JP2012221124A - Production plan creation system - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a production plan creation system for supporting production plan creation for producing a plurality of types of products in the same production facility while maintaining production efficiency.SOLUTION: A production plan creation system for performing order production and expected production of a plurality of types of products in the same production facility includes: a storage part 30 for storing order reception information of a plurality of types of products, expected production information of the plurality of types of products and the similarity of the mutual products; and a production plan making part 22 for creating a production plan of the order production and expected production. The production plan making part 22 is configured to arrange a production schedule of order products in the production facility on the basis of the time of delivery of the order reception information, and to arrange a production schedule of expected products on the basis of the expected production information so that the expected products whose similarity with the order products is much higher can be continued with respect to an empty schedule after the arrangement of the production schedule of the order products.

Description

  The present invention relates to a production plan creation system for performing order-made production and prospective production of a plurality of types of products in the same production facility.

  Conventionally, as one of the production management classification patterns, a classification pattern based on order production and prospective production is known. Then, as a technology for producing a build-to-order product and a prospective product with the same production equipment (same line), refer to “Assembly record DB 8 storing assembly record of expected product and build-to-order product” The calculation means calculates the dive frame ratio, and based on the expected production plan DB7 including the order base of the made-to-order product, review the production of the number of dive frames and the expected production using the calculated dive frame ratio. The planned number of units is calculated and stored in the production plan DB 14. Based on the production plan DB 14 and the order order specification information DB 18, the allocation jump control unit 23 converts the order base to the same expected product for each order order. The technology was proposed that the allocation was made, the reserved order production was allocated to the number of the planned production review, and the unordered production was allocated to the number of slots. Are (e.g., see Patent Document 1).

Japanese Patent Laying-Open No. 2005-128795 (Summary, FIG. 1)

In a system that responds to changes in the order-made product by adjusting the production plan of the expected product, the more types of products produced at the same production facility, the more difficult it is to adjust the production plan while maintaining production efficiency. There are challenges.
Although the thing of the said patent document 1 is aimed at the order production and the prospective production in the production of the same product, each when producing a plurality of types of products with the same production equipment (on the same line) There is no mention of the production schedule arrangement of the product.

  The present invention was made to solve the above problems, and can support production of a production plan for producing a plurality of types of products in the same production facility while maintaining production efficiency. A production planning system is provided.

  The production plan creation system according to the present invention is a production plan creation system for performing a build-to-order production and a prospective production of a plurality of types of products in the same production facility, wherein the order information of the plurality of types of products, the plurality of types Storage means for storing the expected production information of the product and the similarity between the products, and production plan creation means for creating a production plan for the build-to-order production and the prospective production, and the similarity is obtained from one product. It is determined based on at least one of the number of parts change points required when switching production to the other product, the procurement time of the parts to be changed, the time required for production switching, and the production loss due to equipment suspension at the time of production switching. The production plan creation means arranges the production schedule of the order-made product in the production facility based on the order information, and Arrange the production schedule of the prospective product based on the prospective production information so that the prospective production product having a higher degree of similarity to the order production product continues to the empty schedule after the production schedule is arranged To do.

  In the production plan creation system according to the present invention, the production schedule of the build-to-order production in the production facility is arranged based on the order information, and the similarity to the production of the made-to-order product with respect to the empty schedule after the production schedule of the build-to-order production is set The production schedules of the prospective products are arranged based on the prospective production information so that the higher expected products are consecutive. For this reason, it is possible to create a production plan that can maintain the production efficiency in the same production facility, including the order-made product and the prospective product.

It is a block diagram which shows the production plan preparation apparatus which concerns on embodiment. It is a figure explaining the change process of the production plan which concerns on embodiment. It is a figure explaining an example of the change process of the production plan which concerns on embodiment.

  FIG. 1 is a configuration diagram illustrating a configuration of a production plan creation device 100 according to an embodiment. The production plan creation device 100 is a device such as a personal computer used to create a production plan. The production plan creation apparatus 100 includes a control unit 20, a storage unit 30, an input unit 40, and an output unit 50. The production plan creation apparatus 100 according to the present embodiment creates a production plan for producing a plurality of types of products composed of a plurality of parts in the same production facility (on the same line). In the following description, each of a plurality of types of products may be referred to as a “model”.

