JP2010020665A - Production management method, production management system, and production management program - Google Patents

Abstract

Kind Code: A1 A production management method, a production management system, and a production management program capable of complying with an answer delivery date answered to a customer even in a production line composed of a plurality of manufacturing processes, even when there is a stagnation period that becomes a bottleneck. provide.
A production management method includes a lead time storage step S200 for storing a lead time in a production record of a plurality of lots for each manufacturing process in a single production line composed of a plurality of manufacturing processes, and a lead in the production record. Based on the time, a lead time setting step S210 for setting a target lead time for each manufacturing process, a stagnation period calculation step S220 for calculating a stagnation period that becomes a bottleneck in each manufacturing process, and completion of the in-process lot And a scheduled completion date setting step S230 for setting a scheduled completion date in each manufacturing process not yet started for each lot by adding the stagnation period to the target lead time starting from the actual date.
[Selection] Figure 9

Description

  The present invention relates to a production management method, a production management system, and a production management program.

  For example, in a semiconductor production line, one production line including a plurality of manufacturing processes such as a photoetching process, a diffusion process, a grinding process, an inspection process, and an assembly process is configured. There is a case where a period from when it is put into the production line to completion is over a long period of one month or more. For this reason, if there is a delay from the production plan in each manufacturing process, the delivery date of the finished product rising from the final manufacturing process is delayed, and the response delivery date answered to the customer may not be observed. Therefore, for example, in Patent Document 1, a recommended delivery date period that can be delivered to a customer is calculated based on a scheduled production completion date based on a production plan, and production is performed in accordance with the production plan based on that. A method has been proposed for complying with the delivery date of reply to customers.

JP 2003-85346 A

However, in Patent Document 1, in the manufacturing process, for example, if the production capacity of the apparatus is reduced due to maintenance of the apparatus, a stagnation period that becomes a bottleneck occurs, and the reply delivery date that is replied to the customer may not be observed. .
In such a manufacturing process, a lot is completed with a lead time including a stagnation period and sent to the next manufacturing process. The lot sent to the next manufacturing process is produced until the final manufacturing process, including the stagnation period. In other words, production is delayed until the stagnation period until the final manufacturing process. In addition, when production is performed through a plurality of manufacturing processes having a stagnation period that becomes a bottleneck, the plurality of stagnation periods are accumulated as they are, so that the delay in the final manufacturing process is further increased.
In addition, when lots are being produced behind the original production plan, the production process that is not yet underway can be produced even if the stagnation period that becomes a bottleneck is eliminated and the schedule in the production plan is advanced. Since the system indicates the start date and completion date according to the original production plan, the delay cannot be eliminated.
Therefore, it may not be possible to comply with the answer delivery date answered to the customer.

  SUMMARY An advantage of some aspects of the invention is to solve some of the problems described above, and the invention can be implemented as the following forms or application examples.

  [Application Example 1] In one production line composed of a plurality of manufacturing processes, a lead time storage step for storing a lead time from the start to completion of each model in the production results of a plurality of lots for each manufacturing process, and the production A lead time setting step for setting a target lead time for each manufacturing process based on a lead time in the actual results, a stagnation period calculating step for calculating a stagnation period that becomes a bottleneck in each manufacturing process, and an in-process lot And a scheduled completion date setting step for setting a scheduled completion date in each manufacturing process not yet started for each lot by adding the stagnation period to the target lead time, starting from the actual completion date. The above production management method.

  According to this configuration, a stagnation period calculation step that calculates a stagnation period that becomes a bottleneck in each manufacturing process, and the stagnation period is added to the target lead time, starting from the completion record date of the in-process lot, and for each lot. A scheduled completion date setting step for setting a scheduled completion date for each manufacturing process that has not been started. As a result, in each manufacturing process that has not been started, the completion date of the lot produced in each manufacturing process is set in the scheduled completion date setting step by producing within the total of the target lead time and the stagnation period. It will be less likely to be late than the scheduled completion date. Therefore, the completion date of the lot in the final manufacturing process is less likely to be delayed from the scheduled completion date set in the scheduled completion date setting step. As a result, there is a high possibility of being able to comply with the answer delivery date answered to the customer.

Application Example 2 In the production management method, the lead time setting step creates a frequency distribution of lead times in the production results.
In this way, the target lead time can be set from the frequency distribution of the lead time in the production results.

Application Example 3 In the production management method, the lead time setting step sets a lead time at the maximum frequency in the frequency distribution as the target lead time.
In this way, the target lead time can be set from the frequency distribution of the lead time in the production results.

  [Application Example 4] The method further includes an answer delivery date setting step for setting an answer delivery date to the customer. In the answer delivery date setting step, the scheduled completion date in the final manufacturing process is set as the scheduled completion date in the production line, and the completion schedule is set. If the date is before the due date including the requested delivery date from the customer, the due date of the desired delivery date is set as the response delivery date to the customer, and the due date including the desired due date from the customer is set as the scheduled completion date. When exceeding, the date of the scheduled completion date is set as an answer delivery date to the customer.

  According to this configuration, the scheduled completion date, which is the scheduled completion date in the final manufacturing process, is less likely to exceed the response delivery date to the customer. As a result, the possibility of complying with the answer delivery date answered to the customer is increased by producing the product by the scheduled completion date.

  Application Example 5 In the lead time setting step, a standard lead time longer than the target lead time is set based on the lead time in the production results, and further, a standard in each manufacturing process is set based on the standard lead time. The production management method described above, comprising: a standard delivery date setting step for setting a delivery date; and a progress calculation step for calculating a difference between the scheduled completion date and the standard delivery date in each manufacturing process as a manufacturing process progress.

