Manufacturing line simulation device, data input assistance device, and data input assistance method

In a conventional manufacturing line simulation, there are a number of input items, and therefore, time is required for input. In addition, depending on the objective of the simulation, there are also parameters for which input is not required, and therefore, there is the problem of reducing the number of inputs according to the library. The present invention is configured to be provided with: a simulation library presentation unit which presents, to a user, a plurality of items of model libraries which are stored in a storage unit so as to receive specification of items of the model libraries from the user; a priority degree imparting unit which, with respect to the specified items of the model libraries, uses an input association table stored in the storage unit in order to calculate the priorities of the input items so as to present an input screen to the user on the basis of the calculated priorities; a simulation input receiving unit for receiving input of the input items on the user screen; and a duplicate data generation unit which, with respect to the duplicate items indicated in the input item association table, duplicates data that has been already received at the simulation input receiving unit.

TECHNICAL FIELD

The present invention relates to a manufacturing line design of an industrial machine, a motor, a turbine or the like. In particular, the present invention relates to a technical field of a manufacturing line simulation device for automatically creating a manufacturing line simulation model which becomes input data of manufacturing line simulation conducted to previously verify behavior of a manufacturing line.

BACKGROUND ART

As a technique for evaluating a production quantity and the number in process in manufacturing line design, there is manufacturing line simulation. For utilizing the manufacturing line simulation, facilities, workers and transport equipment which are components of the manufacturing line are first formed into a model on a computer. In a conventional manufacturing line simulation, a model in the manufacturing line simulation is constructed by creating libraries of models created in past simulation and combining libraries in accordance with requirements of the simulation.

For example, in Patent Literature 1, a technique of automatically selecting a library corresponding to process information that is input by a manufacturing line designer from libraries of past simulation is stated.

CITATION LIST

Patent Literature

SUMMARY OF INVENTION

Technical Problem

In Patent Literature 1, a technique of constructing a manufacturing line simulation model by creating libraries of past simulation cases and combining libraries in accordance with requirements of simulation is stated. However, there are a large number of input items of manufacturing line simulation such as working hours, a process route, a shift, and the number of persons that are input to library items of a process, facilities, and workers. It takes a much man-hour to input all items. Furthermore, overlapping input of a common input item is conducted for library items. Therefore, it is a subject to reduce man-hour required for inputting by generating an input sequence implementing minimum input and eliminating overlapping input.

Therefore, it is an object of the present invention to provide means that implements reduction of man-hour required to create input items by systematizing the library input procedure and saving labor in overlapping input procedure in manufacturing line simulation intended for design of a manufacturing line.

Solution to Problem

In order to solve the subject, for example, a configuration stated in claims is adopted. The present application includes means that solves the subject. An example thereof is a manufacturing line simulation device using a manufacturing line model having a configuration including a storage unit for storing a plurality of model library items for creating a manufacturing line model, a storage unit for storing input items in the model library items, and an input item association table indicating a degree of overlapping between input items in the model library items, a simulation library presentation unit for presenting the plurality of model library items stored in the storage unit to a user and receiving specification of a model library item from the user, a priority impartment unit for calculating priorities of the input items by using the input association table stored in the storage unit and presenting an input screen to the user on the basis of the calculated priorities, a simulation input reception unit for receiving an input of an input item on the input screen, an overlapping data generation unit for duplicating data already received in the simulation input reception unit with respect to overlapping items shown in the input item association table, a simulation model generation unit for generating a manufacturing line simulation model by using the specified model library item and an information value of the input item which is received by the simulation input reception unit, and a production simulation execution unit for executing simulation by using the simulation model.

Advantageous Effects of Invention

According to the present invention, it becomes possible to reduce input man-hour in manufacturing line simulation. Subjects, configurations and effects other than those described above will be made clear by ensuing description of embodiments.

DESCRIPTION OF EMBODIMENTS

Hereafter, an embodiment of the present invention will be described.

FIG. 1is a schematic diagram of a manufacturing line simulation input sequence creation device110. As illustrated, the manufacturing line simulation input sequence creation device110includes a control unit111, an input unit112, an output unit113, a communication unit114, and a storage unit115. Furthermore, the control unit111includes a simulation library presentation unit1111, a priority impartment unit1112, a simulation input reception unit1113, an overlapping data generation unit1114, a simulation model generation unit1115, and a production simulation execution unit1116.

The input unit112receives an information input. The output unit113outputs information. The communication unit114transmits and receives information via a network190. The storage unit115includes model library information1151, a product information storage unit1152, a process route information storage unit1153, a facility information storage unit1154, a worker information storage unit1155, a shift information storage unit1156, a preparation storage unit1157, a library—input item association table storage unit1158, and an input association table storage unit1159.