  The input unit 40 is an interface for inputting various information regarding product orders, sales plans, inventory plans, and the like to the control unit 20. The input unit 40 is a concept including, for example, an interface with a user such as a keyboard and a mouse, and an interface with another program or another computer.

  The output unit 50 is for outputting information related to the production plan, a message to the user at the time of planning / changing the production plan, information stored in the storage unit 30, and the like. The output unit 50 includes display means such as a liquid crystal display and sound output means such as a speaker. The output unit 50 can also be configured to output various types of information related to the production plan to various recording media. In this way, the user can acquire information related to production management via the recording medium on which the information output by the output unit 50 is recorded.

  The storage unit 30 includes a memory function such as a RAM and a ROM, and includes order information 1, sales plan information 2, inventory plan information 3, production scale information 4, model master 5, production coefficient 6, order file 7, period A master 8, a similarity master 9, a parts master 10, a production plan 11 and production plan confirmation information 12 are stored.

The order information 1 is information (including products, the number of orders, and delivery date) regarding orders for each product. The order information 1 includes information on provisional order products that indicate expected products that are highly likely to be ordered, in addition to information on order products that are actually confirmed.
Sales plan information 2 is information relating to the sales plan of the produced product.
The inventory plan information 3 is information related to a product inventory plan based on the sales forecast.

  The production scale information 4 is data used as a basis for creating the production plan 11 and is created based on the order information 1, the sales plan information 2, and the inventory plan information 3. The production scale information 4 includes information on the model (product name), its delivery date and quantity. In addition, the production scale information 4 includes information related to a custom-made product whose delivery date is clearly set and information related to a prospective product whose delivery date is not yet determined.

  The model master 5 is basic information about each model, and holds, for example, information on a model code, a model name, a production line name, and a time (lead time) required for shipping.

The production coefficient 6 represents the production time of the target model in the production facility as a ratio with respect to the reference production time in the production facility. In other words, when a certain production facility is produced under the same conditions, the time required to produce the target model is expressed as a ratio with respect to the reference model (reference model). When the production time is longer than that of the standard model production factor of 1.00 (the line speed is slow), the production factor exceeds 1.00, and when the production time is shorter (the line speed is fast) The production coefficient is less than 1.00.
Based on this production factor 6, it is possible to calculate numerically the number of personnel that can be applied to the production of one model and the loss that occurs when the model is switched. The loss that occurs at the time of switching between models is converted by the time difference and the number of models with a slower line speed when switching from model A to model B in production on the same line.

  In the order file 7, information related to orders for each product (including products, number of orders, and delivery date) is recorded. The order file 7 is extracted from the contents of the order information 1 regarding information on the order production that is the latest order production and the production layout needs to be reviewed in detail. Note that the order file 7 and the order information 1 may not be provided separately but may be combined into one.

The period master 8 is information relating to a period in which a custom-made product can be advanced.
Although the delivery date is set for the made-to-order product, there are orders that can be produced ahead of schedule. However, there are cases where harmful effects occur due to too much advance. Therefore, a period in which the production completion date can be advanced with respect to the delivery date of each order is set as a possible advance period.

  The similarity master 9 is information indicating the degree of similarity between models. More specifically, for example, model A, model B, and model C are produced, and model A, model B, and model C are classified and held in a similar group according to similarity. For example, if model A has a relatively high similarity with model B and a relatively low similarity with model C, “model A, model B” is grouped as a model group with a similarity “high”. These are divided into “model A, model C” as the model group having the similarity “low”.

The similarity is determined based on at least one of the following (1) to (4). Further, the similarity may be determined by combining a plurality of the following (1) to (4).
(1) The number of parts changes required when switching production from one product to the other on the same line.
In this case, the similarity is lower as the number of parts is changed, and the similarity is higher as the number of parts is changed.

(2) The procurement time of parts to be changed when production is switched from one product to the other on the same line.
In this case, the longer the parts procurement time, the lower the similarity, and the shorter the parts procurement time, the higher the similarity. In addition, when changing a some component, a similarity can be defined based on the component with the longest procurement time. Further, the parts procurement time is included in the parts master 10.

