JP2019149002A - Loss cost reduction system and method - Google Patents

Abstract

To provide a loss cost reduction system reducing loss cost by allowing a user to grasp a remaining amount of components used for assembling a product.SOLUTION: An loss cost reduction system 100 is a system reducing loss cost of components used for assembling a product, comprising: an information collection unit 101 collecting information on a remaining amount that is difference between a purchase amount and a used amount of object components; and an information providing unit 102 generating remaining component confirmation information including information identifying object components, a remaining amount, a remaining money value obtained by conversing the remaining amount to a money value, and occurrence reason for the remaining amount, and providing the generated remaining component confirmation information to a user terminal. Thereby, since the remaining component confirmation information is presented on the user terminal, a user can confirm the remaining amount, the remaining money value, and the occurrence reason for the object components, which can be utilized for a next component arrangement.SELECTED DRAWING: Figure 1

Description

  The present invention relates to a loss cost reduction system and method.

  Ideally, it is preferable to have a small inventory of parts, but it is necessary to have a certain amount of inventory in order to keep the delivery date promised with the customer. A technique for managing inventory has been known (Patent Document 1).

JP 2014-191605 A

  In the conventional technology, when old parts and new parts are mixed, the new parts are used preferentially, so the situation where the old parts remain is reduced, and the number of discarded old parts is reduced. The remaining parts are not visualized and the loss cost is not reduced.

  The present invention has been made in view of the above problems, and its object is to achieve loss cost reduction by allowing a user to grasp the amount of extra material used for assembling a product. It is to provide a reduction system and method.

  In order to solve the above problems, the loss cost reduction system according to the present invention is a system for reducing the loss cost of parts used for assembling products, and information on the amount of remaining material, which is the difference between the purchase amount and the usage amount of the target part. Generates and generates surplus material confirmation information that includes the information collection unit that collects information, the information for identifying the target part, the surplus material amount, the surplus material amount converted to the amount, and the reason for the surplus material amount And an information providing unit for providing the used material confirmation information to the user terminal.

  According to the present invention, since the remaining material confirmation information is presented to the user terminal, the user can confirm the amount of remaining material, the amount of remaining material, and the reason for the occurrence of the target component, which can be used for the next part arrangement. be able to.

Explanatory drawing which shows the whole outline | summary of this embodiment. The hardware block diagram of the computer system containing a loss cost reduction system. The flowchart of a loss cost reduction process. The data flow figure regarding a loss cost reduction system. Screen for collecting surplus material information. Check screen for surplus material information. Screen for checking surplus material information in parts code units. Screen for reviewing the lot size. A screen for stocking repeatedly arranged items. A screen to check the amount of reduction of surplus material. Parts arrangement screen. Screen to modify the design BOM (Bill of materials). The table structure figure of surplus material information. The table structure figure of unit price information. FIG. 5 is a table configuration diagram of parts information. The table block diagram of production plan information. The table block diagram of parts arrangement information. The table block diagram of design BOM. The flowchart of the process which concerns on 2nd Example and calculates a reduction effect. The flowchart of the process which concerns on 3rd Example and determines arrangement | positioning classification. The schematic diagram of the system which concerns on 4th Example and shares surplus material information over a some corporate body.

  Hereinafter, embodiments of the present invention will be described with reference to the drawings. In this embodiment, as will be described in detail later, information on surplus materials generated after assembly is collected to grasp the amount of surplus materials for each part, and the amount of parts used is predicted from past arrangement results and order information. , Allowing the user to select an optimal purchase method. Thereby, in this embodiment, a surplus material item can be reduced and a disposal loss cost can be reduced.

  For example, in the form of a single order made-to-order product (individual product) such as plant equipment, detailed design is advanced from schematic design while determining specifications with the customer. However, if the parts are arranged for the purchased product after all the designs are completed, it will not be in time for the delivery date desired by the customer, so a large amount will be arranged at the initial stage. In other words, taking into account risks such as changes in specifications and additions, we will arrange a large amount including spare parts.

  Here, the parts that are repeatedly used as a standard are held as stocks. However, having all the parts as stock in stock is too expensive. Therefore, many parts are purchased every time an order is received in order to reduce costs. The parts that are purchased each time include parts that cannot be purchased unless the lot size is specified by the vendor, so there is always a surplus.

  Since all the remaining parts of purchased parts need to be discarded so as not to become out-of-book items for accounting purposes, this results in a loss cost. In view of this, in the present embodiment, the amount of surplus material generated (the amount of surplus material) is suppressed by allowing the user to grasp information on the surplus material.

  A first embodiment will be described with reference to FIGS. FIG. 1 is an explanatory diagram showing an overall outline of the loss cost reduction system 100. The configuration described below is merely an example for realizing the present embodiment, and is not limited to the illustrated configuration example. The present embodiment is suitably used for, for example, small-lot production of a variety of products such as a uniform product, a customized product, and a prototype.

