JP2007179306A - Production planning method and device for joint product item - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a production planning method and device, capable of forming a production plan not causing running out of stock while considering stock amounts of a plurality of items by previously preparing a plurality of production methods each having a different generation ratio of the item and allocating the production method to each production device to efficiently perform control of the stock of a large number of items because it is very difficult to carefully form the production plan of the plurality of items because the plurality of items are simultaneously produced at a fixed ratio by difference of the production method from raw material. <P>SOLUTION: Based on a characteristic in joint production, a stock control condition of each the item is set. Next, a stock reference value is statistically calculated from a demand amount of each item, and the stock amount is indexed as a stock rate. The stock rate is found by (an effective stock amount/a stock reference amount). Subsequently, a production amount of each item is determined. Temporary allocation of capability of one unit lot device is repeated by the number of the production methods of all the devices until all the items each produced such that the stock reference value does not become insufficient within a range of the capability of the device or to the stock reference value each reach the stock reference value. With balance of the stock rates in all the items at that time as an index, it is determined that the capability is allocated to any production method of any device, and the production plan is formed. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to a production planning method and a production planning system in a manufacturing process called co-production in which a plurality of items are produced at a fixed ratio in a process of processing raw materials. In particular, the present invention is suitable for a production planning method and a production planning system in which an excess or shortage of inventory does not occur between items when the ratio of a plurality of items generated due to a difference in manufacturing method is different.

Conventionally, in the above technical field, the production conditions are complicated, and production plans are often drawn up based on the experience and intuition of workers on the production site. As a basis for this, a large number of items are generated at the same time under joint production conditions, and therefore excess inventory and under-invention will occur unless production is performed while maintaining a balance of inventory quantities of multiple items. Therefore, it was necessary to devise a production plan that balances inventory while adjusting to the demand of all items. Further, in a manufacturing process in a manufacturing plant having characteristics of co-production, the stable operation state of the apparatus must be maintained, so that the generation ratio of items generated by co-production cannot be adjusted intentionally.
As a production planning method in a conventional manufacturing plant, for example, there is a conventional technique described in Japanese Patent Laid-Open No. 2003-15716. This prior art discloses a production planning method in which production is performed in ascending order of inventory rate (margin).

JP 2003-15716 A

  However, because multiple items are produced at a fixed ratio from raw materials at the same time due to differences in manufacturing methods, if you focus on only one item and make a production plan, other items may become overstocked or out of stock. There is a problem that occurs. Because it is a joint production, it is very difficult to make a production plan with attention to multiple items, and a simple production planning method is required. In addition, it took time to make a production plan because a production plan was made while making delicate adjustments based on the know-how and experience of experienced personnel. Therefore, a production planning method that can make a production plan in a short time is necessary. In addition, it was necessary to develop a plan for production while taking into account the inventory of multiple items.

  An object of the present invention is to prepare a plurality of manufacturing methods with different generation ratios of items in advance, assign a manufacturing method for each production device to efficiently control the inventory of multiple items, It is an object of the present invention to provide a production planning method and apparatus capable of drafting a production plan that does not cause a break.

  A plurality of different production methods for producing a plurality of items from raw materials are prepared, and a production plan for a plurality of items is created by applying these different production methods to a production apparatus (production facility). Set inventory control conditions for each item based on the characteristics of joint production. Next, a stock reference value is statistically calculated from the demand amount of each item, and the stock amount is indexed as a stock rate. The inventory rate is obtained by (effective stock quantity / stock standard quantity). Subsequently, the production amount of each item is determined. Temporary allocation of equipment capacity for all manufacturing processes by the number of manufacturing processes for all equipment, until all items that are produced within the scope of equipment capacity, or inventory items that do not run short of the stock standard value, reach the stock standard value. repeat. At that time, the balance of the inventory ratios of all items is used as an index to decide which capacity is assigned to which manufacturing method of which apparatus. In this way, a production plan is drafted using the balance of inventory ratios for all items as an evaluation index.

Therefore, the production planning method of the present invention is
The production method used is a method of planning a production plan for a production facility to which multiple production methods that produce a plurality of items at a fixed ratio from raw materials can be applied,
A processing device that stores a processing program and realizes a processing function by executing the processing program, a storage device that stores information, an input device that inputs data, an output device that outputs data, and an external communication means Prepare a computer with
Data acquired from the outside via the input device or the communication means, and storing in the storage device data including production items that have been demanded in the past and the amount of demand (S110);
An inventory standard value calculation step for acquiring an inventory standard value, which is a standard quantity that should be held as stock, for each of a plurality of production items, based on past demand (S120)
An inventory control condition setting step for setting an item that should satisfy the inventory standard value as a standard inventory sufficient item from among a plurality of production items, (S115)
Creating a production plan in which a plurality of co-production methods are combined so that an inventory rate based on an inventory standard value of the standard inventory satisfaction item exceeds 1.