(3) Time required for production switching such as change of part arrangement, change of personnel arrangement, change of production method, etc. when production is switched from one product to the other on the same line.
In this case, the longer the time required for production switching, the lower the similarity, and the shorter the time required for production switching, the higher the similarity.

(4) Loss of production due to line suspension when switching production from one product to the other on the same line.
For example, it is possible to calculate the number of production units that could be produced when production switching was not performed based on the difference between the downtime at the time of production switching and the line speed before and after the production switching, and this can be used as the production loss. it can. In this case, the similarity is lower as the production loss is larger, and the similarity is higher as the production loss is smaller.

  The part master 10 is information indicating a part configuration of a part used for each model. The part master 10 includes information on parts to be used, the number of parts of each part, and the procurement period of each part.

  The production plan 11 is information relating to the production plan created based on the production scale information 4, model master 5, production coefficient 6, order file 7, period master 8, and similar master 9. The production plan 11 relates to a production facility (line), an arrangement of production schedules of models (for example, a model A and a model B) produced in the line (hereinafter sometimes referred to as production arrangement), and a production number. Contains information.

  The production plan confirmation information 12 is information created based on the production plan 11, the production factor 6, the order file 7, the period master 8, the similar master 9, and the parts master 10, and is used in actual production. Information about the plan. The production plan proposal 11 is an undetermined production plan, whereas the production plan decision information 12 is a decided production plan. When no change is made to the production plan 11, the production plan 11 and the production plan confirmation information 12 have the same contents. In the present embodiment, an example in which the production plan finalization information 12 is held in the storage unit 30 separately from the production plan draft 11 is shown. However, when the content of the production plan draft 11 is finalized, this is used as the production plan finalization information 12. You may make it replace with.

  The control unit 20 includes a calculation unit such as a CPU, and includes a production scale creation unit 21, a production plan planning unit 22, and a production plan change unit 23. The production plan planning unit 22 and the production plan changing unit 23 correspond to a production plan creation unit of the present invention.

  The production scale creation unit 21 creates the production scale information 4 based on the order information 1, the sales plan information 2, and the inventory plan information 3. In this embodiment, an example in which the production scale creation unit 21 is provided in the production plan creation apparatus 100 is shown. However, the production scale creation unit 21 may be a device different from the production plan creation apparatus 100. In this case, the production scale information 4 is input from the input unit 40.

  The production plan planning unit 22 creates a production plan 11 based on the production scale information 4, model master 5, production coefficient 6, order file 7, period master 8, and similar master 9.

The production plan change unit 23 creates the production plan finalization information 12 based on the production plan 11, the production factor 6, the order file 7, the period master 8, the similar master 9, and the parts master 10.
The production plan changing unit 23 changes the production plan 11 to create production plan finalization information 12 in order to cope with a change in the order of a product when the produced production plan 11 is changed.

  The production plan change unit 23 can create the production plan finalization information 12 at any timing. For example, information related to the increase / decrease in the number of product orders is input to the order file 7 by the input unit 40. Can be done at the timing. Further, for example, the production plan change unit 23 may create the production plan decision information 12 on the plan decision date in the planning cycle.

Next, the operation of the production plan creation apparatus 100 will be described.
The order information, sales plan, and inventory plan information input by the input unit 40 at a predetermined timing are stored in the order information 1, the sales plan information 2, and the inventory plan information 3, respectively.
The production scale creation unit 21 creates the production scale information 4 based on the order information, the sales plan, and the inventory plan. The production scale creation unit 21 creates the production scale information 4 at any timing determined based on the timing at which the order information 1, the sales plan information 2 or the inventory plan information 3 is updated, a fixed period, or a plan cycle. Timing can be used.

The production plan planning unit 22 creates a production plan 11 based on the production scale information 4, model master 5, production coefficient 6, order file 7, period master 8, and similar master 9.
Specifically, first, the production planning unit 22 for each model, based on the time required to ship the model master 5 (lead time) and the delivery date of the order file 7, Completion date) is calculated.

  Next, the production planning unit 22 performs production arrangement for each production facility (on the same line). Here, the total time required for production is shortened based on the production factor 6 of each model, and the change of parts is reduced when the model is switched based on the similarity of the similar master 9. (That is, the models are switched between models with high similarity).

