JPWO2019163498A1 - Production control equipment, production control methods and programs - Google Patents

Abstract

The pre-change forecast amount calculation unit (61) calculates the estimated amount of the accumulated cost of the product when the product is produced according to the current production plan. When the estimated value after change calculation unit (63) produces the product according to the new production plan planned again when there is a timing when the estimated value of the accumulated cost of the product and the planned amount have a predetermined relationship. Calculate the estimated cost of the product of. The forecast information generation unit (67) determines the estimated amount of the accumulated cost of the product when the product is produced according to the current production plan and the accumulated cost of the product when the product is produced according to the new production plan. The forecast information that can identify the forecast amount is generated, and the forecast information output unit (72) outputs the forecast information.

Description

The present invention relates to a production control device, a production control method and a program.

Manufacturers that adopt the make-to-order method need to keep costs down by keeping work-in-process in the factory at an appropriate level while observing the delivery dates required by customers. Regarding the management of product delivery dates and costs, it is indispensable to manage using an information processing system including a computer device because it is not possible to deal with unpredictable situations simply by relying on the intuition and experience of employees. ..

As an example of such an information processing system, Patent Document 1 discloses a manufacturing cost management system that analyzes factors that have deteriorated the manufacturing cost of a product. The manufacturing cost management system described in Patent Document 1 calculates the difference between the actual unit price and the target unit price for each product, gives a high priority to the product having a large calculated difference, and then assigns the priority. Therefore, the factors that deteriorated the manufacturing cost of each product are analyzed.

Further, as an example of such an information processing system, Patent Document 2 discloses a progress management system that manages the cost and delivery date of a product. The progress management system described in Patent Document 2 calculates the difference value between the actual cost and the planned cost for each part of the product, and if there is a part whose difference value is larger than the threshold value, the difference cause information and countermeasures corresponding to each part. Get information and display from the database. Further, the progress management system described in Patent Document 2 calculates the difference value between the estimated delivery date and the planned delivery date for each part of the product, and if there is a part whose calculated difference value is larger than the threshold value, it corresponds to each part. The difference cause information and countermeasure information are acquired from the database and displayed.

Japanese Unexamined Patent Publication No. 2013-45430 Japanese Unexamined Patent Publication No. 2012-247964

The manufacturing cost management system described in Patent Document 1 manages the cost of the product, but does not control the delivery date of the product. On the other hand, the progress management system described in Patent Document 2 not only manages the cost of parts but also manages the delivery date. However, since the progress management system described in Patent Document 2 performs cost management and delivery date management separately, for example, if cost measures are taken on the cost management side, there is a risk that the delivery date cannot be met. Further, the cost of the progress management system described in Patent Document 2 may increase if, for example, the delivery date management side takes measures for the delivery date.

The present invention has been made in view of the above circumstances, and an object of the present invention is to suppress production costs while observing the delivery date of products.

In order to achieve the above object, the production control device according to the present invention is a device that manages a production plan of a product. The production management device includes a plan information storage unit, a performance information generation unit, a pre-change forecast amount calculation unit, a post-change forecast amount calculation unit, a forecast information generation unit, and a forecast information output unit. The plan information storage unit stores plan information that can specify the planned amount of the accumulated cost of the product. The performance information generation unit generates performance information that can specify the actual amount of the accumulated cost of the product. The pre-change forecast amount calculation unit calculates the estimated amount of the product's accumulated cost when the product is produced according to the current production plan, based on the actual amount of the product's accumulated cost. The post-change forecast amount calculation unit is the estimated amount of the accumulated cost of the product when the product is produced according to the current production plan calculated by the pre-change forecast amount calculation unit during the production period from the start of production of the product to the shipment. If there is a timing when the planned amount of the product's accumulated cost and the planned amount of the product's accumulated cost have a predetermined relationship, a new plan is made again on a date and time earlier than the planned shipping date of the product based on the actual amount of the accumulated cost of the product. Calculate the estimated amount of the accumulated cost of the product when the product is produced in the production plan. The forecast information generation unit is the forecast amount of the accumulated cost of the product when the product is produced according to the current production plan calculated by the forecast amount calculation unit before the change, and the new production calculated by the forecast amount calculation unit after the change. Generate forecast information that can identify the estimated value of the accumulated cost of the product when the product is produced in the plan. The prediction information output unit outputs the prediction information generated by the prediction information generation unit.

According to the present invention, the estimated amount of the accumulated cost of the product when the product is produced according to the current production plan and the accumulated cost of the product when the product is produced according to the re-planned new production plan. Forecast information that can identify the estimated amount is output. Therefore, it is possible to determine whether or not to change the production plan from the current production plan to a new production plan in order to reduce the production cost of the product. Also, by re-planning a new production plan for the product before the scheduled shipping date of the product, the product will be completed in time for the scheduled shipping date, so even if the product is produced with the new production plan, the delivery date Can be observed. As a result, the production cost can be suppressed while observing the delivery date of the product.

The figure which shows the functional structure of the production control apparatus which concerns on embodiment of this invention. Block diagram showing the hardware configuration of the production control device according to this embodiment The figure which shows the display example of the planned amount information which concerns on this embodiment The figure which shows the display example of the actual amount information which concerns on this embodiment The figure which shows the display example 1 of the difference information which concerns on this embodiment The figure which shows the display example 2 of the difference information which concerns on this embodiment The figure which shows the display example 1 of the prediction information which concerns on this Embodiment The figure which shows the display example 2 of the prediction information which concerns on this Embodiment Flowchart showing prediction information output processing according to this embodiment Flow chart following FIG.

Hereinafter, the production control device, the production control method, and the program according to the embodiment for carrying out the present invention will be described in detail with reference to the drawings. The same or corresponding parts in the figure are designated by the same reference numerals.
The production control device, production control method, and program according to the embodiment of the present invention generate a production plan of a product, generate a production record of the product from the information input by the user, and cannot meet the delivery date or produce. If there is a risk that the cost will rise, it proposes and adjusts changes in the production plan.

FIG. 1 is a diagram showing a functional configuration of a production control device according to an embodiment of the present invention. As shown in FIG. 1, the production management device 1 according to the present embodiment generates a storage unit 2 for storing information, an input unit 3 for receiving input of information from a user, and planning information indicating a product production plan. Plan information generation unit 4, performance information generation unit 5 that generates performance information indicating the production performance of the product, change judgment that generates change judgment information used to judge whether to change from the current production plan to a new production plan Change judgment Information generation unit 6, change judgment information output unit 7 that outputs change judgment information, change judgment information display unit 8 that displays change judgment information, change decision indicating a decision to change from the current production plan to a new production plan Change decision information generation unit 9 that generates information, production start instruction generation unit 10 that generates production start instruction information indicating that the start of production plan has been instructed, form information that indicates that a new production plan has been approved The form generation unit 11 for generating and the alarm output unit 12 for outputting alarm information to an external terminal are provided.

The storage unit 2 includes a product information storage unit 21 that stores product information, a parts information storage unit 22 that stores product parts information, a calendar information storage unit 23 that stores calendar information, and a large schedule showing a production plan based on sales information. Large schedule information storage unit 24 that stores plan information, medium schedule plan information storage unit 25 that stores monthly production plans, and plan information storage unit that stores plan information that indicates product production plans. 26, Performance information storage unit 27 that stores performance information indicating the production performance of the product, Calculation information storage unit 28 that stores calculation information used when calculating the estimated amount of accumulated cost of the product, New production plan The change judgment information storage unit 29, which stores the change judgment information indicating the production forecast of the product when the product is changed to, stores the change judgment information before the change of the product when the product is changed to the new production plan. The pre-change determination information storage unit 30 is provided.

The product information stored in the product information storage unit 21 includes a model code indicating the model of the product, a process code indicating the production process of the product, a processing cost indicating the processing cost of the part, and a lead time for processing the part. Information that can identify the indicated machining lead time is included. The model code is a search key, and if the model code is specified, the remaining information described above can also be specified. The process code is information that can identify each process from the procurement of parts to the shipment of finished products. The processing cost and the processing lead time are information that can specify the processing cost and the processing lead time in the process from the procurement of parts to the shipment of the finished product.