In another configuration of the production planning method of the present invention,
The production method used is a method of planning a production plan for a production facility to which multiple production methods that produce a plurality of items at a fixed ratio from raw materials can be applied,
A processing device that stores a processing program and realizes a processing function by executing the processing program, a storage device that stores information, an input device that inputs data, an output device that outputs data, and an external communication means Prepare a computer with
Data acquired from the outside via the input device or the communication means, and storing in the storage device data including production items that have been demanded in the past and the amount of demand (S110);
An inventory standard value calculation step for acquiring an inventory standard value, which is a standard quantity that should be held as stock, for each of a plurality of production items, based on past demand (S120)
An inventory control condition setting step for setting an inventory excess control item having an inventory control condition not to be an excess inventory and an inventory control condition item having an inventory control condition not to be an excess inventory from a plurality of production items; , (S115)
The first inventory rate obtained from the inventory quantity and the inventory reference value of the inventory excess control item by trialing multiple types of joint production methods applicable to the production facility, and the inventory quantity and inventory of the inventory inventory control item Assigning a co-production method that minimizes the difference between the second inventory rate obtained from the reference value as the co-production method of the production facility;
And producing a production plan by a joint production method obtained by repeating the assigning step.

In another configuration of the production planning method of the present invention,
The production method used is a method of planning a production plan for a production facility to which multiple production methods that produce a plurality of items at a fixed ratio from raw materials can be applied,
A processing device that stores a processing program and realizes a processing function by executing the processing program, a storage device that stores information, an input device that inputs data, an output device that outputs data, and an external communication means Prepare a computer with
Data acquired from the outside via the input device or the communication means, and storing in the storage device data including production items that have been demanded in the past and the amount of demand (S110);
An inventory standard value calculation step for acquiring an inventory standard value, which is a standard quantity that should be held as stock, for each of a plurality of production items, based on past demand (S120)
An inventory control condition setting step for setting an item that should satisfy the inventory standard value as a standard inventory sufficient item from among a plurality of production items, (S115)
Combining a plurality of co-production methods to formulate a production plan that satisfies the inventory standard value of the standard inventory satisfaction item.

In another configuration of the production planning method of the present invention,
The production method used for each production facility is a continuous production method for producing a plurality of items at a fixed ratio from raw materials, and a production plan planning method for a plurality of production facilities to which the different production methods can be applied,
A processing device that stores a processing program and realizes a processing function by executing the processing program, a storage device that stores information, an input device that inputs data, an output device that outputs data, and an external communication means Prepare a computer with
Data acquired from the outside via the input device or the communication means, and storing in the storage device data including production items that have been demanded in the past and the amount of demand (S110);
An inventory standard value calculation step for acquiring an inventory standard value, which is a standard quantity that should be held as stock, for each of a plurality of production items, based on past demand (S120)
An inventory control condition setting step for setting an item satisfying the inventory control condition from among a plurality of production items, (S115)
Trial application of the plurality of co-production methods to the plurality of production facilities to calculate a trial inventory amount for each of the co-produced items, and a trial inventory amount and an inventory reference value for the item set as the inventory control condition In accordance with the inventory rate obtained based on the above, the co-production method to be applied to each of the plurality of production facilities is sequentially determined, and a production plan is formulated by combining the co-production methods determined for the plurality of production facilities. And steps to
Have
The production planning device of the present invention is
A production planning device that creates a production plan for multiple production facilities to which different production methods can be applied. There,
A processing device that stores a processing program and realizes a processing function by executing the processing program, a storage device that stores information, an input device that inputs data, an output device that outputs data, and an external communication means And
The processor is
Data acquired from the outside via the input device or the communication means, and data including production items that have been demanded in the past and the amount of the demand are input to the storage device (S110, 215),
An inventory standard value calculation unit for acquiring an inventory standard value, which is a standard quantity to be stocked, for each of a plurality of production items, based on past demand quantities, (S120, 225)
An inventory control condition setting unit for setting an item satisfying the inventory control condition from among a plurality of production items, (S115, 220)
Trial application of the plurality of co-production methods to the plurality of production facilities to calculate a trial inventory amount for each of the co-produced items, and a trial inventory amount and an inventory reference value for the item set as the inventory control condition In accordance with the inventory rate obtained based on the above, the combined production method to be sequentially applied to each of the plurality of production facilities, and a production method combination planning unit that combines the determined continuous production methods for the plurality of production facilities, (S125,230)
And a production plan output unit for outputting the production plan obtained by the manufacturing method combination planning unit (S130, 235).
It is characterized by having.

  In a manufacturing process that carries out joint production, production plans can be formulated so as to prevent excess and shortage of the inventory of each item within the range of owned production capacity. This has the effect of supplying and reducing excess inventory.

Hereinafter, an embodiment of the present invention will be described with reference to the drawings.
<System configuration diagram>
FIG. 1 is a diagram illustrating a configuration of the entire system according to the present embodiment. The computer includes a processing device 205, an input device 210, a display device 275, a printer 280, a storage device 285, and a communication device. A plurality of computers / terminals 295 are connected to the communication device via the network 290. The storage device 285 stores each table from the item table 10 to the production volume table 55 constituting the database. The display device 275 is a device that displays a guidance screen for data input. The input device 210 is a device for inputting data to be set in various tables of the storage device 285 or inputting parameters when executing a program. The printer 280 is a device that outputs the production recipe table 50, the production volume table 55, and the like created according to this embodiment. The computer / terminal 295 is a server computer or terminal device installed in a warehouse, a production department, etc., and a terminal device that inputs data to be set in the table, a production recipe table 50, and another computer that receives the production volume table 55 establish a network. Connected through.

