indication for each manufacturing apparatus, process control data (32) for controlling automation of a production indication for each production process in a production procedure, lot control data (33) for controlling automation of lot progress for each production lot or product type, event control data (34) for controlling automation of a production indication for each event forming a production plan;

a memory unit (11) for storing each type of said data inputted from said input unit, state data (22) changing with time indicating state of production lots and manufacturing apparatuses, event data (23) relating to different events from a time production state changes, irregular flow data (24) relating to a production procedure of production lots violating a limitation time, limitation time data (26) relating to a holding time limitation of production lots between manufacturing processes in connection with production orders, and production history data (27) relating to production histories of production lots, limitation time state data (25) relating to a limitation state by an entire lot holding time, in-process limitation data relating to a production lot number that can be in process between manufacturing processes and a manufacturing process an introduction control is carried out by that, in-process lot data (28) relating to positions where production lots are in process, grouping data (30) relating to production lot group related to a lot having completed in production for each manufacturing apparatus;

a central processing unit (1) comprising;

an event receiving part (2) for receiving an event of which production state changes, a pseudo event generation part (4) for forming said event data and for generating a pseudo event, a holding time limitation observation part (5) for changing a production procedure of production lots violating a holding limitation time between manufacturing processes utilizing said irregular flow data, limitation time data, production history data, and limitation time state data, in-process number introduction control part (6) for carrying out introduction limitation of production lots to said manufacturing apparatus to maintain an in-process lot number between manufacturing processes within a predetermined number utilizing said in-process control data and in-process lot data, dynamic lot group control part (7) for distinguishing a representative lot of a production lot group grouped dynamically from a production procedure of other production lots utilizing said grouping data, an automatic planning control part (8) for determining outputs of a production indication and for determining progress of production lots by receiving said unit control data, process control data, lot control data, event control data from said input unit, a dispatching part (3) for carrying out a production indication by determining lots produced in said manufacturing apparatus among in-process lots; and

a display unit (12) for displaying contents and forming state of the production plan;

wherein said pseudo event generation part (4) comprises;

an event analyzing part (9) for analyzing contents of the event received at said event receiving part;

an event reservation part (42) for forming event data (23) by determining a time when a production indication is carried out and an event generated at the determined time in case a production indication has to be carried out at a different time from a time when the analyzed event occurred; and

an event generation part (41) for generating and outputting a pseudo (14a), referring to said event data at a certain time interval, with respect to the event data at the time when the production indication is carried out;

wherein, said central processing unit carries out

a comparison procedure for comparing a holding time of entire production lots and a limitation time from limitation time data with respect to a minimum time said production lots have to hold and a maximum time said production lots are able to hold between manufacturing processes in connection with production orders, and production history data having recorded a time of production of each manufacturing process of each of said production lots;

a limitation time judgment procedure for forming and outputting limitation time state data by judging an observance state of the limitation time based on a result of comparison in said comparison procedure;

a limitation event generation procedure for generating a limitation event with respect to a production lot where said holding time violates said limitation time;

a production route determination procedure for determining a production procedure of a production lot in connection with said limitation event generated from irregular flow data having recorded a production procedure of a production lot violating the limitation time and said limitation time state data;

a procedure for carrying out a production indication using a dispatching part immediately, in case a holding lot violates the limitation time based on determination by said production route determination procedure;

a between-process in-process number calculation procedure for calculating out a production lot number being in process between said manufacturing processes from an in-process control data having recorded manufacturing processes where production in a particular production lot is stopped when a production lot number between manufacturing processes in connection with a production order has reached a maximum production lot number that can be held between said manufacturing processes, and in-process lot data showing positions of manufacturing processes where said production lots are in process in the production order;

an introduction lot control procedure for controlling an introduction to the manufacturing process relating to said production lot in accordance with said production lot number being in process and said in-process control data; and

a procedure for carrying out a production indication for maintaining the in-process lot number between the manufacturing processes within a predetermined number using the dispatching part.

