JP4883934B2 - Steel product production shipment plan creation system and production shipment plan creation method thereof - Google Patents
Steel product production shipment plan creation system and production shipment plan creation method thereof Download PDFInfo
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- 238000004519 manufacturing process Methods 0.000 title claims description 316
- 238000000034 method Methods 0.000 title claims description 73
- 229910000831 Steel Inorganic materials 0.000 title claims description 37
- 239000010959 steel Substances 0.000 title claims description 37
- 238000003860 storage Methods 0.000 claims description 72
- 238000012384 transportation and delivery Methods 0.000 claims description 66
- 230000008569 process Effects 0.000 claims description 58
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims description 32
- 230000008439 repair process Effects 0.000 claims description 22
- 229910052742 iron Inorganic materials 0.000 claims description 16
- 238000013439 planning Methods 0.000 claims description 10
- 238000010276 construction Methods 0.000 claims description 5
- 230000003111 delayed effect Effects 0.000 claims description 2
- 239000000047 product Substances 0.000 description 125
- 238000005097 cold rolling Methods 0.000 description 10
- 238000005098 hot rolling Methods 0.000 description 8
- 238000000137 annealing Methods 0.000 description 5
- 238000013500 data storage Methods 0.000 description 5
- 238000007747 plating Methods 0.000 description 4
- 238000009628 steelmaking Methods 0.000 description 4
- 238000007726 management method Methods 0.000 description 3
- 239000000463 material Substances 0.000 description 3
- 238000002360 preparation method Methods 0.000 description 3
- 230000008859 change Effects 0.000 description 2
- 238000010586 diagram Methods 0.000 description 2
- 238000005246 galvanizing Methods 0.000 description 2
- 239000013067 intermediate product Substances 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 230000008520 organization Effects 0.000 description 2
- 238000004381 surface treatment Methods 0.000 description 2
- 229910001335 Galvanized steel Inorganic materials 0.000 description 1
- ATJFFYVFTNAWJD-UHFFFAOYSA-N Tin Chemical compound [Sn] ATJFFYVFTNAWJD-UHFFFAOYSA-N 0.000 description 1
- 238000004364 calculation method Methods 0.000 description 1
- 238000005266 casting Methods 0.000 description 1
- 230000002860 competitive effect Effects 0.000 description 1
- 238000009749 continuous casting Methods 0.000 description 1
- 230000008094 contradictory effect Effects 0.000 description 1
- 238000007796 conventional method Methods 0.000 description 1
- 239000012467 final product Substances 0.000 description 1
- 239000008397 galvanized steel Substances 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 230000006872 improvement Effects 0.000 description 1
- 230000002452 interceptive effect Effects 0.000 description 1
- 230000007774 longterm Effects 0.000 description 1
- 239000002994 raw material Substances 0.000 description 1
- 238000007670 refining Methods 0.000 description 1
- 238000005096 rolling process Methods 0.000 description 1
- 239000010935 stainless steel Substances 0.000 description 1
- 229910001220 stainless steel Inorganic materials 0.000 description 1
- 239000002436 steel type Substances 0.000 description 1
- 239000000725 suspension Substances 0.000 description 1
- 239000013077 target material Substances 0.000 description 1
- 230000003442 weekly effect Effects 0.000 description 1
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
- Y02P90/02—Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
- Y02P90/30—Computing systems specially adapted for manufacturing
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
- Y02P90/80—Management or planning
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Description
本発明は、複数の製造工程を有する製鉄所から製品を出荷するための鉄鋼製品の生産出荷計画作成システム及びその生産出荷計画作成方法に関する。 The present invention relates to a production / shipment plan creation system for steel products and a production / shipment plan creation method for shipping products from an ironworks having a plurality of manufacturing processes.
従来、鉄鋼製品の製造に際しては、上工程である製鋼及び鋳造工程における製造ロットの制約が非常に厳しく、競争力のある製品を製造するためには、上工程の製造ロット編成における高歩留な計画が不可欠であった。また、運用面に着目すると、保有設備の稼働率を最大限にすることが重要であり、そのために、例えば、熱延（熱間圧延）工程、冷延（冷間圧延）工程、及びめっき（連続亜鉛めっき）工程を有する下工程の需要供給バランスを精度良く予測し、生産計画を立案する必要があった。更に、顧客に対する納期確約を履行するためにも、下工程の需要供給バランスを考慮した生産計画の立案が必要であった。
生産計画の立案に関しては、例えば、自動車のような組み立て産業における部品供給コントロール（即ち、在庫管理）を中心とした内容のものが開示されているが、この生産計画では、主として自製原料を取り扱う素材産業に対応できるものではなかった。この素材産業としての特異性として、例えば、鉄鋼業においては、各製造工程の生産効率化の因子（例えば、製鋼転炉は成分単位、熱延は加熱温度）が異なるため、各製造工程の最大能力を指向すると、二律背反の要素を有する等の恐れがある。
Conventionally, when manufacturing steel products, the restrictions on production lots in the steelmaking and casting processes, which are the upper processes, are very strict, and in order to produce competitive products, a high yield in the production lot organization in the upper processes is required. Planning was essential. Also, from the operational aspect, it is important to maximize the operating rate of the owned equipment. For this purpose, for example, a hot rolling (hot rolling) process, a cold rolling (cold rolling) process, and plating ( It was necessary to accurately predict the supply and demand balance of the lower process having the (continuous galvanizing) process and to formulate a production plan. Furthermore, in order to fulfill delivery date promises to customers, it was necessary to create a production plan that takes into account the supply and demand balance of the lower process.
Regarding production planning, for example, contents centering on parts supply control (ie, inventory management) in the assembly industry such as automobiles are disclosed, but in this production plan, materials that mainly handle self-produced raw materials are disclosed. It was not compatible with industry. As a peculiarity of this material industry, for example, in the steel industry, the production efficiency factors of each manufacturing process (for example, steelmaking converters are component units, hot rolling is the heating temperature) are different. If the ability is oriented, there is a risk of having a contradictory element.
そこで、素材産業に適用する生産計画として特許文献１に、例えば、１週間分の注文群に対して製鋼及び熱延工程の制約を考慮した製造ロット編成を実施し、その結果を下工程の生産計画に連携させる対話型スケジューリングシステムが開示されている。
また、特許文献２には、遡り計画作成処理工程で作成された生産計画の注文群を第１の取り合わせ制約に基づいて処理をして、上工程の製造ロットの粗生産計画を作成する上工程粗計画処理工程と、この上工程粗計画処理工程で作成された生産計画の注文群のうち至近の着手分を第２の取り合わせ制約に基づいて処理をして、上工程の製造ロットの精生産計画を作成する上工程精計画処理工程とを有する鉄鋼中間製品の生産計画作成方法が開示されている。
そして、特許文献３には、注文情報、注文投入情報、及び納期情報から対象材源を抽出して、揚港ごと又は河岸ごとに情報を集約し、その結果に基づいて予定配船ロット番号を付与する方法が開示されている。
以上の方法により、納期遅れが発生しにくく、更には中間製品の在庫量も抑制した設備運用が可能になる。
Therefore, as a production plan to be applied to the material industry, for example, in Patent Document 1, a production lot organization that considers steelmaking and hot-rolling process restrictions is implemented for an order group for one week, and the result is produced in the lower process. An interactive scheduling system that is linked to a plan is disclosed.
Further, in Patent Document 2, an upper process for processing a group of production plans created in the retrospective plan creation process based on the first assortment constraint to create a rough production plan for the production lot of the upper process. The rough production process and the production order created in this coarse production process are processed based on the second assortment, and the production lot of the production process is refined. A method for creating a production plan for a steel intermediate product having an upper process fine planning process for creating a plan is disclosed.