  In the memory of the processing device 205, the data input unit 215, the inventory control condition setting unit 220, the inventory reference value calculation unit 225, the manufacturing method combination planning unit 230, the production plan output unit 235, and the database access unit 240 are realized. A processing program is stored and executed by the processing device 205. (Similarly, the function of the processing in the processing device 205 is assumed to be realized by a corresponding processing program.) The inventory control condition setting unit 220 includes a reference inventory sufficiency item setting unit 260, an overstock control item setting unit 265. The inventory under control item setting unit 270 is configured. The manufacturing method combination planning unit 230 includes a manufacturing method allocation trial unit 245, an inventory rate calculation unit 250, and a manufacturing method allocation determination unit 255.

<Processing content>
FIG. 2 is a flowchart showing an outline of processing of the entire embodiment.
First, the data input unit 215 takes in the data acquired from the input device 210 or the computer / terminal 295 via the network into the processing device 205, the item table 10, the device table 15, the manufacturing method table 20, the co-production ratio table 25, They are stored in the inventory table 30 and the demand table 35 (step 110).
Next, the inventory control condition is set and the inventory reference value is calculated (steps 115 and 120). In setting the inventory control condition, the inventory control condition of the item input from the input device is stored in the item table 10. For the calculation of the stock standard value, a combination of manufacturing methods based on steps 115 and 120 is planned (step 125). Finally, the production plan prepared in step 125 is output (step 130).

The individual steps in FIG. 2 will be described in order.
FIG. 3 is a flowchart showing the detailed processing flow of step 110, and this processing is processed by the data input unit 215.
The item code 151 is stored in the item table 10 (step 310). FIG. 4 is a diagram showing a data structure of the item table 10. The item table 10 is a table for storing control conditions, lead times, and production plans for item inventory, and each item code 151 has a record. The item code 151 is a code for identifying an item. The reference stock satisfaction item 152 represents that the production amount to be produced is planned until the item reaches the stock reference value. In this embodiment, when 1 is input to the reference stock satisfaction item 152, a plan for producing the item until reaching the stock reference value is made. In step 630, the excess inventory control item 153 is a target item for obtaining the maximum inventory rate between items when calculating the difference of the inventory quantity (hereinafter, inventory rate) with respect to the inventory reference value. That is, the maximum inventory rate is obtained from the inventory rate excess control item. The inventory under-control item 154 is a target item for obtaining the minimum inventory rate between items when calculating the difference in inventory rate in Step 630. That is, the minimum inventory rate is obtained from the inventory rate under-controlled item. In the example of FIG. 4, the item α is a reference inventory sufficiency item and is an overstock control item, but is not an understock control item. The lead time 155 represents the time taken to produce the corresponding item. A planning cycle 156 represents an interval at which a production plan is made.

  FIG. 8 shows the data structure of the inventory table 30. As shown in FIG. The item code 551 and the inventory quantity 552 are stored in the inventory table 30 (step 315). The inventory table 30 is a table for storing the inventory amount of each item, and has a record for each item. The stock quantity 552 is the stock quantity of each item. The stock quantity may be the sum of the production process in-process stock and the on-hand stock. The stock reference value 553 is a value calculated in step 120 based on the demand amount.

  FIG. 5 shows the data structure of the device table 15. The device code 251 and the number of devices 252 are stored in the device table 15 (step 320). The device table 15 is a table representing the device type and the number of devices. The device code 251 is a code for identifying a device. In the example of FIG. 5, there are 80 devices called A. In this embodiment, there is only one type of device A, but there may be a plurality of types of devices.

  FIG. 6 shows the data structure of the manufacturing method table 20. In the manufacturing method table 20, the manufacturing method code 351, the device code 352, the production amount / day / stand 353, and the assigned lot 354 are stored (step 325). The manufacturing method table 20 stores the characteristics of the manufacturing method, and has a record for each manufacturing method. The manufacturing method code 351 is a code for identifying the manufacturing method. An apparatus code 352 represents an apparatus that performs production by the manufacturing method. Production volume / day / unit 353 represents the production amount per vehicle per day when production is performed by the production method using the apparatus. The assigned lot 354 represents a unit quantity to be assigned when the production amount is planned. In the example of FIG. 6, when producing with the manufacturing method x1a, 20 can be produced per vehicle per day. In addition, 20 amounts are allocated.

  FIG. 7 is a diagram showing a data configuration of the joint production ratio table 25. The production method code 451, device code 452, item code 453, and co-production ratio 454 are stored in the co-production ratio table 25 (step 330). The co-production ratio table 25 represents the co-production ratio for each manufacturing method. The manufacturing method code 451, the item code 452, and the joint production ratio 453 indicate how many items are generated when which manufacturing method is produced by which device. In the example of FIG. 7, when 1 unit quantity production is performed by the manufacturing method called x1a, it represents that it is produced in the ratio of item α: β: γ = 0.3: 0.5: 0.2.

  FIG. 9 is a diagram showing a data structure of the demand amount table 35. The demand code table 35 stores the item code 651, the demand date 652, and the demand quantity 653 (step 335). The demand amount table 35 represents the past demand amount, which item and how much demand was on which day. The demand amount 653 represents the demand amount of the corresponding item. The demand date 652 represents the date when the demand occurred. In the example of FIG. 9, the item α represents that there was a demand of 900 on July 1, 2005.

  FIG. 10 is a flowchart showing a detailed flow of step 115 in FIG. 1, and this process is processed by the inventory condition setting unit 220. When the inventory control condition setting unit 220 receives setting of conditions for each item from the input device 210 (step 115), the inventory control condition setting unit 220 performs the processing of steps 415 to 430 for the number of items in the item table 10. Repeat (step 410).

