JP2011096141A - Method of preparing production schedule of two or more industrial plants - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method of preparing production schedules of two or more industrial plants, for visualizing the entire supply chain, shortening the lead time of the entire supply chain, reducing the stock and realizing keeping of the delivery date. <P>SOLUTION: In order to generate the production schedule of the supply chain including at least one supplier, a plurality of plants and at least one customer, processing to be executed by an MPRS 110 includes a step of inputting the buying order and/or demand prediction of an object, a raw material or a component and information on an inventory track record, a first buying order allocation step, a manufacture order generation step, a manufacture order allocation step, and a second purchase order generation step. In the first and second purchase order allocation steps by arithmetic processing that uses setting information of buying BOM set for each combination of a supply destination and a supply origin and for each selectable delivery resource, respectively, the supply origin of the object and the delivery resources are determined, and the buying order is allocated to the determined delivery resources. <P>COPYRIGHT: (C)2011,JPO&INPIT

Description

  The present invention enables the visualization of the schedule of the entire supply chain (Visualization), reduction of the lead time of the entire supply chain, reduction of inventory, and compliance with delivery date by linking production schedules of multiple production bases. The present invention relates to a production schedule creation method.

  A production scheduler that is mounted on a computer and schedules a production process has been used in many manufacturing industries as a tool for creating a short-term production schedule. After that, the production scheduler is developing into a tool that schedules orders and purchases and creates not only short-term but also medium- and long-term schedules.

In the manufacturing industry with multiple production plants in the world,
(A) Purchasing raw materials / parts from a supplier, producing a product through multiple factories (Production), and delivering the product to a customer (Customer) (Distribution) Visualization, i.e. display graphically on a computer system,
(B) I want to shorten the lead time of the entire supply chain.
(C) We want to reduce inventory throughout the supply chain.
(D) Want to perform MRP (Material Requirements Planning) at high speed throughout the entire supply chain.
(E) We want to distribute production among multiple factories, taking into account the load, delivery time, and cost of each plant.
There is a growing demand.

  In the conventional system, first, a rough production plan, such as which factory at which factory among a plurality of factories, how many to produce, is calculated by MRP with a fixed lead time, and a large schedule is drawn up. And the result of the large schedule is distributed to each factory.

  Each factory creates detailed production schedules based on the results of the large schedule. In other words, the production scheduler in each factory responds to orders by allocating multiple jobs related to the production process in the time axis direction for each resource required to produce objects of each order. Generated production plan. The present inventor has already proposed a production schedule method that is suitable for the purpose of planning and managing a high-variety, multi-step production plan with high speed and accuracy in particular (Patent Document 1).

JP 2002-373013 A

  As described above, the conventional system is a method in which the result of the large schedule obtained by the MRP having the fixed lead time is distributed to each factory, and the detailed schedule is performed in each factory. This method has the following problems.

(1) A manufacturing BOM (Bill of Material) for large-scale planning and a manufacturing BOM for a detailed schedule at each factory cannot be integratedly managed, and a large amount of manufacturing BOMs are managed separately. Therefore, there is a possibility that troubles for inputting the manufacturing BOM twice and inconsistency at the time of inputting may occur.
(2) The result of the detailed schedule at each factory cannot be reflected in the large schedule. In the large schedule, the manufacturing order of each factory is determined as a result of calculating the MRP of a plurality of factories, and each factory performs a detailed schedule based on the manufacturing order. However, for example, even if it is found from the detailed schedule result that the load is overloaded, it cannot be returned to the MRP of a plurality of factories and recalculated. Such reflection work must be performed manually through communication between the person in charge of preparing the large schedule and the person in charge at each factory.
(3) Detailed schedule results cannot be linked to each other between factories. As described above, in the large schedule, the production order of each factory is determined as a result of calculating the MRP of a plurality of factories, and each factory performs a detailed schedule based on the production order. However, for example, even if it is found from the detailed schedule result that the delivery date is late, it is not possible to communicate with other factories and to coordinate with each other so as to eliminate the delivery date delay. Such work also needs to be performed manually through communication between persons in charge at each factory.
(4) Since the large schedule is calculated with a fixed lead time, the lead time of the entire supply chain cannot be shortened.

  Therefore, the present invention solves the above-mentioned problems by coordinating the production schedules of a plurality of production bases in a situation where the manufacturing industry is globalized and has production bases in various parts of the world. The purpose is to provide a production schedule creation method for multiple factories that realizes overall lead time reduction, inventory reduction, and delivery date compliance.

The present invention relates to a raw material for an object (Xi) by assigning purchase orders and / or demand forecasts of at least one object (Xi) produced in a plurality of factories (Fn) and a production order in the time axis direction. Alternatively, a production schedule creation method for a plurality of factories that generates a production plan for a supply chain including at least one supplier (Sm) that supplies parts (Yj), a plurality of factories (Fn), and at least one customer (Cl). In
Inputting the purchase order and / or demand forecast of the object and raw materials or parts (Xi, Yj), and inventory information via an input device;
For the purchase order and / or demand forecast of the object (Xi), a first factory and a delivery resource that supply the object (Xi) to a customer (Cl) are determined, and the object (Xi) A first purchase order allocation step of allocating a purchase order and / or demand forecast of the distribution resource to the delivery resource;
When the inventory result of the object (Xi) in the first factory is insufficient as a result of the first purchase order allocation step, a production order for the object (Xi) is generated, and the production order is A production order assignment step for assigning to the production resources of one factory;
As a result of the manufacturing order allocation step, when the inventory of the raw material or part (Yj) in the first factory is insufficient, a purchase order of the raw material or part (Yj) with the first factory as a customer is generated A first purchase order generation step;
For a purchase order of the raw material or part (Yj) generated as a result of the first purchase order generation step, a supplier and a delivery resource for supplying the raw material or part (Yj) to the first factory are determined. A second purchase order assigning step for assigning a purchase order of the raw material or part (Yj) to the delivery resource;
The purchase order and / or demand forecast assigned to the delivery resource, stored in relation to each other in the storage device, and the start date and time information of the production order assigned to the production resource are read from the storage device, Outputting a supply chain schedule result to an output device, and
The first and second purchase order allocating steps are performed by an arithmetic process using purchase BOM setting information set for each combination of a supply destination and a supply source and for each selectable delivery resource. It is characterized in that a supplier and a delivery resource are determined, and a purchase order is assigned to the decided delivery resource.

Further, the present invention provides a first object (Xi) produced at a first factory downstream of a plurality of factories (Fn) and a second object produced at a second factory upstream. At least one supplier (Sm) that supplies raw materials or parts (Zk) of the second object (Yj) by assigning purchase orders and / or demand forecasts of (Yj) and production orders in the time axis direction. ), Generating a production plan for a supply chain including a plurality of factories (Fn) and at least one customer (Cl);
Inputting the purchase order and / or demand forecast of the first and second objects and raw materials or parts (Xi, Yj, Zk), and inventory information via an input device;
For a purchase order and / or demand forecast of the first object (Xi), a first factory and a delivery resource for delivering the first object (Xi) to a customer are determined, and the first object A first purchase order allocating step of allocating a purchase order and / or demand forecast of (Xi) to the delivery resource;
When the inventory result of the first object (Xi) in the first factory is insufficient as a result of the first purchase order allocation step, a production order for the first object (Xi) is generated, A first production order assignment step for assigning the production order to the production resource of the first factory;
As a result of the first production order assignment step, there is a shortage of inventory results of the second object (Yj) held by the first factory, which is a raw material or part of the first object (Xi). A first purchase order generation step of generating a purchase order of the second object (Yj) with the first factory as a customer;
A second factory that supplies the second object (Yj) to the first factory for the purchase order of the second object (Yj) generated as a result of the first purchase order generation step. A second purchase order assigning step for determining a delivery resource and assigning a purchase order for the second object (Yj) to the delivery resource;
As a result of the second purchase order allocating step, when the inventory record of the second object (Yj) in the second factory is insufficient, a production order of the second object (Yj) is generated, A second production order assigning step for assigning the production order to production resources of the second factory;
As a result of the second production order assigning step, when the raw materials or parts of the second object (Yj) and the raw materials or parts (Zk) held by the second factory are insufficient, A second purchase order generation step of generating a purchase order of the raw material or part (Zk) with the second factory as a customer;
For a purchase order of the raw material or part (Zk) generated as a result of the second purchase order generation step, a supplier and a delivery resource for supplying the raw material or part (Zk) to the second factory are determined. A third purchase order assigning step for assigning a purchase order of the raw material or part (Zk) to the delivery resource;
The purchase order and / or demand forecast assigned to the delivery resource, stored in relation to each other in the storage device, and the start date and time information of the production order assigned to the production resource are read from the storage device, Outputting a supply chain schedule result to an output device, and
In the first, second, and third purchase order allocation steps, calculation processing using the purchase BOM setting information set for each combination of a supply destination and a supply source and for each selectable delivery resource Thus, the supply source and the delivery resource of the object are determined, and the purchase order is allocated to the determined delivery resource.