FIG. 2is a diagram representing an embodiment of a file format of the model library information1151stated inFIG. 1. InFIG. 2, the file format1151includes a field for registering a library number which is an identification number of a model library, and a field for registering a library item which indicates a function of manufacturing line simulation.

FIG. 3is a diagram representing an embodiment of a file format of the product information storage unit1152. InFIG. 3, the file format1152includes a field for registering a product number which is an identification number allocated when an order is received from a delivery destination who is a customer, a field for registering a working process route number which is an identification number of a working process route, a field for registering a due date of delivery when the product is to be shipped to the delivery destination, and a field for registering a delivery destination of a customer.

FIG. 4is a diagram representing an embodiment of a file format of the working process route information storage unit1153. InFIG. 4, the file format1153includes a field for registering a working process route number which is an identification number of a working process route, a field for registering a working order number which indicates an order of working in the working process route number, a field for registering a working process number which indicates an identification number of a working process, a field for registering a working process number which indicates an identification number of a working process, a field for registering a working process name which indicates a name of a working process, a field for registering facility time required to process the pertinent working process number in facilities, a field for registering worker service in a case where a worker is needed in the pertinent working process number, and a field for registering working time required for a worker to conduct working in the pertinent working process number.

FIG. 5is a diagram representing an embodiment of a file format of the facility information storage unit1154stated inFIG. 1. InFIG. 5, the file format1154includes a field for registering a facility number, a field for registering a facility name of pertinent facilities, a field for registering a working process number, and a field for registering a shift which is a name of a working period in which the facilities can operate.

FIG. 6is a diagram representing an embodiment of a file format of the worker information storage unit1155stated inFIG. 1, InFIG. 5, the file format1154includes a field for registering a name of a worker service in a case where workers are needed in the working process number, a field for registering the number of workers who can work in the pertinent working service, and a field for registering a shift which is a name of a working period for which workers of the pertinent working service can work.

FIG. 7is a diagram representing an embodiment of a file format of the shift information storage unit1156stated inFIG. 1. InFIG. 7, the file format1156includes a field for registering a shift which is a name of a working period for which facilities or workers can operate, a field for registering start time of the working period, a field for registering end time of the working period, and a field for registering a break time in the working time.

FIG. 8is a diagram representing an embodiment of a file format of the preparation change information storage unit1157stated inFIG. 1. InFIG. 8, the file format1157includes a field for registering a facility number, a field for registering a product number which is an identification number allocated when an order is received from a delivery destination who is a customer, and a field for registering a preparation change time required for a preparation change at the time of pertinent facilities and pertinent product number.

FIG. 9is a diagram representing an embodiment of a file format of the library—input item association table information1158. InFIG. 9, the file format1158includes a field for registering a library number which is an identification number of a model library, a field for registering a library item which indicates a function of the manufacturing line simulation, a field for registering a table required to execute the pertinent model library, and a field for registering an input item required to execute the pertinent model library.

FIG. 10is a diagram representing an embodiment of a file format of the input item association table information1159. In the input item association table information1159, table information and input items required to execute simulation are registered in the ordinate axis and abscissa axis as a two-dimensional table, and degrees of overlapping between input items are registered as input values.FIG. 23is an example of a flow chart for creating the input item association table information1159shown inFIG. 10. First, (1) tables required to execute manufacturing line simulation are extracted (S61). For example, in the example shown inFIG. 10, the product information storage unit1152, the process route information storage unit1153, the facility information storage unit1154, the worker information storage unit1155, the shift information storage unit1156, and the preparation storage unit1157described with reference toFIGS. 3 to 8are extracted. Then, (2) input items that overlap in items of the tables are extracted and arranged on the ordinate axis and the abscissa axis of the input association storage unit (S62). For example, in the example shown inFIG. 10, input items having an overlapping relation are extracted from among input items of the product information storage unit1152, the process route information storage unit1153, the facility information storage unit1154, the worker information storage unit1155, the shift information storage unit1156, and the preparation storage unit1157described with reference toFIGS. 3 to 8. For example, the product number in the product information storage unit1152and the product number in the preparation storage unit1157overlap each other, the product number is registered. In the same way, input items having an overlapping relation are extracted from among other input items as well.

Then, degrees of overlapping between input items are registered as input values. In this example, the degree of overlapping is defined in two stages in order to provide priority with a weight according to an inclusion relation between input items. (3) In a case where when an overlapping input item in a certain table is input earlier, all inputs of the input item in a remaining table can be omitted, a value “2” is registered (S63). Furthermore, (4) in a case where when an overlapping input item in a certain table is input earlier, partial inputs of the input item in a remaining table can be omitted, a value “1” is registered (S64). For example, in a case where the product number in the product information storage unit1152is input earlier than the product number in the preparation storage unit1157, all product numbers in the preparation storage unit1157can be input. In this case, therefore, the value “2” is registered. In the table inFIG. 10, “2” is input to a place of product number in preparation change information in a thirteenth column in product number in product information in a first row. On the other hand, in a case where the product number in the preparation storage unit1157is input earlier than the product number in the product information storage unit1152, all product numbers in the product information storage unit1152are not necessarily input. In this case, therefore, the value “1” is registered. In the table inFIG. 10, “1” is input to a place of product number in product information in a first column in product number in preparation change information in a thirteenth row.

The manufacturing line design device110can be implemented by using, for example, a general computer900including a CPU (Central Processing Unit)901, a memory902, an external storage device903such as an ND (Hard Disk Drive), a reading device905which reads and writes information on a portable storage medium904such as a CD (Compact Disk) or a DVD (Digital Versatile Disk), an input device906such as a keyboard and a mouse, an output device907such as a display, and a communication device908for connection to a communication network such as an NIC (Network Interface Card) as shown inFIG. 11(a schematic diagram of the computer900).

Processing programs executed by the manufacturing line simulation input sequence creation device110according to the present invention will now be described in order with reference toFIG. 12.FIG. 12is a flow chart showing processing that creates an input sequence for creating a model of manufacturing line simulation executed by the manufacturing line simulation input sequence creation device110according to the present invention.

First, the simulation library presentation unit1111presents library functions of manufacturing line simulation to a user, and the user specifies a required library (S10). By the way, details of the step S10will be described with reference toFIG. 13.

Then, the priority impartment unit1112generates an input screen from the library specified at the step S10and generates a sequence of required input items (S20). By the way, details of the step S20will be described with reference toFIG. 14.

Then, the input simulation input reception unit1113receives an input from the user on the basis of an order of an input screen (S30). By the way, details of the step S30will be described with reference toFIGS. 17 and 18.

Then, the simulation model generation unit1115generates a manufacturing line simulation model by using the library functions received by the simulation library presentation unit1111and a value input by the simulation input reception unit1113(S40).

Finally, the production simulation execution unit1116executes production simulation from the present time to the future by using the generated manufacturing line simulation model (S50). Details of the step S50will be described in detail with reference toFIG. 19.

Details of the step S10executed by the manufacturing line simulation input sequence creation device110shown inFIG. 12will now be described with reference toFIG. 13.FIG. 13is a schematic diagram showing an example of an input screen1000. As for the input screen1000, the model library information1151in the storage unit115is acquired and displayed in a display item1001. Furthermore, the input screen1000includes an input item1002represented by a check box every library information. When conducting manufacturing line simulation, the user selects necessary library functions by using the check boxes on the present screen. After finishing selection of all library functions, the user depresses a registration button1003.

FIG. 14is a flow chart showing processing executed by the priority impartment unit1113at the step S20inFIG. 12. First, the priority impartment unit1112narrows down input items required for the manufacturing line simulation on the basis of the library functions input on the input screen1000shown inFIG. 13and the library—input item association table information1158. For example, in a case where “preparation change function” is selected on the input screen1000shown inFIG. 13, the priority impartment unit1112extracts all input items pertinent to the “preparation change function” from the columns of the library function in the library—input item association table information1158shown inFIG. 9.

Then, the priority impartment unit1112extracts the number of input items on the basis of the input items extracted at the step S201and the input item association table information1159, and calculates priority of each input screen (S202). When the input screen is i and the number of input items is j, the degree of overlapping is denoted by Di,j. At this time, priority Piof the input screen is defined by the following expression.
[MATH. 1]
[MATH. 1]

N: Maximum number of input screens, M: Maximum number of input items of input screen i

For example, in the case of values in the input item association table information1159shown inFIG. 10, the degree of overlapping Di,jof all input items are added for two input items on the “product” input screen. As a result, the value of priority Piof the input screen becomes “4” from “2” on the “process” input screen and “2” of “product number” on the “preparation” input screen. Such a calculation is conducted on all input screens.

Then, the priority impartment unit1112detects unnecessary places for input items on the basis of the priority Piof the input screen calculated at the step S202, and displays a result (S203).FIG. 15is an output screen showing the result of the priority Piof the input screen. In this example, a case where all library functions are selected on the input screen1000shown inFIG. 13is shown. A value “4” of priority Piof the “product” input screen is displayed in a display item1021.FIG. 16shows a result in a case where the “preparation change” function in the library is not selected on the input screen1000shown inFIG. 13. In this case, for two input items on the “product” input screen, “2” in the “product number” on the “preparation” input screen is eliminated and the value of priority Pion the input screen becomes “2.” The value “2” of the priority Pion the “product” input screen is displayed in a display item1021shown inFIG. 16.

Then, the priority impartment unit1112rearranges the input screens on the basis of priority of each screen (S204). Specifically, in a case where all library functions are selected on the input screen1000shown inFIG. 13as in the example shown inFIG. 15, the priority impartment unit1112rearranges the input screens in order of “facilities,” “process,” “product,” “shift,” “worker,” and “preparation” screens on the basis of the priority Pi. Furthermore, in a case where the “preparation change” function is not selected on the input screen1000shown inFIG. 13as in the example shown inFIG. 16, the priority impartment unit1112rearranges the input screens in order of “process,” “facilities,” “worker,” “product,” “shift,” and “preparation” screens on the basis of the priority Pi. Since the “preparation” screen is unnecessary, the “preparation” screen is not presented as an input screen.

Finally, the priority impartment unit1112reorganizes screens on the basis of a result of rearrangement at the step S204, and displays reorganized screens to the user (S205). Specifically, an input screen in a case where all library functions are selected on the input screen1000shown inFIG. 13is shown inFIG. 17. An input screen is displayed in a display item1032in order of “facilities,” “process,” “product,” “shift,” “worker,” and “preparation” screens rearranged from a display item1031in order of priority at the step S204.FIG. 18shows an input screen in a case where the “preparation change” function is not selected on the input screen1000shown inFIG. 13. An input screen is displayed in the display item1032in order of “process,” “facilities,” “worker,” “product,” and “shift” screens rearranged from the display item1031in order of priority at the step S204. InFIG. 17andFIG. 18, a state in which input is conducted for the display item1032is shown.

Furthermore, if all input items on the “facility” screen are complete on the input screen1030and an execution item1033“determine” button is depressed, the overlapping data generation unit1114duplicates data input by the screen for the overlapping item.FIG. 19is a flow chart showing processing executed by the overlapping data generation unit1114. First, the overlapping data generation unit1114reads information input on the input screen1030(S301).

Then, the overlapping data generation unit1114extracts overlapping input items on the next screen from input information read at the step S301and the input item association table information1159(S302). In the case of this instance, overlapping “process number” on the “process” screen subsequent to the “facility” screen is extracted.

Then, the overlapping data generation unit1114creates overlapping data on each screen (S303). In the case of this instance, the overlapping data generation unit1114creates data of “process number” on the “process” screen.

Finally, the overlapping data generation unit1114displays the next screen to the user (S304). Specifically, an example in which a shift from the “facilities” screen to the “process” screen is made is shown inFIG. 20. Before the user conducts inputting, overlapping data are already displayed in the “process number” on the “process” screen. Burden on the user is reduced.

FIG. 21is a flow chart showing processing of executing production simulation at the step S50shown inFIG. 12. First, the production simulation execution unit1116takes in a target product, a target process, target facilities, and target working time from the product information storage unit1152, the process mute information storage unit1153, the facility information storage unit1154, the worker information storage unit1155, the shift information storage unit1156, and the preparation storage unit1157stored in the storage unit115(S501).

Then, the production simulation execution unit1116repeats processing steps S503to S509as many times as the number of all products in order to make plans of all products stored in the product information storage unit1152(S502).

Then, the production simulation execution unit1116repeats processing steps S504to S208as many times as the number of all processes in order to make a plan of the target product (S503).

Then, the production simulation execution unit1116repeats processing steps S205to S206the number of facilities pertinent to the target process (S504).

Then, the production simulation execution unit1116ascertains whether there are facilities usable at the pertinent date and hour of the target product and target process (S505).

If there are usable facilities, the production simulation execution unit1116proceeds to step S506, allocates the pertinent product to usable facilities by working hours at pertinent date and hour, proceeds to step S503, and makes the next process a target (S506).

If there are no usable facilities, the production simulation execution unit1116proceeds to step S507, and repeats for all target facilities. If there are no usable facilities in all facilities, the production simulation execution unit1116proceeds to step S508, advances the pertinent date and hour by unit time (S508), and proceeds to step S505.

The production simulation execution unit1116repeats the processing steps S504to S508by the number of all processes in order to make a plan of the target product (S509), and repeats the processing steps S503to S509by the number of all processes in order to make plans of all target products (S510).

FIG. 22is a schematic diagram showing an example of an output screen1040. The output screen1040shows a simulation result of the manufacturing line design device110. A display item1041includes a field for registering a product number which is an identification number allocated when an order is received from a delivery destination who is a customer, field for registering a working number in which the pertinent product number is currently in process, a field for registering a processing state of the pertinent product number, a field for registering facilities or a part storing place in which the pertinent product number is currently in process, a field for registering time when working is started in facilities or a part storing place in which the pertinent product number is currently in process, and a field for registering time when working is finished in facilities or a part storing place in which the pertinent product number is currently in process.