An item that should satisfy an inventory reference value calculated in step 520, which will be described later, is set as a reference inventory satisfaction item (step 415).
Next, under the condition that a plurality of items are created simultaneously by co-production, the item which is particularly desired to suppress excess inventory is set as an inventory excess control item (step 420). The item set as the inventory excess control item is a target item when obtaining the maximum inventory rate between items when calculating the difference in inventory rate in Step 625.

Next, under the condition that the item cannot be produced in an amount that is intended by joint production, the item that prevents understocking is set as an understock control item (step 425). The item set as the inventory shortage control item is a candidate item when extracting the item with the minimum inventory rate when calculating the inventory rate difference in Step 625.
Next, the inventory control conditions of the items set in steps 415 to 425 are stored in the reference inventory sufficiency item 152, the inventory excess control item 153, and the inventory inventory control item 154 in the item table 10 (step 430).

FIG. 11 is a flowchart showing the detailed flow of step 120. The inventory reference value calculation unit 225 refers to the demand table 35 and creates the inventory reference value 553 of the inventory table 30 (step 120). .
The stock standard value 553 is a value that is statistically calculated from demand, and represents a standard amount that should be held as stock.
The stock reference value calculation unit 225 repeats the following processing from steps 515 to 525 for the number of items in the stock table 30 (step 510).

First, all of the demand date 652 and the demand quantity 653 of the demand quantity table 35 having the article code 651 that matches the article code 551 of the inventory table 30 are read (step 515).
Next, all the lead time 155 and plan cycle 156 of the item table 10 having the same item code 551 in the inventory table 30 are read (step 520). Based on the demand date 652, the demand amount 653, the lead time 155, and the planning cycle 156, an inventory reference value based on the past demand is calculated. For example, it is calculated by the following calculation formula (Equation 1) and stored in the inventory reference value 553 of the inventory table 30 (step 525).
(Equation 1)
[Inventory standard value] = [Average demand per day for an item] x ([Lead time] + [Planned cycle])
Alternatively, the stock reference value may be set by another method that takes into account that the future demand exceeds the production amount.

FIG. 12 is a flowchart showing the detailed flow of step 125, which is processed by the manufacturing method combination planning unit 230. Here, a combination of manufacturing methods to be produced is determined. The maximum lot allocation for the manufacturing method is (unit of production / day / unit) / (allocation lot size) for each manufacturing method, and steps 615 to 635 are repeated until the production capacity of all apparatuses is reached (step 610).
It is determined whether or not to continue the production method allocation (step 615). In this embodiment, when all the items specified as the reference stock satisfaction item 152 reach the stock reference value, the production lot assignment is finished.
The number of all combinations of the manufacturing method code 351 and the device code 352 in the manufacturing method table 20 is repeated from step 625 to step 630 (step 620).
For all the manufacturing methods of the manufacturing method code, the allocation lot size 354 division of the manufacturing method table 20 is tried, and the inventory ratio of each item at that time is obtained (step 625).

Next, the item with the highest inventory rate and the item with the smallest inventory rate among the understock control items are selected from among the overstock control items and the difference is calculated (step 630). A table of values is shown in the inventory rate difference table 40 (FIG. 17).
Finally, a manufacturing method having the smallest inventory rate difference is selected from the stock rate difference for each manufacturing method, and it is determined that the allocated lot is allocated to the manufacturing method (step 635).
In this embodiment, when a certain manufacturing method is assigned, a manufacturing method that minimizes the difference between the maximum inventory ratio and the minimum inventory ratio among items is selected. However, as another embodiment, setting of inventory control conditions is selected. At this time, there is also a method of selecting a plurality of items separately and selecting a manufacturing method that minimizes the distribution of the inventory rate among the selected items. Moreover, you may combine the selection of the manufacturing method based on the difference of an inventory rate, and the selection of the manufacturing method based on dispersion | distribution. For example, after selecting a manufacturing method that minimizes the difference in inventory ratio and assigning it to a device, the allocation of the manufacturing method to the next device is determined based on the variance, so that inventory control for selecting the manufacturing method for each device is performed. Conditions can also be set.

FIG. 13 is a flowchart showing details of step 615.
First, step 815 to step 825 are repeated for the number of items in the item table 10 (step 810). If all the items in the item table 10 are not 1 in the standard stock satisfaction item 152 column (YES in step 815), the process of step 620 is performed in order to carry out production until a manufacturing lot is assigned to all devices. If any item is the reference stock supplement item 152 (NO in step 815), the process proceeds to step 820.

If the item is the reference stock satisfaction item 152 (YES in step 820), it is checked whether the stock quantity 552 for the stock reference value 553 in the inventory table 30 of the item exceeds 1 (step 825). This is because, in this embodiment, a production plan for stopping production is made when all the standard stock sufficiency items satisfy the stock standard value.
If the inventory quantity 552 (ie, [Inventory rate] = [Inventory quantity] / [Inventory standard value]) for the inventory standard value 553 of the item does not exceed 1, that is, the inventory quantity of the item has reached the inventory standard value. If not (step 825 NO), the process of step 620 is performed.