  The loss cost reduction system 100 can be configured using a computer as will be described later. As its functions, for example, an information collecting unit 101, an information providing unit 102, a lot size review unit 103, and an arrangement type changing unit 104 are provided. With.

  The lower part of FIG. 1 shows a series of flows until a product in a build-to-order manufacturing form is shipped. Design is performed based on the contents determined at the time of ordering (S1), and parts necessary for manufacturing the product are arranged according to the design (S2).

  Each part can be arranged by any one of three methods, for example, “purchased product”, “stock item in stock”, and “in-house work”. The “purchased product” is a part ordered from the vendor 90 whenever necessary. Since the lot size and the required quantity usually do not always coincide with each other, the surplus material 7 is likely to be generated. A “stock in stock” is a part that is in stock as a stock. Since the necessary number can be taken out from the stock, and the surplus can be returned to the stock, it is difficult to generate extra materials. "In-house work" is a part produced in-house. Since it is sufficient to produce only the necessary number, it is difficult to generate extra materials.

  When the parts are brought into the manufacturing site, assembly production of the product is started (S3). A predetermined test (inspection) is performed after assembly (after manufacture) (S4), and a product that passes the test is shipped to the customer (S5).

  Of the parts remaining in the assembly process, the stock in stock is returned to the warehouse for management (S6). Purchased materials are discarded. The difference between the number of purchased parts arranged and the actual number of parts used is the quantity of the remaining material 7. When the lot size of the purchased product is determined by the purchase contract with the vendor, the purchased product is purchased in lot units so that the quantity is larger than the number of arrangements. For example, when the number of arrangements is 70 and the lot size is 50, parts for 2 lots (100 in total) are arranged. When the number used is 60, the quantity of the remaining material 7 is 40. Hereinafter, the quantity of surplus materials may be referred to as the amount of surplus materials.

  In the loss cost reduction system 100, the information collection unit 101 collects information on surplus materials from the assembly site (manufacturing site). Then, the information providing unit 102 of the loss cost reduction system 100 includes information for specifying the target part, the amount of remaining material, the amount of remaining material obtained by converting the amount of remaining material into an amount, and the reason for occurrence of the amount of remaining material. The product confirmation information is generated and provided to the generated surplus product confirmation information user terminals 2 and 5 (see FIG. 2).

  The loss cost reduction system 100 can also assist the review of the lot size in order to reduce the amount of remaining material. As will be described later, the lot size review unit 103 of the loss cost reduction system 100 can present a plurality of different pairs of lot sizes and unit prices in that case to the user and select one of the pairs. For example, by negotiating between the parts vendor and the design department or procurement department, multiple lot sizes and unit price estimates can be obtained, and a lot size review screen can be generated from information on these estimates. it can.

  The loss cost reduction system 100 can also assist in changing the arrangement type in order to reduce the amount of remaining material. As will be described later, the arrangement type changing unit 104 of the loss cost reduction system 100 generates a screen for changing a purchased item into a stock item, or vice versa, and generating a screen for changing the stock item into a purchased item. Can also be presented.

  FIG. 2 is a hardware configuration diagram of a computer system including the loss cost reduction system 100.

  The computer system shown in FIG. 2 includes, for example, a loss cost reduction server 1, a design terminal 2, a parts arrangement server 3, an inventory management server 4, a management department terminal 5, and devices 61 to 63 used at a manufacturing site 6. A loss cost reduction server 1, a design terminal 2, a parts arrangement server 3, an inventory management server 4, a management department terminal 5, a weighing device 61, and a wireless base station 62 are connected to the communication network CN. The handy terminal 63 is connected to the communication network CN via the radio base station 62.

  The loss cost reduction server 1 is configured as a computer including a processor 11, a memory 12, a communication interface 13, a user interface unit 14, and a storage device 15, for example. In the figure, the processor is abbreviated as CPU (Central Processing Unit), the interface is abbreviated as IF (Interface), and the user interface is abbreviated as UI (User Interface).

  The storage device 15 stores a predetermined computer program for realizing the loss cost reduction system 100. The function as the loss cost reduction system 100 is realized by the processor 11 reading and executing a predetermined computer program. The storage device 15 can also store information such as extra material information T2, which will be described later.

  The design terminal 2 is a computer used in the design department. The designer accesses the parts arrangement server 3 via the design terminal 2 to arrange parts necessary for manufacturing the product to be designed. Further, the designer receives the surplus material information T2 (described later with reference to FIGS. 4 and 13) from the loss cost reduction server 1 via the design terminal 2, thereby confirming the difference between the arranged quantity and the surplus material quantity. You can also

  The parts arrangement server 3 is a computer that arranges parts. The parts arrangement server 3 arranges the parts requested from the design terminal 2 by any one of “purchased goods”, “stock items in stock”, and “in-house works”.