Moreover, this invention made the said supplier who allocated the purchase order of the said raw material or components (Zk) which made the said 2nd factory a customer by the said 3rd purchase order allocation step a 1st supplier. When the first supplier is a third factory upstream of the second factory that produces the raw materials or parts (Zk), and also serves as the first supplier. When the raw material or part (Zk) produced by the factory is a third object, at least one second supplier supplying the raw material or part (At) of the third object (Zk) is If
As a result of the third purchase order allocating step, when the inventory record of the third object (Zk) in the third factory is insufficient, a production order of the third object (Zk) is generated, A third production order assigning step for assigning the production order to the production resources of the third factory;
As a result of the third production order allocation step, when the raw materials or parts of the third object (Zk) and the inventory results of the raw materials or parts (At) held by the third factory are insufficient, A third purchase order generation step of generating a purchase order of the raw material or part (At) with the third factory as a customer;
A second supplier and a delivery resource that supply the raw material or part (At) to the third factory for the purchase order of the raw material or part (At) generated as a result of the third purchase order generation step. And assigning a purchase order of the raw material or part (At) to the delivery resource, a fourth purchase order assigning step;
Further including
In the same manner, the supplier who assigned the purchase order of raw materials or parts (At) whose customers are the (p + 1) factory in the (p + 2) purchase order allocation step is referred to as the (p-1) supplier. The p-th supplier is the (p + 2) factory upstream of the (p + 1) factory where the raw material or part (At) is produced by itself, and the p-th supplier When the raw material or part (At) produced by the (p + 2) factory that also serves as the operator is the (p + 2) target, at least one of the raw material or part (Bu) of the (p + 2) target is supplied. If there are two (p + 1) th suppliers (where p = 2, 3,...),
As a result of the (p + 2) purchase order allocating step, when the inventory record of the (p + 2) th object (At) in the (p + 2) factory is insufficient, the (p + 2) th object (At) A (p + 2) manufacturing order allocation step, wherein the manufacturing order is generated, and the manufacturing order is allocated to the production resource of the (p + 2) factory.
As a result of the (p + 2) manufacturing order allocation step, the raw materials or parts of the (p + 2) target object (At), and the inventory results of the raw materials or parts (Bu) held by the (p + 2) factory (P + 2) purchase order generation step of generating a purchase order of the raw material or part (Bu) with the (p + 2) factory as a customer,
For the purchase order of the raw material or part (Bu) generated as a result of the (p + 2) th purchase order generation step, supply the raw material or part (Bu) to the (p + 2) factory (p + 1) A (p + 3) th purchase order allocation step of determining a supplier and a delivery resource, and allocating a purchase order of the raw material or part (Bu) to the delivery resource;
Further including
In the purchase order allocation step, the supply source and the delivery resource of the target object are calculated by arithmetic processing using the setting information of the purchase BOM set for each combination of the supply destination and the supply source and for each selectable delivery resource. And purchase orders are allocated to the determined delivery resources.

According to a preferred embodiment of the present invention, the production schedule creation method for the plurality of factories comprises:
The production order allocation step includes:
The method includes a step of assigning a production order by finite capacity rough scheduling in which a plurality of production orders that can be assigned to the production resource are assigned in a backward and / or forward manner, and then crushed.

Furthermore, according to a preferred embodiment of the present invention, the production schedule creation method for the plurality of factories comprises:
Order information necessary for creating a detailed schedule for producing an object at each factory of the plurality of factories (Fn) among purchase orders and / or demand forecasts of the object and raw materials or parts, and manufacturing orders. A detailed schedule creation step for creating a detailed schedule for each factory by finite capacity scheduling using the manufacturing BOM setting information set for each process,
A storage step of storing the purchase order and / or demand forecast and the detailed start date and time and the detailed end date and time of the production order created in the detailed schedule creation step in the storage device as a detailed schedule result. Features.

According to a preferred embodiment of the present invention, the production schedule creation method for the plurality of factories includes:
Inputting actual delivery start date and time and delivery end date and time information according to the purchase order as a delivery record for each purchase order;
Analyzing the time required for delivery from a plurality of delivery record information input in the delivery record input step, and outputting a suggestion to change the corresponding purchase BOM setting information according to the analysis result;
Changing the corresponding purchase BOM in response to an input of a signal for approving the change suggested by the purchase BOM change suggestion step.

Furthermore, according to a preferred embodiment of the present invention, the production schedule creation method for the plurality of factories comprises:
A step of generating corrected manufacturing BOM information for each factory by a process of removing information indicating the use of resources used for each process in the factory from among the information of the manufacturing BOM used for creating the detailed schedule. In addition,
In the manufacturing order allocation step, or in the first manufacturing order allocation step and the second manufacturing order allocation step, the setting information of the corrected manufacturing BOM of each factory is referred to, and the manufacturing order is assigned to the production resource of each factory. It is characterized by assigning.

According to a preferred embodiment of the present invention, the production schedule creation method for the plurality of factories includes:
Entering information on the actual start date and time and actual end date and time of actual work according to the production order as work results for each production order;
Analyzing the time required for the work from the information on the plurality of work results input in the work result input step, and outputting a suggestion to change the setting information of the corresponding manufacturing BOM according to the analysis result;
Changing the corresponding manufacturing BOM in response to an input of a signal for approving the change suggested by the manufacturing BOM change suggesting step.

Furthermore, according to a preferred embodiment of the present invention, the production schedule creation method for the plurality of factories comprises:
Of the detailed schedule result created by the detailed schedule creation step, based on the work information of the process of each factory, generating information representing the relationship between orders;
Storing the information generated by the association information generation step and representing the relationship between orders in the storage device; and
Is further included.

Furthermore, according to a preferred embodiment of the present invention, in the production schedule creation method for the plurality of factories, the detailed schedule storage step is at least created by the detailed schedule creation step, and the start dates and times of the plurality of processes in each factory Including the process of obtaining the information of the earliest start date and time and the last end date and time, and setting the detailed start date and time and the detailed end date and time of the manufacturing order.
The detailed start date / time and the detailed end date / time of the purchase order and / or demand forecast or production order stored in the storage device by the detailed schedule storage step are acquired, and the supply chain created before the detailed schedule creation step The method further includes a step of correcting the schedule result based on the acquired detailed start date and time and detailed end date and time.

  According to the present invention, the purchase order and / or demand forecast assigned to the delivery resource stored in relation to each other in the storage device, and the start date and time information of the production order assigned to the production resource are read from the storage device. The supply chain schedule result is output to the output device. Therefore, visualization of the entire supply chain can be realized.

  In addition, the supply source and the delivery resource of the target object are determined by the calculation process using the purchase BOM setting information in which the purchase order assignment is set for each combination of the supply destination and the supply source and for each selectable delivery resource. In addition, since a purchase order is assigned to the determined delivery resource, it is possible to create a schedule that prioritizes compliance with the customer delivery date and further shortens the lead time as viewed from the entire supply chain.

  When the production order allocation is based on finite capacity rough scheduling in which multiple production orders that can be assigned to production resources are allocated in a backward and / or forward manner, and then collapsed, a high-accuracy load is achieved while eliminating overload. It is possible to create production schedules for multiple factories.

  Further, when the purchase order and / or demand forecast, and the detailed start date and time and detailed end date and time of the production order are stored in the storage device as the detailed schedule result, the rough schedule result is more correct based on the detailed schedule result. Can be updated with results.

  The time required for delivery is analyzed from the information of the actual delivery start date and time and the delivery end date and time according to the purchase order input as delivery results, and the setting information of the corresponding purchase BOM is changed according to the analysis result. When a corresponding purchase BOM is changed in response to an input of a signal that outputs a suggestion and approves the suggested change, the construction and maintenance of the purchase BOM can be automated or semi-automated.