The part information stored in the part information storage unit 22 includes a part code indicating a part used in the product, a process code, a direct material cost indicating the direct material cost of the part, and a procurement lead indicating the lead time of parts procurement. Contains information that can identify the time. The part code is a search key, and if the part code is specified, the remaining information described above can also be specified. The direct material cost and procurement lead time are information that can specify the direct material cost and procurement lead time in the process from the procurement of parts to the shipment of the finished product.

The calendar information stored in the calendar information storage unit 23 includes information capable of specifying the planned safety days, which indicates the number of spare days from the start of production of the product to the delivery.
The large schedule information stored in the large schedule information storage unit 24 includes a serial number indicating the serial number of the product, a model code, a process code, a part code, and a customer indicating the delivery date requested by the customer. Contains information that can identify the delivery date requested in advance. The serial number serves as a search key, and if the serial number is specified, the remaining information described above can also be specified.

In the medium schedule planning information stored in the medium schedule planning information storage unit 25, it is possible to specify the serial number, the model code, the process code, the part code, and the estimated shipping date indicating the expected shipping date of the product. Contains information.

The plan information stored in the plan information storage unit 26 includes a serial number, a production start date indicating a production start date, a model code, a process code, a processing cost, a direct material cost, a processing lead time, and procurement. Contains information that can identify the lead time. In addition, the plan information includes the planned amount of the accumulated cost, the planned value of the accumulated lead time, the delivery date compliance flag indicating whether or not the delivery date can be met, and the plan confirmation indicating whether or not the production plan is confirmed. Contains information that can identify the flag. The planned amount of the accumulated cost is the planned amount of the accumulated cost by adding the direct material cost and the processing cost, and the planned value of the accumulated lead time is the procurement lead time and the processing lead time. This is the planned value of the lead time accumulated by adding. The planned value of the accumulated cost and the planned value of the accumulated lead time are information that can specify the planned value of the accumulated cost and the planned value of the accumulated lead time in the process from the procurement of parts to the shipment of the finished product, respectively. ..

The performance information stored in the performance information storage unit 27 includes information that can identify the serial number and the model code. In addition, the performance information includes a process start flag indicating whether or not the process has started, a process completion flag indicating whether or not the process has been completed, and a component arrival flag indicating whether or not the parts have arrived. Contains identifiable information. In addition, the actual information includes information that can identify the actual amount of the accumulated cost indicating the actual amount of the accumulated cost and the actual value of the accumulated lead time indicating the actual value of the accumulated lead time. In addition, the performance information includes information that can identify a shipping completion flag indicating whether or not the product has been shipped. The actual value of the accumulated cost and the actual value of the accumulated lead time are information that can specify the actual value of the accumulated cost and the actual value of the accumulated lead time in the process from the procurement of parts to the shipment of the finished product. Is.

In the calculation information to be stored in the calculation information storage unit 28, the planned amount of the accumulated cost, the planned value of the accumulated lead time, the actual value of the accumulated cost, and the actual value of the accumulated lead time are specified. Contains possible information.
The change determination information stored in the change determination information storage unit 29 includes information similar to the planning information. Specifically, the change determination information includes information that can identify the serial number, model code, process code, processing cost, direct material cost, processing lead time, and procurement lead time. In addition, the change determination information includes information that can identify the estimated amount of accumulated cost indicating the estimated amount of accumulated cost and the estimated value of accumulated lead time indicating the estimated value of accumulated lead time. In addition, the change determination information includes information that can identify the delivery date compliance flag and the plan confirmation flag.

The pre-change determination information stored in the pre-change determination information storage unit 30 includes the same information as the change determination information. That is, the pre-change determination information includes information that can identify the serial number, model code, process code, processing cost, direct material cost, processing lead time, and procurement lead time. In addition, the pre-change judgment information includes information that can specify the estimated amount of the accumulated cost and the estimated value of the accumulated lead time. In addition, the pre-change judgment information includes information that can identify the delivery date compliance flag and the plan confirmation flag.

The plan information generation unit 4 calculates the planned amount calculation unit 41 that calculates the planned amount of the product loading cost, the planned value calculation unit 42 that calculates the planned value of the product loading lead time, and the production start date of the product. The production start date calculation unit 43 is provided.

The change determination information generation unit 6 includes a pre-change forecast amount calculation unit 61 for calculating the estimated amount of the accumulated cost of the product when the product is produced in the current production plan. Further, the change judgment information generation unit 6 is a difference calculation unit 62 that calculates the difference obtained by subtracting the planned amount from the estimated amount of the accumulated cost of the product, and the accumulated cost when the product is produced according to the new production plan. A modified forecast amount calculation unit 63 for calculating the forecast amount is provided. Further, the change determination information generation unit 6 generates a plan amount information generation unit 64 that generates a plan amount information that can specify the planned amount of the product's accumulated cost, and an actual amount information that can specify the actual amount of the product's accumulated cost. The actual amount information generation unit 65 for generating the above is provided. Further, the change determination information generation unit 6 includes a difference information generation unit 66 that generates difference information capable of specifying the difference obtained by subtracting the planned amount from the estimated amount of the accumulated cost of the product. In addition, the change judgment information generation unit 6 predicts the estimated cost of the product when the product is produced according to the current production plan and the cumulative cost of the product when the product is produced according to the new production plan. The forecast information generation unit 67 is provided to generate forecast amount information that can identify the forecast amount of.

The change determination information output unit 7 includes a difference information output unit 71 that outputs the difference information generated by the difference information generation unit 66, and a prediction information output unit 72 that outputs the prediction information generated by the prediction information generation unit 67.

The change determination information display unit 8 includes a difference information display unit 81 that displays the difference information output by the difference information output unit 71, and a prediction information display unit 82 that displays the prediction information output by the prediction information output unit 72.

FIG. 2 is a block diagram showing a hardware configuration of the production control device according to the present embodiment. As shown in FIG. 2, the production control device 1 includes a control unit 51 that executes processing according to the control program 59. The control unit 51 includes a CPU (Central Processing Unit). According to the control program 59, the control unit 51 starts the production management device 1, the plan information generation unit 4, the performance information generation unit 5, the change judgment information generation unit 6, the change judgment information output unit 7, the change decision information generation unit 9, and the production start. It functions as an instruction sheet generation unit 10 and a form generation unit 11. For example, the control unit 51 has a pre-change forecast amount calculation step performed by the pre-change forecast amount calculation unit 61, a post-change forecast amount calculation step performed by the post-change forecast amount calculation unit 63, and a forecast information generation step performed by the forecast information generation unit 67. , The prediction information output step performed by the prediction information output unit 72 is executed.

Further, the production management device 1 includes a main storage unit 52 that loads the control program 59 and is used as a work area of the control unit 51. The main storage unit 52 includes a RAM (Random-Access Memory).

Further, the production management device 1 includes an external storage unit 53 that stores the control program 59 in advance. The external storage unit 53 supplies the data stored in this program to the control unit 51 according to the instruction of the control unit 51, and stores the data supplied from the control unit 51. The external storage unit 53 includes a flash memory, a hard disk, a non-volatile memory such as a DVD (Digital Versatile Disc) -RAM, or a DVD-RW. The external storage unit 53 functions as the storage unit 2.

Further, the production management device 1 includes an operation unit 54 operated by the user. The input information is supplied to the control unit 51 via the operation unit 54. The operation unit 54 includes information input components such as a keyboard and a mouse. The operation unit 54 functions as an input unit 3.

Further, the production management device 1 includes a display unit 55 that displays information input via the operation unit 54 and information output by the control unit 51. The display unit 55 includes information output components such as a display and a printer. The display unit 55 functions as a change determination information display unit 8.

Further, the production management device 1 includes a transmission / reception unit 56 for transmitting / receiving information. The transmission / reception unit 56 includes information communication components such as a network termination device and a wireless communication device connected to the network. The transmission / reception unit 56 functions as an alarm output unit 12.