  The inventory management server 4 is a computer that manages a group of parts registered as a stock inventory. The stock management server 4 manages the stock so that a predetermined quantity of stock is always available. The inventory management server 4 issues the requested parts from the parts arranging server 3 to the manufacturing site 6 in the requested quantity. In addition, the inventory management server 4 accepts parts remaining at the manufacturing site 6 and the like as inventory. Further, the inventory management server 4 manages orders placed to the parts vendor 90 in order to maintain a predetermined quantity of inventory.

  The management department terminal 5 is a computer used in a management department such as a material department, a procurement department, or an accounting department. A user in the management department can check information related to the surplus material information T2 through screens G2 and G3 described later by accessing the loss cost reduction server 1 via the management department terminal 5.

  At the manufacturing site 6, a product is manufactured by assembling or processing a plurality of parts. The weighing device 61 is configured, for example, as a digital balance, and is used to reduce the weight of components that cannot be managed by the number of wires, for example. In the case of an electric wire, if the unit weight is registered in the weighing device 61, the length can be obtained automatically. An operator at the manufacturing site 6 can measure the remaining amount (remaining material amount) of parts that cannot be managed by the number using the weighing device 61 and transmit the measurement result to the loss cost reduction server 1. Although details are omitted, since the measurement result of the weighing device 61 is associated with information for specifying the target product, the loss cost reduction server 1 can grasp which product is the amount of remaining material.

  The handy terminal 63 at the manufacturing site 6 includes an information reading unit such as a barcode reader and a display unit. The user acquires the quantity of surplus material 7 (the amount of surplus material) generated at the manufacturing site 6 using the handy terminal 63 and transmits it to the loss cost reduction server 1 via the radio base station 12. Each part is provided with a management tag 71 (see FIG. 4). The operator causes the handy terminal 63 to read information written on the tag 71 of the surplus parts (surplus material item 7) and inputs the amount of surplus material. Thus, the information of the surplus material 7 acquired at the manufacturing site 6 is sent to the loss cost reduction server 1 via the communication network CN.

  In this embodiment, as an example of a method for collecting information such as the name and quantity of the surplus material 7, a case where the operator inputs predetermined items on the surplus material information collection screen G <b> 1 will be described. However, the present invention is not limited to this. For example, an operator may input surplus material information by voice, or capture the result of analyzing the image of the surplus material state captured by a camera.

  FIG. 3 is a flowchart showing the entire loss cost reduction process. The loss cost reduction system 100 of the loss cost reduction server 1 collects information (remaining material information) of the remaining material 7 from the handy terminal 63 of the manufacturing site 6 (S11).

  That is, the operator counts the number of parts that have become the remaining material 7 after assembly, and then causes the handy terminal 63 to read a part of the part arrangement information T6 described on the tag 71 of the remaining material 7, The amount of surplus material is input to the surplus material information collection screen G1 displayed on the handy terminal 63. Information input to the surplus material information collection screen G1 is transmitted to the loss cost reduction server 1 and accumulated as surplus material information T2.

  If there is a shortage of parts to be purchased due to the length of the wires, etc., the delivery date will be affected. However, in the case of a one-item, one-to-man made-to-order product, it is difficult to accurately predict the required length in advance, and therefore, surplus material 7 is likely to occur. It is difficult to measure the length of the surplus wires after assembling because wires and insulation tubes are packed in bundles. Therefore, the unit weight is registered in advance in the weighing device 61, and the measured weight is converted into a length. Thereby, the length of the remaining material can be measured efficiently in a short time.

  The loss cost reduction system 100 calculates a value obtained by converting the amount of surplus material into an amount based on the collected surplus material information T2 or the like, that is, the amount of surplus material (S12). The loss cost reduction system 100 is a server device having a database function for storing extra material information T2 of parts used for a product for each order item. The surplus material information T2 includes, for example, information such as an order number, a part code, an arrangement quantity, a surplus material quantity, and a surplus material amount.

  The loss cost reduction system 100 reviews the order size (lot size) of the lot purchased product (S13). By using the loss cost reduction system 100, a user such as a procurement staff or a designer can grasp the actual usage quantity from the amount of remaining material that has been repeatedly generated for parts purchased with a lot size specified by the vendor. Can do. Then, the user can negotiate with the component vendor 90 based on the grasped data, and can receive one or a plurality of proposals as a result of the negotiation. As a result, the user can change to an appropriate size adjusted with the component vendor 90. To change the lot size, a lot size review screen G4 described later with reference to FIG. 8 can be used.

  If the component vendor 90 is purchased with an undesignated lot size, a loss such as a material yield occurs. Therefore, the component vendor 90 can set a vendor-specified unit price for each lot size. The unit price specified by the vendor is set in the unit price information T3. If the lot size cannot be changed because the discussion with the component vendor 90 is unsuccessful, the lot purchased item can be changed to a stock item in the next step S14.

