KR100780103B1 - Method for yieding material requirement and product planning requirement and record media recored program for realizing the same - Google Patents

Abstract

The present invention relates to a recording medium on which a material requirement and a production plan requirement calculation method and a program for implementing the same are recorded, the method comprising the steps of: (a) setting a minimum safety stock quantity using a sales quantity and a safety stock ratio of a material or a product; Calculating a pre-running material requirement using the set minimum safety stock quantity, monthly sales plan information, inventory and inventory information, wherein the monthly sales plan information is divided into a plurality of weekly sales plan information; (C) receiving order information input when running; And automatically calculating the requirements using the weekly sales plan information, the release information, the minimum safety stock quantity, the availability and the inventory information after the time when the order information is input among the order information and the weekly sales plan information set at the end of the previous month. It relates to a requirement calculation method comprising d). According to the present invention, it is possible to calculate the material requirements using the exact minimum safety stock quantity, it is possible to secure accurate logistics by adjusting the material requirements and production requirements using the order information, it is possible to accurately calculate the material requirements and change the production requirements There is an advantage.

Material requirements, safety stock, order information, weekly sales plan, MRP, production plan requirements

Description

METHOD FOR YIEDING MATERIAL REQUIREMENT AND PRODUCT PLANNING REQUIREMENT AND RECORD MEDIA RECORED PROGRAM FOR REALIZING THE SAME}

1 illustrates a requirement planning (MRP) process according to the prior art.

2 illustrates an MRP process in accordance with a preferred embodiment of the present invention.

3 is a diagram illustrating a module configuration of an MRP application according to an embodiment of the present invention.

4 illustrates a production instruction system in accordance with the present invention.

5 is a flow chart showing the material requirements and production planning requirements calculation process according to the present invention.

6 illustrates an interface for setting a safety inventory in accordance with the present invention.

7A to 7D illustrate an interface for inputting monthly sales plan information.

8 is a diagram showing a screen for displaying a requirement when only monthly sales plan information is input.

9A to 9D are diagrams showing example screens when order information is input.

10 is a view showing an example screen in the case of automatically calculating the required amount according to the correction information input.

11A to 11D are diagrams showing an example screen in the case of dividing a lot according to automatically calculated requirements.

The present invention relates to a method for calculating a material requirement and a production plan requirement, and a recording medium on which a program for implementing the same is recorded. More specifically, the method for calculating a material requirement and a production plan requirement for maintaining proper logistics and implementing the same The present invention relates to a recording medium having recorded thereon a program.

Material Requirement Planning (MRP), or material requirements planning, is the planning of how much material will be needed for production, and is an activity / sequence system for adjusting the level of timely purchase of required materials, product deliveries, and inventory. it means.

In addition, material requirements planning logically analyzes the correlation of lead time to produce a product, which is based on the demand requirements for the product, that is, on the basis of the delivery time and delivery quantity, Is a necessary activity to minimize inventory costs by determining how much to prepare.

Material requirements planning allows companies to plan ahead for materials that are sensitive to changing conditions, enabling shorter production times, control of pre-delivery times, and an organic combination of production and inventory management.

Material requirements planning, on the other hand, is a complex production process, especially when the product is completed through multiple assembly steps, when manufacturing and purchasing lead times are relatively long, when product costs are high, and when the final product is produced. It can be especially useful for long cases.

This material requirement plan provides a lot of theoretical benefits for the enterprise, but in practice, the material requirement plan applied in the field was not applied theoretically and was decided arbitrarily based on order information.

1 is a diagram illustrating a material requirement planning (MRP) process according to the prior art.

Referring to FIG. 1, order information, product information, material information, BOM information, product inventory information, product availability information, and material inventory information are used to calculate a material requirement. The calculation method was used.

Here, the product information may include information on manufacturing lead time and the safety stock quantity for the product, and manufacturing lead time means a period from the time of receiving the order to the time of shipping.

Safety stock is a stock that is held to meet the uncertainty of production or material procurement, also known as buffer stock.

It is desirable to maintain a safety stock when the loss due to lack of stock is greater than the maintenance cost of the safety stock and when the maintenance cost of the safety stock is small, and the level is dependent on the change in demand and procurement period.

On the other hand, the material information includes the purchase lead time of the material and the safety stock quantity of the material.Bill of Material (BOM) is data about which parts of a specific product are composed, which is the most basic information in the BOM. May be referred to as 'Product Structure Information'.