  According to this configuration, a delay in the manufacturing process can be output as the manufacturing process progress.

  [Application Example 6] A production management method characterized in that, in the progress calculation step, a difference between a scheduled completion date in the final manufacturing process and an answer delivery date for replying to a customer is calculated as a completion progress.

  In this way, it is possible to output information about whether the scheduled completion date in the final manufacturing process is delayed from the answer delivery date answered to the customer as the completion progress.

Application Example 7 In the production management method described above, in the lead time setting step, the standard lead time is set based on a cumulative value of frequencies in the frequency distribution.
In this way, the standard lead time can be set.

  Application Example 8 In the production management method described above, in one manufacturing process, a priority order in which a lot having a larger delay in completion progress is prioritized than a delay in the manufacturing process progress is output.

  Thereby, the manager of the manufacturing process can shorten the delay of the scheduled completion date in the final manufacturing process by preferentially starting the lot with high priority.

  [Application Example 9] The above-described application example further includes an operation status output step of outputting an operation status in the manufacturing process when there is a manufacturing process in which the numerical value of the delay in the manufacturing process progress is larger than a predetermined value. Production management method.

  According to this configuration, the manager of the manufacturing process can detect the factor causing the stagnation period that becomes a bottleneck.

[Application Example 10] The production management method described above, wherein the production process is a manufacturing process in which a first company entrusts production to a second company.
According to this configuration, the completion date of the lot in the final manufacturing process is less likely to be delayed from the scheduled completion date set in the scheduled completion date setting step. As a result, there is a high possibility that the first company can comply with the answer delivery date answered to the customer.

  Application Example 11 In one production line composed of a plurality of manufacturing processes, a lead time storage unit that stores lead times from the start to completion of each model in the production results of a plurality of lots for each manufacturing process, and the production Based on the lead time in the actual results, a lead time setting unit that sets a target lead time for each manufacturing process, a stagnation period calculation unit that calculates a stagnation period that becomes a bottleneck in each manufacturing process, and an in-process lot A scheduled completion date setting unit that sets a scheduled completion date in each manufacturing process not yet started for each lot by adding the stagnation period to the target lead time, starting from an actual completion date. And production management system.

  Application Example 12 In a single production line composed of a plurality of manufacturing processes, a lead time storage function for storing a lead time from the start to completion of each model in the production results of a plurality of lots for each manufacturing process, and the production Based on the actual lead time, a lead time setting function for setting a target lead time for each manufacturing process, a stagnation period calculation function for calculating a stagnation period that becomes a bottleneck in each manufacturing process, and an in-process lot In order to realize a scheduled completion date setting function for setting a scheduled completion date in each manufacturing process not yet started for each lot by adding the stagnation period to the target lead time, starting from the actual completion date A production management program characterized by being executed.

Hereinafter, specific embodiments will be described with reference to the drawings.
(First embodiment)
Fig.1 (a) is a figure explaining the manufacturing-process order of the production line of a present Example. The production line of this embodiment is composed of a plurality of manufacturing processes. As shown in FIG. 1A, the production line of this embodiment includes manufacturing processes A, B, C, manufacturing processes D, E, F ( (Not shown), and arranged in series in the direction of the arrow in the drawing in the production order of the manufacturing process G. The manufacturing processes A to G are, for example, a photoetching process, a diffusion process, a grinding process, an inspection process, an assembly process, and the like in a semiconductor production line.

  Here, a method for calculating a stagnation period that becomes a bottleneck will be described. FIG. 1B is a diagram showing stock at a certain point in the manufacturing process B for one model.

  In the manufacturing process B, for example, apparatuses M1, M2, and M3 constituting the inspection process are arranged. The stocks Z1, Z2, and Z3 indicate the stock quantities of the in-process lots that are inspected by the devices M1, M2, and M3, respectively. The inventory Z4 indicates the amount of inventory of the in-process lot before the production in the process A is completed and the inspection by the apparatuses M1, M2, and M3 is performed. The amount of the stocks Z1 to Z4 is indicated by a time such as a processing time such as etching or vapor deposition or an inspection time such as a continuity test. The total of the in-process lot inventory in the manufacturing process B is the total time of the inventory Z1, Z2, Z3, and Z4.

  In each of the apparatuses M1, M2, and M3, an apparatus capacity indicating a production capacity per unit time in processing and inspection is set as time. The sum of the device capacities in the manufacturing process B is the sum of the device capacities of the devices M1, M2, and M3.

  The devices M1, M2, and M3 may not operate due to device maintenance. Alternatively, there may be a case where the apparatus cannot be operated when the condition setting in the apparatus for processing or inspection is different or the apparatus fails. In such a case, the production capacity in processing and inspection in the manufacturing process B decreases.

  The stagnation period is the time obtained by subtracting the device capacity from the total inventory. For example, when the total of the stocks Z1 and Z2 is 30 hours, if the total device capacity of the devices M1, M2, and M3 is 24 hours, the stagnation period is 6 hours.

  When the stagnation period occurs, for example, by increasing the number of apparatuses in addition to the apparatuses M1, M2, and M3 and arranging them in the manufacturing process B, the total apparatus capacity in the manufacturing process B is increased. In this way, by eliminating the factor causing the stagnation period, the production capacity in the manufacturing process B is increased so that the stagnation period does not occur.

  Although it has been explained that the production capacity in the manufacturing process B is reduced due to the reduction in the apparatus capacity and a stagnation period occurs, the production capacity of the manufacturing process B seems to be reduced by reducing the number of workers arranged in the manufacturing process B. In some cases, a stagnation period occurs.