FIG. 14 is a flowchart showing details of the manufacturing method allocation trial unit 245 and step 625.
The manufacturing method allocation trial unit 245 reads the manufacturing method code 351 of the manufacturing method table 20 corresponding to the device code (step 830).
Next, the item code 453 and the joint production ratio 454 of the joint production ratio table 25 corresponding to the manufacturing method code are read (step 835). Based on the data read in Steps 830 and 835, the processing from Steps 845 to 855 is performed for the number of items in the inventory table 30 in order to calculate the allocation trial inventory ratio of each item when the assigned lot of the manufacturing method is assigned. Repeat (step 840).
The inventory quantity 552 and the inventory reference value 553 corresponding to the item code 551 in the inventory table 30 are read (step 845).

Next, the allocation trial inventory ratio is calculated based on the allotment ratio 453 read in step 830, the co-production ratio 453 read in step 835, the inventory quantity 552 and the inventory reference value 553 read in step 845 (step 850). Formula (Equation 2) is used to calculate the allocation trial inventory rate.
(Equation 2)
[Allocation trial inventory ratio] = ([Stock quantity] + [Allocation lot] x [Co-production ratio]) / [Inventory standard value]
The calculated allocation trial inventory ratio is stored in the allocation trial inventory ratio 852 of the manufacturing allocation allocation trial table 45. Further, the item code is stored in the item code 851 of the manufacturing method allocation trial table 45 (step 855).

  FIG. 15 shows the data structure of the production method trial table 45. As shown in FIG. The production method trial table 45 represents the inventory ratio of each item when a lot assignment of a certain method is tried. The item code 851 is a code for identifying an item. The allocation trial inventory ratio 852 represents the inventory ratio of each item when allocation is attempted.

FIG. 16 is a flowchart showing details of the inventory rate difference calculation unit 250 and step 630. The inventory rate difference calculation unit 250 repeats the processing from step 915 to step 970 for the number of items in the item table 10 (step 910).
Here, when a certain manufacturing method is assigned, the difference between the maximum inventory rate among the overstock items and the minimum stock rate among the understock items is calculated, and the difference is stored in the inventory rate difference table 40. To do.

  FIG. 17 is a diagram showing a data structure of the inventory rate difference table 40. As shown in FIG. When the maximum inventory rate item 752 is produced with the manufacturing method code 751, it represents the item code with the maximum inventory rate among the overstock controlled items. When the minimum inventory rate item 753 is produced with the manufacturing method code 751, it represents the item code having the minimum inventory rate among the items under inventory control. The maximum inventory rate 754 represents the inventory rate of the maximum inventory rate item 752. The minimum inventory rate 755 represents the inventory rate of the minimum inventory rate item 753. The inventory ratio difference 756 is the maximum inventory ratio 754 minus the minimum inventory ratio 755.

First, the inventory excess control item 153 in the item table 10 corresponding to the item is read (step 915).
Next, the maximum inventory rate item 752 and the maximum inventory rate 754 of the inventory rate difference table 40 corresponding to the manufacturing method code are read (step 920).
Here, it is checked whether the item is an overstock control item (step 925).
If the item is an overstock controlled item (YES in step 925), the allocation trial inventory rate 852 of the manufacturing method allocation trial table 45 corresponding to the item code is read (step 930).

Next, it is checked whether the allocation trial inventory rate 852 is larger than the maximum inventory rate 754 (step 935).
When the allocation trial inventory rate 852 is greater than the maximum inventory rate 754 (step 935 YES), the manufacturing code of the inventory rate difference table 40 is the manufacturing method code, the maximum inventory rate item 752 is the item code, and the maximum inventory rate 754 is the allocation trial inventory. The rate 852 is stored (step 940). That is, the maximum inventory rate 754 is updated with the allocation trial inventory rate.
The inventory under-control item 154 in the item table 10 corresponding to the item is read (step 945).
Next, the minimum inventory rate item 753 and the minimum inventory rate 755 of the inventory rate difference table 40 corresponding to the manufacturing method code are read (step 950).
Here, it is checked whether the item is an under-stock control item (step 955).
If the item is an understock control item (YES in step 955), the allocation trial inventory rate 852 of the manufacturing method allocation trial table 45 corresponding to the item code is read (step 960).

Next, it is checked whether the allocation trial inventory rate 852 is smaller than the minimum inventory rate 755 (step 965).
If the allocation trial inventory ratio 852 is smaller than the minimum inventory ratio 755 (YES in step 935), the manufacturing code of the inventory ratio difference table 40 is the manufacturing code, the minimum inventory ratio item 753 is the corresponding item code, and the minimum inventory ratio 755 is the allocation trial inventory. The rate 852 is stored (step 970). That is, the minimum inventory rate 755 is updated with the allocation trial inventory rate.
The difference in the inventory ratio is calculated from the maximum inventory ratio 754 and the minimum inventory ratio 755 obtained in steps 910 to 970 (step 975). Here, the difference between the maximum inventory rate and the minimum inventory rate is obtained as the inventory rate difference.
The obtained inventory rate difference is stored in the inventory rate difference 756 of the inventory rate difference table 40 (step 980).

FIG. 18 is a diagram showing details of the manufacturing method assignment determination unit 255 and step 635.
In this processing unit, a manufacturing method having a minimum difference in inventory ratio is determined, and a process for determining allocation to the manufacturing method is performed.
First, among the manufacturing methods in the inventory rate difference table 40, the manufacturing method with the smallest inventory rate difference 756 is selected (step 1010).
Next, the allocated number in the production manufacturing method table 50 corresponding to the selected manufacturing method is read (step 1015).