In Patent Document 3, the target material sources are extracted from the order information, the order input information, and the delivery date information, and the information is aggregated for every port or riverbank. A method of providing is disclosed.
By the above method, it becomes difficult to delay the delivery date, and it is possible to operate the facility while suppressing the inventory of intermediate products.
しかしながら、前記従来の生産計画の立案には、未だ解決すべき以下のような問題があった。
特許文献１の方法は、選択された注文群のみを対象にしたものであるが、実際の注文群は１ケ月分から２ケ月分存在しており、販売計画に基づいて製造計画を策定し、１週間単位に至近の注文群を選択して製造につなげているため、この点において適用範囲及び処理内容に改善の余地を残している。また、需要家の注文がすべて大口であれば問題は生じにくいが、小口の注文を製造につなげるためには、歩留と納期の両方を考慮した細かな判断が要求される。そのため、１週間単位の注文群選択にそぐわないという問題点があった。
そして、特許文献２は、遡り計画を作成する際の制約条件が１種類に固定されており、作成した遡り計画の精度を十分に高めることができず、その結果より高収益を志向するには至っていない。
特許文献３においても、計画を作成する際の制約条件が１種類に固定されており、高収益を志向するには至っていない。
更に、特許文献１〜３においては、製品の納期を基準にして生産計画を作成しているため、各製造工程の製造装置に、例えば、製品の品種間の切り替え時の制約条件、稼働シフト、又は修繕以外の休止時間が発生する場合があり、製造装置の稼働率を十分に高めた生産計画を作成できるものではない。ここで、生産計画を作成し直す場合でも、やはり製品の納期を基準として生産計画を作成するため、生産計画の作成に際しての自由度がなく、製造装置の稼働率を向上できる緻密な生産計画を作成できず、製品の生産性が悪くなる。
However, the conventional production planning has still had the following problems to be solved.
The method of Patent Document 1 is intended only for a selected order group, but the actual order group exists for one to two months, and a manufacturing plan is formulated based on a sales plan. Since a group of orders close to the weekly unit is selected and linked to manufacturing, there remains room for improvement in terms of application range and processing content. Also, if all of the customer orders are large, problems are unlikely to occur. However, in order to connect small orders to manufacturing, detailed judgment is required in consideration of both yield and delivery date. For this reason, there is a problem that it is not suitable for selection of an order group for one week.
And in patent document 2, the restriction condition at the time of creating a retroactive plan is fixed to one type, and the accuracy of the retroactive plan that has been created cannot be sufficiently increased. Not reached.
Also in patent document 3, the constraint condition at the time of creating a plan is being fixed to one kind, and has not reached high profit.
Furthermore, in Patent Documents 1 to 3, since the production plan is created based on the delivery date of the product, for example, in the manufacturing apparatus of each manufacturing process, for example, the restriction condition at the time of switching between product types, operation shift, Alternatively, downtime other than repair may occur, and a production plan in which the operating rate of the manufacturing apparatus is sufficiently increased cannot be created. Here, even if the production plan is recreated, the production plan is created based on the delivery date of the product, so there is no freedom in creating the production plan, and a precise production plan that can improve the operating rate of the manufacturing equipment It cannot be created, and the product productivity deteriorates.
本発明はかかる事情に鑑みてなされたもので、生産計上から出荷までの緻密な計画を作成でき、製品の生産性を向上可能な鉄鋼製品の生産出荷計画作成システム及びその生産出荷計画作成方法を提供することを目的とする。 SUMMARY OF THE INVENTION The present invention has been made in view of such circumstances. A production / shipment plan creation system and a production / shipment plan creation method for a steel product capable of creating a detailed plan from production recording to shipment and improving product productivity. The purpose is to provide.
前記目的に沿う第１の発明に係る鉄鋼製品の生産出荷計画作成システムは、転炉を有する鉄源製造装置及び前記鉄源製造装置の下流側に配置される加工装置が備えられた製造ラインを品種に応じて１又は複数有する鉄鋼製造設備で製造した製品を出荷するための鉄鋼製品の生産出荷計画作成システムにおいて、
過去の実績から推定される製品の見込み注文に基づいて、出荷する品種ごとに各製造ラインの製品工程から順に転炉まで遡って粗生産計画を立案し、作成した前記粗生産計画のうち転炉の粗生産計画の並べ替えを行い、この並べ替えた前記粗生産計画に基づいて転炉から製造ラインの製品工程まで下る計画を立案することにより複数の見込み生産出荷計画を作成し、この複数作成された見込み生産出荷計画ごとに、予め定められた設定期間内の製品の出荷量から算出する販売価格の合計と、製品を出荷可能とするまでに要する前記設定期間内の製品の処理量の変動費の合計の差を算出し、その差が最も大きくなる見込み生産出荷計画を選択する見込み計画作成手段と、
前記見込み計画作成手段で選択された見込み生産出荷計画において、実際の製品の品種と、その契約納期日を満たす見込み注文の製品の品種とを照合し、その適合する部分の見込み注文を実際の注文に置き換え、前記製造ラインを構成する複数の製造装置の最大稼働能力を基準とする第１の生産出荷計画と、前記各製造装置により製造される製品の納期を基準とする第２の生産出荷計画をそれぞれ作成する計画作成手段と、
前記各製造装置の稼働率を優先させる場合、前記第１の生産出荷計画において、稼働率が１００％を超えている部分の納期を調整し、稼働率が１００％に満たない前記製造装置に振り替え、品種毎の処理量を調整した生産出荷計画データを保存すると共に、実際の注文の製品の納期を優先させる場合、前記第２の生産出荷計画において、製品の注文毎に納期を調整し、納期に余裕がある注文について、その製造日時を遅らせた生産出荷計画データを保存し、予め設定した製品の契約納期日と前記第１、第２の生産出荷計画から得られる製品の出荷日を整合させた前記生産出荷計画データに基づいて製品を出荷する計画決定手段とを有し、
前記各製造装置における品種ごとの単位時間当たり生産量のデータを格納する設備能力記憶部と、
前記各製造装置における品種間の切り替え時の制約条件と稼働シフトのデータを格納する設備稼働記憶部と、
前記各製造装置の修繕及び工事の期間と開始日のデータを格納する設備修繕記憶部とを更に有し、
前記計画作成手段により、前記設備能力記憶部のデータと、前記実際の注文に基づく製品の品種ごとの量から、この量を製造するために要する時間を算出して前記第１の生産出荷計画を作成し、前記設備能力記憶部、前記設備稼働記憶部、及び前記設備修繕記憶部の各データを用いて前記第２の生産出荷計画を作成する。
The production / shipment plan creation system for steel products according to the first aspect of the present invention comprises a production line provided with an iron source production apparatus having a converter and a processing device arranged downstream of the iron source production apparatus. In the production / shipment plan creation system for steel products for shipping products manufactured at one or more steel manufacturing facilities depending on the type,
Based on the prospective order of products estimated from past results, a rough production plan is drawn up from the product process of each production line to the converter in order for each product to be shipped, and the converter is included in the prepared rough production plan. Create multiple prospective production shipment plans by rearranging the rough production plans and creating a plan from the converter to the product process of the production line based on the rearranged rough production plans. For each estimated production shipment plan, the total sales price calculated from the shipment amount of the product within a predetermined setting period and the fluctuation of the processing amount of the product within the setting period required until the product can be shipped A prospective planning tool that calculates the total cost difference and selects the prospective production shipment plan with the largest difference,
In the prospective production shipment plan selected by the prospective plan creation means, the actual product type and the product type of the prospective order product satisfying the contract delivery date are collated, and the prospective order of the matching part is actually ordered. The first production shipment plan based on the maximum operating capacity of the plurality of manufacturing apparatuses constituting the production line, and the second production shipment plan based on the delivery date of the products manufactured by the respective manufacturing apparatuses A plan creation means for creating each
When priority is given to the operating rate of each manufacturing apparatus, the delivery date of the portion where the operating rate exceeds 100% is adjusted in the first production and shipment plan, and transferred to the manufacturing apparatus whose operating rate is less than 100%. When the production shipment plan data in which the processing amount for each product type is adjusted and the delivery date of the product of the actual order is given priority, the delivery date is adjusted for each product order in the second production shipment plan, and the delivery date Production shipment plan data with the manufacturing date delayed for orders with sufficient margins are stored , and the contract delivery date of the preset product and the shipment date of the product obtained from the first and second production shipment plans are matched. and a planning decision means to ship products on the basis of the production shipment plan data,
An equipment capacity storage unit for storing data of the production amount per unit time for each product type in each manufacturing apparatus;
A facility operation storage unit that stores constraint conditions and operation shift data when switching between types in each of the manufacturing apparatuses,
A facility repair storage unit that stores data of repair and construction period and start date of each manufacturing apparatus,
The plan creation means calculates the time required to manufacture this quantity from the data of the equipment capacity storage unit and the quantity of each product type based on the actual order, and calculates the first production shipment plan. The second production / shipment plan is created using the data of the equipment capacity storage unit, the equipment operation storage unit, and the equipment repair storage unit.