  A method for setting the target lead time will be described. FIG. 2 (a) is a histogram showing the frequency distribution of one model produced in one manufacturing process, where the horizontal axis is the number of days of lead time and the vertical axis is the number of completed lots. FIG. 2B is a numerical value table for creating the histogram of FIG. The number of days of lead time and the number of lots are actual values of lots produced in one manufacturing process. The lead time is the period from the start record date to the completion record date in one manufacturing process.

  In this embodiment, the lead time (number of days) when the frequency is the maximum value is set as the target lead time. The target lead time (number of days) when the maximum value of the number of lots is 18 is 12 days indicated by M1 in FIG.

  FIG. 3 is a diagram illustrating a method for setting a scheduled completion date in each manufacturing process. In the figure, the horizontal axis indicates time, and the vertical axis indicates manufacturing steps A to C. Here, an in-process lot that has been produced in the manufacturing process A and is in progress in the manufacturing process B will be described.

  P1, P2, and P3 in the thick alternate long and short dash line L1 indicate target delivery dates in the manufacturing processes A, B, and C, respectively. The period from the point S to the production process A to the target delivery date P1, the period from the target delivery period P1 to the target delivery period P2, and the period from the target delivery period P2 to the target delivery period P3 are the targets in the respective manufacturing processes A, B, and C. This is the lead time period. The target lead times in the manufacturing processes A, B, and C are set based on the lead times in the production results of the manufacturing processes A, B, and C as described above with reference to FIGS.

  A thick broken line L2 indicates the flow rate of the lot. The flow rate in the range of the manufacturing process A indicates the flow rate in the production performance of the manufacturing process A. The period indicated by T1 indicates the period during which the lot has stagnated in the manufacturing process A. Q1 indicates a completion record date, which is a record date when the production of the lot is completed in the manufacturing process A.

  A thick alternate long and short dash line L1 indicates the flow rate of the lot when the target lead times in the manufacturing processes A, B, and C are set. The flow rate L2 in the range of the production process B and the production process C indicates a flow rate to be flowed from now on in the production processes B and C that are not yet started. The flow velocity in the inclined range at the flow velocity L2 is the same as the flow velocity L1. A period indicated by T2 indicates a stagnation period in the manufacturing process B.

  The stagnation period T2 is calculated from the inventory (time) in each manufacturing process based on the production capacity (time) due to the equipment capacity (time) in each manufacturing process (see FIG. 1B).

  As described above, since the flow velocity in the inclined range at the flow velocity L2 is the same as the flow velocity L1, in the period T3 shown in the range of the manufacturing process B, the stagnation period T2 is added to the target lead time shown in T4. It is a period. Therefore, the scheduled completion date Q2 is obtained by adding the stagnation period T2 of the manufacturing process B to the target lead time T4 of the manufacturing process B, starting from the completion record date Q1 of the manufacturing process A.

  The scheduled completion date Q3 in the manufacturing process C is obtained by adding the stagnation period of the manufacturing process C to the target lead time in the manufacturing process C, starting from the scheduled completion date Q2 in the manufacturing process B.

  FIG. 4 is a diagram illustrating a target delivery date and a scheduled completion date in the manufacturing processes A to G. As described in the manufacturing processes B and C, the target delivery dates P4 to P7 and the scheduled completion dates Q4 to Q7 are also obtained in the manufacturing processes D to G.

  The thick two-dot chain line L3 is a line that connects the time point S, the completion record date Q1, and the scheduled completion dates Q2 to Q7 with straight lines.

  The target delivery times P1 to P7 are created by the time when the lot is put into the manufacturing process A, and are fixed until the production of the lot in the final manufacturing process G is completed.

  As for the scheduled completion date, the scheduled completion date in the manufacturing process that has not been started is updated with the completion date each time production in the manufacturing process is completed. In addition, the stagnation period that becomes a bottleneck in the manufacturing process that has not been started is due to changes in the production capacity in the manufacturing process due to fluctuations in the capacity of the equipment arranged in the manufacturing process. Will fluctuate.

  The update of the scheduled completion date may be performed, for example, once a day. Alternatively, in one lot, when production in the manufacturing process is completed, the stagnation period in each manufacturing process may be calculated, and the update process for the scheduled completion date may be performed.

  FIGS. 5A and 5B are diagrams for explaining a method of setting an answer delivery date for replying to a customer according to a desired delivery date from the customer. Here, the scheduled completion date Q7 in FIG. 4 in the final manufacturing process G is the scheduled completion date in the production line.

  As shown in FIG. 5A, when the scheduled completion date Q7 (scheduled completion date Q7) is earlier than the date including the desired delivery date H from the customer, the desired delivery date H of the requested delivery date H Set a due date.

  As shown in FIG. 5B, when the scheduled completion date Q7 (scheduled completion date Q7) exceeds the date including the desired delivery date H from the customer, the due date of the scheduled completion date Q7 as the response delivery date to the customer Set.

  FIG. 6 is a block diagram illustrating a hardware configuration of the production management system according to the present embodiment. The computer 2 includes a CPU 6, a display unit 3, an HDD 4 as an auxiliary storage device, a RAM 5, a ROM 8, and an interface (I / F) 7.

  The ROM 8 stores a program, and the CPU 6 reads the program from the ROM 8 to the RAM 5 and executes the program. The input unit 9 is configured with a mouse, a keyboard, and the like, and data for operating the computer 2 is input thereto. The display unit 3 is composed of, for example, a screen made of liquid crystal, and displays data for operating the computer 2.

  The HDD 4 retains the stored contents even when the power supplied to the computer 2 is turned off. The HDD 4 stores lead times in production results of a plurality of lots produced in the manufacturing processes A to G. Further, the HDD 4 stores a completion date as a result in the manufacturing process in the lot in progress.