  For example, the loss cost reduction system 100 may select any one or a plurality of purchased items with a large surplus amount of money or purchased items with repeated surplus items and change them to a stock in stock. Yes (S14). The parts to be changed to the stock in stock can be selected on the repeatedly arranged goods stocking screen G5 described later with reference to FIG. When a part is selected on the screen G5, the loss cost reduction system 100 generates part information T4 for stocking the part. The loss cost reduction system 100 can change the part management from “purchased item” to “stock item” by transmitting the component information T4 to the inventory management system 40 of the inventory management server 4.

  In inventory management, the required amount of parts is always available in the factory, so that the necessary quantity of parts can be arranged and issued when the design specifications are finalized. Since the surplus parts can be returned to inventory management, the generation of surplus material 7 can be suppressed.

  In addition, by setting thresholds for the number of arrangements and the amount of surplus materials and generating conditions for stocking in stock, parts to be changed from purchased products to stock in stock can be selected automatically, or the selection is automatically performed. Can be released automatically (returning from a stock item to a purchased item). In addition, when changing to a stock item in stock, “stock item in stock” is described in the category C42 of the component information T4 described later in FIG. When canceling the stock in stock, “purchased product” is described in the category C42. As a result, it is possible to easily distinguish between the stock in stock and the purchased product.

  The loss cost reduction system 100 calculates the reduction amount of the remaining material amount for the specified period by the loss cost reduction measure (review of the lot size (S13), stocking of the purchased product (S14)) implemented in step S13 and / or step S14. (S15). Thereby, the reduction amount of the surplus material amount in the designated period can be predicted.

  Here, in the case of a product whose product specifications are almost fixed, a surplus material for a case in which the product code C51 and the design BOM T1 of the production plan information T5, which will be described later with reference to FIG. The amount of money reduction can be calculated. In the case of a product whose customer specifications have not been decided, by registering a similar order number in the past in the production plan information T5, the corresponding parts arrangement information can be provisionally developed, and the reduction amount of the surplus material amount can be predicted.

  A user such as a designer or an administrator can check the total amount of the reduction amount through the surplus material amount reduction amount screen G6 described later with reference to FIG. For example, the user can find a combination with the largest reduction in the amount of surplus material by increasing or decreasing the number of parts to be in stock.

  By the way, because there is a limit to the area of parts storage, for example, parts with a small number of arrangements and parts with a small amount of surplus materials are switched from stock items to purchased items, and parts with a large number of arrangements and parts with a large amount of surplus materials are purchased By switching from goods to stocks in stock, the storage location can be used efficiently.

  FIG. 4 is a data flow diagram regarding the loss cost reduction system 100. The parts arrangement system 30 provided in the parts arrangement server 3 has a function of arranging each part necessary for manufacturing the product. The parts arrangement system 30 can use information of design BOM T1, unit price information T3, parts information T4, production plan information T5, and parts arrangement information T6.

  The parts arrangement system 30 arranges for the production department 80 when the target part is an in-house work, and arranges with the inventory management system 40 provided in the inventory management server 4 when the target part is a stock in stock. If it is a product, arrange it with the component vendor 90.

  Each part arrives at the layout center 81 from an arrangement destination of the parts arrangement system 30. The catering center 81 supplies a necessary number of necessary parts to the assembly process 82 of the manufacturing site 6. The product assembled in the assembly process 82 is sent to the test process 83 and undergoes a predetermined test. Products that pass the test are packed and shipped to customers.

  When the assembling work in the assembling process 82 is completed, the amount of surplus material (the amount of surplus material) is determined. Therefore, in the surplus material information collection process 60, an operator at the manufacturing site 6 reads the tag 71 of the surplus material 7 using the handy terminal 63 or inputs the amount of the surplus material 7. Collect surplus material information T2.

  The collected surplus material information T2 is sent to the loss cost reduction server 1 for management. The loss cost reduction system 100 supports the above-described review of the lot size based on the information such as the remaining material information T2, and registers the new lot size and the new unit price agreed with the component vendor 90 in the unit price information T3. To do. Further, the loss cost reduction system 100 assists in stocking a part having a large number of times of arrangement and a surplus material amount among the repeatedly arranged parts, and rewrites the part information T4. Furthermore, the loss cost reduction system 100 can also correct the design BOM T1 in accordance with the actual usage quantity so that the amount of remaining material is reduced.

  FIG. 5 is an example of a screen G1 used for collecting the surplus material information T2. This screen G1 is displayed on the display unit of the handy terminal 63. Instead of this, the screen G1 may be displayed on a head mounted display or the like worn by the worker.

  The surplus material information collection screen G1 includes, for example, an order number GP10, a part code GP11, a part name GP12, an occurrence reason GP13, a unit price GP14, an arrangement quantity GP15, a unit GP16, a surplus material quantity GP17, a surplus material amount GP18, and an operator GP19. It includes items such as.

