JP2004062655A - Production management method and production management program - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a production management method and a production management program that can compute profit contribution in a flow of production of products and appropriately obtain production value information about the products in relation to a profit contribution destination. <P>SOLUTION: A product data acquisition part 11 acquires product data 5a from a parent product production location, and a part data acquisition part 18 acquires part data 6a from a part production location. A consolidated contribution profit calculation part 22 calculates an upstream consolidated contribution profit and a consolidated contribution profit from the product data held in a product data holding part 12, the part data held in a part data holding part 19 and manufacture data held in a manufacture data holding part 17. A product data transmission part 13 transmits product data 5b including the calculated upstream consolidated contribution profit to the parent product production location, and a part data transmission part 20 transmits part data 6b including the calculated consolidated contribution profit to the part production location. <P>COPYRIGHT: (C)2004,JPO

Description

式（１）右辺の部品Ｘｉの上流所属部門集合Ａ_ｕＸｉは、部品データ取得部１８で各部品生産個所から取得され、部品データ保持部１９に保持される。
【００３８】
同様に、各部品Ｘｊの連結所属部門集合Ａ_ｃＸｊは、部品Ｘｊを部品とする製品Ｐｉｊの連結所属部門集合Ａ_ｃＰｉｊと、部品Ｘｊの上流所属部門集合Ａ_ｕＸｊの和集合である。各部品の連結所属部門集合は、部品データ保持部１９に保持され、部品データ送信部から各部品生産個所に送信される。
【００３９】
【数２】

式（２）右辺の製品Ｐｉｊの連結所属部門集合Ａ_ｃＰｉｊは、製品データ取得部１１で各親製品生産個所から取得され、製品データ保持部１２に保持される。
【００４０】
当該部門では製品ごとに、所属部門集合と上流所属部門集合、連結所属部門集合を、部門ＩＤのリストとして保持している。
【００４１】
（ｂ）部品使用量
又、上流連結貢献利益及び連結貢献利益を計算する際は、各製品に使用される部品の量を把握する必要がある。当該生産部門の製品をＰｉ（ｉ＝１，２，．．．）とし、当該部門のいずれかの製品の部品をＸｊ（ｊ＝１，２，．．．）とする。各Ｘｊは、それぞれ当該部門の複数製品の部品となり得る。製品ごとにどの部品を使用するかの情報は製造データとして製造データ保持部１７に保持されている。
【００４２】
製品Ｐｉの単位生産量あたりの、部品Ｘｊの使用量をｘｉｊとする。ただしｘｉｊはＸｊの単位生産量に換算した値である。この値は製造データ保持部１７に保持されている。ｘｉｊは生産期ごとに異なる場合も有り得る。
【００４３】
（ｃ）上流連結貢献利益
製品Ｐｉ（ｉ＝１，２，．．．）を生産および販売した場合、単に当該生産部門で上げた限界利益のみならず、上流での製品Ｐの部品の生産や販売によっても利益貢献がなされている。上流での利益は、例えばＰの材料費の中に含まれており、当該部門では更に材料費に利益分を積み販売する。このように製品の流れにおいて各生産個所で利益が上げられる。流れの中の複数生産個所が、会社全体や事業本部といった部門に共通に属する場合、これらの各所で上げられた利益貢献は、共にその部門の連結利益に貢献することになる。ある製品Ｐを生産する場合、単に当該部門単独での利益貢献分のみならず、製品Ｐの流れの中の複数個所で上げられる共通所属部門への利益貢献分を知ることにより、利用者は製品の生産価値をより的確に知ることができる。ここではまず、製品Ｐの上流で上げられた利益貢献の累積を算出する方法を示す。
【００４４】
製品Ｐｉについて、次の構造を持つデータを上流連結貢献利益データＲ_ｕＰｉ［ｎ］とする。
【００４５】
Ｒ_ｕＰｉ［ｎ］＝｛（所属部門ＩＤ，所属部門上流連結貢献利益）｝（ｎ；生産期）
Ａ_ｕＰｉのある元ａ（ａ：所属事業本部など）について、所属部門ＩＤ；ＩＤ（ａ）と表し、又、第ｎ期の所属部門上流連結貢献利益；Ｒ_ｕＰｉ（ａ）［ｎ］と表す。これは製品Ｐｉの単位生産量あたりの、製品Ｐｉを含む上流全体の部門ａへの利益貢献を示す。
【００４６】
ここでＲ_ｕＰｉ（ａ）［ｎ］を次のように算出する。ＲＰｉ（ａ）［ｎ］を、Ｐｉの生産による第ｎ期の当該部門単独のａへの利益貢献（限界利益）とすると、
【数３】

式（３）において、Ｒ_ｕＸｊ（ｂｉ）［ｎ］は各部品Ｘｊの所属部門上流連結貢献利益で、ｘｉｊは製品Ｐｉに対するＸｊの使用量である。
【００４７】
図１２では、製品Ｐ１に使用される部品をＸ１ｕ、Ｘ２ｕとし、それぞれの部品の使用量をｘ１１、ｘ１２としている。製品Ｐ１１個あたりの上流連結貢献利益Ｐ１ｕを算出する際には、部品Ｘ１、部品Ｘ２１個あたりの上流連結貢献利益Ｘ１ｕ、Ｘ２ｕと部品の使用量ｘ１１、ｘ１２の積を足し合わせ、これと製品Ｐ１１個あたりの単独貢献利益Ｐ１を加算する。
【００４８】
Ｒ_ｕＸ［ｎ］＝（Ｒ_ｕＸ１（ｂ１）［ｎ］，Ｒ_ｕＸ２（ｂ２）［ｎ］，．．．　Ｒ_ｕＸｎ（ｂｎ）［ｎ］）と表し、ｘｉ＝（ｘｉ１，ｘｉ２，．．．，ｘｉｎ）と表すと、式（３）は、
【数４】

と表せる。製品Ｐｉの一単位生産量あたり、各部品Ｘｊをｘｉｊ使用するので、利益貢献の算出においては、部品の一単位生産量あたりの上流連結利益貢献を使用量倍したものを加算する。式（４）が示すように、所属部門上流連結貢献利益は製品上流から決定される。
【００４９】
製品Ｐｉの部門単独での限界利益が、ａに貢献しない時、つまり、
【数５】

の場合、式（３）においてＲＰｉ（ａ）［ｎ］＝０とし、Ｒ_ｕＰｉ（ａ）［ｎ］＝Σ_ｊＲ_ｕＸｊ（ｂｊ）［ｎ］・ｘｉｊ（＝Ｒ_ｕＸ［ｎ］・ｘｉ^ｔ）となる。又部品を含む全上流製品がａに利益貢献しない場合は、ＩＤ（ｂｊ）＝　ＩＤ（ａ）を満たす、
【数６】

が存在しないので、Ｒ_ｕＰｉ（ａ）［ｎ］＝ＲＰｉ（ａ）［ｎ］となる。
【００５０】
当該部門で生産する各製品Ｐｉ（ｉ＝１，２，．．．）についてＲ_ｕＰｉ（ａ）［ｎ］を算出し、ｉ上流連結貢献利益を製品データ送信部１３から親製品生産個所に向け送信する。
【００５１】
（ｄ）連結貢献利益
次に、製品Ｐの下流で上げられた利益貢献の累積である連結貢献利益を算出する方法を示す。当該生産部門で受け入れる各部品Ｘｊ（ｊ＝１，２，．．．）について、次の構造を持つデータを連結貢献利益データＲ_ｃＸｊ［ｎ］とする。
【００５２】
Ｒ_ｃＸｉ［ｎ］＝｛（所属部門ＩＤ，所属部門連結貢献利益）｝
各部品Ｘｊに対し、第ｎ期の部門ａに対する連結貢献利益；Ｒ_ｃＸｊ（ａ）［ｎ］を次のように算出する。
【００５３】
【数７】

式（７）において、Ｒ_ｃＰｉ（ａ）［ｎ］は，各製品Ｐｉの所属部門連結貢献利益で、親製品生産個所にて同様の算出式で計算される値で、製品データ取得部にて取得される。係数αｉｊは、後述するように利益の種類（確定販売分、生産計画量分、余剰生産量分など）によって異なる。又、式（７）が示すように、所属部門連結貢献利益は製品下流から順次決定される。
【００５４】
図１３は、部品Ｘ１が製品Ｐ１、Ｐ２に使用される部品であるときの状態を示している。図１３では、八角形で囲んだ矩形が連結貢献利益を、三角形で囲んだ矩形が上流連結貢献利益を表している。Ｐ１ｃ、Ｐ２ｃは、それぞれ製品Ｐ１、Ｐ２１個あたりの連結貢献利益であり、Ｐ１ｕ、Ｐ２ｕは、それぞれ製品Ｐ１、Ｐ２１個あたりの上流連結貢献利益、Ｘ１ｕ、Ｘ２ｕ、Ｘ３ｕは、それぞれ部品Ｘ１、Ｘ２、Ｘ３１個あたりの上流連結貢献利益を示す。部品Ｘ１ｃ１個あたりの連結貢献利益Ｘ１ｃを算出する際には、製品Ｐ１、Ｐ２１個あたりの連結貢献利益Ｐ１ｃ、Ｐ２ｃから、部品Ｘ１１個あたりの上流連結貢献利益Ｘ１ｕと使用量ｘ１１、ｘ１２の積を引いたものを足し合わせ、これと係数αｉｊの積に、改めて部品Ｘ１１個あたりの上流連結貢献利益Ｘ１ｕを加算する。
【００５５】
Ｒ_ｃＰ［ｎ］＝（Ｒ_ｃＰ１（ａ）［ｎ］−Ｒ_ｕＸｊ（ａ）［ｎ］，　Ｒ_ｃＰ２（ａ）［ｎ］−Ｒ_ｕＸｊ（ａ）［ｎ］，．．．，　Ｒ_ｃＰｎ（ａ）［ｎ］−Ｒ_ｕＰｊ（ａ）［ｎ］，）と表し、αｊ＝（α１ｊ，α２ｊ，．．．，αｎｊ）と表すと、式（７）は、
【数８】

と表せる。
【００５６】
当該部門で受け入れる各部品Ｘｊ（ｊ＝１，２，．．．）についてＲ_ｃＸｊ（ａ）を算出し、連結貢献利益データを部品データ送信部２０から部品生産個所に向け送信する。
【００５７】
製品Ｐの生産が当該部門単独の利益には貢献しても、所属部門ａの利益に貢献するとは限らず、又、逆に当該部門単独の利益には貢献しなくても、所属部門ａの利益に貢献することも有り得る。本発明に係る生産管理方法によれば、利用者は、上流連結貢献利益、連結貢献利益により、製品の所属部門への利益貢献を的確に知ることができる。
【００５８】
（ｅ）式（７）におけるαｉｊの計算
αｉｊは利益の種類によって異なる。例えば、実効余剰生産量分の連結貢献利益を求める場合は次のようにαｉｊを計算する。第ｎ期の製品Ｘｊの実効余剰生産量をＷ_Ｘｊ−ｅｆｆ［ｎ］とする。実効余剰生産量Ｗ_Ｘｊ−ｅｆｆ［ｎ］は、部品Ｘｊの余剰生産量をＷ_Ｘｊ［ｎ］とすると、
【数９】