  Moreover, the information of the manufacturing BOM used for the detailed schedule creation is generated for each factory by the process of removing the information indicating the use of the production resources used for each process in the factory, Referring to the setting information of the modified manufacturing BOM, when assigning the manufacturing order to the production resource of each factory, the manufacturing BOM for the detailed schedule and the “modified” manufacturing BOM for the rough schedule are integrated. be able to. (In a normal case where there are multiple processes in a factory, a manufacturing BOM for a detailed schedule can be set at least for each process, whereas a “modified” manufacturing BOM for a rough schedule This corresponds to the production BOM when the process is regarded as one process). Also, instead of detailed and enormous manufacturing BOM data for each factory, the modified manufacturing BOM setting information with reduced data volume can be used for creating production schedules for multiple factories, which reduces the processing load. It can be greatly reduced.

  The time required for the work is analyzed from the information about the actual work actual start date and time and the actual end date and time input according to the manufacturing order, which are input as the actual work results, and the setting information of the corresponding manufacturing BOM is changed according to the analysis result. The production BOM construction and maintenance can be automated or semi-automated when the corresponding production BOM is changed in response to an input of a signal that acknowledges the suggested change and approves the suggested change.

  Moreover, based on the work information of the process of each factory among the created detailed schedule results, information indicating the relationship between the orders is generated, and the information indicating the relationship between the orders is stored in the storage device. In each case, the latest detailed schedule results of each other can be referred to at each factory, and the detailed schedule can be linked between the factories.

  In addition, from the detailed schedule results that have been created, the purchase order and / or demand forecast, or the detailed start date and time and detailed end date and time of the production order are obtained, and the supply chain schedule results that were created prior to the creation of the detailed schedule are obtained. If the correction is made based on the detailed start date and time and the detailed end date and time, a schedule result in which the lead time of the entire supply chain is further shortened can be obtained.

  The above objects and advantages of the present invention and other objects and advantages will be more clearly understood through the following description of embodiments. However, the embodiments described below are merely examples, and the present invention is not limited to these.

It is a conceptual diagram which shows an example of the supply chain containing several factories to which this invention is applied. It is a figure which shows the input and output of the multiple factory production plan scheduling system MPPS which concern on this invention. It is a figure which shows the process and data flow in the multiple factory production plan scheduling system MPPS which concerns on this invention. It is a figure which shows the example of the adjusted FO produced | generated by FPA from the input FO and PO. It is a figure which shows the example which displayed the Gantt chart of the whole supply chain from the rough schedule result by MPRS. It is a conceptual diagram which shows an example which carries out rough schedule about the supply chain of FIG. 1 to which this invention is applied. It is a figure which shows the whole flow of the process of rough schedule by MPRS. It is a figure which shows the flow of MO allocation by finite capacity rough scheduling. FIG. 9A is a diagram illustrating a load state of a factory in MO allocation by finite capacity rough scheduling, and FIG. 9A is a diagram illustrating a state of overload immediately after stacking backwards in step S301 of FIG. FIG. 9B is a diagram illustrating a state in which the load is leveled by continuously crushing in the time axis direction by the processing of steps S303 to S306 in FIG. 8. It is a figure explaining the effect of lead time shortening by making a rough schedule recalculate based on the result of a detailed schedule of a factory. It is a conceptual diagram which shows another example of the supply chain containing a some factory. It is a conceptual diagram which shows another example of the supply chain containing a some factory.

100 Multi-factory production plan scheduling system (MPPS)
110 Multiple factory rough scheduling (MPRS)
130 Data Host (DH)
151-154 Detailed scheduling (DS)

  Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the drawings.

  FIG. 1 is a conceptual diagram showing an example of a supply chain to which the present invention is applied. In FIG. 1, S1, S2 are suppliers, F1, F2, F3, F4 are factories, and C1, C2 are customers. The factories F3 and F4 purchase the raw material Z1 from the suppliers S1 and S2, and process it to produce parts, semi-finished products, or raw materials (hereinafter collectively referred to as “parts”) Y1. The factories F1 and F2 purchase the parts Y1 from the factories F3 and F4 (receive supply), manufacture the product X1, and deliver it to the customers C1 and C2. In the present embodiment, the number of suppliers, the number of factories (two or more), the number of customers, the number of raw materials, the number of parts, and the number of products are as described above. However, this is an example, and these numbers are generally arbitrary. (The number of factories shall be 2 or more). That is, the above supply chain has n = 2, 3,... For factory Fn, supplier Sm, customer Cl, raw material Xi, part Yj, product Zk, and m, l, i, j, k = 1, It can be generalized as 2, 3,.

  Regardless of the supply chain illustration of FIG. 1, in general, raw materials may be supplied from any supplier to any factory. For example, a certain raw material may be supplied from the supplier S1 to the factory F1. In general, products may be supplied from any factory to any customer. For example, a certain product may be supplied from the factory F3 to the customer C1. The present invention corresponds to such an arbitrary case.

  FIG. 2 is a diagram showing inputs and outputs of a multi-plant production plan scheduling system MPPS (Multi Plant Planning and Scheduling) 100. The MPPS 100 may be implemented as a program or a group of program modules on a computer including a CPU, a large-capacity storage device such as a memory and a hard disk, and hardware such as a communication control unit. The computer constituting the MPPS 100 may be either a single computer or a plurality of computers connected to each other via a communication line.

  The MPPS 100 has a demand through an input device (for example, a terminal device such as a client computer connected to the computer via a communication network) installed in each factory, head office, or sales office. Prediction (Forecast Order), purchase order (Purchase Order), inventory results (Inventory), delivery results (Transportation Results), and work results (Operation Results) data are input at any time. When new data is input (data is added, changed, or deleted), the MPPS 100 calculates a multi-plant production plan (Multi Plant Planning) and a production schedule (Detail Schedule), and the optimal solution for the input at that time. The production plan / production schedule result calculated as is output. The output includes rough schedule results such as a Gantt Chart for the entire supply chain including multiple factories, detailed Gantt charts for orders, production, and purchases for each factory, and work instructions for production. Including schedule results.

FIG. 3 is a diagram showing a flow of processing and data in the multi-factory production plan scheduling system MPPS 100 according to the present embodiment. The MPPS 100 includes an MPRS (Multi Plant Rough Scheduling) 110 for multi-factory rough scheduling, a data host DH (Data Host) 130, and DS (F1) 151 and DS (F2) for detailed scheduling for each factory. ) 152, DS (F3) 153, DS (F4) 154.
The MPRS 110 creates a rough schedule for the entire supply chain including a plurality of factories. This rough schedule includes the creation of a production plan (Planning) including orders and purchases. DS (F1) 151, DS (F2) 152, DS (F3) 153, and DS (F4) 154 create detailed schedules for factories F1, F2, F3, and F4, respectively. The MPRS 110, DS (F1) 151, DS (F2) 152, DS (F3) 153, and DS (F4) 154 may be implemented in a computer as programs or program modules that run on the memory.

  The DH 130 uses various data (FO, PO, which will be described later) used for processing in the MPRS 110 and / or processing in the DS (F1) 151, DS (F2) 152, DS (F3) 153, and DS (F4) 154. , INV, MO, ROP, MBR, PB, OPR, TRR, etc.) are stored in a predetermined storage area. The DH 130 is preferably a mass storage device such as a hard disk.

Table 1 shows examples of properties (data items) that are commonly used for the demand forecast FO, purchase order PO, inventory INV, and production order MO. The distinction between FO, PO, INV, and MO is distinguished by the property “order type”. Table 1 is an example illustrating main properties of FO, PO, INV, and MO data, and the present invention is not limited to this.

  Hereinafter, the process performed by the MPPS 100 will be described in detail along the process and the data flow shown in FIG.

FOS: Demand Splitting FO (FO Split)

The FOS 121 divides a large time bucket demand forecast FO input from the outside into the DH 130 into designated small time buckets for each item / customer. This is because the demand forecast created in the large time bucket is leveled in the time direction. Specifically, the FOS 121 reads the FO from the DH 130 and generates a “divided FO” in which the FO quantity of the large time bucket is divided into the small time bucket quantities for each item / customer. For example, an FO (10 units per day) is generated by dividing a monthly production quantity (for example, 200 units) into daily production quantities in consideration of working days (for example, 20 days). The small time bucket is usually one day, but it may be half a day or 1/3 day, and is not particularly limited.
FO represents the “predicted quantity” of the period represented by the properties “start date and time” and “period” of the FO.

FPA: Adjustment by purchasing order PO of divided FO (FO-PO Adjustment)

The FPA 123 refers to the purchase order PO input from the outside to the DH 130 and adjusts the “divided FO” as a result of the FOS. This is because PO is a confirmed order from the customer, and it is necessary to adjust the “predicted quantity” in the FO. The adjustment here is performed by subtracting the overlap of FO and PO from the FO. Specifically, the FPA 123 subtracts the FO quantity from the PO quantity of the corresponding time bucket. Also, for a time bucket with a larger PO quantity, the PO quantity is subtracted from the FO of the nearest time bucket before that.
FIG. 4 shows an example of the adjusted FO generated by the FPA 123 from the FO and PO input to the FPA 123. The adjusted quantities of FO and PO are written in the FO and PO in the storage area related to the order in the DH 130. Specifically, the FO property “quantity” represents the adjusted FO quantity. The PO property “quantity” represents the PO quantity.

MPRS: Multi Plant Rough Scheduling

  The MPRS 110 performs multi-factory rough scheduling, which will be described in detail below, using the adjusted FO, PO, and inventory INV written in the FO and PO in the storage area related to the order in the DH 130. The MPRS 110 can output a Gantt chart of the entire supply chain based on the rough schedule result. FIG. 5 shows an example in which a Gantt chart of the entire supply chain is displayed from the rough schedule result by the MPRS 110.

  FIG. 7 shows an overall flow of rough schedule processing by the MPRS 110. As shown in FIG. 7, the processing by the MPRS 110 includes PO allocation (step S10), MO generation (step S20), MO allocation (step S30), and PO generation (step S40). Hereinafter, the flow of processing by the MPRS 110 will be described in detail with reference to FIG.

Step S10: PO assignment (assignment of delivery by purchase BOM to delivery resources)
The MPRS 110 refers to the purchase BOM (PB) from the adjusted FO and PO, selects a delivery resource for delivering the adjusted FO and PO order, and assigns the order. That is, the MPRS 110 first sets the PB setting information (required time, priority) set for each combination of a supplier (purchaser) and a customer (purchaser) and for each delivery resource (for example, truck, ship, aircraft, etc.). , Or cost, or a combination thereof), an evaluation value is obtained by a predetermined calculation formula. Based on this evaluation value, an appropriate supplier and delivery resource are determined, and the order is assigned to the delivery resource.
Table 2 shows examples of PB properties. Table 2 is an example illustrating main properties of PB data, and the present invention is not limited to this.

In the property of PB, “delivery resource” that can be used when “item” is delivered from “supplier” to “customer” is designated. The delivery date is set to “date specification”, and the delivery start time is set to “start”.
The PO properties “rough supplier”, “rough start date”, and “rough end date” are set by determining the supplier, delivery start date and time, and delivery end date and time by the PO assignment in step S10. Here, the supplier corresponds to a factory that manufactures the product (parts) of the order, or a supplier that supplies the product when the customer purchases the product (parts, raw materials).

Step S20: MO generation Next, the MPRS 110 links the FO and PO to the supplier's product inventory INV. When the INV is insufficient, the MPRS 110 automatically generates the production order MO in accordance with the preset production lot size. If INV is not short, MO is not generated.

Step S30: MO allocation MPRS 110 allocates the MO generated in step S20 to the production resource of the factory. For this allocation, the MPRS 110 reads a rough schedule manufacturing BOM (MBR: MB for Rough Scheduling), which will be described later, from the DH 130. If MBR, which is the result of MB Rough Transformation (MBRT), is used, even if the detailed schedule in each factory includes multiple processes, the MPRS110 process will process the entire factory as a single process and produce MO at the factory. Can be assigned to resources. The allocation method at this time may be one of infinite capacity scheduling (also called “infinite capacity scheduling”), finite capacity rough scheduling (Finite Capacity Rough Scheduling), or finite capacity scheduling (Finite Capacity Scheduling). Although it is possible, it is preferable to use finite capacity rough scheduling.

Each schedule method that can be used for MO allocation will be described.
Infinite capacity scheduling is a method of setting a schedule with a fixed lead time of MRP ignoring process interference caused by a plurality of orders, and generally does not lead to a reduction in production lead time. On the other hand, in the limited capacity scheduling, considering the load of resources, the optimal input timing of the process is calculated retroactively from the delivery date of the order, or the completion timing of the process is calculated from the start date and time of the order. Such calculation is performed in units of minutes and seconds. The former is also called “finite capacity backward scheduling”, and the latter is also called “finite capacity forward scheduling”. According to the finite capacity scheduling, it is possible to perform realistic scheduling in consideration of process interference caused by a plurality of orders, and it is possible to significantly reduce the production lead time compared to the infinite capacity scheduling.

  On the other hand, finite capacity rough scheduling is a method proposed by the present inventors in Patent Document 1 as a method capable of load adjustment with higher accuracy than infinite capacity scheduling with a fixed lead time of MRP. The details will be given to the disclosure of Patent Document 1, and here, the outline will be described with reference to FIGS.

FIG. 8 shows a flow of MO allocation by finite capacity rough scheduling. In the limited capacity rough scheduling, a plurality of MOs that can be allocated to a factory are allocated in a backward and / or forward manner, stacked, and then collapsed.
Referring to FIG. 8, first, each MO is allocated to backward and / or forward in a pile (step S301). Next, it is checked whether there is an overload (step S302). The time zone (excess time zone) in which the load is exceeded is specified (step S303). When there is an overload, for each MO related to the overtime zone, an average value of overload in the time zone to which the MO is assigned is calculated (step S304), and a constant (the constant is usually 1.0). By multiplying the above values, an expansion rate is calculated (step S305). Next, the MO occupation time is multiplied by the expansion rate (step S306). As a result, the load amount of the MO is divided by the expansion rate to reduce it. Next, the process returns to step S101 and is piled up again. Then, it is checked whether there is an overload for each resource, and if there is an overload, steps S303 to S306 and S301 are repeated. If there is no excess load, the process ends (step S302). The above process corresponds to a process of continuously mountain-developing from the backward and / or forward piled state in the time axis direction opposite to the allocation direction.

FIG. 9 is a diagram illustrating a load state of a factory in MO allocation by finite capacity rough scheduling, and FIG. 9A is a diagram illustrating a state of overload immediately after stacking backwards in step S301 of FIG. FIG. 9B is a diagram showing a state in which the load is leveled by continuously crushing in the time axis direction by the processing of steps S303 to S306 in FIG. In this way, in the limited capacity rough scheduling, it is possible to calculate the earliest MO input timing (rough start date and time) while eliminating the excess load.
The MO properties “rough start date and time” and “rough end date and time” are set by determining the manufacturing start date and time and the manufacturing end date and time in the factory by the MO assignment in step S30.

Step S40: PO generation (requirement calculation by MBR)
The MPRS 110 uses MBR (MB for Rough Scheduling) to calculate the required amount of raw materials for the MO, and links the necessary raw materials to the INV. When the INV is insufficient, the MPRS 110 automatically generates a PO in accordance with a preset purchase lot size. And it returns to PO allocation of step S10.
The processes from step S10 to step S40 are repeated until there is no PO to be allocated (step S50).
Then, the MPRS 110 writes the rough schedule result to the PO (and / or FO) and MO of the storage area related to the order in the DH 130.

  In the example of the Gantt chart of the entire supply chain shown in FIG. 5, when the process for generating rough scheduling of the supply chain shown in FIG. 6 is confirmed, the processing is as follows. Here, consider a case where the customer C1 purchases a certain quantity of the product X1. The product X1 is manufactured by processing the part Y1 in the factory F1 or F2, and the part Y1 is manufactured based on the raw material Z1 in the factory F3 or F4.

First, by the PO assignment in step S10, the optimum supplier and delivery resource are obtained from the factories F1 and F2 that can supply the product X1 to the customer C1 (as a result, the supplier F2 and the delivery resource 1 are determined), and the product X1 is assigned to the supplier. The PO (and / or FO) of the product X1 is assigned to “delivery resource 1” to be delivered from F2 to the customer C1. At this time, the PO properties “rough supplier” (= F2), “rough start date / time”, and “rough end date / time” related to the product X1 are set. This corresponds to the first purchase order allocation step in the present invention.
In the MO generation of the next step S20, the PO of the product X1 assigned to the “delivery resource 1” is linked to the INV of the product X1 of “F2: product stock” in the factory F2. However, since the INV of the product X1 is insufficient in the factory F2, the MO of the product X1 is generated. This corresponds to the first production order generation step in the present invention.
In the next MO allocation in step S30, the MO of the product X1 is allocated to the production resource “F2: manufacturing process” of the factory F2. At this time, the MO properties “rough start date and time” and “rough end date and time” of the factory X2 related to the product X1 are set. This corresponds to the first production order allocation step in the present invention.
In the PO generation at the next step S40, the MO of the product X1 assigned to the production resource “F2: manufacturing process” is linked to the INV of the part Y1 of “F2: raw material inventory”. However, since the INV of the component Y1 is insufficient, the PO of the component Y1 is generated. This corresponds to the first purchase order generation step in the present invention.