第１の発明に係る鉄鋼製品の生産出荷計画作成システムにおいて、前記計画決定手段で前記予め設定した製品の契約納期日が前記出荷日によって満たされない場合は、前記計画作成手段で前記実際の注文の製品の納期を変更して新たな第１、第２の生産出荷計画を作成し、前記計画決定手段で前記予め設定した製品の契約納期日との整合を再度行うことが好ましい。 In the production and shipping plan creation system for steel products according to the first aspect of the present invention, when the contract delivery date of the product preset by the plan determination means is not satisfied by the shipment date, the plan creation means It is preferable to create new first and second production / shipment plans by changing the delivery date of the product, and to reconcil with the preset contract delivery date of the product by the plan determination means.
第１の発明に係る鉄鋼製品の生産出荷計画作成システムにおいて、前記見込み生産出荷計画は月を単位とする月別生産計画であり、前記第１、第２の生産出荷計画は日を単位とする日別生産計画であることが好ましい。 In the production / shipment plan creation system for steel products according to the first invention, the prospective production / shipment plan is a monthly production plan in units of months, and the first and second production / shipment plans are days in units of days. A separate production plan is preferred.
前記目的に沿う第２の発明に係る鉄鋼製品の生産出荷計画作成方法は、第１の発明に係る鉄鋼製品の生産出荷計画作成システムを使用して、製品の生産から出荷までの計画を作成する。 The production and shipping plan creation method for steel products according to the second invention in accordance with the above object creates a plan from production to shipment of products using the production and shipment plan creation system for steel products according to the first invention. .
請求項１〜３記載の鉄鋼製品の生産出荷計画作成システム、及び請求項４記載の鉄鋼製品の生産出荷計画作成方法は、見込み計画作成手段により、見込み注文に基づいて作成した複数の見込み生産出荷計画毎に、製品の販売価格の合計と処理量の変動費の合計の差の算出を行うので、従来よりも高収益を得ることが可能な見込み生産出荷計画を選択できる。また、計画作成手段により、選択した見込み生産出荷計画に基づいて、各製造装置の最大稼働能力を基準とした第１の生産出荷計画と、製品の納期を基準とした第２の生産出荷計画をそれぞれ作成するので、従来よりも高収益が得られる生産出荷計画の選択範囲を広げることができる。そして、計画決定手段により、製品の契約納期日と作成した第１、第２の生産出荷計画から得られる製品の出荷日とを整合することで、製品の契約納期日を満足し、しかも製品の各製造装置の稼働率を向上可能な生産出荷計画を作成できる。
このように、見込み計画作成手段、計画作成手段、及び計画決定手段を有しているので、生産計上から出荷までの緻密な計画を作成でき、製品の生産性を向上できる。
さらにまた、各製造装置の製品の製造に要する各条件を詳細に設定するので、作成した生産出荷計画の精度を更に高めることができる。
The production / shipment plan creation system for steel products according to claims 1 to 3 and the production / shipment plan creation method for steel products according to claim 4 are a plurality of potential production shipments created based on a prospective order by a prospective plan creation means. For each plan, the difference between the sum of the sales price of the products and the sum of the variable costs of the processing amount is calculated, so that it is possible to select a prospective production shipment plan that can obtain higher profits than before. In addition, based on the selected prospective production shipment plan, the first production shipment plan based on the maximum operating capacity of each manufacturing device and the second production shipment plan based on the delivery date of the product are selected by the plan creation means. Since each is created, it is possible to expand the selection range of the production / shipment plan that can obtain higher profits than before. Then, the plan decision means matches the product contract delivery date with the product shipment dates obtained from the created first and second production shipment plans, thereby satisfying the product contract delivery date. It is possible to create a production shipment plan that can improve the operating rate of each manufacturing apparatus.
As described above, since the prospective plan creation means, the plan creation means, and the plan determination means are provided, it is possible to create a detailed plan from production recording to shipment, and to improve the productivity of the product.
Furthermore, since each condition required for manufacturing the product of each manufacturing apparatus is set in detail, the accuracy of the produced production shipment plan can be further increased.
特に、請求項２記載の鉄鋼製品の生産出荷計画作成システムは、予め設定した製品の契約納期日が第１、第２の生産出荷計画の出荷日によって満たされない場合、製品の納期を変更して新たな第１、第２の生産出荷計画を作成し、再度の整合を行うので、より精度の高い緻密な計画を作成できる。 In particular, the production and shipping plan creation system for steel products according to claim 2 changes the delivery date of the product when the contract delivery date of the preset product is not satisfied by the shipping date of the first and second production and shipping plans. Thus, new first and second production / shipment plans are created and reconciled again, so that a more precise and precise plan can be created.
続いて、添付した図面を参照しつつ、本発明を具体化した実施の形態につき説明し、本発明の理解に供する。
ここで、図１は本発明の一実施の形態に係る鉄鋼製品の生産出荷計画作成システムを使用した生産出荷計画作成方法のフローチャート、図２は同生産出荷計画作成システムで作成した能力制約無し条件の日別生産計画の説明図、図３は同生産出荷計画作成システムで作成した能力制約有り条件の日別生産計画の説明図、図４は同生産出荷計画作成システムを適用したコンピュータの配置構成の説明図である。
Next, embodiments of the present invention will be described with reference to the accompanying drawings for understanding of the present invention.
Here, FIG. 1 is a flowchart of a production / shipment plan creation method using the production / shipment plan creation system for steel products according to one embodiment of the present invention, and FIG. 2 is a condition without capacity restriction created by the production / shipment plan creation system. 3 is an explanatory diagram of the daily production plan, FIG. 3 is an explanatory diagram of the daily production plan with the capacity constraint created by the production shipment plan creation system, and FIG. 4 is an arrangement of computers to which the production shipment plan creation system is applied. It is explanatory drawing of.
本発明の一実施の形態に係る鉄鋼製品の生産出荷計画作成システム（以下、単に計画作成システムともいう）は、転炉を有する鉄源製造装置と、この鉄源製造装置の下流側に配置されるその他の加工装置が備えられた製造ラインを、品種に応じて１又は複数有する鉄鋼製造設備で製造された製品を出荷するための生産出荷計画作成システムであって、製品の見込み注文に基づいて作成する長期的な月別生産計画（見込み生産出荷計画の一例）から、実際の注文に基づいて作成する短期的な日別生産計画を作成することで、生産計上から出荷までの緻密な計画を作成して、製品の生産性を向上するものである。以下、詳しく説明する。 A steel product production and shipping plan creation system (hereinafter also simply referred to as a plan creation system) according to an embodiment of the present invention is disposed on the downstream side of an iron source production apparatus having a converter and the iron source production apparatus. A production / shipment plan creation system for shipping a product manufactured at a steel manufacturing facility having one or more manufacturing lines equipped with other processing devices depending on the product type, based on the prospective order of the product Create a detailed plan from production recording to shipment by creating a short-term daily production plan created based on actual orders from a long-term monthly production plan to be created (an example of a prospective production shipment plan) Thus, the productivity of the product is improved. This will be described in detail below.