  Next, the production planning unit 22 adjusts based on the advance possible period of the period master 8 so that the order-made products are not arranged too much ahead of delivery. At this time, if a production arrangement that exceeds the delivery date of the made-to-order product occurs, the production is advanced beyond the advance possible period and is arranged in time for the delivery date. Then, the production planning unit 22 outputs, as a warning, the output unit 50 as information on the production that has been put forward beyond the possible advance period. Based on this warning, the user considers whether or not the item needs to have a delivery date prioritized, and enters information on whether to give the delivery date a priority or to delay the delivery date and bring it within the possible period. Input by the unit 40. The production planning unit 22 sets the production arrangement so that the delivery date is prioritized when the delivery date is prioritized, and the delivery schedule is placed within the range of the advancement possible period when the delivery date is not prioritized (delayed). Change production layout.

  The production plan created by the production plan drafting unit 22 in the process so far has been created with priority given to the delivery date and similarity of the made-to-order product. In this production plan, there may be a case where there is a blank between the production arrangement of one model and the production arrangement of another model on the same line. That is, there is a case where the production of the order-made product is smaller than the number of products that can be produced in a certain line within a certain period (the number of products that can be produced is not filled). Therefore, the production planning unit 22 assigns the production layout of the expected product calculated by the sales plan and the inventory plan to the remaining vacant schedule for which the production layout of the custom-made product is produced for the number of units that can be produced for a certain period. Do. In the production arrangement of the prospective product, as in the production arrangement of the made-to-order product, the total time required for production is arranged to be shorter based on the production coefficient 6 of each model, and the similar master 9 is similar. Based on the degree, the model is arranged so that the change of the parts is reduced when the model is switched (that is, the model is switched between models with high similarity).

As described above, the production plan draft 11 is created by the production plan drafting unit 22.
Here, after the production plan 11 is created, there is a case where a change such as an additional order for the product occurs. When such an order fluctuation occurs, the production plan change unit 23 performs a change process on the production plan 11 in order to cope with such a change.
Next, the operation of the production plan changing unit 23 will be described. FIG. 2 is a diagram for explaining a production plan change process according to the embodiment. Here, an example will be described in which the production plan changing unit 23 creates the production plan finalization information 12 at the timing when information regarding the increase / decrease in the number of product orders is input to the order file 7 by the input unit 40.

In step S101, it is assumed that new order information is input by the input unit 40 and the order information is registered in the order file 7.
The production plan changing unit 23 determines the production allocation category of the added order product (additional order product) based on the similarity of the similarity master 9. More specifically, with reference to the similar master 9, the production arrangement of the additional order item is set to an empty schedule so as to be continuous with the production arrangement of the model of the similar group having a higher similarity among the similar groups to which the additional order item belongs. (Step S102).

Next, in the production arrangement applied in step S102, the ratio of the number of produced products in the line is confirmed, and it is determined whether or not the predetermined number ratio is maintained (step S103). For example, in the line where the model A and the model B can be produced, if the production arrangement in step S102 results in an arrangement in which only the model A is continuously produced, the production of the model B is delayed. End up. In order to prevent such an excessive increase or decrease in production ratio, the ratio of the number of units produced for each product in the line is confirmed.
And when the ratio of the number of produced units is maintained with a predetermined value (S103; Yes), it progresses to Step S104.

  On the other hand, in step S103, when the ratio of the number of produced units is not maintained at a predetermined value (S103; No), that is, when an imbalance occurs in the production ratio of each product in a certain line, the process returns to step S102. In step S102, the division of the production arrangement of the additional order item is determined again. Here, the similar group having the next highest similarity is selected after the similar group selected in the previous step S102, and the production arrangement of the additional order is applied so as to be continuous with the production arrangement of the model of the similar group ( Step S102). Then, the process proceeds to step S103, and the above-described processing is performed. The processes in steps S102 and S103 are continued until the condition in step S103 is satisfied.

  In step S104, the production plan changing unit 23 performs a production arrangement changing process. The production layout changing process in step S104 detects whether or not a problem occurs with the addition of the production layout of the additional order item in step S102. If a problem occurs, the production layout is reviewed. . For example, the production layout is reviewed from the viewpoint of whether there is any unreasonable effect during the parts procurement period for products including additional orders.