で計算することができる。
【００５９】
式（９）で製品Ｐｉへの割り当て量をγｉとする。このとき、
【数１０】

とする。ｘｉｊは製品Ｐｉに対する部品Ｘｊの使用量であるから、式（１０）の１／ｘｉｊは、部品Ｘｊ単位生産量あたりの製品Ｐｉの生産量である。又、γｉ／Ｗ_Ｘｊ−ｅｆｆ［ｎ］は、製品Ｘｊの実効余剰生産量に対する、製品Ｐｉへの割り当て比率である。これらを用いると式（７）の「Σ_ｉ｛（Ｒ_ｃＰｉ（ｂｉ）［ｎ］−Ｒ_ｕＸｊ（ａ）［ｎ］・ｘｉｊ）・αｉｊ｝」（以下「下流連結貢献利益分」と呼ぶ。）は、
【数１１】

とも記述することができる。これは各製品Ｐｉに部品Ｘｊをγｉずつ割り当てた時に見込める下流連結貢献利益の総額を実効余剰生産量Ｗ_Ｘｊ−ｅｆｆ［ｎ］で割ったものであるから、実効余剰に関する（単位生産量あたりの）下流連結貢献利益である。
【００６０】
利用者は式（７）における連結貢献利益Ｒ_ｃＰｉ（ａ）の大きい製品Ｐｉへの割り当て比率を大きくし、逆に連結貢献利益の小さい親製品への割り当て比率を小さくすることもできる。あるいは過去の販売実績データから割り当て比率γｉ／Ｗ_Ｘｊ−ｅｆｆ［ｎ］を決定してもよい。ただし以上の計算において、γｉ／ｘｉｊは製品Ｘｊをγｉだけ製品Ｐｉに割り当てた時に生産されるＰｉの量であるから、γｉ／ｘｉｊは製品Ｐｉの実効余剰生産量を超えないものとする。γｉ／ｘｉｊ＝製品Ｐｉの実効余剰生産量とすればこれを満たすので、このように設定してもよい。
【００６１】
又、式（１０）において、実効余剰生産量Ｗ_Ｘｊ−ｅｆｆをＸｊの確定販売量Ｚ_Ｘｊに置き換えた場合、割り当て比率は販売が確定している割り当て量γｉから決定される。
【００６２】
販売計画量分や生産計画量分の連結貢献利益を求める場合にも同様にαｉｊが計算される。
【００６３】
（ｆ）生産期ごとの連結貢献利益
次に、本発明に係る生産管理方法を用いて、生産期ごとの連結貢献利益を算出する方法について説明する。第ｎ期に部品Ｘｊを受け入れてから、製品Ｐｉが完成するまでにはリードタイムΔｉｊ［ｎ］がかかる。これを考慮し、第ｎ期の製品Ｐｉの生産による連結貢献利益を次のように見積もることができる。第ｎ期の製品Ｐｉの生産により、製品Ｘｉは第（ｎ−Δｉｊ［ｎ］）期に上流連結貢献利益を計上すると考えられる。したがって、製品Ｐｉの上流連結貢献利益の式（３）右辺の部品Ｘｊの上流連結貢献利益Ｒ_ｕＸｊ（ｂｊ）［ｎ］において、ｎ→ｎ−Δｉｊ［ｎ］とおきかえると、
【数１２】

となる。右辺の各Ｒ_ｕＸｊ（ｂｊ）［ｎ−Δｉｊ［ｎ］］に、Δｉｊ［ｎ］に応じた利率をかけてもよい。
【００６４】
逆に、第ｎ期に部品Ｘｊを受け入れた場合、製品Ｐｉは第（ｎ＋Δｉｊ［ｎ］）期に、連結貢献利益を計上すると考えられる。したがって、連結貢献利益の式（７）についても同様に、右辺のＲ_ｃＰｉ（ａ）［ｎ］について、ｎ→ｎ＋Δｉｊ［ｎ］とおきかえると、
【数１３】

となる。右辺の各Ｒ_ｃＰｉ（ａ）［ｎ＋Δｉｊ［ｎ］］に、Δｉｊ［ｎ］に応じた利率をかけてもよい。これによると、生産期ごとの上流連結貢献利益及び連結貢献利益を把握することができる。
【００６５】
（ｇ）連結所属部門集合とこれを利用した上流連結貢献利益及び連結貢献利益
次に、本発明に係る生産管理方法を用いて、連結所属部門集合、連結所属部門集合を利用した上流連結貢献利益及び連結貢献利益を算出する方法について説明する。図１４に示すように、Ａ、Ｂ、Ｃ、Ｄ、Ｅ、Ｆの６個の生産個所が生産の流れを構成している場合を例にとる。
【００６６】
まず、生産個所の製品ごとの所属部門集合は、図１５に示すものとする。例えば、生産個所Ａの製品Ｐ１の所属部門集合ＡＰ１＝｛Ａ，Ｄ｝である。これらは各生産個所で製品データに保持されている。
【００６７】
＜上流所属部門集合＞
上流所属部門集合は、式（１）に従って製品の上流から決定される。まず、生産個所Ｂの製品Ｘ１には上流が無いので、製品Ｘ１の上流所属部門集合は図１５の所属部門集合に等しく、Ａ_ｕＸ１＝ＡＸ１＝｛Ｂ，Ｄ｝である。同様に生産個所Ｃの製品Ｘ２、Ｘ３にも上流が無いので、Ｘ２、Ｘ３の上流所属部門集合はそれぞれ、Ａ_ｕＸ２＝ＡＸ２＝｛Ｃ，Ｅ｝、Ａ_ｕＸ３＝ＡＸ３＝｛Ｃ，Ｅ｝である。
【００６８】
生産個所Ａの製品Ｐ１の上流はＸ１とＸ２である。上述したこれらの部品の上流所属部門集合は生産個所Ｂ、Ｃから製品データとして送信され、生産個所Ａの部品データ取得部１８で取得され、部品データの項目として部品データ保持部１９に保持される。これらを用いて、製品Ｐ１の上流所属部門集合Ａ_ｕＰ１は、式（１）に従って、
【数１４】

と求まる。製品Ｐ２の上流所属部門集合Ａ_ｕＰ２も同様に、Ａ_ｕＰ２＝｛Ａ，Ｂ，Ｃ，Ｄ，Ｅ｝と求まる。これらは製品データとして、親製品生産個所ＤとＥに送信される。他の生産個所の各製品についても同様に求まる上流所属部門集合を図１６に示す。
【００６９】
＜連結所属部門集合＞
連結所属部門集合は、式（２）に従って下流から決定される。まず、生産個所Ｄの製品Ｙ１には下流が無いので、Ｙ１の連結所属部門集合Ａ_ｃＹ１は上流所属部門集合Ａ_ｕＹ１に等しい。よってＡ_ｃＹ１＝｛Ａ，Ｂ，Ｃ，Ｄ，Ｅ｝である。生産個所Ｄでは、部品であるＰ１について、式（２）に従って連結所属部門集合Ａ_ｃＰ１を求める。
【００７０】
【数１５】

求めたＰ１の連結所属部門集合Ａ_ｃＰ１は、部品データとして部品生産個所であるＡに送信される。Ａでは、製品データ取得部でＡ_ｃＰ１を取得し、Ｐ１の製品データとして保持する。
【００７１】
Ｐ２の連結所属部門集合Ａ_ｃＰ２も同様に生産個所Ｅから送信され、Ａでは製品データ取得部でＡ_ｃＰ２を取得し、Ｐ２の製品データとして保持する。この例ではＡ_ｃＰ２＝｛Ａ，Ｂ，Ｃ，Ｄ，Ｅ，Ｆ｝である。
【００７２】
Ａでは、Ｘ１、Ｘ２、Ｘ３の連結所属部門集合を求め、ＢとＣに部品データとして送信する。Ｘ１はＰ１とＰ２の部品であるから、その連結所属部門集合Ａ_ｃＸ１は式（２）に従って、
【数１６】