  In the manufacturing processes A and B, terminal devices 20 a and 20 b are installed, and the terminal devices 20 a and 20 b are connected to the computer 2 via the network line 30 and the I / F 7. The terminal devices 20a and 20b are respectively provided with input units 21a and 21b including a keyboard, a mouse, and a barcode reader, and display units 22a and 22b including a liquid crystal screen. Production capacities such as apparatus capacities in the respective manufacturing processes are input from the input sections 21a and 21b and stored in storage sections (not shown) of the terminal apparatuses 20a and 20b.

  From the input sections 21a and 21b, the actual start date and the actual completion date as the actual results in the respective manufacturing processes are input, and these data are sent from the actual start date to the actual completion date via the terminal devices 20a and 20b. The result data of the lead time is stored in the HDD 4.

  In the manufacturing processes C to G, similarly to the manufacturing processes A and B, a terminal device, a display unit, and an input unit (not shown) are provided. In addition, production capacities such as apparatus capacities in the respective manufacturing processes are input from the input units of the terminal apparatuses installed in the manufacturing processes C to G and stored in the storage unit of the terminal apparatus.

  FIG. 7 is a block diagram showing a program configuration of the production management system. The lead time storage unit 10 stores lead times in the production results of a plurality of lots for each manufacturing process in one production line including the manufacturing processes A to G.

  The lead time setting unit 11 sets the target lead time based on the lead time stored in the lead time storage unit 10. In this embodiment, as described with reference to FIGS. 2A and 2B, a frequency distribution of lead times in production results is created, and the lead time having the maximum frequency, that is, the number of lots, is set as the target lead time. Calculate and set.

  The stagnation period calculation unit 12 acquires the production capacity such as the apparatus capacity in each manufacturing process from the storage unit of the terminal device via the network line 30 and the I / F 7 and calculates the stagnation period in each manufacturing process. .

  The scheduled completion date setting unit 13 sets the scheduled completion date in the unfinished manufacturing process by adding the stagnation period to the target lead time, starting from the completed record date of one in-process lot.

  The lead time storage unit 10, the lead time setting unit 11, the stagnation period calculation unit 12, the scheduled completion date setting unit 13, and the answer delivery date setting unit 14 are composed of programs, and the CPU 6 reads the programs from the ROM 8 to the RAM 5 and executes the programs. It works by doing.

  Next, processing executed by the production management system program of the first embodiment will be described. FIG. 8 is a flowchart of processing executed by the program of the production management system of the first embodiment.

  In step S <b> 100, the lead time setting unit 11 reads the lead time result data from the lead time storage unit 10 into the RAM 5. In step S110, the lead time setting unit 11 creates frequency distribution data in each manufacturing process. In step S120, the target lead time is calculated and set from the frequency distribution in each manufacturing process (see FIGS. 1A and 1B).

  In step S130, the stagnation period calculation unit 12 acquires the production capacity such as the apparatus capacity in the manufacturing process that has not been started, and calculates the stagnation period. In this embodiment, the production capacity such as the equipment capacity is obtained from the terminal equipment 20b installed in the manufacturing process B which has not been started, and the terminal equipment (not shown) installed in the manufacturing processes C to G, and the stagnation period is calculated. To do.

  In step S <b> 140, the scheduled completion date setting unit 13 acquires the completion record date in the tracked lot record from the HDD 4. In this embodiment, the completion record date in the manufacturing process A is acquired.

  In step S150, the scheduled completion date setting unit 13 sets the scheduled completion date in each manufacturing process that has not been started. The scheduled completion date setting unit 13 starts from the actual completion date of the in-process lot, and adds the stagnation period calculated in step S130 to the target lead time set in step S120, thereby completing the completion schedule in the manufacturing process not yet started. A date is set (see scheduled completion dates Q2 and Q3 in FIG. 3 and scheduled completion dates Q2 to Q7 in FIG. 4).

  The answer delivery date setting unit 14 in FIG. 7 is performed independently of the processing shown in the flowchart in FIG. When the scheduled completion date is after the date including the desired delivery date desired by the customer, the response delivery date setting unit 14 sets the scheduled completion date as an answer delivery date for replying to the customer. On the other hand, when the scheduled completion date is before the date including the desired delivery date desired by the customer, the answer delivery date setting unit 14 sets the desired delivery date desired by the customer as the answer delivery date for replying to the customer.

  This embodiment can be regarded as a production management method. FIG. 9 is a diagram describing each step in the production management method of the present embodiment.

  In the lead time storage step S200, the lead time in the production results of a plurality of lots is stored for each manufacturing process in one production line composed of the manufacturing processes A to G.

  Processing is continuously performed from the lead time setting step S210 to the scheduled completion date setting step S230. In the lead time setting step S210, the target lead time for each manufacturing process is set based on the lead time stored in the lead time storing step S200.

  In the stagnation period calculation step S220, a stagnation period that becomes a bottleneck in each manufacturing process is calculated.

  In the scheduled completion date setting step S230, the stagnation period calculated in the stagnation period calculation step S220 is added to the target lead time set in the lead time setting step S210, starting from the completion record date of one in-process lot. The scheduled completion date in the unstarted manufacturing process is set (see scheduled completion dates Q2 and Q3 in FIG. 3 and scheduled completion dates Q2 to Q7 in FIG. 4).

  The answer delivery date setting step S240 in FIG. 9 sets the scheduled completion date as the answer delivery date for replying to the customer when the scheduled completion date is after the date including the desired delivery date desired by the customer. On the contrary, the answer delivery date setting step S240 sets a desired delivery date as an answer delivery date for replying to the customer when the scheduled completion date is before the date including the desired delivery date desired by the customer.