FIG. 19 is a diagram showing a data structure of the production method table 50. As shown in FIG. The manufacturing method code 951 is the same code as the manufacturing code 351 in the manufacturing table for identifying the manufacturing method. The allocation number 952 indicates how much allocation has been determined for the corresponding manufacturing method.
The assigned number is incremented by 1 for the selected manufacturing method (step 1020).
The updated allocation number is stored in the allocation number 952 of the production method table 50 (step 1025).

最後にトランザクションデータである在庫率差テーブル40、製法割当試行テーブル45を初期化して、次の製法割当の準備を行う（ステップ1060）。 In order to reflect the production amount produced by the selected manufacturing method in the inventory table 30, the processing from steps 1035 to 1055 is repeated for the number of items in the inventory table 30 (step 1030).
First, the inventory quantity 552 of the inventory table 30 corresponding to the item code is read (step 1035). Read the co-production ratio 454 of the co-production ratio table 25 corresponding to the item code and the selected manufacturing method (step 1040). Read the assigned lot size 354 of the manufacturing method table 20 corresponding to the selected manufacturing method. Next, the inventory rate is recalculated from the inventory quantity 552, the joint production ratio 454, and the assigned lot size 354 (step 1050).

Finally, the inventory ratio difference table 40 and the manufacturing method allocation trial table 45, which are transaction data, are initialized to prepare for the next manufacturing method allocation (step 1060).

FIG. 20 shows details of step 130, which is processed by the production plan output unit 235.
The production plan planned in step 125 is output outside the computer.
In order to create the production volume table 55 based on the production method selected in step 125, the processing from step 715 to step 725 is repeated for the number of production methods in the production production method table 50 (step 710).

FIG. 21 shows the data structure of the production volume table 55. As shown in FIG. An item code 1051 represents an item code of an item produced by each manufacturing method. A device code 1052 represents a device code for production. The manufacturing method code 1053 represents each manufacturing method code. The production amount 1054 represents the production amount by which the item of the item code 1053 is produced by the manufacturing method code 1053.
First, the assigned number 952 corresponding to the manufacturing method code is read from the manufacturing method table 50 (step 715).
The item code 452 and the co-production ratio 453 of the co-production ratio table 25 corresponding to the production code 951 of the production process table 50 are read (step 720).
The apparatus code 352 and the assigned lot 354 of the manufacturing method table 20 corresponding to the manufacturing method code 951 of the production manufacturing method table 50 are read (step 725).

Next, the production amount is calculated using the allocation number 952, the item code 452, the joint production ratio 453, and the allocation lot 354 read in Step 715 and Step 720, and the item code and device are displayed in the item code 1051 of the production amount table 55. The device code is stored in the code 1052, the manufacturing code is stored in the manufacturing code 1053, and the production volume is stored in the production volume 1054 (step 730). The production quantity is calculated using the formula (Equation 3).
(Equation 3)
[Production volume] = [Allocation number] x [Allocation lot] x [Co-production ratio]
Finally, the production process table 50 and the production volume table 55 are output to the printer 265 (step 735). Next, as in step 735, the production method table 50 and the production volume table 55 are output to the display device 260 and the computer / terminal 280 (step 740).

  The present invention is applied to a production planning apparatus that creates a production plan for co-produced items in which a plurality of items at a fixed ratio are produced simultaneously by the manufacturing method, and is suitable for use in planning a production plan for chemical products, for example.

1 is a system configuration diagram of a production planning system under co-production conditions according to an embodiment of the present invention. It is a flowchart explaining basic processing procedures, such as the plan of the manufacturing method combination which a process part performs. It is a flowchart explaining the processing operation of a data input part. It is a data block diagram of the database which stores the information regarding an item. It is a data block diagram of the database which stores the information regarding an apparatus. It is a data block diagram of the database which stores the information regarding a manufacturing method. It is a data block diagram of the database which stores the information regarding a joint production ratio. It is a data block diagram of the database which stores the information regarding stock. It is a data block diagram of the database which stores the information regarding a demand amount. It is a flowchart explaining the processing operation of an inventory control condition part. It is a flowchart explaining the processing operation of an inventory reference value calculation part. It is a flowchart explaining the processing operation of a manufacturing method combination plan part. It is a flowchart explaining a manufacturing method allocation continuation determination process. It is a flowchart explaining the processing operation of a manufacturing method allocation trial part. It is a data block diagram of the database which stores the result of trying manufacturing method allocation. It is a data block diagram of the database which stores the processing operation of an inventory ratio calculation part. It is a data block diagram of the database which stores the inventory rate difference according to manufacturing method. It is a data block diagram of the database explaining the processing operation of a manufacturing method allocation determination part. It is a data block diagram of the database which stores the selection result of a manufacturing method. It is a data block diagram of the database explaining the processing operation of a production plan output part. It is a data block diagram of the database which stores the planning result of a production plan.