と求まる。他の生産個所の各製品についても同様に求まる上流所属部門集合を図１７に示す。
【００７３】
＜上流連結貢献利益＞
ある生産期（以下、第ｎ期とする）各製品単位生産量あたりの所属部門（図１５）への単独の貢献利益は図１８に示すものであるとする。ただし図１８の所属部門において網を掛けた部門は、所属部門集合に属さない元である。例えば、生産個所Ｂの製品Ｘ１の所属部門は網を掛けていないＢとＤであり、図１５のそれと同じである。同様に、図１８の貢献利益についても網を掛けていない所属部門にのみ、値が存在する。例えば、生産個所Ｂの製品Ｘ１は単位生産量あたり、所属部門ＢとＤに１．０の利益貢献をする。同様に生産個所Ｃの製品Ｘ２は単位生産量あたり、その所属部門ＣとＥに１．０の利益貢献をする。ここでは計算の簡単のため、全ての製品の各所属部門への単位生産量あたりの貢献利益は１．０であるとするが、一般にはそれぞれ異なる値を取る。貢献利益は、製品データとしてそれぞれの生産個所で製品ごとに保持される。
【００７４】
ここで第ｎ期の各製品の部品使用量を図１９に示すものであるとする。例えばＰ１は、単位生産量あたり、Ｘ１を２、Ｘ２を２、部品として使用する。これらの値は、各生産個所で製造データとして製品ごとに製造データ保持部に保持されている。この時、上流連結貢献利益は式（３）に従って上流から次のように計算される。
【００７５】
まず、生産個所Ｂの製品Ｘ１には上流が無いので、製品Ｘ１の上流所属部門ＢとＤに対する第ｎ期の上流連結貢献利益Ｒ_ｕＸ１（Ｂ）［ｎ］、Ｒ_ｕＸ１（Ｄ）［ｎ］は、それぞれ図１８の単独貢献利益に等しく、Ｒ_ｕＸ１（Ｂ）［ｎ］＝ＲＸ１（Ｂ）［ｎ］＝１．０、Ｒ_ｕＸ１（Ｄ）［ｎ］＝ＲＸ１（Ｄ）［ｎ］＝１．０である。同様に、製品Ｘ２、Ｘ３についても、上流連結貢献利益は単独貢献利益に等しい。これらを図２０に示す。図１８と同様に所属部門について網を掛けた部門は、所属部門集合の元でなく、また貢献利益について網を掛けた部分は値が存在しない（もしくは０である）。
【００７６】
得られた上流連結貢献利益は製品データとして、製品データ送信部から、各親製品生産個所に向けて送信される。
【００７７】
生産個所Ａの製品Ｐ１の各上流所属部門（Ａ，Ｂ，Ｃ，Ｄ，Ｅ）への上流連結貢献利益は、式（３）に従って次のように計算される。
【００７８】
Ｒ_ｕＰ１（Ａ）［ｎ］＝ＲＰ１（Ａ）［ｎ］＝１．０　　　　　　　　　　　　　　……（１７）
Ｒ_ｕＰ１（Ｂ）［ｎ］＝Ｒ_ｕＸ１（Ｂ）［ｎ］・２＝１．０・２＝２．０　　　　　　　　　……（１８）
Ｒ_ｕＰ１（Ｃ）［ｎ］＝Ｒ_ｕＸ２（Ｃ）［ｎ］・２＝１．０・２＝２．０　　　　　　　　　……（１９）
Ｒ_ｕＰ１（Ｄ）［ｎ］＝Ｒ_ｕＸ１（Ｄ）［ｎ］・２＋ＲＰ１（Ａ）［ｎ］＝１．０・２＋１．０＝３．０　　……（２０）
Ｒ_ｕＰ１（Ｅ）［ｎ］＝Ｒ_ｕＸ２（Ｅ）［ｎ］・２＝１．０・２＝２．０　　　　　　　　　……（２１）
例としてＲ_ｕＰ１（Ｄ）［ｎ］について検算を行う。Ｐ１は単位生産量あたりＸ１を２使用する。ここで図１８からＸ１は単位生産量あたり単独でＤへ１．０貢献するので、Ｐ１を１単位生産量生産すれば、Ｘ１を２生産することになり、Ｘ１単独ではＤに２．０貢献することになる。Ｐ１は単独ではＤに１．０貢献するので、上流連結ではＤに合計３．０貢献することになる。これは上のＲ_ｕＰ１（Ｄ）［ｎ］に等しく、式（３）により、生産の流れの中での連結の貢献利益が正しく計算されている。
【００７９】
製品Ｐ２についても同様に、各上流所属部門への上流連結貢献利益が計算される。製品Ｐ１とＰ２の上流連結貢献利益を図２０に示す。製品Ｐ１とＰ２の各上流所属部門への上流連結貢献利益は製品データ送信部から親製品生産個所ＤとＥに送信される。他の生産個所の各製品についても式（３）に従って同様に上流連結貢献利益が計算される。これらを図２０に示す。
【００８０】
＜連結貢献利益＞
式（７）に従って、各生産個所の製品ごとの第ｎ期の連結貢献利益が下流から次のように計算される。
【００８１】
まず、生産個所Ｄの製品Ｙ１には下流が無いので、Ｙ１の各連結所属部門（Ａ，Ｂ，Ｃ，Ｄ，Ｅ）への連結貢献利益は上流連結貢献利益に等しい。同様に、生産個所Ｅの製品Ｙ２にも下流が無いので、Ｙ２の各連結所属部門（Ａ，Ｂ，Ｃ，Ｄ，Ｅ，Ｆ）への連結貢献利益は上流連結貢献利益に等しい。これらを図２１に示す。
【００８２】
生産個所Ｄでは部品Ｐ１の各連結所属部門（部品データとしてＤで保持されている）への連結貢献利益が式（７）に従って次のように計算される。ただし、部品Ｐ１は製品Ｙ１にのみ使用されるので、ＤにおけるＰ１の配分比率は１．０であり、使用量は２であるから式（１０）に準拠して、αｉｊ＝（１／使用量）×（配分比率）＝１／２×１．０＝０．５とする。
【００８３】

これらの値はＤの部品データ送信部から部品データとしてＡに送信される。
【００８４】
例としてＲ_ｃＰ１（Ｄ）［ｎ］について検算を行う。Ｙ１の単位生産量あたり、Ｐ１を２使用するので、Ｐ１を１単位生産量生産すると、Ｙ１は０．５生産されることになる。Ｙ１のＤへの単独貢献利益は図１８から１．０であり、０．５生産する場合の貢献利益は０．５である。また、Ｐ１を１単位生産量生産すると、Ｘ１とＸ２を２づつ生産することになる。この時Ｘ１のＤへの単独貢献利益は１．０×２であり、Ｘ２のＤへの単独貢献利益は０である。またＰ１のＤへの単独貢献利益は１．０である。以上より、Ｐ１を１単位生産量生産した場合のＤへの連結貢献利益は０．５＋２．０＋１．０＝３．５となり、上で求めたＲ_ｃＰ１（Ｄ）［ｎ］に等しい。
【００８５】
以上の計算においては、生産の流れの中で製品Ｐ１に関連する全生産個所・全製品の貢献利益や使用量を用いている。一方、式（７）による連結貢献利益に計算においては、自部門の連結貢献利益と部品の上流連結貢献利益と使用量生産のみを用いている。使用量は自部門の製造データの項目であり、また自部門の連結貢献利益は親製品生産個所から送信されるデータであり、部品の上流連結貢献利益は部品生産個所から送信されるデータである。よって式（７）による連結貢献利益に計算において必要なデータは、生産の流れにおいて隣接する生産個所から送信されるデータと自部門のデータのみである。ある製品が関連する生産個所の数が多数で生産の流れが複雑な場合、上記の検算のような計算を行うことはデータの取得を含め困難である。本発明に係る生産管理システムによれば、連結貢献利益の計算は、隣接する生産個所から送信されるデータと自部門のデータのみで容易に計算でき、利用者は自部門の製品の持つ、生産の流れ全体の中での価値を的確に知ることが可能となる。他の生産個所の各製品についても同様に計算される連結貢献利益を図２１に示す。
【００８６】
（ｈ）実効余剰生産量を生産した場合の上流連結貢献利益及び連結貢献利益
次に、本発明に係る生産管理方法を用いて、自部門で生産する複数の製品について余剰生産量がある場合、自部門単独の利益貢献のみならず、製品上流・下流であげられる連結貢献利益を考慮した上で余剰生産量に対する生産計画を立てる方法について説明する。
【００８７】
第ｎ期の製品Ｐｉの実効余剰生産量をＷ_Ｐｉ−ｅｆｆ［ｎ］とする。製品ＰｉをＷ_Ｐｉ−ｅｆｆ［ｎ］生産した場合に見込める所属部門ａに対する利益貢献は、
自部門を含む製品上流について、Ｗ_Ｐｉ−ｅｆｆ［ｎ］・Ｒ_ｕＰ（ａ）［ｎ］　　……（２７）
自部門を含まない製品下流について、Ｗ_Ｐｉ−ｅｆｆ・Ｒ_ｄＰ（ａ）［ｎ］　……（２８）
製品上流・下流全体について、Ｗ_Ｐｉ−ｅｆｆ・Ｒ_ｃＰ（ａ）［ｎ］　　　　　……（２９）
と算出される。ここで、Ｒ_ｄＰ（ａ）［ｎ］＝　Ｒ_ｃＰ（ａ）［ｎ］−Ｒ_ｕＰ（ａ）［ｎ］で、計算することができる。これらは、製品ごと、所属部門ごとに計算されるので、利用者による多角的な判断が可能となる。
【００８８】
（ｉ）連結キャッシュフロー
次に、本発明に係る生産管理方法を用いて、当該生産部門のある製品Ｐについて余剰生産能力が有るとする場合、製品Ｐを生産した時の上位部門の連結キャッシュフローに及ぼす影響を得る方法について説明する。
【００８９】
本発明に係る生産管理システムは、生産スケジューラ１６によりスケジューリングされる生産計画に基づき、以下の（イ）〜（ホ）の各種キャッシュフローを算出し、表示することができる。
【００９０】
（イ）　　　　Ｚ＿ＣＦ［ｎ］：第ｎ期の現状キャッシュフロー
生産計画どおりに生産し、現状で販売の確定している製品のみを販売した場合のキャッシュフローである。確定している販売による利益と、計画の立っている生産および在庫のコスト、固定費によるキャッシュフロー時系列である。利用者はこの現状キャッシュフロー時系列を見ることで、現状の生産計画のもとでキャッシュフローは現状キャッシュフロー時系列を下回ることはないと推定することができる。α_Ｐ［ｎ］を第ｎ期の製品Ｐの単価、β_Ｐ［ｎ］を第ｎ期の製品Ｐの限界利益、γ_Ｐ［ｎ］を第ｎ期の製品Ｐの在庫費用係数、Ｙ_Ｐ［ｎ］を第ｎ期の製品Ｐの生産計画量、Ｚ_Ｐ［ｎ］を第ｎ期の製品Ｐの確定販売量、Ｉ_Ｐ［ｎ］を第ｎ期の製品Ｐの在庫量、Ｆ［ｎ］を第ｎ期の部門共通固定費とすると、第ｎ期の現状キャッシュフローＺ＿ＣＦ［ｎ］は、以下の式で算出される。
【００９１】
【数１７】

（ロ）Ｙ＿ＣＦ［ｎ］：第ｎ期の生産計画キャッシュフロー
産計画どおりに生産し、製品を各生産期で全て販売し、在庫を持たない場合のキャッシュフローである。現状の生産計画のもとでの最良の販売シナリオに基づくキャッシュフロー時系列である。利用者はこの生産計画キャッシュフロー時系列を見ることで、現状の生産計画のもとでキャッシュフローは上記現状キャッシュフロー以上、生産計画キャッシュフロー以下になると推定することができる。Ｐ_Ｐ［ｎ］を第ｎ期の製品Ｐの来期繰越し在庫量、ＳＩ_Ｐ［ｎ］を第ｎ期の製品Ｐの販売可能在庫量（＝Ｉ_Ｐ［ｎ］−Ｐ_Ｐ［ｎ］）とすると、第ｎ期の生産計画キャッシュフローＹ＿ＣＦ［ｎ］は、以下の式で算出される。
【００９２】
【数１８】

（ハ）Ｉ＿ＣＦ［ｎ］：第ｎ期の在庫各時点販売キャッシュフロー
現状で販売の確定している製品に加え、第ｎ期の販売可能在庫量分を販売した場合のキャッシュフローである。生産計画どおりに生産される製品のうち販売の確定している製品以外は、現状では在庫となる予定である。現状の生産計画のもと、販売確定分の製品に加え、第ｎ期までに積みあがる在庫のうち販売可能なものを第ｎ期に販売した場合のキャッシュフロー時系列である。現状キャッシュフロー以上、生産計画キャッシュフロー以下になる。第ｎ期の在庫各時点販売キャッシュフローＩ＿ＣＦ［ｎ］は、以下の式で算出される。
【００９３】
【数１９】