In the production management device 1, the main storage unit 52, the external storage unit 53, the operation unit 54, the display unit 55, and the transmission / reception unit 56 are all connected to the control unit 51 via the internal bus 50.
In the production control device 1 shown in FIG. 1, the control unit 51 uses the main storage unit 52, the external storage unit 53, the operation unit 54, the display unit 55, the transmission / reception unit 56, and the like as resources, so that the storage unit 2 and the input unit 3 are used. , Plan information generation unit 4, Actual information generation unit 5, Change judgment information generation unit 6, Change judgment information output unit 7, Change judgment information display unit 8, Change decision information generation unit 9, Production start instruction generation unit 10, Form The functions of the generation unit 11 and the alarm output unit 12 are realized.

[About the operation of production control equipment]
Next, the operation of the production planning apparatus 1 will be described. When a user receives an order from a customer and produces a product, the user generates large schedule information and medium schedule information in advance as information that roughly defines the production plan of the product, and the large schedule information storage unit 24 And, it is stored in the medium schedule plan information storage unit 25. Further, the user generates product information and component information in advance as information on the product to be produced and information on the component for producing the product, and stores the product information and the component information in the product information storage unit 21 and the component information storage unit 22. The plan information generation unit 4 periodically refers to the medium schedule plan information stored in the medium schedule plan information storage unit 25, and the production plan for the product to which the serial number is approaching the expected shipping date. Generate planning information indicating. At this time, the plan information generation unit 4 calculates the planned amount of the accumulated cost, the planned value of the accumulated lead time, and the production start date in order to generate the planned information.

The plan information generation unit 4 stores the generated plan information in the plan information storage unit 26. When the plan information is stored in the plan information storage unit 26, approval is performed via the input unit 3 by the factory manager who is a user who periodically refers to the plan information stored in the plan information storage unit 26. Be told. When the approval is given, the production start instruction generation unit 10 generates the production start instruction information, and the production of the product is started according to the plan information.

When the production of the product is started and the parts are received and processed, the information indicating that the parts have been received and received by the user, such as the person in charge of arrangement and the person in charge of work, and the parts Information indicating that the processing has been performed is input. The performance information generation unit 5 generates performance information indicating the production performance of the product from the input information and stores it in the performance information storage unit 27.

In addition, the change determination information generation unit 6 periodically refers to the actual information stored in the actual information storage unit 27. When the actual information stored in the actual information storage unit 27 is updated, the change determination information generation unit 6 generates change determination information from the information stored in the plan information storage unit 26 and the actual information storage unit 27. .. Then, the change judgment information output unit 7 outputs the change judgment information generated by the change judgment information generation unit 6, and the change judgment information display unit 8 displays the change judgment information output by the change judgment information output unit 7. The change judgment information displayed by the change judgment information display unit 8 is used by the factory manager to judge whether or not to change from the current production plan to a new production plan, and the production plan is changed according to the change judgment information. Occasionally, approval is made via the input unit 3. When the approval is made, the change decision information generation unit 9 generates the change decision information, the form generation unit 11 generates the form information, and the production plan of the product is changed according to the change determination information. If there is a problem with the information generated by the plan information generation unit 4 and the change determination information generation unit 6, the alarm output unit 12 generates alarm information and outputs it to an external terminal.

[Generation of planning information]
Next, among the operations of the production control device 1 described above, the operation when the plan information generation unit 4 generates the plan information, particularly, the planned amount of the accumulated cost, the planned value of the accumulated lead time, and the production start date. The operation when calculating is described.

The plan information generation unit 4 acquires a serial number from the middle schedule plan information stored in the middle schedule plan information storage unit 25, and stores the serial number in the plan information storage unit 26 as the serial number of the plan information. Further, the plan information generation unit 4 acquires the model code and the process code from the medium schedule plan information using the serial number as a search key. The plan information generation unit 4 acquires the processing cost and the processing lead time from the product information in which the model code and the process code match among the product information stored in the product information storage unit 21 using the model code as a search key. The plan information generation unit 4 stores the acquired processing cost and processing lead time in the planning information storage unit 26 as the processing cost and processing lead time of the planning information in association with the serial number.

Further, the plan information generation unit 4 acquires the part code and the process code from the medium schedule plan information using the serial number as a search key. The plan information generation unit 4 acquires the direct material cost and the procurement lead time from the part information in which the part code and the process code match among the part information stored in the part information storage unit 22. The plan information generation unit 4 stores the acquired direct material cost and procurement lead time in the plan information storage unit 26 in association with the serial number as the direct material cost and procurement lead time of the plan information. Then, the planned amount calculation unit 41 calculates the planned amount of the accumulated cost and the planned value of the accumulated lead time based on the acquired processing cost, the direct material cost, the processing lead time, and the procurement lead time. The planned amount calculation unit 41 associates the calculated planned amount of the accumulated cost and the planned value of the accumulated lead time with the serial number as the planned amount of the accumulated cost and the accumulated lead time of the planned information, and the planned information storage unit 26. To memorize.

Further, the plan information generation unit 4 acquires the customer request delivery date from the large schedule plan information stored in the large schedule plan information storage unit 24 using the serial number as a search key. Then, the production start date calculation unit 43 calculates the production start date from the acquired customer request delivery date and the planned value of the accumulated lead time of the plan information stored in the plan information storage unit 26.

Specifically, the production start date calculation unit 43 calculates the total number of process days for producing the product from the planned value of the accumulated lead time, and calculates the production start limit date before the total number of process days from the delivery date requested by the customer. To do. When the calculated production start limit date is after the calculation date, the production start date calculation unit 43 acquires the planned safety days from the calendar information stored in the calendar information storage unit 23, and obtains the planned safety days from the production start limit date. Calculate the previous production start safety date. Then, the plan information generation unit 4 sets the production start date of the plan information as the calculated production start safety date, sets the delivery date compliance flag of the plan information to "2" indicating that the delivery date can be observed, and corresponds to the serial number. It is attached and stored in the plan information storage unit 26.

On the other hand, if the production start limit date is before the day before the calculation date, that is, if the delivery date cannot be observed, the plan information generation unit 4 associates the production start date of the plan information with the production start limit date as the calculated production start limit date. It is stored in the plan information storage unit 26. Further, the plan information generation unit 4 sets the delivery date compliance flag of the plan information to "0" indicating that the delivery date cannot be met, and stores the plan information in the plan information storage unit 26 in association with the serial number. At this time, the alarm output unit 12 outputs alarm information to the terminals of the sales department and the factory management department. By doing so, the information is corrected by the person in charge until the production start date is reached so that the delivery date can be met via the input unit 3. For example, information such as operating hours and machining lead times is modified on the assumption that employees will go to work on holidays. Then, when the calculated production start limit date is after the calculation date, the production start date calculation unit 43 associates the production start date of the planning information with the production start limit date as the calculated production start limit date, and associates the production start date with the production number 26. To memorize. Further, the production start date calculation unit 43 sets the delivery date compliance flag of the plan information to "1" indicating that the delivery date can be met by the modification, and stores it in the plan information storage unit 26 in association with the serial number.

[Generation of production start instruction information]
Next, among the operations of the production control device 1 described above, the operation when the production start instruction generation unit 10 generates the production start instruction information will be described.

The factory manager periodically checks the contents of the plan information stored in the plan information storage unit 26, and the plan information in which the delivery date compliance flag of the plan information is set to "1" or "2". Approve. Specifically, when approving, the factory manager sets the plan confirmation flag to "1" indicating that the plan confirmation flag has been approved via the input unit 3 and associates it with the serial number in the plan information storage unit 26. Remember. If the factory manager does not approve the production plan, for example, if the delivery date compliance flag is set to "1" but does not admit that the delivery date can be met by going to work on holidays, the plan confirmation flag Does not change from "0" indicating that is not approved.
The production start instruction generation unit 10 periodically refers to the plan information stored in the plan information storage unit 26, and the limit instruction date for the production plan of the production number in which the plan confirmation flag is set to "1". On the day of the event, production start instruction information is generated.