  FIG. 6 is an example of the surplus material confirmation screen G2. This screen G2 is provided to the management department terminal 5 and the design terminal 2 by the loss cost reduction server 1.

  The surplus material confirmation screen G2 includes, for example, an order number GP20, a part code GP21, a part name GP22, an occurrence reason GP23, a unit price GP24, a lot size GP25, an arrangement quantity GP26, a unit GP27, a surplus material quantity GP28, and a surplus material amount GP29. Includes item and period information. The following example is the same, but the items having the same name correspond to each other like the order number GP10 and the order number GP20. The same applies to the information T1 to T6.

  FIG. 7 is an example of a screen G3 for confirming surplus products in part code units. This screen G3 includes, for example, the order number GP30, the part code GP31, the part name GP32, the generation reason GP33, the unit price GP34, the lot size GP35, the order quantity GP36, the unit GP37, and the surplus material quantity GP38. In addition, items such as surplus material amount GP39 and period information are included.

  FIG. 8 shows an example of the lot size review screen G4. The lot size review screen G4 is provided by the loss cost reduction system 100 in order to support the review of the lot size by a user such as a designer or a person in charge of procurement.

  On this screen G4, the unit price can be set for each different lot size. That is, the user can register at least one lot size / unit price pair in the unit price information T3 through the screen G4.

  The lot size review screen G4 includes, for example, a part code GP40, a history GP41, a part name GP42, a unit GP43, a lot size GP44, a unit price GP45, a lot size 1 GP46, a unit price 1 GP47, a lot size 2 GP48, a unit price 2 GP49, and a lot size. It includes items such as 3 GP4A and unit price 3 GP4B. That is, the lot size review screen G4 includes basic information on the lot size (GP40 to GP45) and unit price information at the time of size change (a set of GP46 and GP47, a set of GP48 and GP49, a set of GP4A and GP4B). It is out.

  FIG. 9 is an example of a screen G5 for stocking repetitively arranged items as a permanent stock. This screen G5 is provided to terminals used by users such as designers and procurement personnel. This screen G5 includes, for example, a selection field GP50, a part code GP51, a part name GP52, a unit price GP53, a lot size GP54, an arrangement quantity GP55, a unit GP56, a surplus material quantity GP57, a surplus material amount GP58, an arrangement number GP59, and an average inventory GP5A. , Including the rotation rate GP5B.

  FIG. 10 is an example of a screen G6 that displays a reduction amount of the surplus material amount. This screen G6 includes, for example, a graph display part GP60 and table format parts GP61 to GP64. The tabular format section displays monthly changes in data related to the reduction amount in tabular format, and includes, for example, a permanent inventory GP61, a lot size review GP62, a total GP63, and a cumulative GP64.

  FIG. 11 is an example of a screen G7 for arranging parts. The parts arrangement screen G7 is provided to the design terminal 2 by the parts arrangement system 30 of the parts arrangement server 3.

  The parts arrangement screen G7 includes, for example, an order number GP70, a model code GP71, a history GP72, an original order number GP73, a consistent number GP74, a part code GP75, a part name GP76, an arrangement quantity GP77, a surplus material quantity GP78, a unit GP79, and an update. Date GP7A is included.

  The designer can call up the parts arrangement information T6 of the past product similar to the design target product by displaying the parts arrangement screen G7 on the design terminal 2. The designer can adjust the arrangement quantity GP77 of the product to be designed with reference to the surplus material quantity generated in the past similar product. Thereby, generation | occurrence | production of the surplus material goods 7 can further be reduced.

  FIG. 12 is an example of a screen G8 for modifying the design BOM. This screen G8 includes, for example, a model code GP80, a history GP81, an order number GP82, a consistent number GP83, a part code GP84, a part name GP85, an arrangement quantity GP86, a surplus material quantity GP87, a unit GP88, and an update date GP89.

  The designer displays the parts arrangement information T6 held by the parts arrangement server 3 and the surplus material information T2 held by the loss cost reduction server 1 via the design BOM correction screen G8 displayed on the design terminal 2. Can do. Then, the designer can confirm the order quantity GP86 and the surplus material quantity GP87, and can reduce the order quantity of the corresponding part of the design BOM T1 which becomes master information for each product model.

  FIG. 13 is a configuration example of the surplus material information T2. The surplus material information T2 describing the content of the surplus material is, for example, order number C20, part code C21, part name C22, reason C23, unit price C24, arrangement quantity C25, unit C26, surplus material quantity C27, operator It includes items such as C28 and collection date C29. The surplus material information T2 is collected through the surplus material information collection screen G1 described in FIG. The surplus material information T2 is a basis for generating the surplus material confirmation screen G2 described in FIG. 6 and the surplus material confirmation screen G3 described in FIG.