（ニ）Ｘ＿ＣＦ［ｎ］：第ｎ期の販売計画キャッシュフロー
販売計画どおりに生産し、製品を各生産期ですべて販売し、在庫を持たない場合のキャッシュフローである。生産計画は販売計画に基づいて、生産スケジューラにより作成されるが、その際、工場の生産能力や部品納入量などの制約により、販売計画分全てを生産できるとは限らない。販売計画キャッシュフローは、販売計画分全て生産したと仮定した場合の、最良の販売シナリオに基づくキャッシュフロー時系列であり、生産計画キャッシュフロー以上となる。販売計画キャッシュフローと生産計画キャッシュフローの差が大きい場合、工場の生産能力を大きく上回る販売計画を立てていることになる。利用者は販売計画キャッシュフローと生産計画キャッシュフローを比較することで、販売計画が生産能力に対して適切なものであるかどうかを知ることができる。Ｘ_Ｐ［ｎ］を第ｎ期の製品Ｐの販売計画量とすると、第ｎ期の販売計画キャッシュフローＸ＿ＣＦ［ｎ］は、以下の式で算出される。
【００９４】
【数２０】

（ホ）Ｗ_Ｐ＿ＣＦ［ｎ］：第ｎ期の製品Ｐの生産能力キャッシュフロー
生産計画キャッシュフローに加え、現状の生産計画のもとでの製品Ｐの余剰生産量を販売した場合のキャッシュフローである。工場の生産能力から、生産計画分の生産力を引いた残りが余剰生産量である。この余剰生産量を使ってある製品Ｐを生産し、在庫を持つことなく販売した場合のキャッシュフロー時系列である。余剰生産量を各製品に割当てた場合の生産計画は生産スケジューラ１６が立てる。利用者は各製品の生産能力キャッシュフロー時系列を比較することにより、余剰生産量に対する最適な製品の割り当てについての情報を得ることができる。Ｗ_Ｐ［ｎ］を第ｎ期の製品Ｐの余剰生産量とすると、第ｎ期の製品Ｐの生産能力キャッシュフローＷ_Ｐ　＿ＣＦ［ｎ］は、以下の式で算出される。
【００９５】
【数２１】