Next, it is determined whether or not the delivery date of the made-to-order product can be observed by the production arrangement changed in step S104 (S105). If the delivery date can be observed (S105; Yes), the production plan changed in step S104 is confirmed and stored in the storage unit 30 as production plan confirmation information 12 (S106). On the other hand, if the delivery date cannot be observed (S105; No), the process returns to step S104, and the process for changing to another production arrangement is performed.
With the flow described above, the production plan for the added order item is added.

  FIG. 2 shows an example in which the production schedule of the additional order item can be arranged with respect to the vacant schedule of the produced production plan. However, the production schedule of the additional order item may not be arranged with respect to the vacant schedule. Therefore, in this embodiment, in such a case, the production plan is adjusted to replace the production schedule of the prospective product with the production schedule of the custom-made product. Hereinafter, an example of replacing the production schedule of the prospective product with the production schedule of the additional order product will be described as an example of the operation change of the production plan when the additional order product occurs.

FIG. 3 is a diagram illustrating an example of a production plan change process according to the embodiment.
As shown in FIG. 3, the production plan changing unit 23 determines the production ratio between the order-made product and the expected product (S401). More specifically, the production arrangement of the made-to-order product is assigned to the number of products that can be produced within a predetermined period so that the delivery date of the made-to-order product is kept. At this time, with respect to the vacant schedule after assigning the made-to-order product, the expected product will be assigned, but if the amount of the expected product is large, the range of the period that can be advanced in the period master 8 is expanded, When the amount of the prospective product is small, the period master 8 is operated so as to narrow the possible period.

Next, in step S402, by comparing the order delivery date of the made-to-order product with the parts procurement possible date (the last date of the parts procurement period) of the made-to-order product, whether or not the parts procurement is in time for the order delivery date. Is determined (S402).
When the parts procurement is in time for the order delivery date (step S402; Yes), the production plan changing unit 23 selects one of the production arrangements of the prospective products based on the production coefficient, the similar master, and the parts master. Substitution processing to replace the production arrangement is performed (S403). In this alternative process, the number of parts to be switched at the time of model switching is calculated based on the parts master and the similar master, and the placement position that can be changed in the shortest with respect to the delivery date is calculated to place the order-made product. Then, production is performed based on the production plan that has been replaced (S405).

  On the other hand, when the parts procurement is not in time for the order delivery date (step S402; No), the production plan planning unit 22 performs the production plan planning process again based on the production coefficient and the similar master (S404). In other words, with the generation of additional orders, the production plan 11 (or production plan confirmation information 12) created so far cannot be produced due to the delivery date, and therefore a production plan is drawn up again. It is. Then, production is performed based on the newly planned production plan (S406).

  As described above, in the present embodiment, when a production plan is produced in a production plan for producing a plurality of models of a custom-made product and a prospective product with the same production facility (same line), the delivery date of the custom-made product (Or advance ahead of time for a certain period of time), and place production schedules so that ordered products with higher similarity and prospective products are consecutive on that empty schedule. I did it. For this reason, models with little difference in production coefficient are arranged side by side on the same line, and when changing production from a made-to-order product to a prospective product on the same line, the amount of change in parts and personnel allocation is suppressed. Can do. Therefore, the loss of speed produced on the line can be suppressed, and as a result, the number of products that can be produced within a certain period can be increased, which contributes to the improvement of production efficiency.

  Further, when a change occurs in the order information, for example, when an order item is added to the created production plan, the production arrangement of the additional order item is performed based on the similarity. For this reason, when switching from the production of a certain model to the production of an additional order product on the same line, it is possible to suppress the amount of change in parts and personnel arrangement. Therefore, as a result, the number of production units that can be produced within a certain period can be increased, which contributes to the improvement of production efficiency. In addition, because it is possible to arrange production of additional orders at a position where the amount of change in parts and personnel allocation can be suppressed, it is possible to reduce losses during production switching, and as a result, it is easy to comply with the delivery date of additional orders. Become. For this reason, it is possible to delay the time for finalizing the production plan, that is, to change the production plan on a date closer to the production start date. Therefore, the production plan can be more flexibly dealt with a changing order.