[About generation of achievement information]
Next, among the operations of the production management device 1 described above, the operation when the actual information generation unit 5 generates the actual information will be described.

The planned amount information generation unit 64 periodically refers to the actual information stored in the actual information storage unit 27 and the plan information stored in the plan information storage unit 26. When the plan confirmation flag of the plan information is set to "1", the plan amount information generation unit 64 has the production plan of the serial number in which the shipment completion flag of the actual information is set to "0" indicating the incomplete shipment. , The planned amount of the accumulated cost of the planned information and the planned value of the accumulated lead time are acquired from the plan information storage unit 26, and the planned amount information is generated. The difference information output unit 71 outputs the difference information including the generated planned amount information, and the difference information display unit 81 displays the planned amount information by displaying the output difference information.

FIG. 3 is a diagram showing a display example of the planned amount information according to the present embodiment. As shown by the broken line in FIG. 3, the planned amount information is displayed as a line graph, so-called S-curve, in which the vertical axis is the cost and the horizontal axis is the lead time. When displaying the planned amount information, the difference information display unit 81 draws points on the graph at positions corresponding to the planned amount of the accumulated cost and the planned value of the accumulated lead time for each process, and draws all the drawn points. The points are connected in order with a straight line to generate an S curve, and the generated S curve is displayed. As shown by the broken line in FIG. 3, the planned amount of the accumulated cost increases as the process from the start of production of the product to the shipment of the product progresses, and becomes the maximum when the product is completed. In addition, the planned amount of the accumulated cost will be 0 yen because when the product is shipped, the manufacturer will not be responsible for managing the produced product and will not have any loss.

Further, after the production start instruction information is generated, the person in charge of arranging inputs information indicating that the parts have arrived via the input unit 3 when the parts arrive from outside the factory. The performance information generation unit 5 acquires the part code, the process code, and the direct material cost of the parts received from the part information storage unit 22 based on the information received by the input unit 3. Further, the actual information generation unit 5 acquires the actual amount of the accumulated cost of the actual information stored in the actual information storage unit 27, adds the direct material cost, and adds the added amount to the product of the actual information of the current process. The actual amount of the upper cost is stored in the actual information storage unit 27 in association with the serial number. Further, the actual information generation unit 5 sets the component arrival flag corresponding to the arrived part to "1" indicating that the part has arrived, and stores the result information storage unit 27 in association with the serial number. Further, the actual information generation unit 5 calculates the actual value of the accumulated lead time based on the information received by the input unit 3, and converts the actual value of the accumulated lead time into the serial number as the actual value of the accumulated lead time of the current process of the actual information. It is stored in the performance information storage unit 27 in association with each other.

Further, when the person in charge of work starts or completes a process such as processing, assembling, and shipping, he / she inputs information indicating that the processing, assembling, and shipping of the product have been performed via the input unit 3. The performance information generation unit 5 acquires the model code, process code, and processing cost of the product information from the product information storage unit 21 based on the information received by the input unit 3. Further, the actual information generation unit 5 acquires the actual amount of the accumulated cost of the actual information stored in the actual information storage unit 27 from the acquired model code and process code, adds the processing cost, and adds the processing cost to the present. It is stored in the actual information storage unit 27 in association with the serial number as the actual amount of the accumulated cost of the actual information of the process. Further, the actual information generation unit 5 calculates the actual value of the accumulated lead time based on the information received by the input unit 3, and converts the actual value of the accumulated lead time into the serial number as the actual value of the accumulated lead time of the current process of the actual information. It is stored in the performance information storage unit 27 in association with each other. Further, when the information is input at the start timing of the process, the actual result information generation unit 5 sets the process start flag of the current process to "1" indicating that the process has started, and associates the actual information with the serial number. It is stored in the storage unit 27. On the other hand, when the information is input at the completion timing, the actual information generation unit 5 is set to "1" indicating that the process completion flag of the current process has been completed, and is associated with the serial number in the actual information storage unit 5. Store in 27.

The actual amount information generation unit 65 periodically refers to the actual information stored in the actual information storage unit 27. When any one of the component arrival flag, the process start flag, and the process completion flag of the actual amount information is set to "1", the actual amount information generation unit 65 receives the actual result from the actual information storage unit 27. The actual amount of the accumulated cost of the information and the actual value of the accumulated lead time are acquired, and the actual amount information is generated. The difference information output unit 71 outputs the difference information including the generated actual amount information, and the difference information display unit 81 displays the actual amount information by displaying the output difference information.

FIG. 4 is a diagram showing a display example of actual amount information according to the present embodiment. The actual amount information is displayed by, for example, the S curve shown by the solid line in FIG. When the difference information display unit 81 displays the planned amount information and the actual amount information, for example, the planned amount information is displayed by the S curve shown by the broken line in FIG. 4, and the actual amount information is displayed by the S curve shown by the solid line in FIG. indicate. As shown by the solid line in FIG. 4, the actual amount information is displayed from the time when the process is started or completed to the current process, that is, the process which is started or completed at the time of updating.

[Generation of change judgment information]
Next, among the operations of the production control device 1 described above, the operation when the change determination information generation unit 6 generates the change determination information will be described.

The change determination information generation unit 6 periodically refers to the actual information stored in the actual information storage unit 27. When the actual information is updated, the change judgment information generation unit 6 acquires the actual amount of the accumulated cost of the actual information and the actual value of the accumulated lead time from the actual information storage unit 27. To do. The planned amount of the accumulated cost of the planned information and the planned value of the accumulated lead time that match the serial number of the actual information are acquired from the plan information storage unit 26. The change determination information generation unit 6 stores the acquired planned amount and actual amount of the accumulated cost and the planned value and actual value of the accumulated lead time in the calculation information storage unit 28 as calculation information. The pre-change forecast amount calculation unit 61 includes the planned amount of the accumulated cost, the planned value of the accumulated lead time, the actual amount of the accumulated cost, and the actual value of the accumulated lead time stored in the information storage unit 28 for calculation. To calculate the estimated amount of accumulated cost when the product is produced according to the current production plan.

When the estimated amount of the accumulated cost when the product is produced in the current production plan is calculated, the difference calculation unit 62 calculates the difference obtained by subtracting the planned amount from the estimated amount of the accumulated cost. The alarm output unit 12 outputs alarm information to the terminal of the factory management department when there is a timing when the difference calculated by the difference calculation unit 62 exceeds the threshold value in the production period from the start of production of the product to the shipment. At this time, the difference information generated by the difference information generation unit 66 is output from the difference information output unit 71 to the terminal of the factory management department. The threshold value is a value preset by the factory manager who is the user. The factory manager can set the threshold value to an arbitrary value, but the present invention is not limited to this, and the threshold value may be set within a specific value range. The difference information output unit 71 outputs the generated difference information, and the difference information display unit 81 displays the output difference information.

FIG. 5A is a diagram showing a display example 1 of the difference information according to the present embodiment. Here, the reason why the estimated accumulated cost exceeds the planned amount is that, for example, the arrival and departure of parts is earlier than the production plan, the processing and assembly processes of the parts are performed earlier than the production plan, and the processing cost is high. It is possible that they have accumulated. As shown in the area X1 of FIG. 5A, when the estimated amount of the accumulated cost shown by the solid line in FIG. 5A becomes the planned amount of the accumulated cost at the completion of the work at an early timing, such a premature process is started. Probably the cause. Further, for example, the delivery date requested by the customer is postponed and the finished product cannot be shipped, so that the timing when the estimated accumulated cost becomes zero may be delayed. As shown in the area X2 of FIG. 5A, if the estimated amount of the accumulated cost does not change from the planned amount at the time of completion of the work even after the timing corresponding to the planned value of the accumulated REIT time of the shipping process, such a delivery date Probably due to the extension. In addition, in order to calculate the estimated amount of the accumulated cost, the sales person inputs the information indicating that the delivery date requested by the customer has been postponed through the input unit 3, and the estimated amount before the change is calculated. The unit 61 needs to calculate the estimated amount of the accumulated cost based on the information that the input unit 3 has received the input.