ここで、当該部門のある上位部門をａとする。本発明に係る生産管理システムによれば、上位部門ＣＦデータ取得部２４により、利用者は部門ａの連結キャッシュフロー時系列データを得ることができる。これをＣＦａ［ｎ］とする。これに、製品Ｐを実効余剰生産量だけ生産した時に製品上流・下流で見込める連結利益貢献の第ｎ期までの累積を加算すると、
ＣＦａ［ｎ］＋Σ_ｊＷ_Ｐ−ｅｆｆ［ｊ］・Ｒ_ｃＰ（ａ）［ｊ］　　　　　　　　　……（３５）
が求まる。これにより利用者は自部門単独の実効余剰生産キャッシュフローだけでなく、余剰生産能力で生産する場合の関連部門全体のキャッシュフローを容易に知ることができ、余剰生産能力に対する的確な生産計画の立案が可能となる。
【００９６】
（その他の実施の形態）
本発明は上記の実施の形態によって記載したが、この開示の一部をなす論述及び図面はこの発明を限定するものであると理解すべきではない。この開示から当業者には様々な代替実施の形態、実施例及び運用技術が明らかとなろう。
【００９７】
例えば、本発明の実施の形態に係る生産管理システムは、製品データ保持部１２、リソース使用量データ保持部１４、製造スケジュール保持部１５、製造データ保持部１７、部品データ保持部１９、ＣＦデータ保持部２８を分けて備えると記述したが、これらの保持部の一部あるいは全部を一つの保持部で代用しても構わない。
【００９８】
このように、本発明はここでは記載していない様々な実施の形態等を含むことは勿論である。従って、本発明の技術的範囲は上記の説明から妥当な特許請求の範囲に係る発明特定事項によってのみ定められるものである。
【００９９】
【発明の効果】
本発明によると、対象となる部門の生産する製品について、その製品に関連する生産の流れの中の複数個所で挙げられる利益から、当該製品の生産の流れの中における利益貢献を算出し、利益貢献先に対する当該製品の生産価値情報を適切に得る生産管理方法及び生産管理プログラムを提供することができる。
【図面の簡単な説明】
【図１】本発明の実施の形態に係る生産管理システムのブロック図である。
【図２】本発明の実施に形態に係る製品と部品の関係を示す図である。
【図３】本発明の実施の形態に係る製品の流れを示す図である（その１）。
【図４】本発明の実施の形態に係る部門構成の一例を示す図である。
【図５】本発明の実施の形態に係る製造データの一例を示す図である。
【図６】本発明の実施の形態に係るリソース使用量データの一例を示す図である。
【図７】本発明の実施の形態に係る製品データの一例を示す図である。
【図８】本発明の実施の形態に係る部品データの一例を示す図である。
【図９】本発明の実施の形態に係る部門データの一例を示す図である。
【図１０】本発明の実施の形態に係る製品データと部品データの流れを示す図である。
【図１１】本発明の実施の形態に係る生産管理方法のフローチャートである。
【図１２】本発明の実施の形態に係る上流連結貢献利益の算出方法を示す図である。
【図１３】本発明の実施の形態に係る連結貢献利益の算出方法を示す図である。
【図１４】本発明の実施の形態に係る製品の流れを示す図である（その２）。
【図１５】本発明の実施の形態に係る所属部門集合を示す図である。
【図１６】本発明の実施の形態に係る上流所属部門集合を示す図である。
【図１７】本発明の実施の形態に係る連結所属部門集合を示す図である。
【図１８】本発明の実施の形態に係る単独貢献利益を示す図である。
【図１９】本発明の実施の形態に係る部品の使用量を示す図である。
【図２０】本発明の実施の形態に係る上流連結貢献利益を示す図である。
【図２１】本発明の実施の形態に係る連結貢献利益を示す図である。
【符号の説明】
５ａ、５ｂ　製品データ
６ａ、６ｂ　部品データ
７ａ　上位部門ＣＦデータ
７ｂ　下位部門ＣＦデータ
７ｃ、７ｄ　自部門ＣＦデータ
１１　製品データ取得部
１２　製品データ保持部
１３　製品データ送信部
１４　リソース使用量データ保持部
１５　製造スケジュール保持部
１６　生産スケジューラ
１７　製造データ保持部
１８　部品データ取得部
１９　部品データ保持部
２０　部品データ送信部
２２　連結貢献利益計算部
２３　実効余剰生産量計算部
２４　上位部門ＣＦデータ取得部
２５　ＣＦデータ計算部
２６　上位部門データ送信部
２７　下位部門データ取得部
２８　ＣＦデータ保持部
２９　下位部門ＣＦデータ送信部
３０　ＣＦデータ表示部
３１　生産箇所[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a production management method and a production management program for calculating a profit contribution in each production department in a product production flow.
[0002]
[Prior art]
In general, when a product is produced in a certain production department, parts produced in various production locations including subordinate departments, other companies, and subcontractors are used to assemble with the production parts in the department and produce the product. Further, the product of the production section may be a part of a plurality of products at a plurality of other production locations. In this way, a product in a production department goes through various production points to a final product on the market.
[0003]
As described above, when a product is produced and sold in a certain production department, the profit is contributed not only by the profit generated by the production department but also by the production and sale of parts of the product in the upstream. The upstream profit is included, for example, in the material cost of the product, and the production department further accumulates and sells the profit on the material cost. In this way, profits can be obtained at each production point in the product flow. If a plurality of production sites in the flow belong to a department such as the entire company or the business headquarters, the profit contributions raised at these locations together contribute to the consolidated profit of that department.
[0004]
[Problems to be solved by the invention]
However, it was difficult to calculate the profit contribution in the production department in the flow of producing the product, for each product and for each profit contribution destination.
[0005]
Accordingly, in view of the above-described problems, the present invention provides a method for manufacturing a product produced by a target production department, based on the benefits listed at a plurality of locations in the production flow related to the product. It is an object of the present invention to provide a production management method and a production management program capable of calculating a profit contribution in a product, and appropriately obtaining production value information of the product for a profit contribution destination.
[0006]
[Means for Solving the Problems]
In order to achieve the above object, a first feature of the present invention is that a production management computer that manages production of a product from a component is: Obtaining a product data including a consolidated contribution profit from a production location; (b) obtaining a component data including an upstream consolidated contribution profit from a component production location for producing a component; and (c) an upstream consolidated contribution profit. Calculating the consolidated upstream contribution profit of the production division that produces products from parts, (d) calculating the consolidated contribution profit of the production division from the consolidated contribution profit and the upstream consolidated contribution profit, and (e) the production division. Transmitting the product data including the upstream consolidated contribution profit to the parent product production site, and transmitting the component data including the consolidated contribution profit of the production department to the component production site. And summarized in that Tsu is a production management method and a flop.
[0007]
According to the production management method according to the first feature, for each product produced in the own department, not only the profit contribution by the department alone, but also the common belonging department raised at a plurality of places in the production flow. The profit contribution is calculated, and the user can more accurately know the production value of the product with respect to the profit contribution destination.
[0008]
Further, the production management method according to the first feature may further include a step of calculating an upstream consolidated contribution profit and a consolidated contribution profit for each production period in consideration of a lead time until the product is completed. According to this production management method, it is possible to grasp the upstream consolidated contribution profit and the consolidated contribution profit for each production period.
[0009]
Further, the production management method according to the first feature may further include a step of calculating an upstream consolidated contribution profit and a consolidated contribution profit when the effective surplus production amount is produced. According to this production management method, it is possible to make a production plan for the surplus production amount in consideration of the consolidated contribution profits that can be obtained upstream and downstream of the product.
[0010]
Further, the production management method according to the first feature calculates the cash flow of the entire related department from the cash flow of the upper department of the production department and the upstream consolidated contribution profit and the consolidated contribution profit when the effective surplus production is produced. Steps may be further included. According to this production management method, it is possible to easily know not only the effective surplus production cash flow of the own department alone, but also the cash flow of the entire related department when producing with surplus production capacity. Planning is possible.
[0011]
A second feature of the present invention resides in that a production management computer that manages the production of products from parts is provided with (a) a consolidated contribution profit from a parent product production location, which is a location where a parent product that directly produces a product as a component is produced. (B) a procedure for acquiring component data including an upstream consolidated contribution profit from a component production location for producing a component, and (c) a product is produced from a component using the upstream consolidated contribution profit. Includes a procedure for calculating the upstream consolidated contribution profit of the production department, (d) a procedure for calculating the consolidated contribution profit of the production department from the consolidated contribution profit and the upstream consolidated contribution profit, and (e) an upstream consolidated contribution profit of the production department. A production management program for executing a procedure for transmitting product data to a parent product production location and a procedure for transmitting component data including a consolidated contribution profit of a production department to a component production location. It is the gist of.
[0012]
By reading the production management program according to the second aspect of the present invention, it is possible to cause a production management system or the like to execute the above procedure.
[0013]
BEST MODE FOR CARRYING OUT THE INVENTION
Next, an embodiment of the present invention will be described with reference to the drawings. In the following description of the drawings, the same or similar parts are denoted by the same or similar reference numerals. However, it should be noted that the drawings are schematic.
[0014]
(Example of production form)
First, the relationship between products and parts according to the production management method of the present invention will be described. In the following description, for a product P produced in a certain production department, the parts that directly constitute the product P will be referred to as “parts of the product P”, and the production place for producing the parts will be referred to as “parts for producing the product P”. . Similarly, a product in which the product P is a direct component is referred to as a “parent product of the product P”, and a production location for producing the parent product is referred to as a “production location of the parent product of the product P”. Further, a parent product of the product P or a further parent product having the parent product of the product P as a part is referred to as a “downstream product of the product P”, and a production location thereof is referred to as a “downstream product production location of the product P”. Further, a part of the product P or a grandchild part that produces a part of the product P as a product is referred to as an “upstream product of the product P”, and a production location thereof is referred to as an “upstream product production location of the product P”.
[0015]
It is assumed that a certain production department produces m kinds of products Pi (i = 1, 2,..., M). In order to produce these products, the department purchases n types of parts Xj (j = 1, 2,..., N) from outside the department. Each Xj is a part of one or more products Pi of the department. This relationship is shown in FIG. In FIG. 2, the center square indicates the production location 31 (in this case, the department), and the arrow indicates the relationship in which the part Xj is a part of the product Pi. For example, the part X1 is a part of the products P1 and P2.
[0016]
Such production is connected in multiple stages, and a product flow as shown in FIG. 3 is created. Here, it is shown that the product P1 of the production location A is a component of the production location D, and the products P2 and P3 of the department A are components of the production location E. The parts X1 and X2 at the production location A are products at the production location B, and the parts X3 at the production location A are products at the production location C. Even if the products are of the same type, if the production locations incorporated as parts are different, they are considered to be different products.
[0017]
(Example of department structure)
Next, the relationship between departments according to the production management method of the present invention will be described. The “department” described here refers to a department that has an affiliation when considering the flow of funds and profits, regardless of the flow of products or parts. For example, there is a relationship in which a factory is located in a lower section of the head office and a manufacturing department is located in a lower section of the factory. In the following description, an upper section to which a target section (hereinafter, referred to as “own section”) directly belongs is referred to as a “parent section”, and a lower section directly belonging to the own section is referred to as “child section”. Each section has at most one parent section and zero or more child sections. FIG. 4 shows an example of the configuration of a department, which indicates that the own department has one parent department and two child departments. In the embodiment of the present invention, a description will be given of a department that has a parent department and a child department and that manufactures and sells products in its own department. Some departments do not have a parent department or a child department, and some departments do not manufacture and sell in their own department, but the present invention is also applicable to these departments.
[0018]
(Example of each data)
Next, manufacturing data, resource usage data, product data, component data, and department data used in the production management method of the present invention will be described.
As shown in FIG. 5, the manufacturing data is data on the manufacturing process of each product Pi (i = 1, 2,...) In the own department. A process name required for manufacturing the product Pi, an order relation between processes, a used resource type, the number of used resources, and the like are described. The used resources X1, X2, and X3 indicate, for example, parts, and the number of resources used for manufacturing the product Pi is indicated as the number of parts. The used resources W1, W2, and W3 indicate, for example, a machine, and the number of resources used for manufacturing the product Pi is indicated as the use time of the machine. The manufacturing data is held in the manufacturing data holding unit 17 of FIG.
[0019]
The resource usage data holds the usage status of each resource required for the production of products such as machines, labor and parts in each production period. As shown in FIG. 6, the resource use status includes a planned amount, a fixed amount, a surplus amount, and the like. The resource usage data is held in the resource usage data holding unit 14 in FIG.
[0020]
As shown in FIG. 7A, the product data is data including a product price, b production direct cost, c marginal profit, and the like of each product Pi (i = 1, 2,...) For each production period. . Further, as shown in FIG. 7B, data relating to the production amount and sales amount such as the planned d sales amount, the planned e production amount, the confirmed f sales amount, and the g stock amount in each production period are also held. Further, as shown in FIG. 7 (c), h surplus production amount, i upstream connection contribution profit, j effective surplus production amount, and k connection contribution profit along the production flow are also held. Here, “upstream consolidated contribution profit” refers to the contribution profit per product from the upstream product production site to the own department. “Consolidated contribution profit” refers to the contribution profit per product from the own department to the downstream production site. The “surplus production amount” refers to the surplus amount of machines and parts at the own department and at upstream product production points. "Effective surplus production" refers to the amount of surplus production that can be actually used by transferring it to other departments. The product data is held in the product data holding unit 12 of FIG.
[0021]
As shown in FIG. 8, the component data is data such as a surplus production amount, b upstream consolidation contribution profit, c effective surplus production amount, and d consolidation profit for each production period. The component data is held in the component data holding unit 19 in FIG.
[0022]
As shown in FIG. 9, the section data is data such as costs, sales, profits, various cash flows, and the like of the entire section in each production period. The department data is held in the CF data holding unit 28 in FIG. The costs include fixed costs common to the departments in each production period, inventory costs required for inventory management of all products and delivered parts in the departments, and resource determination costs required for purchasing resources such as parts. The common fixed cost may be held and calculated for each of more detailed items such as a salary of each employee during each production period and a utility bill. Sales and profits may be held and calculated in detail for each product or for each department. As profits, not only marginal profits but also net profits may be held and calculated.
[0023]
Next, transmission and reception of product data and component data will be described with reference to FIG. 10 along a production flow. The department is assumed to be A, and in A, a product P1 is produced from the part X1. The part production location of the product P1 is B, and the parent product production location is D. Data is exchanged between the department A and the parts production location B as follows.
[0024]
From the department A, for the part X1, the effective surplus production amount of the part data and the d-consolidated contribution profit are transmitted to the part production location B. In the part B, these are acquired by the product data acquisition unit 11, and the j effective The surplus production amount and k-consolidated contribution profit are retained. B transmits the surplus production amount of X1 and the i-upstream consolidated contribution profit from the product data transmission unit 13 to the division A as the product data, and the division data acquisition unit 18 acquires these in the division A. Maintain as production volume and b upstream consolidated contribution profit. Similar data is exchanged between the department A and the parent product production place D.
[0025]
(Example of production management system configuration)
As shown in FIG. 1, the production management system according to the present invention includes a product data acquisition unit 11 for acquiring product data 5a from a parent product production location, a product data retention unit 12 for retaining and editing product data, and a parent product production. A product data transmitting unit 13 for transmitting the product data 5b to the location, a component data acquiring unit 18 for acquiring the component data 6a from the component producing location, a component data retaining unit 19 for retaining and editing the component data, and a component data for the component producing location 6b is provided. Also, a consolidated contribution profit calculator 22 for calculating the upstream consolidated contribution profit and the consolidated contribution profit based on the product data, the manufacturing data and the component data, and an effective surplus production amount calculated based on the product data 5a, the manufacturing data and the component data 6a. A surplus production amount calculation unit 23 is provided. Further, a production scheduler 16 is provided for creating a production schedule for a desired production period by inputting the product data 5a, component data 6a, production data, production schedule, and resource usage data. The production scheduler 16 may receive cash flow data as input.
[0026]
The manufacturing data holding unit 17 holds manufacturing data. The resource usage data holding unit 14 holds resource usage data. The manufacturing schedule holding unit 15 holds a manufacturing schedule of a product of the production department, such as a use schedule of a machine or a use schedule of parts created by the production scheduler 16. When the production schedule is created by the production scheduler 16, the planned amount of the resource usage data, the production planned amount of the product data e, the g stock amount, and the like change accordingly.
[0027]
Furthermore, the production management system according to the present invention includes an upper section CF data acquisition unit 24 for acquiring upper section CF data 7a such as various cash flows, profits, and sales amounts of upper sections, and various cash flows, profits, and sales of lower sections. The lower section CF data acquisition unit 27 for acquiring the lower section CF data 7b such as the amount, various types of cash flow, profit, and sales volume of the own section from the product data and resource usage data, the upper section CF data 7a, and the lower section CF data 7b. A CF data calculation unit 25 for calculating data such as data of the own department, a CF data holding unit 28 for storing CF data of the own department, a CF data display unit for displaying CF data of the own department, CF data including the upper department or the lower department, and the like. 30, an upper section CF data transmission unit 26 for transmitting the CF data 7c of the own section to the upper section, and a CF data of the own section It comprises sub-sectors CF data transmission unit 29 for transmitting 7d to the lower division.
[0028]
(Production management method)
Next, a production management method according to an embodiment of the present invention will be described with reference to FIGS.
[0029]
(A) In step S101 in FIG. 11, the product data acquisition unit 11 acquires the product data 5a from the parent product production location. The product data 5a is held in the product data holding unit 12. Also, in step S102, the component data acquisition unit 18 acquires the component data 6a from the component production location. The component data 6a is held in the component data holding unit 19.
[0030]
(B) Next, in step S104, the consolidated contribution profit calculation unit 22 is stored in the product data storage unit 12, the component data stored in the component data storage unit 19, and stored in the manufacturing data storage unit 17. Calculate the upstream consolidated contribution profit and the consolidated contribution profit from the manufacturing data. Specifically, the upstream consolidated contribution profit is calculated based on the b upstream consolidated contribution profit of the component data 6a, the resource usage amount of the manufacturing data, and the c marginal profit of the product data 5a. The upstream connection contribution profit calculated here is held in the i upstream connection contribution profit of the product data 5b, and is again held in the product data holding unit 12. Consolidated contribution profit includes k-consolidated contribution profit of product data 5a, b-upstream consolidated contribution profit of component data 6a, resource usage of manufacturing data, and types of profit to be calculated (determined sales, planned production, surplus production). Calculated by a coefficient which differs depending on the amount. The calculated consolidation contribution profit is stored in the d-consolidation contribution profit of the component data 6b, and is stored again in the component data storage unit 19. The detailed method of calculating the upstream consolidated contribution profit and the consolidated contribution profit will be described later.
[0031]
(C) Next, in step S105, the product data transmission unit 13 transmits the product data 5b including the i-upstream consolidated contribution profit calculated by the consolidated contribution profit calculation unit 22 to the parent product production site. Based on this product data 5b, the upstream consolidated contribution profit at the parent product production location can be calculated at the parent product production location. Further, in step S106, the component data transmitting unit 20 transmits the component data 6b including the d-consolidated contribution profit calculated by the consolidated-contribution profit calculation unit 22 to the component production location. Based on the component data 6b, the connection contribution profit at the component production location can be calculated at the component production location.
[0032]
According to the production management method according to the present invention, for each product produced in the own department, not only the contribution to the profit of the production department alone, but also the profit to the common belonging department which can be raised at a plurality of places in the production flow. The contribution is calculated, and the user can more accurately know the production value of the product with respect to the profit contribution destination. In addition, it is conceivable that there are generally a plurality of contribution destinations of profits of products manufactured in the own department, for example, an affiliated factory, an affiliated business headquarters, a head office, and the like, which may differ for each product. According to the production management method of the present invention, a consolidated contribution profit in a production flow is calculated for each of a plurality of profit contribution destinations for each product.
[0033]
(Method of calculating consolidated contribution profit)
Next, a detailed calculation method of the upstream consolidated contribution profit and the consolidated contribution profit will be described.
[0034]
(A) Department set
Production of a product in a certain production department can contribute not only to the profit of the department but also to the consolidated profit of a higher-level department that is a set of a plurality of production departments, such as a company or a factory to which the department belongs. Therefore, when calculating the upstream consolidated contribution profit and the consolidated contribution profit, it is necessary to grasp the relations of these departments.
[0035]
In general, there are a plurality of departments to which the production of the product P of a certain production department contributes to profits, and these are assumed to be the departments APij (j = 1, 2,. For example, AP11: the department concerned, AP12: affiliated business headquarters, AP13: company,... Also, the set {APij} is defined as the department set belonging to the product Pi; APi.
[0036]
Upstream department set A of product Pi (i = 1, 2,...) _u Pi is the upstream department set A of all parts Xj _u It is a union of Xj and the department set APi to which the department belongs. If there is no upstream in the product Pi, the upstream department set is equal to the department set of the product Pi. The upstream department group set of each product Pi is held in the product data holding unit 12 and transmitted from the product data transmission unit 13 to each parent product production location.
[0037]
(Equation 1)

Formula (1): upstream section set A of part Xi on the right side _u Xi is acquired from each component production location by the component data acquisition unit 18 and held in the component data holding unit 19.
[0038]
Similarly, a set A of linked departments of each part Xj _c Xj is a set A of linked departments of the product Pij having the part Xj as a part. _c Pij and upstream department set A of part Xj _u Xj is a union set. The linked department set of each component is held in the component data holding unit 19 and transmitted from the component data transmission unit to each component production location.
[0039]
(Equation 2)

Formula (2): Consolidated department set A of product Pij on the right side _c The Pij is acquired from each parent product production site by the product data acquisition unit 11 and is held in the product data holding unit 12.
[0040]
In the department, a department set, an upstream department set, and a connection department set are held as a list of department IDs for each product.
[0041]
(B) Parts usage
Also, when calculating the upstream consolidated contribution profit and the consolidated contribution profit, it is necessary to grasp the amount of parts used for each product. A product of the production department is Pi (i = 1, 2,...), And a part of any product in the department is Xj (j = 1, 2,...). Each Xj can be a part of a plurality of products of the department. Information on which part is used for each product is held in the manufacturing data holding unit 17 as manufacturing data.
[0042]
Let xij be the usage of the part Xj per unit production of the product Pi. Here, xij is a value converted into a unit production amount of Xj. This value is held in the manufacturing data holding unit 17. xij may be different for each production period.
[0043]
(C) Consolidated upstream contribution profit
When a product Pi (i = 1, 2,...) Is produced and sold, the profit contribution is made not only by the marginal profit raised in the production department, but also by the production and sale of parts of the product P upstream. ing. The upstream profit is included in, for example, the material cost of P, and the department further accumulates and sells the profit on the material cost. In this way, profits can be obtained at each production point in the product flow. If a plurality of production sites in the flow belong to a department such as the entire company or the business headquarters, the profit contributions raised at these locations together contribute to the consolidated profit of that department. When producing a certain product P, the user can obtain the product contribution by knowing not only the profit contribution of the department concerned alone but also the profit contribution to the common belonging department which can be raised at a plurality of places in the flow of the product P. Can know the production value more accurately. Here, first, a method of calculating the accumulation of the profit contribution raised upstream of the product P will be described.
[0044]
For the product Pi, the data having the following structure is converted to the upstream consolidated contribution profit data R. _u Pi [n].
[0045]
R _u Pi [n] = {(affiliated department ID, affiliated department upstream consolidated contribution profit)} (n; production period)
A _u For an element a with Pi (a: affiliated business headquarters, etc.), the affiliated department ID; ID (a) is represented, and the affiliated department upstream consolidated contribution profit in the n-th period; R _u Pi (a) [n]. This indicates the profit contribution to the entire upstream department a including the product Pi per unit production amount of the product Pi.
[0046]
Where R _u Pi (a) [n] is calculated as follows. Assuming that RPi (a) [n] is the profit contribution (marginal profit) of the sector alone to a in the n-th period due to the production of Pi,
[Equation 3]

In the formula (3), R _u Xj (bi) [n] is the division unit upstream consolidated contribution profit of each part Xj, and xij is the amount of Xj used for the product Pi.
[0047]
In FIG. 12, the components used for the product P1 are X1u and X2u, and the usage amounts of the respective components are x11 and x12. When calculating the upstream consolidated contribution profit P1u per product P11, the product of the parts X1 and X2u, and the product of the component usage amounts x11 and x12, and the product P11 The individual contribution profit P1 per unit is added.
[0048]
R _u X [n] = (R _u X1 (b1) [n], R _u X2 (b2) [n],. . . R _u Xn (bn) [n]), and xi = (xi1, xi2,..., Xin), the expression (3) becomes
(Equation 4)

Can be expressed as Since each part Xj is used as xij per unit production of the product Pi, in the calculation of the profit contribution, a product obtained by multiplying the upstream consolidated profit contribution per unit production of the part by the used amount is added. As shown in equation (4), the affiliated section upstream consolidated contribution profit is determined from the product upstream.
[0049]
When the marginal profit of the product Pi alone does not contribute to a, that is,
(Equation 5)

In the case of RPi (a) [n] = 0 in the equation (3), R _u Pi (a) [n] = Σ _j R _u Xj (bj) [n] xij (= R _u X [n] · xi ^t ). Also, if all the upstream products including the parts do not contribute profit to a, satisfy ID (bj) = ID (a).
(Equation 6)

Does not exist, so R _u Pi (a) [n] = RPi (a) [n].
[0050]
R for each product Pi (i = 1, 2,...) Produced in the department _u Pi (a) [n] is calculated, and the i-upstream consolidated contribution profit is transmitted from the product data transmission unit 13 to the parent product production site.
[0051]
(D) Contribution profit
Next, a method of calculating a consolidated contribution profit, which is the accumulation of the profit contribution raised downstream of the product P, will be described. For each part Xj (j = 1, 2,...) Accepted by the production department, data having the following structure is converted to consolidated contribution profit data R _c Xj [n].
[0052]
R _c Xi [n] = {(affiliated department ID, affiliated department consolidated contribution profit)}
For each part Xj, the consolidated contribution profit to the division a in the n-th period; R _c Xj (a) [n] is calculated as follows.
[0053]
(Equation 7)

In equation (7), R _c Pi (a) [n] is the division consolidated contribution profit of each product Pi, and is a value calculated by the same calculation formula at the parent product production location, and is acquired by the product data acquisition unit. The coefficient αij differs depending on the type of profit (determined sales amount, planned production amount, surplus production amount, etc.) as described later. Further, as shown by the equation (7), the belonging consolidated contribution profit is determined sequentially from the product downstream.
[0054]
FIG. 13 shows a state where the component X1 is a component used for the products P1 and P2. In FIG. 13, a rectangle surrounded by an octagon represents a connection contribution profit, and a rectangle surrounded by a triangle represents an upstream connection contribution profit. P1c and P2c are consolidated contribution profits per product P1 and P21, respectively, P1u and P2u are upstream connection contribution profits per product P1 and P21, respectively, and X1u, X2u and X3u are components X1, X2 and X3u, respectively. X shows the upstream consolidated contribution profit per 31 pieces. When calculating the consolidated contribution profit X1c per component X1c, the product of the upstream consolidated contribution profit X1u per component X11 and the usage amount x11, x12 is calculated from the consolidated contribution profit P1c, P2c per product P1, P21. The result of subtraction is added, and the product of this and the coefficient αij is added again to the upstream connection contribution profit X1u per 11 parts X.
[0055]
R _c P [n] = (R _c P1 (a) [n] -R _u Xj (a) [n], R _c P2 (a) [n] -R _u Xj (a) [n],. . . , R _c Pn (a) [n] -R _u Pj (a) [n],) and αj = (α1j, α2j,..., Αnj), equation (7) is
(Equation 8)

Can be expressed as
[0056]
R for each part Xj (j = 1, 2,...) Accepted by the department _c Xj (a) is calculated, and the consolidated contribution profit data is transmitted from the component data transmission unit 20 to the component production location.
[0057]
Even if the production of the product P contributes to the profit of the department alone, it does not always contribute to the profit of the department a, to which the department P belongs. It can also contribute to profits. According to the production management method of the present invention, the user can accurately know the contribution of the product to the department to which the product belongs, based on the upstream connection contribution profit and the connection contribution profit.
[0058]
(E) Calculation of αij in equation (7)
αij differs depending on the type of profit. For example, to obtain a consolidated contribution profit for the effective surplus production amount, αij is calculated as follows. The effective surplus production of the product Xj in the nth period is expressed by W _Xj −eff [n]. Effective surplus production W _Xj -Eff [n] is the surplus production amount of the part Xj as W _Xj [N],
(Equation 9)

Can be calculated by
[0059]
In equation (9), the amount allocated to the product Pi is γi. At this time,
(Equation 10)

And Since xij is the used amount of the part Xj with respect to the product Pi, 1 / xij in Expression (10) is the production amount of the product Pi per unit Xj production amount. Also, γi / W _Xj -Eff [n] is an allocation ratio of the product Xj to the product Pi with respect to the effective surplus production amount of the product Xj. When these are used, “Σ” in equation (7) _i ｛(R _c Pi (bi) [n] -R _u Xj (a) [n] .xij) .alpha.ij} (hereinafter referred to as "downstream consolidated contribution profit") is
[Equation 11]

Can also be described. This means that the total amount of downstream consolidated contribution profit expected when parts Xj are assigned to each product Pi by γi is the effective surplus production amount W. _Xj −eff [n], which is the downstream consolidated contribution profit (per unit production) related to the effective surplus.
[0060]
The user calculates the consolidated contribution profit R in equation (7). _c It is also possible to increase the allocation ratio to the product Pi having a large Pi (a) and, conversely, to reduce the allocation ratio to the parent product having a small consolidated contribution profit. Alternatively, the allocation ratio γi / W based on past sales performance data _Xj −eff [n] may be determined. However, in the above calculation, γi / xij is the amount of Pi produced when the product Xj is allocated to the product Pi by only γi, so that γi / xij does not exceed the effective surplus production of the product Pi. Since γi / xij = effective surplus production of the product Pi satisfies this, it may be set in this way.
[0061]
Also, in equation (10), the effective surplus production amount W _Xj -Eff is the fixed sales volume Z of Xj _Xj In this case, the allocation ratio is determined from the allocated amount γi for which the sales have been determined.
[0062]
Similarly, αij is calculated when obtaining the consolidated contribution profit for the planned sales amount or the planned production amount.
[0063]
(F) Consolidated contribution profit for each production period
Next, a method of calculating a consolidated contribution profit for each production period using the production management method according to the present invention will be described. It takes a lead time Δij [n] from the reception of the part Xj in the nth period to the completion of the product Pi. In consideration of this, the consolidated contribution profit from the production of the product Pi in the nth period can be estimated as follows. Due to the production of the product Pi in the nth period, it is considered that the product Xi will record an upstream consolidated contribution profit in the (n-Δij [n]) period. Therefore, the equation (3) of the upstream connection contribution profit R of the product Pi indicates the upstream connection contribution profit R of the component Xj on the right side. _u In Xj (bj) [n], if n → n−Δij [n] is replaced,
(Equation 12)

