JP2001125622A - Method for process consideration type required material amount calculation and recording medium - Google Patents

Abstract

PROBLEM TO BE SOLVED: To optimize all bases in production activity environment wherein selling, manufacturing, and supply bases are decentralized over the world by grasping the influence of a plan change at one base on other bases. SOLUTION: A calculation system based upon a single base is adopted by conventional MRP calculation, so 'which base' is not taken in consideration in master information and a calculation stage managed by the MRP calculation. For the purpose, shops meaning locations placed in respective operation processes on a base are used and two relations between 'item and shop' and 'item and supply process' are adapted to the MRP calculation. To calculate basic information of 'which shop requires how many, what item and when ?' the MRP calculation is carried out concretely not by items, but by items and shops and required amount expansion is performed according to the supply process of the items, thus actualizing batch MRP calculation as to all the shops.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to, when a production plan is input, the required amount of various items (intermediate products, parts, raw materials) required to produce a product produced by the production plan. The present invention relates to a method of calculating a material requirement for obtaining a required period.

[0002]

2. Description of the Related Art When one product such as a motor is designated, one of the methods for automatically calculating the type and the number of parts required to make this product is a material requirement plan (Material Requirements Planning). Requirements Planning (hereinafter referred to as MRP) is known. The material requirement calculation method is
Refers to the calculation method for RP. Hereinafter, the material requirement calculation is referred to as MRP calculation.

[0003] The MRP and the conventional MRP calculation method are described in, for example, "500 illustrated MRP terms" (Nikkan Kogyo Shimbun, published in 1983). Hereinafter, the conventional MRP calculation method will be briefly described. .

[0004] In the MRP calculation, based on a drafted product-level production plan (Master Production Schedule, hereinafter referred to as MPS), "necessary items (items) for parts, raw materials, etc., when necessary (delivery date) ) Calculate a plan to buy or manufacture as much as you need (requirements). This calculation largely requires the following three pieces of information.

(1) MPS Generally, a production plan for an item (product) at the top level in a parts development view. Also called standard production plan.

(2) Parts list This is a list including two master data of "item data" and "product configuration data". The item data is an attribute value unique to each item, and includes, for example, a time (hereinafter, referred to as a lead time or LT) required when manufacturing or purchasing the part. In addition, the product configuration data includes, for example, information such as what child items are required to manufacture a certain item and how many child items are required for each item to be manufactured (this is called the number of components). It is.

[0007] (3) Inventory and backlog For each item, the current stock and the number of products in process, or the delivery date and planned number of items already ordered and scheduled to be delivered in the future (backlog information).

In the MRP calculation, the following five calculations are performed for each item based on the information listed in (1) to (3).

(1) Calculation of total required amount The required amount data of the item is read, the requested amount is put together in a certain period, and the total required amount for each period is calculated.
Hereinafter, for the sake of simplicity, the period will be one day, and daily planning will be described.

(2) Calculation of Net Requirement Based on the calculated total requirement, allocation is made for inventory and backlog, and the required net requirement is calculated for each day.

(3) Lot Summarization Based on the calculated daily net requirement, the lot is set to the most suitable quantity for the order, using the lot size set for the item.

(4) Calculation of Lead Time An order is created by subtracting the lead time from the delivery date of the lot assembled and calculating the order date or start date.

(5) Developing required quantity The created order is developed into lower-level items using the parts table. Specifically, the required amount of each child item is calculated on the basis of the number of components of the product configuration data, and the required amount is written to the required amount data of each item, with the day before the start date of the order as the request date.

[0014]

Since the conventional MRP calculation as described in the "illustrated MRP term selection 500" is a calculation method for a single site, the master information and the calculation process managed by the MRP calculation are "MRP calculation". Where (where the item is handled) is not considered.

However, with the progress of multi-site and globalization of production activities, attribute values (parts manufacturing base, warehouse base, product assembling base, etc.) of the same item differ for each base, and inventory and The remainder exists at sites having different attribute values. In some cases, items are supplied between a plurality of bases. Therefore, it is necessary to understand the effect of a plan change at one site on other sites, or to make overall optimization for all sites, such as more effective use and diversion of inventory and backlog at each site. In order to respond to this demand, basic information is required, which is conscious of the place where the item is to be handled, such as "where and how many items are needed".