FIG. 5B is a display example 2 of the difference information according to the present embodiment. On the other hand, the reason why the estimated value of the accumulated cost is lower than the planned amount is that, for example, the arrival of parts is delayed from the production plan and the direct material cost is not accumulated, or the process of processing and assembling the parts is more than the production plan. It is possible that the processing cost did not accumulate due to the delay. As shown in the area Y of FIG. 5B, when the estimated amount of the accumulated cost shown by the solid line in FIG. 5B is less than the planned amount of the accumulated cost shown by the broken line in FIG. 5B, such arrival delay and processing delay occur. Probably the cause. If warning information is output in which the estimated accumulated cost is less than the planned amount and the arrival / arrival delay is the cause, the person in charge of arranging changes the parts arrival / receipt plan of the parts information via the input unit 3. Information indicating that the processing has been performed is input, and if the cause is a processing delay, information indicating that the processing plan has been changed by the person in charge of arranging is input via the input unit 3. Note that the change determination information generation unit 6 does not generate change determination information used for determining whether or not to change to a new production plan that eliminates the delay, but is not limited to this, and a new one that eliminates the delay. The change judgment information used for judging whether or not to change to a production plan may be generated.

When the product with the serial number having the timing when the difference calculated by the difference calculation unit 62 exceeds the threshold value in the production period is set as the first product, first, the change judgment information generation unit 6 starts from the middle schedule planning information storage unit 25. Refer to the medium schedule information. The change determination information generation unit 6 acquires the serial number of the product whose scheduled shipping date is before the scheduled shipping date of the first product from the referenced medium schedule planning information. The change determination information generation unit 6 refers to the plan information storage unit 26 and acquires the plan information that matches the serial number acquired from the medium schedule plan information. The change determination information generation unit 6 refers to the process start flag, the process completion flag, the parts arrival flag, and the planned amount of the accumulated cost of the acquired plan information. The change determination information generation unit 6 has not started the process performed at the timing when the difference exceeds the threshold value in the first product for the production of the product from the referenced process completion flag and the component arrival flag. If the planned amount of the accumulated cost of the referenced product does not exceed the planned amount of the accumulated cost of the first product, the product is regarded as the second product.

The change judgment information generation unit 6 plans a new production plan again and generates change judgment information. Here, the new production plan re-planned is a production plan in which the production of the first product is postponed and the production of the second product is advanced as long as the completion of the first product is in time for the scheduled shipping date. First, the changed forecast amount calculation unit 63 acquires from the plan information storage unit 26 the planned amount of the accumulated cost of the planned information that matches the serial number of the second product and the planned value of the accumulated lead time. Further, the changed forecast amount calculation unit 63 acquires the actual amount of the accumulated cost and the actual value of the accumulated lead time of the actual information that matches the serial number of the second product from the actual information storage unit 27.

The changed forecast amount calculation unit 63 stores the acquired planned amount and actual amount of the accumulated cost of the second product, and the planned value and actual value of the accumulated lead time in the calculation information storage unit 28 as calculation information. .. The changed forecast amount calculation unit 63 refers to the planned amount and the actual amount of the accumulated cost of the first product and the planned value and the actual value of the accumulated lead time stored in the information storage unit 28 for calculation. Calculate the estimated amount of the accumulated cost of the first product when the first product is produced in the new production plan. Further, the changed forecast amount calculation unit 63 refers to the planned amount and the actual amount of the accumulated cost of the second product and the planned value and the actual value of the accumulated lead time stored in the information storage unit 28 for calculation. Then, the estimated amount of the accumulated cost of the second product when the second product is produced under the new production plan is calculated. The forecast information generation unit 67 includes the estimated amount of the accumulated cost of the first product when the first product is produced in the current production plan, the planned amount of the accumulated cost of the second product, and a new production plan. The estimated amount of the accumulated cost of the first product when the first product is produced and the estimated amount of the accumulated cost of the second product when the second product is produced with the new production plan. Generate identifiable estimated amount information. The prediction information output unit 72 outputs the generated prediction information, and the prediction information display unit 82 displays the output prediction information.

FIG. 6A is a diagram showing a display example 1 of prediction information according to the present embodiment, and FIG. 6B is a diagram showing a display example 2 of prediction information according to the present embodiment. The prediction information display unit 82 displays the prediction information output from the prediction information output unit 72. For example, among the forecast information, the forecast value information of the first product when the first product is produced in the current production plan is displayed by the S curve shown by the dotted line in FIGS. 6A and 6B, and the new production plan. The estimated amount information of the first product when the first product is produced in FIG. 6A is displayed by an S curve shown by a single point chain line in FIGS. 6A and 6B. In addition, among the forecast information, the planned amount information of the second product is displayed by the S curve shown by the solid line in FIGS. 6A and 6B, and the second product when the second product is produced under the new production plan. The estimated amount information is displayed by the S curve shown by the alternate long and short dash line in FIGS. 6A and 6B.

As shown in FIG. 6A, when the estimated accumulated cost exceeds the planned amount due to the start of the process too early, for example, the production of the first product is postponed from T1 to T2 to produce the second product. Prediction information when moving forward is displayed. Further, as shown in FIG. 6B, when the estimated accumulated cost exceeds the planned amount due to the shipping timing being postponed from TA to TB due to the extension of the delivery date, for example, the production of the first product is carried out at T3. The forecast information when the production of the second product is advanced by delaying from to T4 is displayed.

In these cases, for the first product, S until the completion of the first product is performed when the first product is produced under the new production plan than when the first product is produced under the current production plan. It can be seen that the rise of the curve is slow. Therefore, the cumulative cost until the first product is shipped can be kept low. On the other hand, regarding the second product, the S-curve until the completion of the second product is more when the second product is produced under the new production plan than when the second product is produced under the current production plan. It can be seen that the rise is faster. Therefore, the accumulated cost until the shipment of the second product becomes high. However, the S-curve of the second product when the second product is produced under the new production plan is lower than the S-curve of the first product when the first product is produced under the current production plan. I understand. Therefore, at least the accumulated cost until the completion of the second product when the second product is produced under the new production plan is until the shipment of the first product when the first product is produced under the current production plan. It can be seen that it is lower than the cumulative cost of.

7 and 8 are flowcharts showing the prediction information output process according to the present embodiment. The operation of the production control device 1 to output the prediction information will be described with reference to the flowcharts shown in FIGS. 7 and 8. First, as shown in FIG. 7, the change determination information generation unit 6 calculates whether or not the actual information of the first product has been updated (step S1). When the change determination information generation unit 6 does not update the actual information of the first product (step S1; NO), the change determination information generation unit 6 repeats the process of step S1 until the actual information of the first product is updated. On the other hand, when the change determination information generation unit 6 updates the actual information of the first product (step S1; YES), the pre-change forecast amount calculation unit 61 does not change the production plan of the first product. The estimated amount of the accumulated cost of is calculated (step S2). Further, the difference calculation unit 62 calculates the difference obtained by subtracting the planned amount from the estimated accumulated cost of the first product when the first product is produced in the current production plan (step S3). Further, the difference information generation unit 66 generates the difference information (step S4). Further, the difference information output unit 71 outputs the generated difference information (step S5), and calculates whether or not there is a timing when the difference exceeds the threshold value (step S6).

If there is no timing when the difference exceeds the threshold value (step S6; NO), the process ends. On the other hand, when there is a timing when the difference exceeds the threshold value (step S6; YES), as shown in FIG. 8, the changed forecast amount calculation unit 63 refers to the medium schedule planning information and sets the estimated shipping date of the first product. It is calculated whether or not there is a product before the scheduled shipping date (step S7). If there is no product whose scheduled shipping date is before the scheduled shipping date of the first product (step S7; NO), the process ends. On the other hand, when there is a product whose scheduled shipping date is before the scheduled shipping date of the first product (step S7; YES), the changed forecast amount calculation unit 63 acquires the plan information of the product (step S8). In addition, the changed forecast amount calculation unit 63 calculates whether or not the process of producing the product is started at the timing when the difference exceeds the threshold value in the first product (step S9).