  FIG. 14 is a configuration example of the unit price information T3. Unit price information T3 includes, for example, part code C30, history C31, lot size C32, unit price C33, lot size 1 C34, unit price 1 C35, lot size 2 C36, unit price 2 C37, lot size 3 C38, unit price 3 C39, and increment C3A. The update date C3B is included. The unit price information T3 is generated through the lot size review screen G4 described in FIG.

  FIG. 15 shows a configuration example of the component information T4. The component information T4 is information indicating the content of the component. For example, the component code C40, the history C41, the classification C42, the component name C43, the format C44, the rating C45, the manufacturer name C46, the purchase lead time C47, the lot size C48, and the update Including day C49.

  FIG. 16 shows a configuration example of the production plan information T5. Production plan information T5 includes, for example, order number C50, model code C51, history C52, order date C53, delivery date C54, design deadline C55, arrangement deadline C56, delivery deadline C57, assembly start date C58, test start date C59, update date. Includes C5A.

  FIG. 17 shows a configuration example of the parts arrangement information T6. The part arrangement information T6 includes, for example, an order number C60, a model code C61, a log C62, a consistent number C63, a category C64, a part code c65, a part name C66, an arrangement quantity C67, a unit C68, a unit price C69, an amount C6A, and a lot size C6B. , Including arrangement date C6C and delivery deadline C6D. The parts arrangement information T6 is generated through the parts arrangement screen G7 described in FIG.

  FIG. 18 is a configuration example of the design BOM T1. The design BOM T1 includes, for example, a model code C10, a log C11, a consistent number C12, a part code C13, a part name C14, an order quantity C15, a unit C16, and an update date C17. The design BOM T1 is corrected through the design BOM correction screen G8 described in FIG.

  According to this embodiment configured as described above, the surplus material confirmation screens G2 and G3 as surplus material confirmation information can be displayed on the design terminal 2 and the management department terminal 5, so that the designer and the procurement A user such as a person in charge can quickly and easily check the status of the remaining material. Therefore, the user can make use of it for the next part arrangement so that the amount of the remaining material is reduced, and the usability is improved.

  According to the present embodiment, since the lot size review screen G4 is provided to the terminals 2 and 5 used by the user, the review of the lot size by the user can be supported, and the usability is improved.

  According to the present embodiment, the repetitively arranged goods reserve screen G5 for arranging the lot purchased goods as the regularly stocked goods is provided to the user terminals 2 and 5. Therefore, it is possible to assist the user in selecting an appropriate arrangement type according to the amount of remaining material, the number of arrangements, etc., and usability is improved.

  According to this example, the reduction measures implemented to reduce the amount of surplus materials (review of lot size, change of arrangement type) and the effect of reducing the amount of surplus materials (reduction amount) by the reduction measures Presented to the user via the material amount reduction screen G6. Therefore, the user can easily confirm the effect of the implemented reduction measures, and usability is improved.

  In the case of a purchased product in which the unit price for each lot size is set, it may be cheaper to purchase with a vendor-specified lot size than to purchase with a smaller order quantity than the vendor-specified lot size. In that case, the parts arrangement system 30 may automatically select an optimum lot size at the time of parts arrangement, giving priority to reducing the arrangement amount. The combination of lot size and unit price can be increased or decreased.

  In addition, if it can be determined from the production plan information T5 or an order forecast that the part is scheduled to be used in the future in the surplus material information T2, by adding the surplus material of the part to the stock inventory, Remaining materials can be reduced.

  A second embodiment will be described with reference to FIG. Each of the following embodiments, including the present embodiment, corresponds to a modification of the first embodiment, and therefore, differences from the first embodiment will be mainly described. FIG. 19 is a flowchart of a process for calculating the effect of reducing the surplus material amount.

  When the loss cost reduction system 100 acquires the target period input from the user (S21), the loss cost reduction system 100 acquires a data group for calculating the reduction amount within the target period (S22).

  The loss cost reduction system 100 calculates the effect ES by changing the lot purchased item to the stock item (S23). The stock inventory effect ES can be obtained, for example, by subtracting the amount obtained by multiplying the order quantity by the new unit price (new) from the amount obtained by multiplying the lot size (old) by the unit price (old) (ES = old Lot size x unit price (old)-Arranged quantity x unit price (new).

  The loss cost reduction system 100 calculates a lot size change effect (lot size review effect) EL (S24). The lot size change effect EL can be obtained, for example, by subtracting the amount obtained by multiplying the lot size (new) by the unit price (old) from the amount obtained by multiplying the lot size (old) by the unit price (old) (EL = Lot size (old) x Unit price (old)-Arranged quantity-Unit price (new)).

  The loss cost reduction system 100 calculates the surplus material amount reduction amount ΣE by summing the stock inventory effect ES and the lot size change effect EL (S25). The calculated surplus material amount reduction amount ΣE is sent to the terminals 2 and 5 and displayed.