In addition, inventory means information about a finished product or product, and work in progress refers to information about the product being produced.

Conventional material requirements were calculated using safety stock quantities and order information, inventory and inventory numbers for products and materials. Order information, material information, inventory and inventory information for products and materials are realistic objectives, Since the information on the safety stock is information that is predicted to the worker, the quantity of the safety stock must be accurately determined for accurate requirements calculation.

However, despite the existing safety stock calculation formula, the safety stock calculation formula is complicated, and it is difficult for an operator to predict fluctuations in demand and procurement period. Due to inaccuracy and randomness, there is a problem that the inventory of products and materials is greatly increased or insufficient.

On the other hand, in material requirements planning, at the end of the previous month, the requirements are calculated using the safety stock quantity, monthly sales plan, and the inventory and work of the product, the production plan requirements are established accordingly, and the lot is made according to the established production plan requirements. In order to perform the division process, conventionally, only the order production method is applied. Therefore, when the product is entered in the month and the production of the product is progressing (when running), the material requirement should be calculated by closing the period every time there is an order.

However, in the case of companies that mainly produce small quantities of various kinds, in case of frequent order fluctuations and short delivery time (when the order cycle is shorter than the manufacturing lead time), it is impossible to close the period every order fluctuations. In the event that there is frequent order fluctuations in each state, this would result in production according to the production plan requirements at the end of the previous month, resulting in a shortage in the event of a large inventory and provision buildup or vice versa. There was a problem with getting lost.

In the present invention, in order to solve the problems of the prior art as described above, the method for calculating the material requirements and production requirements to accurately determine the safety stock information to calculate the exact material requirements, and a recording medium having a program for implementing the same I would like to propose.

Another object of the present invention is a multi-quantity small quantity production, the present invention to enable the accurate material requirements for the short-term delivery of the present invention provides a method for calculating the material requirements and production planning requirements, and a recording medium recording a program for implementing the same It is.

Another object of the present invention is the present invention that can change the lot at the time of running to produce the product by automatically calculating the requirements for every order change, the material requirements and production planning requirements calculation method and record for recording the program for implementing the same To provide a medium.

Another object of the present invention is to provide a recording medium in which a method for calculating material requirements and production plan requirements and a program for implementing the same are recorded.

In order to achieve the above object, according to a preferred embodiment of the present invention, the step of (a) setting the safety stock quantity using the sales quantity and the safety stock ratio of the material or product; Calculating a pre-running material requirement using the set safety stock quantity, monthly sales plan information, inventory and inventory information, wherein the monthly sales plan information is divided into a plurality of weekly sales plan information; (C) receiving order information input when running; And automatically calculating the requirements using the weekly sales plan information, the release information, the safety stock quantity, the availability and the inventory information after the time the order information is input among the order information and the weekly sales plan information set at the end of the previous month (d A requirement calculation method is provided.

The weekly sales plan information divides the monthly sales plan according to product characteristics, and when the order information is input, the weekly sales plan information of the corresponding week is preferably adjusted to the order information.

Further, according to the present invention, the production planning requirements are determined according to the requirements before running, the determined production planning requirements are divided into one or more lots (LOT), the requirements automatically calculated in the step (d) and the remainder of the week (E) calculating excess or deficiency by comparing the production plan requirements; And adjusting the divided lot according to the calculated excess or deficiency value.

It is preferred that the work be done on the last lot of the lots that have not been run.

On the other hand, according to another aspect of the present invention, there is provided a recording medium on which a program for performing the above method is recorded.

Hereinafter, the present invention according to the present invention with reference to the accompanying drawings will be described in detail a preferred embodiment of a method for calculating the material requirements and production planning requirements and a recording medium on which a program for implementing the same is recorded.

The present invention is to enable the enterprise to hold the appropriate quantity through the automatic calculation of the exact material requirements and production plan requirements, the present invention can be performed in a terminal installed in the enterprise by a predetermined application program, on the contrary, It may be performed in a server provided at a remote location by receiving the necessary information from the installed terminal via the network.

2 is a diagram illustrating an MRP process according to an embodiment of the present invention.

Referring to FIG. 2, the material requirement planning according to the present invention may use order information, weekly sales planning information, product information, material information, BOM information, product release information, product inventory information, product availability information, and material inventory information. .

Unlike the prior art, the material requirement planning according to the present invention uses the minimum safety stock ratio information and the sales information in determining the minimum safety stock quantity.

The minimum safety stock quantity may be required for the product and the material. According to the present invention, the minimum safety stock quantity for the product may be determined as the product of the N-month sales quantity average and the first safety stock ratio, and the minimum safety stock for the material. The quantity can be determined as the product of the N-month sales quantity and the second safety inventory rate.

Here, the first safety stock rate is a safety stock rate for the product, and according to the present invention, it may be determined through the manufacturing lead time and the average monthly working days.

For example, if product A has 5000 N-month sales, manufacturing lead time is 5 days, and the average monthly number of operating days is 22, then the minimum safety stock rate can be determined as 5/22 = 22.72 percent. The minimum safe stock quantity of a product can be determined as 5000 x 0.2272 = 1136.

In addition, if the purchase lead time of material a 'for the manufacture of product A is 7 days, then the minimum safety stock ratio of material a' is determined to be 7/22 = 31.81 percent, so the minimum safety stock quantity is 5000 x 0.3181 = 1590 Can be determined to be dogs.

As described above, in the past, it was common to determine the minimum safety stock quantity only based on the operator's experience, but according to the present invention, the ratio of the safety stock is determined using the purchase and manufacturing lead time of the product or material, The decision is made in conjunction with the sales quantity (demand quantity), which enables the accurate determination of the minimum safety stock quantity.

Meanwhile, according to the present invention, the weekly sales plan information and the product release information may be additionally used in the material requirement calculation and the production plan requirement calculation.

Conventionally, since only the order information is important at the time of running, the requirements are calculated using only the minimum safety stock quantity and the order information. However, according to the present invention, the weekly sales plan information and the product release to parallel the planned production and the order production Use additional information.

In general, in the material requirements planning, the weekly sales plan information according to the monthly sales plan at the end of the previous month is determined. According to the present invention, the order information entered in a particular week is replaced by the weekly sales plan of the week during the run. Material requirements are calculated using order information, goods issue information and weekly sales planning information for the rest of the week.

On the other hand, in production planning requirements planning, pre-running production planning requirements can be determined according to material requirements at the end of the previous month, where pre-running material requirements are calculated using monthly sales plans, minimum safety stock quantities and restocking, and inventory information. -Lots can be determined according to production plan requirements. In the present invention, when the material requirements are automatically calculated for each change in orders, the present invention calculates an oversufficiency between the previous production plan requirements and the automatically calculated material requirements, and thus still works. It carries out the process of changing the lot that has not progressed.

If the lot is changed as described above, production planning requirements for the next run can be calculated.

3 is a view showing the module configuration of the MRP application according to an embodiment of the present invention, as shown in Figure 3, MRP application according to the present invention is a safety inventory setting module 300, order information receiving module 302, the shipment information receiving module 304, the material requirement calculation module 306, the oversufficient calculation module 308, and the lot adjustment module 310 may be included.

Referring to FIG. 3, the production instruction system shown in FIG. 4 will be referred to, and product 1 will be described as an example among products 1 to 3.

The safety inventory setting module 300 sets a minimum safety stock quantity. As described above, the safety stock setting module 300 sets the safety stock using the sales quantity average and the minimum safety stock ratio information for each material and product.

In FIG. 4, the safety stock for product 1 is determined based on the 3-month average sales quantity, and the safety stock ratio is set to 100 percent.

At the end of the previous month in Figure 4 material requirements before the run is determined through the minimum safety stock quantity, product inventory and inventory information, monthly sales planning information.

In other words, the pre-running material requirement is the sum of monthly sales plan information and the minimum safety stock quantity, which is calculated by subtracting the inventory and inventory of the product. The production plan requirement is determined based on the requirements calculated at the end of the previous month. According to the production plan requirements, the operator enters lot splitting information.

In FIG. 4, the production plan requirement is determined by removing one hundred units from the end of the previous month of the product 1, but this is only an example, and other methods may be used to determine the production plan requirement from the material requirement.

Meanwhile, according to a preferred embodiment of the present invention, when the order information is input, a material requirement and a production plan requirement calculation process may be performed on a weekly basis, and the order information receiving module 302 receives the order information when running and release information. When the receiving module 304 receives the release information of the corresponding week, the material requirement calculation module 306 performs a process of calculating the material requirement using the above information and the weekly sales plan information.

Referring to FIG. 4, the end-monthly weekly sales plan information of Product 1 is set to 13000 for each week, and at the end of the previous month, the material requirements are calculated using the weekly sales plan information of each week, but the order information is input to 6500 in the first week. If necessary, the material requirement calculation module 306 calculates by subtracting the inventory, inventory, and release information from the sum of the minimum safety stock quantity, the order information for the first week, and the weekly sales plan information for the rest of the week.

For example, the week 1 requirement of product 1 of FIG. 4 may be automatically calculated as (10333 + 6500 + 13000x3) − (7500 + 16500 + 6500) = 25333.

Meanwhile, in FIG. 4, it is assumed that lots of product 1 are divided into 19000, 15000, and 15000 according to production plan requirements at the end of the previous month, and each lot is sequentially formed in units of 1, 2, and 3 weeks.

As a result, 19000 jobs are already in progress at run time, so the current production plan requirement for Week 1 is 30000.

When the requirement of the first week is calculated as 25333 as described above, there is a difference between the current production planning requirements and the automatically calculated material requirements, the oversufficiency calculation module 308 according to the present invention is a new material requirements In addition, the process of calculating the excess and deficiency between the calculated material requirements and the current production plan requirements is performed.

In FIG. 4, oversight of 4667 occurs for product 1 at week 1.

Since +4667 oversufficiency means that more than necessary products are produced by the value, the lot adjustment module 310 according to the present invention performs a process of adjusting a lot that has not been processed yet according to the oversufficient value.

At this time, the lot number in which the numerical adjustment is performed among the divided lots may be set in various ways. For example, as shown in FIG. 4, the lot number may be set to adjust the last lot. It can be set to adjust the lot evenly.

In FIG. 4, lot 3 is adjusted from the originally planned 15000 according to week 1 oversufficiency 4667, the value of which may be adjusted to 10400, reduced by 4600 with ten units removed for ease of calculation.

However, this is only one example, and it will be apparent to those skilled in the art that the present invention may be used as it is.

As described above, when the lot is adjusted according to the calculated excess or deficiency, the production plan requirement calculation module 312 performs a process of automatically changing the next production plan requirement, and the next production plan requirement of the product 1 in week 1 is 10400. Was changed.

On the other hand, in the second week, if 6500 orders are generated, the material requirement calculation module 306 may include the minimum safety stock quantity 10333, the adjusted weekly sales plan information of the weeks 1 and 2, and the remaining weekly sales plan information (6500). From the sum of + 6500 + 13000x2), the material requirement (4833) is calculated by subtracting the 2nd week's stock, inventory and release information.

On the other hand, the oversufficiency calculation module 310 calculates the oversufficiency by using the material requirements calculated as described above and the production plan requirements of Week 2 (which corresponds to the production plan requirements changed in Week 1), and the lot adjustment module 312 The process of adjusting the current lot 3 to 4900, taking into account excess and deficiency.

Here, the value of the lot 3 is changed and corresponds to the production plan requirement.

In the above, the requirement is calculated for the product, but the requirement calculation process may be performed in the same manner with respect to the material required for producing the product.

As described above, the use of the weekly sales plan information and the actual order information at the end of the previous month to calculate the material requirements and production plan requirements according to the present invention, and because it is calculated without a separate period, the planned production is possible, material requirements and Production plan requirements are calculated in real time.

In addition, it is possible to maintain proper logistics by adjusting the lot previously determined according to the automatically calculated requirements.

5 is a flowchart illustrating a material requirement calculation process according to the present invention.

Referring to FIG. 5, first, the MRP program according to the present invention performs a process of setting a safety inventory for a specific product and material (S500).

FIG. 6 is a diagram illustrating an interface for setting a safety inventory according to the present invention. As illustrated in FIG. 6, an operator may determine the number of months for sales criteria through the interface illustrated in FIG. 6, and the minimum safety. Inventory rates can be determined.

Although FIG. 6 illustrates that a three month sales quantity average and a minimum safety stock rate of 30% are set, this is only an example, and the minimum safety stock rate may be set higher than this.

Then, the present invention performs the material requirements calculation process at the end of the previous month (S502).

As described above, the monthly sales plan information may be used to calculate the requirement at the end of the previous month. FIGS. 7A to 7D illustrate an interface for inputting the monthly sales plan information of each material, and the operator plans the monthly sales plan. In the case of inputting information, as shown in FIG. 8, the MRP process according to the present invention calculates the requirement at the end of the previous month by using the inputted monthly sales plan information, minimum safety stock quantity, and inventory information.