Since it is necessary to assign the PO of the part Y1 to the next delivery resource, the process returns to step S10, and the optimal supplier and delivery resource among the factories F3 and F4 that can supply the part Y1 to the customer F2 by the PO assignment. (As a result, the supplier F4 and the delivery resource 2 are determined), and the PO of the part Y1 is assigned to “delivery resource 2” that delivers the part Y1 from the supplier F4 to the customer F2. At this time, the PO properties “rough supplier” (= F4), “rough start date and time”, and “rough end date and time” for the part Y1 are set. This corresponds to the second purchase order allocation step in the present invention.
In the next MO generation in step S20, the PO of the part Y1 assigned to “delivery resource 2” is linked to the INV of the part Y1 of “F4: product inventory” in the factory F4. However, since the INV of the component Y1 is insufficient in the factory F4, the MO of the component Y1 is generated. This corresponds to the second production order generation step in the present invention.
In the next MO allocation in step S30, the MO of the part Y1 is allocated to the production resource “F4: manufacturing process” of the factory F4. At this time, the properties “rough start date” and “rough end date” of the MO related to the part Y1 in the factory F4 are set. This corresponds to the second production order allocation step in the present invention.
In the PO generation at the next step S40, the MO allocated to the production resource “F4: Manufacturing process” is linked to the INV of the raw material Z1 of “F4: Raw material inventory”. However, since the INV of the raw material Z1 is insufficient, PO of the raw material Z1 is generated. This corresponds to the second purchase order generation step in the present invention.
Returning to step S10, by the PO assignment, the optimum supplier and delivery resource are obtained from the suppliers S1 and S2 that can supply the raw material Z1 to the customer F4 (as a result, the supplier S1 and the delivery resource 3 are determined). The PO of the raw material Z1 is assigned to “delivery resource 3” delivered from the supplier S1 to the customer F4. At this time, the PO properties “rough supplier” (= S1), “rough start date”, and “rough end date” related to the raw material Z1 are set. This corresponds to the third purchase order allocation step in the present invention.

  The MPRS 110 reads FO, PO, and MO data written in the storage area related to the order in the DH 130, and outputs the rough schedule result of the supply chain to an output device such as a display or a printer. Thereby, visualization of the entire supply chain can be realized.

  In the prior art, there was no schedule including delivery of a finished product. In other words, in the prior art, scheduling is not performed with respect to the customer delivery date but with respect to the production completion delivery date, and the delivery is merely taking a fixed buffer period of a rough period. For this reason, the judgment whether it is in time for delivery was not performed accurately. In contrast to such a conventional technique, in this embodiment, in the rough schedule PO allocation by the MPRS 110, the PB setting set for each combination of the supply destination and the supply source and for each selectable delivery resource By a calculation process using information, a supply source and a delivery resource of an object are determined, and a purchase order is assigned to the determined delivery resource. Therefore, according to the present embodiment, the PB is referred to in the rough schedule in the MPRS 110, and the delivery route (where the supply is received from) and the delivery resource (which means is used for delivery) with respect to the customer delivery date. ) Can be created automatically. That is, according to the present embodiment, it is extremely advantageous because it is possible to create a schedule that prioritizes the observance of the customer delivery date and further shortens the lead time as seen from the entire supply chain.

DS (F1), DS (F2), DS (F3), DS (F4): Detailed scheduling of each factory

  Next, creation of a detailed schedule using DS (F1) 151, DS (F2) 152, DS (F3) 153, and DS (F4) 154 will be described.

  Input FO, PO (order of delivery date of the detailed schedule period among all orders), and MO to DS (F1) 151, DS (F2) 152, DS (F3) 153, DS (F4) 154, Schedule in detail. The FO, PO, and MO data necessary for the detailed schedule can be read from the order area in the DH 130. The flow of the detailed schedule process is outlined as follows.

(A) Input necessary ones of FO and PO. What is necessary is an order in which the property “customer” or “supplier” of the FO and PO is the own factory. (For example, when processing with DS (F1) 151, the property “customer” or “supplier” is for F1. When processing with DS (F2) 152, the property is for F2. In addition, when there is a track record, the necessary one of INV is input in the same manner.
(B) Input necessary ones of MOs. What is required is an order in which the property “customer” of the MO is its own factory, that is, an order produced at its own factory.
(C) Refer to the necessary PB. What is needed is a PB whose PB property “customer” or “supplier” is its own factory.
(D) A detailed schedule is made based on the input data. This detailed schedule is preferably by finite capacity scheduling.

  In the production scheduling by the limited capacity scheduling, when a plurality of processes are included in the production schedule of each factory, the plurality of processes are naturally taken into consideration. Specifically, referring to the MB, the MO is expanded to create a network of work OPs, and each work is assigned to each factory resource based on the MB in the order specified by the predetermined plan parameters. (Machines, personnel, tools, etc.). As a result, it is possible to create a detailed production schedule in which all OPs are allocated to resources with limited capacity and production lead time is shortened.

  Next, DS (F1) 151, DS (F2) 152, DS (F3) 153, and DS (F4) 154 of each factory are determined based on the detailed production schedule information created as described above and the necessary amount of raw materials or parts. Calculate the required timing. According to the present embodiment, even in the case of a detailed schedule, by referring to the PB stored in the DH 130 and executing the same process as the PO allocation (step S10) in the rough schedule, the delivery route and delivery A detailed schedule that takes into account resources can be created automatically.

  As described above, DS (F1) 151, DS (F2) 152, DS (F3) 153, DS (F4) 154 are MO, PO, and work information of the process of the own factory as detailed schedule results in the own factory. A certain OP (Operation) is output.

  The detailed schedule result is written in MO and PO in the storage area related to the order in DH130. That is, the MO properties “detailed start date and time” and “detailed end date and time” of the own factory are set as detailed schedule results. Also, the properties “detailed supplier”, “detailed start date / time”, and “detailed end date / time” of the PO whose own factory is “customer” are set. Furthermore, the properties “answer supplier”, “answer start date”, and “answer end date” of the PO whose own factory is “supplier” are set. Here, in a normal case where multiple processes are included in the production schedule of the own factory, the information of the earliest start date and time and the last end date and time is acquired from the start date and time and end date and time of the multiple processes as the detailed schedule result. Then, the detailed start date and time and detailed end date and time of the MO are set.

  On the other hand, the OP as a detailed schedule result has properties (for example, work item, work quantity, task type, start date / time, end date / time, instruction type, order to be linked, etc.) related to work / task / instruction.

OPRT: Rough transformation of detailed schedule results (Operation Rough Transformation)

The DS (F1) 151, DS (F2) 152, DS (F3) 153, and DS (F4) 154 in each factory are provided with OPRTs 161. The OPRT 161 rough-transforms the OP to generate ROP (Rough OP) representing the link information between orders.
Table 3 shows examples of ROP properties. Table 3 is an example illustrating main properties of ROP data, and the present invention is not limited to this.

  As described above, the ROP generated by the OPRT 161 based on the OP (Operation) represents the order link information. Each order (MO, PO, and / or FO) specified by the OP order code can have a plurality of input instructions and a plurality of output instructions as a detailed schedule result. Here, the input instruction indicates the input of the raw material to the order, and the output instruction indicates the output of the product and by-product from the order. The ROP generated by the OPRT 161 is written in the ROP in the storage area related to work in the DH 130.

According to the present embodiment, PO and / or FO start / end information as detailed schedule results of each factory by DS (F1) 151, DS (F2) 152, DS (F3) 153, DS (F4) 154 And the link information between orders at any time (at
any time), stored in the DH. And MPRS110 can refer to the said information stored in DH130 at any time. Therefore, the MPRS 110 can update the rough schedule result to a more correct result based on the detailed schedule result.

  For example, if it is found from the detailed schedule result of a certain factory that the load is overloaded, the PO that was set as the supplier in the rough schedule process immediately before the detailed schedule process is divided, and the other factory is set as the supplier. The MPRS 110 recalculates the multi-factory rough schedule so that a new PO to be generated is generated and the MO allocated to the production resources of the factory is reduced. Thereby, the overload in the detailed schedule can be effectively solved.

  On the other hand, for example, when it is found from the detailed schedule result of a certain factory that the production lead time can be shortened, the MPRS 110 is made to recalculate the rough schedule of a plurality of factories based on the detailed schedule result of each factory. Thereby, the rough schedule result which shortened the lead time of the whole supply chain more can be obtained. The reason will be specifically described with reference to FIG.