When the process of producing the product is not started at the timing when the difference exceeds the threshold value in the first product (step S9; NO), the changed forecast amount calculation unit 63 determines the accumulated cost of the product. Calculate the difference between the planned amount and the planned amount of the accumulated cost of the first product. The changed forecast amount calculation unit 63 calculates from the calculated difference whether or not the planned amount of the accumulated cost of the product exceeds the planned amount of the accumulated cost of the first product (step S10). When the process of production of the product is started at the timing when the difference exceeds the threshold value in the first product (step S9; YES), or the planned amount of the accumulated cost of the product is the first product. When the planned amount of the accumulated cost is exceeded (step S10; YES), the changed forecast amount calculation unit 63 returns to the process of step S7.

On the other hand, when the planned amount of the accumulated cost of the first product is not exceeded (step S10; NO), the changed forecast amount calculation unit 63 uses the first product in a new production plan in which the product is replanned as the second product. Calculate the estimated amount of the accumulated cost of the first product when the production of the first product is performed and the estimated amount of the accumulated cost of the second product when the second product is produced with the new production plan (step S11). ). Further, the forecast information generation unit 67 generates forecast amount information (step S12), and the forecast information output unit 72 outputs the generated forecast information (step S13). After outputting the forecast information, the process returns to the process of step S7, and the processes of steps S7 to S10 are repeated for a new product whose scheduled shipping date is before the scheduled shipping date of the first product. The planned shipping date is before the scheduled shipping date of the first product, the process performed at the timing when the difference exceeds the threshold value in the first product is not completed, and the planned amount of the accumulated cost is the product of the first product. If there is a product that does not exceed the planned amount of the upper cost, the product is regarded as the second product. Then, the processes of steps S11 to S13 are executed for all the products that are the second products, and the prediction information is output.

[About generation of change decision information and form information]
Next, among the operations of the production management device 1 described above, the operation when the change decision information generation unit 9 generates the change decision information and the form generation unit 11 generates the form information will be described.

The factory manager confirms the forecast information displayed by the forecast information display unit 82, determines whether or not to approve the change in the production plan, and if approves, changes the production plan via the input unit 3. Enter the information indicating that you have approved. The change decision information generation unit 9 generates change decision information from the information received by the input unit 3. Further, the change determination information generation unit 9 acquires change determination information from the change determination information storage unit 29, and stores the acquired change determination information in the pre-change determination information storage unit 30 as pre-change determination information.

Further, the change decision information generation unit 9 acquires the plan information of the first product and the plan information of the second product from the plan information storage unit 26. The change decision information generation unit 9 changes the plan information of the first product and the plan information of the second product acquired based on the change determination information. The change decision information generation unit 9 stores the changed plan information of the first product and the plan information of the second product in the plan information storage unit 26 as the plan information after the change of the production plan. At this time, the form generation unit 11 generates form information. The form information and the changed plan information are output to the terminals of all departments related to the production plan. On the other hand, if the factory manager does not approve the change in the production plan, the production of the product is continued without changing the production plan.

When the product is produced according to the production plan and the shipment of the product is completed, the performance information generation unit 5 sets the process completion flag corresponding to the shipping process from the information received by the input unit 3 from the person in charge of the shipping process. Is set to "1", and the shipping completion flag is set to "2" indicating that the shipping is completed, and the result information storage unit 27 is stored.

As described above, according to the production management device 1 according to the present embodiment, the plan information storage unit 26 stores the product plan information, and the performance information generation unit 5 stores the product performance information. Is generating. In addition, the pre-change forecast amount calculation unit 61 calculates the estimated amount of the accumulated cost of the product when the product is produced according to the current production plan, based on the actual amount of the accumulated cost of the product. In addition, the changed forecast amount calculation unit 63 determines the cumulative cost of the product when there is a timing in which the estimated amount of the cumulative cost of the product calculated in the production period of the product and the planned amount have a predetermined relationship. Based on the actual amount, the estimated amount of the accumulated cost of the product when the product is produced according to the new production plan planned again is calculated. Then, the forecast information generation unit 67 determines the estimated amount of the accumulated cost of the product when the product is produced in the current production plan and the accumulated cost of the product when the product is produced in the new production plan. The forecast information that can be specified with the forecast amount of the above is generated, and the forecast information output unit 72 outputs the generated forecast information.

By doing so, the factory manager who is the user can determine whether or not to change the production plan in order to reduce the production cost of the product. Also, by re-planning a new production plan for the product before the scheduled shipping date of the product, the product will be completed in time for the scheduled shipping date, so even if the product is produced with the new production plan, the delivery date Can be observed. As a result, the production cost can be suppressed while observing the delivery date for each product.

Further, according to the production control device 1 according to the present embodiment, the difference calculation unit 62 subtracts the planned amount from the estimated amount of the accumulated cost of the product when the product is produced in the current production plan. Is calculated. Then, when there is a timing when the calculated difference exceeds the threshold value, the changed forecast amount calculation unit 63 calculates the estimated amount of the accumulated cost of the product when the product is produced according to the newly planned new production plan. To do.
By doing so, it is possible to calculate the estimated amount of the accumulated cost of the product when the product is produced by the new production plan when the calculated difference is unacceptable.

Further, according to the production control device 1 according to the present embodiment, the plan information storage unit 26 stores the plan information of the first product and the plan information of the second product. In addition, the pre-change forecast amount calculation unit 61 predicts the accumulated cost of the first product when the first product is produced in the current production plan based on the actual amount of the accumulated cost of the first product. Is calculated. In addition, when the changed forecast amount calculation unit 63 calculates the estimated amount of the accumulated cost of the first product when the first product is produced in the new production plan replanned, the new production plan is used. The estimated amount of the accumulated cost of the second product when the second product is produced is also calculated. The new production plan re-planned is a production plan in which the production of the first product is postponed and the production of the second product is advanced as long as the completion of the first product is in time for the scheduled shipping date. Then, the forecast information generation unit 67 uses the forecast information as the forecast amount of the accumulated cost of the first product when the first product is produced in the current production plan and the planned amount of the accumulated cost of the second product. , The estimated amount of the accumulated cost of the first product when the first product is produced under the new production plan and the accumulated cost of the second product when the second product is produced under the new production plan. It generates information that can identify the estimated amount.
By doing so, the factory manager determines whether or not the production cost of the second product, which is produced ahead of schedule, can be allowed to increase instead of suppressing the production cost of the first product, thereby performing the production plan. Can be determined whether or not to change from the current production plan to a new production plan.

Further, according to the production management device 1 according to the present embodiment, the changed forecast amount calculation unit 63 selects a product whose scheduled shipping date is before the scheduled shipping date of the first product as a candidate for the second product. There is.
By doing so, the second product has a new production plan rather than selecting the second product whose estimated shipping date is later than the estimated shipping date of the first product and calculating the estimated accumulated cost. It becomes difficult for the difference between the estimated value and the planned amount of the accumulated cost of the second product at the time of production to increase. As a result, the factory manager can easily decide to change from the current production plan to the new production plan by allowing the production cost of the second product to increase.

Further, according to the production control device 1 according to the present embodiment, the changed forecast amount calculation unit 63 selects the product if the process performed at the timing when the difference exceeds the threshold value in the first product is completed. Is excluded from the candidates for the second product.
By doing so, the production of the second product with a new production plan is performed rather than selecting the second product that has started the process in which the difference exceeds the threshold value in the first product and calculating the estimated accumulated cost. It becomes difficult to increase the difference between the estimated amount of the accumulated cost of the second product and the planned amount when the above is performed. As a result, the factory manager can easily decide to change from the current production plan to the new production plan by allowing the production cost of the second product to increase.

Further, according to the production management device 1 according to the present embodiment, the changed forecast amount calculation unit 63 selects the selected product if the planned amount of the accumulated cost exceeds the planned amount of the accumulated cost of the first product. 2 Excluded from product candidates.
By doing so, a new production plan is used rather than selecting a second product whose planned accumulated cost exceeds the planned accumulated cost of the first product and calculating the estimated accumulated cost. It becomes difficult to increase the difference between the estimated amount and the planned amount of the accumulated cost of the second product when the two products are produced. As a result, the factory manager can easily decide to change from the current production plan to the new production plan by allowing the production cost of the second product to increase.