図４に示すように、鉄鋼製品の生産出荷計画作成システムは、データ記憶手段、見込み計画作成手段、計画作成手段、及び計画決定手段を備え、データの入力及び削除が可能であり、ホストコンピュータ１０とのデータの送受信が可能なコンピュータ１１に構築されるものである。なお、データ記憶手段、見込み計画作成手段、計画作成手段、及び計画決定手段の各処理は、コンピュータ１１内の記憶装置に格納されたプログラムにより実行される。ここで、各手段は、１台のコンピュータ１１のみに構成することなく、ホストコンピュータ１０とのデータの送受信が可能であり、しかも相互にデータの送受信が可能な複数台のコンピュータ１２〜１４にそれぞれ構築することも可能である。このとき、各コンピュータ１２〜１４に構築された各手段の処理は、それぞれのコンピュータ内の記憶装置に格納されたプログラムにより実行される。
データ記憶手段は、注文記憶部、設備能力記憶部、設備稼働記憶部、設備修繕記憶部、通過工程記憶部、工程毎のロット纏め記憶部、販売価格記憶部、及び変動費記憶部を有している。
As shown in FIG. 4, the production / shipment plan creation system for steel products includes a data storage means, a prospective plan creation means, a plan creation means, and a plan decision means, and can input and delete data. It is constructed in the
The data storage means includes an order storage unit, an equipment capacity storage unit, an equipment operation storage unit, an equipment repair storage unit, a passing process storage unit, a lot summary storage unit for each process, a sales price storage unit, and a variable cost storage unit. ing.
注文記憶部は、注文の品種ごと及び向け先ごとの注文量、輸送条件、及びその納期のデータを格納するものである。
ここで、注文は、見込み（過去の実績）注文と実際の注文を有する。
また、品種とは、最終製品の種類を意味し、月別生産計画と日別生産計画とではその分類のレベル（階層）が異なる。
月別生産計画の作成に使用する品種とは、例えば、熱間圧延（熱延）コイル、冷間圧延（冷延）コイル、薄板、電磁鋼板、ステンレス鋼板、厚板、条鋼、又は形鋼を意味する。
一方、日別生産計画の作成に使用する品種は、月別生産計画の品種よりも更に細かいものを意味し、主要な通過工程によって細分化したものを意味する。このため、日別生産計画の品種は、例えば、同じ溶融亜鉛めっき鋼板でも、めっき処理に使用する鋼板の通過工程（熱間圧延又は冷間圧延）の違いで別品種となり、また同じブリキでも、連続焼鈍を行うか、又は箱型焼鈍を行うかで異なる。
The order storage unit stores order quantity, transportation conditions, and delivery date data for each type of order and each destination.
Here, the orders include a prospect (past performance) order and an actual order.
The product type means the type of the final product, and the classification level (hierarchy) differs between the monthly production plan and the daily production plan.
Variety used to create monthly production plan means, for example, hot rolled (hot rolled) coil, cold rolled (cold rolled) coil, thin plate, electromagnetic steel plate, stainless steel plate, thick plate, long bar, or section steel To do.
On the other hand, the product used for creating the daily production plan means a finer product than that of the monthly production plan, and means a product that is subdivided by the main passing process. For this reason, the varieties of daily production plans are, for example, the same hot-dip galvanized steel sheet, but different varieties due to the difference in the passing process (hot rolling or cold rolling) of the steel sheet used for the plating process, It differs depending on whether continuous annealing or box-type annealing is performed.
なお、品種が決まることで、製品の製造ラインも決定される。
製造ラインは複数の製造装置、即ち、転炉とこれに付帯する二次精錬及び連続鋳造を行う製造手段からなる鉄源製造装置と、更に鉄源製造装置の下流側に配置される１以上の加工装置（例えば、熱延、冷延、焼鈍、及び表面処理（亜鉛めっきなど）のいずれか１又は２以上の処理を行う装置）で構成されている。
ここで、鉄源製造装置は、鉄源工程（製鋼工程ともいう）に配置されている。
Note that the product production line is also determined by determining the product type.
The production line includes a plurality of production apparatuses, that is, an iron source production apparatus comprising a converter and production means for performing secondary refining and continuous casting incidental to the converter, and one or more arranged at the downstream side of the iron source production apparatus. It is comprised with the processing apparatus (For example, the apparatus which performs any 1 or 2 or more processes of hot rolling, cold rolling, annealing, and surface treatment (galvanization etc.)).
Here, the iron source manufacturing apparatus is arranged in an iron source process (also referred to as a steel making process).
そして、輸送条件としては、例えば、国内陸送、国内海送、及び国外海送がある。
国内陸送としては、例えばトラック輸送があり、国内海送としては、例えば小型の船舶による内航船輸送がある。このような国内向けの製品輸送については、その契約納期日を、客先の要求に応じて、Ｊｕｓｔ ｉｎ ｔｉｍｅデリバリー（指定日搬送）又は生産完了時の自動出荷（客先近くの港倉庫までの出荷又は直納もある）とする。
国外海送としては、中型（最大積載量が例えば、２千トン以上３千トン以下程度）又は大型（最大積載量が例えば、１万トン程度）の船舶による輸送がある。この船舶による輸送は、内航船輸送と比較して入港可能な頻度が少なく（例えば、月に３回以上５回以下程度）、しかも複数品種の製品を積載し搬送することができる。
The transportation conditions include, for example, domestic land transportation, domestic sea transportation, and overseas sea transportation.
Domestic land transportation includes, for example, truck transportation, and domestic sea transportation includes, for example, domestic shipping by a small ship. For such domestic product transportation, the contract delivery date shall be set to Just in time delivery (delivery on the specified date) or automatic shipment upon completion of production (to the port warehouse near the customer) according to the customer's request. Shipment or direct delivery is also possible).
As overseas shipping, there is transportation by medium-sized (maximum loading capacity is, for example, about 2,000 to 3,000 tons or less) or large-sized ships (maximum loading capacity is, for example, about 10,000 tons). The shipping by this ship is less frequently possible to enter the port than the domestic shipping (for example, about 3 to 5 times a month), and more than one product can be loaded and transported.
設備能力記憶部は、各製造装置における品種ごとの単位時間当たり生産量（トン／時間）のデータを格納し、設備稼働記憶部は、各製造装置における品種間の切り替え時の制約条件と稼働シフトのデータを格納するものである。ここで、制約条件とは、例えば、表面にめっきする製造ライン（例えば、溶融亜鉛めっきライン）での、品種の切替えに伴う製造ラインの停止又は鋼板パスラインの変更を意味する。また、製造ラインの停止を伴わなくても、例えば、冷間圧延工程では、鋼板の幅を、広い幅から狭い幅に順次通板（同一のロールで圧延する場合）するためのスケジュール的な制約もある。
そして、稼働シフトとは、各製造装置の稼働状況、即ち稼働させる作業者の勤務形態（例えば、２交代又は３交代）で決定されるものである。
なお、同じ製造装置が複数設置されている場合、例えば、Ａ〜Ｃ（複数）の冷延装置が設置されている場合は、採用可能な複数の設備能力パターンのデータ、及び複数の設備稼働パターンのデータ、即ち（１）Ａ〜Ｃのいずれの冷延装置も使用可、（２）Ａのみ使用可、（３）Ｂのみ使用可、のようなデータを、設備能力記憶部又は設備稼働記憶部に格納しておくことが好ましい。
The equipment capacity storage unit stores data on production volume per unit time (ton / hour) for each product type in each manufacturing device, and the equipment operation storage unit stores constraints and operation shifts when switching between product types in each manufacturing device. Is stored. Here, the constraint condition means, for example, the stop of the production line or the change of the steel plate pass line in accordance with the change of the product type in the production line (for example, hot dip galvanizing line) for plating on the surface. Moreover, even if the production line is not stopped, for example, in the cold rolling process, schedule constraints for sequentially passing the steel sheet from a wide width to a narrow width (when rolling with the same roll) are performed. There is also.
The operation shift is determined based on the operation status of each manufacturing apparatus, that is, the working mode (for example, 2 shifts or 3 shifts) of the worker to be operated.
In addition, when the same manufacturing apparatus is installed in multiple numbers, for example, when the cold rolling apparatuses A to C (plurality) are installed, data of a plurality of equipment capacity patterns that can be adopted, and a plurality of equipment operation patterns The data of (1) A to C can be used, (2) Only A can be used, (3) Only B can be used. It is preferable to store it in the section.
設備修繕記憶部は、各製造装置の修繕及び工事の期間と開始日のデータを記憶するものである。ここで、Ａ〜Ｃの冷延装置の修繕計画を例にとって説明すると、各冷延装置ごとに、可能休止期間（開始日時及び終了日時）と工期時間を設定できる。
このように、Ａ〜Ｃの冷延装置が設置されている場合、採用可能な複数の工事の順番、即ち（１）Ａ→Ｂ→Ｃ、（２）Ｂ→Ａ→Ｃ、（３）Ｃ→Ｂ→Ａ、のような設備修繕パターンのデータを、設備修繕記憶部に格納しておくことが好ましい。
通過工程記憶部は、品種ごとに前記した製造ラインの必要通過工程の指定、即ち通過必須工程のデータを格納するものである。
工程毎のロット纏め記憶部は、各工程の製造装置を稼働するに際しての管理条件、例えば、冷間圧延工程では圧延を行う鋼板の厚みの上限値及び下限値を、また焼鈍工程では焼鈍温度の上限値及び下限値を、それぞれ規定したデータを記憶するものである。
The equipment repair storage unit stores data of repair and construction period and start date of each manufacturing apparatus. Here, if it explains taking the repair plan of the cold rolling apparatus of A to C as an example, the possible suspension period (start date / time and end date / time) and construction period time can be set for each cold rolling apparatus.
Thus, when the cold rolling apparatuses A to C are installed, the order of a plurality of constructions that can be adopted, that is, (1) A → B → C, (2) B → A → C, (3) C It is preferable to store the equipment repair pattern data such as → B → A in the equipment repair storage unit.
The passing process storage unit stores the necessary passing process of the manufacturing line described above for each product type, that is, the data of the passing essential process.
The lot summary storage unit for each process is a management condition when operating the manufacturing apparatus of each process, for example, the upper limit value and the lower limit value of the thickness of the steel sheet to be rolled in the cold rolling process, and the annealing temperature in the annealing process. Data defining the upper limit value and the lower limit value is stored.
販売価格記憶部は、品種ごとに販売価格（円／トン）のデータを格納するものである。ここで、販売価格としては、例えば、国内価格Ａ、国内価格Ｂ、輸出価格Ａ、及び輸出価格Ｂがある。
変動費記憶部は、製造ラインの各通過工程及び品種ごとの変動費（円／トン）を格納するものである。ここで、変動費は、例えば、鉄源工程の場合は２基の各転炉について、熱延工程の場合は１基の熱延について、表面処理工程の場合は電気亜鉛めっき及びブリキめっきについて、製造に要する費用がそれぞれ設定される。
以上の各記憶部により、データ記憶手段が構成されている。なお、各記憶部のデータはデータベース化して蓄積されている。
The selling price storage unit stores selling price (yen / ton) data for each product type. Here, examples of the selling price include a domestic price A, a domestic price B, an export price A, and an export price B.
The variable cost storage unit stores variable costs (yen / ton) for each passing process and each kind of production line. Here, the variable cost is, for example, about two converters in the case of the iron source process, about one hot rolling in the case of the hot rolling process, about electrogalvanizing and tin plating in the case of the surface treatment process, The cost required for manufacturing is set.
Each storage unit described above constitutes a data storage unit. The data in each storage unit is stored in a database.
計画作成システムの見込み計画作成手段では、製品の見込み注文（過去の実績）に基づいて、製品の納期から生産までの複数の月別生産計画を立案した後、この中から選択した月別生産計画を格納する。
この複数の月別生産計画の立案に際しては、注文記憶部の各データに基づいて、各品種ごとの契約納期日を使用する。なお、月別生産計画の立案に際しては、注文の大部分が見込み注文であるが、実際の注文が含まれていてもよい。
ここで、国内向けの製品輸送については、その契約納期日を、客先の要求に応じた日を使用し、国外向けの製品輸送については、岸壁作業計画（バース計画：例えば特願２００５−１１１２４１）から得られる船舶の着岸日を使用する。ここで、岸壁作業計画とは、どの船舶をどの岸壁に着岸させ製品の積載を行って離岸させるかの一連の荷役作業の計画を意味する。
Based on the prospective order (past past results) of the product, the prospective plan creation means of the plan creation system prepares multiple monthly production plans from product delivery date to production, and then stores the monthly production plans selected from these To do.
When making a plurality of monthly production plans, the contract delivery date for each product type is used based on each data in the order storage unit. Note that when making a monthly production plan, most of the orders are prospective orders, but actual orders may be included.
Here, for domestic product transportation, the contract delivery date is used according to the customer's request, and for overseas product transportation, a quay work plan (berth plan: for example, Japanese Patent Application No. 2005-111241) is used. ) Use the berth date of the ship. Here, the quay work plan means a series of cargo handling work plans for deciding which ship lands on which quay, loading products, and leaving the berth.
そして、この契約納期日に基づいて、出荷する品種ごとに各製造ラインの製品工程（最終工程）から順に転炉まで遡って粗生産計画を立案し、作成した粗生産計画のうち転炉の粗生産計画の並べ替えを行い、この並べ替えた粗生産計画に基づいて、転炉から製造ラインの製品工程まで下る計画を立案する。この計画の立案に際しては、注文記憶部、設備能力記憶部、設備稼働記憶部、設備修繕記憶部、及び通過工程記憶部の各データを使用する。
なお、この月別生産計画の作成処理に関しては、アスペンテック・ブローナー社が販売している「プロダクションプランナー」というソフトウェアを使用することも可能である。
Based on the contract delivery date, a rough production plan is drawn up from the product process (final process) of each production line to the converter in order for each product type to be shipped. The production plans are rearranged, and a plan from the converter to the product process of the production line is made based on the rearranged rough production plan. When planning this plan, each data of the order storage unit, the equipment capacity storage unit, the equipment operation storage unit, the equipment repair storage unit, and the passage process storage unit is used.
For the monthly production plan creation process, it is also possible to use software called “Production Planner” sold by Aspentech Broner.