  Configuring this embodiment like this also achieves the same operational effects as the first embodiment. Furthermore, according to the present embodiment, the amount of reduction of surplus material during the specified period can be calculated, so that the effect can be accurately grasped with numbers, and the usability is improved.

  A third embodiment will be described with reference to FIG. FIG. 20 is a flowchart of the arrangement type determination process.

  The loss cost reduction system 100 acquires the number of arrangements ON for a part whose order is to be changed (hereinafter, the target part) (S31).

  The loss cost reduction system 100 determines whether the acquired number of arrangements ON is equal to or greater than a predetermined threshold Th1 (S32). When the number of arrangements ON is equal to or greater than the threshold Th1 (S32: YES), the loss cost reduction system 100 calculates an increase ΔSA in the stock amount when the target part is a regular stock (S33), and proceeds to step S34. If the number of arrangements ON is less than the threshold value Th1 (S32: NO), this process ends.

  The loss cost reduction system 100 compares the surplus material amount reduction amount ΣE calculated in the process shown in FIG. 19 with the increase amount ΔSA of the inventory amount calculated in step S33, and the surplus material amount reduction amount ΣE increases the inventory amount. It is determined whether it is larger than the minute ΔSA (S34). You may consider the amount borrowed from the bank.

  When the surplus material amount reduction amount ΣE is larger than the increase amount ΔSA of the inventory amount (S34: YES), the loss cost reduction system 100 sets the target part as a candidate for the stock inventory item (S35). The loss cost reduction system 100 obtains the user's approval by displaying the stock candidates on the design terminal 2 or the management department terminal 5 (S36).

  When approved by the user (S36: YES), the loss cost reduction system 100 changes the arrangement type of the target part from the purchased item to the stock item (S37).

  Configuring this embodiment like this also achieves the same operational effects as the first embodiment. Further, the loss cost reduction system 100 according to the present embodiment automatically selects the stock reduction candidate ΣE as a candidate for stocking when the stock amount reduction amount ΣE is larger than the stock increase ΔSA due to stocking. Therefore, the user can change the arrangement type only when an actual reduction effect can be obtained, and usability is improved.

  The standard for comparing the threshold value Th1 and the reduction amount ΣE of the surplus material amount with the increase ΔSA of the stock balance may be appropriately set according to the circumstances of the company. According to the present embodiment, the user can easily grasp the relationship between the surplus material amount reduction amount ΣE and the increase amount ΔSA of the standing stock balance, and can confirm the effectiveness. Furthermore, according to the present embodiment, not only can replacement of parts to be stocked in stock be supported, but also the replacement process can be performed automatically by automating the approval step of step S36.

  A fourth embodiment will be described with reference to FIG. In the present embodiment, the surplus material information T2 is shared across a plurality of business entities 91A to 91C.

  FIG. 21 shows an overall outline of a loss cost reduction system according to the present embodiment. In this system, information on the surplus products 7A to 7C for each part is collected from the manufacturing sites 82A to 82C operated by a plurality of different main bodies 91A to 91C, and the collected information on each surplus material is stored in each main body 91A. Share between ~ 91C

  FIG. 21 shows a state where at least a part of the surplus material information T2 is shared by the three companies 91A to 91C. Each company 91A-91C purchases parts in a lot size from the respective component vendors 90A-90C (part arrangement systems 30A-30C). When the assembly 82A to 82C of each company 91A to 91C is completed, information on the surplus material items 7A to 7C is collected in the so-called cloud 92 as the surplus material information T2. Information on the surplus materials 7A to 7C in each company 91A to 91C can be referred to by the parts arrangement systems 30A to 30C of each company as necessary.

  The cloud 92 here is a database constructed in a server on a communication network. Instead of the cloud 92, the parts arrangement systems 30A to 30C of the respective companies 91A to 91C may communicate with each other to share the remaining material information of the respective companies.

  As an example of sharing and effectively using surplus material information between different companies, there is a method in which the number of arrangements of each company is totaled when purchasing a lot product, and a batch order is placed with a parts vendor. Even if it performs, the surplus goods are generated.

  This is because the number of employees at each company includes damage reserves in the manufacturing process and spare parts for responding to changes in customer specifications. The generation of surplus materials is determined after the manufacturing process (assembly process) is completed.

  Parts that cannot be used effectively among the remaining materials will eventually become waste. However, since the purchase price of surplus materials is usually much lower than the purchase price, there is no merit for each company even if the surplus materials are disposed of.

  Therefore, in the present embodiment, as described above, different companies 91 </ b> A to 91 </ b> C share the surplus product information T <b> 2 database by building it on the cloud 92.

  For example, it is assumed that the company 91A searches the surplus material information T2 and finds that the company 91B has the desired surplus material 7B. In this case, the company 91A arranges parts to purchase a desired surplus product 7B from the company 91B. Thereby, the surplus material 7B in the company 91B is effectively used in the company 91A. As a result, the company 91B can reduce the loss cost of waste.