Further, according to the production management device 1 according to the present embodiment, the prediction information generation unit 67 generates a plurality of prediction information, and the prediction information output unit 72 outputs all the generated prediction information.
By doing so, as a result, the factory manager can determine the forecast information that minimizes the production cost from all the output forecast information and decide to change the production plan.

The changed forecast amount calculation unit 63 calculated the estimated amount of the accumulated cost of the product when the product was produced with the new production plan at the timing when the calculated difference was determined to exceed the threshold value. , The timing of calculation is not limited to this as long as it is a date and time before the scheduled shipping date of the product. For example, at the timing when it is determined that the factory manager has confirmed the difference information displayed by the difference information display unit 81, the estimated amount of the accumulated cost of the product when the product is produced under the new production plan is calculated. You may. In this case, it is necessary to have a configuration for determining whether or not the factory manager has confirmed the displayed difference information. For example, it may be determined that the factory manager has confirmed the difference information by displaying the difference information when the factory manager is inputting the information via the input unit 3. Further, for example, it may be determined that the factory manager has confirmed the difference information by detecting the factory manager while displaying the difference information using the detection sensor. Further, for example, it may be determined that the factory manager has confirmed the difference information by having the factory manager input information indicating that the difference information being displayed has been confirmed via the input unit 3.

When a plurality of forecast information is generated, the forecast information is output in the order of generation, but the present invention is not limited to this, and the forecast information may be output in the order in which the increase in the cumulative cost of the first product is suppressed. For example, the estimated amount of the accumulated cost of the first product when the first product is produced in the new production plan and the accumulated cost of the first product when the first product is produced in the current production plan. The forecast information may be output in descending order of the difference from the forecast amount of.

When a plurality of forecast information is generated, the forecast information is output in the order of generation, but the present invention is not limited to this, and the forecast information may be output in the order in which the increase in the cumulative cost of the second product is suppressed. For example, the estimated amount of the accumulated cost of the second product when the second product is produced in the new production plan and the accumulated cost of the second product when the second product is produced in the current production plan. Forecast information may be output in ascending order of difference from the planned amount of.

In addition, although the change judgment information when the first product and the second product were produced in the new production plan that puts off the production of the first product and advances the production of the second product, the change judgment information is generated, but the production of the first product It is not necessary to advance the production of the second product by delaying the production. That is, change determination information when the first product is produced in a new production plan that postpones the production of the first product may be generated.

In addition, in order to suppress an increase in the production cost of the second product, it is preferable that the conditions for selecting the second product include the above-mentioned three conditions, but the conditions for selecting the second product are the same. The condition is not limited to, and may be, for example, any two of the above-mentioned three conditions, or any one of the above-mentioned three conditions.

The conditions for selecting the second product are the above-mentioned three conditions, but the conditions are not limited to these, and new conditions may be added. For example, a product that has a timing in which the warehouse occupied area exceeds the allowable area due to the advancement of production may be excluded from the candidates for the second product. In this case, for example, it is necessary for the changed forecast amount calculation unit 63 to calculate whether or not there is a timing when the warehouse occupied area exceeds the selected product. Further, for example, a product whose inventory maintenance cost may exceed the permissible amount due to the advancement of production may be excluded from the candidates for the second product. In this case, for example, it is necessary for the changed forecast amount calculation unit 63 to calculate whether or not there is a timing when the inventory maintenance cost exceeds the permissible amount for the selected product. Further, for example, as shown in FIG. 5B, the actual amount and the estimated amount of the accumulated cost are lower than the planned amount of the accumulated cost due to the arrival delay and the processing delay, and it is difficult to advance the production. The product may be excluded from the candidates for the second product.

In addition, although a new production plan was re-planned to postpone the production of the first product and advance the production of the second product, the type of product to advance the production in order to re-plan the new production plan is the second product. The type is not limited to one, and may be two or more. For example, the types of products whose production is advanced may be two types, the second product and the third product, and a new production plan may be re-planned to advance the production of not only the second product but also the third product. Even in this case, it is preferable that the conditions for selecting the third product are the same as the conditions for selecting the second product described above.

In addition, when the difference obtained by subtracting the planned amount from the estimated amount of the accumulated cost of the product when the product is produced in the current production plan exceeds the threshold value, the estimated amount of the accumulated cost of the product and the planned amount are calculated. The relationship is set in advance, but the relationship is not limited to this. For example, when the estimated cost of a product exceeds the sum of the planned amount and a predetermined coefficient, the estimated cost of the product and the planned amount have a predetermined relationship. May be good. Further, for example, when the value obtained by dividing the estimated cumulative cost of the product by the planned amount exceeds the threshold value, the estimated accumulated cost of the product and the planned amount may have a predetermined relationship.

In addition, when there is a timing when the difference exceeds the threshold value, the estimated amount of the accumulated cost of the product when the product is produced with the new production plan is calculated, but it is also new when there is no timing when the difference exceeds the threshold value. The estimated amount of the accumulated cost of the product when the product is produced in the production plan may be calculated.

The product loading cost is calculated by adding the direct material cost of the parts and the processing cost until the finished product is assembled, but the loading cost is not limited to the direct material cost and the processing cost. Other costs may be included in the top cost. For example, inventory maintenance costs for storing work-in-process such as parts, intermediate products, and finished products in a warehouse may be included. In this case, the product information, the parts information, the plan information, the actual result information, the change judgment information, and the pre-change judgment information need to be information that can identify the inventory maintenance cost.

The actual information generation unit 5 generates the actual information at the timing of the start or completion of the process in which the input unit 3 accepts the input of the information, but the actual information is generated even if it is not the timing of the start or completion of the process. You may. In this case, the person in charge of arranging, the person in charge of work, etc. inputs information even at a timing other than the start or completion of the process, or the performance information generation unit 5 periodically generates performance information even if there is no input. There is a need to.

The change judgment information generation unit 6 generates the change judgment information when the performance information of the performance information storage unit 27 is updated, but the change judgment information is generated even if the performance information is not updated. May be good. For example, the change determination information generation unit 6 may periodically generate new change determination information regardless of whether or not the actual information of the actual information storage unit 27 has been updated.

In addition, the change judgment information generation unit 6 estimates the estimated cost of the product when the product is produced according to the current production plan and the cumulative cost of the product when the product is produced according to the new production plan. The calculation information storage unit 28 stores the calculation information in order to calculate the estimated amount of the product. However, the estimated amount of the accumulated cost may be calculated without storing the calculation information in the calculation information storage unit 28. In this case, for example, it is necessary to temporarily store the calculation information in the main storage unit 52 for calculation. That is, the main storage unit 52 may function as the calculation information storage unit 28 without the external storage unit 53 functioning as the calculation information storage unit 28.

Although the change decision information generation unit 9 generates the change decision information, the change decision information output unit that outputs the generated change decision information and the change decision information display unit that displays the output change decision information. May be provided to output the change decision information to an external terminal or display the change decision information.

Although the production start instruction generation unit 10 generates the production start instruction information, the production start instruction output unit that outputs the generated production start instruction information and the output production start instruction information are output. A production start instruction display unit may be provided to display the production start instruction information, and the production start instruction information may be output to an external terminal or the production start instruction information may be displayed.

Although the form generation unit 11 generates the form information, the form output unit for outputting the generated form information and the form display unit for displaying the output form information are provided to display the form information externally. It may be output to a terminal or display form information.

The central part for processing the production management device 1 including the control unit 51, the main storage unit 52, the external storage unit 53, the operation unit 54, the display unit 55, the transmission / reception unit 56, the internal bus 50, etc. is dedicated. It can be realized by using a normal computer system regardless of the system. For example, a computer program for executing the above operation is stored and distributed in a computer-readable recording medium such as a flexible disk or DVD-ROM (Read-Only Memory), and the computer program is distributed to the computer. By installing it, the production control device 1 that executes the above processing may be configured. Further, the production control device 1 may be configured by storing the computer program in a storage device of a server device on a communication network such as the Internet and downloading it by a normal computer system.