  As described above, the production management method described in the present embodiment includes the lead time storage step S200 for storing the lead times in the production results of a plurality of lots for each manufacturing process in one production line including the manufacturing processes A to G. Based on the lead time in the production results, a lead time setting step S210 for setting a target lead time for each manufacturing process, a stagnation period calculating step S220 for calculating a stagnation period that becomes a bottleneck in each manufacturing process, and an in-process lot And a scheduled completion date setting step S230 for setting a scheduled completion date for each unprocessed manufacturing process for each lot by adding a stagnation period to the target lead time.

  According to this configuration, the stagnation period calculation step S220 that calculates the stagnation period that becomes a bottleneck in each manufacturing process, and the stagnation period is added to the target lead time, starting from the completion record date of the in-process lot, A scheduled completion date setting step S230 for setting a scheduled completion date for each manufacturing process that has not been started. As a result, in each manufacturing process that has not been started, the completion date of the lot produced in each manufacturing process is completed by producing within the total of the target lead time and the stagnation period of each manufacturing process The delay is less than the scheduled completion date set in the scheduled date setting step S230. Therefore, the completion date of the lot in the final manufacturing process G is less likely to be delayed from the planned completion date set in the planned completion date setting step S230. As a result, there is a high possibility of being able to comply with the answer delivery date answered to the customer.

  In addition, it is a factor that causes a stagnation period that becomes a bottleneck, for example, by increasing the number of devices arranged in the manufacturing process, or by repairing a malfunctioning device, the factor causing the stagnation period is eliminated, If the stagnation period is shortened, the scheduled completion date of the manufacturing process that becomes a bottleneck can be brought forward. Therefore, the scheduled completion date in the final manufacturing process G, that is, the completion date of the production system can be advanced.

  Further, it includes an answer delivery date setting step S240 for setting an answer delivery date to the customer. In the answer delivery date setting step S240, the completion date in the final manufacturing process G is set as the expected completion date in the production line, and the expected completion date is determined from the customer. If it is before the due date including the desired delivery date, set the due date of the requested delivery date from the customer as the response delivery date to the customer, and if the scheduled completion date exceeds the due date including the desired delivery date from the customer, Set a due date for the date of completion of the response to the customer.

  According to this configuration, the scheduled completion date that is the scheduled completion date in the final manufacturing process G is less likely to exceed the response delivery date to the customer. As a result, the possibility of complying with the answer delivery date answered to the customer is increased by producing the product by the scheduled completion date.

(Second embodiment)
In the second embodiment, a method for calculating the progress in the manufacturing process will be described. The hardware configuration of the production management system of the second embodiment is the same as the hardware configuration in the first embodiment of FIG.

  FIG. 10A is a diagram in which a line graph is added to the frequency distribution graph of FIG. FIG. 10B is a table in which numerical values for creating a line graph are added to the table of FIG.

  The line graph is accumulated from the smaller lead time days, and is shown as the number of lots (vertical axis on the left side of the drawing) and the cumulative ratio (vertical axis on the right side of the drawing).

  In this embodiment, the lead time (number of days) when the accumulation ratio is 95% is set as the standard lead time, and the standard lead time (number of days) is 15 days indicated by M2 in FIG. The standard lead time (number of days) is longer than the target lead time indicated by M1 for which 12 days are set.

  FIG. 11 is a diagram in which a thick solid line L4 indicating the standard lead time is added to FIG. As described with reference to FIG. 3, even at this time, a lot that is a work-in-process is completed at the manufacturing process A and is about to be put into the manufacturing process B.

  The period from the input time point S to the standard delivery date indicated by R1 is the standard lead time in the manufacturing process A. The period from the standard delivery date R1 to R2 and the period from the standard delivery date R2 to R3 indicate the standard lead time in the manufacturing process B and the standard lead time in the manufacturing process C, respectively.

  FIG. 12 is a diagram for explaining the manufacturing process progress and the completion progress. DT1 in FIG. 12 indicates the manufacturing process progress in the manufacturing process B. The manufacturing process progress DT1 indicates a difference (period) between the standard delivery date R2 in the manufacturing process B and the scheduled completion date Q2 of the lot.

  Similarly, in the manufacturing processes D to G, a standard delivery date (not shown) is set. The standard delivery times for the manufacturing processes A to G are set before the lot is put into the manufacturing process A. The standard delivery times of the manufacturing processes A to G are fixed until the production is completed in the final manufacturing process G. Similarly to the manufacturing process progress DT1 of the manufacturing process B, the manufacturing process progress DT1 in the manufacturing processes C to G is set.

  The due date indicated by K in FIG. 12 is an answer delivery date for replying to the customer. The date indicated by Q7 in FIG. 12 is the scheduled completion date of the manufacturing process G, which is the final manufacturing process. The scheduled completion date Q7 of the final manufacturing process G is the scheduled completion date on the production line in this embodiment. DT2 in FIG. 12 indicates the completion rate of the production line in this embodiment. The completion progress DT2 is the difference (period) between the answer delivery date K that is replied to the customer and the scheduled completion date Q7.

  FIG. 13 is a diagram illustrating a case where the scheduled completion date of the lot is delayed from the standard delivery date. FIG. 12 shows that L3 indicating the scheduled completion date is positioned on the left side of L4 indicating the standard delivery date, and that the manufacturing process progress DT1 of the manufacturing processes A to G is not delayed from the standard delivery date. On the other hand, FIG. 13 shows that L3 indicating the scheduled completion date is located on the right side of L4 indicating the standard delivery date, and the manufacturing process progress DT1 of the manufacturing processes A to G is delayed from the standard delivery date.

  Further, since the scheduled completion date Q7 in FIG. 12 is located on the left side of the answer delivery date K, it indicates that the completion progress DT2 is not delayed. In contrast, the scheduled completion date Q7 in FIG. 13 is located on the right side of the answer delivery date K, indicating that the completion progress DT2 is behind the answer delivery date K.

  FIG. 14 is a table showing the manufacturing process progress DT1 and the completion progress DT2 in the lots manufactured in the manufacturing processes A and B and about to start in the manufacturing process B. The start plan date in FIG. 14 is the start plan date of the production plan when each lot in the model code described in the table is input to the manufacturing process A. The standard delivery date R2 (see FIGS. 12 and 13) is a date obtained by adding the standard lead time in the manufacturing process B to the planned start date.

  The scheduled completion date Q2 (see FIGS. 12 and 13) in FIG. 14 is a date set by adding the stagnation period to the target lead time. The manufacturing process progress DT1 indicates the difference between the standard delivery date R2 and the scheduled completion date Q2. A negative value indicates that the manufacturing process progress is delayed.

  The scheduled completion date Q7 in FIG. 14 indicates the scheduled completion date Q7 of the manufacturing process G, which is the final manufacturing process, that is, the scheduled completion date Q7 in the production line of this embodiment. The completion progress DT2 indicates, as a period, the difference between the reply delivery date K that is returned to the customer as a completed model code and the scheduled completion date Q7. A negative value indicates that the completion progress DT2 is delayed.

  14 shows the priority order to start in the manufacturing process B. The priority is set from the one with the larger delay of the completion progress DT2. The manufacturing process progress of lot ID R0002 in FIG. 14 is larger in negative value than the manufacturing process progress of lot ID R0001. On the other hand, the completion rate of the lot ID R0001 has a negative value larger than the completion rate of the lot ID R0002. In such a case, the priority order that suggests that the lot ID starts with priority R0001 is displayed as a table in FIG. 14 on the display unit 22b of the terminal device 20b installed in the manufacturing process B.

  FIG. 15 is a block diagram showing the configuration of the program in the present embodiment. FIG. 15 is a diagram in which a standard delivery date setting unit 15 and a progress calculation unit 16 are added to FIG. The standard delivery date setting unit 15 and the progress calculation unit 16 are composed of programs, and function when the CPU 6 reads the programs from the ROM 8 to the RAM 5 and executes the programs.

  The standard delivery date setting unit 15 sets a standard delivery date for each manufacturing process in one lot based on the standard lead time. The progress calculation unit 16 calculates the difference between the standard delivery date and the scheduled completion date as the progress.

  FIG. 16 is a flowchart of processing executed by the program of the production management system of the second embodiment. FIG. 16 is a flowchart in which steps S125, S126, S160, and S170 are added to the flowchart of FIG. 8 described in the first embodiment.

  In step S125, the lead time setting unit 11 calculates and sets the standard lead time from the frequency distribution in each manufacturing process. In step S126, the standard delivery date setting unit 15 calculates and sets the standard delivery date from the standard lead time (see R1 to R3 in FIG. 11).

  In step S160, the progress calculation unit 16 calculates the manufacturing process progress DT1 from the standard delivery date and the scheduled completion date. In step S170, the progress calculation unit 16 calculates the completion progress DT2 from the answer delivery date that was answered to the customer and the scheduled completion date of the final manufacturing process G.

In the lead time setting step in the production management method of this embodiment, a standard lead time longer than the target lead time is set based on the lead time in the production results, and further, a standard delivery time in each manufacturing process based on the standard lead time. A standard delivery date setting step for setting the process, and a progress calculation step for calculating a difference between the scheduled completion date and the standard delivery date in each manufacturing process as the manufacturing process progress.
According to this configuration, a delay in the manufacturing process can be output as the manufacturing process progress. Thereby, the administrator of a manufacturing process can acquire the manufacturing process progress for the delay in a manufacturing process. The manager of the manufacturing process can reduce the lead time in the unfinished manufacturing process by eliminating the factors behind the delay in the manufacturing process, such as equipment load. can do.

Further, in the progress calculation step, the difference between the scheduled completion date in the final manufacturing process G, that is, the scheduled completion date in the production line, and the answer delivery date for replying to the customer is calculated as the completion progress DT2.
In this way, it is possible to output information about whether the scheduled completion date (scheduled completion date) in the final manufacturing process G is delayed from the answer delivery date answered to the customer. Thereby, the manager of the manufacturing process can acquire information on whether or not the scheduled completion date (scheduled completion date) in the final manufacturing process G is delayed from the reply delivery date answered to the customer.

Further, in one manufacturing process, a priority order for starting a lot with a larger delay in the completion progress DT2 than the delay in the manufacturing process progress DT1 is output.
Thereby, the manager of the manufacturing process can shorten the delay of the scheduled completion date in the final manufacturing process G by preferentially starting the lot with high priority.

(Third embodiment)
In the third embodiment, a case will be described in which the operating status of a manufacturing process whose manufacturing process progress is delayed is output. The hardware configuration of the production management system of the third embodiment is the same as the hardware configuration in the first embodiment of FIG.

  FIG. 17 is a block diagram showing the configuration of the program in the third embodiment. FIG. 17 is a block diagram in which an operation status output unit 17 is added to FIG. 15 of the second embodiment. The operating status output unit 17 is configured by a program, and functions when the CPU 6 reads the program from the ROM 8 to the RAM 5 and executes the program.