次に、複数作成された月別生産計画に基づいて、予め定められた設定期間（例えば、１ヶ月）内の製品の出荷量から算出する販売価格の合計と、製品を出荷可能とするまでに要する設定期間内の製品の処理量の変動費の合計の差を算出し、その差が最も大きくなる月別生産計画を選択する。この差は、収益の管理指標であるスループット（ＴＰ）と呼ばれるものである。
（ＴＰ）＝（販売単価）×（出荷量）−（変動費単価）×（処理量）
ここで、処理量には、製品の出荷をしなくても、その期間内に処理した量（即ち、製品在庫量）も含まれるため、在庫相当分の変動費を低減し、変動費単価と処理量との積を小さくすることで、スループットを大きくしてより高収益が可能となる計画を立案できる。
なお、この算出処理に際しては、注文記憶部、販売価格記憶部、及び変動費記憶部の各データを使用する。
Next, based on a plurality of monthly production plans created, it is necessary to make the total of the sales price calculated from the shipment amount of the product within a predetermined setting period (for example, one month) and the product can be shipped. The difference between the total variable costs of the product processing amount within the set period is calculated, and the monthly production plan that maximizes the difference is selected. This difference is called throughput (TP), which is a management index of revenue.
(TP) = (Sales unit price) × (shipment amount) − (variable cost unit price) × (processing amount)
Here, the processing amount includes the amount processed within the period even if the product is not shipped (that is, the product inventory amount). By reducing the product with the amount of processing, it is possible to make a plan that increases the throughput and enables higher profits.
In this calculation process, each data of the order storage unit, the sales price storage unit, and the variable cost storage unit is used.
計画作成システムの計画作成手段では、見込み計画作成手段で選択された月別生産計画の見込み注文を実際の注文に置き換え、日別生産計画を作成して格納する。
ここで、日別生産計画を作成するに際しては、注文記憶部の実際の製品の品種と、その契約納期日を満たす見込み注文の製品の品種とを照合し、その適合する部分の見込み注文を実際の注文に置き換える。そして、置き換えた実際の注文に基づき、前記した転炉から製造ラインの最終工程まで下る生産計画を立案する。
なお、日別生産計画としては、能力制約無し条件の日別生産計画（第１の生産出荷計画の一例）と能力制約有り条件の日別生産計画（第２の生産出荷計画の一例）がある。
The plan creation means of the plan creation system replaces the prospective order of the monthly production plan selected by the prospective plan creation means with an actual order, and creates and stores a daily production plan.
Here, when creating the daily production plan, the actual product type in the order storage unit is compared with the product type of the expected order that satisfies the contract delivery date, and the expected order of the matching part is actually Replace with an order. Based on the replaced actual order, a production plan is drawn up from the converter to the final process of the production line.
The daily production plan includes a daily production plan with no capacity constraint (an example of a first production / shipment plan) and a daily production plan with a capacity constraint (an example of a second production / shipment plan). .
能力制約無し条件の日別生産計画とは、図２に示すように、設備稼働記憶部及び設備修繕記憶部の例えば各制約条件を考慮することなく、鉄源工程から製造ラインの製品工程まで下る計画を作成し、各製造装置の最大稼働能力を把握可能とする計画である。この計画の作成に際しては、設備能力記憶部の各製造装置における品種ごとの単位時間当たり生産量（トン／時間）のデータと、実際の注文に基づく製品の品種ごとの量から、この量を製造するために要する時間を算出する。これにより、各製造装置の稼働可能な時間と、製品の製造に要する稼働時間から、各製造装置の稼働率が得られる。
能力制約有り条件の日別生産計画とは、図３に示すように、設備能力記憶部、設備稼働記憶部、及び設備修繕記憶部の例えば各制約条件（図３中の斜線部）を用いて作成し、各製造装置により製造される製品の納期を把握可能とする計画である。この日別生産計画の作成に際しては、工程毎のロット纏め記憶部のデータを使用する。
なお、この日別生産計画の作成処理に関しても、前記した「プロダクションプランナー」というソフトウェアを使用することが可能である。
As shown in FIG. 2, the daily production plan with no capacity constraints falls from the iron source process to the product process on the production line without considering each constraint condition of the equipment operation storage unit and the equipment repair storage unit, for example. A plan is created so that the maximum operating capacity of each manufacturing apparatus can be grasped. When creating this plan, this amount is produced from the data of the production volume per unit time (ton / hour) for each product type in each manufacturing device in the equipment capacity storage unit and the amount for each product type based on the actual order. The time required to do this is calculated. Thereby, the operation rate of each manufacturing apparatus can be obtained from the operating time of each manufacturing apparatus and the operating time required for manufacturing the product.
As shown in FIG. 3, the daily production plan with conditions with capacity constraints uses, for example, each constraint condition (shaded area in FIG. 3) of the equipment capacity storage unit, the equipment operation storage unit, and the equipment repair storage unit. The plan is to make it possible to grasp the delivery date of products manufactured and manufactured by each manufacturing device. When creating this daily production plan, the data in the lot summary storage unit for each process is used.
It should be noted that the aforementioned “production planner” software can also be used for the daily production plan creation process.
計画作成システムの計画決定手段では、予め設定した製品の納期である契約納期日と、各日別生産計画から得られる製品の出荷日とを整合させた日別生産計画データ（生産出荷計画データの一例）に基づいて、出荷する製品を決定する。
ここで、契約納期日は、各製造装置の稼働率及び実際の注文の製品の納期を使用して決定する。なお、この契約納期日の作成に際しては、注文記憶部及び設備能力記憶部の各データを使用する。
この出荷する製品の決定に際しては、例えば、各製造装置の稼働率を優先する場合、能力制約無し条件の日別生産計画から得られる製品の出荷日と整合した日別生産計画データを保存する。また、実際の注文の各製品の納期を優先する場合、能力制約有り条件の日別生産計画から得られる製品の出荷日と整合した日別生産計画データを保存する。
In the plan determination means of the plan creation system, the daily production plan data (the production shipment plan data of the production shipment plan data) in which the contract delivery date, which is a preset delivery date of the product, and the shipment date of the product obtained from each daily production plan are aligned The product to be shipped is determined based on (example).
Here, the contract delivery date is determined using the operating rate of each manufacturing apparatus and the delivery date of the product of the actual order. In creating the contract delivery date, each data in the order storage unit and the equipment capacity storage unit is used.
When determining the product to be shipped, for example, when priority is given to the operating rate of each manufacturing apparatus, daily production plan data that is consistent with the shipment date of the product obtained from the daily production plan with no capacity constraint is stored. In addition, when giving priority to the delivery date of each product of the actual order, the daily production plan data consistent with the product shipment date obtained from the daily production plan under the condition with capacity constraint is stored.
続いて、本発明の一実施の形態に係る鉄鋼製品の生産出荷計画作成方法を、図１を参照しながら前記した計画作成システムを使用して説明するが、見込み計画作成手段による月別生産計画の処理に関しては、例えば、特許文献２に開示されているように、従来行われている方法と略同様であるため、同様の部分については簡略化して説明する。
まず、ステップ１（ＳＴ１）において、日別生産計画を作成するための月別生産計画のデータを入力する。また、前日の操業実績又は見込み生産から得られるデータも入力し、例えば、各製造装置の能力の誤差（実績差）を修正し、製造ラインの余力を修正する。
この月別生産計画は、見込み計画作成手段により作成されるもので、注文記憶部に入力された注文情報、即ち品種及び向け先に基づき、この条件に適した輸送条件を選択して、製品の注文を製品の出荷に使用する輸送条件ごとに集計して作成されるものである。
Subsequently, a steel product production / shipment plan creation method according to an embodiment of the present invention will be described using the plan creation system described above with reference to FIG. For example, as disclosed in Patent Document 2, since the processing is substantially the same as the conventional method, the same parts will be described in a simplified manner.
First, in step 1 (ST1), monthly production plan data for creating a daily production plan is input. In addition, data obtained from the previous day's operation results or expected production is also input, and for example, the capacity error (result difference) of each manufacturing apparatus is corrected, and the remaining capacity of the manufacturing line is corrected.
This monthly production plan is created by the prospective plan creation means. Based on the order information input to the order storage unit, that is, the type and destination, the transportation conditions suitable for this condition are selected, and the product order is selected. Are compiled for each transportation condition used for product shipment.
そして、製品の契約納期日を基準とし、設備能力記憶部、設備稼働記憶部、設備修繕記憶部、及び通過工程記憶部の各データを用いて、出荷する品種ごとに各製造ラインの最終工程から順に鉄源工程まで遡る計画を作成する。この作成した計画のうち転炉の生産計画を使用して、製品を同じ鋼種の鉄源ごとに集約するため並べ替えを行う。
更に、並べ替えた転炉の生産計画でそれぞれ配置された各鉄源の品種の製造日を基準とし、設備能力記憶部、設備稼働記憶部、設備修繕記憶部、及び通過工程記憶部の各データを用いて、転炉から各製造ラインの最終工程まで下る計画を作成する。
Based on the contract delivery date of the product, using the data of the equipment capacity storage unit, equipment operation storage unit, equipment repair storage unit, and passage process storage unit, from the final process of each production line for each product type to be shipped Create a plan going back to the iron source process in order. Of the created plans, the converter production plan is used to rearrange the products for each iron source of the same steel type.
Furthermore, each data of the equipment capacity storage unit, the equipment operation storage unit, the equipment repair storage unit, and the passage process storage unit, based on the production date of each iron source type arranged in the production plan of the rearranged converter. Is used to create a plan from the converter to the final process of each production line.
なお、各製造ラインの最終工程から順に鉄源工程まで遡る計画と、転炉から各製造ラインの最終工程まで下る計画の作成に際しては、設備能力記憶部の複数の設備能力パターン、設備稼働記憶部の複数の設備稼働パターン、及び設備修繕記憶部の複数の設備修繕パターンから、それぞれ１つずつのデータを選択して使用する。
これにより、各製造装置の製造能力、稼働時期、及び修繕時期を考慮した計画を作成できる。
以上の方法で作成される複数の月別生産計画を、見込み計画作成手段によって格納する。
In addition, when creating a plan that goes back to the iron source process in order from the final process of each production line and a plan that goes down from the converter to the final process of each production line, multiple equipment capacity patterns in the equipment capacity storage section, equipment operation storage section From the plurality of equipment operation patterns and the plurality of equipment repair patterns in the equipment repair storage unit, one piece of data is selected and used.
Thereby, the plan which considered the manufacturing capability of each manufacturing apparatus, the operation time, and the repair time can be created.
A plurality of monthly production plans created by the above method are stored by the prospective plan creation means.
次に、作成された複数の月別生産計画を使用してスループットを算出する。
ここで、販売価格の合計は、作成した複数の精生産計画の製品の出荷量と、販売価格記憶部の各販売価格単価との積を求めることで算出する。また、変動費の合計は、作成した複数の精生産計画で、製品を出荷可能とするまでに通過した製造ラインの各工程ごとの処理量（在庫量も含む）と、変動費記憶部の変動費単価との積を求めることで算出する。
以上の方法により、スループットが最大となる月別生産計画を選択し、見込み計画作成手段によって格納する。
Next, the throughput is calculated using the plurality of created monthly production plans.
Here, the sum of the sales prices is calculated by obtaining the product of the shipment amount of the products of the plurality of created production plans and the sales price unit price of the sales price storage unit. In addition, the total of variable costs is the amount of processing (including the amount of inventory) for each process on the production line that has passed until the product can be shipped in the multiple production plans created, and the fluctuation in the variable cost storage unit Calculate by calculating the product of the unit cost.
By the above method, the monthly production plan that maximizes the throughput is selected and stored by the prospective plan creation means.
このように入力された月別生産計画の見込み注文を、例えば、本社に設置されたホストコンピュータ１０から送信され、データ記憶手段の注文記憶部に入力された顧客からの実際の注文情報（例えば、品種、向け先、及びその納期日情報）に置き換える。
そして、ステップ２（ＳＴ２）で、前記した月別生産計画の下り計画について、能力制約無し条件の日別生産計画と能力制約有り条件の日別生産計画をそれぞれ作成する。
能力制約無し条件の日別生産計画では、各製造装置の稼働可能な時間と、製品の製造に要する稼働時間から、各製造装置の稼働率が得られる。ここで、稼働率が１００％を超えれば、この製造装置の製造能力が限界（ボトル・ネック工程）であることを意味する。
The expected order of the monthly production plan input in this way is transmitted from, for example, the
In step 2 (ST2), a daily production plan with no capacity restriction condition and a daily production plan with a capacity restriction condition are created for the above-described monthly production schedule down schedule.
In the daily production plan with no capacity constraint, the operating rate of each manufacturing apparatus can be obtained from the operating time of each manufacturing apparatus and the operating time required for manufacturing the product. Here, if the operating rate exceeds 100%, it means that the manufacturing capability of this manufacturing apparatus is the limit (bottleneck process).
また、能力制約有り条件の日別生産計画では、設備稼働記憶部及び設備修繕記憶部の各データを用いて作成し、各製造装置により製造される製品の納期を把握可能とする計画である。ここで、日別生産計画の納期が契約納期日よりも後（Ｏｖｅｒ ｆｌｏｗ）になれば、納期が間に合わないことを意味する。
なお、いずれの日別生産計画の作成に際しても、工程毎のロット纏め記憶部にある各データを使用する。
そして、ステップ３（ＳＴ３）で、ステップ２で作成した各日別生産工程から得られる出荷日と、予め設定した製品の契約納期日とを整合させる。
In addition, in the daily production plan under the capacity-constrained condition, it is a plan that is created using each data of the equipment operation storage unit and the equipment repair storage unit so that the delivery date of the product manufactured by each manufacturing apparatus can be grasped. Here, if the delivery date of the daily production plan is after the contract delivery date (Over flow), it means that the delivery date is not in time.
Note that, in creating any daily production plan, each data in the lot summary storage unit for each process is used.
In step 3 (ST3), the shipping date obtained from each daily production process created in step 2 is matched with the preset contract delivery date of the product.
契約納期日は、各製造装置の稼働率及び実際の注文の製品の納期を使用して決定する。
ここで、各製造装置の稼働率を優先させる場合、即ち各製造装置の稼働率を可能な限り１００％に近づける場合は、能力制約無し条件の日別生産計画において、例えば、稼働率が１００％を超えている部分の納期を調整し、稼働率が１００％に満たない製造装置に振り替え、品種毎の処理量を調整した日別生産計画データを計画決定手段によって保存する。
また、実際の注文の製品の納期を優先させる場合は、能力制約有り条件の日別生産計画において、製品の注文毎に納期を調整し、納期に余裕がある注文については、その製造日時を遅らせた日別生産計画データを計画決定手段によって保存する。
The contract delivery date is determined by using the operating rate of each manufacturing apparatus and the delivery date of the product of the actual order.
Here, when priority is given to the operating rate of each manufacturing apparatus, that is, when the operating rate of each manufacturing apparatus is as close to 100% as possible, for example, in the daily production plan with no capacity constraint, the operating rate is 100%. The delivery date of the part exceeding the limit is adjusted, transferred to a manufacturing apparatus whose operation rate is less than 100%, and daily production plan data in which the processing amount for each product type is adjusted is stored by the plan determination means.
In addition, when giving priority to the delivery date of the product of the actual order, adjust the delivery date for each product order in the daily production plan with limited capacity, and delay the production date and time for orders with a margin in delivery date. The daily production plan data is stored by the plan determination means.