In the present invention, a place where an item is handled is represented by a shop which means a place in charge of each work process in the base, and two places of “item and shop” and “item and supply process” are used.
Apply the two relationships to the MRP calculation. Then, master information such as MPS, bill of materials, inventory and backorders required for MRP calculation is managed for each item and shop, and MRP calculation is performed for each item and shop, not for each item, and according to the item supply process. The volume development and the realization of the batch MRP calculation for all the bases required for the distributed production activity environment realizes the basic information for optimizing the distributed production activities as a whole. And when and how many items are required. "

[0017]

In order to achieve the above object, the MRP calculation according to the present invention defines a supply process from a manufacturer shop to a use shop for each item as shown in FIG. Item-specific supply process definition information (11) and master information necessary for calculating material requirements such as standard production plans, parts lists, stocks, backlogs, etc. are defined by combinations of items and shops that make up the supply process for the item. Item / shop-specific master information group (12), shop attribute information (13) defining the attributes of each shop, and items closer to raw materials in order from parts closer to products on the parts configuration. The shops that make up the supply process are sequentially changed from downstream shops (shops handling items closer to products) to upstream shops (shops handling items closer to raw materials). Irradiation and constitutes out with 該品 th-the Material Requirements item shop by material requirements computation step of performing calculations on shop (14), M for each item shop
RP calculation and development of requirements according to the supply process of items, and material requirement planning for each item / shop (15),
And a supply plan (16) for each shop.

[0018]

Embodiments of the present invention will be described below with reference to the drawings.

FIG. 7 shows the development of the required quantity of part B in consideration of a plurality of bases when there is an MPS (planned date: 8/10, planned quantity: 100), which is a production plan at the product level of product A. FIG. Parts B to make product A
Are shown in the case where two are required.

In the embodiment shown in FIG. 7, the flow of supply of a certain item, such as manufacturing parts B necessary for assembling a product A at an intermediate manufacturing base, storing them at an intermediate warehouse base, and using them at a product assembling base. Is an example, but such item B
Is referred to as a supply process of the item. Then, the part B in the distributed production activity environment as shown in FIG.
The stock / backlog exists for each site constituting the supply process of the part. In such a case, in order to satisfy the above MPS requirement, it is reasonable to calculate the excess or deficiency of the part B at each base in the order of the product assembling base, the intermediate warehouse base, and the intermediate manufacturing base from an economic viewpoint. It is a target. In the case of FIG. 7, as a result of calculating material requirements for each item and each shop in order from the product A and the product assembling base for assembling the product A, “50 parts B” are newly added at the intermediate manufacturing base. It is necessary to make a production plan. By calculating the material requirement in consideration of a plurality of bases having different attributes, it becomes possible to draft an appropriate production plan in a globalized supply process.

For example, in addition to the base shown in FIG. 7, there is another base (for example, there are a plurality of warehouse bases other than those shown in the figure) having stock and backlog of the part B. If there are more than 70 parts B, by supplying the parts B from the base to the product assembly base, it is possible to eliminate the necessity of drafting a new production plan at the intermediate manufacturing base. The MRP calculation as described above is realized in a material requirement calculation step for each item / shop in FIG.

The MPS of the product A in FIG. 7 is based on the monthly / weekly production target amount.
May be based on user demand. Further, in this case, the request (MPS) from the user can be received via an online system with the store or a communication medium such as the Internet with the individual user.

Next, item-specific supply process definition information (11), shop attribute information (13), and item / shop-specific master information group (12), which are input information in the MRP calculation system of the present invention shown in FIG. 2 to 3
This will be described with reference to FIG.

The supply process definition information for each item (11) is
As shown in FIG. 2, for example, regarding the item “A”, “supplier shops” and “supplier shops” in the supply process from the shop of the manufacturer of the item to the shop that finally uses or stores the shop, including shops that are in progress. This is an example in which the relationship with the "supplier shop" is defined. Then, according to the functions to be implemented in the system of the present invention, the attributes of the supply process such as the supply means between the shops, the supply LT, the transportation cost, etc. can be defined at the same time (in FIG. Examples are shown). By using this information, the required amount of a certain item generated in the supply destination shop is developed in the supply source shop when the required amount is developed. With the data structure shown in FIG. 2, for example, the following MRP calculation can be developed. The quantity of missing items generated in Used # 1 (shop code) at the request of the MPS is M of Used # 1.
It is calculated by RP calculation, and based on the information on the amount of missing items, M in the warehouse (shop code)
The PS calculation is expanded. If Warrehouse could make up for all the shortfalls, the required quantity development would be Ven
It is not set to der # 1 (shop code). W
If there is a deficiency even by the MRP calculation in arehouse, it is expanded to Vendor # 1. Also, although not shown in FIG.
If there are more arehouses, Vender
Before expanding to # 1, an MRP calculation that compensates for the shortage can be performed by another warehouse. By performing such development processing, an efficient material requirement plan can be formulated from an economic viewpoint in the entire supply process. The details of the MRP calculation will be described later.