It becomes. Each R on the right side _u Xj (bj) [n-Δij [n]] may be multiplied by the interest rate according to Δij [n].
[0064]
Conversely, when the part Xj is received in the nth period, the product Pi is considered to record a consolidated contribution profit in the (n + Δij [n]) period. Accordingly, the equation (7) for the consolidated contribution profit is similarly calculated using R _c When Pi (a) [n] is replaced with n → n + Δij [n],
(Equation 13)

It becomes. Each R on the right side _c Pi (a) [n + Δij [n]] may be multiplied by an interest rate according to Δij [n]. According to this, it is possible to grasp the upstream consolidated contribution profit and the consolidated contribution profit for each production period.
[0065]
(G) Consolidated affiliation department set and upstream consolidated contribution profit and consolidated contribution profit using this
Next, a description will be given of a method of calculating the consolidated contribution profit and the consolidated contribution profit using the consolidated department set and the consolidated department set using the production management method according to the present invention. As shown in FIG. 14, a case where six production points A, B, C, D, E, and F constitute a production flow will be described as an example.
[0066]
First, it is assumed that the department set belonging to each product at the production location is as shown in FIG. For example, the department set AP1 = {A, D} to which the product P1 of the production place A belongs. These are stored in product data at each production site.
[0067]
<Upstream department set>
The upstream department set is determined from the upstream of the product according to equation (1). First, since the product X1 at the production location B has no upstream, the upstream department set of the product X1 is equal to the department set of FIG. _u X1 = AX1 = {B, D}. Similarly, since there is no upstream in the products X2 and X3 of the production place C, the upstream department sets of X2 and X3 are A _u X2 = AX2 = {C, E}, A _u X3 = AX3 = {C, E}.
[0068]
Upstream of the product P1 at the production location A are X1 and X2. The above-described set of upstream departments of these parts is transmitted as product data from the production locations B and C, acquired by the component data acquisition unit 18 of the production location A, and held in the component data holding unit 19 as items of component data. . Using these, the upstream department set A of the product P1 _u P1 is calculated according to equation (1).
[Equation 14]

Is obtained. Upstream department set A of product P2 _u Similarly for P2, A _u P2 = {A, B, C, D, E}. These are transmitted to the parent product production locations D and E as product data. FIG. 16 shows the upstream department set obtained in the same manner for each product at other production locations.
[0069]
<Consolidated belonging department set>
The connected department set is determined from downstream according to equation (2). First, since there is no downstream in the product Y1 of the production place D, the consolidated belonging department set A of Y1 _c Y1 is upstream department set A _u Equal to Y1. Therefore A _c Y1 = {A, B, C, D, E}. At the production place D, the connected department set A for the part P1 according to the equation (2) _c Find P1.
[0070]
[Equation 15]

Consolidated department set A of P1 found _c P1 is transmitted as part data to A, which is a part production location. In A, the product data acquisition unit _c P1 is acquired and held as product data of P1.
[0071]
Consolidated department set A of P2 _c P2 is also transmitted from the production site E in the same manner. _c P2 is acquired and held as product data of P2. In this example, A _c P2 = {A, B, C, D, E, F}.
[0072]
In A, the linked department set of X1, X2, and X3 is obtained, and transmitted to B and C as part data. Since X1 is a part of P1 and P2, its linked belonging department set A _c X1 is calculated according to equation (2).
(Equation 16)

Is obtained. FIG. 17 shows a set of upstream departments similarly obtained for each product at other production locations.
[0073]
<Upstream consolidated profit>
It is assumed that the sole contribution profit to the department (FIG. 15) belonging to each production unit of a certain production period (hereinafter, referred to as n-th period) is as shown in FIG. However, the shaded departments in the belonging departments in FIG. 18 do not belong to the belonging department set. For example, the departments to which the product X1 of the production place B belongs are B and D, which are not shaded, and are the same as those in FIG. Similarly, the contribution profit in FIG. 18 also has a value only for the department to which it is not shaded. For example, the product X1 at the production location B contributes 1.0 profit to the departments B and D belonging to the unit production volume. Similarly, the product X2 at the production location C contributes 1.0 profit to the departments C and E to which it belongs per unit production. Here, for the sake of simplicity of calculation, it is assumed that the contribution profit per unit production amount of each product to each department is 1.0, but generally different values are taken. The contribution profit is held for each product at each production location as product data.
[0074]
Here, it is assumed that the component usage of each product in the n-th period is as shown in FIG. For example, P1 uses 2 as X1 and 2 as X2 as a part per unit production amount. These values are held in the manufacturing data holding unit for each product as manufacturing data at each production location. At this time, the upstream connection contribution profit is calculated as follows from the upstream according to the equation (3).
[0075]
First, since there is no upstream in the product X1 of the production location B, the upstream consolidated contribution profit R in the n-th period with respect to the upstream departments B and D of the product X1. _u X1 (B) [n], R _u X1 (D) [n] is equal to the sole contribution profit of FIG. _u X1 (B) [n] = RX1 (B) [n] = 1.0, R _u X1 (D) [n] = RX1 (D) [n] = 1.0. Similarly, for the products X2 and X3, the upstream consolidated contribution profit is equal to the single contribution profit. These are shown in FIG. In the same way as in FIG. 18, the departments shaded for the belonging departments are not the origin of the belonging department set, and the portion shaded for the contribution profit has no value (or 0).
[0076]
The obtained upstream consolidated contribution profit is transmitted as product data from the product data transmission unit to each parent product production location.
[0077]
The upstream consolidated contribution profit of the product P1 of the production location A to each of the upstream departments (A, B, C, D, E) is calculated as follows according to the equation (3).
[0078]
R _u P1 (A) [n] = RP1 (A) [n] = 1.0 (17)
R _u P1 (B) [n] = R _u X1 (B) [n] · 2 = 1.0 · 2 = 2.0 (18)
R _u P1 (C) [n] = R _u X2 (C) [n] · 2 = 1.0 · 2 = 2.0 (19)
R _u P1 (D) [n] = R _u X1 (D) [n] · 2 + RP1 (A) [n] = 1.0 · 2 + 1.0 = 3.0 (20)
R _u P1 (E) [n] = R _u X2 (E) [n] · 2 = 1.0 · 2 = 2.0 (21)
R as an example _u P1 (D) [n] is checked. P1 uses 2 of X1 per unit production. From FIG. 18, X1 alone contributes 1.0 to D per unit production. Therefore, if one unit of P1 is produced, X1 is produced twice, and X1 alone contributes 2.0 to D. Will be. Since P1 alone contributes 1.0 to D, it will contribute a total of 3.0 to D in the upstream connection. This is the upper R _u Equal to P1 (D) [n], equation (3) correctly calculates the contributory contribution in the production flow.
[0079]
Similarly, for the product P2, the upstream consolidated contribution profit to each upstream belonging section is calculated. FIG. 20 shows the upstream connection contribution profit of the products P1 and P2. The upstream consolidated contribution profits of the products P1 and P2 to the respective upstream sections are transmitted from the product data transmission unit to the parent product production locations D and E. The upstream consolidated contribution profit is similarly calculated for each product at the other production sites according to the equation (3). These are shown in FIG.
[0080]
<Consolidated contribution profit>
According to equation (7), the consolidated contribution profit in the n-th period for each product at each production location is calculated from the downstream as follows.
[0081]
First, since there is no downstream in the product Y1 at the production place D, the consolidated contribution profit to each of the connected departments (A, B, C, D, E) of Y1 is equal to the upstream consolidated contribution profit. Similarly, since there is no downstream in the product Y2 of the production place E, the consolidated contribution profit to each of the connected departments (A, B, C, D, E, F) of Y2 is equal to the upstream consolidated contribution profit. These are shown in FIG.
[0082]
At the production location D, the consolidated contribution profit of the component P1 to each of the linked departments (held as component data in D) is calculated as follows according to equation (7). However, since the part P1 is used only for the product Y1, the distribution ratio of P1 in D is 1.0 and the used amount is 2, so that αij = (1 / used amount) according to the equation (10). ) × (distribution ratio) = １ ／ × 1.0 = 0.5.
[0083]

These values are transmitted to A as component data from the D component data transmission unit.
[0084]
R as an example _c P1 (D) [n] is checked. Since P1 is used twice per unit production amount of Y1, if one unit production amount of P1 is produced, 0.5 of Y1 will be produced. The independent contribution profit of Y1 to D is 1.0 from FIG. 18, and the contribution profit when producing 0.5 is 0.5. Also, if one unit of P1 is produced, two X1 and two X2 will be produced. At this time, the sole contribution profit of X1 to D is 1.0 × 2, and the sole contribution profit of X2 to D is zero. The sole contribution profit of P1 to D is 1.0. From the above, the consolidated contribution profit to D when P1 is produced in one unit production amount is 0.5 + 2.0 + 1.0 = 3.5, and R calculated above is obtained. _c It is equal to P1 (D) [n].
[0085]
In the above calculations, the contribution profits and usage amounts of all the production sites and all products related to the product P1 in the production flow are used. On the other hand, in the calculation of the consolidated contribution profit by the equation (7), only the consolidated contribution profit of the own department, the upstream consolidated contribution profit of the parts, and the production of the used amount are used. Usage is an item of manufacturing data of own department, consolidated contribution profit of own department is data transmitted from parent product production site, and upstream consolidated contribution profit of parts is data transmitted from component production site . Therefore, the only data necessary for calculating the consolidated contribution profit by the equation (7) is the data transmitted from the adjacent production site and the data of the own department in the production flow. When the number of production locations associated with a product is large and the production flow is complicated, it is difficult to perform calculations such as the above-mentioned verification including data acquisition. According to the production management system of the present invention, the calculation of the consolidated contribution profit can be easily calculated only by the data transmitted from the adjacent production site and the data of the own department, and the user can obtain the production of the product of the own department. Value in the overall flow can be accurately known. FIG. 21 shows consolidated contribution profits similarly calculated for each product at other production locations.
[0086]
(H) Consolidated upstream contribution profit and consolidated contribution profit when effective surplus production is produced
Next, using the production management method according to the present invention, when there is a surplus production amount for a plurality of products produced in the own department, not only the contribution to the profit of the own department alone, but also the consolidated contribution profit that can be obtained upstream and downstream of the product. A method of establishing a production plan for surplus production in consideration of the above will be described.
[0087]
The effective surplus production of product Pi in the nth period is W _Pi −eff [n]. Product Pi W _Pi -Eff [n] The profit contribution to the department a that can be expected when producing
For product upstream including own department, W _Pi -Eff [n] · R _u P (a) [n] (27)
For products downstream that do not include your department, _Pi -Eff ・ R _d P (a) [n] (28)
For the entire product upstream and downstream, W _Pi -Eff ・ R _c P (a) [n] (29)
Is calculated. Where R _d P (a) [n] = R _c P (a) [n] -R _u It can be calculated by P (a) [n]. Since these are calculated for each product and for each department, it is possible for the user to make diversified decisions.
[0088]
(I) Consolidated cash flow
Next, using the production management method according to the present invention, if there is surplus production capacity for a certain product P in the production department, a method of obtaining the effect on the consolidated cash flow of the higher-level department when the product P is produced Will be described.
[0089]
The production management system according to the present invention can calculate and display the following various cash flows (a) to (e) based on the production plan scheduled by the production scheduler 16.
[0090]
(B) Z_CF [n]: Current cash flow for the nth period
This is the cash flow when the product is manufactured according to the production plan and only the products for which sales are currently determined are sold. Cash flow time series with fixed sales profits, planned production and inventory costs, and fixed costs. By viewing the current cash flow time series, the user can estimate that the cash flow will not be lower than the current cash flow time series under the current production plan. α _P [N] is the unit price of the product P in the nth period, β _P [N] is the marginal profit of the product P in the nth period, γ _P [N] is the inventory cost coefficient of the n-th product P, Y _P [N] is the production plan quantity of the product P in the nth period, Z _P [N] is the fixed sales volume of the product P in the nth period, I _P Assuming that [n] is the inventory amount of the product P in the n-th period and F [n] is the common fixed cost of the department in the n-th period, the current cash flow Z_CF [n] in the n-th period is calculated by the following formula. .
[0091]
[Equation 17]