8. A production plan forming apparatus comprising:

an input unit for inputting basic data (21) necessary for forming a production procedure of production lots or a production plan having information on manufacturing apparatuses necessary for production, unit control data (31) for controlling automation of a production indication for each manufacturing apparatus, process control data (32) for controlling automation of a production indication for each production process in a production procedure, lot control data (33) for controlling automation of lot progress for each production lot or product type, event control data (34) for controlling automation of a production indication for each event forming a production plan;

a memory unit (11) for storing each type of said data inputted from said input unit, state data (22) changing with time indicating state of production lots and manufacturing apparatuses, event data (23) relating to different events from a time production state changes, irregular flow data (24) relating to a production procedure of production lots violating a limitation time, limitation time data (26) relating to a holding time limitation of production lots between manufacturing processes in connection with production orders, and production history data (27) relating to production histories of production lots, limitation time state data (25) relating to a limitation state by an entire lot holding time, in-process limitation data relating to a production lot number that can be in process between manufacturing processes and a manufacturing process an introduction control is carried out by that, in-process lot data (28) relating to positions where production lots are in process, grouping data (30) relating to production lot group related to a lot having completed in production for each manufacturing apparatus;

a central processing unit (1) comprising;

an event receiving part (2) for receiving an event of which production state changes, a pseudo event generation part (4) for forming said event data and for generating a pseudo event, a holding time limitation observation part (5) for changing a production procedure of production lots violating a holding limitation time between manufacturing processes utilizing said irregular flow data, limitation time data, production history data, and limitation time state data, in-process number introduction control part (6) for carrying out introduction limitation of production lots to said manufacturing apparatus to maintain an in-process lot number between manufacturing processes within a predetermined number utilizing said in-process control data and in-process lot data, dynamic lot group control part (7) for distinguishing a representative lot of a production lot group grouped dynamically from a production procedure of other production lots utilizing said grouping data, an automatic planning control part (8) for determining outputs of a production indication and for determining progress of production lots by receiving said unit control data, process control data, lot control data, event control data from said input unit, a dispatching part (3) for carrying out a production indication by determining lots produced in said manufacturing apparatus among in-process lots; and

a display unit (12) for displaying contents and forming state of the production plan;

wherein said pseudo event generation part (4) comprises;

an event analyzing part (9) for analyzing contents of the event received at said event receiving part;

an event reservation part (42) for forming event data (23) by determining a time when a production indication is carried out and an event generated at the determined time in case a production indication has to be carried out at a different time from a time when the analyzed event occurred; and

an event generation part (41) for generating and outputting a pseudo (14a), referring to said event data at a certain time interval, with respect to the event data at the time when the production indication is carried out;

wherein, said central processing unit carries out

a comparison procedure for comparing a holding time of entire production lots and a limitation time from limitation time data with respect to a minimum time said production lots have to hold and a maximum time said production lots are able to hold between manufacturing processes in connection with production orders, and production history data having recorded a time of production of each manufacturing process of each of said production lots;

a limitation time judgment procedure for forming and outputting limitation time state data by judging an observance state of the limitation time based on a result of comparison in said comparison procedure;

a limitation event generation procedure for generating a limitation event with respect to a production lot where said holding time violates said limitation time;

a production route determination procedure for determining a production procedure of a production lot in connection with said limitation event generated from irregular flow data having recorded a production procedure of a production lot violating the limitation time and said limitation time state data;

a procedure for carrying out a production indication using a dispatching part immediately, in case a holding lot violates the limitation time based on determination by said production route determination procedure;

a grouping procedure for forming grouping data dynamically by being related to a production lot having completed production for each manufacturing apparatus based on a predetermined rule;

a representative lot judgment procedure for designating a production lot representing a group of the related production lots as a representative lot from said grouping data;

a representative lot control procedure for determining a particular production procedure for said representative lot;

a same group control procedure for carrying out an introduction control to a subsequent manufacturing process depending on state of the representative lot for a production lot of the same group other than said representative lot; and

a procedure for distinguishing a product procedure and for carrying out a production indication of the representative lot of production lots dynamically grouped using the dispatching part, and production lots of the same group, based on determination of said representative lot control procedure and said same group control procedure.