The shop attribute information (13) includes attributes of each shop constituting the supply process of the item, for example, as shown in FIG. Define shop types such as "warehouse" and "parts vendor". MRP for each item / shop
Since the calculation content differs depending on the type of shop, the shop attribute information (13) is used for switching the calculation content.

Master information group by item / shop (12)
Defines the master information necessary for MRP calculation such as MPS, bill of materials, stock / unscheduled, etc. in "by item / shop". For example, if the MPS is based on the conventional single base, it is information such as "100 products A on August 15", but when considering multiple bases, it is necessary to define each item / shop. "Product A is manufactured in shop # 1
100 on August 15 ". One of the specific objects of the present invention is to "understand the excess / deficiency situation of MPS and inventory / back-order in each shop constituting the supply process of a certain item". It is necessary to perform the calculation for each item / shop, and accordingly, the master data also needs to be managed and input for each item / shop. The data of the item-specific supply process definition information (11), the shop attribute information (13), and the item / shop-specific master information group (12) are not limited to the data existing in the database as the core system.
A storage device such as a computer or a workstation may be used.

Next, the "step of calculating the required material amount for each item / shop" in FIG. 1 will be described with reference to FIG.

First, a low-level code (0: product, 1: child part, 2: grandchild part,...) Meaning a hierarchy in the part configuration
The items belonging to the low-level code are acquired one by one in ascending order of the value of. Then, the shops constituting the supply process of the item are acquired in order from the downstream shop (shop handling items closer to products) to the upstream shop (shop handling items closer to raw materials). For example, in the case of FIG. 2, “Used # 1”, “Used # 2”,
Obtain "Warehouse" and "Vendor # 1" in this order.

Next, the MRP calculation for the acquired item and the shop is performed, and the calculation content is switched according to the type of the shop. Hereinafter, the contents of the MRP calculation for each shop type will be described.

The "manufacturing (manufacturer) shop" of the shop type means a shop that manufactures the item. The MRP calculation for the shop can be processed with basically the same contents as the conventional MRP calculation, but the master information used when calculating the MRP is the master information (12) for "item / shop". Different in that. “Gross requirement calculation”, “Net requirement calculation”, “Lot summarization”, “LT calculation”, “Requirement for child parts” while referring to the master information (12) for the item / shop and item / shop. Deployment ”.

The “manufacturing (use destination) shop” of the shop type means a shop that manufactures another item using the item. The MRP calculation for the shop differs from the conventional MRP calculation in the processing content of “expanding required amount”. "Expanding required amount" here does not expand to child parts.
According to the supply process, the required quantity is developed to the shop that supplies the shop. For example, in the case of FIG. 2, it is assumed that the shop is “Used # 1”, and that the plan “50 items A in Used # 1 on August 7” has been developed to the supplier. as a result,
"Warehouse will ship 50 items A to Used # 1 on August 6, and Used # 1 will receive 50 items A from Warehouse on August 7". A material requirement plan of "50 pieces per day" is generated. When calculating these plans, supply process definition information for each item (11)
According to the attribute value.

The “warehouse shop” of the shop type means a shop that stores the item. The MRP calculation for the shop is the same as the calculation for the “manufacturing (use) shop”.

[Parts vendor shop] of shop type
Means a supplier or the like from which the item is purchased. The processing of the MRP calculation for the shop is different from that of other shops in that “the required amount is not developed”.

When the above processing has been performed for all shops and all items, the calculation step ends.
In the above description of the material requirement calculation step for each item / shop, "lot summarization" and "LT calculation" are described as being performed. However, if the functions required for the system of the present invention are not required, the steps need to be performed. There is no. For example, for "warehouse shop", "there is no reference lot size", "L
In the case of "T does not occur" or the like, "Lot summarization" and "LT calculation" may be excluded from the MRP calculation of the "warehouse shop".

In the process of calculating the material requirement by item / shop described above, the material requirement plan by item / shop (15) and the supply plan by shop (1) shown in FIG.
6) is output. 4 and 5 for each output information.
This will be described with reference to FIG.

Material requirement planning by item / shop (15)
As shown in FIG. 4, the output is basically the same as "where and how many items are needed at which shop", and the output is basically the same as the output of the conventional MRP calculation except that the shop information is added. Can be displayed.

As shown in FIG. 5, the shop-by-shop supply plan (16) basically has the content of "what item and how many items are supplied from which shop to which shop". This is impossible with MRP calculation at a single site.