  FIG. 10A is a diagram illustrating an example of a Gantt chart showing a rough schedule result by the MPRS 110 at a time point before the latest detailed schedule in the factory F1 is calculated and reflected. The Gantt chart shows the POs that are supplied from the factory F1, the MOs that are linked to the POs, and the POs that are linked to the production resources of the factory F1, and the POs that are supplied from the factory F1. ing. FIG. 10B is a diagram showing an example of a Gantt chart showing the latest detailed schedule result of the factory F1 by the DS (F1) 151. In this example, the production schedule of the factory F1 includes a plurality of processes A, B, C, and D in which the MO is expanded. However, among the start date / time and end date / time of a plurality of processes in the detailed schedule result, the earliest start date / time and last end date / time are set as the detailed start date / time and detailed end date / time of the MO shown in FIG. By comparison, it can be seen that the earliest start date / time may be later than the detailed start date / time of the MO. That is, it can be seen that the MO production lead time can be shortened. FIG. 10C obtains the detailed start date and time and the detailed end date and time of PO, FO, and MO as at least the detailed schedule result of the factory F1 by the DS (F1) 151 from the DH 130, and based on this. It is a figure which shows an example of the Gantt chart which shows the rough schedule result when making MPRS110 recalculate. It can be seen that the production lead time can be further reduced as compared with FIG. Further, in accordance with the shortening of the production lead time, the timing (raw material ordering timing) P at which the factory F1 places an order with the raw material or component supplier can be delayed to P '. As a result, it can be seen that the stock of raw materials or parts in the factory F1 can be further reduced.

  According to the present embodiment, in addition to the above-described advantages, the DH 130 includes schedule results (PO, F1) 151, DS (F2) 152, DS (F3) 153, and DS (F4) 154 of each factory. MO, ROP) is stored as needed, so that the latest detailed schedule results of each other can be referred to at each factory. Thus, at each factory, for example, PO delivery date reply information (PO properties “answer start date” and “answer end date”) for purchasing raw materials or parts from suppliers can be obtained between factories. The detailed schedules can be linked.

MBRT: MB Rough Transformation

MBRT163 is provided in DS (F1) 151, DS (F2) 152, DS (F3) 153, DS (F4) 154 of each factory. The MBRT 163 converts the MB for the detailed schedule into a manufacturing schedule BOM (MBR: MB for Rough Scheduling) for the rough schedule, and outputs it to the DH 130.
Table 4 shows an example of MB properties. Table 4 is an example illustrating main properties of MB data, and the present invention is not limited to this.

  Specifically, the MB rough conversion by MBRT 163 is based on the MB of the own factory that DS (F1) 151, DS (F2) 152, DS (F3) 153, and DS (F4) 154 of each factory refer to. This means that the MBR is generated by the process of removing the MB property “instruction type” that is the use instruction. The use instruction indicates each resource (machine, personnel, tool, etc.) used in the order.

  The MBR generated by the MBRT 163 based on the MB is used for the rough schedule in the MPRS 110 as described above. That is, according to the present embodiment, the MB for the detailed schedule and the MBR for the rough schedule can be integrated through conversion by MBRT.

  Since the MB data of each factory is detailed and enormous, it is not realistic for the MPRS 110 to execute a rough schedule using an MB because it takes a huge amount of time for processing, but it is generated by MBRT163. The use of the MBR helps to greatly reduce the rough schedule load on the MPRS 110.

  By the way, MB and PB are conventionally created, input, and maintained by an operator. However, since these BOM data are detailed and enormous, these operations require a great deal of labor and time. In the present embodiment, the OPRE 165 described below supports MB construction and maintenance based on work results, and the TRRE 125 supports PB construction and maintenance based on delivery results.

OPRE: Operation Results Evaluation

In each factory DS (F1) 151, DS (F2) 152, DS (F3) 153, DS (F4) 154, an OPRE 165 is provided. The OPRE 165 analyzes the work performance OPR that is input from the input device of each factory at any time, and suggests a change of the MB.
The OP includes information about when to start and end which task (pre-setup, manufacturing, post-setup) is used in which resource in a certain work process for a certain item. The OP information is presented to the worker as a work instruction, and the worker performs work according to the work instruction. Then, OPR is input when the worker starts the work and when the work is completed. When an identification tag such as an RFID (Radio Frequency Identification) or a barcode is attached to the raw material / part / product, the OPR may be automatically recorded by reading it in the manufacturing process. The DH 130 stores OPR input from the outside as needed.
Table 5 shows examples of OPR properties. Table 5 is an example illustrating main properties of OPR data, and the present invention is not limited to this.

As described above, OPR is information representing the actual required time (work end date-work start date) of the finished work.
The OPRE 165 of each factory uses a plurality of OPRs read out from the DH 130 and the MB of the own factory, and (a) distribution of required times in factories, items, processes, resources, and tasks from a plurality of OPRs by statistical processing. The average value, minimum value, maximum value, standard deviation, and probability distribution graph of the required time are output, and (b) the deviation from the set value of the current MB is output and the ranking with a large deviation is output. Is output. In addition, the OPRE 165 of each factory is configured to list (c) work results that have not occurred so far (for example, when resources (for example, machines) not specified in the current MB are exceptionally used). can do. This means that there is a possibility that new usage instructions (use of workers and machines), input instructions (input of raw materials and parts), and output instructions (output of products and by-products) must be added to the current MB. Show.

  For example, statistical processing of the time required for a plurality of OPRs for a certain work at its own factory resulted in an average of 10 minutes, but the time required for the process specified by the current MB is set to 15 minutes. If so, OPRE 165 can be configured to suggest a change in MB.

  After these reports from the OPRE 165 are checked by the person in charge, when the operation input instructing the MB change is given to the OPRE 165 by the person in charge, the OPRE 165 changes the MB.

  In the conventional system, it was necessary for an operator to create, input, and maintain a detailed and enormous MB. However, according to the present embodiment, the OPRE 165 converts the MB into an MB based on a plurality of OPRs. Data can be added or changed and MB construction and maintenance can be automated or semi-automated.

TRRE: Delivery Results Evaluation

The MPRS 110 is provided with a TRRE 125. The TRRE 125 analyzes the delivery record TRR and suggests a change in the PB.
The TRR is information on when a certain item is delivered from a certain supplier to a certain customer using a certain delivery resource, and when it starts and ends and how long it takes. TRR is input when PO delivery starts or when delivery is completed. When an identification tag such as an RFID or a barcode is attached to the raw material / part / product, the TRR may be automatically recorded by reading it in the delivery process. The DH 130 stores TRR input from the outside as needed.
Table 6 shows examples of TRR properties. Table 6 is an example illustrating main properties of TRR data, and the present invention is not limited to this.

As described above, TRR is information representing the actual time required for completed delivery.
The TRRE 125 uses the plurality of TRRs read out from the DH 130 and the PB, and (a) obtains a distribution of required times in the supplier, customer, item, and delivery resource from the plurality of TRRs by statistical processing. A graph of an average value, a minimum value, a maximum value, a standard deviation, and a probability distribution is output, and (b) a deviation from the current PB set value is output, and a ranking with a large deviation is output. The TRRE 125 can also be configured to list (c) delivery results that have not occurred so far. This indicates the possibility of adding a new PB to the current PB.

  For example, the statistical processing of the time required for a plurality of TRRs for a certain delivery whose own factory is “customer” resulted in an average of 1 hour, but the time required for the delivery resource specified by the current PB If set to 1 hour 20 minutes, TRRE 125 can be configured to suggest a change in PB.

  After these reports from the TRRE 125 are checked by the person in charge, the TRRE 125 changes the PB when an operation input instructing the change of the PB is given to the TRRE 125 by the person in charge. As a result, for example, the change in PB is reflected in the subsequent rough schedule or the detailed schedule, so that the PO raw material ordering timing can be delayed to reduce the inventory.

  In the conventional system, a detailed and enormous amount of PB also has to be created, input, and maintained by an operator. According to the present embodiment, the PRE is based on a plurality of TRRs using TRRE 125. Data can be added to or changed, and PB construction and maintenance can be automated or semi-automated.

  In this embodiment, communication between the MPRS 110 and the DH 130, and between the DH 130 and the DS (F1) 151, DS (F2) 152, DS (F3) 153, and DS (F4) 154 of each factory. There are no particular limitations on the communication method and transmission path in communication. For example, it may be via a communication network including various communication lines such as a dedicated line, a public telephone line, a satellite communication line, and various servers. Moreover, it is good also as a structure which ISP (Internet Service Provider) and NSP (Network Service Provider) interpose in a communication network.