According to the requirement at the end of the previous month, the operator can input the lot split information, MRP process according to the invention receives and stores the lot split information (S504).

Next, when the production of the product according to the order is started, the MRP process receives the order information input by the worker (S506). The operator's order information input may be performed as shown in FIGS. 9A to 9D.

In addition, it receives the goods issue information of the product (S508), the MRP process automatically receives the material requirements by using the received order information, release information and the rest of the weekly sales planning information, minimum safety stock quantity, release information, work in progress, inventory information A calculation process is performed (S510).

FIG. 10 is a diagram illustrating an example screen in which a requirement is automatically calculated according to correction information input. As shown in FIG. 10, when an operator inputs order information without closing a separate period, requirements of each product are shown. This is calculated automatically.

Thereafter, the MRP process determines whether there is an oversufficiency between the newly calculated material (product) requirements and the production plan requirements at the end of the previous month (S512), and if the oversufficiency occurs (S514).

11A to 11D are diagrams illustrating an example of a case in which a lot is divided according to automatically calculated requirements, and as illustrated in FIGS. 11A to 11D, lot adjustment may be performed according to the calculated oversufficiency.

The MRP process according to the present invention performs a process of adjusting the final lot according to the above-mentioned shortage, or increasing or decreasing each lot that has not been in operation yet by an equal or preset ratio.

On the other hand, as described above, when the lot is adjusted, the MRP process performs a process of calculating the production plan requirements (S516).

In this specification, the term production plan requirement is calculated by lot adjustment, but the production plan requirement may be automatically changed by lot adjustment.

Thereafter, the MRP process determines whether the reference period has expired (S518), and if the reference period has not yet expired, repeats the steps (S506 to S516).

Here, the reference period may mainly mean monthly units.

Preferred embodiments of the present invention described above are disclosed for purposes of illustration, and those skilled in the art will be able to make various modifications, changes, and additions within the spirit and scope of the present invention. Additions should be considered to be within the scope of the following claims.

As described above, according to the present invention, since the safety stock information is determined using the sales quantity and the ratio information, the minimum safety stock quantity can be determined by reflecting the market requirement, and thus there is an advantage that the required amount can be accurately calculated.

In addition, according to the present invention, since the requirements are calculated immediately every time the order changes without performing a separate period, there is an advantage in that it is possible to calculate the exact material requirements for the small quantity production, especially for short-term products.

In addition, according to the present invention, there is an advantage that the running lot to produce a product by automatically calculating the requirements for each change in order to change to the current level.

In addition, according to the present invention, there is an advantage that the planned production is possible because the demand is continuously calculated using the weekly sales plan information during the run.

Claims (6)

In the material requirements and production planning requirements calculation method performed by a material requirement planning (MRP) application, (A) setting a minimum safety stock quantity using the sales quantity and the minimum safety stock rate of the material or product; (B) calculating the pre-running material requirement, which is a product production progress period, by using the set minimum safety stock quantity, monthly sales plan information, inventory and inventory information (b)-the monthly sales plan information is divided into a plurality of weekly sales plan information being-; (C) receiving order information input when running; And Automatically calculating the requirements using the weekly sales plan information, the release information, the minimum safety stock quantity and the availability and inventory information after the time the order information is input among the order information and the weekly sales plan information set at the end of the previous month (d ), The monthly sales plan is divided into a plurality of weekly sales plan information according to a product characteristic, and the weekly sales plan information of the corresponding week is adjusted by the received order information. The method of claim 1, The sales quantity is determined as the average of sales quantity for N months, The method for calculating material requirements and production plan requirements, characterized in that N is any natural number. delete The method of claim 1, Production plan requirements are determined according to the material requirements at the end of the previous month, the determined production plan requirements are divided into one or more lots, (E) calculating an excess or deficiency by comparing the requirement automatically calculated in the step (d) with the previous production plan requirement of the week; And And adjusting the divided lot in accordance with the calculated excess or deficiency value. The method of claim 4, wherein The step (f) is a method for calculating material requirements and production planning requirements, characterized in that for adjusting the final lot of the divided lot (LOT) that is not in progress. A recording medium on which a program for executing any one of claims 1, 2, 4 or 5 is recorded.

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