  The operating status output unit 17 outputs the operating status of the manufacturing process that generates a stagnation period that is a bottleneck in the manufacturing process. FIG. 18 is a table showing, for example, the device capacity (time) in each device arranged in the manufacturing process B and the load as the operating status on the dates shown in the table.

  In the present embodiment, for example, as shown in the table of FIG. 18, the background color with a numerical value of 90% or more is displayed differently from the background color with a numerical value of 90% or less.

Thus, when there is a manufacturing process in which the numerical value of the manufacturing process progress delay is larger than a predetermined numerical value, an operation status output step of outputting the operating status in the manufacturing process is included.
According to this configuration, it is possible to output the operation status of the apparatus related to the factor causing the stagnation period that becomes a bottleneck. As a result, the manager of the manufacturing process can eliminate the cause of the stagnation period with reference to the operation status of the apparatus, and can shorten the lead time in the manufacturing process.

  In the first embodiment, in the lead time setting step S210 in FIG. 9, the lead time (number of days) when the frequency is the maximum value in the frequency distribution is set as the target lead time, but the target lead time is the cumulative value of the frequency. A lead time of 50% may be used. Alternatively, if the target lead time is shorter than the standard lead time, an average value of the actual lead times may be set as the target lead time. Alternatively, the median value of the distribution of the actual lead times may be set as the target lead time.

(Fourth embodiment)
In the fourth embodiment, a production line production management method including a manufacturing process in which a first company entrusts production to a second company will be described. FIG. 19 is a diagram showing that one production line is configured by a plurality of manufacturing processes in which a first company entrusts production to a plurality of second companies.

  The first company A in FIG. 19 includes an input unit including a computer 54, a keyboard (not shown), and a mouse. The second companies F1 to F4 entrusted with production in the manufacturing process by the first company A are provided with input units including computers 50 to 53, a keyboard, a mouse, and a barcode reader (not shown). The computer 54 and the computers 50 to 53 are connected by a network 55.

  In this embodiment, the first company A entrusts the production in the wafer process as the manufacturing process to the second company F1. The first company A entrusts production in the probing test process as a manufacturing process to the second company F2. Similarly, the first company A entrusts production in the packaging process and final test process as manufacturing processes to the second companies F3 and F4, respectively.

  In the lead time storage step S200 of FIG. 9 described in the first embodiment, the start date as the actual result in each manufacturing process is completed by the input unit of the computers 50 to 53 provided in the second companies F1 to F4. The actual date is input, and the data is stored in the storage unit (not shown) of the computer 50 as actual data of the lead time from the start actual date to the completed actual date via the network 55.

  In the lead time setting step S210, as described in the first embodiment, the target lead time is set based on the lead time result data stored in the storage unit of the computer 50.

  The computers 50 to 53 provided in the second companies F1 to F4 are input with data as time about production capacity such as apparatus capacity in each manufacturing process. The input production capacity data is transmitted via the network 55 and stored in a storage unit (not shown) of the computer 54 provided in the first company A.

  In the stagnation period calculation step S220, as described in the first embodiment, the computer 54 provided in the first company A calculates the stagnation period based on the production capacity and the inventory in each manufacturing process.

  In the scheduled completion date setting step S230, as described in the first embodiment, the computer 54 calculates the scheduled completion date in the unfinished manufacturing process based on the completion record date, the target lead time, and the stagnation period (FIG. 3) scheduled completion dates Q2, Q3, and scheduled completion dates Q2-Q7 in FIG.

  In the progress calculation step, as described in the second embodiment with reference to FIGS. 12 and 13, the computer 54 calculates the manufacturing process progress DT1 in each manufacturing process of the second companies F1 to F4. Further, the computers 50 to 53 provided in the second companies F1 to F4 display the manufacturing process progress in the respective manufacturing processes of the second companies F1 to F4, that is, the completion progress DT2 in the production line. In addition, in one manufacturing process, priority is given to starting a lot with a large delay in the completion progress DT2, which is the manufacturing process progress in the second company F4, which is the final manufacturing process, over the delay in the manufacturing process progress DT1. Output (see FIG. 14).

  In the operating status output step, as described in the third embodiment, the operating status of the apparatus in the respective manufacturing processes of the second companies F1 to F4 is displayed on the computers 50 to 53 (see FIG. 18).

As described above, the manufacturing process in the fourth embodiment is a manufacturing process in which the first company A entrusts the production to the second companies F1 to F4.
According to this configuration, the completion date of the lot in the final manufacturing process in the production entrusted to the second company F4 is less likely to be delayed from the scheduled completion date set in the scheduled completion date setting step. As a result, there is a high possibility that the first company can comply with the answer delivery date answered to the customer.

  In this embodiment, the first company A entrusts the production in one manufacturing process to the second companies F1 to F4, respectively, but entrusts the production in a plurality of manufacturing processes to one second company. Good. The present invention is also applied to the case where production is performed on a production line including a manufacturing process in the first company A and a manufacturing process in which the first company entrusts production to the second company.

  According to this configuration, the completion date of the lot in the second company F4, which is the final manufacturing process, is less likely to be delayed from the scheduled completion date set in the scheduled completion date setting step. As a result, there is a high possibility that the first company A can comply with the answer delivery date answered to the customer.