  The price when the surplus materials of each company 91A to 91C are accommodated may be determined by a prior agreement, for example. For example, the price at the time of accommodation may be determined at a predetermined ratio with respect to the price at the time of purchase. Alternatively, it may be the limit price of a company that releases surplus materials.

  Although FIG. 21 shows a case where surplus materials are interchanged between three companies, the present invention is not limited to this, and surplus materials can be interchanged between two companies or four or more companies.

  Configuring this embodiment like this also achieves the same operational effects as the first embodiment. Furthermore, according to the present embodiment, by sharing the surplus material information T2 among a plurality of companies, it is possible to easily interchange the surplus material generated at each company.

  In addition, this invention is not limited to the said Example, Various modifications are included. For example, the above-described embodiments have been described in detail for easy understanding of the present invention, and are not necessarily limited to those having all the configurations described. Further, a part of a certain embodiment can be replaced with a configuration of another embodiment, and a configuration of another embodiment can be added to a configuration of a certain embodiment. In addition, it is possible to add, delete, and replace other configurations in a part of the configuration of each embodiment. Each of the above-described configurations, functions, processing units, processing means, and the like may be realized by hardware by designing a part or all of them with, for example, an integrated circuit. Each of the above-described configurations, functions, and the like may be realized by software by interpreting and executing a program that realizes each function by the processor. Information such as programs, tables, and files that realize each function can be stored in a recording device such as a memory, a hard disk, or an SSD (Solid State Drive), or a recording medium such as an IC card, an SD card, or a DVD. The handy terminal can be placed on a barcode reader, smartphone, tablet, or the like. The terminal can be placed on a smartphone, tablet or the like. The digital scale can be placed on other devices that can measure. Each server can be replaced with a virtual configuration on the cloud.

  1: Loss cost reduction server, 2: Design terminal, 3: Parts arrangement server, 4: Inventory management server, 5: Management department terminal, 6: Manufacturing site, 30: Parts arrangement system, 40: Inventory management system, 61: Weighing device 62: Radio base station, 63: Handy terminal, 71: Tag, 81: Labeling center, 82: Manufacturing process, 83: Test process, 90: Parts vendor, 100: Loss cost reduction system, 101: Information collection unit, 102: Information providing unit, 103: Lot size review unit, 104: Arrangement type changing unit, T1: Design BOM, T2: Remaining material information, T3: Unit price information, T4: Parts information, T5: Production plan information, T6: Parts arrangement information

Claims (7)

A system that reduces the loss cost of parts used in product assembly,
An information collection unit that collects information on the amount of remaining material, which is the difference between the purchased amount and the used amount of the target part;
Generating surplus material confirmation information including information identifying the target part, the surplus material amount, a surplus material amount obtained by converting the surplus material amount into a monetary amount, and a reason for the generation of the surplus material amount, and the generated surplus An information providing unit for providing material confirmation information to the user terminal;
Loss cost reduction system with Further, the information providing unit is a lot size review screen including a plurality of different lot size and unit price pairs when the target part is a lot purchased product, so that the user can select one of the groups. Generating a configured lot size review screen and providing the generated lot size review screen to the user terminal;
The loss cost reduction system according to claim 1. Further, the information providing unit generates an arrangement type change screen that can change the arrangement type of the target part from the lot purchased item to the stocked item when the remaining material of the target part is generated at a predetermined frequency or more. And providing the generated arrangement type change screen to the user terminal,
The loss cost reduction system according to claim 2. Furthermore, the information providing unit is a surplus achieved by at least one of the review of the lot size on the lot size review screen and the change from the lot purchased product to the stock on the order type change screen. Providing the user terminal with a reduction amount of the material amount and information on the amount of reduction of the remaining material amount including information indicating the cause of the reduction amount;
The loss cost reduction system according to claim 3. In the arrangement type change screen, the reduction amount of the surplus material amount by changing the target part from the lot purchased product to the regular stock item is the stock amount when the target part is changed to the regular stock item If it ’s larger than the increase in, present it as a candidate for inventory
The loss cost reduction system according to claim 4. Collecting information on surplus materials for each part from a manufacturing site operated by a plurality of different entities, and sharing the collected information on each remaining material between the plurality of entities;
The loss cost reduction system according to claim 1. A method for reducing the loss cost of parts used to assemble products using a computer,
The calculator is
Collect information on the amount of remaining material, which is the difference between the purchase amount and usage amount of the target part,
Generating surplus material confirmation information including information for identifying the target part, the surplus material amount, a surplus material amount obtained by converting the surplus material amount into an amount, and a reason for the occurrence of the surplus material amount;
Providing the generated surplus product confirmation information to the user terminal;
Loss cost reduction method.

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