Explanation of symbols

10 Material table
15 Equipment table
20 recipe table
25 Co-production ratio table
30 stock table
35 Demand table
40 Inventory rate difference table
45 Process assignment trial table
50 Production recipe table
55 Production table
210 Input device
215 Data input section
220 Inventory control condition setting section
225 Inventory standard value calculator
230 Manufacturing combination planning department
235 Production plan output section
240 Database access part
245 Manufacturing method allocation trial part
250 Inventory rate difference calculator
255 Manufacturing Allocation Determination Department
260 Standard inventory satisfaction item setting section
265 Overstock control item setting section
270 Understock Control Item Setting Department
275 display device
280 printer
285 storage devices
290 network
295 Computer / Terminal

Claims (27)

The production method used is a method of planning a production plan for a production facility to which multiple production methods that produce a plurality of items at a fixed ratio from raw materials can be applied,
A processing device that stores a processing program and realizes a processing function by executing the processing program, a storage device that stores information, an input device that inputs data, an output device that outputs data, and an external communication means Prepare a computer with
Storing data in the storage device, which is data acquired from the outside via the input device or the communication means, and includes the production items that have been demanded in the past and the demand amount thereof;
An inventory standard value calculation step for obtaining an inventory standard value that is a standard quantity to be stocked for each of a plurality of production items based on a past demand amount;
An inventory control condition setting step for setting, from among a plurality of production items, an item that should satisfy the inventory reference value as a reference inventory sufficient item,
Formulating a production plan in which a plurality of co-production methods are combined such that an inventory rate based on an inventory standard value of the standard inventory-satisfying item exceeds 1,
A production planning method for co-produced items, comprising:   The data acquired from the outside via the input device or the communication means further includes information on a co-production method applicable to production facilities, information on a plurality of production items and co-production ratios produced by the co-production method. The production planning method according to claim 1, further comprising: inventory quantity information of production items.   3. The production planning method according to claim 2, wherein in each of the co-production methods applicable to the production facility, the co-production ratio of a plurality of production items to be produced is different. The production method used is a method of planning a production plan for a production facility to which multiple production methods that produce a plurality of items at a fixed ratio from raw materials can be applied,
A processing device that stores a processing program and realizes a processing function by executing the processing program, a storage device that stores information, an input device that inputs data, an output device that outputs data, and an external communication means Prepare a computer with
Storing data in the storage device, which is data acquired from the outside via the input device or the communication means, and includes the production items that have been demanded in the past and the demand amount thereof;
An inventory standard value calculation step for obtaining an inventory standard value that is a standard quantity to be stocked for each of a plurality of production items based on a past demand amount;
An inventory control condition setting step for setting an inventory excess control item having an inventory control condition not to be an excess inventory and an inventory control condition item having an inventory control condition not to be an excess inventory from a plurality of production items; ,
The first inventory rate obtained from the inventory quantity and the inventory reference value of the inventory excess control item by trialing multiple types of joint production methods applicable to the production facility, and the inventory quantity and inventory of the inventory inventory control item Assigning a co-production method that minimizes the difference between the second inventory rate obtained from the reference value as the co-production method of the production facility;
Creating a production plan by a joint production method obtained by repeating the assigning step;
A production planning method for co-produced items, comprising:   The data acquired from the outside via the input device or the communication means further includes information on a co-production method applicable to production facilities, information on a plurality of production items and co-production ratios produced by the co-production method. The production planning method according to claim 4, further comprising: information on an inventory amount of production items.   6. The production planning method according to claim 5, wherein in each of the co-production methods applicable to the production facility, the co-production ratio of a plurality of production items to be produced is different. The production method used is a method of planning a production plan for a production facility to which multiple production methods that produce a plurality of items at a fixed ratio from raw materials can be applied,
A processing device that stores a processing program and realizes a processing function by executing the processing program, a storage device that stores information, an input device that inputs data, an output device that outputs data, and an external communication means Prepare a computer with
Data acquired from the outside via the input device or the communication means, and storing in the storage device data including production items that have been demanded in the past and the amount of demand (S110);
An inventory standard value calculation step for obtaining an inventory standard value that is a standard quantity to be stocked for each of a plurality of production items based on a past demand amount;
An inventory control condition setting step for setting, from among a plurality of production items, an item that should satisfy the inventory reference value as a reference inventory sufficient item,
Combining a plurality of co-production methods to formulate a production plan that satisfies the inventory standard value of the standard inventory satisfaction item;
A production planning method for co-produced items, comprising:   The data acquired from the outside via the input device or the communication means further includes information on a co-production method applicable to production facilities, information on a plurality of production items and co-production ratios produced by the co-production method. The production planning method according to claim 7, further comprising: inventory quantity information of production items.   9. The production planning method according to claim 8, wherein in each of the co-production methods applicable to the production facility, the co-production ratio of a plurality of production items to be produced is different. The production method used for each production facility is a continuous production method for producing a plurality of items at a fixed ratio from raw materials, and a production plan planning method for a plurality of production facilities to which the different production methods can be applied,
A processing device that stores a processing program and realizes a processing function by executing the processing program, a storage device that stores information, an input device that inputs data, an output device that outputs data, and an external communication means Prepare a computer with
Storing data in the storage device, which is data acquired from the outside via the input device or the communication means, and includes the production items that have been demanded in the past and the demand amount thereof;
An inventory standard value calculation step for obtaining an inventory standard value that is a standard quantity to be stocked for each of a plurality of production items based on a past demand amount;
An inventory control condition setting step for setting an item satisfying inventory control conditions from a plurality of production items,
Trial application of the plurality of co-production methods to the plurality of production facilities to calculate a trial inventory amount for each of the co-produced items, and a trial inventory amount and an inventory reference value for the item set as the inventory control condition In accordance with the inventory rate obtained based on the above, sequentially determine the joint production method to be applied to each of the plurality of production facilities, and formulate a production plan by combining the joint production methods determined for the plurality of production facilities And steps to
A production planning method for co-produced items, comprising:   11. The production planning method according to claim 10, wherein, in the inventory control condition setting step, a reference inventory fulfillment item having an inventory control condition that inventory reference values are not deficient is set.   The inventory control condition setting step sets an inventory excess control item having an inventory control condition not to be an excess inventory and an inventory undercontrol item having an inventory control condition not to be an excess inventory. Item 11. The production planning method according to Item 11.   The co-production method to be applied to each of the plurality of production facilities is sequentially determined in the step of formulating the production plan until the reference stock satisfaction item satisfies a stock reference value. 11 production planning methods.   The method of allocating a production method that minimizes a difference between an inventory rate of the over-inventory controlled item and an inventory rate of the under-inventory controlled item to determine the joint production method of the production equipment to be tried. 12 production planning methods. A plurality of arbitrary items are set in the inventory control condition setting step,
The method of allocating a production method that minimizes the variance of the inventory ratio of the plurality of arbitrary items set in the inventory control condition setting step is assigned to the determination of the joint production method of the production equipment to be tried. 12 production planning methods. In the inventory control condition setting step, an arbitrary plurality of items, an inventory excess control item having an inventory control condition not to be overstocked, and an inventory undercontrol item having an inventory control condition not to be understocked are set. And
Assigning a production method that minimizes the difference between the inventory rate of the over-inventory controlled item and the inventory rate of the under-inventory controlled item to the determination of the joint production method of the production equipment to be trialed, and setting the inventory control condition setting 13. The production planning method according to claim 12, wherein a production method that minimizes the variance of the plurality of arbitrary item inventory rates set in the step is mixed.   The data acquired from the outside via the input device or the communication means further includes information on a co-production method applicable to production facilities, information on a plurality of production items and co-production ratios produced by the co-production method. The production planning method according to claim 10, further comprising: information on an inventory amount of production items.   18. The production planning method according to claim 17, wherein in each of the co-production methods applicable to the production facility, the co-production ratio of a plurality of production items to be produced is different. A production planning device that creates a production plan for multiple production facilities to which different production methods can be applied. There,
A processing device that stores a processing program and realizes a processing function by executing the processing program, a storage device that stores information, an input device that inputs data, an output device that outputs data, and an external communication means And
The processor is
Data acquired from the outside via the input device or the communication means, the production unit that has been in demand in the past and data including the demand amount to the storage device as an input unit,
An inventory reference value calculation unit that acquires an inventory reference value, which is a reference amount that should be held as stock, for each of a plurality of production items, based on past demand amounts,
Inventory control condition setting part that sets items that satisfy inventory control conditions from among multiple production items,
Trial application of the plurality of co-production methods to the plurality of production facilities to calculate a trial inventory amount for each of the co-produced items, and a trial inventory amount and an inventory reference value for the item set as the inventory control condition In accordance with the inventory rate obtained based on the above, the combined production method to be sequentially applied to each of the plurality of production equipment, the production method combination planning unit that combines the joint production methods determined for the plurality of production equipment,
And a production plan output unit for outputting the production plan obtained in the manufacturing method combination planning unit,
A production planning device for co-produced items, characterized by comprising:   20. The production planning apparatus according to claim 19, wherein the inventory control condition setting unit sets a reference inventory satisfaction item whose inventory control condition is not to make the inventory reference value insufficient.   The inventory control condition setting unit is configured to set an inventory excess control item having an inventory control condition not to be an excess inventory and an inventory undercontrol item having an inventory control condition not to be an excess inventory. Item 20. The production planning device according to Item 20.   21. The method according to claim 20, wherein the manufacturing method combination planning unit sequentially determines a co-production method to be applied to each of the plurality of production facilities until the reference inventory satisfaction item satisfies an inventory reference value. Production planning device.   The method of allocating a production method that minimizes a difference between an inventory rate of the over-inventory controlled item and an inventory rate of the under-inventory controlled item to determine the joint production method of the production equipment to be tried. 21 production planning devices. Set any plurality of items in the inventory control condition setting unit,
In the manufacturing method combination planning unit, the manufacturing method that minimizes the variance of the inventory ratio of the plurality of items set in the inventory control condition setting unit in determining the continuous production method of the production equipment to be the trial target. 20. The production planning device according to claim 19, wherein the production planning device is assigned. In the inventory control condition setting unit, an arbitrary plurality of items, an inventory excess control item whose inventory control condition is not to be overstocked, and an inventory undercontrol item whose inventory control condition is not to be understocked are set. And
In the manufacturing method combination planning unit, in determining the joint manufacturing method of the production equipment subject to the trial, the difference between the inventory rate of the inventory excess control item and the inventory rate of the inventory control item is minimized. 20. The production planning apparatus according to claim 19, wherein the allocation and the allocation of the manufacturing method that minimizes the variance of the plurality of arbitrary item inventory rates set by the inventory control condition setting unit are mixed.   The data acquired from the outside via the input device or the communication means further includes information on a co-production method applicable to production facilities, information on a plurality of production items and co-production ratios produced by the co-production method. The production planning apparatus according to claim 19, further comprising: information on an inventory amount of production items.   27. The production planning apparatus according to claim 26, wherein in each of the co-production methods applicable to the production facility, the co-production ratio of a plurality of production items produced is different.

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