(A) is a figure explaining the manufacturing process sequence of the production line of a present Example, (b) is a figure which shows the stock at a certain time in a manufacturing process about one model. (A) is a histogram which shows frequency distribution, (b) is a table | surface of the numerical value which has created the histogram. The figure explaining the method of setting the completion date in a manufacturing process. The figure which shows the target delivery date in a manufacturing process, and a completion date. The figure explaining the method of setting the reply delivery date which answers to a customer. The block diagram which shows hardware constitutions. The block diagram which shows the program structure in 1st Example. The flowchart of the process which the program in 1st Example performs. The figure which described each step in a production management method. (A) is the figure which added the line graph to the graph of the frequency distribution of FIG. 2, (b) is a table | surface which shows the numerical value which created the line graph. The figure which added the thick continuous line L4 which shows a standard lead time to FIG. The figure explaining manufacturing process progress and completion progress. The figure which shows the case where the completion date of completion of a lot is late from standard delivery date. A table that describes the manufacturing process progress and completion progress. The block diagram which shows the structure of the program in 2nd Example. The flowchart of the process which the program in 2nd Example performs. The block diagram which shows the structure of the program in 3rd Example The table | surface which shows the load condition in the capacity | capacitance time in each apparatus arrange | positioned at a manufacturing process, and the date shown in a table | surface. The figure which shows that one production line is comprised by the some manufacturing process which the 1st company entrusted production to the some 2nd company.

Explanation of symbols

  DESCRIPTION OF SYMBOLS 1 ... Production management system, 10 ... Lead time memory | storage part, 11 ... Lead time setting part, 12 ... Stagnation period calculation part, 13 ... Completion scheduled date setting part, 14 ... Answer delivery date setting part, 15 ... Standard delivery date setting part, 16 ... progress calculation part, 17 ... operation status output part, A to G ... manufacturing process, DT1 ... manufacturing process progress, DT2 ... completion progress, H ... desired delivery date, K ... answer delivery date, Q1 ... completion date, Q2 to Q7 ... Scheduled completion date, R1 to R3 ... standard delivery date, S200 ... lead time storage step, S210 ... lead time setting step, S220 ... stagnation period calculation step, S230 ... scheduled completion date setting step, S240 ... answer delivery date setting step, T1, T2 ... stagnation period, T4 ... target lead time.

Claims (12)

In a production line consisting of a plurality of manufacturing processes, a lead time storage step for storing the lead time from the start to completion of each model in the production results of a plurality of lots for each manufacturing process;
Based on the lead time in the production results, a lead time setting step for setting a target lead time for each manufacturing process;
A stagnation period calculation step of calculating a stagnation period that becomes a bottleneck in each of the manufacturing steps;
A scheduled completion date setting step for setting a scheduled completion date in each manufacturing process not yet started for each lot by adding the stagnation period to the target lead time, starting from the actual completion date of the in-process lot. A production management method comprising: The production management method according to claim 1,
In the lead time setting step, a frequency distribution of lead times in the production results is created. The production management method according to claim 2,
In the lead time setting step, a lead time at the maximum value of the frequency in the frequency distribution is set as the target lead time. A production management method according to any one of claims 1 to 3,
Further, it includes an answer delivery date setting step for setting an answer delivery date to the customer. In the answer delivery date setting step, the scheduled completion date in the final manufacturing process is set as the scheduled completion date in the production line, and the scheduled completion date is determined from the customer. Is set before the due date including the desired delivery date, the due date of the desired delivery date is set as an answer delivery date to the customer, and when the scheduled completion date exceeds the due date including the desired delivery date from the customer, A production management method, characterized in that a due date for the completion date is set as an answer delivery date to a customer. A production management method according to any one of claims 1 to 4,
In the lead time setting step, a standard lead time longer than the target lead time is set based on the lead time in the production results,
Furthermore, a standard delivery date setting step for setting a standard delivery date in each manufacturing process based on the standard lead time;
And a progress calculation step of calculating a difference between the scheduled completion date and the standard delivery date in each manufacturing process as a manufacturing process progress. The production management method according to claim 5,
In the progress calculating step, a difference between a scheduled completion date in the final manufacturing process and an answer delivery date for replying to a customer is calculated as a completion progress. The production management method according to claim 5 or 6,
In the lead time setting step, the standard lead time is set based on a cumulative value of frequencies in the frequency distribution. The production management method according to claim 6 or 7,
In one manufacturing process, a production management method is characterized in that a priority order for starting a lot with a larger delay in the completion progress is output over a delay in the progress in the manufacturing process. A production management method according to any one of claims 5 to 8,
The production management method further includes an operation status output step of outputting an operation status in the manufacturing process when there is a manufacturing process in which the numerical value of the delay of the manufacturing process progress is larger than a predetermined value. A production management method according to any one of claims 1 to 9,
A production management method, characterized in that the manufacturing process is such that the first company entrusts production to a second company. In one production line composed of a plurality of manufacturing processes, a lead time storage unit that stores lead times in production results of a plurality of lots for each manufacturing process;
A lead time setting unit for setting a target lead time for each manufacturing process based on a lead time from the start to completion of each model in the production results;
A stagnation period calculation unit that calculates a stagnation period that becomes a bottleneck in each manufacturing process,
A scheduled completion date setting unit that sets a scheduled completion date in each manufacturing process not yet started for each lot by adding the stagnation period to the target lead time, starting from the actual completion date of the in-process lot. A production management system characterized by including. In one production line consisting of a plurality of manufacturing processes, a lead time storage function for storing a lead time in the production results of a plurality of lots for each manufacturing process;
A lead time setting function for setting a target lead time for each manufacturing process based on a lead time from the start to completion of each model in the production results;
A stagnation period calculation function for calculating a stagnation period that becomes a bottleneck in each manufacturing process,
A completion date setting function for setting a scheduled completion date in each manufacturing process not yet started for each lot by adding the stagnation period to the target lead time starting from the completion actual date of the in-process lot. A production management program characterized by being executed to realize.

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