(B) Y_CF [n]: nth production plan cash flow
This is the cash flow when the product is manufactured according to the production plan, the product is sold in each production period, and there is no stock. It is a cash flow time series based on the best sales scenario under the current production plan. By looking at the time series of the production plan cash flow, the user can estimate that the cash flow is equal to or higher than the current cash flow and lower than the production plan cash flow under the current production plan. P _P [N] is the carry-over stock amount of the product P in the next period, SI _P [N] is the available inventory amount of the product P in the nth period (= I _P [N] -P _P [N]), the n-th production plan cash flow Y_CF [n] is calculated by the following equation.
[0092]
(Equation 18)

(C) I_CF [n]: Cash flow for each point of sale of inventory in the nth period
This is the cash flow when selling the available inventory in the nth term in addition to the products whose sales are currently determined. Of the products produced according to the production plan, products other than those whose sales are confirmed are currently in stock. Based on the current production plan, in addition to the products for which the sales have been confirmed, the cash flow is a time series in the case where, in the n-th period, the available inventory of the stocks accumulated by the n-th period is sold. It is above current cash flow and below production plan cash flow. The inventory cash flow I_CF [n] at each point in time of the n-th period is calculated by the following equation.
[0093]
[Equation 19]

(D) X_CF [n]: Sales plan cash flow for the nth period
This is the cash flow when products are manufactured according to the sales plan, products are sold in each production period, and no inventory is held. The production schedule is created by the production scheduler based on the sales plan. At this time, however, not all of the sales plan can be produced due to restrictions such as the production capacity of the factory and the amount of parts delivered. The sales plan cash flow is a time series of cash flows based on the best sales scenario, assuming that all of the sales plan has been produced, and is equal to or greater than the production plan cash flow. If the difference between the sales plan cash flow and the production plan cash flow is large, it means that the sales plan is much higher than the production capacity of the factory. By comparing the sales plan cash flow and the production plan cash flow, the user can know whether the sales plan is appropriate for the production capacity. X _P Assuming that [n] is the sales plan amount of the product P in the n-th period, the sales plan cash flow X_CF [n] in the n-th period is calculated by the following formula.
[0094]
(Equation 20)

(E) W _P _CF [n]: cash flow of production capacity of product P in the nth period
This is a cash flow when the surplus production amount of the product P under the current production plan is sold in addition to the production plan cash flow. The surplus production is the remainder of the production capacity of the factory minus the production capacity for the production plan. This is a cash flow time series when a certain product P is produced using the surplus production amount and sold without having stock. The production scheduler 16 sets up a production plan when the surplus production amount is allocated to each product. By comparing the production capacity cash flow time series of each product, the user can obtain information on the optimal allocation of the product to the surplus production amount. W _P Assuming that [n] is the surplus production amount of the product P in the n-th period, the production capacity cash flow W of the product P in the n-th period _P _CF [n] is calculated by the following equation.
[0095]
(Equation 21)

Here, a higher-level department of the department is referred to as a. According to the production management system of the present invention, the user can obtain the consolidated cash flow time-series data of the department a by the higher department CF data acquisition unit 24. This is CFa [n]. When adding the accumulated profit up to the n-th term, which can be expected upstream and downstream of the product P when the product P is produced by the effective surplus production amount,
CFa [n] + Σ _j W _P -Eff [j] · R _c P (a) [j] (35)
Is found. As a result, users can easily know not only the effective surplus production cash flow of their own department alone, but also the cash flow of the entire related department when producing with surplus production capacity, and formulate an accurate production plan for surplus production capacity. Becomes possible.
[0096]
(Other embodiments)
Although the present invention has been described with the above embodiments, it should not be understood that the description and drawings forming part of this disclosure limit the present invention. From this disclosure, various alternative embodiments, examples, and operation techniques will be apparent to those skilled in the art.
[0097]
For example, the production management system according to the embodiment of the present invention includes a product data holding unit 12, a resource usage data holding unit 14, a manufacturing schedule holding unit 15, a manufacturing data holding unit 17, a component data holding unit 19, and a CF data holding. Although it has been described that the unit 28 is provided separately, a part or all of these holding units may be substituted by one holding unit.
[0098]
As described above, the present invention naturally includes various embodiments and the like not described herein. Therefore, the technical scope of the present invention is determined only by the invention specifying matters according to the claims that are appropriate from the above description.
[0099]
【The invention's effect】
According to the present invention, for a product produced by a target department, the profit contribution in the production flow of the product is calculated from the profits listed at a plurality of locations in the production flow related to the product, and the profit is calculated. It is possible to provide a production management method and a production management program for appropriately obtaining production value information of the product for the contribution destination.
[Brief description of the drawings]
FIG. 1 is a block diagram of a production management system according to an embodiment of the present invention.
FIG. 2 is a diagram showing a relationship between products and parts according to the embodiment of the present invention.
FIG. 3 is a diagram showing a flow of a product according to the embodiment of the present invention (part 1).
FIG. 4 is a diagram showing an example of a department configuration according to the embodiment of the present invention.
FIG. 5 is a diagram showing an example of manufacturing data according to the embodiment of the present invention.
FIG. 6 is a diagram showing an example of resource usage data according to the embodiment of the present invention.
FIG. 7 is a diagram showing an example of product data according to the embodiment of the present invention.
FIG. 8 is a diagram showing an example of component data according to the embodiment of the present invention.
FIG. 9 is a diagram showing an example of department data according to the embodiment of the present invention.
FIG. 10 is a diagram showing a flow of product data and component data according to the embodiment of the present invention.
FIG. 11 is a flowchart of a production management method according to the embodiment of the present invention.
FIG. 12 is a diagram illustrating a method for calculating an upstream connection contribution profit according to the embodiment of the present invention.
FIG. 13 is a diagram showing a method for calculating a consolidated contribution profit according to the embodiment of the present invention.
FIG. 14 is a diagram showing a product flow according to the embodiment of the present invention (part 2).
FIG. 15 is a diagram showing a department set belonging to the embodiment of the present invention.
FIG. 16 is a diagram showing an upstream belonging department set according to the embodiment of the present invention.
FIG. 17 is a diagram showing a consolidated belonging department set according to the embodiment of the present invention.
FIG. 18 is a diagram showing a single contribution profit according to the embodiment of the present invention.
FIG. 19 is a diagram showing the usage of components according to the embodiment of the present invention.
FIG. 20 is a diagram showing an upstream connection contribution benefit according to the embodiment of the present invention.
FIG. 21 is a diagram showing a consolidated contribution profit according to the embodiment of the present invention.
[Explanation of symbols]
5a, 5b Product data
6a, 6b Parts data
7a CF data of upper section
7b CF data of lower section
7c, 7d Own department CF data
11 Product Data Acquisition Department
12 Product data storage
13 Product data transmission section
14 Resource usage data holding unit
15 Manufacturing schedule holding unit
16 Production scheduler
17 Manufacturing data storage
18 Parts data acquisition unit
19 Parts data storage
20 Parts data transmission unit
22 Consolidated Contribution Income Calculator
23 Effective surplus production calculation section
24 Upper section CF data acquisition section
25 CF data calculation unit
26 upper section data transmission section
27 Lower Section Data Acquisition Unit
28 CF data storage
29 Lower section CF data transmitter
30 CF data display
31 Production sites

Claims (5)

A production management computer that manages the production of products from parts
A step of obtaining product data including a consolidated contribution profit, from a parent product production location, which is a location where a parent product is produced with the product as a direct component;
Acquiring part data including an upstream consolidated contribution profit from a part production location that produces the part,
Calculating, by the upstream consolidated contribution profit, an upstream consolidated contribution profit of a production department that produces the product from the component;
Calculating a consolidated contribution profit of the production department based on the consolidated contribution profit and the upstream consolidated contribution profit;
Transmitting product data including the upstream consolidated contribution profit of the production department to the parent product production location;
Transmitting component data including the consolidated contribution profit of the production department to the component production location. The production management method according to claim 1, further comprising a step of calculating an upstream consolidated contribution profit and a consolidated contribution profit for each production period in consideration of a lead time until the product is completed. 3. The production management method according to claim 1, further comprising calculating an upstream consolidated contribution profit and a consolidated contribution profit when the effective surplus production amount is produced. The method according to claim 11, further comprising: calculating a cash flow of the related division as a whole from a cash flow of a higher rank division of the production division and an upstream consolidated contribution profit and a consolidated contribution profit when the effective surplus production amount is produced. 3. The production management method according to 3. A production management computer that manages the production of products from parts,
A procedure for obtaining product data including a consolidated contribution profit from a parent product production location, which is a location for producing a parent product having the product as a direct component,
A procedure for obtaining component data including an upstream consolidated contribution profit from a component production location that produces the component,
Calculating the upstream consolidated contribution profit of the production department that produces the product from the component by the upstream consolidated contribution profit;
A step of calculating a consolidated contribution profit of the production department based on the consolidated contribution profit and the upstream consolidated contribution profit;
A procedure for transmitting product data including the upstream consolidated contribution profit of the production department to the parent product production location,
Transmitting the component data including the consolidated contribution profit of the production department to the component production location.

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