The contents of the above output can be changed according to the functions required of the system of the present invention.
For example, when it is desired to give an instruction to a manufacturing site using the result of the system of the present invention, the date such as “when to start” is calculated as a result of performing “LT calculation”. can do. Further, the display form of the output is not limited to the display form shown in the tables of FIGS. 4 and 5, but may be an information display output by a graphic screen. In particular, in FIG. Any display form that includes the relationship of “where to supply to the shop” is within the scope of the output display according to the present invention.

[0039]

By performing the MRP calculation for each item and shop, and by developing the required amount according to the item supply process, it becomes possible to calculate the required amount for each base and develop the required amount across the bases. And collective MRP calculation for all the bases can be realized.

This makes it possible to formulate a plan in consideration of the attribute values of different items for each site, to understand the effect of a plan change occurring at a certain site, or to determine the inventory and backlog at each site.
It becomes possible to grasp the moving stock between the bases and the like, and to make a more aggressive production plan in a distributed production activity environment.

[Brief description of the drawings]

FIG. 1 is an overall block diagram.

FIG. 2 is a definition example of item-specific supply process definition information.

FIG. 3 is a definition example of shop attribute information.

FIG. 4 is an output example of a material requirement plan by item / shop.

FIG. 5 is an output example of an inter-shop supply plan.

FIG. 6 is an explanatory diagram of a flowchart of a material requirement calculating step for each item / shop.

FIG. 7 is an explanatory diagram of the stock status of the same item present at each base.

[Explanation of symbols]

 11… Supply process definition information by item 12… Master information group by item / shop 13… Shop attribute information 14… Material requirement calculation step by item / shop 15… Material requirement planning by item / shop 16… Supply plan by shop

 ──────────────────────────────────────────────────続 き Continued on the front page (72) Inventor Ken Igarashi 292 Yoshida-cho, Totsuka-ku, Yokohama-shi, Kanagawa Prefecture Inside of Hitachi, Ltd. Address F term in Hitachi, Ltd. Software Division 5B049 AA02 BB07 CC24 CC27 EE02 5H215 AA01 AA06 BB09 CC07 CX01

Claims (8)

[Claims] In a method of calculating a material requirement for a certain item, the number of missing items of the item is calculated for each of the plurality of shops in a supply process including a plurality of shops having different attributes. Requirements calculation method. 2. A step of calculating a material requirement in said destination shop based on item-specific supply process definition information indicating a relationship between a source shop and a destination shop of an item. Performing a material requirement calculation in the supplier shop when the shortage of the item is not resolved. 3. In a method of calculating a material requirement for a certain item, information (MPS information) relating to a planning plan at a product level having the item is input in a supply process including a plurality of shops having different attributes. A method of calculating a required material amount, wherein the number of missing items of the item can be calculated for each of the plurality of shops within a range satisfying the MPS information. 4. A method for calculating a material requirement for a certain item, wherein information (MPS information) relating to a planning plan at a product level having the item is input in a supply process including a plurality of shops having different attributes. And, within the range satisfying the MPS information, based on the item-specific supply process definition information indicating a relationship between a supply source shop and a supply destination shop of the plurality of shops for the item, A material requirement calculation method characterized in that, if the shortage of the item is not resolved as a result of the calculation process of the material requirement in the shop, the material requirement calculation can be further developed in the shop of the supplier. . 5. A material requirement calculation method according to claim 3, wherein said MPS information is inputted via a communication medium. 6. Item-specific supply process definition information defining a supply process from a manufacturer shop to a use shop for each item, a standard production plan, a bill of materials, inventory and backlog required for calculating material requirements. Inputting the master information group for each item and shop that defines each piece of master information by the combination of the item and the shop that constitutes the supply process of the item, and the shop attribute information that defines the attribute of each shop; From items closer to products to items closer to raw materials in order, and from downstream shops (shops handling items closer to products) to upstream shops (shops handling items closer to raw materials) in order For each shop with different attributes. By calculating a material requirement plan of an item and a supply plan of each item between shops having different attributes, it is possible to perform inventory management distributed to each shop for each shop in the same item. Material requirement calculation method. 7. A method for calculating a material requirement for a certain item in a supply process including a plurality of shops having different attributes within a range that satisfies information (MPS information) relating to a planning plan at a product level having the item. And calculating and outputting a planning plan for at least the number of missing items for each of the plurality of shops as a result of the material requirement calculation. 8. A recording medium storing a program using the material requirement calculation method according to claim 1. Description: