JP2008015962A - Computing device of proposed change of production shipment plan which allows production increase - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To compute a proposed change of a production shipment plan, in which production shipment plans are provided by every process forming a chain of preprosses-present process-postprocess and when the postprocess desires production increase, inventory of other postprocesses is utilized. <P>SOLUTION: A data base 20 stores: products; components used for the products; components which can be diverted to components; kinds of products for which the components which can be diverted are used and the postprocesses which produce the kinds of products. An insufficient component number computing means 12 computes the number of insufficient components from kinds of products whose production increase is desired and the number of desired production increase. Inventory number computing means 16, 18 specify kinds of products in which other components which can be diverted to insufficient components are used and postprocesses which produce the kinds of product to compute the number of inventories of the kinds of products of the postprocesses. A diverted component number specification means 12 specifies the number of components to be diverted to the insufficient components from the number of inventories and the number of insufficient components. A proposed change computing means 12 computes the production shipment plan obtained by diverting the specified number of components to the insufficient components. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  In the present invention, a production shipment plan of parts is given to a process of producing a plurality of types of parts and shipping them to a plurality of subsequent processes. The present invention relates to a device that recalculates a production shipment plan for a part to be satisfied.

For example, an automobile engine factory produces a plurality of types of engines a, b, c,... Used for production of automobiles A, B, C,. In some cases, the engine b for the automobile B is shipped to the assembly factory of the automobile B, and the engine c for the automobile C is shipped to the assembly factory of the automobile C. In order to produce the engine a, many kinds of engine parts a1, a2, a3,... Are needed, and in order to produce the engine b, many kinds of engine parts b1, b2, b3,. In order to produce the engine c, many kinds of engine parts c1, c2, c3. Automobile engine factories procure multiple types of engine components from multiple engine component factories.
In this specification, the product produced in the subsequent process is called a product, and the process of shipping parts necessary for the production of the product implemented in the subsequent process is called the self-process. The necessary pre-stage parts are called low-order parts, and the factory (or warehouse) that ships the low-order parts is called a pre-process.
In the above example, the engine part is a low order part, the engine is a part, the car is a product, the engine parts factory is a pre-process, the engine factory is its own process, and the car assembly factory is This corresponds to the subsequent process.
Production activities form a multi-stage chain, and engines are products for engine factories. In this case, the engine factory is the post-process, the engine parts factory is the self-process, and the factory that produces the parts in the previous stage is the pre-process.

The production system is composed of a chain of pre-process, self-process, and post-process. The engine is further produced between the pre-process for producing engine parts and the self-process for producing engines using the engine parts. There should be no contradiction between the self-process to be used and the post-process to produce automobiles using the engine. That is, by producing and shipping the necessary items at the necessary time, excessive parts inventory and missing parts of the necessary parts must not occur.
In a production system consisting of a chain of pre-process, self-process, and post-process, in order to prevent overstocking and missing parts, a production shipment plan for producing and shipping in that process in advance for each process The method to decide is known. For example, the engine factory is given a plan to produce A1 engine a for car A on ** month * and ship A2 to the assembly factory of car A. Here, the difference between the production quantity A1 and the shipment quantity A2 is reflected in the inventory quantity in the own process.

  The production shipment plan given to the own process corresponds to the production shipment plan given to the previous process and the production shipment plan given to the subsequent process. When each process produces and ships as planned, the low-order parts required by the process are shipped from the previous process to the process when necessary, and the parts required by the subsequent process are required from the process to the subsequent process. Sometimes shipped. Production activities can be continued while avoiding overstock and shortage.

  Subsequent processes may want or need to change production shipment plans. For example, when the automobile A is sold more than planned, the post-process for producing the automobile A desires or needs to increase the production of the automobile A.

  As described above, in a production system composed of a chain of pre-process, self-process, and post-process, the production / shipment plan given to the pre-process, the production / shipment plan given to the self-process, and the post-process The production / shipment plan given to the production process corresponds to this, and the production / shipment plan given to the preceding process must be changed in order to meet the demand for increased production in the subsequent process.

  In a production system composed of a chain of pre-process, self-process, and post-process, one process produces multiple types of parts and ships them to multiple post-processes. In order to respond to the demand for increased production from one subsequent process, it is not necessary to review the production and shipment plan for parts for the subsequent process, and it is necessary to review the production and shipment plan for parts to be shipped to other subsequent processes. Occurs.

In the current technology, no method has been developed for reviewing production shipment plans for parts to be shipped to other post-processes in response to the desire to increase production from one post-process.
At present, we will respond within the range that can be handled by reversing the inventory of the post-process that requires increased production and the parts inventory of the own process (parts inventory for products that require increased production) It is only there. For example, if the assembly plant of car A wants to increase the production of 20 cars A every day for 5 consecutive days, the assembly factory of car A has 25 cars A in stock and the factory that produces engine a If there are 25 engines a in stock, the inventory of the car A provided in the assembly factory of the car A will be reversed and five more cars A will be shipped per day. The inventory is reversed and five engines a per day are shipped to the assembly plant of the car A, and the assembly factory of the car A is changed to a production shipment plan that can increase the production of the car A by five units per day. In this case, it becomes possible to ship 10 more cars A per day than the production shipment plan before the change, but there are still 10 less. With the current technology, it is not possible to change the production shipment plan any more.

  Patent Document 1 describes a technology for reviewing a production / shipment plan. This technology assumes that all parts necessary for production are in stock and that a necessary number of parts can be shipped from a parts warehouse at any time. In this technology, the production system consists of a chain of pre-process, self-process, and post-process, and each process requires production when necessary, thereby eliminating excessive waste from the logistics process. Not applicable to When a production / shipment plan for parts is given for each production process consisting of a chain of pre-process, self-process, and post-process, the current technology is more than the reversal of inventory for increased production. Measures cannot be taken.

JP 7-114600 A

  In the present invention, a production shipment plan of parts is given for each process of the production system composed of a chain of a pre-process, a self-process, and a post-process, and when a specific post-process desires or requires an increase in production. In addition, we will provide a technology for calculating a change in the production / shipment plan in our own process after taking into account the impact on the post-process where we do not want to increase production.

In the device of the present invention, a production shipment plan for parts is given to a process of producing a plurality of types of parts and shipping them to a plurality of subsequent processes. Calculate proposed changes to production shipment plans that can be met.
The apparatus of the present invention includes a database, a shortage low order part number calculating means, a stock quantity calculating means, a diverted low order part number specifying means, and a change plan calculating means.
The database associates with the product produced in the subsequent process, uses the low-order parts used for the product, the low-order parts that can be converted to the low-order parts, and the product types that use the low-order parts that can be converted. , Remembers the subsequent process of producing the product type.
The deficient low order part number calculating means calculates the deficient low order part number when the production / shipment plan before the change is based on the product type and the desired number of increase in the subsequent process.
The inventory quantity calculation means searches the database, identifies the product type that uses a low-order part that can be diverted to a low-order low-order part, and the post-process that produces the product type, and is based on the production shipment plan before the change. The stock quantity of the specified product type in the specified post-process is calculated.
The diverted low-order part number specifying means specifies the number of low-order parts to be diverted to the shortage low-order parts from the calculated inventory number and shortage low-order parts number.
The change plan calculation means calculates a change plan of the production shipment plan obtained by diverting the specified number of lower order parts to the missing lower order parts.

In the present invention, when the post-process hopes to increase production, it is possible to avoid shortage of low-order parts by diverting other low-order parts, and the post-process by utilizing inventory in the post-process that does not want to increase production. Even if the shipment to the company is delayed from the plan, the problem does not become obvious, and if that amount is used, the possibility that it may be able to respond to the demand for increased production is examined.
For example, engine a for car A is produced and shipped to an assembly factory for car A, engine b for car B is produced and shipped to an assembly factory for car B, and engine c for car C is produced. An example will be given in which the vehicle C is shipped to the assembly plant of the automobile C, the engine d for the automobile D is produced and shipped to the assembly factory of the automobile D, and the assembly factory of the automobile A desires to increase production. At this time, for example, the low-order component b1 for the engine b for the vehicle B and the low-order component a1 for the engine a for the vehicle A are common, and a sufficient amount of the vehicle B or If the number of the engine b is in stock, there is no problem even if the production of the engine b which is planned to be shipped to the assembly factory of the automobile B is delayed (the automobile B or the engine in the assembly factory of the automobile B). The inventory of b is sufficient and the inventory can be withdrawn, so even if the delivery of engine b is delayed, the problem does not become obvious.) If the production of engine b is delayed, the low-order parts for engine b are engineered. Consider the possibility that it can be diverted to the production of a and that it may be able to meet the demand for increased production at the assembly plant of car A.

The deficient low order part number calculating means calculates the deficient low order part number when the production / shipment plan before the change is based on the product type and the desired number of increase in the subsequent process. For example, the assembly plant of car A wants to increase the production of 20 units per day over 5 days, and the assembly plant of car A stocks 25 vehicles, including car A and engine a. If the production factory stocks 25 engine parts a1 (low-order parts) used for the engine a and the engine a in total, use the stock of the car A of the assembly factory of the car A or the 25 parts of the engine a. It is possible to ship 5 cars A per day more than planned, and the engine a production plant uses 5 units of engine a and engine parts a1 to stock 5 engines a per day. It can be seen that it is possible to produce and ship more than planned, and by utilizing the inventory, it is understood that up to 10 can be accommodated for the increase in production of 20 units. In this case, it can be seen that the engine parts a1 (lower order parts) for ten engines a are insufficient.
The database includes a low-order part (for example, a1) used for the product in association with a product (in this case, automobiles A, B,...) Produced in a later process, and a low-order part that can be diverted to the low-order part. Stores the product types that use divertable low-order parts and the post-process that produces the product types. If the low-order component a1 and the low-order component b1 are common, the low-order component b1 can be diverted instead of the low-order component a1, and the divertable low-order component b1 is the product B (in this case It is for the automobile B), and it is stored in the database that the low-order part b1 used for the engine b shipped to the assembly factory of the automobile B can be diverted.
The diversion possible here is not limited to common parts. For example, if the parts a1 and b1 are shipped from the same part factory and there is no problem in shipping the part a1 instead of the part b1, the part b1 can be diverted to the part a1. It can be.

From the above, it can be seen that when there is a shortage of 10 low-order parts a1 per day for increasing production, the low-order parts b1 can be diverted to the shortage low-order parts a1.
The stock quantity calculation means includes a product type (car B in the example) that uses a low-order part (engine part b1 in the example) that can be diverted to the insufficient low-order part (in the example, the engine part a1), The post-process that produces the product type (in the example, the assembly plant of the car B) is specified, and the identified post-process (the assembly factory of the car B) when specified by the production shipment plan before the change is specified The number of types (car B) in stock is calculated. At this time, if the assembly factory of the car B stocks the engine b, the number of stocks is also calculated as the stock number of the car B. This is because even if the acquisition of the engine b is delayed, the automobile B can be assembled using the inventory of the engine b, and therefore the inventory of the engine b may be the inventory of the automobile B.
If the total inventory number of the automobile B and the engine b is 50 or more, it is understood that the engine factory may produce the engine a by diverting 10 low-order parts b1 to the low-order parts a1 per day. As a result of the diversion, the number of engines b shipped to the assembly plant of car B will be reduced by 10 per day, but the total inventory of cars B and engines b will be more than 50, which will last for 5 days. Even if the number of engines b shipped to the assembly plant of automobile B decreases by 10 units per day, the assembly factory of automobile B uses the inventory of automobile B and engine b to ship automobile B as planned. be able to.
The diverted low-order component number specifying means calculates the calculated inventory number (in this case, the inventory number of the vehicle B in the assembly plant of the vehicle B that ships the engine b that uses the low-order component b1 that can be diverted to the shortage low-order component a1. If the engine b is in stock, that is also the number of cars B in stock) and the number of insufficient parts (the number of insufficient low-order parts a1 in this case) is diverted to the low-order low-order parts a1. The number of low-order parts b1 is specified. In the example, the number of shortage of low-order parts a1 is 10 per day, and the number of products B (or parts b) that use low-order parts b1 that can be diverted to shortage of low-order parts a1 is 1 day. Since the number is 10 or more, it is determined that 10 low-order parts b1 per day are diverted to the production of the engine a.
The change plan calculation means diverts the specified number (in the example, 10 per day) of the low-order parts (b1 in the example) to the insufficient low-order parts (in the example, a1) (engine part b1 as the engine). The change plan of the production shipment plan obtained by diverting to the production of a) is calculated.
By the above processing, when the post-process hopes to increase production, it is possible to avoid the shortage of low-order parts by diverting other low-order parts, and by utilizing inventory in the post-process that does not wish to increase production After that, even if the shipment for the process is delayed from the original plan, the problem does not become obvious, and if that amount is used, the possibility that the necessary low-order parts will be secured and it may be possible to meet the demand for increased production may be examined. it can. A new production shipment plan that satisfies the desire to increase production without revealing the problem is calculated.

Each process may not have inventory of low-order parts used in the process. Alternatively, the parts produced in the process may not be in stock. In the case of a production system in which no inventory exists in each process, the increased number of production desired by the subsequent process is the same as the number of low-order parts that are insufficient when the production shipment plan before the change is made.
On the other hand, there are cases where there is a stock of low-order parts used in the process or parts produced in the process. In this case, it is possible to meet the demand for increased production by releasing inventory, and therefore the number of increased production desired by the post-process does not necessarily become the number of low-order parts.
If there is a stock, the means to calculate the number of low-order parts that are insufficient when the post-production process plans the change from the product type and the desired number of production increases in the post-process is to increase the production in the post-process that wants to increase production. The number of desired products in stock, the number of parts used for products that want to increase production in later processes that want to increase production, the number of parts used for products that want to increase production in their own processes, and the lower order used for products that want to increase production in their own processes Taking into account the number of parts in stock, it is preferable to calculate the number of insufficient low-order parts from the desired number of production increases. When a product completed in a subsequent process is shipped without being stocked, the number of products in the subsequent process is zero.
As illustrated above, the assembly plant of car A wants to increase production of 20 units per day over 5 days, and the assembly factory of car A (the post process that wants to increase production) Products) and engine a (parts used for products whose production is to be increased) are in stock, and the engine a production plant (own process) is used for engines a (parts used for products whose production is to be increased) and engines a. When 25 engine parts a1 (low-order parts used for a product whose production is desired to be increased) are in stock, those stocks can be utilized. It is calculated that there is a shortage of engine parts a1 (low-order parts used for products for which production is desired).

If there is a post-process that exceeds the shortage of low-order parts in the number of stocks calculated for each post-process, the ship-to party in the post-process that wants to increase production from the parts shipped to the post-process It is preferable to specify the number of parts to be changed.
In the case of the above example, the shortage of the low-order parts a1 is 10 per day, and the number of products that use the low-order parts b1 that can be diverted to the shortage parts a1 (total number of stocks of the automobile B and the engine b). Is 10 or more per day, and therefore, in the above-mentioned conditions, there is a case where “there is a post-process with an inventory quantity exceeding the number of insufficient low-order components”.
In contrast, the low-order parts c1 and d1 can also be diverted to the engine a, and the number of products C that use the divertable low-order parts c1 is 6 per day. Assume that the number of products D that use the part d1 is nine per day. In this case, by itself, there is no post-process that results in an inventory that exceeds the number of low-order parts that are insufficient. In consideration of a combination of a plurality of post-processes (an assembly factory for the car C and an assembly factory for the car D), there will be a post-process that has an inventory exceeding the number of insufficient parts, but the post-process is not independent.
In the case where the number of inventory exceeds the number of insufficient low-order parts in a single subsequent process, it is preferable to specify the number of parts to be shipped to the subsequent process and the number of shipment destinations that are desired to be increased. This is because there are fewer changes in the production shipment plan.

There may be a case where there is no post-process in which the number of stocks exceeds the number of insufficient low-order parts among the stock numbers calculated for each post-process. In the case of the above example, the stock number of the product C using the divertable low-order part c1 is 6 per day, and the stock number of the product D using the divertable low-order part d1 is 9 per day. There is no single post-process that results in a stock count that exceeds the shortage of 10 shortages per day.
In this case, a combination of subsequent processes in which the total number of stocks of a plurality of subsequent processes exceeds the number of insufficient low-order parts is specified. In the case of the example, when the assembly factory of the car C and the assembly factory of the car D are combined, the set of the post-process that becomes the number of inventory (15 per day) exceeding the number of low-order parts (10 per day) A match is obtained.
In this case, in proportion to the number of stocks in each post process (6 in the assembly factory of the car C and 9 in the assembly factory of the car D), the post process (in which the production is desired among the parts shipped to each post process ( It is preferable to specify the number of shipping destinations to be changed to the assembly plant of the automobile A. That is, the shortage number of 10 is proportionally distributed between 6 and 9. In this case, four of the low-order parts c1 are diverted to the production of the engine a, and six of the low-order parts d1 are diverted to the production of the engine a.
In this way, the inventory of each subsequent process is utilized uniformly, and it is possible to prepare for an unpredictable event thereafter.

In a large-scale production system in which a chain of pre-process, self-process, and post-process is repeated in multiple stages, it is preferable that a production shipment plan is determined for each process.
The unit period of the production / shipment plan may be a time unit if it is short, or may be a year / month unit if it is long, but preferably the production / shipment plan is determined every day. preferable. When a plurality of work groups change and continue production activities during one day, a production shipment plan may be determined for each work group within one day.

It is preferable that a means for calculating an increase in transportation costs caused by the change when the production / shipment plan change plan is calculated is added.
When a plurality of change proposals are possible, it is easy to determine which change proposal is to be adopted if an increase in transportation costs caused by the change is calculated for each change proposal.

A means for calculating a point corresponding to a cost that accompanies the change when the production / shipment plan change plan is calculated may be added.
Implementing the change is costly. The work of creating the change proposal itself takes man-hours, and it takes cost to present the change proposal and coordinate with the related process, and additional transportation costs are required. It is difficult to calculate these accurately. However, the general cost is known from past results and can be pointed out. For example, if it is found that it takes about 10,000 yen per hour for the calculation of the plan change plan, it is possible to know the approximate cost by calculating 1 hour as 1 point. If it has been found that an average of 10,000 yen is required for the adjustment work with the related process, it is understood that one adjustment work may be calculated as one point.
If the cost estimate can be calculated by calculating the points, it is easy to determine which change plan is adopted when a plurality of change plans are possible.

The present invention is particularly useful when the part shipped to the post-process is a power generation device that uses a large number of low-order parts.
For example, there are usually many types of power generation devices such as engines, motors, and generators, and many low-order parts are used. Therefore, there are many opportunities for diverting low-order parts. The present invention often provides useful results.

The features of the present invention will be described below.
(Characteristic 1) A process-process-process-process chain is repeated to produce a final product. There is a pre-process, self-process, and post-process at any stage. The present invention can be applied to any stage where a pre-process-self process-post-process relationship exists.
(Characteristic 2) A production shipment plan within a month is given to each process at a timing one month or more in advance. For example, a production shipment plan for March is given in late January. A specific post-process may wish to increase production after a monthly production shipment plan has been determined.
(Characteristic 3) When searching for a post-process that has a stock quantity exceeding the number of insufficient low-order parts, the period (lead time) from receiving an order from the post-process to shipping corresponding to that order is short. Search in order.

FIG. 1 illustrates the relationship between the pre-process and the post-process with respect to the self-process. The own process produces multiple types of engines and ships the engines to multiple subsequent processes. Of the post processes, car factory 1 produces and ships cars A and B, car factory 2 produces and ships car C, car factory 3 produces and ships car D, car factory 4 The car C is produced and shipped, and the car factory 5 produces and ships the car D. The own process is an engine factory, which produces an engine a for car A and ships to car factory 1, produces engine b for car B and ships to car factory 1, produces engine c for car C and Ship to the factory 2 and the automobile factory 4, produce the engine d for the automobile D, and ship it to the automobile factory 3 and the automobile factory 5.
In its own process, low-order parts necessary for engine production are procured from the previous process. The engine parts factory I produces parts a1 and b1 and ships them to its own process. Here, the part a1 is an engine part for the engine A for the car A, and the part b1 is an engine part for the engine b for the car B. The same symbol is used in the following. Parts Factory II produces part c1 and ships it to its own process, Parts Factory III produces parts c1 and d1, ships to its own process, Parts Factory IV produces part d1 and ships to its own process, Parts factory V produces part d2 and ships it to its own process, and parts factory VI produces part a2 and ships it to its own process. The above shows only part of the production and shipment of parts, and many engine parts are used for one engine.
Here, it can be said that the engine part is a low-order part, the engine is a high-order part, and the automobile is a product. The process chain is multi-stage, and engine parts factories procure lower-order parts to produce engine parts. There is also a pre-process-self-process-relationship between the process of producing lower-order parts, the engine parts factory, and the engine factory. In this case, the subsequent process produces and ships a product called an engine. In this embodiment, the case where the present invention is applied to the stage of engine parts factory-engine factory-automobile factory will be described. However, the present invention is applied to the stage of lower-order parts factory-engine parts factory-engine factory. You can also. The engine factory can hope or need to increase its production beyond the predetermined production shipment plan. The present invention can be applied to any stage, and can also be applied to an upstream stage.

FIG. 2 shows the configuration of the apparatus 10 that changes to a production shipment plan that satisfies the production increase request when the automobile factory desires to increase production. The apparatus 10 is configured by a computer system, and the hardware configuration is a normal computer system, and detailed description thereof is omitted.
The plan change plan calculation device 10 includes a device 14 that stores a production shipment plan given to each process. Here, a production shipment plan corresponding to the monthly production shipment plan is stored. The production / shipment plan is given for each operation day of the factory, and the types of parts to be produced, the number of productions, and the number of shipments are stored. FIG. 4 shows an example of a production shipment plan given to the own process. For example, in the column “To automobile factory 1”, 20 engines a for car A are produced per day. It illustrates that a plan to ship is given. The horizontal axis indicates the factory working day. The monthly production / shipment plan is given at a timing one month or more ahead of the actual operation day. For example, a production shipment plan for March is given in late January. After a monthly production and shipping plan is given, there may be a process that requires or needs to increase production.

  As shown in FIG. 2, the plan change plan calculation apparatus 10 includes an input device 26, and a process that needs to be increased after a monthly production / shipment plan is given indicates the contents of the desired increase in production. You can enter it. In the present embodiment, the car factory 3 that produces and ships the car C was planned to produce and ship 10 units per day, whereas the production increase of 30 units per day is required. explain.

  As shown in FIG. 2, the plan change plan calculation device 10 includes a device 16 that detects and stores the number of stocks in its own process. Since the own process produces and ships the engines a to e, each of the engines a to e has a stock. Furthermore, an inventory of engine parts (low-order parts) necessary for producing the engines a to e is provided. The stock quantity detection storage device 16 detects and stores the stock quantity of each of the engines a to e and the stock quantity of engine parts (low order parts) necessary for producing the engines a to e. The number of engine parts in stock is stored as the number of engines that can be produced with the number of stocks. The stock quantity detection storage device 16 may detect the stock quantity from time to time, or the stock quantity is calculated by adding the cumulative difference between the production quantity and the shipment quantity to the initial stock quantity. You may calculate and calculate.

  As shown in FIG. 2, the plan change plan calculation device 10 includes a device 18 that detects and stores the number of stocks for each subsequent process. For example, since the post-process (automobile factory) 1 produces and ships automobiles A and B, each of the automobiles A and B has an inventory. Furthermore, it has a stock of engines a and b necessary for producing automobiles A and B. The stock quantity detection storage device 18 detects and stores the stock quantity for each product type (car type) and the stock quantity for each of the engines a to e for each subsequent process (car factory). The stock quantity detection storage device 18 may detect the stock quantity from time to time, or the stock quantity is obtained by adding the cumulative difference between the production quantity and the shipment quantity to the initial stock quantity. You may calculate and calculate.

  As illustrated in FIG. 2, the plan change plan calculation apparatus 10 includes a database 20 that stores a relationship between a low-order component and a low-order component that are in a divertable relationship. In the case of FIG. 2, the case where the engine component c1 and the engine component b1 are common components is illustrated. In the database 20, a part c 1 that can be diverted to the part b 1 is a part that is used by the engine c for the car C, and a part b 1 that can be diverted to the part c 1 is a part that is used by the engine b for the car B. It is remembered. The production shipment plan storage device 14 stores that the engine b is shipped to the automobile factory 1 and the engine c is shipped to the automobile factories 2 and 4. The production / shipment plan storage device 14 and the database 20 can be diverted to a low-order part (engine part b1) used for the product in association with a product (for example, automobile B) produced in the subsequent process, and the low-order part. Low-order parts (c1), product types produced using divertable lower-order parts (c1) (car C), and subsequent processes for producing the product types (car C) (car factory 2, 4) Is remembered. Similarly, a low-order part (engine part c1) used for the product (C) in association with a product (automobile C) produced in the post-process (automobile factory 2, 4) can be diverted to the low-order part. A low-order part (b1), a product type (car B) that is produced using the divertable low-order part (b1), and a post-process (car factory 1) that produces the product type (car B) It is remembered.

  The divertable parts are not limited to common parts. For example, the parts factory III ships low-order parts c1 and d1. In this case, when the parts factory III can easily ship the low-order part d1 instead of the low-order part c1, the part d1 can also be regarded as a low-order part that can be diverted to the part c1. This is because if the parts factory III ships the part c1 instead of the part d1, the engine c necessary for increasing the production of the automobile C can be increased.

As shown in FIG. 2, the plan change plan calculation device 10 includes a calculation device 12. The arithmetic device 12 performs the process shown in FIG.
As shown in FIG. 3, the arithmetic unit 12 stores the production shipment plan in the production shipment plan storage device 14 (step S2). The arithmetic unit 12 determines whether or not information for increasing the production is changed by changing the production shipment plan from the subsequent process (step S4). If the plan change request is not input, the production and shipment activities are expanded according to the given production shipment plan (step S6).

If the desire to increase production is entered by changing the production shipment plan from the post-process (if YES in step S4), the number of units that can meet the demand for increased production and the number of stocks are utilized by utilizing the number of stocks. The number of necessary low-order parts is insufficient because the demand for increased production cannot be met. Below, the case where it is necessary to increase the production | generation of the motor vehicle C by 20 over 5 consecutive days is demonstrated.
In step S8, the inventory quantity of the engine c existing in its own process is grasped. In step S8, the inventory quantity of engine parts (for example, engine part c1) for engine c existing in its own process is also grasped. Information necessary for this processing is stored in the inventory quantity detection storage device 16 of its own process in FIG.
In this example, the total number of inventories of the engine c of the in-process engine c and the engine parts group for the engine c is 25 units, and even if low-order parts are not procured more than the original plan, An example will be described in which many engines c can be shipped in units of five.
In step S10, the inventory quantity of the engine c or the car C existing in the post-process 2 that desires to increase production is grasped. Necessary information is stored in the inventory quantity detection storage device 18 for each subsequent process in FIG. In the present embodiment, the case where the total number of stocks of the engine c and the automobile C in the post-process 2 is 25, and a case where more automobiles C can be shipped per day than the original plan will be described as an example.

  In step S12, the production / shipment plan corresponding to the production increase request is changed by releasing the inventory. In the case of the above example, by using the engine c existing in the own process and the inventory of the engine parts group for the engine c, 5 units per day are increased from the original process to the subsequent process 2 than the original plan. To the plan to produce and ship the engine c. In the post-process 2, a plan is made to increase the production of the automobile C by utilizing the engine c delivered five times a day from the self-process and the inventory of the engine c existing in the post-process 2. Furthermore, the plan is changed to a plan to ship more cars C than the original plan by utilizing the inventory of the cars C existing in the post-process 2. In this embodiment, at this time, the plan is changed to a plan for shipping 10 cars C per day.

In step S14, the number of low-order parts that are insufficient for the production increase request is grasped. Here, the shortage number = the increased number of automobiles C- (the number of low-order parts for the engine c existing in the own process + the number of the engine c existing in the own process)-(the inventory of the engine c existing in the subsequent process) (Number + stock number of car C existing in the post process).
In this embodiment, the description will be continued assuming that the shortage number = 20−10−10 = 10.

  In step S16, it is determined whether the number of low-order parts that are insufficient is zero or one or more. If it is zero, since the production / shipment plan satisfying the production increase request has been changed in the step S12, the process is terminated. If the number of shortages is 1 or more, it can be seen that it is not possible to change to a production / shipment plan that satisfies the desire to increase production by simply withdrawing inventory. Therefore, after step S18, the possibility of diverting low-order parts to meet the demand for increased production is examined.

In the following description, a case where 10 engine parts c1 per day are insufficient for a production increase request will be described. Since similar calculations may be performed for other low-order engine parts c2, c3, c4,.
If there is a shortage of engine parts (low-order parts), step S18 is executed to search the database 20 in FIG. 2 to search for other low-order parts that can be diverted to the shortage parts (in this case, c1). In this embodiment, it can be seen that the part c1 and the part b1 are common parts, and the part b1 can be diverted to c1. Also, it can be seen that the parts factory III can easily ship the part c1 instead of the part d1, and the delivered part d1 can be diverted to the delivery of the part c1.

  When attention is paid to the divertable part b1, the divertable part b1 is a part used for the engine b to be shipped to the automobile factory 1, and the engine b or the inventory of the engine parts for the engine b in the own process, or the automobile factory 1 If there is room in the inventory of the engine b or the automobile B in FIG. 5, it can be seen that the low-order component b1 can be diverted to the low-order component c1, thereby increasing the production of the engine c. Similarly, when attention is paid to the divertable lower-order component d1, the divertable component d1 is a component used for the engine d shipped to the automobile factory 3, and the engine d or the engine component for the engine d in its own process is used. It can be seen that if the inventory or the engine d or the inventory of the automobile D in the automobile factory 3 has a margin, the low-order part d1 can be diverted to the low-order part c1, thereby increasing the production of the engine c.

  In step S20 of FIG. 3, when attention is paid to the divertable part b1, the inventory of the engine part for the engine b in the own process, the inventory of the engine b in the own process, and the inventory of the engine b in the car factory 1 The inventory of the car B in the car factory 1 is checked. When attention is paid to the divertable part d1, the inventory of the engine parts for the engine d in its own process, the inventory of the engine d in its own process, the inventory of the engine d in the automobile factory 3, and the automobile D in the automobile factory 3 Check inventory of. Here, the number of inventory when the production shipment plan before the change is followed is examined.

  In step S22 of FIG. 3, instead of the automobile B or the automobile D, a change plan of the production / shipment plan for increasing the production of the automobile C is calculated. Here, the production shipment plan is corrected within a range in which the inventory of the automobile B or the automobile D does not become zero and the automobile B or the automobile D cannot be shipped.

FIG. 4 shows that when the low-order part d1 can be diverted to the deficient part c1 and the car D using the diverted low-order part d1 is stocked in the car factory 3, production is performed within the range that can be handled by the number of stocks. The example which changed the shipping plan is shown.
The horizontal axis in FIG. 4 indicates the factory working days, and the production shipment quantity is planned for each working day. Here, the working day 1 indicates the day after the lead time from the date on which the production / shipment plan is reviewed because the desire to increase production of the automobile C is input from the automobile factory 2. The lead time here means a period from when an order is received until the ordered article is delivered. In this production system, a production shipment plan is given to each process, but this is a guideline, and actual production delivery activities are carried out based on orders. If you review the production shipment plan and review the production shipment plan after the day after the lead time has passed, then the production shipment plan based on the order and the standard production shipment plan will work together without difficulty. .

  The column before the change to “Automobile Factory 1” in FIG. 4 exemplifies a production shipment plan from the own process to the automobile factory 1, and 20 engines a and 30 engines b are converted into the car factory 1 every day. It illustrates that a plan to ship is given. The column before the change to “automobile factory 2” exemplifies that a plan to ship 10 engines c every day from the own process to the automobile factory 2 is given. The column before the change to “automobile factory 3” exemplifies that a plan for shipping 40 engines d every day from the own process to the automobile factory 3 is given. The column before the change to “automobile factory 4” exemplifies that a plan for shipping 40 engines c from the own process to the automobile factory 4 every day is given. The column before the change to “automobile factory 5” exemplifies that a plan to ship 30 engines d from the own process to the automobile factory 5 every day is given.

In the present embodiment, as shown in the column of the changed shipment number “to automobile factory 2”, the automobile factory 2 needs to ship 30 cars C during the five days from the working day 1 to the working day 5. The case is shown as an example.
The “immediately preceding” column of “to automobile factory 2” in FIG. 4 indicates the number of cars C in stock on the last working day before the plan change. If 25 cars C are in stock at the car factory 2, it can be seen that 5 cars C per day can be shipped more than the planned number by pulling it down. As a result, it can be seen that the number of stocks of the car C in the car factory 2 decreases by 5 every day, and the number of stocks becomes zero on the working day 5. In the present embodiment, the case where the engine c is not in stock at the automobile factory 2 immediately before is described.
In the column of “in-process engine c and engine c parts inventory” in FIG. 4, the total inventory quantity of the engine c for the automobile C that requires increased production and the engine parts c1 used in the engine c in the own process. Show. If the engine parts c1 to be used for the engine c are stocked in the process immediately before, it is understood that the engine c can be produced more than the planned number without procuring more engine parts c1 than the planned number. If the engine c and engine parts c1 to be used for the engine c are in stock in the own process “just before”, 5 engines c per day from the own process to the car factory 2 are more than the planned number. You can see that it can be shipped. As a result, it can be seen that the number of the engine c of the own process decreases by 5 every day, and the stock quantity becomes zero on the working day 5.

  In the above case, in response to the desire to increase the production of 20 cars C every day, 5 of them can be dealt with by releasing the inventory of the cars C and engines c that the car factory 2 has, and the other 5 cars It can be dealt with by removing the stock of the engine c and the engine component c1 provided in the process, and as a result, it can be seen that 10 low-order components c1 for the engine c are insufficient per day.

  As described above, the low-order component d1 can be diverted to the insufficient component c1. The engine d produced using the divertable low-order parts d1 is delivered to the automobile factory 3 and the automobile factory 5. If the total inventory number of the automobile D and the engine d in the automobile factory 3 is 50, and if 10 cars are withdrawn per day and shipped, the number of engines d shipped from the own process to the automobile factory 3 is 1 than planned. It can be seen that the car D can be shipped as planned even if there are not enough 10 cars per day. At this stage, one change plan that satisfies the desire to increase production is searched.

As shown in the column after changing to “Automobile Factory 3” in FIG. 4, the number of engines d shipped from the in-house process to the automobile factory 3 is reduced by 10 per day, and the inventory quantity of cars D, etc. is reversed by that amount. Can be shipped from the automobile factory 3 as planned. The part factory III ships the part c1 and the part d1, and can deliver the part c1 instead of the part d1. As shown in the column “From Parts Factory III”, before the change, the plan was to “ship 40 low-order parts c1 and ship 40 low-order parts d1”. By assigning to 10 parts c1, it is possible to increase the production of 10 engines c in the own process.
Eventually, 10 engines c were planned to be shipped in the own process, but the engine c was increased by 10 units by diverting the low-order part d1 to the missing part c1, and the engine c in stock in the own process. Alternatively, a plan is planned for shipping five extra units by removing the inventory of the low-order parts. As a result, the plan is changed so that 25 engines c are shipped every day from the own process to the automobile factory 2. The number of 25 units is still insufficient, but this can be dealt with by removing the inventory of the car C or the engine c in the car factory 2.
Note that the downward arrow in FIG. 4 means that there is no change in the production shipment plan.

  According to the above, due to inventory withdrawal and parts diversion, a production shipment plan corresponding to an increase in production that was impossible with the prior art is calculated.

  The column of working days 6 to 9 in FIG. 4 shows a production shipment plan for increasing the number of engine parts to be recovered and recovering the engine or vehicle inventory to the previous level in order to recover the lost inventory. . With this production / shipment plan, the lost inventory can be recovered.

  FIG. 5 illustrates another proposed change. FIG. 5 shows that the low-order parts b1 and d1 can be diverted to the deficient part c1, and the car B or the engine b that uses the diverted low-order part b1 is in stock at the car factory 1 and uses the diverted low-order part d1. When the car D or engine d to be stocked is stocked in the car factory 5, an example in which the production / shipment plan is changed within a range that can be handled by the number of stocks is shown.

The production shipment plan before the change is the same as in the case of FIG. In the present embodiment, as shown in the column of the changed shipment number “to automobile factory 2”, the automobile factory 2 needs to ship 30 cars C during the five days from the working day 1 to the working day 5. The case is shown as an example. This is also the same as in FIG.
The “immediately preceding” column of “to automobile factory 2” in FIG. 5 indicates the number of cars C in stock on the last working day before the plan change. If 25 cars C are in stock at the car factory 2, it can be seen that 5 cars C per day can be shipped more than the planned number by pulling it down. As a result, it can be seen that the number of stocks of the car C in the car factory 2 decreases by 5 every day, and the number of stocks becomes zero on the working day 5. In the present embodiment, the case where the engine c is not in stock at the automobile factory 2 immediately before is described. This is also the same as in FIG.
In the column of “in-process engine c and engine c parts inventory” in FIG. 5, the total inventory quantity in the own process of the engine c for the automobile C that requires increased production and the engine component c1 used for the engine c is shown. Show. If the engine parts c1 to be used for the engine c are stocked in the process immediately before, it is understood that the engine c can be produced more than the planned number without procuring more engine parts c1 than the planned number. If the engine c and engine parts c1 to be used for the engine c are in stock in the own process “just before”, 5 engines c per day from the own process to the car factory 2 are more than the planned number. You can see that it can be shipped. As a result, it can be seen that the number of the engine c of the own process decreases by 5 every day, and the stock quantity becomes zero on the working day 5. This is also the same as in FIG.

  In the above case, in response to the desire to increase the production of 20 cars C every day, 5 of them can be dealt with by releasing the inventory of the cars C and engines c that the car factory 2 has, and the other 5 cars It can be dealt with by removing the stock of the engine c and the engine component c1 provided in the process, and as a result, it can be seen that 10 low-order components c1 for the engine c are insufficient per day.

As described above, the low order parts b1 and d1 can be diverted to the lacking part c1.
The engine b that uses the low-order component b1 that can be diverted to the insufficient component c1 is delivered to the automobile factory 1. The total inventory number of cars B and engines b in the car factory 1 at “just before” is 24. If 4 cars are withdrawn per day and shipped, the number of engines b shipped from the own process to the car factory 2 is It can be seen that the car B can be shipped as planned even if there are four more cars per day than planned. However, there are only four engine parts b1 that can be diverted to low-order parts c1 that are short of 10 per day, and it is not possible to satisfy the demand for increased production.
The engine d that uses a low-order component d1 that can be diverted to the insufficient component c1 is delivered to the automobile factory 5. The total inventory number of cars D and engines d at the automobile factory 5 at “just before” is 36. If 7 cars are withdrawn per day and shipped, the number of engines d shipped from the own process to the automobile factory 5 is It can be seen that the car D can be shipped as planned even if there are seven more cars per day than planned. However, only 7 engine parts d1 can be diverted to 10 low-order parts c1 that are insufficient per day, and it is not possible to satisfy the demand for increased production.

As long as the car factory 1 and the car factory 5 are independently examined, there will be no post-process that has a stock quantity exceeding the number of insufficient low-order parts in the stock quantity calculated for each post-process. In contrast to the low-order parts c1 that lack 10 pieces per day, the number of stocks in the car factory 1 is 4 pieces per day, the number of stocks in the car factory 5 is 7 pieces per day, and the car factory 1 and the car As long as the factory 5 is considered independently, there is no rear process that exceeds the number of low-order parts in the inventory calculated for each subsequent process. However, the car factory 1 and the car factory 5 are combined. Considering this, the number of inventory exceeds the number of low-order components. In this case, the number of parts whose shipment destination is changed to a subsequent process for which production is desired is specified from among the parts shipped to each subsequent process in proportion to the number of stocks in each subsequent process. In the case of FIG. 5, the inventory number of the automobile B or the engine b immediately before the automobile factory 1 is 24, and the inventory quantity of the automobile D or the engine d immediately before the automobile factory 5 is 36, which is proportional to the inventory quantity. Thus, the number of parts to be diverted to the low-order parts c1 that are insufficient 10 per day is determined. In this case, four of the parts b1 used for the automobile B with the inventory quantity of 24 are diverted to the deficient parts c1, and six of the parts d1 used for the automobile D with the inventory quantity of 36 are diverted to the deficient parts c1. . The number of diversions of the parts b1 and d1 to be diverted is 4: 6, which is equal to the ratio of the inventory quantity, 24:36. Even if the four parts b1 are diverted, the product B can be shipped as planned. As shown in the column of the number of stocks of the engine b in “To car factory 1”, even if the working day is 5, four cars B are in stock, and the cars B will not be unshipped. Similarly, even if the six parts d1 are diverted, the product D can be shipped as planned. As shown in the column of the number of inventory “To car factory 5”, even if the working day is 5, six cars D are in stock, and car B will not be unshipped.

As shown in the column “After Change” in “Number of Ships of Engine b” of “To Car Factory 1” in FIG. 5, even if the number of engines b shipped from the own process to the car factory 1 is reduced by four per day. If the amount of the stock of the automobile B or the like is reversed and shipped, the automobile B can be shipped from the automobile factory 1 as planned. As shown in the column “After change” of “To car factory 5”, even if the number of engines d shipped from the own process to the car factory 5 is reduced by 6 per day, the number of stocks of cars D, etc. is reduced by that amount. Can be shipped from the automobile factory 5 as planned.
The part b1 to be diverted to the part c1 is common to the part c1, and it is not necessary to change the production / shipment plan in the previous process in order to divert the part b1 to the part c1. As shown in the part b1 column from the part factory I, the part factory I may produce and ship as planned. In this case, out of 30 engine parts b1 delivered every day, 26 are used for production of the engine b, and the remaining 4 are diverted for production of the engine c.
The part factory III ships the part c1 and the part d1, and can deliver the part c1 instead of the part d1. As shown in the column “From the parts factory III”, before the change, the plan was to “ship 40 low-order parts c1 and ship 40 low-order parts d1”. Is allocated to the six parts c1, and it becomes possible to increase the production of six engines c in the own process.
In response to the change to a plan for producing six engines c instead of six engines d, the parts factory V that produces and ships the parts d2 used for the engines d has six parts. Reduction is required.

According to the above change, the company planned to ship 10 engines c every day in its own process, but by diverting the low-order parts d1 to the parts c1 that are insufficient, the engine c was increased by 6 units per day. By diverting b1 to the missing part c1, the engine c is increased by 4 units per day, and the engine c or its low-order parts stocked in its own process is retired and 5 more engines c are shipped per day. Possible plans are drawn up. As a result, the plan is changed so that 25 engines c are shipped every day from the own process to the automobile factory 2. The number of 25 units is still insufficient, but this can be dealt with by removing the inventory of the car C or the engine c in the car factory 2.
Note that the downward arrow in FIG. 5 means that there is no change in the production shipment plan.

  According to the above, due to inventory withdrawal and parts diversion, a production shipment plan corresponding to an increase in production that was impossible with the prior art is calculated.

  The column of working days 6 to 9 in FIG. 5 shows a production shipment plan for increasing the number of engine parts procured and recovering the inventory of the engine or automobile to restore the previous level in order to recover the lost inventory. . With this production / shipment plan, the lost inventory can be recovered.

In step S24 of FIG. 3, it is determined whether the number of divertable parts can be calculated. If it cannot be calculated, it is a case where it is not possible to cope with an increase in production by diverting parts. Therefore, the change of the production / shipment plan is abandoned (step S26), and the result is transmitted to the process where the increase in production is desired.
If the number of parts that can be diverted can be calculated, a change plan for the production shipment plan is calculated (step S28). The calculation process has been described with reference to FIGS.
As shown in step S32, when a plurality of possible change plans are calculated, all the change plans are calculated.

Changing the production shipment plan is expensive. The work of creating the change proposal itself takes man-hours, and it takes cost to present the change proposal and coordinate with the related process, and additional transportation costs are required. It is difficult to calculate these accurately. However, the general cost is known from past results and can be pointed out. For example, if it is found that it takes about 10,000 yen per hour for the calculation of the plan change plan, it is possible to know the approximate cost by calculating 1 hour as 1 point. If it has been found that an average of 10,000 yen is required for the adjustment work with the related process, it is understood that one adjustment work may be calculated as one point. When 10 related processes exist, it turns out that 10 points are required for the change of a production shipment plan. If it becomes necessary to arrange a truck as a result of a change in the production / shipment plan, the cost required for this can be understood and pointed out.
As shown in FIG. 2, the plan change plan calculation apparatus 10 includes a point storage device 24, and calculates and stores points indicating an approximate cost increase necessary for each plan change plan. The plan change plan calculation device 10 includes a device 22 that stores information necessary for calculating transportation costs, such as a distance between processes, an operation time of a regularly traveling truck, a load amount, a unit price, and the like. It also has.

In step S34 of FIG. 3, a plurality of calculated production / shipment plan change proposals are displayed in the order of points indicating an approximate cost generated in accordance with the change, and presented to related parties.
Stakeholders can see the production revision plan corresponding to the increase in production by looking at it, and whether or not to change the plan taking into account the cost estimate etc., and what change when changing the plan Decide whether to adopt the draft. If the proposed change is not calculated, it will be clear that it will not be possible to meet the demand for increased production even if the diversion of parts and the utilization of inventory are taken into account, and it will be easier for stakeholders to take the next best measure.

Specific examples of the present invention have been described in detail above, but these are merely examples and do not limit the scope of the claims. The technology described in the claims includes various modifications and changes of the specific examples illustrated above.
In addition, the technical elements described in the present specification or the drawings exhibit technical usefulness alone or in various combinations, and are not limited to the combinations described in the claims at the time of filing. In addition, the technology illustrated in the present specification or the drawings achieves a plurality of objects at the same time, and has technical utility by achieving one of the objects.

The figure which illustrates the relationship of pre-process-self process-post process. The figure which shows the system configuration | structure of a plan change plan calculation apparatus. The figure which shows the process sequence which a plan change plan calculation apparatus performs. The figure which shows an example of the production shipment plan before and behind a change. The figure which shows another example of the production shipment plan before and behind a change.

Explanation of symbols

10: Plan change plan calculation device 12: Arithmetic device (deficient low order part number calculation means)
(Inventory calculation method for the specified product type in the specified post-process)
(Means for identifying the number of low-order parts to be diverted)
(Means to calculate the proposed change in production shipment plan obtained by diverting low-order parts)
14: Production shipment plan storage device 16: Own process inventory number detection storage device 18: Inventory number detection storage device 20 for each subsequent process 20: Database 22: Transportation cost information storage device 24: Point storage device 26: Input device 28: Output device

Claims (8)

A production / shipment plan for parts is produced for a process that produces multiple types of parts and is shipped to multiple subsequent processes. A device that calculates a plan,
Corresponding to the product to be produced in the post-process, the low-order parts used for the product, the low-order parts that can be diverted to the low-order parts, the product types that use the divertable low-order parts, and the products A database that stores post-processes to produce types,
A means to calculate the number of low-order parts that are insufficient when the post-production schedule is based on the production shipment plan before the change, from the product type and the desired number of production increase
After the database is searched, the product type that uses the low-order part that can be diverted to the low-order low-order part, the post-process that produces the product type is specified, and the product / shipping plan before the change is specified Means for calculating the number of stocks of the product type identified in the process;
A means for identifying the number of low-order parts to be diverted to the shortage of low-order parts from the calculated inventory quantity and the number of low-order low-order parts;
Production that satisfies the demand for increased production in the post-process, characterized by the provision of a means to calculate a proposed change in the production / shipment plan obtained by diverting the specified number of low-order parts to shortage low-order parts A device that calculates proposed changes to a shipping plan. The means to calculate the number of low-order parts that are insufficient when the post-production process is based on the production shipment plan before the change is based on the product type and the desired number of production increases.
The number of inventories of products desired to be increased in the post-process that desires to increase production, the number of parts used in the products for which production is desired to increase in the post-process that desires to increase production, the number of parts in stock for the products desired to increase production in the in-process, and the in-process 2. The apparatus according to claim 1, wherein the number of low-order parts to be used is calculated from the number of desired production increases, taking into account the number of low-order parts to be used in a product for which production is desired to be increased.   If there is a post-process that exceeds the shortage of low-order parts in the number of stocks calculated for each post-process, the ship-to party in the post-process that wants to increase production from the parts shipped to the post-process 2. The apparatus of claim 1, wherein the number of parts to be changed is specified.   If there are no post-processes that exceed the number of missing low-order parts in the number of stocks calculated for each post-process, after the total number of stocks of multiple back-processes exceeds the shortage of low-order parts It is characterized by specifying the combination of processes and specifying the number of parts whose shipment destination is changed to the post-process that wants to increase production from the parts shipped to each post-process in proportion to the number of stocks of each post-process. The apparatus of claim 1.   2. The apparatus according to claim 1, wherein the production shipment plan is calculated for each process and schedule.   2. The apparatus according to claim 1, further comprising means for calculating an increase in transportation costs caused by the change when the change proposal is calculated.   The apparatus according to claim 1, further comprising means for calculating a point corresponding to a cost incurred when the proposed change is calculated.   2. The apparatus according to claim 1, wherein the part to be shipped to a subsequent process is a power generation apparatus that uses a large number of low-order parts to produce.

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