  In the above embodiment, the example shown in the supply chain shown in FIGS. 1 and 6 and the Gantt chart shown in FIG. 5 is that the raw material or component (raw material Z1) is supplied from the (external) supplier to the second factory. The second object (part Y1) is produced in the second factory and supplied to the first factory, and the first object (product X1) is produced in the first factory and supplied to the consumer. An example is shown. That is, in the above embodiment, a supply chain of a plurality of factories has a first factory on the downstream side that supplies a first object to a customer, and an upstream side that supplies raw materials or parts to the first factory. It was an example including a second factory. However, the present invention is not limited to this. For example, the supply chain may include a third factory upstream from the second factory where the supply chain itself produces raw materials or parts to be supplied to the second factory. Good.

FIG. 11 is a conceptual diagram showing another example of a supply chain including a plurality of factories, and includes a third factory that supplies the parts Z1 to the second factory. The third factory receives supply of the part A1 from the (external) supplier.
The third factory, the second factory downstream, the first factory further downstream, and the process that generates rough scheduling of the customer's supply chain, the third factory, the raw material Z1 itself Then, a process for generating rough scheduling of the supply chain shown in FIG. 6 when it is regarded as a “(first) supplier” to be supplied to the second factory downstream (first purchase order allocation step) To the third purchase order allocation step), and detailed description thereof is omitted here. As a result of the PO allocation in step S10 corresponding to the third purchase order allocation step, the PO properties “rough supplier” (= F5), “rough start date” and “rough end date” related to the raw material Z1 are set. It shall be.

Subsequent to the PO allocation in step S10 corresponding to the third purchase order allocation step, in the MO generation in step S20, the raw material Z1 allocated to “delivery resource 3” (in the following description, this is referred to as “part Z1”). The PO in the third factory (F5) is linked to the INV of the part Z1 of “F5: product inventory”. However, since the INV of the part Z1 is insufficient in the factory F5, the MO of the part Z1 is generated. This corresponds to the third production order generation step in the present invention.
In the next MO allocation in step S30, the MO of the part Z1 is allocated to the production resource “F5: manufacturing process” of the factory F5. At this time, the properties “rough start date and time” and “rough end date and time” of the MO related to the part Z1 in the factory F5 are set. This corresponds to the third production order allocation step in the present invention.
In the PO generation of the next step S40, the MO allocated to the production resource “F5: Manufacturing process” is linked to the INV of the raw material A1 of “F5: Raw material inventory”. However, since the INV of the raw material A1 is insufficient, PO of the raw material A1 is generated. This corresponds to the third purchase order generation step in the present invention.
Returning to Step S10, the optimal supplier and delivery resource are obtained from the suppliers S1 and S2 that can supply the raw material A1 to the customer F5 by PO allocation. As a result, the supplier S1 and the delivery resource 4 are determined. The PO of the raw material A1 is assigned to “delivery resource 4” delivered from the supplier S1 to the customer F5. At this time, the PO properties “rough supplier” (= S1, corresponding to the second supplier in the present invention), “rough start date”, and “rough end date” are set for the raw material A1. This corresponds to the fourth purchase order allocation step in the present invention.

  The present invention further illustrates an example of a supply chain including the first factory, the second factory upstream thereof, and the third factory upstream thereof described with reference to FIG. As shown, supply the raw materials or parts At to the (p + 2) factory and the (p + 2) factory that supply the raw materials or parts At to the downstream (p + 1) factory. It can be generalized and applied in the case of a supply chain. That is, the present invention can further include the following configurations. Here, for the (p + 1) th factory and the (p + 2) factory, p = 2, 3,..., And for the raw materials or parts At and Bu, t, n = 1, 2, 3,.・ It is.

  When the supplier who assigned the purchase order of raw materials or parts (At) whose customers are the (p + 1) factory in the (p + 2) purchase order allocation step is the (p-1) supplier, The p-th supplier is the (p + 2) factory upstream of the (p + 1) factory where the raw material or part (At) is produced by itself, and also serves as the p-th supplier. When the raw material or part (At) produced by the (p + 2) factory is the (p + 2) th object, at least one (p + 1) supplying the raw material or part (Bu) of the (p + 2) th object. ) (Where p = 2, 3,...), As a result of the (p + 2) purchase order allocation step, the (p + 2) th object in the (p + 2) factory. When the inventory performance of (At) is insufficient, A (p + 2) manufacturing order allocation step of generating a manufacturing order of the (p + 2) th object (At) and allocating the manufacturing order to the production resources of the (p + 2) factory; As a result of the (p + 2) production order assignment step, the raw materials or parts of the (p + 2) -th object (At) are insufficient, and the inventory results of the raw materials or parts (Bu) possessed by the (p + 2) factory are insufficient. A purchase order generation step of (p + 2) and (p + 2) purchase order generation step of generating a purchase order of the raw material or part (Bu) with the (p + 2) factory as a customer. (P + 1) supplier and delivery of the raw material or part (Bu) to the (p + 2) factory for the resulting raw material or part (Bu) purchase order Determining a source and allocating a purchase order of the raw material or part (Bu) to the delivery resource, a (p + 3) th purchase order allocation step, wherein the purchase order allocation step includes: The supply source and the delivery resource of the target object are determined by the arithmetic processing using the purchase BOM setting information set for each combination with the supply source and for each selectable delivery resource, and the purchase order is assigned to the determined delivery resource. Is assigned.

  In the supply chain shown in FIGS. 1, 6, 11, and 12, there are two factories that produce the same objects, raw materials or parts, and two suppliers that supply the same raw materials or parts. Although an example is shown, if the same object can be produced in three or more factories, if there are three or more suppliers, the (p + 2) th from the first factory The present invention is applied to the above-described embodiment even when there is only one q-th factory (q = 2, 3,..., Or p + 1) that produces a certain target object, raw material, or part. Of course, it is possible to obtain the same effect as in the above.

  As described above, the embodiments have been described with reference to the drawings. However, the present invention is not limited to these, and appropriate modifications can be made without departing from the spirit of the present invention.

  The present invention is applied to the production schedule system of companies that have globalized manufacturing industries, have production bases in various parts of the world, and want to link production schedules of multiple factories, and visualize the entire supply chain, leading the entire supply chain. Helps reduce time, reduce inventory, and meet delivery times.

Claims (10)