ステップ４（ＳＴ４）において、契約納期日と、使用した日別生産計画の出荷日とを整合させ、整合した日別生産計画データを保存する。ここで、契約納期日と、使用した日別生産計画の出荷日とが整合しない場合、即ち、出荷日が契約納期日を満たさない場合（例えば、船舶の接岸日時が同一になっている場合）は、再度実際の注文の製品の納期変更（納期の調整）を行い、ステップ２で能力制約無し条件の日別生産計画と能力制約有り条件の日別生産計画の作成を再度行う。そして、全ての製品についての日別生産計画データを保存する。
ステップ５（ＳＴ５）において、この日別生産計画データに基づく日別生産計画が決定され、この計画に基づいて製品の出荷が行われる。
In step 4 (ST4), the contract delivery date is matched with the shipping date of the used daily production plan, and the matched daily production plan data is stored. Here, when the contract delivery date and the shipping date of the daily production plan used do not match, that is, when the shipment date does not meet the contract delivery date (for example, when the ship berthing date is the same) Then, the delivery date of the product of the actual order is changed again (adjustment of the delivery date), and in step 2, the daily production plan with no capacity constraint and the daily production plan with the capacity constraint are created again. Then, daily production plan data for all products is stored.
In step 5 (ST5), a daily production plan based on the daily production plan data is determined, and products are shipped based on this plan.
以上、本発明を、一実施の形態を参照して説明してきたが、本発明は何ら上記した実施の形態に記載の構成に限定されるものではなく、特許請求の範囲に記載されている事項の範囲内で考えられるその他の実施の形態や変形例も含むものである。例えば、前記したそれぞれの実施の形態や変形例の一部又は全部を組合せて本発明の鉄鋼製品の生産出荷計画作成システム及びその生産出荷計画作成方法を構成する場合も本発明の権利範囲に含まれる。
また、前記実施の形態においては、見込み生産出荷計画を月別生産計画とし、第１、第２の生産出荷計画を日別生産計画とした場合について説明したが、見込み生産出荷計画を複数月又は年単位で作成することも、また、第１、第２の生産出荷計画を複数日又は数週間単位で作成することも可能である。
As described above, the present invention has been described with reference to one embodiment. However, the present invention is not limited to the configuration described in the above embodiment, and is described in the claims. Other embodiments and modifications conceivable within the scope of the above are also included. For example, the scope of rights of the present invention also includes a case where a production shipment plan creation system and production shipment plan creation method for steel products according to the present invention are configured by combining some or all of the above-described embodiments and modifications. It is.
In the above embodiment, the case has been described where the estimated production shipment plan is a monthly production plan and the first and second production shipment plans are daily production plans. It is possible to create in units, and it is also possible to create the first and second production shipment plans in units of multiple days or weeks.
１０：ホストコンピュータ、１１〜１４：コンピュータ 10: Host computer, 11-14: Computer
Claims (4)
過去の実績から推定される製品の見込み注文に基づいて、出荷する品種ごとに各製造ラインの製品工程から順に転炉まで遡って粗生産計画を立案し、作成した前記粗生産計画のうち転炉の粗生産計画の並べ替えを行い、この並べ替えた前記粗生産計画に基づいて転炉から製造ラインの製品工程まで下る計画を立案することにより複数の見込み生産出荷計画を作成し、この複数作成された見込み生産出荷計画ごとに、予め定められた設定期間内の製品の出荷量から算出する販売価格の合計と、製品を出荷可能とするまでに要する前記設定期間内の製品の処理量の変動費の合計の差を算出し、その差が最も大きくなる見込み生産出荷計画を選択する見込み計画作成手段と、
前記見込み計画作成手段で選択された見込み生産出荷計画において、実際の製品の品種と、その契約納期日を満たす見込み注文の製品の品種とを照合し、その適合する部分の見込み注文を実際の注文に置き換え、前記製造ラインを構成する複数の製造装置の最大稼働能力を基準とする第１の生産出荷計画と、前記各製造装置により製造される製品の納期を基準とする第２の生産出荷計画をそれぞれ作成する計画作成手段と、
前記各製造装置の稼働率を優先させる場合、前記第１の生産出荷計画において、稼働率が１００％を超えている部分の納期を調整し、稼働率が１００％に満たない前記製造装置に振り替え、品種毎の処理量を調整した生産出荷計画データを保存すると共に、実際の注文の製品の納期を優先させる場合、前記第２の生産出荷計画において、製品の注文毎に納期を調整し、納期に余裕がある注文について、その製造日時を遅らせた生産出荷計画データを保存し、予め設定した製品の契約納期日と前記第１、第２の生産出荷計画から得られる製品の出荷日を整合させた前記生産出荷計画データに基づいて製品を出荷する計画決定手段とを有し、
前記各製造装置における品種ごとの単位時間当たり生産量のデータを格納する設備能力記憶部と、
前記各製造装置における品種間の切り替え時の制約条件と稼働シフトのデータを格納する設備稼働記憶部と、
前記各製造装置の修繕及び工事の期間と開始日のデータを格納する設備修繕記憶部とを更に有し、
前記計画作成手段により、前記設備能力記憶部のデータと、前記実際の注文に基づく製品の品種ごとの量から、この量を製造するために要する時間を算出して前記第１の生産出荷計画を作成し、前記設備能力記憶部、前記設備稼働記憶部、及び前記設備修繕記憶部の各データを用いて前記第２の生産出荷計画を作成することを特徴とする鉄鋼製品の生産出荷計画作成システム。 For shipping a product manufactured by a steel manufacturing facility having one or a plurality of manufacturing lines provided with an iron source manufacturing device having a converter and a processing device arranged downstream of the iron source manufacturing device according to the product type In the production and shipping plan creation system for steel products,
Based on the prospective order of products estimated from past results, a rough production plan is drawn up from the product process of each production line to the converter in order for each product to be shipped, and the converter is included in the prepared rough production plan. Create multiple prospective production shipment plans by rearranging the rough production plans and creating a plan from the converter to the product process of the production line based on the rearranged rough production plans. For each estimated production shipment plan, the total sales price calculated from the shipment amount of the product within a predetermined setting period and the fluctuation of the processing amount of the product within the setting period required until the product can be shipped A prospective planning tool that calculates the total cost difference and selects the prospective production shipment plan with the largest difference,
In the prospective production shipment plan selected by the prospective plan creation means, the actual product type and the product type of the prospective order product satisfying the contract delivery date are collated, and the prospective order of the matching part is actually ordered. The first production shipment plan based on the maximum operating capacity of the plurality of manufacturing apparatuses constituting the production line, and the second production shipment plan based on the delivery date of the products manufactured by the respective manufacturing apparatuses A plan creation means for creating each
When priority is given to the operating rate of each manufacturing apparatus, the delivery date of the portion where the operating rate exceeds 100% is adjusted in the first production and shipment plan, and transferred to the manufacturing apparatus whose operating rate is less than 100%. When the production shipment plan data in which the processing amount for each product type is adjusted and the delivery date of the product of the actual order is given priority, the delivery date is adjusted for each product order in the second production shipment plan, and the delivery date Production shipment plan data with the manufacturing date delayed for orders with sufficient margins are stored , and the contract delivery date of the preset product and the shipment date of the product obtained from the first and second production shipment plans are matched. and a planning decision means to ship products on the basis of the production shipment plan data,
An equipment capacity storage unit for storing data of the production amount per unit time for each product type in each manufacturing apparatus;
A facility operation storage unit that stores constraint conditions and operation shift data when switching between types in each of the manufacturing apparatuses,
A facility repair storage unit that stores data of repair and construction period and start date of each manufacturing apparatus,
The plan creation means calculates the time required to manufacture this quantity from the data of the equipment capacity storage unit and the quantity of each product type based on the actual order, and calculates the first production shipment plan. A production / shipment plan creation system for steel products, characterized in that the second production / shipment plan is created using each data of the facility capacity storage unit, the facility operation storage unit, and the facility repair storage unit .
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