  Also, when the ratio of custom-made products to the total production volume is high, the priority of adherence to delivery date is increased, and when the ratio of custom-made products is small (that is, the ratio of prospective products is high), it is based on similarity. Therefore, it is possible to adjust the production plan according to the order ratio, such as a production plan that prioritizes production efficiency. In this way, the production plan can be flexibly dealt with the order quantity.

  In addition, since the production arrangement of the additional order item is performed based on the similarity, the ordering of parts when the production plan is changed due to the increase in the order amount can be collected. For this reason, inventory management and procurement of parts can be performed efficiently.

Also, the degree of similarity can be determined by (1) the number of parts changes required when switching production from one product to the other on the same line, or (2) production from one product to the other on the same line. When switching based on the procurement time of parts to be changed, the production can be switched while maintaining the efficiency of securing the parts at the time of the production switching.
The similarity is based on (3) the time required for production switching, such as part placement change, personnel placement change, production method change, etc. when switching production from one product to the other on the same line. Therefore, production can be switched while maintaining work efficiency on the line.
In addition, when the similarity is determined based on the production loss due to the suspension of the line when switching from one product to the other product on the same line (4), the overall production efficiency of that line is maintained. Meanwhile, production can be switched.

  In the present embodiment, the production plan is arranged using the production coefficient. The production coefficient is the ratio of the production time of the target model with respect to the standard model (standard model) for each model that can be produced by one production facility (on the same line). Use this production coefficient. Thus, it is possible to calculate the number of personnel that can be applied to the production of one model as a numerical value. Further, by using the production coefficient, it is possible to calculate the loss that occurs when the model is switched as a numerical value. For this reason, based on the number of personnel calculated using the production coefficient and the loss at the time of switching between models, it is possible to perform production arrangement so that these are in an optimum state, which contributes to the production plan production with high production efficiency.

  1 Order information 2 Sales plan information 3 Inventory plan information 4 Production scale information 5 Model master 6 Production factor 7 Order file 8 Period master 9 Similar master 10 Parts master 11 Production plan draft 12 Production Plan decision information, 13 similarity master, 20 control unit, 21 production scale creation unit, 22 production plan planning unit, 23 production plan change unit, 30 storage unit, 40 input unit, 50 output unit, 100 production plan creation device.

Claims (4)

A production plan creation system for order production and prospective production of multiple types of products in the same production facility,
Storage means for storing order information of the plurality of types of products, expected production information of the plurality of types of products, and similarity between the products;
A production plan creation means for creating a production plan for the build-to-order production and prospective production;
The similarity is at least the number of parts change required when switching production from one product to the other product, the procurement time of the parts to be changed, the time required for production switching, and the production loss due to equipment suspension at the time of production switching. It is determined based on either
The production plan creation means includes
Based on the received order information, the production schedule of the made-to-order product in the production facility is arranged, and the degree of similarity with respect to the made-to-order product is compared with the vacant schedule after the production schedule of the made-to-order product is arranged. A production plan creation system, wherein production schedules of the prospective products are arranged based on the prospective production information so that higher expected products are continuous. The storage means stores an advanceable period, which is a period in which production can be advanced with respect to the delivery date of the made-to-order product,
The production plan creation means includes
2. The production schedule according to claim 1, wherein when the production schedule for the made-to-order production is arranged, the production schedule is arranged such that the high-similarity made-to-order products are continuous within the range of the advance possible period. Production planning system. The production plan creation means, when an additional order is generated for the created production plan,
Of the vacant schedules of the production plan, the additional build-to-order production can be performed on a schedule that is compliant with the delivery date of the additional build-to-order product and that is continuous with the production schedule of the product having a higher similarity with the additional build-to-order product. Arrange the production schedule of goods,
If there is no vacant schedule that corresponds to this, it is possible to comply with the delivery date of the additional custom-made product in the production schedule of the prospective product, and it is expected that the similarity to the additional custom-made product will be higher The production schedule creation system according to claim 1 or 2, wherein a production schedule of a product is replaced with a production schedule of the additional order production product. The storage means
Storing information related to similar groups in which a plurality of types of products produced in the same production facility are classified according to the degree of similarity between the products;
The production plan creation means includes
When arranging the production schedule of the made-to-order product or the prospective product, it is determined whether or not it is possible to arrange in order from the group with the highest similarity among the similar groups to which the target product belongs. The production plan creation system according to any one of claims 1 to 3.

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