By assigning purchase orders and / or demand forecasts and production orders of at least one object (Xi) produced in a plurality of factories (Fn) in the time axis direction, raw materials or parts (Yj) of the object (Xi) A multi-factory production schedule generation method for generating a supply chain production plan including at least one supplier (Sm), a plurality of factories (Fn), and at least one customer (Cl).
Inputting the purchase order and / or demand forecast of the object and raw materials or parts (Xi, Yj), and inventory information via an input device;
For the purchase order and / or demand forecast of the object (Xi), a first factory and a delivery resource that supply the object (Xi) to a customer (Cl) are determined, and the object (Xi) A first purchase order allocation step of allocating a purchase order and / or demand forecast of the distribution resource to the delivery resource;
When the inventory result of the object (Xi) in the first factory is insufficient as a result of the first purchase order allocation step, a production order for the object (Xi) is generated, and the production order is A production order assignment step for assigning to the production resources of one factory;
As a result of the manufacturing order allocation step, when the inventory of the raw material or part (Yj) in the first factory is insufficient, a purchase order of the raw material or part (Yj) with the first factory as a customer is generated A first purchase order generation step;
For a purchase order of the raw material or part (Yj) generated as a result of the first purchase order generation step, a supplier and a delivery resource for supplying the raw material or part (Yj) to the first factory are determined. A second purchase order assigning step for assigning a purchase order of the raw material or part (Yj) to the delivery resource;
The purchase order and / or demand forecast assigned to the delivery resource, stored in relation to each other in the storage device, and the start date and time information of the production order assigned to the production resource are read from the storage device, Outputting a supply chain schedule result to an output device, and
The first and second purchase order allocating steps are performed by an arithmetic process using purchase BOM setting information set for each combination of a supply destination and a supply source and for each selectable delivery resource. A production schedule creation method for a plurality of factories, characterized in that a supplier and a delivery resource are determined, and a purchase order is assigned to the decided delivery resource. Purchase orders of a first object (Xi) produced at a first factory downstream of a plurality of factories (Fn) and a second object (Yj) produced at a second factory upstream. And / or at least one supplier (Sm) supplying a raw material or part (Zk) of the second object (Yj) by allocating the demand forecast and the production order in the time axis direction, a plurality of factories ( Fn), and a multi-factory production schedule creation method for generating a production plan for a supply chain including at least one customer (Cl),
Inputting the purchase order and / or demand forecast of the first and second objects and raw materials or parts (Xi, Yj, Zk), and inventory information via an input device;
For a purchase order and / or demand forecast of the first object (Xi), a first factory and a delivery resource for delivering the first object (Xi) to a customer are determined, and the first object A first purchase order allocating step of allocating a purchase order and / or demand forecast of (Xi) to the delivery resource;
When the inventory result of the first object (Xi) in the first factory is insufficient as a result of the first purchase order allocation step, a production order for the first object (Xi) is generated, A first production order assignment step for assigning the production order to the production resource of the first factory;
As a result of the first production order assignment step, there is a shortage of inventory results of the second object (Yj) held by the first factory, which is a raw material or part of the first object (Xi). A first purchase order generation step of generating a purchase order of the second object (Yj) with the first factory as a customer;
A second factory that supplies the second object (Yj) to the first factory for the purchase order of the second object (Yj) generated as a result of the first purchase order generation step. A second purchase order assigning step for determining a delivery resource and assigning a purchase order for the second object (Yj) to the delivery resource;
As a result of the second purchase order allocating step, when the inventory record of the second object (Yj) in the second factory is insufficient, a production order of the second object (Yj) is generated, A second production order assigning step for assigning the production order to production resources of the second factory;
As a result of the second production order assigning step, when the raw materials or parts of the second object (Yj) and the raw materials or parts (Zk) held by the second factory are insufficient, A second purchase order generation step of generating a purchase order of the raw material or part (Zk) with the second factory as a customer;
For a purchase order of the raw material or part (Zk) generated as a result of the second purchase order generation step, a supplier and a delivery resource for supplying the raw material or part (Zk) to the second factory are determined. A third purchase order assigning step for assigning a purchase order of the raw material or part (Zk) to the delivery resource;
The purchase order and / or demand forecast assigned to the delivery resource, stored in relation to each other in the storage device, and the start date and time information of the production order assigned to the production resource are read from the storage device, Outputting a supply chain schedule result to an output device, and
In the first, second, and third purchase order allocation steps, calculation processing using the purchase BOM setting information set for each combination of a supply destination and a supply source and for each selectable delivery resource A method for creating a production schedule for a plurality of factories, wherein a supply source and a delivery resource of an object are determined and a purchase order is assigned to the determined delivery resource. When the supplier who assigned the purchase order of the raw material or part (Zk) whose customer is the second factory in the third purchase order assignment step is the first supplier, the first supplier The supplier produces the raw material or part (Zk) by itself, is a third factory upstream from the second factory, and is produced by the third factory that also serves as the first supplier. When the raw material or part (Zk) is the third object, when there is at least one second supplier supplying the raw material or part (At) of the third object (Zk),
As a result of the third purchase order allocating step, when the inventory record of the third object (Zk) in the third factory is insufficient, a production order of the third object (Zk) is generated, A third production order assigning step for assigning the production order to the production resources of the third factory;
As a result of the third production order allocation step, when the raw materials or parts of the third object (Zk) and the inventory results of the raw materials or parts (At) held by the third factory are insufficient, A third purchase order generation step of generating a purchase order of the raw material or part (At) with the third factory as a customer;
A second supplier and a delivery resource that supply the raw material or part (At) to the third factory for the purchase order of the raw material or part (At) generated as a result of the third purchase order generation step. And assigning a purchase order of the raw material or part (At) to the delivery resource, a fourth purchase order assigning step;
Further including
In the same manner, the supplier who assigned the purchase order of raw materials or parts (At) whose customers are the (p + 1) factory in the (p + 2) purchase order allocation step is referred to as the (p-1) supplier. The p-th supplier is the (p + 2) factory upstream of the (p + 1) factory where the raw material or part (At) is produced by itself, and the p-th supplier When the raw material or part (At) produced by the (p + 2) factory that also serves as the operator is the (p + 2) target, at least one of the raw material or part (Bu) of the (p + 2) target is supplied. If there are two (p + 1) th suppliers (where p = 2, 3,...),
As a result of the (p + 2) purchase order allocating step, when the inventory record of the (p + 2) th object (At) in the (p + 2) factory is insufficient, the (p + 2) th object (At) A (p + 2) manufacturing order allocation step, wherein the manufacturing order is generated, and the manufacturing order is allocated to the production resource of the (p + 2) factory.
As a result of the (p + 2) manufacturing order allocation step, the raw materials or parts of the (p + 2) target object (At), and the inventory results of the raw materials or parts (Bu) held by the (p + 2) factory (P + 2) purchase order generation step of generating a purchase order of the raw material or part (Bu) with the (p + 2) factory as a customer,
For the purchase order of the raw material or part (Bu) generated as a result of the (p + 2) th purchase order generation step, supply the raw material or part (Bu) to the (p + 2) factory (p + 1) A (p + 3) th purchase order allocation step of determining a supplier and a delivery resource, and allocating a purchase order of the raw material or part (Bu) to the delivery resource;
Further including
In the purchase order allocation step, the supply source and the delivery resource of the target object are calculated by arithmetic processing using the setting information of the purchase BOM set for each combination of the supply destination and the supply source and for each selectable delivery resource. The production schedule creation method for a plurality of factories according to claim 2, wherein purchase orders are allocated to the determined delivery resources. The production order allocation step includes:
The method includes the steps of: allocating production orders by finite capacity rough scheduling in which a plurality of production orders that can be allocated to the production resources are allocated in a backward and / or forward manner, and then collapsed. A production schedule creation method for a plurality of factories according to 1 or 2. Order information necessary for creating a detailed schedule for producing an object at each factory of the plurality of factories (Fn) among purchase orders and / or demand forecasts of the object and raw materials or parts, and manufacturing orders. A detailed schedule creation step for creating a detailed schedule for each factory by finite capacity scheduling using the manufacturing BOM setting information set for each process,
A detailed schedule storage step of storing the purchase order and / or demand forecast and the detailed start date and time and the detailed end date and time of the production order created in the detailed schedule creation step in the storage device as a detailed schedule result; The production schedule creation method for a plurality of factories according to claim 1, wherein the production schedule is created. Inputting actual delivery start date and time and delivery end date and time information according to the purchase order as a delivery record for each purchase order;
Analyzing the time required for delivery from a plurality of delivery record information input in the delivery record input step, and outputting a suggestion to change the corresponding purchase BOM setting information according to the analysis result;
The plurality of plants according to claim 1, further comprising: changing the corresponding purchase BOM in response to an input of a signal for approving the change suggested by the purchase BOM change suggestion step. Production schedule creation method. A step of generating corrected manufacturing BOM information for each factory by a process of removing information indicating the use of resources used for each process in the factory from among the information of the manufacturing BOM used for creating the detailed schedule. In addition,
In the manufacturing order allocation step, or in the first manufacturing order allocation step and the second manufacturing order allocation step, the setting information of the corrected manufacturing BOM of each factory is referred to, and the manufacturing order is assigned to the production resource of each factory. The production schedule creation method for a plurality of factories according to claim 5, wherein the production schedules are assigned. Entering information on the actual start date and time and actual end date and time of actual work according to the production order as work results for each production order;
Analyzing the time required for the work from the information on the plurality of work results input in the work result input step, and outputting a suggestion to change the setting information of the corresponding manufacturing BOM according to the analysis result;
The multi-factory production according to claim 5, further comprising: changing the corresponding manufacturing BOM in response to an input of a signal that approves the change suggested by the manufacturing BOM change suggesting step. Schedule creation method. Of the detailed schedule result created by the detailed schedule creation step, based on the work information of the process of each factory, generating information representing the relationship between orders;
Storing the information generated by the association information generation step and representing the relationship between orders in the storage device; and
The production schedule creation method for a plurality of factories according to claim 5, further comprising: The detailed schedule storage step, at least, of the start date and time and the end date and time of a plurality of processes in each factory created by the detailed schedule creation step, obtain the information of the earliest start date and time and the last end date and time, Including the process of setting the detailed start date and time and the detailed end date and time of the manufacturing order;
The detailed start date / time and the detailed end date / time of the purchase order and / or demand forecast or production order stored in the storage device by the detailed schedule storage step are acquired, and the supply chain created before the detailed schedule creation step The production schedule creation method for a plurality of factories according to claim 5, further comprising a step of correcting a schedule result based on the acquired detailed start date and time and detailed end date and time.

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