Further, when the function of the production control device 1 is realized by sharing the OS (operating system) and the application program, or by coordinating the OS and the application program, only the application program part is stored in the recording medium or the storage device. You may.

It is also possible to superimpose a computer program on a carrier wave and provide it via a communication network. For example, the computer program may be posted on a bulletin board system (BBS, Bulletin Board System) on a communication network, and the computer program may be provided via the network. Then, the above processing may be executed by starting this computer program and executing it in the same manner as other application programs under the control of the OS.

The present invention allows for various embodiments and modifications without departing from the broad spirit and scope of the present invention. Moreover, the above-described embodiment is for explaining the present invention, and does not limit the scope of the present invention. That is, the scope of the present invention is indicated not by the embodiment but by the claims. Then, various modifications made within the scope of the claims and the equivalent meaning of the invention are considered to be within the scope of the present invention.

This application is based on Japanese Patent Application No. 2018-029470 filed on February 22, 2018. The specification, claims, and the entire drawing of Japanese Patent Application No. 2018-209470 shall be incorporated into this specification as a reference.

1 Production control device, 2 Storage unit, 3 Input unit, 4 Plan information generation unit, 5 Actual information generation unit, 6 Change judgment information generation unit, 7 Change judgment information output unit, 8 Change judgment information display unit, 9 Change decision information Generation unit, 10 Production start instruction generation unit, 11 Form generation unit, 12 Alarm output unit, 21 Product information storage unit, 22 Parts information storage unit, 23 Calendar information storage unit, 24 Large schedule information storage unit, 25 Medium schedule Planning information storage unit, 26 Planning information storage unit, 27 Actual information storage unit, 28 Calculation information storage unit, 29 Change judgment information storage unit, 30 Pre-change judgment information storage unit, 41 Plan amount calculation unit, 42 Plan value calculation unit , 43 Production start date calculation unit, 50 Internal bus, 51 Control unit, 52 Main storage unit, 53 External storage unit, 54 Operation unit, 55 Display unit, 56 Transmission / reception unit, 59 Control program, 61 Pre-change forecast amount calculation unit, 62 Difference calculation unit, 63 Predicted amount calculation unit after change, 64 Planned amount information generation unit, 65 Actual amount information generation unit, 66 Difference information generation unit, 67 Prediction information generation unit, 71 Difference information output unit, 72 Prediction information output unit , 81 Difference information display unit, 82 Prediction information display unit.

Claims (8)

A production control device that manages product production plans.
A plan information storage unit that stores plan information that can specify the planned amount of the accumulated cost of the product,
A performance information generation unit that generates performance information that can specify the actual amount of the accumulated cost of the product,
An unchanged forecast amount calculation unit that calculates the estimated amount of the accumulated cost of the product when the product is produced in the current production plan based on the actual amount of the accumulated cost of the product.
The estimated amount of the accumulated cost of the product and the product when the product is produced according to the current production plan calculated by the pre-change forecast value calculation unit during the production period from the start of production of the product to the shipment. If there is a timing when the planned amount of the accumulated cost of the product has a predetermined relationship, a new plan is made again on a date and time earlier than the planned shipping date of the product based on the actual amount of the accumulated cost of the product. A modified forecast amount calculation unit that calculates the estimated amount of the accumulated cost of the product when the product is produced in the production plan,
The estimated amount of the accumulated cost of the product when the product is produced according to the current production plan calculated by the pre-change forecast amount calculation unit, and the new production calculated by the post-change forecast amount calculation unit. A forecast information generation unit that generates forecast information that can specify the estimated amount of the accumulated cost of the product when the product is produced in the plan.
A prediction information output unit that outputs the prediction information generated by the prediction information generation unit,
Production control equipment equipped with. The relationship is such that the difference obtained by subtracting the planned amount of the accumulated cost of the product from the estimated amount of the accumulated cost of the product when the production plan is not changed exceeds the threshold value.
The production control device according to claim 1. The plan information stored in the plan information storage unit can specify the planned amount of the accumulated cost of the first product and the planned amount of the accumulated cost of the second product.
The performance information generation unit generates performance information capable of specifying the actual amount of the accumulated cost of the first product.
The pre-change forecast amount calculation unit determines the accumulated cost of the first product when the first product is produced in the current production plan based on the actual amount of the accumulated cost of the first product. Calculate the estimated amount,
The post-change forecast amount calculation unit is a product of the first product when the first product is produced according to the current production plan calculated by the pre-change forecast amount calculation unit during the production period of the first product. When there is a timing when the estimated amount of the accumulated cost and the planned amount of the accumulated cost of the first product have the same relationship, the actual amount of the accumulated cost of the first product and the accumulated cost of the second product The first product when the first product and the second product are produced under the new production plan re-planned on a date and time before the scheduled shipping date of the first product based on the planned amount. Calculate the estimated amount of the accumulated cost of the second product and the estimated amount of the accumulated cost of the second product.
The new production plan re-planned is a production plan in which the production of the first product is postponed and the production of the second product is advanced as long as the completion of the first product is in time for the scheduled shipping date.
The forecast information generated by the forecast information generation unit is a forecast of the accumulated cost of the first product when the first product is produced in the current production plan calculated by the forecast amount calculation unit before change. The amount, the planned amount of the accumulated cost of the second product when the second product is produced in the current production plan stored in the plan information storage unit, and the changed forecast amount calculation unit. The estimated amount of the accumulated cost of the first product when the first product is produced in the new production plan calculated by the above, and the new production plan calculated by the changed forecasted amount calculation unit. It is possible to specify the estimated amount of the accumulated cost of the second product when the second product is produced.
The production control device according to claim 1 or 2. The second product is a product whose scheduled shipping date is before the scheduled shipping date of the first product.
The production control device according to claim 3. The second product is the estimated amount of the accumulated cost of the first product and the estimated amount of the first product when the first product is produced according to the current production plan calculated by the pre-change forecast amount calculation unit. It is a product that has not started the process that is being performed at the timing when the planned amount of accumulated cost is related to the above.
The production control device according to claim 3 or 4. The second product is a product in which the planned amount of the accumulated cost does not exceed the planned amount of the accumulated cost of the first product in the planned information stored in the planned information storage unit.
The production control device according to any one of claims 3 to 5. It is a production control method that manages the production plan of a product.
A pre-change forecast amount calculation step for calculating the estimated amount of the accumulated cost of the product when the product is produced in the current production plan based on the actual amount of the accumulated cost of the product.
Based on the actual value of the accumulated cost of the product, the accumulated cost of the product when the product is produced under the new production plan re-planned at a date and time before the scheduled shipping date of the product. The changed forecast amount calculation step to calculate the forecast amount,
The estimated amount of the accumulated cost of the product when the product is produced in the current production plan calculated in the pre-change forecast amount calculation step, and the new calculated amount in the post-change forecast amount calculation step. A forecast information generation step for generating forecast information that can specify the estimated amount of the accumulated cost of the product when the product is produced in the production plan, and
A prediction information output step that outputs the prediction information generated in the prediction information generation step, and a prediction information output step.
Production control methods including. A computer that manages product production plans,
An unchanged forecast amount calculation unit that calculates the estimated amount of the accumulated cost of the product when the product is produced in the current production plan based on the actual amount of the accumulated cost of the product.
Based on the actual value of the accumulated cost of the product, the accumulated cost of the product when the product is produced under the new production plan re-planned at a date and time before the scheduled shipping date of the product. Changed forecast amount calculation unit to calculate the forecast amount,
The estimated amount of the accumulated cost of the product when the product is produced according to the current production plan calculated by the pre-change forecast amount calculation unit, and the new production calculated by the post-change forecast amount calculation unit. Forecast information generation unit that generates forecast information that can identify the estimated amount of accumulated cost of the product when the product is produced in the plan.
A prediction information output unit that outputs the prediction information generated by the prediction information generation unit,
A program that functions as.

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